Sie sind auf Seite 1von 43

MAINTENANCE INTERVALS

Operation and Maintenance


Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
SEBU8543
April 2011

Operation and
Maintenance
Manual
C15 Petroleum Engines
SWE1-Up (Engine)
HAZ1-Up (Engine)

SAFETY.CAT.COM
66 SEBU8543
Maintenance Section
Maintenance Interval Schedule

i04195409 Initial 250 Service Hours


Maintenance Interval Schedule Engine Valve Lash - Check ................................... 90
Engine Valve Rotators - Inspect ........................... 90
SMCS Code: 1000; 4450; 7500 Fuel Injector - Inspect/Adjust ................................ 93

Ensure that all safety information, warnings, Initial 500 Hours (for New Systems, Refilled
and instructions are read and understood before Systems, and Converted Systems)
any operation or any maintenance procedures
are performed. The user is responsible for the Coolant Sample (Level 2) - Obtain ....................... 78
performance of all maintenance including the
following procedures: all adjustments, the use of Every 500 Service Hours
proper lubricants, fluids, filters, and the installation
of new components due to normal wear and aging . Engine Oil and Filter - Change ............................. 88
The performance of this product may be diminished if
proper maintenance intervals and procedures are not Every Year
followed. Components may experience accelerated
Coolant Sample (Level 2) - Obtain ....................... 78
wear if proper maintenance intervals and procedures
are not followed.
Every 8000 Service Hours
Note: Use whichever of the following that occurs Fan Drive Bearing - Replace ................................ 91
first in order to determine the maintenance intervals:
service hours and calendar time . Before each
PM Level 1 - Every 12 750 L (3375 US gal) of
consecutive interval is performed, all maintenance
from the previous intervals must be performed.
Fuel or 250 Service Hours or 6 Months
Air Shutoff - Test ................................................... 70
Products that operate in severe operating conditions Battery Electrolyte Level - Check .......................... 71
may require more frequent maintenance. Refer to Belts - Inspect/Replace ......................................... 73
this Operation and Maintenance Manual, “Severe Coolant Sample (Level 1) - Obtain ....................... 77
Service Applications” to determine if the engine is Engine Crankcase Breather - Clean ..................... 84
operating in a severe service application. Engine Oil Sample - Obtain .................................. 87
Engine Protective Devices - Check ...................... 89
When Required Fan Drive Bearing - Lubricate ............................... 91
Fuel System Primary Filter (Water Separator)
Battery or Battery Cable - Disconnect .................. 72
Element - Replace .............................................. 95
Coolant - Change .................................................. 74
Fuel System Secondary Filter - Replace .............. 96
Coolant Extender (ELC) - Add .............................. 76
Fuel Tank Water and Sediment - Drain ................. 97
Engine Air Cleaner Element (Dual Element) - Grounding Stud - Inspect/Clean/Tighten ............... 98
Inspect/Clean/Replace ........................................ 81
Hoses and Clamps - Inspect/Replace .................. 98
Engine Oil Level Gauge - Calibrate ...................... 86
Engine Storage Procedure - Check ...................... 90
Flame Arrestor - Inspect/Clean ............................. 91 PM Level 2 - Every 114 000 L (30 000 US gal)
Fuel System - Prime ............................................. 93 of Fuel or 3000 Service Hours or 2 Years
Aftercooler Core - Clean/Test ............................... 69
Daily Fuel Tank Water and Sediment - Drain ................. 97
Coolant Level - Check .......................................... 77
Driven Equipment - Check .................................... 80 PM Level 3 - Every 153 000 L (40 500 US gal)
Engine Air Cleaner Service Indicator - Inspect ..... 83 of Fuel or 3000 Service Hours or 2 Years
Engine Air Precleaner - Check/Clean ................... 84
Belt Tensioner - Check .......................................... 72
Engine Oil Level - Check ...................................... 85 Coolant Temperature Regulator - Replace ........... 78
Fuel System Primary Filter/Water Separator -
Cooling System Supplemental Coolant Additive
Drain ................................................................... 94
(SCA) - Test/Add ................................................. 79
Walk-Around Inspection ...................................... 105 Crankshaft Vibration Damper - Inspect ................. 80
Engine - Clean ...................................................... 80
Every 50 Service Hours Engine Mounts - Inspect ....................................... 85
Aftercooler Condensate Drain Valve - Engine Speed/Timing Sensor - Clean/Inspect ...... 90
Inspect/Clean ...................................................... 68 Engine Valve Lash - Check ................................... 90
Aftercooler Condensate Drain Valve - Engine Valve Rotators - Inspect ........................... 90
Inspect/Clean ...................................................... 69 Fuel Injector - Inspect/Adjust ................................ 93
SEBU8543 67
Maintenance Section
Maintenance Interval Schedule

Every 256 000 L (67 500 US gal) of Fuel or


5000 Service Hours
Starting Motor - Inspect ...................................... 104
Turbocharger - Inspect ........................................ 104
Water Pump - Inspect ......................................... 106

Every 380 000 L (100 000 US gal) of Fuel or


10 000 Service Hours
Overhaul Considerations .................................... 101
68 SEBU8543
Maintenance Section
Aftercooler Condensate Drain Valve - Inspect/Clean

i04345749

Aftercooler Condensate Drain


When replacement parts are required for this
Valve - Inspect/Clean product, Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
SMCS Code: 1063-042-DN fications including, but not limited to, physical
dimensions, type, strength, and material.
S/N: HAZ1-Up
Never reuse any clamps, seals, or gaskets in the
flameproof intake or exhaust system. Always re-
place clamps, seals, and gaskets with new Cat
parts which match the parts being replaced by the
exact Cat part number.

Failure to heed this warning may lead to prema-


ture failures, product damage, personal injury, or
death.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
g02500916 ing, adjusting, and repair of the product. Be prepared
Illustration 36
to collect the fluid with suitable containers before
Aftercooler with flame arrestor and drain valve opening any compartment or disassembling any com-
(1) Flame arrestor ponent containing fluids.
(2) Aftercooler drain valve
(3) Plunger for the drain valve
Refer to Special Publication, NENG2500, “Cat Dealer
(4) Valve seat for the drain valve
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” for
The engine boost pressure forces the plunger to
tools and supplies suitable to collect and contain fluids
move down to the valve seat. The plunger must
on Cat products.
close against the seat at a pressure of 27.5 kPa
(4 psi). When the engine is stopped, the absence of
Dispose of all fluids according to local regulations and
boost pressure allows the plunger to rise to the open
mandates.
position allowing condensation from the aftercooler
to drain.
1. Remove the aftercooler condensate drain valve
The plunger must be able to move freely in order to from the flame arrestor.
close the system when the engine is running. The
plunger must be able to move freely in order to allow 2. Check the aftercooler condensate drain valve in
condensation to drain from the aftercooler when order to determine if the plunger moves freely. If
the engine is stopped. Residue from normal engine the plunger does not move easily, clean the valve
operation could cause the plunger to stick. with solvent.

3. Reassemble the aftercooler condensate drain


valve. See Specifications Manual, SENR3130,
“Torque Specifications” for more information on
the proper torques.

4. Reassemble the aftercooler condensate drain


valve to the flame arrestor. Attach the flame
arrestor to the aftercooler.
SEBU8543 69
Maintenance Section
Aftercooler Condensate Drain Valve - Inspect/Clean

i04345729 1. Remove the valve from the adapter. Check the


valve in order to determine if the plunger moves
Aftercooler Condensate Drain freely. If the plunger does not move easily, clean
Valve - Inspect/Clean the valve with solvent.

SMCS Code: 1063-042-DN 2. Reassemble the aftercooler condensate drain


valve. See Specifications Manual, SENR3130,
S/N: SWE1-Up “Torque Specifications” for more information on
the proper torques.

i04363377

Aftercooler Core - Clean/Test


SMCS Code: 1064-070; 1064-081

Note: An aftercooler that circulates fresh water


or treated water may require cleaning less often
than an aftercooler which circulates salt water.
The maintenance interval for an aftercooler which
circulates fresh water or treated water should be
evaluated when the aftercooler is cleaned and tested
g02500896 after the first 1000 hours of engine operation. The
Illustration 37
interval will vary depending on operating conditions.
Aftercooler drain valve
(1) Drain valve for the aftercooler
(2) Plunger Clean the Aftercooler Core
(3) Valve seat
Remove the core. Refer to the Disassembly and
The engine boost pressure forces the plunger to Assembly Manual, “Aftercooler - Remove” for the
move down to the valve seat. The plunger must procedure.
close against the seat at a pressure of 27.5 kPa
(4 psi). When the engine is stopped, the absence 1. Turn the aftercooler core on one side in order
of boost pressure allows the plunger to rise to the to remove debris. Remove the debris that is
open position, which allows condensation from the accessible.
aftercooler to drain out.
NOTICE
The plunger must be able to move freely in order to Do not use a high concentration of caustic cleaner to
close the system when the engine is running. The clean the core. A high concentration of caustic cleaner
plunger must be able to move freely in order to allow can attack the internal metals of the core and cause
condensation to drain from the aftercooler when leakage. Only use the recommended concentration of
the engine is stopped. Residue from normal engine cleaner.
operation could cause the plunger to stick.
2. Back flush the core with cleaner.
NOTICE
Care must be taken to ensure that fluids are contained Caterpillar recommends the use of Hydrosolv
during performance of inspection, maintenance, test- liquid cleaner. Table 17 lists Hydrosolv liquid
ing, adjusting, and repair of the product. Be prepared cleaners that are available from your Cat dealer.
to collect the fluid with suitable containers before
opening any compartment or disassembling any com- Table 17
ponent containing fluids. Hydrosolv Liquid Cleaners(1)
Refer to Special Publication, NENG2500, “Cat Dealer Part
Description Size
Service Tool Catalog” or refer to Special Publication, Number
PECJ0003, “Cat Shop Supplies and Tools Catalog” for 1U-5490 Hydrosolv 4165 19 L (5 US gallon)
tools and supplies suitable to collect and contain fluids
on Cat products. 174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner at
Dispose of all fluids according to local regulations and temperatures up to 93°C (200°F). Consult your Cat dealer for
mandates. more information.
70 SEBU8543
Maintenance Section
Air Shutoff - Test

3. Steam clean the core in order to remove any i04355249


residue. Flush the fins of the aftercooler core.
Remove any other trapped debris from the inside Air Shutoff - Test
and from the outside of the core.
SMCS Code: 1078-081
Note: Do not use high pressure when the fins are
cleaned. High pressure can damage the fins. Emergency Stop Control
4. Wash the core with hot, soapy water. The customer or the OEM is responsible for wiring the
“EMERGENCY STOP” into the customer connection
5. Flush the core thoroughly in order to remove (J1) side of the ECM. Refer to the Troubleshooting
residue and remaining debris. Flush the core with Guide for more information.
clean, fresh water until the water that is exiting the
core is clear and free of debris.

Personal injury can result from air pressure.

Personal injury can result without following prop-


er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

The maximum air pressure for cleaning purposes


must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
g00104303
Illustration 38
6. Dry the core with compressed air. Direct the air in Typical emergency stop switch
the reverse direction of the normal flow.
The “EMERGENCY STOP” switch is in the OUT
Test the Aftercooler Core position for normal engine operation. Push the
“EMERGENCY STOP” switch to stop the engine in
1. Inspect the core for trapped debris and an emergency situation. The engine will not start
cleanliness. If necessary, remove the debris and when the button is locked. Turn the button clockwise
repeat the cleaning procedure. in order to reset.

2. Inspect the core for damage and perform a


pressure test in order to detect leaks. Many shops
that service radiators are equipped to perform
pressure tests.

3. Plug both ends of the aftercooler core and


pressurize the core to 205 kPa (30 psi). Submerge
the core in water. Look for bubbles which are
being emitted from the core. The bubbles are
evidence of leaks.

