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MAINTENANCE INTERVALS - Safety

1. 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the ground plane Disconnect the cable from the NEGATIVE battery terminal 4 The POSITIVE cable connects the POSITIVE battery terminal to the starting motor Disconnect the cable from the POSITIVE battery terminal SEBU8083 09 163 Maintenance Section Battery Replace 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 164 SEBU8083 09 Maintenance Section Battery Electrolyte Level Check 102601752 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 battery from freezing 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 ad
2. Engine Oil and Filter Change SMCS Code 1318 510 1348 044 103017821 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE The vehicle must be parked on a level surface for this maintenance procedure Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase with the engine stopped Drain the crankcase while the oil is warm This draining method will allow the waste particles that are suspended in the oil to be properly drained Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new engine oil NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJ0003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local
3. Initial 24 000 km 15 000 miles or 7500 L 2000 US gal of Fuel or 400 Service Hours or 6 Months Compression Brake InSpect AGjUSt 0 0 eeeeeeeeeeeeeeeeeeteenneeeeeeeeneeees 167 Engine Valve Lash Inspect AdjUst cceceeeeeeeeeeeeeeeeneeeeeesnieeeeeeeees 213 Initial 24 000 km 15 000 miles or 5700 L 1500 US gal of Fuel or 400 Service Hours or 6 Months Engine Valve Lash Inspect AdjUst 0 00 0 cceceeeeeteeeeeeeeteeeeeetnteeeeeeeeee 213 Every 24 000 km 15 000 miles or 7500 L 2000 US gal of Fuel or 400 Service Hours or 6 Months Aftercooler Core Clean TeSt eecccceeeeeeeeeeeeeeecareeeeeenueeeeeeetsaeeeeeeenaaes 159 Battery Electrolyte Level Check cicecceeeeeeereeceeeeetieeeeeetnieeeeerenee 164 Belts Inspect Adjust REplace 2 0 0 cccccceeeeeeeeeeeeceeceeeeeeeeeeeeeeeeensnaeeees 166 Cooling System Supplemental Coolant Additive SCA Test Add 180 Cylinder Head Grounding Stud Inspect Clean Tighten 0 188 Engine Crankcase Breather Clean 0 0 ec ec ceee settee eteeeeeeeees 198 Engine Oil Sample Obtain 2 2 cece ee eeteeeeeeeeeteeeeeesnaeeeeeeeneeeeeeaaas 203 Engine Oil and Filter Change 0 0 ce ceeeeeeeeeeeeeeeeeeeeeeeeeetaeeeeeeeneeeeeeeees 205 Fan Drive Bearing Lubricate 0 ccc eeceeeeeeeeeeneeeeeeteteeeeeetneeeeeneeee 214 Fuel System Primary Filter Water Separator Element Replace 218 Fuel System Secondary Filter Replace 0 c
4. The cleaning port is located on the left side of the engine next to the oil filler tube on the C7 Engine SEBU8083 09 155 Maintenance Section ARD Nozzle Clean T Re pees 3 A ae ep eG hee STP PO nee awd ah Illustration 36 g01351825 The cleaning port is located on the left side of the engine to the left of the fuel filter on the C9 Engine The priming pump that is shown is optional Note Remove the red cap from the dispenser immediately before use Ensure that no debris is present on the dispenser Make sure that the cleaning port is free of debris G g01348096 Illustration 37 Insert the tip of the dispenser completely into the cleaning port lt Illustration 38 g01346064 156 SEBU8083 09 Maintenance Section ARD Spark Plug Inspect Replace Squeeze the container in order to dispense the fluid All of the fluid should be dispensed before the dispenser is removed from the cleaning port Remove the dispenser and ensure that all of the liquid was dispensed Inspect the cleaning port in order to ensure that no part of the dispenser remains in the cleaning port Insert an undamaged access plug into the cleaning port Torque the plug to 10 1 N m 7 4 0 7 lb ft Start the engine and run the engine for at least five minutes at low idle 103340980 ARD Spark Plug Inspect Replace SMCS Code 1555 040 1555 510 Removing the Spark Plug NOTICE If the engine is
5. Battery or Battery Cable Disconnect ssseeesseeeerreseerrssererrserrerressne 165 Cooling System Coolant Sample Level 1 Obtain ees 178 Cooling System Coolant Sample Level 2 Obtain eee 180 Diesel Particulate Filter Clean ecccececeeeeee eset eeeeeeecneeeeeetnieeeeeeeeee 189 Engine Gleainisic3oc0 e sessed techie tet A shea ee ca atlas 192 Engine Air Cleaner Element Dual Element Clean Replace 193 Engine Air Cleaner Element Clean Replace eccsceeesereeeenees 195 Engine Oil Level Gauge Calibrate teeter sete 200 Engine Storage Procedure Check 0 eecccceeeeeeeeeeeeeenneeeeeeeeneeeeeeeaas 212 Fuel System Prime teicceteacnetetiescthvstecnesnhsoettath duets atv EEE tead betes 215 Fuel Tank Water and Sediment Drain eceeceeeesseeeeeeeesteeeeeenees 225 Severe Service Application Check 0 cceeeeeeeeeeeceeeeeeeeeeeeeeeeneneees 230 SEBU8083 09 151 Maintenance Section Maintenance Interval Schedule Daily Cooling System Coolant Level Check ec cceeeeeeeeeeeeeeeeeeeeeenaeeees 177 Engine Air Cleaner Service Indicator Inspect 0 ceeeeeetteeeeeeeeeee 195 Engine Oil Level Check cece eecceeeeeeeeeteneee eee eeieeeeeeeaaeeeeeetneeeeerteee 198 Fuel System Water Separator Check Drain ccccecceeeeeteeeeeeeteee 224 Walk Around Inspection 0 0 0 0 ccccceeeeeeeeeeeeececeeceeeeeeeeesetenenecsaeaeeeseeeeeess 236
6. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJO003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Drain any water from the water separator daily For more information on the checking and draining procedures for the water separator refer to the literature that is provided by the OEM of the vehicle or refer to the literature that is provided by the OEM of the water separator SEBU8083 09 225 Maintenance Section Fuel Tank Water and Sediment Drain 103071053 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 To
7. level Use an engraving pen in order to engrave the new ADD mark 7 Pour quantity B of oil into the crankcase Allow enough time for the oil to drain into the crankcase 202 SEBU8083 09 Maintenance Section Engine Oil Level Gauge Calibrate 8 Check the oil level on the oil level gauge The oil level should be at the FULL mark If the oil level is not at the existing FULL mark grind off the FULL mark Use an engraving pen in order to engrave the new FULL mark 9 Pour quantity C of oil into the crankcase in order to allow oil to fill the oil filter NOTICE Do not crank the engine for more than 30 seconds Allow the starting motor to cool for two minutes before cranking again 10 Start the engine and run the engine enough to ensure that the lubrication system is filled Inspect the engine for oil leaks 11 Stop the engine and allow enough time for the oil to drain into the crankcase 12 Check the oil level on the oil level gauge If the oil level is not at the calibrated FULL mark fill the crankcase to the calibrated FULL mark Record the amount of oil that was added as quantity D Record the oil capacity of the lubrication system for future oil changes Table 16 C7 Quantity of Oil Shallow Sump Standard Deep Sump A 13 L 13 7 qt 20 L 21 1 qt B 3 L 3 2 qt 3 L 3 2 qt C 2 L 2 1 qt 2 L 2 1 qt D Total Capacity of the Lubricat
8. 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 SEBU8083 09 193 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace 102353651 Engine Air Cleaner Element Dual Element Clean Replace If Equipped SMCS Code 1054 037 1054 510 See this Operation and Maintenance Manual Engine Air Cleaner Element Clean Replace for information on servicing the primary air filter Inspecting and Replacing the Secondary Air Cleaner Element If Equipped 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 cl
9. Around Inspection cccceceeeeeeeeeeeeececeeceeeeeeeeeseteneanccueeeeeeeeeeeess 236 Initial 17 700 km 11 000 miles or 4150 L 1100 US gal of Fuel or 250 Service Hours or 6 Months Engine Valve Lash Inspect AdjUst ccc eeteeeeeeeetneeeeeetnneeeeereeee 213 PM Level 1 Every 17 700 km 11 000 miles or 4150 L 1100 US gal of Fuel or 250 Service Hours or 6 Months Aftercooler Core Clean TeSt eececceeeeeeeeeeeeeeccaeeeeeeenneeeeeeetnaeeeeenenaaes 159 Battery Electrolyte Level Check 0 cccccceeeeeeneeeceeeeenieeeeeetnneeeeeeeees 164 Belts Inspect Adjust REplace cccccceeeeeeseceeeceeceeeeeeeeeeeeteesennnaeeees 166 Cooling System Supplemental Coolant Additive SCA Test Add 180 Cylinder Head Grounding Stud Inspect Clean Tighten 0e 188 Engine Crankcase Breather Clean eeeceeceeeeseteeeeeesenneeeeeeenneeeeeeeees 198 Engine Oil Sample Obtain 2 eee cece e tee eee nett nee eeeneees 203 Engine Oil and Filter Change 0 2 eee eeceeeee teeter eee eeeeteeeeeeenieeeeeeeeae 205 Fan Drive Bearing Lubricate 0 cc ceececeeeeeeeneeeeeee tennessee tnieeeeeeeees 214 Fuel System Primary Filter Water Separator Element Replace 218 Fuel System Secondary Filter Replace eceeeeesceeeeeeeeeeeeeeeeeeees 221 Fuel Tank Water and Sediment Drain 0 ceeeeeeeeeeeeeeeeenteeeeeeeeee 225 Hoses and Clamps Inspect Replace cccccece
10. Equipped SMCS Code 7452 040 Some engines may be equipped with a different service indicator 196 SEBU8083 09 Maintenance Section Engine Air Cleaner Service Indicator Inspect 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 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 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 SEBU8083 09 197 Maintenance Section Engine Air Cleaner Service Indicator Inspect e Check the movement of the yellow core when the engine is accelerated to the engine rated speed The
