SAFETY.CAT.

COM

3306B
INDUSTRIAL ENGINES
Maintenance Intervals

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

2007 Caterpillar
All Rights Reserved

57
Maintenance Section
Maintenance Interval Schedule

i01252429

Maintenance Interval Schedule

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

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

60
61
68
77
78
88

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

59
64
67
71
73
82
87
90

Fuel System Primary Filter/Water Separator Element

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

Every 34 000 L (9000 US gal) of Fuel or 1000

Service Hours
Engine Protective Devices - Check ....................... 75
Fuel Control Linkage - Check/Lubricate ............... 77

Every 67 000 L (18 000 US gal) of Fuel or

2000 Service Hours
Crankshaft Vibration Damper - Inspect .................
Engine Mounts - Inspect .......................................
Engine Valve Lash - Inspect/Adjust ......................
Engine Valve Rotators - Inspect ............................
Fuel Injection Nozzles - Test/Exchange ................
Fuel Ratio Control - Inspect/Adjust .......................
Turbocharger - Inspect ..........................................

67
72
76
76
77
78
89

Every 91 000 L (24 000 US gal) of Fuel or

3000 Service Hours
Aftercooler Core - Clean/Test ...............................
Cooling System Coolant (DEAC) - Change ..........
Cooling System Coolant Extender (ELC) - Add ....
Cooling System Water Temperature Regulator Replace ...............................................................
Water Pump - Inspect ...........................................

58
61
64
66
91

PM Level 2 - Every 114 000 L (30 000 US gal)

of Fuel or 4000 Service Hours or 2 Years
Air Compressor - Inspect ...................................... 58

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

Service Hours

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

4000 Service Hours

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

Alternator - Inspect ............................................... 59

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

Between 250 Service Hours and 1000 Service

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

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

Every 8500 L (2200 US gal) of Fuel or 250

Service Hours
Alternator and Fan Belts - Inspect/Adjust/
Replace ...............................................................
Battery Electrolyte Level - Check ..........................
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .................................................
Engine Crankcase Breather - Clean .....................
Engine Oil Sample - Obtain ..................................
Engine Oil and Filter - Change .............................
Fan Drive Bearing - Lubricate ...............................

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

6000 Service Hours

Overhaul
59
60
65
72
73
74
77

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

58
Maintenance Section
Aftercooler Core - Clean/Test

i00744980

Aftercooler Core - Clean/Test

SMCS Code: 1064-070; 1064-081

Personal injury can result from air pressure.

1. Remove the core. Refer to the Service Manual

for the procedure.

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

2. Turn the aftercooler core upside-down in order

to remove debris.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

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

6. Dry the core with compressed air. Direct the air

in the reverse direction of the normal flow.

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 33 lists Hydrosolv liquid
cleaners that are available from your Caterpillar
dealer.

7. Inspect the core in order to ensure cleanliness.

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

Table 33

i01183385

Hydrosolv Liquid Cleaners(1)

Description

Container

1U-8812 Hydrosolv 4165

4 L (1 US gal)

1U-5490 Hydrosolv 4165

19 L (5 US gal)

8T-7570 Hydrosolv 4165

208 L (55 US gal)

1U-8804 Hydrosolv 100

4 L (1 US gal)

1U-5492 Hydrosolv 100

19 L (5 US gal)

8T-7571 Hydrosolv 100

208 L (55 US gal)

(1)

Use a two to five percent concentration of the cleaner

at temperatures up to 93C (200F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more
information.

Air Compressor - Inspect

SMCS Code: 1803-040

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

4. Steam clean the core in order to remove any

residue. Flush the fins of the aftercooler core.
Remove any other trapped debris.
5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.

