SAFETY.CAT.

COM

3306B
INDUSTRIAL ENGINES
Maintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU7205-02-01)

© 2007 Caterpillar
All Rights Reserved

57
Maintenance Section
Maintenance Interval Schedule

i01252429

Maintenance Interval Schedule
SMCS Code: 1000; 7500
Note: Ensure that the Safety Information, Warnings,
and Instructions are read and understood
before operation or maintenance procedures are
performed.
Before each consecutive interval is performed, all
of the maintenance requirements from the previous
interval must also be performed.
Note: Some maintenance items are for optional
equipment.

When Required
Battery - Replace ..................................................
Battery or Battery Cable - Disconnect ..................
Engine Air Cleaner Element (Dual Element) Clean/Replace ....................................................
Ether Starting Aid Cylinder - Replace ...................
Fuel System - Prime .............................................
Severe Service Application - Check ......................

60
61
68
77
78
88

Daily
Air Tank Moisture and Sediment - Drain ...............
Cooling System Coolant Level - Check ................
Driven Equipment - Check ....................................
Engine Air Cleaner Service Indicator - Inspect .....
Engine Oil Level - Check ......................................
Fuel System Water Separator - Drain ...................
Power Take-Off Clutch - Check/Adjust/Lubricate ..
Walk-Around Inspection ........................................

59
64
67
71
73
82
87
90

Fuel System Primary Filter/Water Separator Element
- Replace ............................................................. 80
Fuel System Secondary Filter - Replace .............. 81
Fuel Tank Water and Sediment - Drain ................. 82
Hoses and Clamps - Inspect/Replace .................. 83
Radiator - Clean .................................................... 87

Every 34 000 L (9000 US gal) of Fuel or 1000
Service Hours
Engine Protective Devices - Check ....................... 75
Fuel Control Linkage - Check/Lubricate ............... 77

Every 67 000 L (18 000 US gal) of Fuel or
2000 Service Hours
Crankshaft Vibration Damper - Inspect .................
Engine Mounts - Inspect .......................................
Engine Valve Lash - Inspect/Adjust ......................
Engine Valve Rotators - Inspect ............................
Fuel Injection Nozzles - Test/Exchange ................
Fuel Ratio Control - Inspect/Adjust .......................
Turbocharger - Inspect ..........................................

67
72
76
76
77
78
89

Every 91 000 L (24 000 US gal) of Fuel or
3000 Service Hours
Aftercooler Core - Clean/Test ...............................
Cooling System Coolant (DEAC) - Change ..........
Cooling System Coolant Extender (ELC) - Add ....
Cooling System Water Temperature Regulator Replace ...............................................................
Water Pump - Inspect ...........................................

58
61
64
66
91

PM Level 2 - Every 114 000 L (30 000 US gal)
of Fuel or 4000 Service Hours or 2 Years
Air Compressor - Inspect ...................................... 58

Every 1900 L (500 US gal) of Fuel or 50
Service Hours

Every 136 000 L (36 000 US gal) of Fuel or
4000 Service Hours

Engine Air Precleaner - Check/Clean ................... 72

Alternator - Inspect ............................................... 59
Magnetic Pickups - Clean/Inspect ........................ 84
Starting Motor - Inspect ........................................ 89

Between 250 Service Hours and 1000 Service
Hours (or between first and fourth oil change)
Engine Valve Lash - Inspect/Adjust ...................... 76
Magnetic Pickups - Clean/Inspect ........................ 84

Cooling System Coolant (ELC) - Change ............. 63

Every 8500 L (2200 US gal) of Fuel or 250
Service Hours
Alternator and Fan Belts - Inspect/Adjust/
Replace ...............................................................
Battery Electrolyte Level - Check ..........................
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .................................................
Engine Crankcase Breather - Clean .....................
Engine Oil Sample - Obtain ..................................
Engine Oil and Filter - Change .............................
Fan Drive Bearing - Lubricate ...............................

Every 204 000 L (54 000 US gal) of Fuel or
6000 Service Hours

Overhaul
59
60
65
72
73
74
77

Overhaul Considerations ...................................... 84

58
Maintenance Section
Aftercooler Core - Clean/Test

i00744980

Aftercooler Core - Clean/Test
SMCS Code: 1064-070; 1064-081

Personal injury can result from air pressure.

1. Remove the core. Refer to the Service Manual
for the procedure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

2. Turn the aftercooler core upside-down in order
to remove debris.

Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.

NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
cleaner.

6. Dry the core with compressed air. Direct the air
in the reverse direction of the normal flow.

3. Back flush the core with cleaner.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 33 lists Hydrosolv liquid
cleaners that are available from your Caterpillar
dealer.

7. Inspect the core in order to ensure cleanliness.
Pressure test the core. Many shops that service
radiators are equipped to perform pressure tests.
If necessary, repair the core.
8. Install the core. Refer to the Service Manual for
the procedure.
For more information on cleaning the core, consult
your Caterpillar dealer.

Table 33

i01183385

Hydrosolv Liquid Cleaners(1)
Description

Container

1U-8812 Hydrosolv 4165

4 L (1 US gal)

1U-5490 Hydrosolv 4165

19 L (5 US gal)

8T-7570 Hydrosolv 4165

208 L (55 US gal)

1U-8804 Hydrosolv 100

4 L (1 US gal)

1U-5492 Hydrosolv 100

19 L (5 US gal)

8T-7571 Hydrosolv 100

208 L (55 US gal)

(1)

Use a two to five percent concentration of the cleaner
at temperatures up to 93C (200F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more
information.

Air Compressor - Inspect
SMCS Code: 1803-040

Do not disconnect the air line from the air compressor governor without purging the air brake
and the auxiliary air systems. Failure to purge the
air brake and the auxiliary air systems before removing the air compressor and/or the air lines
could cause personal injury.

4. Steam clean the core in order to remove any
residue. Flush the fins of the aftercooler core.
Remove any other trapped debris.
5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.

Illustration 17
(1) Air compressor pressure relief valve

g00633741

wear protective gloves. possibly ice blockage. a protective face shield. the batteries may not fully charge. your engine may have insufficient air for normal brake operation. the battery will not crank the engine. Check the air supply pressure. . If the battery is too cold. To check the belt tension.Drain If the air compressor pressure relief valve that is mounted in the air compressor cylinder head is bypassing compressed air.Inspect SMCS Code: 1405-040 Caterpillar recommends a scheduled inspection of the alternator. Under these conditions.50 to 0.75 inch). personal injury. Inspect the ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system. Inspect the alternator for loose connections and proper battery charging. The maximum air pressure must not exceed 1550 kPa (225 psi). Close the drain valve. The function of the air compressor pressure relief valve is to bypass air when there is a malfunction in the air compressor system. When the engine is not run for long periods of time or if the engine is run for short periods. Adjust the belt tension in order to minimize belt slippage. the ammeter reading should be very near zero.Drain (If Equipped) 1. Failure to heed this warning could lead to property damage. Belt slippage will decrease the life of the belts. SMCS Code: 1466-543-M&S Moisture and sediment in the air starting system can cause the following conditions: i00841051 • Freezing Alternator and Fan Belts Inspect/Adjust/Replace • Corrosion of internal parts SMCS Code: 1357-039 • Malfunction of the air starting system Inspection When opening the drain valve. The batteries should be kept warm because temperature affects the cranking power. 2. even if the engine is warm. as required. The normal air pressure will be 758 to 965 kPa (110 to 140 psi). Make repairs. i00847451 Air Tank Moisture and Sediment . Do not operate the engine until the reason for the air bypass is identified and corrected. All personnel should also stay clear of the air compressor when the engine is operating and the air compressor is exposed. If the batteries are properly charged. To maximize the engine performance. Check the belt tension. protective clothing. A correctly adjusted belt will deflect 13 to 19 mm (0. Refer to the Service Manual. i00072207 Alternator . All batteries should be kept charged. or death to the operator or bystanders. 3. apply 110 N (25 lb) of force midway between the pulleys. The air compressor pressure relief valve releases air at 1723 kPa (250 psi). A battery with a low charge will freeze more easily than a battery with a full charge. Allow the moisture and sediment to drain. inspect the belts for wear and for cracking. The battery will not crank the engine. Open the drain valve that is on the bottom of the air tank. It is very important that all personnel stand clear of the air compressor pressure relief valve when compressed air is released. Check the alternator and the battery charger for proper operation. The air starting motor requires a minimum of 620 kPa (90 psi) of air pressure to operate properly.59 Maintenance Section Air Tank Moisture and Sediment . Pressurized air could cause debris to be blown and result in personal injury. Refer to the Service Manual or refer to the OEM specifications in order to find information concerning the air compressor. and protective shoes. Consult your Caterpillar dealer for assistance. there is a malfunction in the air system.