11. Ga a AS E RE A a a S 162 Battery or Battery Cable Disconnect sessseesreerrrerrrrerrrrerrerrrerere 165 Cooling System Coolant Sample Level 1 Obtain eee 178 Cooling System Coolant Sample Level 2 Obtain cere 180 Diesel Particulate Filter Clean ccceeececeeeeeeeeeteeeeeeeeteeeeeeetneeeeeeeeee 189 Engine CBM unane a e E A EN 192 Engine Air Cleaner Element Dual Element Clean Replace 193 Engine Air Cleaner Element Clean Replace eee 195 Engine Oil Level Gauge Calibrate 0 cccecceeeeeeenteeeeeeeenteeeeeeeaas 200 Engine Storage Procedure Check 0 eeccceeeeeeeeeeeeeeeenteeeeeeeneeeeeeeaaas 212 Fuel System PME serseri antennae ni a 215 Fuel Tank Water and Sediment Drain 0 eeeeeeeeceeeeeeeeteeeeeeeeeee 225 Severe Service Application Check 0 ccceeeeeeeeeeeceeceeeeeeeeeeeeteeneeee 230 148 SEBU8083 09 Maintenance Section Maintenance Interval Schedule Daily Cooling System Coolant Level Check e cc cceeeeeeeeeeeeeeeteeeeeeeeneeeees 177 Engine Air Cleaner Service Indicator Inspect 0 ce ceeeeeeeeeteeeeeeeeee 195 Engine Oil Level Check 0 eee eeceeeeeeeeeetneee eee etneeeeeeeaaeeeeeetneeeeeneeee 198 Fuel System Water Separator Check Drain cccceeceeeeeeteeeeeeeeeee 224 Walk Around Inspection cccceceeeeeeeeeeecececeeceeeeeeeeesececeancnieeeeeseeeeeess 236 Initial 24 000 km 15 000 m
12. Light Medium Heavy Severe Model Duty Duty Duty Service KM Miles to Next Oil Change C7 Engine 17380 13905 10430 6950 with a 10800 8640 6480 4320 Shallow Sump 18L 19 qt C7 Engine 24140 19300 14500 9660 with a 15000 12000 9000 6000 Standard Deep Sump 25 L 26 4 qt C9 Engine 30900 24720 18540 12360 with a 19200 15360 11520 7680 Standard Deep Sump 30 L 31 7 qt 1 Typical applications are recreational vehicles and intercity delivery average that is greater than 10 mpg 2 Typical applications are intracity driving average 8 to 10 mpg 3 Typical applications are bus services and pickup and or delivery services 5 to 7 mpg 4 Refer to the Operation and Maintenance Manual Severe Service Application Check for the requirements 4 mpg or less For more information on optimizing oil change intervals see your Caterpillar dealer 212 SEBU8083 09 Maintenance Section Engine Storage Procedure Check 101458399 Engine Storage Procedure Check SMCS Code 1000 535 The oil change interval may be extended to 12 months for a vehicle that is operated seasonally and placed in storage for the remainder of the year by using the required storage procedures and the required start up procedures This extension is permitted if the following categories for oil change intervals in the Operation and Maintenance Manual Maintenance Interva
13. Remove the oil filler cap Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations topic for more information about selecting the correct engine oil and finding the correct refill capacity for your engine Fill the crankcase with the proper amount of oil 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 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 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes 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 Remove the DO NOT OPERATE tag from the ignition keyswitch SEBU8083 09 209 Maintenance Section Engine Oil and Filter Change Adjustments to the Oil Change Intervals Many conditions affect the selection of an oil change interval Proper oil change int
14. Section Crankcase Fumes Fitting Inspect Clean 3 If fitting 3 is accessible this procedure may be performed with the fitting on the combustion head If the fitting is not accessible remove the fitting and use a vise to hold the fitting 4 Install a 6V 7092 Brush into a drill and clean the fitting 5 Reinstall the nut onto the tube and tighten the nut Refer to the engine s Specifications manual for the proper torque 6 Reinstall the end of the tube through the hose into the breather Reinstall the hose clamps Refer to Specifications SENR3130 for the proper torque for the hose clamp SEBU8083 09 187 Maintenance Section Crankshaft Vibration Damper Inspect 102933380 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 the crankshaft and to other engine components A damper that is damaged can cause excessive gear train noise at variable points in the speed range The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine Visconic Damper The visconic damper has a weight that is located inside a fluid filled case The weight moves in the case in order to limit torsional vibration Inspect the damper for evidence of fluid leaks If a fluid leak is found determine the type of fluid The fluid in the damper is
15. 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 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 SEBU8083 09 173 Maintenance Section Cooling System Coolant ELC Change 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 regardi
16. 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 214 SEBU8083 09 Maintenance Section Fan Drive Bearing Lubricate 101771215 Fan Drive Bearing Lubricate SMCS Code 1359 086 BD Illustration 53 g00746166 Typical location of the grease fitting that is for the fan drive bearing The belt guards have been removed in this illustration Note In some applications the fan drives are supplied by the OEM Refer to the OEM specifications if the fan drive is not supplied by Caterpillar 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 information SEBU8083 09 215 Maintenance Section Fuel System Prime 102686443 Fuel System Prime SMCS Code 1258 548 Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury tur
17. or 1500 Service Hours ARD Nozzle Clena a E T S 153 Every 144 800 km 90 000 mi or 1500 Service Hours ARD Spark Plug Inspect Replace c ceceecceeeeeeeeteeteesensneeeeees 156 Crankcase Fumes Fitting Inspect Clean 0 ececeeeeseeeeeeeeeeeeeeeeeees 185 PM Level 2 Every 161 000 km 100 000 miles or 56 850 L 15 000 US gal of Fuel or 2000 Service Hours or 2 Years Air Compressor Inspect ccccececeeeeeeeeeeeeeaeeeeeeeeeeeeeseeeeesnsnanaeeees 159 Alternator INSPe Ct maea a a ea aea te Aaea Sa an aaa T Eae eaa aAa ne dadaa 161 Cooling System Water Temperature Regulator Replace 183 Crankshaft Vibration Damper Inspect 2 cecceeeceeeeeeeeteeteeneeee 187 SEBU8083 09 149 Maintenance Section Maintenance Interval Schedule Engine Valve Lash Inspect Adjust 0 000 eet ee etree eee teens 213 Starting Motor MS pE E oo eee eee ee ro TEENETE EREA 233 Water Pump lt INSpect iec c ser scabs der hie dest aeae oea Ea es oe aid ey anes 239 PM Level 3 Every 483 000 km 300 000 miles or 190 000 L 50 000 US gal of Fuel or 6000 Service Hours or 3 Years Turbocharger INSPe Ct cccccceeeseceeceeesdeeeeeeceesenteeceeesedaeeceeseenaeeneeseneaee 233 Every Year Engine Air Cleaner Element Clean Replace ececeeeesseeeeeeeee 195 Every 3 Years or 322 000 km 200 000 miles Cooling System Coolant DEAC Change s es 168 Every 6 Y
18. 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 166 SEBU8083 09 Maintenance Section Belts Inspect Adjust Replace 102719973 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 Illustration 41 g01272337 Your engine is equipped with a serpentine belt 1 For maximum engine performance and maximum utilization of your engine inspect the belt for the following conditions wear cracks and damage If necessary replace the belt To replace the serpentine belt perform the following steps 1 Insert a ratchet with a square drive into the square hole that is located in belt tensioner 2 Rotate the belt tensioner clockwise in order to relieve tension on the fan drive belt Remove the belt 2 Install the new belt correctly as shown Be sure that the belt is fully seated on the pulleys The correct tension will automatically be applied when the ratchet is removed SEBU8083 09 167 Maintenance Section Compression Brake Inspect Adjust 102768003 Compression Brake Inspect Adjust Caterpillar
19. 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 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 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 2 Start and run the engine at low idle Increase the eng
20. 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 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 103196558 Severe Service Application Check SMCS Code 1000 535 Operation and maintenance practices affect the service life of the components when the engine is operated in severe service applications The following factors are crucial to the service life of the engine e The level of maintenance e Operating speeds e Operating loads e Gross vehicle weights SEBU8083 09 231 Maintenance Section Severe Service Application Check Reduce the maintenance intervals for engines that operate in severe service applications An application is a severe service application if any of the following conditions apply e The weight is higher than the weight that is listed in the table e The average mpg is less than the mpg listed in the table e The average kilometer per liter is less than the kilometer per liter listed in the table Table 19 Severe Service Applications Average Averag
21. CS 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 The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the air nozzle is deadheaded 230 SEBU8083 09 Maintenance Section Severe Service Application Check 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
22. Compression Brake SMCS Code 1119 025 1119 040 S N MFF1 Up S N C9S1 Up S N C9W1 Up The maintenance of the Caterpillar compression brake should be performed in conjunction with scheduled maintenance of the valve lash Note The adjustment of the actuator piston lash must be performed after the engine valve lash adjustment is performed Make the adjustment of the actuator piston lash while the engine is stopped Refer to the Systems Operation Testing and Adjusting module for additional information Table 13 Component Required Maintenance pene and Terminal Inspect onnections Clutch Throttle Buffer Screw Inspect Adjust oo inspectAdust Crosshead Bridges Valve Inspect Stem Caps Housing Inspect Hold Down Bolts Inspect Control Valve Inspect Oil Seal Ring Inspect Replace 1 Inspect the oil seal rings for signs of wear and for signs of damage If necessary replace the oil seal rings Refer to the Parts Manual for further information 168 SEBU8083 09 Maintenance Section Cooling System Coolant DEAC Change 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 coolin