4. If any leaks are found, do not attempt to repair the


core.

Install a core that is clean and a core that passes the


pressure test in step 3. Refer to the Disassembly
and Assembly Manual, “Aftercooler - Install” for the
procedure.

For more information on cleaning the core, consult


your Cat dealer.
SEBU8543 71
Maintenance Section
Battery Electrolyte Level - Check

Type 1 Type 2

g01402506
Illustration 40
Air shutoff with the valve mechanism in the OPEN position

1. With the power for the engine control panel in the


ON position, activate the “EMERGENCY STOP”
switch. If the valve mechanism closes, proceed to
Illustration 39
g02504916 step 2. If the valve mechanism does not close,
check the wiring for the air shutoff switch and
Air shutoff with the “STOP HANDLE” in the RUN position
check the wiring for the solenoids. Activate the
“EMERGENCY STOP” switch again. When the
Note: Refer to this Operation and Maintenance valve mechanism closes, proceed to step 2.
Manual, “Starting the Engine” for information about
starting the engine after an emergency stop with this 2. Reset the valve mechanism to the CLOSED
type of air shutoff. position. Operate the engine normally. Ensure that
the valve mechanism continues to be latched.
Test Using the “EMERGENCY STOP”
Control Refer to the Troubleshooting Guide, “Air Shutoff
System” information in your Service Manual for
With the power for the engine control panel in the further information about the electrical system for the
ON position, activate the “EMERGENCY STOP” air shutoff system.
switch. If the valve mechanism does not close, check
the wiring for the air shutoff switch. Activate the
i02601752
“EMERGENCY STOP” switch again.
Battery Electrolyte Level -
Refer to the Troubleshooting Guide, “Air Shutoff
System” information in your Service Manual for Check
further information about the electrical system for the
air shutoff system. SMCS Code: 1401-535-FLV

When the engine is not run for long periods of time or


Test Using the “STOP HANDLE” on the when the engine is run for short periods, the batteries
Air Shutoff may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing.
Move the “STOP HANDLE” counterclockwise until the
handle reaches the stop in order to stop the engine.

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.
72 SEBU8543
Maintenance Section
Battery or Battery Cable - Disconnect

If the addition of water is necessary, use distilled 1. Turn the start switch to the OFF position. Turn the
water. If distilled water is not available use clean ignition switch (if equipped) to the OFF position
water that is low in minerals. Do not use artificially and remove the key and all electrical loads.
softened water.
2. Disconnect the negative battery terminal at the
2. Check the condition of the electrolyte with the battery that goes to the start switch. Ensure that
245-5829 Coolant Battery Tester Refractometer. the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
3. Keep the batteries clean. two batteries must be disconnected.

Clean the battery case with one of the following 3. Tape the leads in order to help prevent accidental
cleaning solutions: starting.

• A mixture of 0.1 kg (0.2 lb) of baking soda and 4. Proceed with necessary system repairs. Reverse
1 L (1 qt) of clean water the steps in order to reconnect all of the cables.

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L i04284650


(1 qt) of clean water

Thoroughly rinse the battery case with clean water.


Belt Tensioner - Check
SMCS Code: 1358-535
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.

i02039603

Battery or Battery Cable -


Disconnect
SMCS Code: 1401; 1402-029

The connection of battery cables to a battery and


the disconnection of battery cables from a battery
may cause an explosion which may result in injury
or death. The connection and the disconnection
of other electrical equipment may also cause an
explosion which may result in injury or death. The
procedures for the connection and the disconnec-
tion of battery cables and other electrical equip-
ment should only be performed in a nonexplosive
atmosphere. g02451658
Illustration 41
Typical

The battery cables or the batteries should not be


removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.

Removing the battery cables or the batteries with


the cover in place may cause a battery explosion
resulting in personal injury.
SEBU8543 73
Maintenance Section
Belts - Inspect/Replace

i04275869

Belts - Inspect/Replace
SMCS Code: 1397-040; 1397-510

g02352075
Illustration 42
Side view of the belt tensioner
(1) Bolt
(2) Jamming Locknut (Jam nut)
g02294633
Ensure that the tensioner is at the forward stop. Illustration 43
Ensure that the torque for the bolt is 260 N·m View of the front of a typical C15 Engine
(192 lb ft). (1) Belt
(2) Belt tensioner
(3) Alternator
(4) Idler pulley
(5) Crankshaft pulley

Inspecting the Belt


Inspect the belt for the following conditions: cracks,
wear, stretch, frayed areas, and missing pieces.

Replacing the Belt


For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.
74 SEBU8543
Maintenance Section
Coolant - Change

Drain the Coolant

Pressurized System: Hot coolant can cause seri-


ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.

NOTICE
Care must be taken to ensure that fluids are contained
g02457182 during performance of inspection, maintenance, test-
Illustration 44
ing, adjusting, and repair of the product. Be prepared
Belt Tensioner to collect the fluid with suitable containers before
(6) Adjusting bolt opening any compartment or disassembling any com-
(7) Jamming locknut (Jam nut) ponent containing fluids.
1. Loosen the bolt in order to relieve pressure on the Refer to Special Publication, NENG2500, “Cat Dealer
jam nut. Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” for
2. Move the tensioner in towards the engine to tools and supplies suitable to collect and contain fluids
relieve tension on the belt. on Cat products.
3. Remove the old belts and replace with new belt. Dispose of all fluids according to local regulations and
Contact your Cat dealer for assistance in choosing mandates.
and ordering new belts.

4. Move out the tensioner towards the front of the 1. Stop the engine and allow the engine to cool.
engine until the tensioner stops. Tighten the bolt Loosen the cooling system filler cap slowly in
to a torque of 260 N·m (192 lb ft). order to relieve any pressure. Remove the cooling
system filler cap.

i04317341 2. Open the cooling system drain valve (if equipped).


If the cooling system is not equipped with a drain
Coolant - Change valve, remove one of the drain plugs.
SMCS Code: 1350-044; 1352; 1395-044; 1395 Note: If equipped, be sure to drain the heater and
any related supply and return lines.
Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for the correct intervals Allow the coolant to drain.
for changing the coolant.

Clean the cooling system and flush the cooling NOTICE


system before the recommended maintenance Dispose of used engine coolant properly or recycle.
interval if the following conditions exist: 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
• The engine overheats frequently. Caterpillar to reclaim the used coolant.
• Foaming is observed.
For information regarding the disposal and the
• The oil has entered the cooling system and the recycling of used coolant, consult your Cat dealer or
coolant is contaminated. consult Cat Dealer Service Tool Group:

• The fuel has entered the cooling system and the Inside USA: 1-800-542-TOOL
coolant is contaminated. Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
International: 1-309-578-7372
SEBU8543 75
Maintenance Section
Coolant - Change

Flush 6. Choose 1 of the following options.

Systems Filled with Cat ELC, Cat ELI, or a • Add 0.5 L (1 pint) of cleaner per 15 L (4 US gal)
of the cooling system capacity.
Conventional Coolant that Meets the Cat
EC-1 Requirements and the Standards • For cooling systems with heavy deposits or
of ASTM D6210 plugging, add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
3. Flush the cooling system with clean water in order capacity.
to remove any debris.
7. Install the cooling system filler cap.
4. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to 8. Start and run the engine at low idle for a minimum
the Specifications Manual, SENR3130, “Torque of 30 minutes. The coolant temperature should be
Specifications” for more information on the proper at least 82 °C (180 °F).
torques.
NOTICE
NOTICE Improper or incomplete rinsing of the cooling system
Fill the cooling system no faster than 19 L (5 US gal) can result in damage to copper and other metal com-
per minute to avoid air locks. ponents.

To avoid damage to the cooling system, make sure


5. Fill the cooling system with clean water. Install the to completely flush the cooling system with clear wa-
cooling system filler cap. ter. Continue to flush the system until all signs of the
cleaning agent are gone.
6. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
9. Stop the engine and allow the engine to cool.
7. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly
Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the
in order to relieve any pressure. Remove the cooling system filler cap. Open the drain valve
cooling system filler cap. Open the drain valve (if equipped) or remove the cooling system drain
(if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling
plugs. Allow the water to drain. Flush the cooling system with clean water. If equipped, be sure to
system with clean water. Close the drain valve flush the heater and any related supply and return
(if equipped). Clean the drain plugs. Install the lines. Close the drain valve (if equipped). Clean
drain plugs. Refer to the Specifications Manual, the drain plugs. Install the drain plugs. Refer to
SENR3130, “Torque Specifications” for more the Specifications Manual, SENR3130, “Torque
information on the proper torques. Specifications” for more information on the proper
torques.
Systems Filled with Cat DEAC or
Conventional Coolant which does not Fill
Meet the Cat EC-1 Requirements
NOTICE
3. Flush the cooling system with clean water in order Fill the cooling system no faster than 19 L (5 US gal)
to remove any debris. per minute to avoid air locks.

4. Close the drain valve (if equipped). Clean the 10. Fill the cooling system. Refer to this Operation and
drain plugs. Install the drain plugs. Refer to Maintenance Manual, “Fluid Recommendations”
the Specifications Manual, SENR3130, “Torque for more information on cooling system
Specifications” for more information on the proper specifications Refer to this Operation and
torques. Maintenance Manual, “Refill Capacities” for
information about the capacity of the cooling
NOTICE system. Do not install the cooling system filler cap.
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks. 11. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for 1 minute in order to purge the air from the
5. Fill the cooling system with a mixture of clean cavities of the engine block. Stop the engine.
water and Cat Fast Acting Cooling System
Cleaner.
76 SEBU8543
Maintenance Section
Coolant Extender (ELC) - Add

12. 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
Personal injury can result from hot coolant, steam
13 mm (0.5 inch) to the proper level on the sight
and alkali.
glass (if equipped).
At operating temperature, engine coolant is hot
13. Clean the cooling system filler cap. Inspect the
and under pressure. The radiator and all lines
gasket that is on the cooling system filler cap.
to heaters or the engine contain hot coolant or
Only install the used filler cap if the gasket is not
steam. Any contact can cause severe burns.
damaged. Use a 9S-8140 Pressurizing Pump to
pressure test a reinstalled cooling system filler
Remove cooling system pressure cap slowly to
cap. The correct pressure for the cooling system
relieve pressure only when engine is stopped and
filler cap is stamped on the face of the cooling
cooling system pressure cap is cool enough to
system filler cap. If the cooling system filler cap
touch with your bare hand.
does not retain the correct pressure, install a new
cooling system filler cap.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
14. Start the engine. Inspect the cooling system for
burns.
leaks and for proper operating temperature.
Cooling System Coolant Additive contains alkali.
i04340410 Avoid contact with skin and eyes.

Coolant Extender (ELC) - Add


NOTICE
SMCS Code: 1352-544-NL Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Note: Refer to this Operation and Maintenance ing, adjusting, and repair of the product. Be prepared
Manual, “Fluid Recommendations” (Cooling System) to collect the fluid with suitable containers before
for the maintenance interval for the addition of the opening any compartment or disassembling any com-
coolant extender. ponent containing fluids.

Cat ELC (Extended Life Coolant) and Cat ELI Refer to Special Publication, NENG2500, “Cat Dealer
(Extended Life Inhibitor) do not require the frequent Service Tool Catalog” or refer to Special Publication,
additions of any supplemental cooling additives PECJ0003, “Cat Shop Supplies and Tools Catalog” for
which are associated with the present conventional tools and supplies suitable to collect and contain fluids
coolants. The Cat ELC Extender will only be added on Cat products.
one time.
Dispose of all fluids according to local regulations and
Note: Do not use conventional supplemental coolant mandates.
additive (SCA) with Cat ELC or with Cat ELI.
1. Loosen the cooling system filler cap slowly in
Check the cooling system only when the engine is order to relieve pressure. Remove the cooling
stopped and cool. system filler cap.