Replace SMCS Code: 1401-510 Batteries give off combustible gases which can explode. Do not smoke when batteries are serviced. Clean the battery case with one of the following cleaning solutions: . 2. replace the belts in matched sets. 7. These stresses will shorten the life of the belts and of the pulley bearings. ammeter reading should be very near zero. If batteries are properly charged. If new belts are installed. 3. A spark can cause the combustible gases to ignite. 8. Disconnect the cable from the POSITIVE “+” battery terminal. check the tension again after 30 minutes of engine operation at the rated rpm. If distilled water is not available use clean water that is low in minerals. The NEGATIVE “-” cable connects the NEGATIVE “-” battery terminal to the ground plane. Remove the used battery. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched. Replacement For applications that require multiple drive belts. Disconnect the charger. 2. Maintain the electrolyte level to the “FULL” mark on the battery. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Ensure proper ventilation for batteries that are in an enclosure. Disconnect the cable from the NEGATIVE “-” battery terminal. This can result in severe personal injury or death. Remove the key and all electrical loads. the batteries may not fully recharge. 1. ensure that the key start switch is OFF. Keep the batteries clean. 3. 1. 5. i01206348 Battery Electrolyte Level Check SMCS Code: 1401-081 i01179608 Battery . Never discard a battery. Install the new battery. 6. Ensure a full charge in order to help prevent the battery from freezing. Do not use artificially softened water. unnecessary stresses are placed upon the pulley bearings and upon the belts. Remove the filler caps. Always wear a face shield and protective clothing when working on or near batteries. 4. Refer to the Service Manual for more information on the procedures for the following topics: belt removal and belt installation procedure. Return used batteries to an appropriate recycling facility. The additional load on the new belt could cause the new belt to break. Turn the key start switch to the OFF position. Connect the cable from the ground plane to the NEGATIVE “-” battery terminal. The POSITIVE “+” cable connects the POSITIVE “+” battery terminal to the starting motor. This vibration is enough to cause unnecessary wear on the belts and on the pulleys. Check the condition of the electrolyte with the 1U-7298 Coolant/Battery Tester (C) or the 1U-7297 Coolant/Battery Tester (F). All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Note: Before the cables are connected. Turn OFF the battery charger.Replace Adjustment If the belts are too loose.60 Maintenance Section Battery . If the addition of water is necessary. When the engine is not run for long periods of time or when the engine is run for short periods. If the belts are too tight. Connect the cable from the starting motor to the POSITIVE “+” battery terminal. the belts will vibrate. use distilled water. Note: Always recycle a battery.

3.1 L (0. Stop the engine and allow the engine to cool. . remove one of the drain plugs. Loosen the cooling system filler cap slowly in order to relieve any pressure. Tape the leads in order to help prevent accidental starting. NOTICE Dispose of used engine coolant properly or recycle. the water temperature regulator and the hoses. For information regarding the disposal and the recycling of used coolant. 2. Open the cooling system drain valve (if equipped). i01206425 Cooling System Coolant (DEAC) . Remove the cooling system filler cap. Loosen the cooling system pressure cap slowly in order to relieve the pressure. consult your Caterpillar dealer or consult Caterpillar Service Technology Group: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL Flush 1. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant. If the cooling system is not equipped with a drain valve. 2. • The oil has entered the cooling system and the coolant is contaminated. 4. Use a fine grade of sandpaper to clean the terminals and the cable clamps. 1395-044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist: • The engine overheats frequently. Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. Clean the items until the surfaces are bright or shiny.1 L (0.11 qt) of ammonia and 1 L (1 qt) of clean water Thoroughly rinse the battery case with clean water. • Foaming is observed. To open the cooling system filler cap. Drain i00095575 Battery or Battery Cable Disconnect SMCS Code: 1402-029 1. Allow the coolant to drain. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. DO NOT remove material excessively. the negative side of two batteries must be disconnected. Turn the start switch to the OFF position. • A mixture of 0. Reverse the steps in order to reconnect all of the cables. Excessive removal of material can cause the clamps to not fit properly.Disconnect • A mixture of 0.61 Maintenance Section Battery or Battery Cable . Ensure that the cable cannot contact the terminal. NOTICE Use of commercially available cooling system cleaners may cause damage to cooling system components.11 qt) of baking soda and 1 L (1 qt) of clean water • The fuel has entered the cooling system and the coolant is contaminated. When four 12 volt batteries are involved. Use only cooling system cleaners that are approved for Caterpillar engines. This is a good opportunity to replace the water pump. Coat the clamps and the terminals with 5N-5561 Silicone Lubricant.Change SMCS Code: 1350-070. petroleum jelly or MPGM grease. 1. Proceed with necessary system repairs. Disconnect the negative battery terminal at the battery that goes to the start switch. stop the engine and wait until the cooling system components are cool. Flush the cooling system with clean water in order to remove any debris. Pressurized System: Hot coolant can cause serious burns. if necessary. Turn the ignition switch (if equipped) to the OFF position and remove the key and all electrical loads.

Install the drain plugs. NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. Flush the cooling system with clean water. To avoid damage to the cooling system. Flush the cooling system with clean water in order to remove any debris. Install the cooling system filler cap. Stop the engine and allow the engine to cool. Flush the cooling system with clean water. “Torque Specifications” topic (Maintenance Section) for more information on the proper torques. Start and run the engine at low idle for a minimum of 90 minutes.Change 2. Add 0. Stop the engine and allow the engine to cool. 1. Install the cooling system filler cap. 5. Add 0. Allow the water to drain.8 to 7. NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. Continue to flush the system until all signs of the cleaning agent are gone. Install the drain plugs. there must be some active flow through the cooling system components. 4. Clean the drain plugs. To avoid damage to the cooling system. Start and run the engine at low idle. NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.62 Maintenance Section Cooling System Coolant (DEAC) . Refer to the Operation and Maintenance Manual. 4. 2. Loosen the cooling system filler cap slowly in order to relieve any pressure. Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner.5 L (1 pint) of cleaner per 15 L (4 US gal) of the cooling system capacity. . The coolant temperature should be at least 82 C (180 F). 3. Install the drain plugs. Loosen the cooling system filler cap slowly in order to relieve any pressure. NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. Open the drain valve (if equipped) or remove the cooling system drain plugs. The coolant temperature should be at least 82 C (180 F). Fill the cooling system with coolant/antifreeze. make sure to completely flush the cooling system with clear water. 2. Do not install the cooling system filler cap. Fill NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. Open the drain valve (if equipped) or remove the cooling system drain plugs. Refer to the Operation and Maintenance Manual. Increase the engine rpm to 1500 rpm. Refer to the Operation and Maintenance Manual. “Torque Specifications” topic (Maintenance Section) for more information on the proper torques.6 L (1 to 2 US gal) of the cooling system capacity. 1. Allow the water to drain.5 L (1 pint) of cleaner per 3. Remove the cooling system filler cap. “Cooling System Specifications” topic (Maintenance Section) for more information on cooling system specifications. Close the drain valve (if equipped). Remove the cooling system filler cap. Refer to the Operation and Maintenance Manual. 5. make sure to completely flush the cooling system with clear water. Cooling Systems with Heavy Deposits or Plugging Note: For the following procedure to be effective. Close the drain valve (if equipped). “Torque Specifications” topic (Maintenance Section) for more information on the proper torques. Close the drain valve (if equipped). Clean the drain plugs. Refer to the Operation and Maintenance Manual. “Torque Specifications” topic (Maintenance Section) for more information on the proper torques. Close the drain valve (if equipped). Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Stop the engine. Continue to flush the system until all signs of the cleaning agent are gone. Clean the drain plugs. 3. Install the drain plugs. Start and run the engine at low idle for a minimum of 30 minutes. Clean the drain plugs.

Install the cooling system filler cap. For information regarding the disposal and the recycling of used coolant. If the cooling system is not equipped with a drain valve. If the gasket that is on the cooling system filler cap is not damaged. 2. Inspect the cooling system for leaks and for proper operating temperature.5 inch) below the bottom of the pipe for filling. Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. 5. Flush 1. “Torque Specifications” topic (Maintenance Section) for more information on the proper torques.5 inch) to the proper level on the sight glass (if equipped). • The fuel has entered the cooling system and the coolant is contaminated. 2. only clean water is needed when the ELC is drained and replaced. Inspect the gasket that is on the cooling system filler cap. Drain Pressurized System: Hot coolant can cause serious burns. Open the cooling system drain valve (if equipped). Clean 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.Change SMCS Code: 1350-070. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. if necessary. Loosen the cooling system filler cap slowly in order to relieve any pressure. Note: When the cooling system is cleaned. 1. To open the cooling system filler cap. NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. Refer to the Operation and Maintenance Manual. the water temperature regulator and the hoses. stop the engine and wait until the cooling system components are cool. Remove the cooling system filler cap. A 9S-8140 Pressurizing Pump is used to perform the pressure test. discard the old cooling system filler cap and install a new cooling system filler cap. Maintain the coolant level within 13 mm (0.Change 3. 1395-044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist: • The engine overheats frequently. This is a good opportunity to replace the water pump. Check the coolant level. Install the drain plugs. Fill the cooling system with clean water. 3. perform a pressure test. Clean the drain plugs. Close the drain valve (if equipped). • Foaming is observed. Start the engine. . 4. i01206445 Cooling System Coolant (ELC) . Flush the cooling system with clean water in order to remove any debris. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant. If the gasket that is on the cooling system filler cap is damaged. consult your Caterpillar dealer or consult Caterpillar Service Technology Group: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL coolant is contaminated. Maintain the coolant level within 13 mm (0. Stop the engine and allow the engine to cool.63 Maintenance Section Cooling System Coolant (ELC) . install a new cooling system filler cap. Allow the coolant to drain. If the cooling system filler cap does not retain the correct pressure. remove the cooling system drain plugs. • The oil has entered the cooling system and the NOTICE Dispose of used engine coolant properly or recycle. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