23. E 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 information on cooling system specifications Do not install the cooling system filler cap 2 Start and run the engine at low idle for 5 minutes Then 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 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 SEBU8083 09 175 Maintenance Section Cooling System Coolant Extender ELC Add 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 correc
24. ICE The vehicle must be parked on a level surface in order to perform this maintenance procedure 1 Operate the engine until normal operating temperature is achieved Stop the engine Remove the crankcase oil drain plugs The oil drain plug from the deep portion of the oil pan should be removed Drain the oil from the crankcase for 20 minutes 2 Remove the used oil filter s Install the new oil filter s Install the oil drain plugs and tighten to 70 15 N m 50 11 Ib ft Caterpillar recommends the use of Cat Advanced Efficiency oil filters Note Your engine may be equipped with auxiliary oil filters The auxiliary oil filters require a different volume of oil Refer to the OEM specifications for the auxiliary oil filter 3 Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations for information about choosing the correct oil for your engine 4 Refer to the table that is correct for your engine and oil pan below Pour quantity A of engine oil into the crankcase 5 Allow enough time for the oil to drain into the crankcase Approximately 20 minutes should be allowed Check the oil level Wait for several minutes and check the oil level again Proceed after the oil level stops changing 6 Check the oil level on the oil level gauge The oil level should be at the ADD mark If the oil level is not at the existing ADD mark grind off the ADD mark and engrave the new ADD
25. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt 2010 Caterpillar CATERPILLAR All Rights Reserved CATERPILLAR March 2008 co Operation and Maintenance Manual C7 and C9 On highway Engines MFF1 Up Engine C7S1 Up Engine C9S1 Up Engine C7W1 Up Engine C9W1 Up Engine Includes C9 Mass Transit Bus Engines SAFETY CAT COM 144 SEBU8083 09 Maintenance Section Maintenance Interval Schedule 102871972 Maintenance Interval Schedule C7 Engines with Shallow Sumps SMCS Code 1000 7500 S N C7S1 Up Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption mileage service hours and calendar time Products that operate in severe operating conditions may require more frequent maintenance Before each consecutive interval is performed all maintenance from the
26. and in the combustion chamber De posits in the combustion chamber lead to the following problems guttering of the valves packing of carbon under the piston rings and wear of the cylinder liner If the oil level is above the FULL mark on the oil level gauge drain some of the oil immediately 2 Remove oil filler cap 2 and add oil if necessary For the correct oil to use refer to this Operation and Maintenance Manual Refill Capacities and Recommendations Do not fill the crankcase above FULL mark X on the oil level gauge Clean the oil filler cap Install the oil filler cap 3 Record the amount of oil that is added For the next oil sample and analysis include the total amount of oil that has been added since the previous sample This will help to provide the most accurate oil analysis 102944876 Engine Oil Level Gauge Calibrate SMCS Code 1326 524 Check Calibration at the First Oil Change The engine oil level will vary depending on the angle and the slant of the engine installation The angle is the front to back tilt The slant is the sideways tilt SEBU8083 09 201 Maintenance Section Engine Oil Level Gauge Calibrate The oil level gauge markings must be verified in order to ensure that it is correct Verify the oil level gauge markings at the first oil change Verify the ADD mark and verify the FULL mark that is on the oil level gauge Use the following procedure NOT
27. atalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death 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 Clean the outside of the fuel filter Remove the used fuel filter and discard the used fuel filter 3 Clean the gasket sealing surface of the fuel filter base Ensure that all of the old gasket is completely removed SEBU8083 09 223 Maintenance Section Fuel System Secondary Filter Replace NOTICE In order to meet expected fuel system component life 4 micron c absolute or less secondary fuel fil tration is required for all Caterpillar Diesel Engines that are equipped with unit injected fuel systems Note that all current Caterpillar Di
28. atile vapors are removed by simply running the engine to operating temperature A mineral oil base is left behind after the volatile vapors are removed SEBU8083 09 213 Maintenance Section Engine Valve Lash Inspect Adjust 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 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
29. ator 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 two articles in the Disassembly and Assembly Manual Water Temperature Regulators Remove and Water Temperature Regulators Install 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 SEBU8083 09 185 Maintenance Section Crankcase Fumes Fitting Inspect Clean 102678214 Crankcase Fumes Fitting Inspect Clean SMCS Code 1317 040 1317 070 Sa IG AL aie Lae lt Illustration 44 g01345683 1 Clamps 2 Nut 3 Fitting 1 Loosen the clamps that attach the tube that carries fumes from the engine crankcase breather to the aftertreatment regeneration device ARD Remove the end of the tube from the breather 2 Remove the nut at the end of the tube from the fitting and move the tube to one side The fitting will remain in the ARD 186 SEBU8083 09 Maintenance
30. bus tion pressure to blow past the seal Serious damage to the engine can occur Use the proper torque 2 Install the spark plug by hand until the spark plug contacts the ARD Torque the spark plug to the proper specification Refer to Specifications Spark Plug for the proper torque specification 3 Connect the wiring harness Aftercooler Core Clean Test Air To Air Aftercooler SMCS Code 1064 070 1064 081 The air to air aftercooler is OEM installed in many applications Please refer to the OEM specifications for information that is related to the aftercooler 102426101 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 air brake and the auxiliary air systems before re moving the air compressor and or the air lines could cause personal injury 160 SEBU8083 09 Maintenance Section Air Compressor Inspect Illustration 40 g01212654 Typical example 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 t
31. dis connected fuel system components NOTICE Do not fill the primary 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 SEBU8083 09 219 Maintenance Section Fuel System Primary Filter Water Separator Element Replace NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJO003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Caterpillar Primary Fuel Filter and Water Separator 1 Close the main fuel supply valve OO Illustration 55 g01453091 1 Element 2 Bowl 3 Drain 2 Remove element 1 from the element mounting base while bowl 2 is attached 220 SEBU8083 09 Maintenance Section Fuel System Primary Filter Water Separator Element Replace 3 Dispose of the contents of the filter Remove bowl 2 from element 1 The bowl is reusab
32. dition 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 SEBU8083 09 165 Maintenance Section Battery or Battery Cable Disconnect 101492654 Battery or Battery Cable Disconnect SMCS Code 1402 029 The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Turn the start switch to the OFF position Turn the ignition switch if equipped to the OFF position and
33. e Average Engine Model Gross Vehicle Miles Kilometer liters per 9 Weight per per Liter 100 km Gallon C7 On highway 22680 kg 10 4 3 23 5 Engine 50000 Ib C9 On highway 27215 kg 8 3 4 29 4 Engine 60000 Ib C9 On highway 27215 kg 4 1 7 58 8 Engine Urban 60000 Ib transit bus application C13 On highway 36287 kg 6 2 6 39 2 Engine 80000 Ib C15 On highway 36287 kg 5 2 1 47 Engine 80000 Ib 1 An engine is operating in a severe service application when the gross operating weight is higher than the gross operating weight in this table 2 An engine is operating in a severe service application when the fuel consumption is greater than the fuel consumption in this table 3 An engine for an urban transit bus generally operates in severe service conditions e Frequent low speed operation less than 20 Miles per Hour e Use of fuel with more than 15 ppm sulfur e No water separator 232 SEBU8083 09 Maintenance Section Severe Service Application Check Frequent operation in dusty conditions or off highway operation Off highway operation Frequent high altitude operation above 1525 m 5000 ft Extreme ambient temperature conditions that may cause the lubricating properties of the fuel to diminish Frequent plugging of the fuel filter Extended maintenance intervals of the fuel system Inadequate maintenance of fuel storage tanks excessive water sediment microorganism growth etc Extending maint
34. e 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 208 SEBU8083 09 Maintenance Section Engine Oil and Filter Change 5 Install the oil filter Tighten the oil filter until the oil filter gasket contacts the base Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Fill the Engine Crankcase 1
35. eaner 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 Operating conditions dust dirt and debris may require more frequent service of the air cleaner element 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 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 194 SEBU8083 09 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace Illustration 46 g00736431 1 Cover 2 Primary air cleaner element 3 Secondary air cleaner element 4 Air inlet for the turbocharger 1 Remove the cover Remove the primary air cleaner element 2 Cover the air inlet for the turbocharger with adhesive material in order to keep dirt out of the turbocharger 3 Clean the inside of the air cleaner cover and body with a clean dry cloth 4 Remove the adhesive covering that covers the air inlet for the turbocharger Install the secondary air cleaner element Install a p