Illustration 17
(1) Air compressor pressure relief valve

g00633741

59
Maintenance Section
Air Tank Moisture and Sediment - Drain

If the air compressor pressure relief valve that is

mounted in the air compressor cylinder head is
bypassing compressed air, there is a malfunction
in the air system, possibly ice blockage. Under
these conditions, your engine may have insufficient air for normal brake operation.
Do not operate the engine until the reason for the
air bypass is identified and corrected. Failure to
heed this warning could lead to property damage,
personal injury, or death to the operator or bystanders.
The function of the air compressor pressure relief
valve is to bypass air when there is a malfunction in
the air compressor system.
The air compressor pressure relief valve releases
air at 1723 kPa (250 psi). It is very important that
all personnel stand clear of the air compressor
pressure relief valve when compressed air is
released. All personnel should also stay clear of the
air compressor when the engine is operating and
the air compressor is exposed.
Refer to the Service Manual or refer to the OEM
specifications in order to find information concerning
the air compressor. Consult your Caterpillar dealer
for assistance.
i00847451

Air Tank Moisture and

Sediment - Drain
(If Equipped)

1. Open the drain valve that is on the bottom of

the air tank. Allow the moisture and sediment
to drain.
2. Close the drain valve.
3. Check the air supply pressure. The air starting
motor requires a minimum of 620 kPa (90 psi) of
air pressure to operate properly. The maximum
air pressure must not exceed 1550 kPa (225 psi).
The normal air pressure will be 758 to 965 kPa
(110 to 140 psi).
i00072207

Alternator - Inspect
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection
of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect
the ammeter (if equipped) during engine operation
in order to ensure proper battery performance
and/or proper performance of the electrical system.
Make repairs, as required. Refer to the Service
Manual.
Check the alternator and the battery charger for
proper operation. If the batteries are properly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time
or if the engine is run for short periods, the batteries
may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.

SMCS Code: 1466-543-M&S

Moisture and sediment in the air starting system
can cause the following conditions:

i00841051

Freezing

Alternator and Fan Belts Inspect/Adjust/Replace

Corrosion of internal parts

SMCS Code: 1357-039

Malfunction of the air starting system

Inspection

When opening the drain valve, wear protective

gloves, a protective face shield, protective clothing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal
injury.

To maximize the engine performance, inspect the

belts for wear and for cracking. Check the belt
tension. Adjust the belt tension in order to minimize
belt slippage. Belt slippage will decrease the life
of the belts.
To check the belt tension, apply 110 N (25 lb)
of force midway between the pulleys. A
correctly adjusted belt will deflect 13 to 19 mm
(0.50 to 0.75 inch).

60
Maintenance Section
Battery - Replace

Adjustment
If the belts are too loose, the belts will vibrate. This
vibration is enough to cause unnecessary wear on
the belts and on the pulleys.
If the belts are too tight, unnecessary stresses are
placed upon the pulley bearings and upon the
belts. These stresses will shorten the life of the belts
and of the pulley bearings.
If new belts are installed, check the tension again
after 30 minutes of engine operation at the rated
rpm.

Replacement
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to
carry more load because the older belt is stretched.
The additional load on the new belt could cause the
new belt to break.
Refer to the Service Manual for more information on
the procedures for the following topics: belt removal
and belt installation procedure.

4. The POSITIVE + cable connects the POSITIVE

+ battery terminal to the starting motor.
Disconnect the cable from the POSITIVE +
battery terminal.
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that
the key start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE + battery terminal.
8. Connect the cable from the ground plane to the
NEGATIVE - battery terminal.
i01206348

Battery Electrolyte Level Check

SMCS Code: 1401-081

i01179608

Battery - Replace
SMCS Code: 1401-510

Batteries give off combustible gases which can

explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
1. Turn the key start switch to the OFF position.
Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the
charger.
3. The NEGATIVE - cable connects the NEGATIVE
- battery terminal to the ground plane.
Disconnect the cable from the NEGATIVE -
battery terminal.

When the engine is not run for long periods of

time or when the engine is run for short periods,
the batteries may not fully recharge. Ensure a full
charge in order to help prevent the battery from
freezing. If batteries are properly charged, ammeter
reading should be very near zero.

All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the filler caps. Maintain the electrolyte
level to the FULL mark on the battery.
If the addition of water is necessary, use distilled
water. If distilled water is not available use
clean water that is low in minerals. Do not use
artificially softened water.
2. Check the condition of the electrolyte with the
1U-7298 Coolant/Battery Tester (C) or the
1U-7297 Coolant/Battery Tester (F).
3. Keep the batteries clean.
Clean the battery case with one of the following
cleaning solutions:

61
Maintenance Section
Battery or Battery Cable - Disconnect

A mixture of 0.1 L (0.11 qt) of baking soda and

1 L (1 qt) of clean water

The fuel has entered the cooling system and the

coolant is contaminated.