2. If necessary, drain enough coolant from the


cooling system in order to add the Cat ELC
Extender.

3. Add Cat ELC Extender according to the


requirements for the cooling system capacity.
Refer to this Operation and Maintenance Manual,
“Refill Capacities” for the coolant capacity.

4. Clean the cooling system filler cap. Inspect the


gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.

For further information, refer to Special Publication,


SEBU6251, “Fluid Recommendations for Cat
Commercial Diesel Engines”.
SEBU8543 77
Maintenance Section
Coolant Level - Check

i04354770 • Complete the information on the label for the


sampling bottle before you begin to take the
Coolant Level - Check samples.
SMCS Code: 1395-082 • Keep the unused sampling bottles stored in plastic
bags.
Check the level of coolant daily. Add the amount
of coolant required. Refer to this Operation and • Obtain coolant samples directly from the coolant
Maintenance Manual, “Refill Capacities” for the sample port. You should not obtain the samples
amount of coolant required to fill the cooling system. from any other location.
Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for the types of coolant • Keep the lids on empty sampling bottles until you
that may be used in the engine. are ready to collect the sample.

i04333559 • Place the sample in the mailing tube immediately


after obtaining the sample in order to avoid
Coolant Sample (Level 1) - contamination.
Obtain • Never collect samples from expansion bottles.
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
• Never collect samples from the drain for a system.
Testing the engine coolant is important to ensure
that the engine is protected from internal cavitation Timing of the Sampling
and corrosion. The analysis also tests the ability of
Table 18
the coolant to protect the engine from boiling and
freezing. S·O·S Systems Coolant Analysis can be Recommended Interval
done at your Cat dealer. Cat S·O·S coolant analysis is
Type of Coolant Level 1 Level 2
the best way to monitor the condition of your coolant
and your cooling system. S·O·S coolant analysis is a Cat DEAC
program that is based on periodic samples. Cat SCA
Conventional Every 250 hours Yearly(1)
Note: Obtaining a Coolant Sample (Level 1) is Heavy-Duty
optional if the cooling system is filled with one of Coolants
the following coolants: Cat ELC (Extended Life Cat ELC
Coolant)., Cat ELI (Extended Life Inhibitor), and Cat ELI
Optional(1) Yearly(1)
Conventional Heavy-Duty Coolant. Commercial
EC-1 Coolants
Note: Obtain a Coolant Sample (Level 1) if the (1) The Level 2 Coolant Analysis should be performed sooner if a
cooling system is filled with any of the following problem is suspected or identified.
coolants: Cat DEAC, Cat SCA, and Conventional
Heavy-Duty Coolants. Note: Check the SCA (Supplemental Coolant
Additive) of the conventional coolant at every oil
For additional information about coolant analysis change or at every 250 hours. Perform this check at
and about other coolants, see this Operation and the interval that occurs first.
Maintenance Manual, “Fluid Recommendations” or
consult your Cat dealer. Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order to
Sampling Conditions receive the full effect of S·O·S analysis, establish
a consistent trend of data. In order to establish
If the engine is equipped with a sampling port, the a pertinent history of data, perform consistent
engine should be running at operating temperature samplings that are evenly spaced. Supplies for
when the sample is obtained. collecting samples can be obtained from your Cat
dealer.
If the engine is not equipped with a sampling port, the
coolant should be warm.

Use the following guidelines for proper sampling of


the coolant:
78 SEBU8543
Maintenance Section
Coolant Sample (Level 2) - Obtain

A water temperature regulator that fails in the closed


NOTICE position can cause excessive overheating. Excessive
Always use a designated pump for oil sampling, and overheating could result in cracking of the cylinder
use a separate designated pump for coolant sampling. head or piston seizure problems.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This NOTICE
contaminate may cause a false analysis and an incor- Failure to replace your water temperature regulator
rect interpretation that could lead to concerns by both on a regularly scheduled basis could cause severe
dealers and customers. engine damage.

Submit the sample for Level 1 analysis. Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water
Note: Level 1 results may indicate a need for Level temperature regulator installed.
2 Analysis.
If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder head
i04169969 damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
Coolant Sample (Level 2) - the water temperature regulator vent hole is open.
Obtain
Do not use liquid gasket material on the gasket or
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 cylinder head surface.

Refer to Operation and Maintenance Manual,


“Coolant Sample (Level 1) - Obtain” for the guidelines NOTICE
for proper sampling of the coolant. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Submit the sample for Level 2 analysis. ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
For further information, refer to this Operation and opening any compartment or disassembling any com-
Maintenance Manual, “Fluid Recommendations”. ponent containing fluids.

Refer to Special Publication, NENG2500, “Cat Dealer


i04240223 Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” for
Coolant Temperature tools and supplies suitable to collect and contain fluids
Regulator - Replace on Cat products.

SMCS Code: 1355-510 Dispose of all fluids according to local regulations and
mandates.
Replace the water temperature regulator before the
water temperature regulator fails. Replacing the Note: If replacing only the water temperature
water temperature regulator reduces the chances for regulator, only drain the coolant to a level that is
unscheduled downtime. below the water temperature regulator housing.
A water temperature regulator that fails in a Refer to two articles in the Disassembly and
partially opened position can cause overheating or Assembly Manual, “Water Temperature Regulator -
overcooling of the engine. Remove and Water Temperature Regulator - Install”
for the replacement procedure or consult your Cat
A water temperature regulator that fails in the open dealer.
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.
SEBU8543 79
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i04269112
NOTICE
Cooling System Supplemental Use Only Approved SCAs. Conventional coolants
Coolant Additive (SCA) - require the maintenance addition of SCA throughout
their expected life. Do NOT use an SCA with a coolant
Test/Add unless specifically approved by the coolant supplier
(Systems Which are Filled with for use with their coolant. It is the responsibility of the
coolant manufacturer to ensure compatibility and ac-
Conventional Coolant) ceptable performance.
SMCS Code: 1352-045; 1395-081 Failure to follow the recommendations can result in
shortened cooling system component life.
This maintenance procedure is required for
conventional coolants such as DEAC.Do not
perform this maintenance for cooling systems NOTICE
that are filled with Cat Extended Life Coolant (Cat Care must be taken to ensure that fluids are contained
ELC) or Cat Extended Life Inhibitor (Cat ELI). during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with
Refer to Special Publication, NENG2500, “Cat Deal-
the skin and eyes. Do not drink cooling system
er Service Tool Catalog” and to Special Publication,
coolant additive.
GECJ0003, “Cat Shop Supplies and Tools” for tools
and supplies suitable to collect and contain fluids on
NOTICE Cat products.
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur- Dispose of all fluids according to applicable regula-
faces of the cooling system, reducing the engine's tions and mandates.
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other Note: Caterpillar recommends that an S·O·S Coolant
high temperature components. Analysis (Level 1) be performed to check the
concentration of SCA.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat exchang-
er, overheating, and/or accelerated wear of the water Maintain the Proper Concentration
pump seal. of SCA in the Coolant
Do not exceed the recommended amount of supple-
mental coolant additive concentration.
Pressurized System: Hot coolant can cause seri-
NOTICE ous burns. To open the cooling system filler cap,
Do NOT mix brands or types of SCA. Do NOT mix stop the engine and wait until the cooling system
SCAs and extenders. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
Failure to follow the recommendations can result in sure.
shortened cooling system component life.
1. Remove the cooling system filler cap slowly.

2. Test the concentration of the SCA with a


286-2578 Nitrite Test Strip or review the results
of the S·O·S Coolant Analysis (Level 1).

3. If necessary, drain some coolant in order to allow


space for the addition of the SCA.

4. Add the amount of SCA required to maintain a


concentration of 3 percent to 6 percent SCA in
the coolant.
80 SEBU8543
Maintenance Section
Crankshaft Vibration Damper - Inspect

5. Clean the cooling system filler cap. Install the Refer to the Disassembly and Assembly Manual,
cooling system filler cap. “Vibration Damper and Pulley - Remove and Install”
or consult your Caterpillar dealer for information
For further information, refer to Special Publication, about damper replacement.
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.
i00174798

i02933380 Driven Equipment - Check


Crankshaft Vibration Damper SMCS Code: 3279-535
- Inspect Refer to the OEM specifications for more information
on the following maintenance recommendations for
SMCS Code: 1205-040
the driven equipment:
Damage to the crankshaft vibration damper or failure
of the crankshaft vibration damper can increase • Inspection
torsional vibrations. This can result in damage to
the crankshaft and to other engine components. A • Adjustment
damper that is damaged can cause excessive gear
train noise at variable points in the speed range. • Lubrication

The damper is mounted to the crankshaft which is • Other maintenance recommendations


located behind the belt guard on the front of the
Perform any maintenance for the driven equipment
engine.
which is recommended by the OEM.

Visconic Damper
i02106981

The visconic damper has a weight that is located


inside a fluid filled case. The weight moves in the
Engine - Clean
case in order to limit torsional vibration. SMCS Code: 1000-070
Inspect the damper for evidence of fluid leaks. If
a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has
the following characteristics: transparent, viscous, Personal injury or death can result from high volt-
smooth, and adhering. age.

If the fluid leak is oil, inspect the crankshaft seals for Moisture can create paths of electrical conductiv-
leaks. If a leak is observed, replace the crankshaft ity.
seals.
Make sure that the electrical system is OFF. Lock
Inspect the damper and repair or replace the damper out the starting controls and tag the controls “DO
for any of the following reasons: NOT OPERATE”.

• The damper is dented, cracked, or leaking. NOTICE


Accumulated grease and oil on an engine is a fire haz-
• The paint on the damper is discolored from heat. ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
• The engine has had a failure because of a broken the engine.
crankshaft.

• Analysis of the oil has revealed that the front main Periodic cleaning of the engine is recommended.
bearing is badly worn. Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
• There is a large amount of gear train wear that is benefits:
not caused by a lack of oil.
• Easy detection of fluid leaks
• Maximum heat transfer characteristics
SEBU8543 81
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

• Ease of maintenance Replace the dirty paper air cleaner elements with
clean air cleaner elements. Before installation,
Note: Caution must be used in order to prevent thoroughly check the air cleaner elements for tears
electrical components from being damaged by and/or holes in the filter material. Inspect the gasket
excessive water when you clean the engine. Avoid or the seal of the air cleaner element for damage.
electrical components such as the alternator, the Maintain a supply of suitable air cleaner elements
starter, and the engine control module. for replacement purposes.

i04322011
Dual Element Air Cleaners
Engine Air Cleaner The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner
Element (Dual Element) - element. The primary air cleaner element can be
Inspect/Clean/Replace used up to six times if the element is properly cleaned
and inspected. The primary air cleaner element
SMCS Code: 1051; 1054-040; 1054-070; 1054-510 should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.
NOTICE
Never run the engine without an air cleaner element The secondary air cleaner element is not serviceable
installed. Never run the engine with a damaged air or washable. The secondary air cleaner element
cleaner element. Do not use air cleaner elements with
should be removed and discarded for every three
damaged pleats, gaskets or seals. Dirt entering the cleanings of the primary air cleaner element. When
engine causes premature wear and damage to engine the engine is operating in environments that are
components. Air cleaner elements help to prevent air-
dusty or dirty, air cleaner elements may require more
borne debris from entering the air inlet. frequent replacement.

NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements


If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
engine wear. Your Cat dealer has the proper air
cleaner elements for your application. Consult your
Cat dealer for the correct air cleaner element.
g00736431
Illustration 45
• Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt (1) Cover
(2) Primary air cleaner element
and debris, as needed. (3) Secondary air cleaner element
(4) Turbocharger air inlet
• Operating conditions (dust, dirt, and debris) may
require more frequent service of the air cleaner 1. Remove the cover. Remove the primary air
element. cleaner element.

