Manual de Motor c1 1 Caterpillar Luminarias

SAFETY.CAT.
COM
C0.5, C0.7, C1.1, C1.5, C1.6

and C2.2 INDUSTRIAL
ENGINES
Maintenance Intervals
Excerpted from Operation & Maintenance Manual (SEBU8312-00-01)
2007 Caterpillar
All Rights Reserved
SEBU8312
51
Maintenance Section
Maintenance Interval Schedule
Maintenance Interval Schedule
Engine Protective Devices - Check ...................... 71

Hoses and Clamps - Inspect/Replace .................. 80
Radiator - Clean .................................................... 82
SMCS Code: 1000; 7500
Every 1000 Service Hours
When Required
Alternator and Fan Belts - Replace ....................... 53

Engine Valve Lash - Inspect/Adjust ...................... 71
Turbocharger - Inspect .......................................... 84
i02639288
Battery - Replace ..................................................

Battery or Battery Cable - Disconnect ..................
Engine - Clean ......................................................
Engine Air Cleaner Element (Dual Element) Clean/Replace ....................................................
Engine Air Cleaner Element (Single Element) Inspect/Replace ..................................................
Fuel System - Prime .............................................
Severe Service Application - Check .....................
53
54
62
62
65
73
83
Alternator - Inspect ...............................................

Engine Crankcase Breather - Replace .................
Engine Mounts - Inspect .......................................
Starting Motor - Inspect ........................................
52
67
68
84
Every Year
Daily
Cooling System Coolant Level - Check ................
Driven Equipment - Check ....................................
Engine Air Cleaner Service Indicator - Inspect .....
Engine Air Precleaner - Check/Clean ...................
Engine Oil Level - Check ......................................
Fuel System Primary Filter/Water Separator Drain ...................................................................
Walk-Around Inspection ........................................
58
62
66
67
68
77
84
Cooling System Coolant Sample (Level 2) Obtain ................................................................. 60

Fuel Injector - Test/Change ................................... 72
Water Pump - Inspect ........................................... 85
Every 3000 Service Hours or 2 Years
Fuel Tank Water and Sediment - Drain ................. 80
Cooling System Coolant (DEAC) - Change .......... 54

Cooling System Water Temperature Regulator Replace ............................................................... 61
Every 6000 Service Hours or 3 Years
Cooling System Coolant Extender (ELC) - Add .... 58
Every 50 Service Hours or Weekly
Every 250 Service Hours or 6 Months
Cooling System Coolant (ELC) - Change ............. 56
Alternator and Fan Belts - Inspect/Adjust ............. 52

Engine Oil Sample - Obtain .................................. 69
Initial 500 Hours (for New Systems, Refilled

Systems, and Converted Systems)

Fuel System Secondary Filter - Replace .............. 77
Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check ..........................
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .................................................
Engine Air Cleaner Element (Dual Element) Clean/Replace ....................................................
Engine Air Cleaner Element (Single Element) Replace ...............................................................
Engine Oil and Filter - Change .............................
Every 12 000 Service Hours or 6 Years
54
60
62
66
69
Overhaul
Overhaul Considerations ...................................... 81
52
Maintenance Section
Alternator - Inspect
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i02676048
Alternator - Inspect
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection
of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or
proper performance of the electrical system. Make
repairs, as required.
Check the alternator and the battery charger for
proper operation. If the batteries are properly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time
or if the engine is run for short periods, the batteries
may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
i02226340
Alternator and Fan Belts Inspect/Adjust
Illustration 35
g01003936
Typical example
(1) 144-0235 Belt Tension Gauge
Install the gauge (1) at the center of the belt between

the alternator and the crankshaft pulley and check
the belt tension. The correct tension for a new belt is
400 N (90 lb) to 489 N (110 lb). The correct tension
for a used belt that has been in operation for 30
minutes or more at the rated speed is 267 N (60 lb)
to 356 N (80 lb).
If twin belts are installed, check and adjust the
tension on both belts.
Adjustment
SMCS Code: 1357-025; 1357-040
Inspection
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to
carry more load because the older belt is stretched.
The additional load on the new belt could cause the
new belt to break.
If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
To accurately check the belt tension, Gauge
144-0235 Belt Tension Gauge should be used.
Illustration 36
g01091158
Typical example
(1) Adjusting bolt
(2) Mounting bolts
1. Loosen the mounting bolts (2) and the adjusting

bolt (1).
SEBU8312
53
Maintenance Section
Alternator and Fan Belts - Replace
2. Move the alternator in order to increase or

decrease the belt tension.
3. Tighten the adjusting bolt (1). Tighten the mounting
bolts (2). Refer to the Specifications Manual for
the correct torque settings.
i02226343
Alternator and Fan Belts Replace

SMCS Code: 1357-510
i02153996
Battery - Replace
SMCS Code: 1401-510
Batteries give off combustible gases which can

explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
The battery cables or the batteries should not be

removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the key start switch to the OFF position.
Remove the key and all electrical loads.
Illustration 37
g01091158
2. Turn OFF the battery charger. Disconnect the

charger.
Typical example
(1) Adjusting bolt
(2) Mounting bolts
For applications that require multiple drive belts,

replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to
carry more load because the older belt is stretched.
The additional load on the new belt could cause the
new belt to break.
Note: When new belts are installed, check the belt
tension again after 20 hours of engine operation.
Refer to the Disassembly and Assembly Manual for
the installation procedure and the removal procedure
for the belt.
3. The NEGATIVE - cable connects the NEGATIVE

- battery terminal to the ground plane. Disconnect
the cable from the NEGATIVE - battery terminal.
4. The POSITIVE + cable connects the POSITIVE
+ battery terminal to the starting motor.
Disconnect the cable from the POSITIVE +
battery terminal.
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that
the key start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE + battery terminal.
54
Maintenance Section
Battery Electrolyte Level - Check
SEBU8312
8. Connect the cable from the ground plane to the

NEGATIVE - battery terminal.
i02601752
Battery Electrolyte Level Check

SMCS Code: 1401-535
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing.
All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the filler caps. Maintain the electrolyte
level to the FULL mark on the battery.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
i01492654
Battery or Battery Cable Disconnect

SMCS Code: 1402-029
The battery cables or the batteries should not be

removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
two batteries must be disconnected.
3. Tape the leads in order to help prevent accidental
starting.
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.
3. Keep the batteries clean.

i02242514
Clean the battery case with one of the following

cleaning solutions:
A mixture of 0.1 kg (0.2 lb) of baking soda and

1 L (1 qt) of clean water
A mixture of 0.1 L (0.11 qt) of ammonia and 1 L

(1 qt) of clean water
Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
Cooling System Coolant

(DEAC) - Change
SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
The engine overheats frequently.