36. ears or 966 000 km 600 000 miles Cooling System Coolant ELC Change ccececeeseeeeeeeeetteeeeeees 172 Every 483 000 km 300 000 miles or 3 Years Cooling System Coolant Extender ELC Add s es 175 150 SEBU8083 09 Maintenance Section Maintenance Interval Schedule 102871975 Maintenance Interval Schedule C9 Engines SMCS Code 1000 7500 S N MFF1 Up S N C9S1 Up Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption mileage service hours and calendar time Products that operate in severe operating conditions may require more frequent maintenance Before each consecutive interval is performed all maintenance from the previous intervals must be performed When Required Air Dryer CROCK saninin anean aaa aaa Aa EEA ARASEN EOE AEA EES 161 Battery Replat oean a E E E E a a 162
37. eceeeesseeeeeeeeesteeeeeeeeee 221 Fuel Tank Water and Sediment Drain eceeeeeeeeeeeeeeeeeeeeeeeeeeee 225 Hoses and Clamps Inspect Replace ccccceceeeeeeeeeeseneteaeeees 227 Radiator Clean cena oe sects eit ieee tien tenant edie agate an A 229 Every 80 500 km 50 000 miles or 1500 Service Hours ARD Nozzle Clean n eee aaa aeaa a enata aaeain 153 Every 144 800 km 90 000 mi or 1500 Service Hours ARD Spark Plug Inspect Replace c sececcceeeeeeeeeeeeeesenseeeeeees 156 Crankcase Fumes Fitting Inspect Clean n 185 152 SEBU8083 09 Maintenance Section Maintenance Interval Schedule PM Level 2 Every 161 000 km 100 000 miles or 56 850 L 15 000 US gal of Fuel or 2000 Service Hours or 2 Years Air Compressor Inspect cccceceeeeeeeeeeeeeencaeeeeeeeeeeeeeteesessnesnnaeenes 159 Alternator Inspect cecceccccccccecceceeeeeeteeeeeeaeeaeeeceeeeeeeeeseesennnnsaneeeees 161 Compression Brake Inspect AdjUSt ecceceeeeeeeeeeeeeeeeteteeeeetteeee 167 Cooling System Water Temperature Regulator Replace 05 183 Crankshaft Vibration Damper Inspect eeeeeeeeceeceeeeeeeeeeeeteeneeee 187 Engine Valve Lash Inspect AdjUst cceceeeeeeteeeeeeeetneeeeeetnteeeeeeeeee 213 Starting Motor INS poct oe rrr ar e EER E EEEE EES AETA EEKE 233 Water Pump Inspect snossssnsnnnennsteestertrtrnrnnertestertnnnnnnnnnnnnennnen
38. eeeeeeeeeseseeeeeees 227 Radiator Clean siciiciote ahi asain ietna adenine Sai eta 229 Every 80 500 km 50 000 miles or 1500 Service Hours ARD Nozzle Clena a E T S 153 Every 144 800 km 90 000 mi or 1500 Service Hours ARD Spark Plug Inspect Replace ceccccceeeeeeeeteeeeeseesnneeeees 156 Crankcase Fumes Fitting Inspect Clean 0 ececeeeeseeeeeeeeeeeeeeeeeees 185 PM Level 2 Every 161 000 km 100 000 miles or 56 850 L 15 000 US gal of Fuel or 2000 Service Hours or 2 Years Air Compressor Inspect ccccececeeeeeeeeeeeeeaeeeeeeeeeeeeeseeeeesnsnanaeeees 159 Alternator INSPe Ct maea a a ea aea te Aaea Sa an aaa T Eae eaa aAa ne dadaa 161 Cooling System Water Temperature Regulator Replace 183 Crankshaft Vibration Damper Inspect 2 cecceeeceeeeeeeeteeteeneeee 187 146 SEBU8083 09 Maintenance Section Maintenance Interval Schedule Engine Valve Lash Inspect Adjust 0 00 0 eet ee etree eee 213 Starting Motor MS paet srera eaa EEE AARE ERREN 233 Water Pump INSPe Ct miesi araa a eae aae aoee aaa E e a ah 239 PM Level 3 Every 483 000 km 300 000 miles or 190 000 L 50 000 US gal of Fuel or 6000 Service Hours or 3 Years Turbocharger INSpeCtiiia inina iseni eiriaa dedi iaa a aA 233 Every Year Engine Air Cleaner Element Clean Replace ssiieeeeeeeeeeereeeereeee 195 Every 3 Years or 322 000 km 200 000 miles Cooling System Co
39. el Check SMCS Code 1348 535 FLV Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin SEBU8083 09 199 Maintenance Section Engine Oil Level Check g01182634 Illustration 49 Typical configuration 1 Oil level gauge 2 Oil filler cap e lt ADD FULL 5 g00110310 Illustration 50 Y ADD mark X FULL mark NOTICE Perform this maintenance with the engine stopped Note Before you perform this maintenance do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan 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 200 SEBU8083 09 Maintenance Section Engine Oil Level Gauge Calibrate NOTICE Engine damage can occur if the crankcase is filled above the FULL mark on the oil level gauge dip stick An overfull crankcase can cause the crankshaft to dip into the oil This will reduce the power that is devel oped and also force air bubbles into the oil These bubbles foam can cause the following problems re duction of the oil s ability to lubricate reduction of oil pressure inadequate cooling oil blowing out of the crankcase breathers and excessive oil consumption Excessive oil consumption will cause deposits to form on the pistons
40. em filler cap with a new cooling system filler cap Install the cooling system filler cap 102623972 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 the engine operating temperature to be too low during partial load operation Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner 184 SEBU8083 09 Maintenance Section Cooling System Water Temperature Regulator Replace 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 regul
41. enance Section Cooling System Coolant Sample Level 2 Obtain 103085829 Cooling System Coolant Sample Level 2 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 Note Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations for the proper maintenance interval for your application 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 this Operation and Maintenance Manual Cooling System Coolant Sample Level 1 Obtain for the guidelines for proper sampling of the coolant Submit the sample for Level 2 analysis For additional information about coolant analysis see Special Publication SEBU6385 Caterpillar On highway Diesel Engines Fluids Recommendations or consult your Caterpillar dealer 103085828 Cooling System Supplemental Coolant Additive SCA Test Add SMCS Code 1352 045 1395 081 Note This procedure is NOT required for applications that use Cat Extended Life Coolant ELC SEBU8083 09 181 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add NOTICE Cooling system coolant additive contains alkali To help preve
42. enance beyond the recommended maintenance intervals Use of fuels coolants or lubricants that are not specified by Caterpillar in Special Publication SEBU6385 Caterpillar On highway Diesel Truck Engine Fluids Recommendations Frequent operation at low idle more than 20 Frequent cold starts at temperatures below 18 C 0 F Frequent dry starting starting after more than 3 days of shutdown Frequent hot shutdowns minimum five minute cool down periods after high load factor operation If the engine is stored over 3 months see Special Instruction SEHS9031 Storage Procedure for Caterpillar Products For additional information about severe service applications consult your Caterpillar dealer SEBU8083 09 Maintenance Section Starting Motor Inspect 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 Turbocharger Inspect SMCS Code 1052 040 1052 Hot engine components can cause injury from burns Before performing maintenance on the engine allow the engine and the component
43. epaired 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 NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life SEBU8083 09 235 Maintenance Section Turbocharger Inspect 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 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 exhaus
44. erpillar 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 to remove any debris 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 170 SEBU8083 09 Maintenance Section Cooling System Coolant DEAC Change 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 allo
45. ervals are important for maintaining engine service life and engine performance and fully utilizing the lubricant The engine oil must be able to control the following items corrosion oxidation soot and wear metals The engine oil must be able to control the conditions during the time between oil changes In some severe service applications reducing the oil change interval may be necessary in order to maintain the integrity of the engine lubricant Refer to this Operation and Maintenance Manual Severe Service Operation Check or consult with your Cat dealer in order to determine whether your engine is operating under severe service conditions Fuel consumption and oil consumption are the most important factors that are used in order to calculate an oil change interval All engines do not consume fuel and oil at the same rate due to several factors manufacturing tolerances maintenance variations and engine application Extended Oil Change Intervals Note The following requirements must be met in order to use table 18 Cat DEO ULS is used or an oil that meets the requirements of the Caterpillar ECF 3 Engine Crankcase Fluid specification 3 specification is used S O S Services oil analysis is performed at 16 100 km 10 000 mile intervals and all oil change intervals The S O S Services lab must be notified of the extended oil change interval The use of an extended oil change interval makes a difference in the interpretati
46. esel Engines are factory equipped with Caterpillar Advanced Efficiency 4 mi cron c absolute fuel filters Caterpillar does not warrant the quality or perfor mance of non Caterpillar fluids and filters 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 4 Apply clean diesel fuel to the gasket that is located on the new fuel filter 5 Install the new fuel filter Spin the fuel filter onto the fuel filter base until the gasket contacts the base Instructions for the installation of the filter are printed on the side of each Caterpillar spin on filter For non Caterpillar filters refer to the installation instructions that are provided by the supplier of 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 7 Turn on the ignition or reconnect the battery cable 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 224 SEBU8083 09 Maintenance Section Fuel System Water Separator Check Drain 103009440 Fuel System Water Separator Check Drain SMCS Code 1263 535 1263 543