• The air cleaner element may be cleaned up to 2. The secondary air cleaner element should be
six times if the element is properly cleaned and removed and discarded for every three cleanings
inspected. of the primary air cleaner element.

• The air cleaner element should be replaced at least Note: Refer to “Cleaning the Primary Air Cleaner
one time per year. This replacement should be Elements”.
performed regardless of the number of cleanings.
3. Cover the turbocharger air inlet with tape in order
to keep out dirt.

4. Clean the inside of the air cleaner cover and body


with a clean, dry cloth.
82 SEBU8543
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

5. Remove the tape for the turbocharger air inlet. There are two common methods that are used to
Install the secondary air cleaner element. Install a clean primary air cleaner elements:
primary air cleaner element that is new or cleaned.
• Pressurized air
6. Install the air cleaner cover.
• Vacuum cleaning
7. Reset the air cleaner service indicator.
Pressurized Air
Cleaning the Primary Air Cleaner
Elements
Personal injury can result from air pressure.
NOTICE
Caterpillar recommends certified air filter cleaning ser-
Personal injury can result without following prop-
vices that are available at Cat dealers. The Cat clean-
er procedure. When using pressure air, wear a pro-
ing process uses proven procedures to assure consis-
tective face shield and protective clothing.
tent quality and sufficient filter life.
Maximum air pressure at the nozzle must be less
Observe the following guidelines if you attempt to
than 205 kPa (30 psi) for cleaning purposes.
clean the filter element:

Do not tap or strike the filter element in order to re- Pressurized air can be used to clean primary air
move dust. cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
Do not wash the filter element. deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
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. Illustration 46
g00281692
The primary air cleaner element should be replaced
at least one time per year. This replacement should Note: When the primary air cleaner elements are
be performed regardless of the number of cleanings. cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
Use clean primary air cleaner elements while dirty (outside).
elements are being cleaned.
To help prevent damage to the paper pleats, aim the
NOTICE hose so that the air flows inside the element along
Do not clean the air cleaner elements by bumping or the length of the filter. Do not aim the stream of air
tapping. This could damage the seals. Do not use el- directly at the primary air cleaner element. Dirt could
ements with damaged pleats, gaskets or seals. Dam- be forced further into the pleats.
aged elements will allow dirt to pass through. Engine
damage could result. Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
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.
SEBU8543 83
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not remove
deposits of carbon and oil.

Note: Refer to “Inspecting the Primary Air Cleaner


Elements”.

Inspecting the Primary Air Cleaner


Elements
g00281694
Illustration 48

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
g00281693
Illustration 47
• Number of cleanings
Inspect the clean, dry primary air cleaner element. Store the box in a dry location.
Use a 60W blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element. i01900118
Inspect the primary air cleaner element for tears
and/or holes. Inspect the primary air cleaner element Engine Air Cleaner Service
for light that may show through the filter material. If
necessary, compare the primary air cleaner element
Indicator - Inspect
to a new primary air cleaner element that has the (If Equipped)
same part number.
SMCS Code: 7452-040
Do not use a primary air cleaner element that has
any tears and/or holes in the filter material. Do not Some engines may be equipped with a different
use a primary air cleaner element with damaged service indicator.
pleats, gaskets, or seals. Discard damaged primary
air cleaner elements. Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
Storing Primary Air Cleaner Elements air pressure displays the difference in the pressure
that is measured before the air cleaner element and
If a primary air cleaner element that passes inspection the pressure that is measured after the air cleaner
will not be used, the primary air cleaner element can element. As the air cleaner element becomes dirty,
be stored for future use. 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.
84 SEBU8543
Maintenance Section
Engine Air Precleaner - Check/Clean

i02927289

Engine Air Precleaner -


Check/Clean
SMCS Code: 1055-070; 1055-535

g00103777
Illustration 49
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: Illustration 50
g01453058

Typical engine air precleaner


• The yellow diaphragm enters the red zone. (1) Wing nut
(2) Cover
• The red piston locks in the visible position. (3) Body

Test the Service Indicator Remove wing nut (1) and cover (2). Check for an
accumulation of dirt and debris in body (3). Clean the
Service indicators are important instruments. body, if necessary.

• Check for ease of resetting. The service indicator After cleaning the precleaner, install cover (2) and
should reset in less than three pushes. wing nut (1).

• Check the movement of the yellow core when the Note: When the engine is operated in dusty
engine is accelerated to the engine rated speed. applications, more frequent cleaning is required.
The yellow core should latch approximately at the
greatest vacuum that is attained.
i02263740

If the service indicator does not reset easily, or if the Engine Crankcase Breather -
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new Clean
service indicator will not reset, the hole for the service
indicator may be plugged. SMCS Code: 1317-070

The service indicator may need to be replaced NOTICE


frequently in environments that are severely dusty, if Perform this maintenance with the engine stopped.
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and If the crankcase breather is not maintained on a
whenever major engine components are replaced. regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
Note: When a new service indicator is installed, excessive crankcase pressure that may cause
excessive force may crack the top of the service crankshaft seal leakage.
indicator. Tighten the service indicator to a torque
of 2 N·m (18 lb in).
SEBU8543 85
Maintenance Section
Engine Mounts - Inspect

i04285577

Engine Oil Level - Check


SMCS Code: 1348-535-FLV

g01136454
Illustration 51
Typical example
(1) Hose clamp
(2) Breather assembly
(3) Retaining clamp
(4) Seal

1. Loosen hose clamp (1) and remove the hose from


breather assembly (2).

2. Loosen retaining clamp (3). Remove the breather


assembly and seal (4). g02452641
Illustration 52

3. Wash the breather element in solvent that is clean View of the right side of a C15 Petroleum Engine
and nonflammable. Allow the breather element to (1) Oil filler cap
dry before installation. (2) Oil gauge

4. Install a breather element that is clean and dry. The engine oil gauge may be located on the left side
Install the seal, the breather assembly, and the of the engine.
clamp. Refer to the Specifications, SENR3130 in
order to locate the proper torques.

5. Install the hose. Install the hose clamp. Refer to


the Specifications, SENR3130 in order to locate
the proper torques.

i02436689 g00110310
Illustration 53
Engine Mounts - Inspect (Y) “ADD” mark
(X) “FULL” mark
SMCS Code: 1152-040; 1152
NOTICE
Inspect the engine mounts for deterioration and for Perform this maintenance with the engine stopped.
proper bolt torque. Engine vibration can be caused
by the following conditions:
1. Maintain the oil level between the “ADD” mark (Y)
• Improper mounting of the engine and the “FULL” mark (X) on the oil level gauge . Do
not fill the crankcase above the “FULL” mark (X).
• Deterioration of the engine mounts
• Loose mounting bolts
Any engine mount that shows deterioration should
be replaced. Refer to the Specifications Manual,
SENR3130, “Torque Specifications”. Refer to your
Caterpillar dealer for more information.
86 SEBU8543
Maintenance Section
Engine Oil Level Gauge - Calibrate

NOTICE NOTICE
Engine damage can occur if the crankcase is filled Care must be taken to ensure that fluids are contained
above the “FULL” mark on the oil level gauge (dip- during performance of inspection, maintenance, test-
stick). ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
An overfull crankcase can cause the crankshaft to dip ing any compartment or disassembling any compo-
into the oil. This will reduce the power that is devel- nent containing fluids.
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re- Refer to Special Publication, NENG2500, “Caterpillar
duction of the oil's ability to lubricate, reduction of oil Dealer Service Tool Catalog” or refer to Special Pub-
pressure, inadequate cooling, oil blowing out of the lication, PECJ0003, “Caterpillar Shop Supplies and
crankcase breathers, and excessive oil consumption. Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De- Dispose of all fluids according to local regulations and
posits in the combustion chamber lead to the following mandates.
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner. 1. Operate the engine until normal operating
temperature is achieved. Stop the engine.
If the oil level is above the “FULL” mark on the oil level Remove the crankcase oil drain plugs. The
gauge, drain some of the oil immediately. oil drain plug from the deep portion of the oil
pan should be removed. Drain the oil from the
2. Remove the oil filler cap and add oil, if necessary. crankcase for 20 minutes.
For the correct oil to use, see this Operation and
Maintenance Manual, “Fluid Recommendations” 2. Remove the used oil filter(s). Install the new oil
topic. Do not fill the crankcase above the “FULL” filter(s). Install the oil drain plugs and tighten to
mark (X) on the oil level gauge. Clean the oil filler 70 ± 15 N·m (50 ± 11 lb ft).
cap. Install the oil filler cap.
Note: Your engine may be equipped with auxiliary
3. Record the amount of oil that is added. For the oil filters. The auxiliary oil filters require a different
next oil sample and analysis, include the total volume of oil. Refer to the OEM specifications for the
amount of oil that has been added since the auxiliary oil filter.
previous sample.
3. Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for information about
i04288233 choosing the correct oil for your engine.
Engine Oil Level Gauge - Table 19
Calibrate Quantity of Oil

SMCS Code: 1326-524; 1326 A 30 L (31.7 qt)


B 1 L (1.1 qt)
Check Calibration at the First Oil C 3 L (3.2 qt)
Change D

The engine oil level will vary depending on the angle Total Capacity of the
and the slant of the engine installation. Ensure that Lubrication System for
Engine Oil
the engine is properly aligned.

The oil level gauge markings must be verified in order 4. Pour quantity “A” of engine oil into the crankcase.
to ensure that the markings are correct. Verify the oil
level gauge markings at the first oil change. 5. Allow enough time for the oil to drain into the
crankcase. Approximately 20 minutes should
Verify the “ADD” mark and verify the “FULL” mark that be allowed. Check the oil level. Wait for several
is on the oil level gauge. Use the following procedure. minutes and check the oil level again. Proceed
after the oil level stops changing.
SEBU8543 87
Maintenance Section
Engine Oil Sample - Obtain

6. Check the oil level on the oil level gauge. The oil Before you take the oil sample, complete the Label,
level should be at the “ADD” mark. If the oil level PEEP5031 for identification of the sample. In order
is not at the existing “ADD” mark, grind off the to help obtain the most accurate analysis, provide
“ADD” mark and engrave the new “ADD” level. the following information:
Use an engraving pen in order to engrave the new
“ADD” mark. • Engine model
7. Pour quantity “B” of oil into the crankcase. Allow • Service hours on the engine
enough time for the oil to drain into the crankcase.
• The number of hours that have accumulated since
8. Check the oil level on the oil level gauge. The oil the last oil change
level should be at the “FULL” mark. If the oil level
is not at the existing “FULL” mark, grind off the • The amount of oil that has been added since the
“FULL” mark. Use an engraving pen in order to last oil change
engrave the new “FULL” mark.
To ensure that the sample is representative of the oil
9. Pour quantity “C” of oil into the crankcase in order in the crankcase, obtain a warm, mixed oil sample.
to allow oil to fill the oil filter.
To avoid contamination of the oil samples, the tools
NOTICE and the supplies that are used for obtaining oil
Do not crank the engine for more than 30 seconds. samples must be clean.
Allow the starting motor to cool for two minutes before
cranking again. Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
10. Start the engine. Ensure that the lubrication sampling valve is used. The location of the sampling
system is filled. Inspect the engine for oil leaks. valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
11. Stop the engine and allow enough time for the oil
to drain into the crankcase. The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
12. Check the oil level on the oil level gauge. If the oil fluid sampling bottle includes the parts that are
level is not at the calibrated “FULL” mark, fill the needed for obtaining oil samples. Instructions are
crankcase to the calibrated “FULL” mark. Record also provided.
the amount of oil that was added as quantity D.
Record the oil capacity of the lubrication system
for future oil changes. NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
i04237495 Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
Engine Oil Sample - Obtain contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
SMCS Code: 1348-554-SM dealers and customers.
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil If the engine is not equipped with a sampling valve,
analysis at regularly scheduled intervals. S·O·S oil use the 1U-5718 Vacuum Pump. The pump is
analysis provides infrared analysis, which is required designed to accept sampling bottles. Disposable
for determining nitration and oxidation levels. tubing must be attached to the pump for insertion
into the sump.