5 inch) to the proper level on the sight glass (if equipped). “Torque Specifications” topic (Maintenance Section) for more information on the proper torques. Add Extender according to the requirements for your engine’s cooling system capacity. i00259474 Cooling System Coolant Extender (ELC) . Replace the cooling system filler cap if the cooling system filler cap gaskets are damaged. Remove the cooling system filler cap. Allow the water to drain. Stop the engine. Refer to the Operation and Maintenance Manual. Check the coolant level. If the cooling system filler cap does not retain the correct pressure. Open the drain valve (if equipped) or remove the cooling system drain plugs. 3. discard the old cooling system filler cap and install a new cooling system filler cap. Start the engine. It may be necessary to drain enough coolant from the cooling system in order to add the Extender. Close the drain valve (if equipped). Fill NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. If the gasket that is on the cooling system filler cap is not damaged. The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap. 1. Refer to the Operation and Maintenance Manual. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve pressure. “Cooling System Specifications” information for the Caterpillar ELC Extender additions. 1395-081 Caterpillar Extended Life Coolant (ELC) does not require the frequent Supplemental Coolant Additive (SCA) additions associated with the present conventional coolants. “Cooling System Specifications” topic (Maintenance Section) for more information on cooling system specifications. install a new cooling system filler cap. Install the cooling system filler cap. 4. Loosen the cooling system filler cap slowly in order to relieve any pressure.Add 4. use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system filler cap. Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block. Refer to the Operation and Maintenance Manual. Remove the cooling system filler cap. Inspect the cooling system filler cap gaskets. Flush the cooling system with clean water. 5. Install the drain plugs. Inspect the gasket that is on the cooling system filler cap. Clean the drain plugs. 3. Refer to the Operation and Maintenance Manual.5 inch) below the bottom of the pipe for filling. 4. Maintain the coolant level within 13 mm (0. Do not install the cooling system filler cap. Start and run the engine at low idle until the temperature reaches 49 to 66 C (120 to 150 F). The Extender only needs to be added once.Add SMCS Code: 1352-045. . Maintain the coolant level within 13 mm (0. Increase the engine rpm to high idle. 5. 2. 1. Check the cooling system only when the engine is stopped and cool. “Refill Capacities” in the Maintenance Section for the capacity of the cooling system for your engine.Check SMCS Code: 1395-082 Check the coolant level when the engine is stopped and cool. i01197583 Cooling System Coolant Level . Inspect the cooling system for leaks and for proper operating temperature. Fill the cooling system with Extended Life Coolant (ELC). If the gasket that is on the cooling system filler cap is damaged. 2. Clean the cooling system filler cap. Clean the cooling system filler cap. Start and run the engine at low idle.64 Maintenance Section Cooling System Coolant Extender (ELC) .

S·O·S Coolant Analysis S·O·S coolant samples can be analyzed at your Caterpillar dealer. “Conventional Coolant/Antifreeze Cooling System Maintenance” topic (Maintenance Section). 4. . 1. Replace the cooling system filler cap if the filler cap gaskets are damaged. Inspect the cooling system for leaks. Illustration 19 g00103639 Typical filler cap gaskets 3. Refer to the Operation and Maintenance Manual. Test for SCA Concentration Coolant/Antifreeze and SCA NOTICE Do not exceed the recommended six percent supplemental coolant additive concentration. avoid contact with the skin and the eyes. To help prevent personal injury. maintain the coolant level to the proper level in the sight glass.65 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) . S·O·S Coolant Analysis is a program that is based on periodic samples. Water and SCA NOTICE Do not exceed the recommended eight percent supplemental coolant additive concentration. Refer to the Operation and Maintenance Manual. Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. “Water/Supplemental Coolant Additive (SCA)” topic (Maintenance Section). Clean the cooling system filler cap and check the condition of the filler cap gaskets. 2. Use the 8T-5296 Coolant Conditioner Test Kit or use the 4C-9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA.Test/Add i00992487 Cooling System Supplemental Coolant Additive (SCA) Test/Add SMCS Code: 1352-045.5 inch) of the bottom of the filler pipe. Refer to the Operation and Maintenance Manual for more information on conventional coolant/antifreeze cooling system maintenance. Reinstall the cooling system filler cap. Cooling system filler cap Note: Test the concentration of the Supplemental Coolant Additive (SCA) or test the SCA concentration as part of an S·O·S Coolant Analysis. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Do not drink cooling system coolant additive. Maintain the coolant level within 13 mm (0. To open the cooling system filler cap. 1395-081 Illustration 18 g00285520 Cooling system coolant additive contains alkali. Remove the cooling system filler cap slowly in order to relieve pressure. stop the engine and wait until the cooling system components are cool. If the engine is equipped with a sight glass. Pressurized System: Hot coolant can cause serious burns.

Excessive supplemental coolant additive concentration could also result in radiator tube blockage. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Never use both liquid supplemental coolant additive and the spin-on element (if equipped) at the same time. Inspect the gaskets of the cooling system filler cap. Excessive overheating could result in cracking of the cylinder head or piston seizure problems. Clean the cooling system filler cap. Pressurized System: Hot coolant can cause serious burns.66 Maintenance Section Cooling System Water Temperature Regulator . and recommendations are made according to the results. Refer to the Operation and Maintenance Manual for more information on SCA requirements. A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine. This is a recommended preventive maintenance practice. Note: Always discard drained fluids according to local regulations. replace the old cooling system filler cap with a new cooling system filler cap. Remove the cooling system filler cap.Replace Level 1 Level 1 is a basic analysis of the coolant. Cooling System Water Temperature Regulator Replace SMCS Code: 1355-510 Replace the water temperature regulator before the water temperature regulator fails. The use of those additives together could result in supplemental coolant additive concentration exceeding the recommended maximum. If the gaskets are damaged. Replacing the water temperature regulator reduces the chances for unscheduled downtime. causing cylinder head damage. drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA. overheating. • pH i00912898 • Conductivity The results are reported. Consult your Caterpillar dealer for information on the benefits of managing your equipment with an S·O·S Coolant Analysis. stop the engine and wait until the cooling system components are cool. A water temperature regulator that fails in the closed position can cause excessive overheating. This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner. Add the SCA. If the water temperature regulator is installed incorrectly. Ensure that the water temperature regulator vent hole is open. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage. 2. reducing the engine’s heat transfer characteristics. The following items are tested: • Glycol Concentration • Concentration of SCA 3. Do not use liquid gasket material on the gasket or cylinder head surface. the engine may overheat. and/or accelerated water pump seal wear. To open the cooling system filler cap. Ensure that the new water temperature regulator is installed in the original position. Slowly loosen the cooling system filler cap in order to relieve the pressure. If Necessary NOTICE Do not exceed the recommended amount of supplemental coolant additive concentration. If necessary. Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders. Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed. . 4. A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation. 1. Add the proper amount of SCA. Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system. Install the cooling system filler cap.

Inspect the damper and repair or replace the damper for any of the following reasons: • The damper is dented. replace the crankshaft seals. Inspect the damper for evidence of fluid leaks. The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine. Driven Equipment . determine the type of fluid. The rubber damper uses a ring which is mounted in rubber in order to reduce vibrations in the crankshaft. Visconic Damper Your engine may be equipped with a visconic damper. viscous. inspect the crankshaft seals for leaks. • Analysis of the oil has revealed that the front main bearing is badly worn. • There is a large amount of gear train wear that is not caused by a lack of oil. Rubber Damper Your engine may be equipped with a rubber damper. or consult your Caterpillar dealer. and difficult to remove from surfaces. Inspect the damper and repair or replace the damper for any of the following reasons: i00174798 • There is deterioration and cracking of the rubber.Inspect SMCS Code: 1205-040 Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations. • There is a large amount of gear train wear that is not caused by lack of oil. • The engine has had a failure because of a broken crankshaft. If the fluid leak is oil. Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement. or leaking.67 Maintenance Section Crankshaft Vibration Damper . A deteriorating damper can cause excessive gear train noise at variable points in the speed range.Check • There is slippage of the outer ring from the SMCS Code: 3279-535 • The engine has had a failure because of a broken Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment: • Analysis of the oil has revealed that the front main • Inspection original position. If a fluid leak is found. The visconic damper has a weight that is located inside a fluid filled case. smooth. Silicone has the following characteristics: transparent. • Adjustment • Lubrication • Other maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM. cracked. i00894991 Crankshaft Vibration Damper . If a leak is observed. drain the coolant from the cooling system to a level that is below the water temperature regulator housing. • The paint on the damper is discolored from heat. The weight moves in the case in order to limit torsional vibration. The fluid in the damper is silicone.Inspect Refer to the Service Manual for the replacement procedure of the water temperature regulator. . crankshaft. Note: If only the water temperature regulators are replaced. Refer to the Service Manual or consult your Caterpillar dealer for information about damper replacement. bearing is badly worn. This can result in damage to the crankshaft and to other engine components.

Inspect the gasket or the seal of the air cleaner element for damage. Before installation. Servicing the Air Cleaner Elements If the air cleaner element becomes plugged. (4) Turbocharger air inlet. (3) Secondary air cleaner element. Never run the engine with a damaged air cleaner element. the air can split the material of the air cleaner element. • Check the precleaner (if equipped) daily for accumulation of dirt and debris. The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected. The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element. Consult your Caterpillar dealer for the correct air cleaner element. This replacement should be performed regardless of the number of cleanings. gaskets or seals. Remove the primary air cleaner element. This replacement should be performed regardless of the number of cleanings. Your Caterpillar dealer has the proper air cleaner elements for your application. Replace the dirty paper air cleaner elements with clean air cleaner elements. Dirt entering the engine causes premature wear and damage to engine components. 1054-510 Perform the Operation and Maintenance Manual. 3. Unfiltered air will drastically accelerate internal engine wear.Clean/Replace i01089660 Engine Air Cleaner Element (Dual Element) .Clean/Replace SMCS Code: 1054-037. Illustration 20 g00123209 (1) Cover.68 Maintenance Section Engine Air Cleaner Element (Dual Element) . Note: Refer to “Cleaning the Primary Air Filter Elements”. 1. (2) Primary air cleaner element. dirt and debris) may require more frequent service of the air cleaner element. Air cleaner elements help to prevent airborne debris from entering the air inlet. “Engine Air Cleaner Service Indicator-Inspect” procedure and perform the Operation and Maintenance Manual. The primary air cleaner element should be replaced at least one time per year. air cleaner elements may require more frequent replacement. When the engine is operating in environments that are dusty or dirty. “Engine Air Precleaner Check/Clean” procedure (if equipped) before performing the following procedure. • The air cleaner element may be cleaned up to six times if the element is properly cleaned and inspected. NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine. 2. The secondary air cleaner element is not serviceable or washable. the air cleaner elements should be thoroughly checked for tears and/or holes in the filter material. • Operating conditions (dust. 4. Maintain a supply of suitable air cleaner elements for replacement purposes. Do not use air cleaner elements with damaged pleats. The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element. Air Cleaners With Dual Elements An air cleaner with a dual element contains a primary air cleaner element and a secondary air cleaner element. . Cover the turbocharger air inlet with tape in order to keep dirt out. as needed. • The air cleaner element should be replaced at least one time per year. NOTICE Never run the engine without an air cleaner element installed. dry cloth. Remove any dirt and debris. Remove the cover. Clean the inside of the air cleaner cover and body with a clean.