47. g system and the coolant is contaminated NOTICE Use of commercially available cooling system clean ers may cause damage to cooling system compo nents Use only cooling system cleaners that are ap proved for Caterpillar engines 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 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 Drain 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 SEBU8083 09 169 Maintenance Section Cooling System Coolant DEAC Change 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 Cat
48. harged 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 162 SEBU8083 09 Maintenance Section Battery Replace 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 near 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 1 Turn the key start switch to the OFF position Remove the key and all electrical loads 2 Turn OFF the battery charger Disconnect the charger
49. iles or 5700 L 1500 US gal of Fuel or 400 Service Hours or 6 Months Engine Valve Lash Inspect AdjUSt 0 00 cceceeeeteeeeeeeenneeeeeeteneeeeereeee 213 PM Level 1 Every 24 000 km 15 000 miles or 5700 L 1500 US gal of Fuel or 400 Service Hours or 6 Months Aftercooler Core Clean TeSt eececceeeeeeeeeeeeeeecereeeeeenneeeeeeennaeeeeenenaaes 159 Battery Electrolyte Level Check 0 ccccccceeeeeeeeeeeeeeeetieeeeeeenieeeeeeeeee 164 Belts Inspect Adjust REplace ccccccceeceeeeceeeceeceeeeeeeeeeeeteessnnnsaeeees 166 Cooling System Supplemental Coolant Additive SCA Test Add 180 Cylinder Head Grounding Stud Inspect Clean Tighten 0e 188 Engine Crankcase Breather Clean eeeceeceeeeseteeeeeesenneeeeeeenneeeeeeeees 198 Engine Oil Sample Obtain 2 eee cece e tee eee nett nee eeeneees 203 Engine Oil and Filter Change 0 2 eee eeceeeee teeter eee eeeeteeeeeeenieeeeeeeeae 205 Fan Drive Bearing Lubricate 0 cc ceececeeeeeeeneeeeeee tennessee tnieeeeeeeees 214 Fuel System Primary Filter Water Separator Element Replace 218 Fuel System Secondary Filter Replace eceeeeesceeeeeeeeeeeeeeeeeeees 221 Fuel Tank Water and Sediment Drain 0 ceeeeeeeeeeeeeeeeenteeeeeeeeee 225 Hoses and Clamps Inspect Replace ccccceceeeeeeeeeeseseeeeeees 227 Radiator Clean siciiciote ahi asain ietna adenine Sai eta 229 Every 80 500 km 50 000 miles
50. ine 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 172 SEBU8083 09 Maintenance Section Cooling System Coolant ELC Change 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 95 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 103292691 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
51. ine the minimum maintenance interval for a DPF with a reduced volume e 128750 kilometers 80000 miles e 2400 hours SEBU8083 09 191 Maintenance Section Diesel Particulate Filter Clean Note This minimum maintenance interval is only valid for engines that are built in 2007 2008 or 2009 Note The following vehicles are not qualified for reduced maintenance intervals even when the vehicles are included in the above list e Any vehicle with an exhaust system that is mounted vertically e Any vehicle that has a DPF that is mounted behind the cab and outside of the frame rails Please consult your Caterpillar dealer in order to determine if a DPF with a reduced volume is installed in your vehicle A DPF with a reduced volume requires a more frequent maintenance interval Recommended Maintenance Interval Caterpillar strongly recommends the cleaning of ash from the DPF at no later than 2882000 kilometers 175000 miles from the initial start up or from the last cleaning The removal of ash from the DPF is a key factor in the following the performance of the engine aftertreatment system the life of the DPF and fuel economy 282000 kilometers 175000 miles 192 SEBU8083 09 Maintenance Section Engine Clean 101646701 Engine Clean SMCS Code 1000 070 Personal injury or death can result from high volt age Moisture can create paths of electrical conductiv ity Make sure that the electrical system is OFF Lock
52. ion System for Engine Oil SEBU8083 09 203 Maintenance Section Engine Oil Sample Obtain Table 17 c9 Quantity of Oil Center Rear and Front Sump A 24 L 25 4 qt B 4 L 4 2 qt C 2 L 2 1 qt D Total Capacity of the Lubrication System for Engine Oil 101935337 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 complete 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 204 SEBU8083 09 Maintenance Section Engine Oil Sample Obtain 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 a
53. l Schedule have not been reached e Mileage e Operating hours e Fuel consumption If an engine is out of operation and if use of the engine is not planned special precautions should be made If the engine will be stored for more than three months a complete protection procedure is recommended For more detailed information on engine storage see Special Instruction SEHS9031 Storage Procedure For Caterpillar Products If the engine will not be started for several weeks the lubricating oil will drain from the cylinder walls and from the piston rings Rust can form on the cylinder liner surface Rust on the cylinder liner surface will cause increased engine wear and a reduction in engine service life Caterpillar recommends the use of volatile corrosion inhibitor VCI oil in order to prevent internal engine damage due to moisture during storage These inhibitors in the VCI oil act by evaporating inside the engine The inhibitors then condense over the inside surfaces of the engine The evaporation process and the condensing process offers full protection to surfaces that cannot be reached with preservatives 0 9 L 1 0 qt of 4C 6792 VCI oil will treat 28 4 L 30 0 qt of engine oil This will give a 3 percent concentration of VCI oil The engine must be completely sealed when the engine is stored in order for the VCI oil to function properly The VCI oil is easily cleaned from the engine when you remove the engine from storage The vol
54. l regulations and mandates 1 Check the cooling system only when the engine is stopped and cool 2 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 3 It may be necessary to drain enough coolant from the cooling system in order to add Cat ELC Extender A Refer to the schedule that is found in Operation and Maintenance Manual Maintenance Interval Schedule This schedule lists the interval for adding Cat ELC Extender to this engine 5 Use the formula in Table 14 to determine the proper amount of Cat ELC Extender for your cooling system The total cooling capacity will vary depending on the radiator that is provided by the vehicle manufacturer Table 14 Formula For Adding Cat ELC Extender To Cat ELC V x 0 02 X V is the total capacity of the cooling system X is the amount of Cat ELC Extender that is required 6 Clean the cooling system filler cap Inspect the filler cap gaskets Replace the filler cap if the filler cap gaskets are damaged Install the cooling system filler cap SEBU8083 09 177 Maintenance Section Cooling System Coolant Level Check For more information about Cat ELC Extender refer to Special Publication SEBU6385 Caterpillar On highway Diesel Engine Fluid Recommendations 101197583 Cooling System Coolant Level Check SMCS Code 1395 082 Check the coolant level when the engine is stopped and co
55. le 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 If necessary replace the old O ring with a new O ring 5 Lubricate the O ring with clean diesel fuel Place the lubricated O ring into the gland of the bowl 6 Install bowl 2 on a new element Tighten the bowl by hand Do not use tools in order to tighten the bowl 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 Start the engine and check for leaks Run the engine for one minute Stop the engine and check for leaks again Detecting leaks is difficult while the engine is running The primary filter water separator is under suction A leak will allow air to enter the fuel The air in the fuel can cause low power due to aeration of the fuel If air enters the fuel check the components for overtightening or undertightening SEBU8083 09 221 Maintenance Section Fuel System Secondary Filter Replace Primary Fuel Filter and Water Separator which are Provided by an OEM 1 Close
56. llow Sump PM1 Every 17700 km 11000 miles or 4150 L 1100 US gal of fuel or 250 service hours or 6 months Every 80500 km 50000 miles or 1500 service hours C7 Engine with a Deep Sump PM1 Every 24000 km 15000 miles or 5700 L 1500 US gal of fuel or 400 service hours or 6 months Every 80500 km 50000 miles or 1500 service hours C9 Engine Every 24000 km 15000 miles or 7500 L 2000 US gal of fuel or 400 service hours or 6 months Every 80500 km 50000 miles or 1500 service hours 1 Use the interval that occurs first 2 An acceptable biodiesel blend must consist of at least 95 percent ULSD and five percent or less of an acceptable biodiesel 154 SEBU8083 09 Maintenance Section ARD Nozzle Clean Procedure for Cleaning the ARD Nozzle The liquid cleaner that is used to clean the nozzle for the Aftertreatment Regeneration Device ARD is available at your Caterpillar dealer The cleaner is already measured into a dispenser Contact your authorized Caterpillar dealer for the current part number for the filled bottle Turn off the engine Use an allen wrench in order to remove the access plug from the cleaning port Inspect the access plug for damage An undamaged plug may be reused a 7 p v Illustration 35 g01351823