Obtain the Sample and the Analysis For instructions, see Special Publication, PEGJ0047,
“How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
88 SEBU8543
Maintenance Section
Engine Oil and Filter - Change

i04288629
NOTICE
Engine Oil and Filter - Change Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
SMCS Code: 1318-510
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
Note: The maintenance interval is correct for engines ing any compartment or disassembling any compo-
operating with fluids preferred by Caterpillar. If the
nent containing fluids.
fluids being used are not preferred, refer to this
Operation and Maintenance Manual, “Severe Service Refer to Special Publication, NENG2500, “Caterpillar
Application” for further information about a reduction
Dealer Service Tool Catalog” or refer to Special Pub-
the oil change interval.
lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col-
Caterpillar recommends using Cat S·O·S Services oil
lect and contain fluids on Caterpillar products.
analysis at regularly scheduled intervals in order to
monitor the condition and maintenance requirements Dispose of all fluids according to local regulations and
of the engine. S·O·S oil analysis provides infrared
mandates.
analysis, which is required for determining nitration
and oxidation levels. Refer to this Operation and
Maintenance Manual, “Fluid Recommendations” for 1. Remove the oil drain plug in order to allow the oil
more information about the use of S·O·S oil analysis. to drain.

2. After the oil has drained, the oil drain plug should
be cleaned and installed.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to Replace the Oil Filter
contact the skin.
NOTICE
Do not drain the oil when the engine is cold. As the oil Caterpillar oil filters are built to Caterpillar speci-
cools, suspended waste particles settle on the bottom fications. Use of an oil filter not recommended by
of the oil pan. The waste particles are not removed Caterpillar could result in severe engine damage to
with the draining cold oil. Drain the crankcase with the engine bearings, crankshaft, etc., as a result of
the engine stopped. Drain the crankcase with the the larger waste particles from unfiltered oil entering
oil warm. This draining method allows the waste the engine lubricating system. Only use oil filters
particles that are suspended in the oil to be drained recommended by Caterpillar.
properly.

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. Attach a “DO NOT
OPERATE” or a similar warning tag to the ignition
keyswitch before the engine is serviced.

g00103713
Illustration 54
Typical filter mounting base and filter gasket

1. Remove the oil filter with a 185-3630 Strap


Wrench.

2. Clean the sealing surface of the filter mounting


base. Ensure that all of the old oil filter gasket is
removed.
SEBU8543 89
Maintenance Section
Engine Protective Devices - Check

3. Apply clean engine oil to the new oil filter gasket. i00626013

NOTICE
Engine Protective Devices -
Do not fill the oil filters with oil before installing them. Check
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to SMCS Code: 7400-535
engine components.
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
4. Install the oil filter. Tighten the oil filter until the to prevent damage to the engine. It is impossible
oil filter gasket contacts the base. Tighten the oil to determine if the engine protective devices are
filter by hand according to the instructions that are in good working order during normal operation.
shown on the oil filter. Do not overtighten the oil Malfunctions must be simulated in order to test the
filter. engine protective devices.

Fill the Engine Crankcase A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate
1. Remove the oil filler cap. Fill the crankcase with the at the setpoints. Ensure that the engine protective
proper amount of oil. Refer to this Operation and devices are functioning properly.
Maintenance Manual, “Fluid Recommendations”
topic and the Operation and Maintenance Manual, NOTICE
“Refill Capacities” for more information. During testing, abnormal operating conditions must be
simulated.
NOTICE
If equipped with an auxiliary oil filter or system, extra The tests must be performed correctly in order to pre-
oil must be added when filling the crankcase. Follow vent possible damage to the engine.
the OEM or filter manufacturer's recommendations. If
the extra oil is not added, the engine may starve for To prevent damage to the engine, only authorized
oil. service personnel or your Caterpillar dealer should
perform the tests.
NOTICE
To help prevent crankshaft or bearing damage, crank Visual Inspection
engine to fill all filters before starting. Do not crank
engine for more than 30 seconds. Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that
2. Start the engine and run the engine at “LOW are loose, broken, or damaged. Damaged wiring
IDLE” for 2 minutes. Perform this procedure in or components should be repaired or replaced
order to ensure that the lubrication system has immediately.
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 10 minutes.

4. Remove the oil level gauge in order to check the


oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the “ENGINE STOPPED”
side of the oil level gauge.
90 SEBU8543
Maintenance Section
Engine Speed/Timing Sensor - Clean/Inspect

i04314747 i04242309

Engine Speed/Timing Sensor - Engine Valve Lash - Check


Clean/Inspect SMCS Code: 1105-535
SMCS Code: 1905-040; 1905-070; 1907-040;
The initial valve lash adjustment on new engines,
1907-070 rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of
the valve train components and to the seating of the
valve train components.

The maintenance is recommended by Caterpillar as


part of a lubrication and preventive maintenance
schedule to help provide maximum engine life.

Note: Only qualified service personnel should


perform this maintenance. For procedures on
adjusting the valve lash and adjusting the valve
bridge, see System Systems Operation/Testing and
Adjusting, “Engine Valve Lash - Inspect/Adjust”.
Consult your Cat dealer for assistance.

Ensure that the engine can not be started while


this maintenance is being performed. To help pre-
Illustration 55
g02475300 vent possible injury, do not use the starting motor
View of the left side of a C15 Petroleum Engine
to turn the flywheel.
(1) Secondary speed/timing sensor
(2) Primary speed/timing sensor
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
1. Remove the speed/timing sensors from the front suring/adjusting valve lash clearance.
housing. Check the condition of the plastic end
of the speed/timing sensors for wear and/or
contaminants. i01597115

2. Clean the metal shavings and other debris from


Engine Valve Rotators - Inspect
the face of the speed/timing sensors. Install the
SMCS Code: 1109-040
sensors into the front housing.

i03585580

Engine Storage Procedure - When inspecting the valve rotators, protective


glasses or face shield and protective clothing
Check must be worn, to help prevent being burned by
hot oil or spray.
SMCS Code: 1000-535
Engine valve rotators rotate the valves when the
See your Caterpillar dealer for the storage procedure
engine runs. This helps to prevent deposits from
if the engine will be stored for more than one year.
building up on the valves and the valve seats.
Refer to this Operation and Maintenance Manual,
Perform the following steps after the engine valve
“Product Storage” if the engine will be stored for less
lash is set, but before the valve covers are installed:
than one year.
1. Start the engine according to Operation and
Maintenance Manual, “Engine Starting” (Operation
Section) for the procedure.
SEBU8543 91
Maintenance Section
Fan Drive Bearing - Lubricate

2. Operate the engine at low idle. i02053753

3. Observe the top surface of each valve rotator. The Fan Drive Bearing - Replace
valve rotators should turn slightly when the valves
close. SMCS Code: 1359-510-BD

1. Remove Bearings. Refer to Disassembly and


NOTICE
Assembly, “Bearing Removal”.
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
2. Measure the bearing housings for roundness and
shorten valve life. If a damaged rotator is not replaced,
for proper size.
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
3. Replace the bearings.
and cylinder head damage.

i04345709
If a valve fails to rotate, consult your Caterpillar
dealer. Flame Arrestor - Inspect/Clean
i02784507
SMCS Code: 1092-571

Fan Drive Bearing - Lubricate S/N: HAZ1-Up

SMCS Code: 1359-086-BD

Some of the fan drives have grease fittings and some


of the fan drives do not have grease fittings. If there is
no grease fitting, periodic lubrication is not required.
The fan drive requires grease only if the fan drive
is equipped with a zerk.

g02501758
Illustration 57
Flameproof system
(1) Aftercooler
(2) Air shutoff
(3) Air intake for the turbocharger
(4) Flame arrestor for the intake air
(5) Flame arrestor for the aftercooler condensate drain valve
(6) Aftercooler condensate drain valve

g00746166
Illustration 56 The C15 Hazardous Location SCAC (separate
Typical location of the grease fitting (if equipped) that is for the fan circuit aftercooled) Diesel Engine is equipped with a
drive bearing flameproof intake system. The system has been type
The pulley is shown with the belt guards that have been removed. tested and approved to the following standards:

Lubricate the grease fitting that is on the fan drive • EN 1834-1 for Gas Group IIA
bearing with High Speed Ball Bearing Grease or the
equivalent. • Temperature Class T3 with an ambient capability
of 50° C (122° F)
Inspect the fan drive pulley assembly for wear or for
damage. If the shaft is loose, an inspection of the The flameproof system includes the following
internal components should be performed. Refer to components:
the Systems Operation Testing and Adjusting Manual
for additional information. • An intake air flame arrestor mounted on the inlet
of the turbocharger
92 SEBU8543
Maintenance Section
Flame Arrestor - Inspect/Clean

• A flame arrestor on the aftercooler condensate Flame Arrestor for the Intake Air
drain valve
System
The flameproof intake system is designed with tight
seals, closely matched joints, and robust enclosures
to prevent any internal flames or explosions from
propagating to the exterior atmosphere.

Note: Inspect the flame arrestor for the aftercooler


and clean the flame arrestor if necessary at the
following interval:

Table 20
Maintenance Intervals for Inspecting and Cleaning(1)
of the Flame Arrestors
Flame Arrestor for the PM Level 1 - Every 12750
Turbocharger Air Inlet (3375 US gal) of Fuel or 250
g02502237
System Service Hours or 6 Months Illustration 58

Flame Arrestor for the Turbocharger intake air system


Aftercooler Condensate Every 50 Service Hours (7) Bolts
Drain Valve (8) O-ring seal
(1) If necessary
Residue from normal engine operation may begin to
plug the engine intake flame arrestor.

1. Remove the bolts that attach the flame arrestor


When replacement parts are required for this to the inlet air line.
product, Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci- 2. Remove and dispose of the seal.
fications including, but not limited to, physical
dimensions, type, strength, and material. 3. Remove the flame arrestor and hold the flame
arrestor up to a light to ensure that the passages
Never reuse any clamps, seals, or gaskets in the are clear. If necessary, clean the flame arrestor
flameproof intake or exhaust system. Always re- with isopropyl alcohol or suitable solvent. Use
place clamps, seals, and gaskets with new Cat filtered dry air with a maximum pressure of 30
parts which match the parts being replaced by the psi to remove the solvent and dry the flame
exact Cat part number. arrestor. Do not clean by inserting probes as the
fine passages may be enlarged which impairs the
Failure to heed this warning may lead to prema- performance of the flame arrestor.
ture failures, product damage, personal injury, or
death. 4. Always replace the O-ring seal with a new Cat
O-ring seal with the same part number. Replace
the seal.

g02502636
Illustration 59

5. Tighten the bolts in the order specified in figure


59. Refer to Specifications, SENR3130 for the
torque information.
SEBU8543 93
Maintenance Section
Fuel Injector - Inspect/Adjust

Flame Arrestor for the Aftercooler i04292450

Condensate Drain Valve Fuel Injector - Inspect/Adjust


NOTICE SMCS Code: 1290-025; 1290-040
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com- Be sure the engine cannot be started while this
ponent containing fluids. maintenance is being performed. To prevent pos-
sible injury, do not use the starting motor to turn
Refer to Special Publication, NENG2500, “Cat Dealer the flywheel.
Service Tool Catalog” or refer to Special Publication,
Hot engine components can cause burns. Allow
PECJ0003, “Cat Shop Supplies and Tools Catalog” for
tools and supplies suitable to collect and contain fluids additional time for the engine to cool before mea-
on Cat products. suring/adjusting the unit injectors.