dry air with a maximum pressure of 207 kPa (30 psi). Aim the hose so that the water flows inside the element along the length of the filter in order to help prevent damage to the paper pleats. Note: Refer to “Drying the Primary Air Cleaner Elements”. Pressurized air will not remove deposits of carbon and oil. Do not use elements with damaged pleats. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi). Install the secondary air cleaner element. always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). Note: Refer to “Inspecting the Primary Air Cleaner Elements”. Reset the service indicator. Pressurized Water Pressurized water will clean the primary air cleaner element unless carbon and oil have accumulated on the surface of the primary air cleaner element. Cleaning the Primary Air Cleaner Elements The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected. Install a primary air cleaner element that is new or cleaned. Use filtered. Discard any damaged air cleaner elements. Inspect the air cleaner elements for damage to the seal. Damaged elements will allow dirt to pass through. Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry. Install the air cleaner cover. Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times. Engine damage could result. gaskets or seals. The primary air cleaner element should be replaced at least one time per year. 7. Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats. Remove the tape for the turbocharger air inlet. Refer to “Inspecting the Primary Air Cleaner Elements”. Cleaning with pressurized air is recommended prior to vacuum cleaning. Dirt could be forced further into the pleats. the gaskets. Do not use a spray nozzle. Use clean primary air cleaner elements while dirty elements are being cleaned. Dirt could be forced further into the pleats.Clean/Replace 5. and the outer cover. 6. NOTICE Do not clean the air cleaner elements by bumping or tapping. check for rips or tears in the filter material.69 Maintenance Section Engine Air Cleaner Element (Dual Element) . Do not aim the stream of air directly at the primary air cleaner element. This replacement should be performed regardless of the number of cleanings. dusty environment. This could damage the seals. Vacuum cleaning will not remove deposits of carbon and oil. When the primary air cleaner element is cleaned. There are four common methods that are used to clean primary air cleaner elements: • Pressurized water • Pressurized air • Vacuum cleaning • Washing with nonsudsing detergent Illustration 21 g00281692 Note: When the primary air cleaner elements are cleaned. . Note: When the primary air cleaner element is cleaned. Do not aim the stream of water directly at the primary air cleaner element. Visually inspect the primary air cleaner elements before cleaning. always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside).

Doing so can cause fire or an engine runaway and can result in personal injury. Inspecting the Primary Air Cleaner Elements Do not wash air cleaner elements in any flammable solution such as diesel fuel or gasoline. 1. gaskets or seals. Drain the wash tank. Note: Caterpillar does not recommend a process for washing the primary air cleaner element which includes vigorously shaking. Illustration 22 g00281693 Inspect the clean. Inspect the primary air cleaner element for tears and/or holes. Place the primary air cleaner element into a wash tank so that the gasket is up.Clean/Replace Note: Refer to “Inspecting the Primary Air Cleaner Elements”. Do not use an primary air cleaner element with damaged pleats. Use a cleaning agent that is specifically manufactured for cleaning primary air cleaner elements. Drying the Primary Air Cleaner Elements The oven method may be used in order to dry primary air cleaner elements. or a vacuum is recommended prior to washing with nonsudsing detergent. Place the blue light in the primary air cleaner element. Do not use the cleaning agent more than one time. Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will not be used. Discard damaged primary air cleaner elements. Allow the primary air cleaner element to soak for six hours. Washing the Primary Air Cleaner Elements with Nonsudsing Detergent Primary air cleaner elements may be allowed to air dry. Follow the manufacturers recommendations for the cleaning agent. Rinse the primary air cleaner element with the method for using pressurized water. compare the primary air cleaner element to a new primary air cleaner element that has the same part number. carbon particles may be distributed. do not expose the primary air cleaner elements to temperatures that exceed 82C (160F).70 Maintenance Section Engine Air Cleaner Element (Dual Element) . By vigorously shaking the element. Allow two days for the primary air cleaner elements to air dry before the elements are inspected and installed. Note: Refer to “Drying the Primary Air Cleaner Elements”. pressurized air. Fill the wash tank with the cleaning agent and warm water to a maximum temperature of 60C (140F). Rotate the primary air cleaner element. If an oven is used. Cleaning with pressurized water. Do not use a primary air cleaner element that has any tears and/or holes in the filter material. Washing with nonsudsing detergent is effective for cleaning primary air cleaner elements that have deposits of carbon or oil. dry primary air cleaner element. Refer to “Inspecting the Primary Air Cleaner Elements”. Remove the primary air cleaner element from the wash tank. . If it is necessary in order to confirm the result. 3. Note: Do not use compressed air in order to dry the primary air cleaner elements. the primary air cleaner element can be stored for future use. 2. Inspect the primary air cleaner element for light that may show through the filter material. The wash tank should be equipped with a rack so that the primary air cleaner element does not sit on the bottom of the wash tank. Use a 60 watt blue light in a dark room or in a similar facility.

follow the OEM recommendations in order to service the air cleaner service indicator. Service indicators are important instruments. or plastic as a protective covering for storage. . the service indicator should be replaced. excessive force may crack the top of the service indicator. • Check for ease of resetting. mark the outside of the box and mark the primary air cleaner element. SEBF8062. a waterproof cover. and whenever major engine components are replaced. Place the primary air cleaner element into a box for storage. should reset in less than three pushes. or if the yellow core does not latch at the greatest vacuum. The yellow core should latch approximately at the greatest vacuum that is attained. As the air cleaner element becomes dirty.Inspect The service indicator may be mounted on the air cleaner element or in a remote location. The service indicator may need to be replaced frequently in environments that are severely dusty. if necessary. the hole for the service indicator may be plugged. refer to Special Publication. If the new service indicator will not reset.71 Maintenance Section Engine Air Cleaner Service Indicator . Note: When a new service indicator is installed. Include the following information: Illustration 24 g00103777 Typical service indicator Observe the service indicator. For more detailed information on cleaning the primary air cleaner element. • Check the movement of the yellow core when the engine is accelerated to the engine rated speed. If your engine is equipped with a different type of service indicator. Illustration 23 g00281694 Do not use paint. If the service indicator does not reset easily. Some engines are equipped with a differential gauge for inlet air pressure. The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur: • The yellow diaphragm enters the red zone. the pressure differential rises.Inspect SMCS Code: 7452-040 Some engines may be equipped with a different service indicator. “Procedure to Inspect and Clean Air Filters”. Restricted air flow may result. • Date of the cleaning • Number of cleanings Test the Service Indicator Store the box in a dry location. The service indicator i01175055 Engine Air Cleaner Service Indicator . wrap the primary air cleaner elements in Volalite Corrosion Inhibited (VCI) paper. To protect against dirt and damage. Replace the service indicator annually regardless of the operating conditions. 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. Tighten the service indicator to a torque of 2 N·m (18 lb in). For identification. • The red piston locks in the visible position. Replace the service indicator when the engine is overhauled.

A plugged crankcase breather will cause excessive crankcase pressure that may cause crankshaft seal leakage. Allow the breather element to dry before installation.Inspect SMCS Code: 1152-040 Inspect the engine mounts for deterioration and for proper bolt torque. Install hose clamp (2). If the crankcase breather is not maintained on a regular basis. Install bolt (1) and tighten. 1055-535 Illustration 26 (1) (2) (3) (4) Illustration 25 g00287039 g00495506 Bolt Hose clamp Breather assembly Seal 1. Do not overtighten the bolt. (1) Wing nut (2) Cover (3) Body Remove wing nut (1) and cover (2). Refer to the Operation and Maintenance Manual. if necessary. 3. more frequent cleaning is required. i00972776 Engine Crankcase Breather Clean SMCS Code: 1317-070 NOTICE Perform this maintenance with the engine stopped. 4. Wash the breather element in solvent that is clean and nonflammable. Clean the body.72 Maintenance Section Engine Air Precleaner . Install a breather element that is clean and dry. Engine vibration can be caused by the following conditions: • Improper mounting of the engine • Deterioration of the engine mounts Any engine mount that shows deterioration should be replaced. the crankcase breather will become plugged. i00687861 Engine Mounts . 5. Refer to the Service Manual for the recommended torques. Refer to Specifications for the proper torque. Loosen hose clamp (2) and remove the hose from breather assembly (3). Check for an accumulation of dirt and debris in body (3). Refer to your Caterpillar dealer for more information. . Install the hose. Install seal (4) and breather assembly (3). After cleaning the precleaner. Remove breather assembly (3) and seal (4). Typical engine precleaner 2. Remove bolt (1). install cover (2) and wing nut (1). “Torque Specifications” topic (Maintenance Section) for the proper torque.Check/Clean i00720883 Engine Air Precleaner Check/Clean SMCS Code: 1055-070. Note: When the engine is operated in dusty applications.