Foaming is observed.
The oil has entered the cooling system and the
coolant is contaminated.
The fuel has entered the cooling system and the

SEBU8312
NOTICE
Use of commercially available cooling system cleaners may cause damage to cooling system components. Use only cooling system cleaners that are approved for Caterpillar engines.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
valve, remove one of the drain plugs.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Dealer Service Tools Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
55
Maintenance Section
Cooling System Coolant (DEAC) - Change
2. Close the drain valve (if equipped). Clean the

drain plugs. Install the drain plugs. Refer to Torque
Specifications, SENR3130 for more information
on the correct torques.
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine damage.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
4. Start and run the engine at low idle for a minimum
of 30 minutes. The coolant temperature should be
at least 82 C (180 F).
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal components.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear water. Continue to flush the system until all signs of the
cleaning agent are gone.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
plugs. Refer to Torque Specifications, SENR3130
for more information on the correct torques.
Cooling Systems with Heavy

Deposits or Plugging
Note: For the following procedure to be effective,
there must be some active flow through the cooling
system components.
56
Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the cooling system filler cap.
4. Start and run the engine at low idle for a minimum
of 90 minutes. The coolant temperature should be
at least 82 C (180 F).
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal components.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear water. Continue to flush the system until all signs of the
cleaning agent are gone.
Fill
NOTICE
1. Fill the cooling system with coolant/antifreeze.
Refer to this Operation and Maintenance Manual,
Refill Capacities and Recommendations topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
cooling system filler cap.
2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
SEBU8312
3. Check the coolant level. Maintain the coolant level

within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, perform a pressure test. A
9S-8140 Pressurizing Pump is used to perform
the pressure test. The correct pressure for the
cooling system filler cap is stamped on the face of
the cooling system filler cap. If the cooling system
filler cap does not retain the correct pressure,
install a new cooling system filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for the correct operating temperature.
i02242512
Cooling System Coolant (ELC)

- Change
SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
The engine overheats frequently.

Foaming is observed.
The oil has entered the cooling system and the
The fuel has entered the cooling system and the

Note: When the cooling system is cleaned, only

clean water is needed when the ELC is drained and
replaced.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
SEBU8312
Drain
Loosen the cooling system filler cap slowly in
system filler cap.
2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
valve, remove the cooling system drain plugs.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Dealer Service Tools:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
NOTICE
3. Fill the cooling system with clean water. Install the
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 C (120 to 150 F).
57
Maintenance Section
Cooling System Coolant (ELC) - Change

Fill
NOTICE
1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to this Operation and Maintenance
Manual, Refill Capacities and Recommendations
topic (Maintenance Section) for more information
on cooling system specifications. Do not install the
2. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap is
not damaged, use a 9S-8140 Pressurizing Pump
in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
leaks and for proper operating temperature.
58
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
SEBU8312
i02482066

Extender (ELC) - Add
SMCS Code: 1352-045; 1395-081
Cat ELC (Extended Life Coolant) does not require
the frequent additions of any supplemental cooling
additives which are associated with the present
conventional coolants. The Cat ELC Extender only
needs to be added once.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender
with Cat ELC.
Dispose of all fluids according to local regulations and

mandates.
Do NOT use conventional supplemental coolant additive (SCA) with Cat ELC. Mixing Cat ELC with conventional coolants and/or conventional SCA reduces the
Cat ELC service life.
1. Loosen the cooling system filler cap slowly in

order to relieve pressure. Remove the cooling
system filler cap.
Check the cooling system only when the engine is

stopped and cool.
2. It may be necessary to drain enough coolant from

the cooling system in order to add the Cat ELC
Extender.
Personal injury can result from hot coolant, steam

and alkali.
3. Add Cat ELC Extender according to the

requirements for your engines cooling system
capacity. Refer to the Operation and Maintenance
Manual, Refill Capacities and Recommendations
article for more information.
At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.

gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
i01197583
Cooling System Coolant Level

- Check
SMCS Code: 1395-082
Check the coolant level when the engine is stopped
and cool.
SEBU8312
59
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
i02603581

Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Note: Obtaining a Coolant Sample (Level 1) is
optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems that
are filled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended interval
that is stated in the Maintenance Interval Schedule.
Illustration 38
g00285520
Cooling system filler cap
1. Remove the cooling system filler cap slowly in
order to relieve pressure.
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
Note: Obtain a Coolant Sample (Level 1) if the

cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
types of coolants:
Commercial long life coolants that meet the

Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)
Cat DEAC (Diesel Engine Antifreeze/Coolant)

Commercial heavy-duty coolant/antifreeze
Table 28
Recommended Interval
Type of Coolant
Level 1
Level 2
Cat DEAC
Every 250
Hours(1)
Yearly(1)(2)
Cat ELC
Optional(2)
Yearly(2)
(1)
This is the recommended interval for coolant samples for all

conventional heavy-duty coolant/antifreeze. This is also the
recommended interval for coolant samples of commercial
coolants that meet the Cat EC-1 specification for engine
coolant.
(2) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
Illustration 39
g00103639
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
Typical filler cap gaskets
3. Clean the cooling system filler cap and check the

condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.
4. Inspect the cooling system for leaks.
Note: Level 1 results may indicate a need for

Level 2 Analysis.
60
Maintenance Section
SEBU8312
Obtain the sample of the coolant as close as possible

to the recommended sampling interval. In order
to receive the full effect of SOS analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Submit the sample for Level 2 analysis.
Use the following guidelines for proper sampling of

the coolant:
Cooling System Supplemental

Coolant Additive (SCA) Test/Add
Complete the information on the label for the

sampling bottle before you begin to take the
samples.
For additional information about coolant

analysis, see Special Publication, SEBU6251,
Caterpillar Commercial Diesel Engines Fluids
Recommendations or consult your Caterpillar dealer.
i02456600
SMCS Code: 1352-045; 1395-081
Keep the unused sampling bottles stored in plastic

bags.
Obtain coolant samples directly from the coolant

sample port. You should not obtain the samples
from any other location.
Keep the lids on empty sampling bottles until you

are ready to collect the sample.
Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
contamination.
Never collect samples from expansion bottles.

Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis,
see Special Publication, SEBU6251, Caterpillar
Commercial Diesel Engine Fluids Recommendations
or consult your Caterpillar dealer.
i01987714

Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Refer to Operation and Maintenance Manual,
for the guidelines for proper sampling of the coolant.
Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact with
the skin and the eyes. Do not drink cooling system
coolant additive.
Note: Test the concentration of the Supplemental
Coolant Additive (SCA) or test the SCA concentration
as part of an SOS Coolant Analysis.
Test for SCA Concentration

Coolant and SCA
NOTICE
Do not exceed the recommended six percent supplemental coolant additive concentration.
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.
Refer to this Operation and Maintenance Manual,
Refill Capacities and Recommendations for more
information.
Water and SCA

NOTICE
Do not exceed the recommended eight percent supplemental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Refer to the Special
Publication, SEBU6251, Caterpillar Commercial
Diesel Engine Fluids Recommendations for more
information.
SEBU8312
61
Maintenance Section
Cooling System Water Temperature Regulator - Replace
SOS Coolant Analysis

SOS coolant samples can be analyzed at your
Caterpillar dealer. SOS Coolant Analysis is a
program that is based on periodic samples.
Level 1
Level 1 is a basic analysis of the coolant. The
following items are tested:
Glycol Concentration
Concentration of SCA
pH
Conductivity
The results are reported, and recommendations
are made according to the results. Consult your
Caterpillar dealer for information on the benefits of
managing your equipment with an SOS Coolant
Analysis.
Level 2
This level coolant analysis is recommended when the
engine is overhauled. Refer to this Operations and
Maintenance Manual, Overhaul Considerations for
further information.
1. Slowly loosen the cooling system filler cap in
order to relieve the pressure. Remove the cooling
system filler cap.
Note: Always discard drained fluids according to
local regulations.
2. If necessary, drain some coolant from the cooling
system into a suitable container in order to allow
space for the extra SCA.
3. Add the proper amount of SCA. Refer
to the Special Publication, SEBU6251,
Caterpillar Commercial Diesel Engines Fluids
Recommendations for more information on SCA
requirements.
gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.
Add the SCA, If Necessary

NOTICE
Do not exceed the recommended amount of supplemental coolant additive concentration. Excessive
supplemental coolant additive concentration can form
deposits on the higher temperature surfaces of the
cooling system, reducing the engines heat transfer
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high temperature components. Excessive supplemental coolant
additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated water
pump seal wear. Never use both liquid supplemental
coolant additive and the spin-on element (if equipped)
at the same time. The use of those additives together
could result in supplemental coolant additive concentration exceeding the recommended maximum.
i02625506
Cooling System Water

Temperature Regulator Replace
SMCS Code: 1355-510
Replace the water temperature regulator before
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime.
A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.
62
Maintenance Section
Driven Equipment - Check
SEBU8312
A water temperature regulator that fails in the open

position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner.
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water
temperature regulator installed.
If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature regulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or
cylinder head surface.
Refer to Disassembly and Assembly, Water
Temperature Regulator - Remove and Install.
Consult your Caterpillar dealer for more information.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
i00174798
Driven Equipment - Check

SMCS Code: 3279-535
Refer to the OEM specifications for more information
on the following maintenance recommendations for
the driven equipment:
Inspection
Adjustment
Lubrication
Other maintenance recommendations
Perform any maintenance for the driven equipment
which is recommended by the OEM.
i01646701
Engine - Clean
SMCS Code: 1000-070
Personal injury or death can result from high voltage.

Moisture can create paths of electrical conductivity.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls DO
NOT OPERATE.
NOTICE
Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
Easy detection of fluid leaks

Maximum heat transfer characteristics
Ease of maintenance
Note: Caution must be used in order to prevent
electrical components from being damaged by
excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
starter, and the ECM.
i01553486
Engine Air Cleaner Element

(Dual Element) - Clean/Replace
SMCS Code: 1054-037; 1054-510
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
SEBU8312
63
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
wear. Your Caterpillar dealer has the proper air
cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.
Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt

and debris, as needed.
Operating conditions (dust, dirt and debris) may

require more frequent service of the air cleaner
element.
Illustration 40
(1)
(2)
(3)
(4)
g00736431
Cover
Primary air cleaner element
Secondary air cleaner element
Turbocharger air inlet
1. Remove the cover. Remove the primary air

cleaner element.
The air cleaner element may be cleaned up to
2. The secondary air cleaner element should be

removed and discarded for every three cleanings
of the primary air cleaner element.
The air cleaner element should be replaced at least
Note: Refer to Cleaning the Primary Air Cleaner

Elements.
six times if the element is properly cleaned and

inspected.
one time per year. This replacement should be
performed regardless of the number of cleanings.
Replace the dirty paper air cleaner elements with

clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked
for tears and/or holes in the filter material. Inspect
the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner
elements for replacement purposes.
Dual Element Air Cleaners

The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner
element. The primary air cleaner element can be
used up to six times if the element is properly cleaned
and inspected. The primary air cleaner element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.
The secondary air cleaner element is not serviceable
or washable. The secondary air cleaner element
should be removed and discarded for every three
cleanings of the primary air cleaner element. When
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more
frequent replacement.
3. Cover the turbocharger air inlet with tape in order

to keep dirt out.
4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
5. Remove the tape for the turbocharger air inlet.
Install the secondary air cleaner element. Install a
primary air cleaner element that is new or cleaned.
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.
64
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Cleaning the Primary Air Cleaner

Elements
NOTICE
Caterpillar recommends certified air filter cleaning services that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
SEBU8312
Pressurized Air
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
Observe the following guidelines if you attempt to

clean the filter element:
Do not tap or strike the filter element in order to remove dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
The primary air cleaner element can be used up
to six times if the element is properly cleaned and
inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
The primary air cleaner element should be replaced
at least one time per year. This replacement should
be performed regardless of the number of cleanings.
Use clean primary air cleaner elements while dirty
elements are being cleaned.
NOTICE
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the primary air cleaner elements
before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
There are two common methods that are used to
clean primary air cleaner elements:
Pressurized air
Vacuum cleaning
Illustration 41
g00281692
Note: When the primary air cleaner elements are

cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
of air directly at the primary air cleaner element. Dirt
could be forced further into the pleats.
Note: Refer to Inspecting the Primary Air Cleaner
Elements.
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not remove
deposits of carbon and oil.
Note: Refer to Inspecting the Primary Air Cleaner
Elements.
SEBU8312
65
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Replace
Inspecting the Primary Air Cleaner