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

1 L (1 qt) of clean water
Thoroughly rinse the battery case with clean
water.
Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit
properly. Coat the clamps and the terminals with
5N-5561 Silicone Lubricant, petroleum jelly or
MPGM grease.

NOTICE
Use of commercially available cooling system cleaners may cause damage to cooling system components. Use only cooling system cleaners that are approved for Caterpillar engines.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator
and the hoses, if necessary.

Drain

i00095575

Battery or Battery Cable Disconnect

SMCS Code: 1402-029
1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side
of two batteries must be disconnected.
3. Tape the leads in order to help prevent accidental
starting.
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.
i01206425

Cooling System Coolant

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

The engine overheats frequently.

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

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap.
2. Open the cooling system drain valve (if
equipped). If the cooling system is not equipped
with a drain valve, remove one of the drain plugs.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology
Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

Flush
1. Flush the cooling system with clean water in
order to remove any debris.

62
Maintenance Section
Cooling System Coolant (DEAC) - Change

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

drain plugs. Install the drain plugs. Refer to the
Operation and Maintenance Manual, Torque
Specifications topic (Maintenance Section) for
more information on the proper torques.

NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

3. Fill the cooling system with a mixture of clean

water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the cooling system filler cap.

3. Fill the cooling system with a mixture of clean

water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.

4. Start and run the engine at low idle for a

minimum of 90 minutes. The coolant temperature
should be at least 82 C (180 F).

4. Start and run the engine at low idle for a

minimum of 30 minutes. The coolant temperature
should be at least 82 C (180 F).

NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal components.

NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal components.

To avoid damage to the cooling system, make sure

to completely flush the cooling system with clear water. Continue to flush the system until all signs of the
cleaning agent are gone.

To avoid damage to the cooling system, make sure

to completely flush the cooling system with clear water. Continue to flush the system until all signs of the
cleaning agent are gone.

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

Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system
drain plugs. Allow the water to drain. Flush the
cooling system with clean water. Close the drain
valve (if equipped). Clean the drain plugs. Install
the drain plugs. Refer to the Operation and
Maintenance Manual, Torque Specifications
topic (Maintenance Section) for more information
on the proper torques.

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

Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system
drain plugs. Allow the water to drain. Flush the
cooling system with clean water. Close the drain
valve (if equipped). Clean the drain plugs. Install
the drain plugs. Refer to the Operation and
Maintenance Manual, Torque Specifications
topic (Maintenance Section) for more information
on the proper torques.

Cooling Systems with Heavy

Deposits or Plugging
Note: For the following procedure to be effective,
there must be some active flow through the cooling
system components.
1. Flush the cooling system with clean water in
order to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the
Operation and Maintenance Manual, Torque
Specifications topic (Maintenance Section) for
more information on the proper torques.

Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Fill the cooling system with coolant/antifreeze.
Refer to the Operation and Maintenance
Manual, Cooling System Specifications topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
cooling system filler cap.
2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.

63
Maintenance Section
Cooling System Coolant (ELC) - Change

3. Check the coolant level. Maintain the coolant

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

Drain

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap.
2. Open the cooling system drain valve (if
equipped). If the cooling system is not equipped
with a drain valve, remove the cooling system
drain plugs.
Allow the coolant to drain.

i01206445

Cooling System Coolant (ELC)

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

The engine overheats frequently.

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

NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology
Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

coolant is contaminated.

The fuel has entered the cooling system and the

coolant is contaminated.

Note: When the cooling system is cleaned, only

clean water is needed when the ELC is drained
and replaced.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator
and the hoses, if necessary.

Flush
1. Flush the cooling system with clean water in
order to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the
Operation and Maintenance Manual, Torque
Specifications topic (Maintenance Section) for
more information on the proper torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with clean water. Install
the cooling system filler cap.

64
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

4. Start and run the engine at low idle until the

temperature reaches 49 to 66 C (120 to 150 F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system
drain plugs. Allow the water to drain. Flush the
cooling system with clean water. Close the drain
valve (if equipped). Clean the drain plugs. Install
the drain plugs. Refer to the Operation and
Maintenance Manual, Torque Specifications
topic (Maintenance Section) for more information
on the proper torques.

Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to the Operation and Maintenance
Manual, Cooling System Specifications topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
cooling system filler cap.
2. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant
level within 13 mm (0.5 inch) below the bottom
of the pipe for filling. Maintain the coolant level
within 13 mm (0.5 inch) to the proper level on the
sight glass (if equipped).
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap
is not damaged, use a 9S-8140 Pressurizing
Pump in order to pressure test the cooling
system filler cap. The correct pressure for the
cooling system filler cap is stamped on the face
of the cooling system filler cap. If the cooling
system filler cap does not retain the correct
pressure, install a new cooling system filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.

i00259474

Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352-045; 1395-081
Caterpillar Extended Life Coolant (ELC) does not
require the frequent Supplemental Coolant Additive
(SCA) additions associated with the present
conventional coolants. The Extender only needs to
be added once.
Check the cooling system only when the engine is
stopped and cool.
1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling
system filler cap.
2. It may be necessary to drain enough coolant
from the cooling system in order to add the
Extender.
3. Add Extender according to the requirements for
your engines cooling system capacity. Refer to
the Operation and Maintenance Manual, Refill
Capacities in the Maintenance Section for the
capacity of the cooling system for your engine.
Refer to the Operation and Maintenance Manual,
Cooling System Specifications information for
the Caterpillar ELC Extender additions.
4. Clean the cooling system filler cap. Inspect the
cooling system filler cap gaskets. Replace the
cooling system filler cap if the cooling system
filler cap gaskets are damaged. Install the
cooling system filler cap.
i01197583

Cooling System Coolant Level

- Check
SMCS Code: 1395-082
Check the coolant level when the engine is stopped
and cool.

65
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i00992487

Cooling System Supplemental

Coolant Additive (SCA) Test/Add
SMCS Code: 1352-045; 1395-081

Illustration 18

g00285520

Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact with
the skin and the eyes. Do not drink cooling system
coolant additive.

Cooling system filler cap

Note: Test the concentration of the Supplemental

Coolant Additive (SCA) or test the SCA concentration
as part of an SOS Coolant Analysis.
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
1. Remove the cooling system filler cap slowly in
order to relieve pressure.
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.

Test for SCA Concentration

Coolant/Antifreeze and SCA
NOTICE
Do not exceed the recommended six percent supplemental coolant additive concentration.
Use the 8T-5296 Coolant Conditioner Test Kit
or use the 4C-9301 Coolant Conditioner Test Kit
in order to check the concentration of the SCA.
Refer to the Operation and Maintenance Manual for
more information on conventional coolant/antifreeze
cooling system maintenance.

Water and SCA

NOTICE
Do not exceed the recommended eight percent supplemental coolant additive concentration.

Illustration 19

g00103639

Typical filler cap gaskets

3. Clean the cooling system filler cap and check the

condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets
are damaged. Reinstall the cooling system filler
cap.
4. Inspect the cooling system for leaks.

Test the concentration of the SCA with the 8T-5296

Coolant Conditioner Test Kit. Refer to the Operation
and Maintenance Manual, Water/Supplemental
Coolant Additive (SCA) topic (Maintenance
Section). Refer to the Operation and Maintenance
Manual, Conventional Coolant/Antifreeze Cooling
System Maintenance topic (Maintenance Section).

SOS Coolant Analysis

SOS coolant samples can be analyzed at your
Caterpillar dealer. SOS Coolant Analysis is a
program that is based on periodic samples.

66
Maintenance Section
Cooling System Water Temperature Regulator - Replace

Level 1
Level 1 is a basic analysis of the coolant. The
following items are tested:

Glycol Concentration
Concentration of SCA

3. Add the proper amount of SCA. Refer to the

Operation and Maintenance Manual for more
information on SCA requirements.
4. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.

pH
i00912898

Conductivity
The results are reported, and recommendations
are made according to the results. Consult your
Caterpillar dealer for information on the benefits of
managing your equipment with an SOS Coolant
Analysis.

Add the SCA, If Necessary

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

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
1. Slowly loosen the cooling system filler cap in
order to relieve the pressure. Remove the cooling
system filler cap.
Note: Always discard drained fluids according to
local regulations.
2. If necessary, drain some coolant from the cooling
system into a suitable container in order to allow
space for the extra SCA.