NOTICE Operating your engine when the oil level is above the “FULL” mark could cause your crankshaft to dip into the oil. Do not fill the crankcase above “FULL” mark (X). 1348-554-SM. To avoid contamination of the oil samples. 7542-554-OC.73 Maintenance Section Engine Oil Level . Caterpillar recommends using the sampling valve in order to obtain oil samples. Clean the oil filler cap. the tools and the supplies that are used for obtaining oil samples must be clean. Reinstall the oil filler cap. well mixed oil sample. provide the following information: Illustration 27 g00501786 • Engine model (1) Oil filler cap (2) Oil level gauge • Service hours on the engine • The number of hours that have accumulated since the last oil change • The amount of oil that has been added since the last oil change (Y) “ADD” mark (X) “FULL” mark To ensure that the sample is representative of the oil in the crankcase. obtain a warm. . Do not allow hot oil or hot components to contact the skin. if necessary. Do not allow hot oil or hot components to contact the skin. The quality and the consistency of the samples are better when the sampling valve is used. NOTICE Perform this maintenance with the engine stopped. The 8T-9190 Fluid Sampling Bottle Group is recommended for use with the sampling valve. In addition to a good preventive maintenance program. PEEP5031 for identification of the sample.Check Engine Oil Sample . Before you take the oil sample. SM Hot oil and hot components can cause personal injury. In order to help obtain the most accurate analysis. 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. 2. Remove oil filler cap (1) and add oil. Instructions are also provided. The bottle group includes the parts that are needed for obtaining oil samples. complete the Label. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation. The air bubbles created from the crankshaft dipping into the oil reduces the oil’s lubricating characteristics and could result in the loss of power. Obtain the Sample and the Analysis Hot oil and hot components can cause personal injury. Illustration 28 g00110310 1.Obtain SMCS Code: 1348-535-FLV SMCS Code: 1000-008. Maintain the oil level between “ADD” mark (Y) and “FULL” mark (X) on oil level gauge (2).Check i00985714 i01070756 Engine Oil Level .

1348-044 Hot oil and hot components can cause personal injury..Change • If the engine is equipped with a drain valve. and cylinder heads. turn NOTICE Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant samples. Cut the oil filter open with a 4C-5084 Oil Filter Cutter. The pump is designed to accept sampling bottles. As the oil cools. “How To Take A Good Oil Sample”. Remove the oil filter with a 1U-8760 Chain Wrench. An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure. After the oil has drained. Nonferrous metals may indicate wear on the aluminum parts. Replace the Oil Filter If the engine is not equipped with a sampling valve. turbocharger bearings. it is not uncommon to find small amounts of debris in the oil filter. PEHP6001. Use one of the following methods to drain the engine crankcase oil: 2. • If the engine is not equipped with a drain valve. etc. 1. A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken. see Special Publication. suspended waste particles settle on the bottom of the oil pan. the oil drain plugs should be cleaned and installed. Ferrous metals may indicate wear on the steel and cast iron parts of the engine. Drain the Engine Oil After the engine has been run at the normal operating temperature. the drain valve knob counterclockwise in order to drain the oil. i00652130 Engine Oil and Filter . Do not allow hot oil or hot components to contact the skin. This draining method allows the waste particles that are suspended in the oil to be drained properly. Drain the crankcase with the engine stopped. rod bearings. Always use a designated pump for oil sampling and a designated pump for coolant sampling. turn the drain valve knob clockwise in order to close the drain valve. Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil. After the oil has drained. as a result of the larger waste particles from unfiltered oil entering the engine lubricating system.Change SMCS Code: 1318-510. brass parts or bronze parts of the engine. Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element. If the engine is equipped with a shallow sump. For instructions. remove the bottom oil drain plugs from both ends of the oil pan. Failure to do so may cause a false analysis which could lead to customer and dealer concerns. Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter. Do not drain the oil when the engine is cold. Parts that may be affected include the following items: main bearings. The waste particles are not removed with the draining cold oil. NOTICE Caterpillar oil filters are built to Caterpillar specifications. use the 1U-5718 Vacuum Pump.74 Maintenance Section Engine Oil and Filter . remove the oil drain plug in order to allow the oil to drain. Break apart the pleats and inspect the oil filter for metal debris. . Disposable tubing must be attached to the pump for insertion into the sump. Consult your Caterpillar dealer for complete information and assistance in establishing an S·O·S program for your engine. Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings. Drain the crankcase with the oil warm. Due to normal wear and friction. Only use oil filters recommended by Caterpillar. stop the engine. crankshaft.

Refer to the Operation and Maintenance Manual for more information on refill capacities. abnormal operating conditions must be simulated. Shutoffs help to prevent damage to the engine. Visual Inspection Visually check the condition of all gauges. Tighten the oil filter by hand according to the instructions that are shown on the oil filter. Ensure that all of the old oil filter gasket is removed. NOTICE During testing. The tests must be performed correctly in order to prevent possible damage to the engine. follow the OEM or filter manufacturer’s recommendations. 4. NOTICE To prevent crankshaft bearing damage. Install the oil filter. Fill the Engine Crankcase 1. Malfunctions must be simulated in order to test the engine protective devices. To prevent damage to the engine. 3. Do not overtighten the oil filter.75 Maintenance Section Engine Protective Devices . Ensure that the engine protective devices are functioning properly. Tighten the oil filter until the oil filter gasket contacts the base. Apply clean engine oil to the new oil filter gasket. Remove the oil filler cap.Check 2. crank the engine with the fuel OFF. Under filling or overfilling the crankcase with oil can cause engine damage. NOTICE If equipped with an auxiliary oil filter system or a remote oil filter system. NOTICE Do not fill the oil filters with oil before installing them. i00626013 Illustration 29 g00103713 Typical filter mounting base and filter gasket 3. Look for wiring and components that are loose. . Damaged wiring or components should be repaired or replaced immediately. Contaminated oil can cause accelerated wear to engine components. It is impossible to determine if the engine protective devices are in good working order during normal operation. This will fill the oil filters before starting the engine. Maintain the oil level between the “ADD” and “FULL” marks on the oil level gauge. This oil would not be filtered and could be contaminated. Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled. Fill the crankcase with the proper amount of oil. Alarms provide timely warning to the operator. Do not crank the engine for more than 30 seconds. broken. Refer to the Operation and Maintenance Manual for more information on lubricant specifications. Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes. Clean the sealing surface of the filter mounting base. 5. Inspect the oil filter for oil leaks. 4. Engine Protective Devices Check SMCS Code: 7400-535 Alarms and shutoffs must function properly. Remove the oil level gauge in order to check the oil level. sensors and wiring. Start the engine and run the engine at “LOW IDLE” for two minutes. A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints. only authorized service personnel or your Caterpillar dealer should perform the tests. or damaged.

Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjustment procedure. If a damaged rotator is not replaced. “Engine Starting” procedure (Operation Section). When inspecting the valve rotators. To obtain an accurate measurement. allow the valves to cool before this maintenance is performed. but before the valve covers are installed: 1. Ensure that the engine is stopped before measuring the valve lash. 2. This can cause piston and cylinder head damage. Refer to the Service Manual for more information. do not use the starting motor to turn the flywheel. NOTICE A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life. This helps to prevent deposits from building up on the valves and the valve seats. . Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency. Allow additional time for the engine to cool before measuring/adjusting valve lash clearance. If a valve fails to rotate. protective glasses or face shield and protective clothing must be worn. To help prevent possible injury. rebuilt engines. consult your Caterpillar dealer. The valve rotators should turn slightly when the valves close. This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life. Ensure that the engine can not be started while this maintenance is being performed. The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components.Inspect SMCS Code: 1109-040 SMCS Code: 1102-025 The initial valve lash adjustment on new engines.Inspect/Adjust i00869628 Engine Valve Lash Inspect/Adjust i00937014 Engine Valve Rotators . Valve rotators cause the valves to rotate when the engine runs. to help prevent being burned by hot oil or spray. Hot engine components can cause burns. Observe the top surface of each valve rotator. Start the engine according to this Operation and Maintenance Manual. valve face guttering could result and cause pieces of the valve to fall into the cylinder. Perform the following steps after the valve lash is set.76 Maintenance Section Engine Valve Lash . NOTICE Only qualified service personnel should perform this maintenance. Operate the engine at low idle. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life. or remanufactured engines is recommended at the first scheduled oil change.

an inspection of the internal components should be performed. 1257-535 Check the fuel control linkage for proper operation. Hand tighten the ether cylinder. If the shaft is loose. Refer to the Service Manual for the adjustment procedures. Illustration 31 Typical Fan Drive Bearing Grease Fitting g00123252 NOTICE Do not allow dirt to enter the fuel system. 3. . 2. Lubricate the grease fittings with 1P-0808 Multipurpose Grease or the equivalent. Inspect the fan drive pulley assembly. SMCS Code: 1359-086-BD i00626014 Fuel Injection Nozzles Test/Exchange SMCS Code: 1254-013. Illustration 32 g00309003 Typical grease fittings on the fuel control linkage i00175571 Fan Drive Bearing .Replace i00805059 Ether Starting Aid Cylinder Replace (If Equipped) SMCS Code: 1456-510-CD Lubricate the fan drive bearing grease fitting with Bearing Lubricant Special Purpose Grease or the equivalent. Install the new gasket that is provided with each new ether cylinder. Tighten the ether cylinder clamp securely. 1254-081 Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. adjust the fuel control linkage . Thoroughly clean the area around a fuel system component that will be disconnected.Lubricate Some fuel control linkages require lubrication. Illustration 30 g00104888 Typical example 1. If necessary. i00705823 Fuel Control Linkage Check/Lubricate SMCS Code: 1257-086. Install the new ether cylinder. Remove the used gasket. Refer to the Service Manual. Unscrew and remove the empty ether cylinder. Fit a suitable cover over disconnected fuel system component. Loosen the ether cylinder clamp.77 Maintenance Section Ether Starting Aid Cylinder .