57. may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death 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 228 SEBU8083 09 Maintenance Section Hoses and Clamps Inspect Replace e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extreme temperature changes the hose will heat set Heat setting causes hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Each installation application can be different The differences depend on the foll
58. n nenn 239 PM Level 3 Every 483 000 km 300 000 miles or 190 000 L 50 000 US gal of Fuel or 6000 Service Hours or 3 Years Turbocharger Inspect esssssrssrrrrssessreerrrerrrnssrestrtetrntnnnnnnnasnteereeeerenn 233 Every Year Engine Air Cleaner Element Dual Element Clean Replace 193 Engine Air Cleaner Element Clean Replace s s s 195 Every 3 Years or 322 000 km 200 000 miles Cooling System Coolant DEAC Change s es 168 Every 6 Years or 966 000 km 600 000 miles Cooling System Coolant ELC Change ceceececeeeeeeeetetteeeeeees 172 Every 483 000 km 300 000 miles or 3 Years Cooling System Coolant Extender ELC Add s es 175 SEBU8083 09 153 Maintenance Section ARD Nozzle Clean 103528370 ARD Nozzle Clean SMCS Code 1050 070 The Effect of Fuel Selection on the Interval for Cleaning the Nozzle for the Aftertreatment Regeneration Device ARD Nozzle Using a blend of biodiesel and ultralow sulfur diesel ULSD shortens the intervals between cleanings of the ARD nozzle Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations for information about the types of fuels that may be used in this Caterpillar On highway Engine Use the following table to determine the correct interval for cleaning the ARD nozzle Table 12 Intervals for Cleaning the ARD Nozzle Engine Biodiesel Blend 2 ULSD C7 Engine with a Sha
59. n the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Use a suitable container to catch any fuel that might spill Clean up any spilled fuel immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any dis connected fuel system components Refer to this Operation and Maintenance Manual General Hazard Information before any adjustments or repairs are performed Refer to this Operation and Maintenance Manual High Pressure Fuel Lines before any adjustments or repairs are performed Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training 216 SEBU8083 09 Maintenance Section Fuel System Prime After the engine has stopped you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install The fuel system should be primed under the following conditions e The fuel tank is empty or the f
60. nd the terminals for the cylinder head ground strap with a clean cloth If the connections are corroded clean the connections with a solution of baking soda and water Keep the cylinder head grounding stud and the strap clean and coated with MPGM grease or petroleum jelly SEBU8083 09 189 Maintenance Section Diesel Particulate Filter Clean 103536467 Diesel Particulate Filter Clean SMCS Code 1091 070 Note Caterpillar recommends the use of the Caterpillar ash service tool Caterpillar does not endorse the use of non Caterpillar ash service tools Improper cleaning or repair of the diesel particulate filter DPF can damage the DPF and the engine aftertreatment system Contact your Caterpillar dealer for more information Minimum Maintenance Intervals Refer to table 15 in order to determine the minimum maintenance interval for cleaning ash from the DPF The intervals may vary because of the following operational factors idle time for the engine route and ambient conditions Optimum intervals for cleaning the DPF require the use of the following products e Oil that meets the performance requirements of the Caterpillar ECF 3 specification e Ultralow sulfur diesel fuel ULSD Refer to this Operation and Maintenance Manual Refill Capacities and Recommendations for more information Table 15 Minimum Maintenance Intervals for Cleaning Ash from the DPF Minimum Interval Minimum Engine Rating Commen
61. ng 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 to remove any debris Note If equipped be sure to flush the heater and any related supply and return lines 174 SEBU8083 09 Maintenance Section Cooling System Coolant ELC Change 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 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 NOTIC
62. nt personal injury avoid contact with the skin and the eyes Do not drink cooling system coolant additive Note Test the Supplemental Coolant Additive SCA or test the SCA concentration as part of an S O S Coolant Analysis Test the SCA Concentration Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and the eyes Do not drink cooling system coolant additive Use the 4C 9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA Refer to the Special Publication SEBU6385 Caterpillar On highway Diesel Engine Fluid Recommendations for more information 182 SEBU8083 09 Maintenance Section Cooling System Supplemental Coolant Additive SCA Test Add Add the SCA If Necessary NOTICE Do not exceed the recommended amount of sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s heat transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temper ature components Excessive supplemental coolant additive concentration could also result in radiator tube blockage overheating and or accelerated water pump seal wear Neve
63. o 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 system for the air compressor The pressure relief valve for the air compressor releases air at 1723 kPa 250 psi If the pressure relief valve for the air compressor exhausts all personnel should be at a safe distance away from the air compressor All personnel should also stay clear of the air compressor when the engine is operating and the air compressor is exposed SEBU8083 09 161 Maintenance Section Air Dryer Check 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 100863920 Air Dryer Check SMCS Code 4285 535 Follow the maintenance recommendations that are provided by the OEM or consult your Caterpillar dealer for assistance 102676048 Alternator Inspect SMCS Code 1405 040 Caterpillar recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and proper battery charging Inspect the ammeter if equipped during engine operation in order to ensure proper battery performance and or proper performance of the electrical system Make repairs as required Check the alternator and the battery charger for proper operation If the batteries are properly c
64. ol 4 Illustration 42 g00285520 Cooling system filler cap Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly in order to relieve pressure 2 Maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe If the engine is equipped with a sight glass maintain the coolant level to the proper level in the sight glass 178 SEBU8083 09 Maintenance Section Cooling System Coolant Sample Level 1 Obtain Illustration 43 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 102762476 Cooling System Coolant Sample Level 1 Obtain SMCS Code 1350 008 1395 008 1395 554 7542 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 con
65. ol Catalog or refer to Special Pub lication PECJO003 Caterpillar Shop Supplies and Tools Catalog for tools and supplies suitable to col lect 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 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 226 SEBU8083 09 Maintenance Section Fuel Tank Water and Sediment Drain 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 condensa
66. olant DEAC Change s es 168 Every 6 Years or 966 000 km 600 000 miles Cooling System Coolant ELC Change eeseeeesseeeeeeeeresserees 172 Every 483 000 km 300 000 miles or 3 Years Cooling System Coolant Extender ELC Add s es 175 SEBU8083 09 147 Maintenance Section Maintenance Interval Schedule 102871969 Maintenance Interval Schedule C7 Engines with Deep Sumps SMCS Code 1000 7500 S N C7S1 Up Ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed The user is responsible for the performance of maintenance including all adjustments the use of proper lubricants fluids filters and the installation of new components due to normal wear and aging The performance of this product may be diminished if proper maintenance intervals and procedures are not followed Components may experience accelerated wear if proper maintenance intervals and procedures are not followed Use whichever of the following that occurs first in order to determine the maintenance intervals fuel consumption mileage service hours and calendar time Products that operate in severe operating conditions may require more frequent maintenance Before each consecutive interval is performed all maintenance from the previous intervals must be performed When Required Air Dryer Check nerina iia aiia a a nian 161 Battery Replace a n
67. on of coolant additive conditioner mineral deposits from hard water or cooling system contamination can accelerate the wear on the water pump seal Replace the Water Pump Seal If Necessary Inspect the water pump for leaks 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 Removal and Installation Refer to the Service Manual for more information on the removal and installation of the water pump or consult your Caterpillar dealer for assistance Inspect the Bearing for the Water Pump Pulley Inspect the water pump pulley for unusual noise excessive looseness and or vibration of the bearings Refer to the Service Manual for more information on the removal and installation of the water pump pulley or consult your Caterpillar dealer for assistance