Elements
Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air cleaner element into a box
for storage. For identification, mark the outside of
the box and mark the primary air cleaner element.
Include the following information:
Date of cleaning
Number of cleanings
Store the box in a dry location.
Illustration 42
g00281693
i01432811
Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears
and/or holes. Inspect the primary air cleaner element
for light that may show through the filter material. If it
is necessary in order to confirm the result, compare
the primary air cleaner element to a new primary air
cleaner element that has the same part number.
Do not use a primary air cleaner element that has
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
pleats, gaskets or seals. Discard damaged primary
air cleaner elements.
Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes inspection
will not be used, the primary air cleaner element can
be stored for future use.
Engine Air Cleaner

Element (Single Element) Inspect/Replace
SMCS Code: 1054-040; 1054-510
Perform the Operation and Maintenance Manual,
Engine Air Cleaner Service Indicator-Inspect
procedure and perform the Operation and
Maintenance Manual, Engine Air Precleaner
Check/Clean procedure (if equipped) before
performing the following procedure.
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
NOTICE
Illustration 43
g00281694
66
Maintenance Section
Engine Air Cleaner Element (Single Element) - Replace
Illustration 44
g00310664
(1) Air cleaner cover

(2) Air filter element
(3) Air inlet
SEBU8312
Illustration 45
g00109823
(1) Air cleaner element. (2) Clamp.
1. Remove air cleaner cover (1) and remove air filter

element (2).
2. Cover air inlet (3) with tape or a clean cloth so that
debris cannot enter the air inlet.
3. Clean the inside of air cleaner cover (1). Clean the
body that holds the air cleaner element.
4. Inspect the replacement element for the following
items:damage, dirt, and debris.
1. Loosen clamp (2) which fastens air cleaner

element (1) to the air inlet. Remove the dirty air
cleaner element and clamp.
2. Install clamp (2) on new air cleaner element (1).
3. Install new air cleaner element (1) to the air
inlet and tighten clamp (2). Refer to Torque
Specifications, SENR3130 for the correct torque.
i01900118
6. Install a clean, undamaged air filter element (2).
Engine Air Cleaner Service

Indicator - Inspect
(If Equipped)
7. Install air cleaner cover (1).
SMCS Code: 7452-040
8. Reset the air cleaner service indicator.
Some engines may be equipped with a different

service indicator.
5. Remove the seal from the opening of the air inlet.
i02242500
Engine Air Cleaner Element

(Single Element) - Replace
SMCS Code: 1051; 1054-510
NOTICE
Some engines are equipped with a differential gauge

for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner housing or in a remote location.
SEBU8312
67
Maintenance Section
Engine Air Precleaner - Check/Clean
i00720883
Engine Air Precleaner Check/Clean

SMCS Code: 1055-070; 1055-535
Illustration 46
g00103777
Typical service indicator
Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner element
should be replaced when one of the following
conditions occur:
The yellow diaphragm enters the red zone.

The red piston locks in the visible position.
Test the Service Indicator

Service indicators are important instruments.
Illustration 47
g00287039
Typical engine precleaner

(1) Wing nut
(2) Cover
(3) Body
Remove wing nut (1) and cover (2). Check for an

accumulation of dirt and debris in body (3). Clean the
body, if necessary.
Check for ease of resetting. The service indicator
After cleaning the precleaner, install cover (2) and

wing nut (1).
Check the movement of the yellow core when the
Note: When the engine is operated in dusty

applications, more frequent cleaning is required.
should reset in less than three pushes.
engine is accelerated to the engine rated speed.

The yellow core should latch approximately at the
greatest vacuum that is attained.
i02657607
If the service indicator does not reset easily, or if the

yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be plugged.
Engine Crankcase Breather Replace
The service indicator may need to be replaced

frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and
whenever major engine components are replaced.
NOTICE
Keep all parts clean from contaminants.
Note: When a new service indicator is installed,

excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque
of 2 Nm (18 lb in).
SMCS Code: 1317-510
Contaminants may cause rapid wear and shortened

component life.
68
Maintenance Section
Engine Mounts - Inspect
SEBU8312
6. Install a new diaphragm and plate (4) for the

breather assembly into the cavity (7) of the
valve mechanism cover or the spacer (5) for
turbocharged engines.
7. Install a new spring (3).
8. Install the breather cover (2) and the four screws
(1). Tighten the screws.
i02456872
Engine Mounts - Inspect

SMCS Code: 1152-040
Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused
by the following conditions:
Improper mounting of the engine

Deterioration of the engine mounts
Illustration 48
g01335247
Typical example
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Screws for the breather cover

Breather cover
Spring
Diaphragm and plate
Spacer for turbocharged engines only
Joint for turbocharged engines only
Cavity
Vent hole
1. Loosen the screws (1) and remove the breather

cover (2) from the valve mechanism cover.
2. Remove the spring (3). Remove the diaphragm
and plate (4).
Any engine mount that shows deterioration should be

replaced. Refer to Special Publication, SENR3130,
Torque Specifications for the recommended
torques. Refer to the OEM recommendations for
more information.
i00623423
Engine Oil Level - Check

SMCS Code: 1348-535-FLV
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
3. For turbocharged engines, remove the spacer (5)

and the joint (6).
4. Clean the vent hole (8) and the cavity (7) in the
valve mechanism cover.
NOTICE
Make sure that the components of the breather assembly are installed correctly. Engine damage may
occur if the breather assembly is not working correctly.
5. For turbocharged engines, install a new joint (6)
and the spacer (5).
Illustration 49
g00110310
(Y) ADD mark. (X) FULL mark.
NOTICE
Perform this maintenance with the engine stopped.
1. Maintain the oil level between ADD mark (Y) and
FULL mark (X) on oil level gauge (1). Do not fill
the crankcase above FULL mark (X).
SEBU8312
69
Maintenance Section
Engine Oil Sample - Obtain
NOTICE
Operating your engine when the oil level is above the
FULL mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oils lubricating characteristics and could result in the loss of power.
2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap.
Caterpillar recommends using the sampling valve

in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
i01935337
Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1348-554-SM;
7542-554-OC, SM
In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine. SOS oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
Obtain the Sample and the Analysis

contact the skin.
NOTICE
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
For instructions, see Special Publication, PEHP6001,
How To Take A Good Oil Sample. Consult your
Caterpillar dealer for complete information and
assistance in establishing an SOS program for your
engine.
i02625985
Before you take the oil sample, complete the Label,

PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
Engine Oil and Filter - Change

SMCS Code: 1318-510; 1348-044
Engine model
Service hours on the engine
The number of hours that have accumulated since

contact the skin.
the last oil change
The amount of oil that has been added since the

last oil change
To ensure that the sample is representative of the

oil in the crankcase, obtain a warm, well mixed oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
NOTICE
mandates.
70
Maintenance Section
Engine Oil and Filter - Change
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed
with the draining cold oil. Drain the crankcase with
the engine stopped. Drain the crankcase with the
oil warm. This draining method allows the waste
particles that are suspended in the oil to be drained
correctly.
SEBU8312
Use a magnet to differentiate between the ferrous

metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
Failure to follow this recommended procedure will

cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
Drain the Engine Oil

After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
If the engine is equipped with a drain valve, turn the

drain valve knob counterclockwise in order to drain
the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.
If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil to

drain. After the oil has drained, the oil drain plug
should be cleaned and installed.
Replace the Oil Filter

NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
1. Remove the oil filter with a 1U-8760 Chain
Wrench.
Note: The following actions can be carried out as
part of the preventive maintenance program.
2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount
of metal debris in the oil filter may indicate early
wear or a pending failure.
Illustration 50
g01334593
(1) Oil cooler

(2) Adapter
(3) Oil filter
Note: Oil cooler (1) and adapter (2) are not installed
on all engines.
3. Clean the sealing surface of the cylinder block or
the oil cooler (1).
4. Apply clean engine oil to the new oil filter seal (3).
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminated. Contaminated oil can cause accelerated wear to
engine components.
SEBU8312
71
Maintenance Section
Engine Protective Devices - Check
5. Install the oil filter. Tighten the oil filter until the
oil filter seal contacts the cylinder block or the oil
cooler. Tighten the oil filter by hand according to
the instructions that are shown on the oil filter. Do
not overtighten the oil filter.
i00626013
Engine Protective Devices Check

SMCS Code: 7400-535
Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to this Operation
and Maintenance Manual , Refill Capacities
and Recommendations for more information on
lubricant specifications. Fill the crankcase with the
correct amount of oil. Refer to this Operation and
Maintenance Manual , Refill Capacities for more
information on refill capacities.
NOTICE
If equipped with an auxiliary oil filter system or a remote oil filter system, follow the OEM or filter manufacturers recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
NOTICE
To prevent crankshaft bearing damage, crank the engine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
2. Start the engine and run the engine at LOW
IDLE for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
3. Stop the engine and allow the oil to drain back to
the sump for a minimum of ten minutes.
Alarms and shutoffs must function properly. Alarms

provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.
A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective
devices are functioning properly.
NOTICE
During testing, abnormal operating conditions must be
simulated.
The tests must be performed correctly in order to prevent possible damage to the engine.
To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
perform the tests.
Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
immediately.
i02676796
Engine Valve Lash Inspect/Adjust

Illustration 51
g00110310
4. Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the ADD
and FULL marks on the oil level gauge.
SMCS Code: 1102-025

This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life. The maintenance for the valve lash is important
in order to keep the engine compliant.
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
72
Maintenance Section
Fuel Injector - Test/Change
SEBU8312
Rough running
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Systems Operation/Testing
and Adjusting Manual, Valve Lash and Valve Bridge
Adjustmentarticle or consult your Caterpillar dealer
for the complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage
and/or shortened engine component life.
Fuel injectors should be cleaned, inspected,

tested, and replaced, if necessary. Refer to Special
Instruction, SEHS7292 for using the 8S-2245
Injector Cleaning Tool Gp. Consult your Caterpillar
dealer about cleaning the fuel injectors and testing
the fuel injectors.
NOTICE
Never wire brush or scrape a fuel injection nozzle.
Wire brushing or scraping a fuel injection nozzle will
damage the finely machine orifice. Proper tools for
cleaning and testing the fuel injection nozzles can be
obtained from Caterpillar dealers.
Ensure that the engine can not be started while

this maintenance is being performed. To help prevent possible injury, do not use the starting motor
to turn the flywheel.
The following items are symptoms of a malfunction

of the fuel injectors:
Hot engine components can cause burns. Allow

additional time for the engine to cool before measuring/adjusting valve lash clearance.
Smoke emission
Abnormal engine operation
Engine knock
Ensure that the engine is stopped before measuring

the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance is
performed.
Each fuel injector must be isolated one at a time in

order to determine the malfunctioning fuel injector.
Refer to the Service Manual for more information.
2. Loosen each fuel line nut one at a time at the fuel

injection pump. A cloth or similar material must be
used in order to prevent fuel from spraying on the
hot exhaust components. Tighten each nut before
loosening the next nut.
i02625315
Fuel Injector - Test/Change

SMCS Code: 1290-081; 1290-510
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
1. Start the engine.
3. A faulty fuel injector 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.
Engine performance is not affected.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
Fuel injectors are subject to tip wear. Tip wear is a
result of fuel contamination. Tip wear can cause the
following problems:
Increased fuel consumption

Black smoke
Misfire
A fuel injector that is suspected of being faulty

should be removed. A new fuel injector should be
installed in the cylinder in order to determine if the
removed fuel injector is faulty.
Removal and Installation of the

Fuel Injection Nozzles
For the removal and the installation of fuel injectors,
special tooling is required. Refer to the Service
Manual for more information. Consult your Caterpillar
dealer for assistance.
SEBU8312
73
Maintenance Section
Fuel System - Prime
i02596360
Fuel System - Prime

SMCS Code: 1258-548
NOTICE
during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids.
mandates.
Use the following procedure in order to prime the fuel
system:
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:
Illustration 52
g01316878
This filter may not be installed on the engine.

(1) Vent screws
The fuel tank is empty or the fuel tank has been
Fuel filters
The low pressure fuel lines are disconnected.
There are three types of fuel filter that may be

installed on the engine.
partially drained.
A leak exists in the low pressure fuel system.