Dispose of all fluids according to local regulations and The electronic unit injectors use high voltage. Dis-
mandates. connect the unit injector enable circuit connector
in order to prevent personal injury. Do not come
in contact with the injector terminals while the en-
gine is running.

The operation of a Cat Diesel Engine with improper


adjustments of the electronic unit injectors can
reduce engine efficiency. This reduced efficiency
could result in excessive fuel usage and/or shortened
g02502236 engine component life.
Illustration 60
Flame arrestor and aftercooler condensate drain valve Only qualified service personnel should perform
(10) O-ring seal for the flame arrestor this maintenance. Refer to the Systems Operation,
Testing and Adjusting, “Electronic Unit Injector -
1. Remove the aftercooler condensate drain valve. Test” for the test procedure, and Systems Operation,
Testing and Adjusting, “Electronic Unit Injector -
2. Remove and dispose of the seal. Adjust” for the adjustment procedure for the injectors.

3. Remove the flame arrestor and hold the flame


arrestor up to a light to ensure that the passages i04292515
are clear. If necessary, clean the flame arrestor
with isopropyl alcohol or suitable solvent. Use
Fuel System - Prime
filtered dry air with a maximum pressure of 30
SMCS Code: 1250-548; 1258-548
psi to remove the solvent and dry the flame
arrestor. Do not clean by inserting probes as the
fine passages may be enlarged which impairs the
performance of the flame arrestor.
Fuel leaked or spilled onto hot surfaces or elec-
4. Always replace the O-ring seal with a new Cat trical components can cause a fire. To help pre-
O-ring seal with the same part number. Replace vent possible injury, turn the start switch off when
the seal. changing fuel filters or water separator elements.
Clean up fuel spills immediately.
5. Install the flame arrestor to the aftercooler. Install
the condensate drain valve to the flame arrestor.
94 SEBU8543
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

5. Crank the engine for 30 seconds. Use a suitable


NOTICE container to catch the fuel while you crank the
Care must be taken to ensure that fluids are contained engine. Allow the starter motor to cool for 2
during performance of inspection, maintenance, test- minutes.
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before Note: You may use the fuel priming pump (if
opening any compartment or disassembling any com- equipped) for the fuel filter instead of cranking the
ponent containing fluids. engine.

Refer to Special Publication, NENG2500, “Cat Dealer 6. Crank the engine for 30 seconds. Allow the starter
Service Tool Catalog” or refer to Special Publication, motor to cool for 2 minutes.
PECJ0003, “Cat Shop Supplies and Tools Catalog” for
tools and supplies suitable to collect and contain fluids 7. Repeat Step 6 until the engine starts and the
on Cat products. engine runs.

Dispose of all fluids according to local regulations and Note: Failure to tighten all fittings could result in
mandates. serious fuel leaks.

8. After the engine has operated smoothly for 30


NOTICE seconds, turn the priming valve to the “OPEN”
Do not allow dirt to enter the fuel system. Thoroughly position.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon- Note: Shortened injector life may occur if the priming
nected fuel system component. valve is left in the “CLOSED” position.

9. Clean any residual fuel from the engine


components.

i02927285

Fuel System Primary


Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543

g02459157
Fuel leaked or spilled onto hot surfaces or elec-
Illustration 61 trical components can cause a fire. To help pre-
Fuel filter with priming pump vent possible injury, turn the start switch off when
(1) Secondary fuel filter changing fuel filters or water separator elements.
(2) Air purge screw Clean up fuel spills immediately.
(3) Fuel priming pump

1. Turn the ignition switch to the “OFF” position. NOTICE


Care must be taken to ensure that fluids are contained
2. If necessary, fill the fuel tank with clean diesel fuel. during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
3. Turn the priming valve (if equipped) to the collect the fluid with suitable containers before open-
“CLOSED” position in order to prime the fuel ing any compartment or disassembling any compo-
system. nent containing fluids.

4. Open the air purge screw for the fuel filter by 3 full Refer to Special Publication, NENG2500, “Caterpillar
turns. Do not remove the air purge screw. Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
NOTICE products.
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two Dispose of all fluids according to local regulations and
minutes before cranking the engine again. mandates.
SEBU8543 95
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

The primary filter/water separator also provides


NOTICE filtration in order to help extend the life of the
Do not allow dirt to enter the fuel system. Thoroughly secondary fuel filter. The element should be changed
clean the area around a fuel system component that regularly. If a vacuum gauge is installed, the
will be disconnected. Fit a suitable cover over discon- primary filter/water separator should be changed at
nected fuel system component. 50 to 70 kPa (15 to 20 inches Hg).

Replace the Element

Fuel leaked or spilled onto hot surfaces or elec-


trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Care must be taken to ensure that fluids are contained
g01453091 during performance of inspection, maintenance, test-
Illustration 62
ing, adjusting and repair of the product. Be prepared to
(1) Element collect the fluid with suitable containers before open-
(2) Bowl
(3) Drain
ing any compartment or disassembling any compo-
nent containing fluids.
Bowl (2) should be monitored daily for signs of water.
If water is present, drain the water from the bowl. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
1. Open drain (3). The drain is a self-ventilated drain. suitable to collect and contain fluids on Caterpillar
Catch the draining water in a suitable container. products.
Dispose of the water properly.
Dispose of all fluids according to local regulations and
2. Close drain (3). mandates.

NOTICE NOTICE
The water separator is under suction during normal Do not allow dirt to enter the fuel system. Thoroughly
engine operation. Ensure that the drain valve is tight- clean the area around a fuel system component that
ened securely to help prevent air from entering the fuel will be disconnected. Fit a suitable cover over discon-
system. nected fuel system component.

1. Close the main fuel supply valve.


i02927282

Fuel System Primary Filter


(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ

Water in the fuel can cause the engine to run rough.


Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.

g01453091
Illustration 63
(1) Element
(2) Bowl
(3) Drain
96 SEBU8543
Maintenance Section
Fuel System Secondary Filter - Replace

2. Remove element (1) from the element mounting i03478081


base while bowl (2) is attached.
Fuel System Secondary Filter -
3. Dispose of the contents of the filter. Remove bowl
(2) from element (1). The bowl is reusable. Do not
Replace
discard the bowl. Dispose of the used element. SMCS Code: 1261-510-SE
4. Remove the O-ring from the gland of the bowl.
Clean the following components:

• Bowl Fuel leaked or spilled onto hot surfaces or elec-


trical components can cause a fire. To help pre-
• O-ring vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
• Mounting base Clean up fuel spills immediately.

Inspect the O-ring for damage and for


NOTICE
deterioration. Replace the O-ring, if necessary.
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
5. Lubricate the O-ring with clean diesel fuel.
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
6. Install bowl (2) on a new element. Tighten the
bowl by hand. Do not use tools in order to tighten
the bowl. NOTICE
Care must be taken to ensure that fluids are contained
NOTICE during performance of inspection, maintenance, test-
The primary filter/water separator may be prefilled with ing, adjusting and repair of the product. Be prepared to
fuel to avoid rough running/stalling of the engine due collect the fluid with suitable containers before open-
to air. Do not fill the secondary filter with fuel before ing any compartment or disassembling any compo-
installation. The fuel would not be filtered and could nent containing fluids.
be contaminated. Contaminated fuel will cause accel-
erated wear to fuel system parts. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and
7. Lubricate the top seal of element (1) with clean
Tools Catalog” for tools and supplies suitable to col-
diesel fuel. The element may be filled with fuel at
lect and contain fluids on Caterpillar products.
this time. Install the new element on the mounting
base. Tighten the element by hand.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
The water separator is under suction during normal 1. Stop the engine. Turn the ignition switch to the
engine operation. Ensure that the vent plug is tight-
OFF position or disconnect the battery. Refer to
ened securely to help prevent air from entering the fu-
the Operation and Maintenance Manual, “Battery
el system. or Battery Cable - Disconnect” topic (Maintenance
Section) for more information. Shut off the fuel
8. Open the main fuel supply valve. supply valve (if equipped).

9. Start the engine and check for leaks. Run the 2. It may be necessary to relieve residual fuel
engine for one minute. Stop the engine and check pressure from the fuel system before the fuel
for leaks again. filter is removed. Wait for one to five minutes until
the fuel pressure has lowered. Use a suitable
Detecting leaks is difficult while the engine is container in order to catch any fuel that may spill.
running. The primary filter/water separator is
under suction. A leak will allow air to enter the fuel. 3. Remove the used fuel filter and discard the used
The air in the fuel can cause low power due to fuel filter.
aeration of the fuel. If air enters the fuel, check the
components for overtightening or undertightening. 4. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.

5. Apply clean diesel fuel to the new fuel filter gasket.


SEBU8543 97
Maintenance Section
Fuel Tank Water and Sediment - Drain

Fuel Tank
NOTICE
Do not fill the secondary fuel filter with fuel before in- Fuel quality is critical to the performance and to the
stalling. The fuel would not be filtered and could be service life of the engine. Water in the fuel can cause
contaminated. Contaminated fuel will cause acceler- excessive wear to the fuel system. Condensation
ated wear to fuel system parts. 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
NOTICE causes water to accumulate in fuel tanks. Draining
In order to meet expected fuel system component the fuel tank regularly and obtaining fuel from reliable
life, 4 micron(c) absolute or less secondary fuel fil- sources can help to eliminate water in the fuel.
tration is required for all Caterpillar Diesel Engines
that are equipped with unit injected fuel systems. Note
that all current Caterpillar Diesel Engines are factory
Drain the Water and the Sediment
equipped with Caterpillar Advanced Efficiency 4 mi- Fuel tanks should contain some provision for draining
cron(c) absolute fuel filters.
water and draining sediment from the bottom of the
fuel tanks.
Caterpillar does not warrant the quality or perfor-
mance of non-Caterpillar fluids and filters.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
6. Install the new fuel filter. Spin the fuel filter onto the drain valve.
the fuel filter base until the gasket contacts the
base. Use the rotation index marks on the filters Note: Failure to properly close the drain can allow air
as a guide for proper tightening. Tighten the filter into the system, which could have detrimental results
according to the instructions that are on the fuel to performance.
filter. Do not overtighten the filter.
Check the fuel daily. Drain the water and sediment
7. Open the fuel supply valve. The engine will need from the fuel tank after operating the engine or drain
to be purged of air. Refer to the Operation and the water and sediment from the fuel tank after the
Maintenance Manual, “Fuel System - Prime” topic fuel tank has been filled. Allow five to ten minutes
(Maintenance Section) for more information. before performing this procedure.

Fill the fuel tank after operating the engine in


i04363480 order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
Fuel Tank Water and Sediment fuel expands as the fuel gets warm. The tank may
- Drain overflow.

SMCS Code: 1273-543-M&S Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
NOTICE supply pipe. Some fuel tanks use supply lines that
Care must be taken to ensure that fluids are contained take fuel directly from the bottom of the tank. If
during performance of inspection, maintenance, test- the engine is equipped with this system, regular
ing, adjusting, and repair of the product. Be prepared maintenance of the fuel system filter is important.
to collect the fluid with suitable containers before
opening any compartment or disassembling any com- Fuel Storage Tanks
ponent containing fluids.
Drain the water and the sediment from the fuel
Refer to Special Publication, NENG2500, “Cat Dealer storage tank during the following conditions:
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” for • Weekly
tools and supplies suitable to collect and contain fluids
on Cat products. • Oil change
Dispose of all fluids according to local regulations and • Refill of the tank
mandates.
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank. A four micron(c) absolute filter for the breather
vent on the fuel tank is also recommended.
98 SEBU8543
Maintenance Section
Grounding Stud - Inspect/Clean/Tighten

If a bulk storage tank has been refilled or moved The electronics grounding stud must have a wire
recently, allow adequate time for the sediment to ground to the battery. Tighten the electronics
settle before filling the engine fuel tank. Internal grounding stud at every oil change. Ground wires
baffles in the bulk storage tank will also help trap and straps should be combined at engine grounds.
sediment. Filtering fuel that is pumped from the All grounds should be tight and free of corrosion.
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. • Clean the electronics grounding stud and the
terminals for the electronics ground strap with a
clean cloth.
i04176149

Grounding Stud - • If the connections are corroded, clean the


connections with a solution of baking soda and
Inspect/Clean/Tighten water.