68. on of the data A Cat Advanced Efficiency oil filter is used A Cat Advanced Efficiency 4 micron c absolute or less fuel filter is used Fuel with 0 015 15 ppm or less sulfur is used NOTICE Contact your Caterpillar dealer for more information about extended oil change intervals 210 SEBU8083 09 Maintenance Section Engine Oil and Filter Change Note Caterpillar cannot guarantee the performance of lubricants or filters that are not sold by Caterpillar The performance guarantee of any commercially available lubricant is the responsibility of that oil company The performance guarantee of any commercially available filter is the responsibility of the filter manufacturer Table for Extended Oil Change Intervals In order to understand the tables for maximum permissible oil change intervals use the following procedures 1 Determine your type of vehicle application Locate the column which lists your type of vehicle application 2 Determine your available oil in liters or quarts The oil quantity equals the sum of the capacities of the oil sump and the oil filter Locate the row which lists your available oil 3 The intersection of the column and the row lists the maximum permissible number of kilometers or miles between oil change intervals SEBU8083 09 211 Maintenance Section Engine Oil and Filter Change Table 18 Maximum Permissible Oil Change Intervals Vehicle Applications Engine
69. owing 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 SEBU8083 09 229 Maintenance Section Radiator Clean 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 cap s gaskets Replace the cooling system filler cap if the gaskets are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks 102559063 Radiator Clean SM
70. previous intervals must be performed When Required Air Dryer Check nerenin iia aiia a a a 161 Battery Replace oa n Ga a AS E EE A aa a AAS 162 Battery or Battery Cable Disconnect sessssereerrrerrrrerrrrrrrerrrereree 165 Cooling System Coolant Sample Level 1 Obtain eee 178 Cooling System Coolant Sample Level 2 Obtain cere 180 Diesel Particulate Filter Clean ccceeececeeeeeeeeeteeeeeeeeteeeeeeetneeeeeeeeee 189 Engine CBM unane a e E A EN 192 Engine Air Cleaner Element Dual Element Clean Replace 193 Engine Air Cleaner Element Clean Replace eee 195 Engine Oil Level Gauge Calibrate 0 cccecceeeeeeenteeeeeeeenteeeeeeeaas 200 Engine Storage Procedure Check 0 eeccceeeeeeeeeeeeeeeenteeeeeeeneeeeeeeaaas 212 Fuel System PME serseri antennae ni a 215 Fuel Tank Water and Sediment Drain 0 eeeeeeeeceeeeeeeeteeeeeeeeeee 225 Severe Service Application Check 0 ccceeeeeeeeeeeceeceeeeeeeeeeeeteeneeee 230 SEBU8083 09 145 Maintenance Section Maintenance Interval Schedule Daily Cooling System Coolant Level Check ecceeceeeeeeeeeeeentteeeeeeeneeees 177 Engine Air Cleaner Service Indicator Inspect 0 ce eceeeeteeeeereeeeeeee 195 Engine Oil Level Check 0 eee eeeeeeeeeeeeetneee eee enneeeeeeeaaeeeeeetnieeeeereeae 198 Fuel System Water Separator Check Drain c ccecceeeeeeeeeeeeeeeee 224 Walk
71. prime the fuel system These procedures will allow only filtered fuel to enter the fuel system 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 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 218 SEBU8083 09 Maintenance Section Fuel System Primary Filter Water Separator Element Replace 103342138 Fuel System Primary Filter Water Separator Element Replace SMCS Code 1260 510 FQ 1263 510 FQ Water in the fuel can cause the engine to run rough Water in the fuel may cause an electronic unit injector to fail If the fuel has been contaminated with water the element should be changed before the regularly scheduled interval Note Caterpillar requires the use of a 10 micron c absolute primary fuel filter with a water separator 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
72. r use both liquid supplemental coolant additive and the spin on element if equipped at the same time The use of those additives together could result in supplemental coolant additive concen tration exceeding the recommended maximum 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 Follow the instructions that are provided by the OEM or follow the instructions that are provided by the manufacturer of the coolant conditioner element on engines that are equipped with a coolant conditioner element 1 Slowly loosen the cooling system filler cap in order to relieve the pressure Remove the cooling system filler cap Note Always discard drained fluids according to local regulations 2 If necessary drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA 3 Add the proper amount of SCA Refer to Special Publication SEBU6385 Caterpillar On highway Diesel Truck Engine Fluid Recommendations for more information on SCA requirements SEBU8083 09 183 Maintenance Section Cooling System Water Temperature Regulator Replace 4 Clean the cooling system filler cap Inspect the gaskets of the cooling system filler cap If the gaskets are damaged replace the old cooling syst
73. rapes debris from the seat and from the threads NOTICE Do not use a thread tap A thread tap will remove metal unnecessarily The threads could be stripped and the combustion group could be damaged Inspecting the Spark Plug Inspect the spark plug closely for damage The condition of the spark plug can indicate the operating condition of the engine The terminal post must not move If the terminal post can be moved by hand discard the spark plug Inspect the insulator for cracks If a crack is found discard the spark plug Inspect the shell for damage Cracks can be caused by overtightening the spark plug Overtightening can also loosen the shell Discard any spark plug that has a shell that is cracked or loose Inspect the electrode for excessive wear Installing the Spark Plug Note Do not use anti seize compound on the spark plug Most of the heat is transferred through the threads and the seat area of the spark plug Contact of the metal surfaces must be maintained in order to provide the heat transfer that is required 1 Ensure that the spark plug is clean and free of dirt and oil SEBU8083 09 159 Maintenance Section Aftercooler Core Clean Test NOTICE Do not overtighten the spark plug The shell can be cracked and the gasket can be deformed The met al can deform and the gasket can be damaged The shell can be stretched This will loosen the seal that is between the shell and the insulator allowing com
74. regulations and mandates 206 SEBU8083 09 Maintenance Section Engine Oil and Filter Change 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 Tighten the oil drain plug to the following torque 70 15N m 11 Ib 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 Chain Wrench Illustration 51 g00588944 Element with debris SEBU8083 09 207 Maintenance Section Engine Oil and Filter Change 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 Us
75. rimary air cleaner element that is new or clean 5 Install the air cleaner cover 6 Reset the air cleaner service indicator SEBU8083 09 195 Maintenance Section Engine Air Cleaner Element Clean Replace i00857000 Engine Air Cleaner Element Clean Replace SMCS Code 1054 070 1054 510 NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine 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 e Operating conditions dust dirt and debris may require more frequent service of the air cleaner element e The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty paper air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes Your Caterpillar dealer has the proper air cleaner elements for your application Consult your Caterpillar dealer for the correct air cleaner element or follow the instructions that are provided by the OEM Engine Air Cleaner Service Indicator Inspect If
76. running or the key is in the ON position the ARD plug will continue to fire Turn the key to the OFF position before servicing the ARD plug SEBU8083 09 157 Maintenance Section ARD Spark Plug Inspect Replace Illustration 39 g01308813 1 Wiring harness 2 Spark plug 1 Remove wire harness 1 from spark plug 2 Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing The maximum air pressure for cleaning purposes must be reduced to 205 kPa 30 psi when the air nozzle is deadheaded 2 Debris may have collected in the spark plug well Thoroughly remove any debris Use compressed air The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi Ensure that the area around the spark plug is clean and free of dirt and debris 158 SEBU8083 09 Maintenance Section ARD Spark Plug Inspect Replace 3 Use a deep well socket and a breaker bar to loosen the spark plug If necessary see your Caterpillar dealer for the part number of the socket After the spark plug has been loosened use the socket to remove the spark plug by hand in order to detect problems with the threads After the spark plug has been removed inspect the used spark plug and the gasket If the spark plug could not be removed by hand clean the threads with a 305 2389 brush This tool sc
77. s oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup If it is necessary make repairs or correct fluid levels The guards must be in the proper place Repair damaged guards or replace missing guards Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination Check the cooling system coolant level Ensure that the cooling lines are properly clamped and that the cooling lines are tight Check for leaks Check the condition of all pipes Inspect the water pumps for coolant leaks 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 Check the engine oil level 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 tie wraps around fuel lines 238 SEBU8083 09 Maintenance Section Walk Around Inspection Check the water separator if equipped for water on a daily basis Drain any water from the water separator If necessary drain
78. s to cool Personal injury can result from rotating and mov ing parts Stay clear of all rotating and moving parts Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified The machine must be parked on a level surface and the engine stopped 234 SEBU8083 09 Maintenance Section Turbocharger Inspect A risk of corrosion exists for the compressor side of the turbocharger if ultralow sulfur diesel fuel is not used A risk of corrosion exists for the compressor side of the turbocharger if unfiltered air intake occurs 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 A failed turbocharger can cause damage to the diesel particulate filter NOTICE Turbocharger bearing failures can cause large quan tities of oil to enter the air inlet and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of a turbocharger housing under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not oc curred When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm up at no load do not continue engine operation until the turbocharger is r