To help prevent possible injury. A new fuel injection nozzle should be installed in the cylinder in order to determine if the removed fuel injection nozzle is defective. special tooling is required. 1. . if necessary. Refer to the Service Manual or your Caterpillar dealer for the complete adjustment procedure on the fuel ratio control. and replaced.Prime SMCS Code: 1258-548 Prime the fuel system in order to fill dry fuel filters and purge air from the fuel system. Refer to Special Instruction. i00976042 Fuel System . A defective fuel injection nozzle may be identified when a fuel line nut is loosened and the following conditions are present: • The exhaust smoke is partially eliminated or the exhaust smoke is completely eliminated. Tip wear can cause the following problems: • Increased fuel consumption • Black smoke • Misfire • Rough running Fuel Injection nozzles should be cleaned. tested. NOTICE Never wire brush or scrape a fuel injection nozzle. Proper tools for cleaning and testing the fuel injection nozzles can be obtained from Caterpillar dealers. 2. Tip wear is a result of fuel contamination. turn the start switch off when changing fuel filters or water separator elements. SEHS7292 for using the 8S-2245 Injection Cleaning Tool Group. Start the engine. i00908934 Fuel Ratio Control Inspect/Adjust SMCS Code: 1278-025. • Engine performance is not affected. The following items are symptoms of a malfunction of the fuel injection nozzle: • Abnormal engine operation • Smoke emission • Engine knock Each fuel injection nozzle must be isolated one at a time in order to determine the malfunctioning fuel injection nozzle. Removal and Installation of the Fuel Injection Nozzles For the removal and the installation of fuel injection nozzles. Refer to the Service Manual for more information. 3.Inspect/Adjust Fuel injection nozzles are subject to tip wear. Prime the fuel system after the following occurrences: • Running the fuel system dry • Removal of the engine from storage • Maintenance of the fuel filter • Disconnecting fuel lines and installing fuel lines • Repair of leaks in the fuel lines Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. inspected. 1278-040 Slow engine response and low power may indicate a need for adjustment or repair of the fuel ratio control. Consult your Caterpillar dealer about cleaning the fuel injection nozzle and testing the fuel injection nozzle. Wire brushing or scraping a fuel injection nozzle will damage the finely machine orifice. Consult your Caterpillar dealer for assistance. Clean up fuel spills immediately. Loosen each fuel line nut one at a time at the fuel injection pump.78 Maintenance Section Fuel Ratio Control . A cloth or similar material must be used in order to prevent fuel from spraying on the hot exhaust components. A fuel injection nozzle that is suspected of being defective should be removed. Tighten each nut before loosening the next nut.

Illustration 34 Illustration 33 (1) Vent plug (2) Fuel injection pump housing g00502366 g00496813 . The engine may run rough. • The engine starts but the engine continues to smoke. Allow the starting motor to cool for two minutes before cranking the engine again. 2. Push in and hand tighten the priming pump plunger. 8. The engine may run rough. 5.79 Maintenance Section Fuel System . Start the engine. proceed to Step 4. • The engine starts but the engine continues to smoke. Unlock and operate the priming pump plunger until a resistance is felt. Clean up any spilled fuel immediately. • The engine starts but the engine continues to misfire. Run the engine at low idle until the engine runs smoothly. 1. If the following conditions exist. Fit a suitable cover over disconnected fuel system component.Prime NOTICE Do not allow dirt to enter the fuel system. 7. 3. Start the engine. 4. repeat Steps 1 through 3: • The engine will not start. Loosen vent plug (1) on fuel injection pump housing (2). NOTICE Do not crank the engine continuously for more than 30 seconds. If operating problems persist after repeating Steps 1 through 3. Unlock and operate the priming pump plunger until the flow of fuel from the vent valve is continuous and free of air bubbles. • The engine will not start. Tighten the vent plug. 6. Proceed to Step 9 if the following conditions exist: misfire. Thoroughly clean the area around a fuel system component that will be disconnected. This may require a considerable number of strokes. Clean up any spilled fuel immediately. Push in and hand tighten the priming pump plunger. Run the engine at low idle until the engine runs smoothly. • The engine starts but the engine continues to NOTICE Use a suitable container to catch any fuel that might spill. Allow the starting motor to cool for two minutes before cranking the engine again. NOTICE Do not crank the engine continuously for more than 30 seconds.

Illustration 35 (1) (2) (3) (4) (5) g00467033 Vent valve Base Can Element Drain plug 1.Replace SMCS Code: 1260-510-FQ. Replace the Element Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Install the drain plug. Clean up any spilled fuel immediately. 4. Allow the starting motor to cool for two minutes before cranking the engine again. 14. To help prevent possible injury. Tighten the fuel injection line nut. the element should be changed before the regularly scheduled interval. 12. Close the main fuel supply valve. 6. The element should be changed regularly. 2. The engine will be damaged if a defective fuel injection nozzle is used because the shape of fuel (spray pattern) that comes out of the nozzles will not be correct.Replace NOTICE Do not let the tops of fuel nozzles turn when the fuel line nuts are loosened or tightened. Clean up fuel spills immediately. Perform Steps 9 through 11 on each fuel injection line. turn the start switch off when changing fuel filters or water separator elements. Water in the fuel may cause fuel system components to fail. Remove drain plug (5). NOTICE Use a suitable container to catch any fuel that might spill. Unlock and operate the priming pump plunger until the flow of fuel from the fuel injection line is continuous and free of air bubbles. Refer to Specifications for the proper torque. 11. Start the engine. 10.80 Maintenance Section Fuel System Primary Filter/Water Separator Element . Clean up any spilled fuel immediately. NOTICE Do not crank the engine continuously for more than 30 seconds. Remove element (4) from the can. Dispose of the used element. Push in and hand tighten the priming pump plunger. Clean the following components: • Can • Gasket • Base . Depress vent valve (1) in order to start the flow of fuel. Remove the gasket. 3. Loosen one fuel injection line nut at the fuel injection nozzle. i00914347 Fuel System Primary Filter/Water Separator Element . 5. If the fuel has been contaminated with water. 13. The primary filter/water separator should be changed when the vacuum gauge (if equipped) registers 50 to 70 kPa (15 to 20 In Hg). The primary filter/water separator also provides filtration in order to help extend the life of the secondary fuel filter. 9. Remove can (3) from base (2). Dispose of the fuel properly. Allow the fuel to drain into a suitable container. 1263-510-FQ Water in the fuel can cause the engine to run rough. The nozzles will be damaged if the top of the nozzle turns in the body.

The air in the fuel can cause low power due to aeration of the fuel. Spin the fuel filter onto the fuel filter base until the gasket contacts the base. Lubricate the gasket with clean diesel fuel. Replace the gasket. A leak will allow air to enter the fuel. if necessary. Illustration 36 g00502378 (1) Fuel filter NOTICE Do not allow dirt to enter the fuel system. 4. Tighten the can by hand. Contaminated fuel will cause accelerated wear to fuel system parts. i00986685 Fuel System Secondary Filter Replace SMCS Code: 1261-510-SE Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Use the rotation index marks on the filters as a guide for proper tightening. The fuel would not be filtered and could be contaminated. Ensure that the vent plug is tightened securely to help prevent air from entering the fuel system. Ensure that all of the old gasket is removed. The fuel would not be filtered and could be contaminated. 3. 2. NOTICE The primary filter/water separator may be prefilled with fuel to avoid rough running/stalling of the engine due to air. NOTICE Do not loosen fuel lines or fittings at the fuel manifold or ECM. .Replace Inspect the gasket for damage and for deterioration. 10. If air enters the fuel. Clean the gasket sealing surface of the fuel filter base.81 Maintenance Section Fuel System Secondary Filter . Install the gasket. NOTICE Use a suitable container to catch any fuel that might spill. Fit a suitable cover over any disconnected fuel system components. ensure that all components are properly tightened. Install the new fuel filter. Install a new element in the can. To help prevent possible injury. Do not overtighten the filter. Do not fill the secondary filter with fuel before installation. 8. The can may be filled with fuel at this time. Start the engine and check for leaks. Stop the engine and check for leaks again. Contaminated fuel will cause accelerated wear to fuel system parts. Do not use tools in order to tighten the can. turn the start switch off when changing fuel filters or water separator elements. Open the main fuel supply valve. Thoroughly clean the area around a fuel system component that will be disconnected. The primary filter/water separator is under suction. Remove the used fuel filter. NOTICE The water separator is under suction during normal engine operation. Clean up any spilled fuel immediately. 9. Clean up fuel spills immediately. Run the engine for one minute. 1. Install the can on the base. 7. Apply clean diesel fuel to the new fuel filter gasket. Tighten the filter for an additional 3/4 turn by hand. NOTICE Do not fill the secondary fuel filter with fuel before installing. Leaks are difficult to detect while the engine is running. 11. The engine components may be damaged.

Condensation occurs during the heating and cooling of fuel. 2. Allow the water to flow until fuel flows from the drain. • Weekly • Oil change • Refill of the tank . Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. Close the drain valve. Drain the water separator more frequently when a large concentration of water is present in the fuel system. Clean up any spilled fuel immediately.Drain i00909035 i00073301 Fuel System Water Separator . Drain the water separator daily. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel. NOTICE Use a suitable container to catch any fuel that might spill. Illustration 37 (1) (2) (3) (4) (5) g00467033 Vent valve Base Can Element Drain plug Water in the fuel can cause fuel system components to fail.Drain SMCS Code: 1263-543 SMCS Code: 1273-543-M&S Fuel Tank Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. This will help prevent condensation. Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. regular maintenance of the fuel system filter is important. 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. Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Remove drain plug (5). Water in the fuel can cause excessive fuel system wear. Fuel quality is critical to the performance and to the service life of the engine. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. Fuel Storage Tanks 4. 3. Drain the water and the sediment from the fuel storage tank during the following conditions: NOTICE The water separator is under suction during normal engine operation. Install the drain plug. If the engine is equipped with this system. Close the fuel supply valve. 1.82 Maintenance Section Fuel System Water Separator . Dispose of the liquid properly. The tank may overflow. Depress vent valve (1) in order to start the flow. Check the fuel daily. The fuel expands as the fuel gets warm. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system. 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. Do not fill the tank to the top.Drain Fuel Tank Water and Sediment . Allow five to ten minutes before performing this procedure. Open the fuel supply valve. Fill the fuel tank after operating the engine in order to drive out moist air. This causes water to accumulate in fuel tanks. Allow the water to drain into a suitable container.