SMCS Code: 7423-040; 7423-070; 7423-079 • Keep the electronics grounding stud and the strap
clean and coated with MPGM grease or petroleum
jelly.

The connection of battery cables to a battery and i04301694


the disconnection of battery cables from a battery
may cause an explosion which may result in injury Hoses and Clamps -
or death. The connection and the disconnection
of other electrical equipment may also cause an
Inspect/Replace
explosion which may result in injury or death. The
SMCS Code: 7554-040; 7554-510
procedures for the connection and the disconnec-
tion of battery cables and other electrical equip-
Hoses and clamps must be inspected periodically
ment should only be performed in a nonexplosive
in order to ensure safe operation and continuous
atmosphere.
operation of the engine. Take proper safety
precautions before inspecting or replacing hoses and
clamps.

Note: Always use a board or cardboard when the


engine components are checked for leaks. Leaking
fluid that is under pressure can cause serious
injury or possible death. Leaks that are the size
of a pin hole are included. Refer to Operation and
Maintenance Manual, “General Hazard Information”
for more information.

Inspect the Hoses and the Clamps


Inspect all hoses for leaks that are caused by the
following conditions. Replace any hose which exhibits
any of the following conditions. Failure to replace a
hose which exhibits any of the following conditions
may result in a hazardous situation.

• Hoses which are cracked


g00765094
Illustration 64 • Hoses which are soft
Typical example
Electronics grounding stud (side view) • Outer covering that is chafed or cut

Inspect the OEM harness for good connections. • Exposed wire that is used for reinforcement
Inspect the condition of the OEM harness.
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
SEBU8543 99
Maintenance Section
Hoses and Clamps - Inspect/Replace

• Hoses which exhibit signs of leakage which are not Cooling System
the result of loose couplings or clamps

Inspect all clamps for the following conditions.


Replace any clamp which exhibits signs of any of the
following conditions. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
• Cracking components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
• Looseness sure.
• Damage
Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.
Personal injury can result from removing hoses or
Each installation application can be different. The fittings in a pressure system.
differences depend on the following factors:
Failure to relieve pressure can cause personal in-
jury.
• Type of hose
Do not disconnect or remove hoses or fittings un-
• Type of fitting material til all pressure in the system has been relieved.
• Anticipated expansion and contraction of the hose
1. Stop the engine.
• Anticipated expansion and contraction of the
fittings 2. Allow the engine to cool.

Due to extreme temperature changes, the hose will 3. Before servicing a coolant hose, slowly loosen the
heat set. Heat setting causes hose clamps to loosen filler cap for the cooling system in order to relieve
which can result in leaks. A constant torque hose any pressure.
clamp will help to prevent loose hose clamps.
4. Remove the filler cap for the cooling system.
Replace hoses that are cracked or soft. Replace
hoses that show signs of leakage. Replace hoses 5. Drain the coolant from the cooling system to a
that show signs of damage. Replace hose clamps level that is below the hose that is being replaced.
that are cracked or damaged. Tighten or replace Drain the coolant into a suitable clean container.
hose clamps which are loose. The coolant can be reused.

Replace the Hoses and the Clamps 6. Remove the hose clamps.

7. Disconnect the old hose.


NOTICE
Care must be taken to ensure that fluids are contained 8. Replace the old hose with a new hose.
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared 9. Install hose clamps which have been inspected or
to collect the fluid with suitable containers before install new hose clamps. Refer to Specifications,
opening any compartment or disassembling any com- SENR3130, “Torque Specifications”, “Hose
ponent containing fluids. Clamps” for information about selecting and
installing the proper hose clamps.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication, 10. Refill the cooling system.
PECJ0003, “Cat Shop Supplies and Tools Catalog” for
tools and supplies suitable to collect and contain fluids 11. Clean the filler cap for the cooling system. Inspect
on Cat products. the gaskets on the filler cap. Replace the filler cap
if the gaskets are damaged. Install the filler cap.
Dispose of all fluids according to local regulations and
mandates. 12. Start the engine. Inspect the cooling system for
leaks.
100 SEBU8543
Maintenance Section
Hoses and Clamps - Inspect/Replace

Fuel System 5. Install hose clamps which have been inspected or


install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and
installing the proper hose clamps.
Personal injury can result from removing hoses or
fittings in a pressure system. 6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
Failure to relieve pressure can cause personal in- engine.
jury.
Note: Fuel must be added to the fuel system ahead
Do not disconnect or remove hoses or fittings un- of the fuel filter.
til all pressure in the system has been relieved.
7. Refill the fuel system. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime” for
information about priming the engine with fuel.
Contact with high pressure fuel may cause fluid 8. Start the engine. Inspect the fuel system for leaks.
penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in- Lubrication System
structions may cause personal injury or death.

NOTICE
Hot oil and hot components can cause personal
Do not bend or strike high pressure lines. Do not in-
injury. Do not allow hot oil or hot components to
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and contact the skin.
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec- 1. Drain the oil from the lubrication system to a level
ommended torque. that is below the hose that is being replaced.

2. Remove the hose clamps.


NOTICE
Do not allow dirt to enter the fuel system. Thoroughly 3. Disconnect the old hose.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis- 4. Replace the old hose with a new hose.
connected fuel system components.
5. Install hose clamps which have been inspected or
Note: High-pressure fuel lines may be installed install new hose clamps. Refer to Specifications,
between the high-pressure fuel pump and the fuel SENR3130, “Torque Specifications”, “Hose
injectors. High-pressure fuel lines are constantly Clamps” for information about selecting and
charged with high pressure. Do not check the installing the proper hose clamps.
high-pressure fuel lines with the engine or the starting
motor in operation. Wait for 10 minutes after the 6. Refill the lubrication system. Refer to this
engine stops before you perform any service or repair Operation and Maintenance Manual, “Engine
on high-pressure fuel lines. Waiting for 10 minutes Oil Level - Check” in order to ensure that the
will to allow the pressure to be purged. lubrication system is filled with the proper amount
of engine oil.
1. Drain the fuel from the fuel system to a level that
is below the hose that is being replaced. 7. Start the engine. Inspect the lubrication system
for leaks.
2. Remove the hose clamps.
Air System
3. Disconnect the old hose.
1. Remove the hose clamps.
4. Replace the old hose with a new hose.
2. Disconnect the old hose.

3. Replace the old hose with a new hose.


SEBU8543 101
Maintenance Section
Overhaul Considerations

4. Install hose clamps which have been inspected or When an engine's oil consumption has risen to three
install new hose clamps. Refer to Specifications, times the original oil consumption rate due to normal
SENR3130, “Torque Specifications”, “Hose wear, an engine overhaul should be scheduled.
Clamps” for information about selecting and There may be a corresponding increase in blowby
installing the proper hose clamps. and a slight increase in fuel consumption.

Note: The bellows and the V-clamps that are used Overhaul Options
on the bellows should never be reused.
Before Failure Overhaul
5. Start the engine. Inspect the air lines for leaks.
A planned overhaul before failure may be the best
i02018788
value for the following reasons:

Overhaul Considerations • Costly unplanned downtime can be avoided.


SMCS Code: 7595-043 • Many original parts can be reused according to the
standards for reusable parts.
Reduced hours of operation at full load will result in a
lower average power demand. A decreased average • The engine service life can be extended without the
power demand should increase both the engine risk of a major catastrophe due to engine failure.
service life and the overhaul interval.
• The best cost/value relationship per hour of
The need for an overhaul is generally indicated by extended life can be attained.
increased fuel consumption and by reduced power.
After Failure Overhaul
The following factors are important when a decision
is being made on the proper time for an engine If a major engine failure occurs and the engine
overhaul: must be removed, many options are available. An
overhaul should be performed if the engine block or
• The need for preventive maintenance the crankshaft needs to be repaired.

• The quality of the fuel that is being used If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
• The operating conditions percent and 50 percent of the cost of a new engine
with a similar exchange core.
• The results of the S·O·S analysis
This lower cost can be attributed to three aspects:
Oil Consumption as an Overhaul • Specially designed Caterpillar engine features
Indicator
• Caterpillar dealer exchange components
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total • Caterpillar Inc. remanufactured exchange
operating cost for your Caterpillar engine. Oil components
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable Overhaul Recommendation
for the maintenance intervals.
To minimize downtime, a scheduled engine overhaul
Oil consumption is in proportion to the percentage by your Caterpillar dealer is recommended. This will
of the rated engine load. As the percentage of the provide you with the best cost/value relationship.
engine load is increased, the amount of oil that is
consumed per hour also increases. Note: Overhaul programs vary according to the
engine application and according to the dealer that
The oil consumption rate (brake specific oil performs the overhaul. Consult your Caterpillar
consumption) is measured in grams per kW/h (lb per dealer for specific information about the available
bhp). The brake specific oil consumption (BSOC) overhaul programs and about overhaul services for
depends on the engine load. Consult your Caterpillar extending the engine life.
dealer for assistance in determining the typical oil
consumption rate for your engine. If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the following
maintenance recommendations.
102 SEBU8543
Maintenance Section
Overhaul Considerations

Unit Fuel Injector • Thrust bearings


Clean the fuel injector body and replace the O-rings. • Main bearings
Replace the O-rings and the gasket on the injector
sleeve. Clean the area around the injector seating • Rod bearings
in the injector sleeve. Refer to the Service Manual
for the complete procedure, or consult with your • Valve rotators
Caterpillar dealer for assistance.
• Crankshaft seals
Rebuild or Exchange
Caterpillar Inc. recommends the installation of new
Cylinder Head Assembly, Connecting Rods, parts at each overhaul period.
Pistons, Cylinder Liners, Turbocharger, Cylinder
Packs, Oil Pump, and Fuel Transfer Pump Inspect these parts while the engine is disassembled
for an overhaul.
These components should be inspected according to
the instructions that are found in various Caterpillar Inspect the crankshaft for any of the following
reusability publications. The Special Publication, conditions:
SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts. • Deflection

If the parts comply with the established inspection • Damage to the journals
specifications that are expressed in the reusable
parts guideline, the parts should be reused. • Bearing material that has seized to the journals
Parts that are not within the established inspection Check the journal taper and the profile of the
specifications should be dealt with in one of the crankshaft journals. Check these components by
following manners: interpreting the wear patterns on the following
components:
• Salvaging
• Rod bearing
• Repairing
• Main bearings
• Replacing
Note: If the crankshaft is removed for any reason,
Using out-of-spec parts can result in the following use the magnetic particle inspection process to check
problems: for cracks in the crankshaft.