79. silicone Silicone has the following characteristics transparent viscous smooth and adhering If the fluid leak is oil inspect the crankshaft seals for leaks If a leak is observed replace the crankshaft seals Inspect the damper and repair or replace the damper for any of the following reasons e The damper is dented cracked or leaking e The paint on the damper is discolored from heat e The engine has had a failure because of a broken crankshaft e Analysis of the oil has revealed that the front main bearing is badly worn e There is a large amount of gear train wear that is not caused by a lack of oil Refer to the Disassembly and Assembly Manual Vibration Damper and Pulley Remove and Install or consult your Caterpillar dealer for information about damper replacement 188 SEBU8083 09 Maintenance Section Cylinder Head Grounding Stud Inspect Clean Tighten 102370278 Cylinder Head Grounding Stud Inspect Clean Tighten SMCS Code 7423 040 7423 070 7423 079 Illustration 45 g01182654 Cylinder head grounding stud Inspect the OEM harness for good connections and condition The cylinder head grounding stud must have a wire ground to the battery Tighten the cylinder head 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 Clean the cylinder head grounding stud a
80. sistent 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 e Complete the information on the label for the sampling bottle before you begin to take the samples SEBU8083 09 179 Maintenance Section Cooling System Coolant Sample Level 1 Obtain Keep the unused sampling bottles stored in plastic bags Obtain coolant samples directly from the coolant sample port You should not obtain the samples from any other location Keep the lids on empty sampling bottles until you are ready to collect the sample e 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 NOTICE Always use a designated pump for oil sampling and use a separate designated pump for coolant sampling Using the same pump for both types of samples may contaminate the samples that are being drawn This contaminate may cause a false analysis and an incor rect interpretation that could lead to concerns by both dealers and customers Submit the sample for Level 1 analysis For additional information about coolant analysis see this Operation and Maintenance Manual Refill Capacities and Recommendations article or consult with your Caterpillar dealer 180 SEBU8083 09 Maint
81. t 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 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing the turbocharger must be reconditioned 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 236 SEBU8083 09 Maintenance Section Walk Around Inspection 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 Inspect the bore of the turbine housing for corrosion 5 Clean the turbocharger housing with standard shop solvents and a soft bristle brush 6 Fasten the air inlet piping and the exhaust outle
82. t piping to the turbocharger housing 102528180 Walk Around Inspection SMCS Code 1000 040 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 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 SEBU8083 09 237 Maintenance Section Walk Around Inspection 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 For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such a
83. t pressure install a new cooling system filler cap 5 Start the engine Inspect the cooling system for leaks and for proper operating temperature 103085827 Cooling System Coolant Extender ELC Add SMCS Code 1352 045 1395 081 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 176 SEBU8083 09 Maintenance Section Cooling System Coolant Extender ELC Add 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 loca
84. the main fuel supply valve 2 In order to replace the primary fuel filter use the instructions which are provided by the OEM 3 Open the main fuel supply valve 4 Start the engine and check for leaks Run the engine for one minute Stop the engine and check for leaks again Detecting leaks is difficult while the engine is running The primary filter water separator is under suction A leak will allow air to enter the fuel The air in the fuel can cause low power due to aeration of the fuel If air enters the fuel check the components for overtightening or undertightening 103365140 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 222 SEBU8083 09 Maintenance Section Fuel System Secondary Filter Replace NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Dealer Service Tool Catalog or refer to Special Pub lication PECJO003 Caterpillar Shop Supplies and Tools C
85. the water and the sediment from fuel tanks in order to ensure that only clean fuel enters the fuel system 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 Check the air cleaner service indicator if equipped 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 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 SEBU8083 09 239 Maintenance Section Water Pump Inspect 100864339 Water Pump Inspect SMCS Code 1361 040 1361 Overconcentrati
86. tion 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 four micron c absolute filter for the breather vent on the fuel tank is also recommended Refer to Special Publication SENR9620 Improving Fuel System Durablity 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 SEBU8083 09 227 Maintenance Section Hoses and Clamps Inspect Replace 102357283 Hoses and Clamps Inspect Replace SMCS Code 7554 040 7554 510 Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray
87. ts Interval Distance Hours 241400 kilometers C7 190 350 150000 miles n Including 241400 kilometers c9 285 425 RV 150000 miles 4500 190 SEBU8083 09 Maintenance Section Diesel Particulate Filter Clean Exceptions to Minimum Maintenance Intervals A number of vehicle applications impose certain restraints on the locations of exhaust system components These applications are primarily classified as medium service and heavy duty service The Environmental Protection Agency has determined that a DPF that has a reduced size may be installed in a vehicle if the DPF is cleaned more frequently The EPA has issued a list of vehicle applications which may be suitable for a DPF with a reduced volume The vehicle applications are listed below Beverage truck Maintenance truck with integral toolbox Trash collection truck with hydraulic packing or picking apparatus Fire truck Airport refueling truck with exhaust directed toward the front of the truck Utility truck with integral toolboxes and outrigger apparatus Snowplow with the plow located under the chassis Dump truck Concrete mixer Car hauler with integral open racks Street sweeper Armored car Day cab truck with no rear seat only a day cab truck for which the entire DPF is located in front of the vertical plane established by the back side of the cab Use the interval which occurs first in order to determ
88. uel tank has been partially drained e The engine has been in storage e The fuel filter has been replaced e The low pressure fuel lines have been disconnected 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 Illustration 54 g01327092 Secondary fuel filter and optional fuel priming pump 1 Fuel priming pump 2 Secondary fuel filter SEBU8083 09 217 Maintenance Section Fuel System Prime 1 Check that the fuel supply valve if equipped is in the ON position 2 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 3 Promptly start the engine If the engine runs rough continue to operate the engine at low idle Do not raise the engine rpm above an idle until the engine operates smoothly 4 If the engine does not start open the fuel priming pump and repeat Steps 2 and 3 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
89. void 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 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 SEBU8083 09 205 Maintenance Section Engine Oil and Filter Change
90. w the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain valve if equipped or remove the cooling system drain plugs Allow the water to drain Flush the cooling system with clean water If equipped be sure to flush the heater and any related supply and return lines Close the drain valve if equipped Clean 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 SEBU8083 09 171 Maintenance Section Cooling System Coolant DEAC Change 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
91. yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be plugged The service indicator may need to be replaced frequently in environments that are severely dusty if necessary Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenever major engine components are replaced Note When a new service indicator is installed excessive force may crack the top of the service indicator Tighten the service indicator to a torque of 2 N m 18 Ib in 198 SEBU8083 09 Maintenance Section Engine Crankcase Breather Clean 102333200 Engine Crankcase Breather Clean SMCS Code 1317 070 M el q e a ae els o oll Jo ud slo oro Q D ic cs og ESN ee 5 Illustration 48 g01164541 1 Remove the cover on breather 1 Remove the breather assembly and the seal 2 Wash the breather element in solvent that is clean and nonflammable Allow the breather element to dry before installation 3 Install a breather element that is clean and dry Install the breather assembly and the seal 4 Install the cover on breather 1 i02526978 Engine Oil Lev

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