The fuel filter is replaced.
NOTICE
Element
Canister
Spin-on filter with fuel priming pump

mandates.
Primary filter
Ensure that the air is removed from the primary filter
before you prime the fuel filters. Refer to illustration
52.
Illustration 53
Element
(2) Fuel valve
(3) Vent screw
g01327360
74
Maintenance Section
Fuel System - Prime
SEBU8312
Note: Some fuel system will use gravity in order to

prime the primary fuel filter. If gravity is used ensure
that the fuel tank is full and that all stop valves in the
fuel line are open.
There is four different types of systems that can be
installed on the engine in order to prime the fuel
system. Refer to illustration 56.
Hand priming pump

In-line hand priming pump
Electrical priming pump
Transfer pump that is operated by the starting
motor
Illustration 54
g01327361
Canister
(4) Vent screw
Illustration 55
g01327363
Spin-on filter with fuel priming pump

(5) Vent screw
Vent screw (3) is installed on the filter that has an

element. Vent screw (4) is installed on the fuel filter
that has a canister. Vent screw (5) is installed on the
spin-on filter.
Priming the system

Ensure that the air is removed from the primary filter.
Loosen vent screws (1). Refer to illustration 52.
Operate the priming pump. When fuel free from air
flows from the vent screw tighten the vent screw.
SEBU8312
75
Maintenance Section
Fuel System - Prime
Illustration 56
g01301853
(6) Hand priming pump

(7) In-line priming pump
(8) Electrical priming pump

(9) Fuel transfer pump
g01304597
Illustration 57
(10) Connector bolt
(11) Fuel return line
Hand Priming Pump 6

In order to identify the hand priming pump, refer to
illustration 56.
(12) Connector bolt
1. Ensure that fuel valve (2) for the fuel filter that
has an element is in the ON position. Refer to
illustration 53.
2. Loosen vent screw (3 4 or 5) on the fuel filter.
76
Maintenance Section
Fuel System - Prime
SEBU8312
3. Operate hand priming pump (6). When fuel free

from air flows from the vent screw tighten the vent
screw.
illustration 53.
4. Loosen connection (10 or 12) at the fuel injection

pump. Refer to illustration 57.
Note: Fuel return line (11) may need to be removed

in order to prime the fuel system.
5. Operate the hand priming pump. When fuel free
from air flows from the connections tighten the
connecting bolt.
6. The engine should now be able to start. Operate
the starting motor in order to start the engine.
Note: Do not operate the starting motor for more
than 15 seconds. If the engine does not start after 15
seconds, stop and wait for 30 seconds before trying
again.
In-line Priming Pump 7
3. Operate electrical priming pump (8). When fuel

free from air flows from the vent screw tighten the
vent screw. Switch off the electrical priming pump.
5. Operate the in-line priming pump. When fuel free
connecting bolt.
In order to identify the in-line priming pump, refer to

illustration 56.

again.
illustration 53.
Fuel Transfer Pump 9

3. Operate in-line priming pump (7). When fuel free
screw.
5. Operate the in-line priming pump. When fuel free
connecting bolt.
again.
Electrical Priming Pump 8

In order to identify the electrical priming pump, refer
to illustration 56.
In order to identify the fuel transfer pump, refer to

illustration 56.
Note: In order to use the transfer pump, you must
operate the starting motor. Do not operate the starting
motor for more than 15 seconds. After 15 seconds,
stop and wait for 30 seconds before operating the
starting motor.
illustration 53.
3. Operate fuel transfer pump (9). When fuel free
screw. Stop the fuel transfer pump.
5. Operate the fuel transfer pump. When fuel free
connecting bolt. Stop the transfer pump.
SEBU8312
77
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

again.
i02627223
Fuel System Primary

Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel
system.
i02627769
Fuel System Secondary Filter Replace

SMCS Code: 1261-510-SE
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
The water separator is not a filter. The water separator separates water from the fuel. The engine should
never be allowed to run with the water separator more
than half full. Engine damage may result.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
NOTICE
mandates.
Fuel Filter with Canister

1. Close the fuel supply valve.
Illustration 58
g01316965
Typical example
1. Open drain (1). Catch the draining fluid in a

suitable container. Dispose of the drained fluid
correctly.
2. Close drain (1).
78
Maintenance Section
Fuel System Secondary Filter - Replace
SEBU8312
The fuel system will need to be primed after the

new filter is installed. Refer to this Operation and
Maintenance Manual, Fuel System - Prime.
Fuel Filter with Element

1. Close the fuel supply valve (1).
Illustration 59
g01307792
Typical example
2. Clean the outside of the fuel filter assembly (1).

3. Remove setscrew (2).
4. Remove the canister (3). Ensure that any fluid is
drained into a suitable container.
Illustration 61
g01334893
Typical example
2. Clean the outside of the fuel filter assembly.

3. Loosen locking ring (2).
4. Remove the casing for the filter (3) and the
element. Ensure that any fluid is drained into a
suitable container.
Illustration 60
g01334877
Typical example
5. Assemble the following items: seals (8), seal (7),

canister (3), and bowl (10). Place washer (5) and
seal (6) on setscrew (2).
6. Fasten the assembly to the fuel filter base with
setscrew (2).
SEBU8312
79
Maintenance Section
Fuel System Secondary Filter - Replace
Illustration 63
g01306131
Typical example
3. Remove spin-on filter (1). Use a 1U-8760 Chain

Wrench in order to remove the filter. Ensure that
any fluid is drained into a suitable container.
Note: Do not fill the fuel filter with fuel. This fuel will
not be filtered and the fuel could be contaminated.
Contaminated fuel can damage the fuel system.
Illustration 62
g01334895
Typical example
5. Assemble the following items: seal (5), filter

element (6) and casing (3).
Note: Do not fill the fuel filter with fuel. This fuel will
not be filtered and the fuel could be contaminated.
Contaminated fuel can damage the fuel system.
6. Install the assembled items to the filter base (4).
7. Install the locking ring (2) to the filter base. Rotate
the locking ring in order to lock the assembly.
Fuel filter with priming pump

1. Close the fuel supply valve.
2. Clean the outside of the fuel filter assembly.
4. Install the new spin-on filter. Tighten the spin-on

filter by hand.
80
Maintenance Section
Fuel Tank Water and Sediment - Drain
SEBU8312
i02571779
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
NOTICE
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
mandates.
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
Drain the Water and the Sediment

Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
Fill the fuel tank after operating the engine in
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
Some fuel tanks use supply pipes that allow water

and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Fuel Storage Tanks

Drain the water and the sediment from the fuel
storage tank during the following conditions:
Weekly
Oil change
Refill of the tank
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank. A 4 micron [c] filter for the breather vent on
the fuel tank is also recommended. Refer to Special
Publication, SENR9620, Improving Fuel System
Durablity.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
i02121526
Hoses and Clamps Inspect/Replace

SMCS Code: 7554-040; 7554-510
Inspect all hoses for leaks that are caused by the
following conditions:
Cracking
Softness
Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
NOTICE
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the recommended torque.
SEBU8312
81
Maintenance Section
Overhaul Considerations
Check for the following conditions:
5. Disconnect the old hose.
End fittings that are damaged or leaking
6. Replace the old hose with a new hose.
Outer covering that is chafed or cut
7. Install the hose clamps with a torque wrench.
Exposed wire that is used for reinforcement

Outer covering that is ballooning locally
Note: Refer to the Specifications, SENR3130,

Torque Specifications in order to locate the proper
torques.
Flexible part of the hose that is kinked or crushed
8. Refill the cooling system.
Armoring that is embedded in the outer covering

cooling system filler caps gaskets. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
A constant torque hose clamp can be used in place

of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
clamp.
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
Each installation application can be different. The
differences depend on the 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

leaks.
i02677504
Overhaul Considerations
SMCS Code: 7595-043
Reduced hours of operation at full load will result in a
lower average power demand. A decreased average
power demand should increase both the engine
service life and the overhaul interval.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
The following factors are important when a decision
is being made on the proper time for an engine
overhaul:
The need for preventive maintenance

1. Stop the engine. Allow the engine to cool.
2. Loosen the cooling system filler cap slowly in
system filler cap.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
4. Remove the hose clamps.
The quality of the fuel that is being used

The operating conditions
The results of the SOS analysis
Oil Consumption as an Overhaul

Indicator
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
for the maintenance intervals.
Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
consumed per hour also increases.
82
Maintenance Section
Radiator - Clean
SEBU8312
The oil consumption rate (brake specific oil

consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
consumption rate for your engine.
Caterpillar Inc. recommends an SOS Coolant

Analysis (Level II).
SOS Coolant Analysis (Level II)
An SOS Coolant Analysis (Level II) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An SOS Coolant Analysis (Level II) provides
the following information:
When an engines oil consumption has risen to three

times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
Complete SOS Coolant Analysis (Level I)
Overhaul Recommendation
Visual inspection of properties
Caterpillar recommends replacement of the

engine. For more information about replacement
of the engine, see your Caterpillar dealer. Engine
components are available in a standard size only.
Identification of metal corrosion

Identification of contaminants
Identification of built up impurities (corrosion and
scale)
Cleaning
Caterpillar recommends the use of Hydrosolv
Liquid Cleaners. Table 29 lists the Hydrosolv Liquid
Cleaners that are available from your Caterpillar
dealer.
Table 29
SOS Coolant Analysis (Level II) provides a report of

the results of both the analysis and the maintenance
recommendations.
For more information about coolant analysis, see
your Caterpillar dealer.
HydrosolvLiquid Cleaners
Part
Number
Description
i02559063
Size
Radiator - Clean
SMCS Code: 1353-070
1U-8812
4 L (1 US gallon)
Hydrosolv4165
1U-5490
19 L (5 US gallon)
8T-7570
208 L (55 US gallon)
1U-8804
4 L (1 US gallon)
1U-5492
Hydrosolv100
8T-5571
Note: Adjust the frequency of cleaning according to

the effects of the operating environment.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.
19 L (5 US gallon)
208 L (55 US gallon)
Obtain Coolant Analysis

The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits or
with SOS Coolant Analysis (Level I).
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
by consulting your local water utility company or
an agricultural agent. Private laboratories are also
available for water analysis.
Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
of the fans air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move the
air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.
SEBU8312
83
Maintenance Section
Severe Service Application - Check
Pressurized water may also be used for cleaning.

The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Severe service operation can accelerate component

wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention of
full service life.
Use a degreaser and steam for removal of oil and

grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
Due to individual applications, it is not possible to

identify all of the factors which can contribute to
severe service operation. Consult your Caterpillar
dealer for the unique maintenance that is necessary
for the engine.
After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
Inspect the fins for damage. Bent fins may be opened
with a comb. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
For more detailed information on cleaning and
inspection, refer to Special Publication, SEBD0518,
Know Your Cooling System.
i00151038
Severe Service Application Check

SMCS Code: 1000-535
Severe service is an application of an engine that
exceeds current published standards for that engine.
Caterpillar maintains standards for the following
engine parameters:
The operating environment, improper operating

procedures and improper maintenance procedures
can be factors which contribute to severe service
conditions.
Environmental Factors
Ambient temperatures The engine may be
exposed to extended operation in extremely
cold environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
cold temperatures. Extremely hot inlet air reduces
engine performance.
Air Quality The engine may be exposed to
extended operation in an environment that is dirty
or dusty, unless the equipment is cleaned regularly.
Mud, dirt and dust can encase components.
Maintenance can be very difficult. The buildup can
contain corrosive chemicals.
Buildup Compounds, elements, corrosive
chemicals and salt can damage some components.
Performance (power range, speed range, and fuel
Altitude Problems can arise when the engine is

operated at altitudes that are higher than the intended
settings for that application. Necessary adjustments
should be made.
Fuel quality
Improper Operating Procedures
Altitude range
Extended operation at low idle
Maintenance intervals
Frequent hot shutdowns
Oil selection and maintenance
Operating at excessive loads
Coolant selection and maintenance
Operating at excessive speeds
Environmental qualities
Operating outside the intended application
Installation
Improper Maintenance Procedures
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.
Extending the maintenance intervals
consumption)
Failure to use recommended fuel, lubricants and

coolant/antifreeze
84
Maintenance Section
Starting Motor - Inspect
SEBU8312
i00651416
Starting Motor - Inspect
Removal and Installation

Note: The turbochargers that are supplied are
nonserviceable.
SMCS Code: 1451-040; 1453-040

Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
Check the starting motor for proper operation. Check
the electrical connections and clean the electrical
connections. Refer to the Service Manual for more
information on the checking procedure and for
specifications or consult your Caterpillar dealer for
assistance.
i02226957
Turbocharger - Inspect
(If Equipped)
SMCS Code: 1052-040
A regular visual inspection of the turbocharger is
recommended. Any fumes from the crankcase are
filtered through the air inlet system. Therefore,
by-products from oil and from combustion can collect
in the turbocharger compressor housing. Over time,
this buildup can contribute to loss of engine power,
increased black smoke and overall loss of engine
efficiency.
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder
head.
NOTICE
Turbocharger bearing failures can cause large quantities of oil to enter the air intake and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
For options regarding the removal, installation, repair

and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine for the
procedure and specifications.
Inspecting
NOTICE
The compressor housing for the turbocharger must
not be removed from the turbocharger for cleaning.
The actuator linkage is connected to the compressor
housing. If the actuator linkage is moved or disturbed
the engine may not comply with emmissions legislation.
1. Remove the pipe from the turbocharger exhaust
outlet and remove the air intake pipe to the
turbocharger. Visually inspect the piping for the
presence of oil. Clean the interior of the pipes
in order to prevent dirt from entering during
reassembly.
2. Check for the presence of oil. If oil is leaking from
the back side of the compressor wheel, there is a
possibility of a failed turbocharger oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
for the intake air (clogged air filters), which causes
the turbocharger to slobber.
3. Inspect the bore of the housing of the turbine
outlet for corrosion.
4. Fasten the air intake pipe and the exhaust outlet
pipe to the turbocharger housing.
i00632301
Minor leakage of oil into a turbocharger under extended low idle operation should not cause problems as
long as a turbocharger bearing failure has not occured.
Walk-Around Inspection
When a turbocharger bearing failure is accompanied

by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is renewed.
Inspect the Engine for Leaks and

for Loose Connections
A visual inspection of the turbocharger can minimize

unscheduled downtime. A visual inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
SMCS Code: 1000-040
A walk-around inspection should only take a few

minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
SEBU8312
85
Maintenance Section
Water Pump - Inspect
For maximum engine service life, make a thorough

inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
Belts for multiple groove pulleys must be replaced as

matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
The guards must be in the proper place. Repair
Drain the water and the sediment from fuel tanks
damaged guards or replace missing guards.
Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system

contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
on a daily basis in order to ensure that only clean

fuel enters the fuel system.
Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed

wires.
Inspect the ground strap for a good connection and

for good condition.
Inspect the engine-to-frame ground strap for a

good connection and for good condition.
Disconnect any battery chargers that are not
protected against the current drain of the starting

motor. Check the condition and the electrolyte level
of the batteries, unless the engine is equipped with
a maintenance free battery.
Check the condition of the gauges. Replace any

Ensure that cooling lines are properly clamped and
gauges which are cracked or can not be calibrated.
tight. Check for leaks. Check the condition of all

pipes.
Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
the parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
water pump and the installation of water pump and/or
seals, refer to the Service Manual for the engine or
consult your Caterpillar dealer.
Inspect the lubrication system for leaks at the front

crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
Inspect the fuel system for leaks. Look for loose
fuel line clamps.
Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
Inspect the alternator belt and the accessory drive

belts for cracks, breaks or other damage.
i02226958
Water Pump - Inspect

SMCS Code: 1361-040; 1361
A failed water pump may 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
Note: The water pump seal is lubricated by the
coolant in the cooling system. It is normal for a small
amount of leakage to occur as the engine cools down
and parts contract.
Visually inspect the water pump for leaks. Renew
the water pump seal or the water pump if there
is an excessive leakage of coolant. Refer to the
Disassembly and Assembly Manual, Water Pump
- Remove and Install for the disassembly and
assembly procedure.

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C0.5, C0.7, C1.1, C1.5, C1.6

Excerpted from Operation & Maintenance Manual (SEBU8312-00-01)

Maintenance Interval Schedule

Engine Protective Devices - Check ...................... 71

SMCS Code: 1000; 7500

Every 1000 Service Hours

Alternator and Fan Belts - Replace ....................... 53

Battery - Replace ..................................................

Alternator - Inspect ...............................................

Every 2000 Service Hours

Cooling System Coolant Sample (Level 2) Obtain ................................................................. 60

Every 3000 Service Hours

Every 3000 Service Hours or 2 Years

Fuel Tank Water and Sediment - Drain ................. 80

Cooling System Coolant (DEAC) - Change .......... 54

Every 250 Service Hours

Every 6000 Service Hours or 3 Years

Cooling System Coolant Sample (Level 1) Obtain ................................................................. 59

Cooling System Coolant Extender (ELC) - Add .... 58

Every 50 Service Hours or Weekly

Every 250 Service Hours or 6 Months

Cooling System Coolant (ELC) - Change ............. 56

Alternator and Fan Belts - Inspect/Adjust ............. 52

Initial 500 Hours (for New Systems, Refilled

Every 500 Service Hours

Every 500 Service Hours or 1 Year

Every 12 000 Service Hours or 6 Years

Alternator and Fan Belts Inspect/Adjust

Install the gauge (1) at the center of the belt between

SMCS Code: 1357-025; 1357-040

1. Loosen the mounting bolts (2) and the adjusting

2. Move the alternator in order to increase or

Alternator and Fan Belts Replace

Batteries give off combustible gases which can

The battery cables or the batteries should not be

2. Turn OFF the battery charger. Disconnect the

For applications that require multiple drive belts,

3. The NEGATIVE - cable connects the NEGATIVE

8. Connect the cable from the ground plane to the

Battery Electrolyte Level Check

All lead-acid batteries contain sulfuric acid which

Battery or Battery Cable Disconnect

The battery cables or the batteries should not be

3. Keep the batteries clean.

Clean the battery case with one of the following

A mixture of 0.1 kg (0.2 lb) of baking soda and

A mixture of 0.1 L (0.11 qt) of ammonia and 1 L

Thoroughly rinse the battery case with clean water.

Cooling System Coolant

The engine overheats frequently.

The fuel has entered the cooling system and the

2. Close the drain valve (if equipped). Clean the

Cooling Systems with Heavy

3. Check the coolant level. Maintain the coolant level

Cooling System Coolant (ELC)

The engine overheats frequently.

The fuel has entered the cooling system and the

Note: When the cooling system is cleaned, only

5. Stop the engine and allow the engine to cool.

Cooling System Coolant

Dispose of all fluids according to local regulations and

1. Loosen the cooling system filler cap slowly in

Check the cooling system only when the engine is