• Unscheduled downtime Inspect the camshaft for damage to the journals and
to the lobes.
• Costly repairs
Note: If the camshaft is removed for any reason, use
• Damage to other engine parts the magnetic particle inspection process to check for
cracks in the camshaft.
• Reduced engine efficiency
Inspect the following components for signs of wear or
• Increased fuel consumption for signs of scuffing:

Reduced engine efficiency and increased fuel • Camshaft bearings


consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing • Camshaft followers
out-of-spec parts or replacing out-of-spec parts.
Caterpillar Inc. recommends replacing the crankshaft
vibration damper.
Inspection and/or Replacement
Oil Cooler Core and Aftercooler Core
Piston Rings, Crankshaft Bearings, Valve
Rotators, and Crankshaft Seals
During an overhaul, the removal of the oil cooler
core and the aftercooler core is recommended. The
The following components may not last until the
oil cooler core and the aftercooler core should be
second overhaul.
cleaned and pressure tested.
SEBU8543 103
Maintenance Section
Overhaul Considerations

NOTICE
Do not use caustic cleaners to clean the core. Personal injury can result from air pressure.
Caustic cleaners can attack the internal metals of the Personal injury can result without following prop-
core and cause leakage. er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Note: Use this cleaning procedure to clean the oil
cooler core and the aftercooler core. Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
1. Remove the oil cooler core and the aftercooler
core. 6. Dry the oil cooler core and the aftercooler core
with compressed air. Direct the air in the reverse
2. Remove any debris from the oil cooler core and direction of the normal flow.
the aftercooler core. To remove debris from the oil
cooler core, turn the oil cooler core onto one end. 7. Inspect the components in order to ensure
To remove debris from the aftercooler core, turn cleanliness. The oil cooler core and the aftercooler
the aftercooler core upside-down. core should be pressure tested. Repair the oil
cooler core and the aftercooler core, if necessary.
3. Flush the oil cooler core and the aftercooler core Install the oil cooler core and the aftercooler core.
internally with cleaner in order to loosen foreign
substances. This will also help to remove oil from For more information about cleaning the cores,
the oil cooler core and the aftercooler core. consult your Caterpillar dealer.
Note: The use of Hydrosolv Liquid Cleaners is
recommended. Table 21 lists the Hydrosolv Liquid
Obtain Coolant Analysis
Cleaners that are available from your Caterpillar
The concentration of supplemental coolant additive
dealer.
(SCA) should be checked regularly with test kits
Table 21 or with S·O·S Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine
Hydrosolv Liquid Cleaners(1) is overhauled.
Part
Description Size A coolant analysis can be conducted in order to verify
Number
the condition of the water that is being used in the
1U-5490 Hydrosolv 4165 19 L (5 US gallon) cooling system. A full water analysis can be obtained
174-6854 Hydrosolv 100 19 L (5 US gallon) by consulting your local water utility company or
(1)
an agricultural agent. Private laboratories are also
Use a two to five percent concentration of the cleaner
at temperatures up to 93°C (200°F). Refer to Application available for water analysis.
Guide, NEHS0526 or consult your Caterpillar dealer for more
information. Caterpillar Inc. recommends an S·O·S Coolant
Analysis (Level 2).
4. Use steam to clean the oil cooler core and the
aftercooler core. This removes any remaining S·O·S Coolant Analysis (Level 2)
residue from the cleaner. Flush the fins of the oil
cooler core and the aftercooler core. Remove any An S·O·S Coolant Analysis (Level 2) is a
other trapped debris. comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
5. Wash the oil cooler core and the aftercooler core system. An S·O·S Coolant Analysis (Level 2) provides
with hot, soapy water. Rinse the oil cooler core and the following information:
the aftercooler core thoroughly with clean water.
• Complete S·O·S Coolant Analysis (Level 2)
• Visual inspection of properties
• Identification of metal corrosion
• Identification of contaminants
• Identification of built up impurities (corrosion and
scale)
104 SEBU8543
Maintenance Section
Starting Motor - Inspect

S·O·S Coolant Analysis (Level 2) provides a report of


the results of both the analysis and the maintenance
recommendations.
Personal injury or death can result from improp-
erly checking for a leak.
For more information about coolant analysis, consult
your Caterpillar dealer.
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure,
i04292969 even a pin-hole size leak, can penetrate body tis-
sue causing serious injury, and possible death.
Starting Motor - Inspect
If fluid is injected into your skin, it must be treated
SMCS Code: 1451-040; 1453-040 immediately by a doctor familiar with this type of
injury.

Inspect all of the components in the air circuit for


The connection of battery cables to a battery and the starting motor. Inspect all of the air lines and
the disconnection of battery cables from a battery connections for leaks.
may cause an explosion which may result in injury
or death. The connection and the disconnection If damaged teeth are found, the air circuit for
of other electrical equipment may also cause an the starting motor must be examined in order to
explosion which may result in injury or death. The determine the cause of the problem.
procedures for the connection and the disconnec-
tion of battery cables and other electrical equip-
ment should only be performed in a nonexplosive Electric Starting Motor
atmosphere.
Problems with the electric starting motor can be
caused by the following conditions: malfunction of
OEM Starting Motor the solenoid and malfunction of the electric starting
system.
The OEM may be responsible for the starting motor
for this engine application. Air starting motors are Inspect the electrical system for the following
recommended if an explosive atmosphere may be conditions: loose connections, corrosion, wires that
present. If the starting motor is supplied by an OEM, are worn or frayed, and cleanliness
refer to the Service Manual for the starter in order
to locate additional information on the checking i04293097
procedure and for specifications.
Turbocharger - Inspect
Air Starting Motor SMCS Code: 1052-040
If the starting motor fails, the engine may not start in
Note: If the engine operates in a hazardous
an emergency situation. A scheduled inspection of
environment and a thermal event occurs, inspect the
the starting motor is recommended.
turbocharger .
The starting motor pinion and the flywheel ring gear
Periodic inspection and cleaning are recommended
must be in good condition in order for the engine
for the turbocharger compressor housing (inlet side).
to start properly. The engine will not start if the
Any fumes from the crankcase are filtered through
starting motor pinion does not engage the flywheel
the air inlet system. Therefore, by-products from oil
ring gear. The teeth of the starting motor pinion and
and from combustion can collect in the turbocharger
the flywheel ring gear can be damaged because of
compressor housing. Over time, this buildup can
irregular engagement.
contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.
Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
If the turbocharger fails during engine operation,
teeth of the starting motor pinion and the flywheel
damage to the turbocharger compressor wheel
ring gear. Look for patterns of wear on the teeth. Look
and/or to the engine may occur. Damage to the
for teeth that are broken or chipped. If damaged teeth
turbocharger compressor wheel can cause additional
are found, the starting motor pinion and the flywheel
damage to the pistons, the valves, and the cylinder
ring gear must be replaced.
head.
SEBU8543 105
Maintenance Section
Walk-Around Inspection

3. Check the compressor wheel for cleanliness.


NOTICE If only the blade side of the wheel is dirty, dirt
Turbocharger bearing failures can cause large quan- and/or moisture is passing through the air filtering
tities of oil to enter the air inlet and exhaust systems. system. If oil is found only on the back side of the
Loss of engine lubricant can result in serious engine wheel, there is a possibility of a failed turbocharger
damage. oil seal.

Minor leakage of a turbocharger housing under ex- The presence of oil may be the result of extended
tended low idle operation should not cause problems engine operation at low idle. The presence of oil
as long as a turbocharger bearing failure has not oc- may also be the result of a restriction of the line for
curred. the inlet air (plugged air filters), which causes the
turbocharger to slobber.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust 4. Inspect the bore of the turbine housing for
smoke or engine rpm up at no load), do not continue corrosion.
engine operation until the turbocharger is repaired or
replaced. 5. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.
An inspection of the turbocharger can minimize 6. Fasten the air inlet piping and the exhaust outlet
unscheduled downtime. An inspection of the piping to the turbocharger housing.
turbocharger can also reduce the chance for potential
damage to other engine parts. 7. Install the turbocharger onto the engine. Refer
to the Disassembly and Assembly Manual,
Note: Turbocharger components require precision “Turbocharger - Install” for the installation process.
clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Applications can accelerate component wear. i01185304
Severe Service Applications require more frequent
inspections of the cartridge. Walk-Around Inspection
Note: Shutting down the engine without the benefit of SMCS Code: 1000-040
a cool down period may decrease the maintenance
interval for the repair and replacement of the Inspect the Engine for Leaks and
turbocharger.
for Loose Connections
Removal and Installation A walk-around inspection should only take a few
minutes. When the time is taken to perform these
Refer to the Disassembly and Assembly Manual, checks, costly repairs and accidents can be avoided.
“Turbocharger - Remove” for the removal process.
For maximum engine service life, make a thorough
Cleaning and Inspecting inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
1. Remove the exhaust outlet piping and remove leaks, loose bolts, worn belts, loose connections and
the air inlet piping from the turbocharger. Visually trash buildup. Make repairs, as needed:
inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt • The guards must be in the proper place. Repair
from entering during reassembly. damaged guards or replace missing guards.

2. Turn the compressor wheel and the turbine wheel • Wipe all caps and plugs before the engine is
by hand. The assembly should turn freely. Inspect serviced in order to reduce the chance of system
the compressor wheel and the turbine wheel for contamination.
contact with the turbocharger housing. There
should not be any visible signs of contact between NOTICE
the turbine wheel or compressor wheel and the For any type of leak (coolant, lube, or fuel) clean up the
turbocharger housing. If there is any indication of fluid. If leaking is observed, find the source and correct
contact between the rotating turbine wheel or the the leak. If leaking is suspected, check the fluid levels
compressor wheel and the turbocharger housing, more often than recommended until the leak is found
the turbocharger must be reconditioned. or fixed, or until the suspicion of a leak is proved to be
unwarranted.
106 SEBU8543
Maintenance Section
Water Pump - Inspect

• Disconnect any battery chargers that are not


NOTICE protected against the current drain of the starting
Accumulated grease and/or oil on an engine or deck is motor. Check the condition and the electrolyte level
a fire hazard. Remove this debris with steam cleaning of the batteries, unless the engine is equipped with
or high pressure water. a maintenance free battery.

• Check the condition of the gauges. Replace any


• Ensure that the cooling lines are properly clamped gauges that are cracked. Replace any gauge that
and that the cooling lines are tight. Check for leaks. can not be calibrated.
Check the condition of all pipes.

• Inspect the water pumps for coolant leaks. i03543200

Note: The water pump seal is lubricated by coolant Water Pump - Inspect
in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and SMCS Code: 1361-040
the parts contract.
A failed water pump might cause severe engine
Excessive coolant leakage may indicate the need overheating problems that could result in the following
to replace the water pump seal. For the removal of conditions:
water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the • Cracks in the cylinder head
engine or consult your Caterpillar dealer.
• A piston seizure
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil • Other potential damage to the engine
pan, the oil filters and the valve cover.
A failed water pump might cause severe engine
overheating problems that could result in cracks in
• Inspect the fuel system for leaks. Look for loose the cylinder head, a piston seizure or other potential
fuel line clamps or for loose fuel line tie-wraps.
damage to the engine.
• Inspect the piping for the air inlet system and the Visually inspect the water pump for leaks. If leaking
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other of the water pump seals is observed, replace all of
hoses, tubes, wiring harnesses, etc. the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump
- Disassemble and Water Pump - Assemble” for
• Inspect the alternator belt and the accessory drive the disassembly and assembly procedure. If it is
belts for cracks, breaks or other damage.
necessary to remove the water pump, refer to two
Belts for multiple groove pulleys must be replaced as articles in the Disassembly and Assembly Manual,
matched sets. If only one belt is replaced, the belt will “Water Pump - Remove and Water Pump - Install”.
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on Inspect the water pump for wear, cracks, pin holes
the new belt could cause the belt to break. and proper operation. Refer to the Parts Manual
for the correct part numbers for your engine or
consult your Caterpillar dealer if repair is needed or
• Drain the water and the sediment from fuel tanks replacement is needed.
on a daily basis in order to ensure that only clean
fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for


loose connections and for worn wires or frayed
wires.

• Inspect the ground strap for a good connection and


for good condition.

• Inspect the ECM to the cylinder head ground strap


for a good connection and for good condition.