Drain the coolant from the cooling system to a level that is below the hose that is being replaced. Note: For torques on hose clamps. Replace the old hose with a new hose. clean container.83 Maintenance Section Hoses and Clamps . Stop the engine. A constant torque hose clamp will help to prevent loose hose clamps. Inspect all lines. i00907072 Hoses and Clamps Inspect/Replace SMCS Code: 7554-040. 5. If a bulk storage tank has been refilled or moved recently. Note: Drain the coolant into a suitable. Heat setting causes hose clamps to loosen. “Coolant Recommendations” (Maintenance Section). allow adequate time for the sediment to settle before filling the engine fuel tank. Do not install bent or damaged lines. “Torque Specifications” (Maintenance Section). Ensure that the constant torque hose clamp is the same size as the standard clamp. Allow the engine to cool. Check for the following conditions: • End fittings that are damaged or leaking • Outer covering that is chafed or cut • Exposed wire that is used for reinforcement • Outer covering that is ballooning locally • Flexible part of the hose that is kinked or crushed • Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp. Loosen the cooling system pressure cap slowly in order to relieve the pressure. see this Operation and Maintenance Manual. 7554-510 Due to extreme temperature changes. the hose will heat set. 4. 7. Install the hose clamps with a torque wrench. Internal baffles in the bulk storage tank will also help trap sediment. When possible. 2. The differences depend on the following factors: • Type of hose • Type of fitting material • Anticipated expansion and contraction of the hose • Anticipated expansion and contraction of the fittings Replace the Hoses and the Clamps Inspect all hoses for leaks that are caused by the following conditions: • Cracking • Softness • Loose clamps Replace hoses that are cracked or soft. 6. NOTICE Do not bend or strike high pressure lines. Each installation application can be different. Leaks can cause fires. The coolant can be reused. Disconnect the old hose. Tighten any loose clamps.Inspect/Replace This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank. . Loosen the cooling system filler cap slowly in order to relieve any pressure. stop the engine and wait until the cooling system components are cool. 8. Pressurized System: Hot coolant can cause serious burns. Remove the hose clamps. 3. tubes or hoses. tubes and hoses. tubes and hoses carefully. To open the cooling system filler cap. water separators should be used. see this Operation and Maintenance Manual. This can result in leaks. Refill the cooling system. Note: For the proper coolant to use. Remove the cooling system filler cap. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel. Repair any loose or damaged fuel and oil lines. 1. Tighten all connections to the recommended torque.

2. Check for signs of wear and contaminants. 10. i00984589 Overhaul Considerations SMCS Code: 7595-043 Reduced hours of operation at full load will result in a lower average power demand. i00906366 Magnetic Pickups Clean/Inspect SMCS Code: 1907-040. Inspect the cooling system for leaks. Clean the metal shavings and other debris from the face of the magnet. The following factors are important when a decision is being made on the proper time for an engine overhaul: • Need for preventive maintenance • Quality of the fuel that is being used • Operating conditions • Results of the S·O·S analysis Illustration 38 g00293335 Oil Consumption as an Overhaul Indicator Typical example (1) Magnetic pickup (2) Flywheel housing Oil consumption. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals. an engine overhaul should be scheduled.Clean/Inspect 9. 7400-070 3. Illustration 39 g00293337 Typical magnetic pickup 1. The oil consumption rate (brake specific oil consumption) is measured in grams per kW/h (lb per bhp). fuel consumption. 7400-040. Check the condition of the end of the magnetic pickup. Clean the cooling system filler cap. The need for an overhaul is generally indicated by increased fuel consumption and by reduced power. Replace the cooling system filler cap if the gaskets are damaged. Install the cooling system filler cap. Refer to the Service Manual for the installation procedure. Inspect the cooling system filler cap’s gaskets. There may be a corresponding increase in blowby and a slight increase in fuel consumption.84 Maintenance Section Magnetic Pickups . Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine. A decreased average power demand should increase both the engine service life and the overhaul interval. . The brake specific oil consumption (BSOC) depends on the engine load. Install the magnetic pickup and adjust the magnetic pickup. the amount of oil that is consumed per hour also increases. Oil consumption is in proportion to the percentage of the rated engine load. Remove magnetic pickup (1) from flywheel housing (2). When an engine’s oil consumption has risen to three times the original oil consumption rate due to normal wear. As the percentage of the engine load is increased. Start the engine. and maintenance information can be used to estimate the total operating cost for your Caterpillar engine.

• Reuse many original parts according to the standards for reusable parts. recommends repairing out-of-spec parts or replacing out-of-spec parts. • Timing advance This lower cost can be attributed to three aspects: • Fuel transfer pump • Valve rotators If the parts comply with the established inspection specifications that are expressed in the reusable parts guideline. Component Replacement Replace the following components during the overhaul: • Piston rings . If an overhaul is performed without overhaul service from your Caterpillar dealer. • Turbocharger • Oil pump After Failure Overhaul • Fuel ratio control Many options are available if a major engine failure occurs. Therefore. Note: Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul. This will provide you with the best cost/value relationship. Caterpillar Inc. A planned overhaul before failure may be the best value for the following reasons: • Avoid costly unplanned downtime. recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails. SEBF8029 lists the reusability publications that are needed for inspecting the engine parts. Parts that are not within the established inspection specifications should be salvaged. repaired. be aware of the following maintenance recommendations.85 Maintenance Section Overhaul Considerations Overhaul Options Rebuild or Exchange Before Failure Overhaul Inspect the following components according to the instructions that are found in various Caterpillar reusability publications. The Special Publication. • Attain the best cost/value relationship per hour of extended life. An overhaul should be performed if the engine block or the crankshaft needs to be repaired. Using out-of-spec parts can result in the following problems: • Unscheduled downtime • Costly repairs • Damage to other engine parts • Reduced engine efficiency • Increased fuel consumption Reduced engine efficiency and increased fuel consumption translates into higher operating costs. or replaced. • Specially designed Caterpillar engine features • Caterpillar dealer exchange components • Caterpillar remanufactured exchange components Overhaul Recommendation To minimize downtime. the parts should be reused. Consult your Caterpillar dealer for specific information about the available overhaul programs and about overhaul services for extending the engine life. • Cam followers If the engine block is repairable and/or the crankshaft is repairable. the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core. • Extend the engine’s service life without the risk of • Cylinder head assembly • Connecting rods • Pistons a major catastrophe due to engine failure. Caterpillar Inc.

Further coolant analysis is recommended when the engine is overhauled. Obtain Coolant Analysis The concentration of supplemental coolant additive (SCA) should be checked regularly with test kits or with S·O·S Coolant Analysis (Level 1). Check these components by interpreting the wear patterns on the rod bearings and main bearings. Cleaning • Damage to the journals The following components should be cleaned and pressure tested during the overhaul: • Bearing material that has seized to the journals • Engine oil cooler Check the journal taper and the profile of the crankshaft journals. • Worn gear teeth • Unusual fit • Unusual wear Testing • Camshaft • Camshaft bearings • Crankshaft • Crankshaft vibration damper • Gear train Inspect the camshaft for damage to the journals and the lobes. cracked. Your Caterpillar dealer can provide these services and components in order to ensure that your fuel system is operating within the appropriate specifications. use the magnetic particle inspection process to check for cracks. “Aftercooler Core . Inspect the camshaft bearings for signs of wear and/or for signs of fatigue.86 Maintenance Section Overhaul Considerations • Thrust bearings • Excessive wear of the gear train that is not caused by a lack of lubrication • Main bearings • Connecting rod bearings • Visconic damper that is dented. SEBF8029. • Aftercooler Note: If the crankshaft or the camshaft are removed for any reason. . or leaking • Gaskets and seals • Visconic damper that is discolored from heat • Engine mounts • Rubber damper that is deteriorated and cracked • Hoses • Rubber damper with slippage of the outer ring Inspection Inspect the gear train for the following conditions: Inspect the following components according to the instructions that are in Caterpillar reusability publications. “Index of Publications on Reusability or Salvage of Used Parts”. Replace the crankshaft vibration damper if any of the following conditions are found: • Engine failure due to a broken crankshaft • Excessive wear of the front main bearing Refer to the Operation and Maintenance Manual. Refer to Guidelines for Reusable Parts and Salvage Operations. Inspect the crankshaft for any of the following conditions: • Deflection Test the following components during the overhaul: • Fuel injection nozzles • Fuel injection pump • Governor Testing the fuel system during the overhaul will ensure that your engine operates at peak efficiency.Inpect/Clean” topic (Maintenance Section) for the cleaning procedure.

Clean the radiator.Clean SMCS Code: 3055-036. grease. i01206548 Inspect the radiator for these items: damaged fins. Caterpillar Inc. The coolant water probably contained minerals that were deposited on the engine over time. leaves. consult your Caterpillar dealer. A full water analysis can be obtained by consulting your local water utility company or an agricultural agent. insects.87 Maintenance Section Power Take-Off Clutch . oil. corrosion. For more information about coolant analysis. 3055-086 SMCS Code: 1353-070 NOTICE New power take-offs should have the clutch adjustment checked before being placed into service. (2) Typical serial number plate for the clutch. Perform the maintenance that is specified on the instruction plate. Illustration 40 g00108044 (1) Typical instruction plate for the clutch. and the clutch may require several adjustments until the new plates are “worn in”. If the clutch is damaged to the point of burst failure. S·O·S Coolant Analysis (Level 2) An S·O·S Coolant Analysis (Level 2) is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system. • Visual inspection of properties • Identification of metal corrosion • Identification of contaminants • Identification of built up impurities (corrosion and scale) S·O·S Coolant Analysis (Level 2) provides a report of the results of both the analysis and the maintenance recommendations that are based on the analysis. but the concentrations of coolant additives were carefully maintained. and other debris. New clutch plates have a “wear in” period. i00339617 Power Take-Off Clutch Check/Adjust/Lubricate Radiator . The clutch adjustment should be checked again after the first ten hours of operation. considerable deposits are found in the water jacket areas on the external cooling system. Refer to the OEM information and instruction plate (1) for instructions on the following items: lubrication. . Heavy-duty applications which have engagements that are frequent and relatively long periods of clutch slippage require more frequent adjustment than light-duty applications. Proper safeguards must be followed to help prevent accidents. and other service recommendations. adjustment. Do not operate the engine with the Instruction Plate cover removed from the clutch. expelled pieces can cause personal injury to anyone in the immediate area. if necessary. Note: Adjust the frequency of cleaning according to the effects of the operating environment. recommends an S·O·S Coolant Analysis (Level 2). An S·O·S Coolant Analysis (Level 2) provides the following information: • Complete S·O·S Coolant Analysis (Level 1) The clutch adjustment should be checked regularly after “wear in”. The operating torque should be measured in order to determine if a clutch adjustment is required. dirt. Private laboratories are also available for water analysis. Personal injury may result.Check/Adjust/Lubricate For example. A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system.

see Special Publication. Clean both sides of the core. Clean the core from both sides. Pressurized water may also be used for cleaning. This will help in the removal of debris and drying of the core. Caterpillar maintains standards for the following engine parameters: • Environmental qualities • Installation Refer to the standards for the engine or consult with your Caterpillar dealer in order to determine if the engine is operating within the defined parameters. Extremely hot inlet air reduces engine performance. Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures. Inspect these items for good condition: welds. Due to individual applications.88 Maintenance Section Severe Service Application . and seals. Bent fins may be opened with a “comb”. After cleaning. Air Quality – The engine may be exposed to extended operation in an environment that is dirty or dusty. and fuel consumption) Personal injury can result from air pressure. SEBD0518. Make repairs. This will remove debris that is between the tubes. connections. Use a light bulb behind the core in order to inspect the core for cleanliness. i00151038 Severe Service Application Check SMCS Code: 1000-082 Severe service is an application of an engine that exceeds current published standards for that engine. Wash the core with detergent and hot water. The buildup can contain corrosive chemicals. Maintenance can be very difficult. Direct the air in the opposite direction of the fan’s air flow. unless the equipment is cleaned regularly. elements. • Oil selection and maintenance • Maintenance intervals • Coolant selection and maintenance Pressurized air is the preferred method for removing loose debris. Slowly move the air nozzle in a direction that is parallel with the tubes. Hold the nozzle approximately 6 mm (0. speed range. Use a degreaser and steam for removal of oil and grease.25 inch) away from the fins. Inspect the fins for damage. Repeat the cleaning. it is not possible to identify all of the factors which can contribute to severe service operation. Consult your Caterpillar dealer for the unique maintenance that is necessary for the engine. Stop the engine. if necessary. The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Mud.Check • Performance (power range. Engines that operate under severe conditions may need more frequent maintenance intervals in order to ensure maximum reliability and retention of full service life. dirt and dust can encase components. Environmental Factors Ambient temperatures – The engine may be exposed to extended operation in extremely cold environments or hot environments. Thoroughly rinse the core with clean water. wear a protective face shield and protective clothing. Buildup – Compounds. The operating environment. clamps. For more detailed information on cleaning and inspection. mounting brackets. Severe service operation can accelerate component wear. Use pressurized water in order to soften mud. air lines. “Know Your Cooling System”. corrosive chemicals and salt can damage some components. start the engine and accelerate the engine to high idle rpm. if necessary. When using pressure air. . • Fuel quality Personal injury can result without following proper procedure. • Altitude range Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. improper operating procedures and improper maintenance procedures can be factors which contribute to severe service conditions.

Any fumes from the crankcase are filtered through the air inlet system. Note: Turbocharger components require precision clearances. Refer to the Service Manual for this engine for the procedure and specifications. There should not be any visible signs of contact between the turbine wheel or compressor wheel and the turbocharger housing. and the cylinder head. If the starting motor fails. Check the electrical connections and clean the electrical connections. If there is any indication of contact between the rotating turbine wheel or the compressor wheel and the turbocharger housing. An inspection of the turbocharger can minimize unscheduled downtime. . Removal and Installation For options regarding the removal. do not continue engine operation until the turbocharger is repaired or replaced. Inspect the compressor wheel and the turbine wheel for contact with the turbocharger housing. An inspection of the turbocharger can also reduce the chance for potential damage to other engine parts. repair and replacement. When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine rpm up at no load). this buildup can contribute to loss of engine power. Loss of engine lubricant can result in serious engine damage. i00912946 Minor leakage of a turbocharger housing under extended low idle operation should not cause problems as long as a turbocharger bearing failure has not occurred. • Extended operation at low idle • Frequent hot shutdowns • Operating at excessive loads • Operating at excessive speeds • Operating outside the intended application Improper Maintenance Procedures • Extending the maintenance intervals • Failure to use recommended fuel. Turbocharger . the valves. Turn the compressor wheel and the turbine wheel by hand. damage to the turbocharger compressor wheel and/or to the engine may occur. lubricants and coolant/antifreeze i00651416 Starting Motor . Remove the exhaust outlet piping and remove the air inlet piping from the turbocharger. Over time.Inspect Cleaning and Inspecting SMCS Code: 1052-040 1. 1453-040 Caterpillar Inc. the turbocharger must be reconditioned. Damage to the turbocharger compressor wheel can cause additional damage to the pistons.Inspect Altitude – Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application. Severe Service Applications require more frequent inspections of the cartridge.89 Maintenance Section Starting Motor . NOTICE Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems. Therefore. recommends a scheduled inspection of the starting motor. Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Caterpillar dealer for assistance. Visually inspect the piping for the presence of oil. The turbocharger cartridge must be balanced due to high rpm. consult your Caterpillar dealer. Periodic inspection and cleaning is recommended for the turbocharger compressor housing (inlet side). 2. the engine may not start in an emergency situation. Improper Operating Procedures If the turbocharger fails during engine operation. by-products from oil and from combustion can collect in the turbocharger compressor housing. increased black smoke and overall loss of engine efficiency. Severe Service Applications can accelerate component wear. Check the starting motor for proper operation. installation. The assembly should turn freely. Necessary adjustments should be made.Inspect SMCS Code: 1451-040.

dirt and/or moisture is passing through the air filtering system. • Inspect the water pump for coolant leaks. Use a dial indicator to check the end clearance on the shaft. The additional load on the new belt could cause the belt to break. or fuel) clean up the fluid. The presence of oil may be the result of extended engine operation at low idle. • Inspect the alternator belt and the accessory drive belts for cracks. • Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps. . Excessive coolant leakage may indicate the need to replace the water pump seal. the rear crankshaft seal. For the removal of water pump and the installation of water pump and/or seals. For maximum engine service life. the belt will carry more load than the belts that are not replaced. 5. the oil pan. Check the compressor wheel for cleanliness. Look for loose Inspect the Engine for Leaks and for Loose Connections A walk-around inspection should only take a few minutes. Repair damaged guards or replace missing guards. find the source and correct the leak. 6. worn belts. The turbocharger should be disassembled for cleaning and for inspection if the measured end play is less than the minimum Service Manual specifications. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing. Belts for multiple groove pulleys must be replaced as matched sets. If only the blade side of the wheel is dirty. as needed: • The guards must be in the proper place. If only one belt is replaced. make a thorough inspection of the engine compartment before starting the engine. which causes the turbocharger to slobber. costly repairs and accidents can be avoided. Inspect the bore of the turbine housing for corrosion. fuel line clamps. Check for leaks. NOTICE Accumulated grease and/or oil on an engine or deck is a fire hazard. the oil filters and the valve cover.90 Maintenance Section Walk-Around Inspection 3. Look for items such as oil leaks or coolant leaks. there is a possibility of a failed turbocharger oil seal. or until the suspicion of a leak is proved to be unwarranted. SMCS Code: 1000-040 • Inspect the fuel system for leaks. loose bolts. the turbocharger should be repaired or replaced. Remove this debris with steam cleaning or high pressure water. If the measured end play is greater than the Service Manual specifications. loose connections and trash buildup. 7. It is normal for a small amount of leakage to occur as the engine cools down and the parts contract. If leaking is observed. If leaking is suspected. When the time is taken to perform these checks. i00632301 Walk-Around Inspection • Inspect the lubrication system for leaks at the front crankshaft seal. • Ensure that cooling lines are properly clamped and tight. • Drain the water and the sediment from fuel tanks on a daily basis in order to ensure that only clean fuel enters the fuel system. • Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination. lube. 4. check the fluid levels more often than recommended until the leak is found or fixed. If oil is found only on the back side of the wheel. refer to the Service Manual for the engine or consult your Caterpillar dealer. The presence of oil may also be the result of a restriction of the line for the inlet air (plugged air filters). breaks or other damage. An end play measurement that is less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel. Clean the turbocharger housing with standard shop solvents and a soft bristle brush. Note: The water pump seal is lubricated by coolant in the cooling system. The older belts are stretched. Check the condition of all pipes. Make repairs. NOTICE For any type of leak (coolant.

Inspect SMCS Code: 1361-040. i01057943 Water Pump . Check the condition and the electrolyte level of the batteries. • Disconnect any battery chargers that are not protected against the current drain of the starting motor. • Inspect the ground strap for a good connection and for good condition.91 Maintenance Section Water Pump . • Inspect the engine-to-frame ground strap for a good connection and for good condition. Replace any gauges which are cracked or can not be calibrated. . If any leaking is observed. replace the water pump seal or the water pump assembly. 1361 A failed water pump might cause severe engine overheating problems that could result in the following conditions: • Cracks in the cylinder head • A piston seizure • Other potential damage to the engine Visually inspect the water pump for leaks. Refer to the Service Manual for the disassembly and assembly procedure.Inspect • Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires. • Check the condition of the gauges. unless the engine is equipped with a maintenance free battery. Note: Refer to the Service Manual or consult your Caterpillar dealer if any repair is needed or any replacement is needed.