Cooling System Water

Temperature Regulator Replace
SMCS Code: 1355-510
Replace the water temperature regulator before
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime.
A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the
closed position can cause excessive overheating.
Excessive overheating could result in cracking of
the cylinder head or piston seizure problems.
A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside
the cylinders. This excessive carbon buildup could
result in an accelerated wear of the piston rings and
wear of the cylinder liner.
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water
temperature regulator installed.
If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature regulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or
cylinder head surface.

67
Maintenance Section
Crankshaft Vibration Damper - Inspect

Refer to the Service Manual for the replacement

procedure of the water temperature regulator, or
consult your Caterpillar dealer.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system
to a level that is below the water temperature
regulator housing.
i00894991

Crankshaft Vibration Damper

- Inspect
SMCS Code: 1205-040
Damage to the crankshaft vibration damper or
failure of the crankshaft vibration damper can
increase torsional vibrations. This can result in
damage to the crankshaft and to other engine
components. A deteriorating damper can cause
excessive gear train noise at variable points in the
speed range.
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the
engine.

Visconic Damper
Your engine may be equipped with a visconic
damper. The visconic damper has a weight that is
located inside a fluid filled case. The weight moves
in the case in order to limit torsional vibration.
Inspect the damper for evidence of fluid leaks. If
a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has
the following characteristics: transparent, viscous,
smooth, and difficult to remove from surfaces.
If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace the crankshaft
seals.
Inspect the damper and repair or replace the
damper for any of the following reasons:

The damper is dented, cracked, or leaking.

The paint on the damper is discolored from heat.
The engine has had a failure because of a broken
crankshaft.

Analysis of the oil has revealed that the front main

bearing is badly worn.

Rubber Damper
Your engine may be equipped with a rubber
damper. The rubber damper uses a ring which is
mounted in rubber in order to reduce vibrations in
the crankshaft.

There is a large amount of gear train wear that is

not caused by a lack of oil.

Refer to the Service Manual or consult your

Caterpillar dealer for information about damper
replacement.

Inspect the damper and repair or replace the

damper for any of the following reasons:

i00174798

There is deterioration and cracking of the rubber.

Driven Equipment - Check

There is slippage of the outer ring from the

SMCS Code: 3279-535

The engine has had a failure because of a broken

Refer to the OEM specifications for more information

on the following maintenance recommendations for
the driven equipment:

Analysis of the oil has revealed that the front main

Inspection

original position.
crankshaft.

bearing is badly worn.

There is a large amount of gear train wear that is

not caused by lack of oil.

Refer to the Service Manual or consult your

Caterpillar dealer for information about damper
replacement.

Adjustment
Lubrication
Other maintenance recommendations
Perform any maintenance for the driven equipment
which is recommended by the OEM.

68
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

i01089660

Engine Air Cleaner Element

(Dual Element) - Clean/Replace
SMCS Code: 1054-037; 1054-510
Perform the Operation and Maintenance Manual,
Engine Air Cleaner Service Indicator-Inspect
procedure and perform the Operation and
Maintenance Manual, Engine Air Precleaner
Check/Clean procedure (if equipped) before
performing the following procedure.
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

Replace the dirty paper air cleaner elements with

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

Air Cleaners With Dual Elements

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

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the
air can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
engine wear. Your Caterpillar dealer has the proper
air cleaner elements for your application. Consult
your Caterpillar dealer for the correct air cleaner
element.

Check the precleaner (if equipped) daily for

accumulation of dirt and debris. Remove any dirt
and debris, as needed.

Operating conditions (dust, dirt and debris) may

require more frequent service of the air cleaner
element.

The air cleaner element may be cleaned up to

six times if the element is properly cleaned and

inspected.

The air cleaner element should be replaced

at least one time per year. This replacement
should be performed regardless of the number
of cleanings.

Illustration 20

g00123209

(1) Cover. (2) Primary air cleaner element. (3) Secondary air
cleaner element. (4) Turbocharger air inlet.

1. Remove the cover. Remove the primary air

cleaner element.
2. The secondary air cleaner element should be
removed and discarded for every three cleanings
of the primary air cleaner element.
Note: Refer to Cleaning the Primary Air Filter
Elements.
3. Cover the turbocharger air inlet with tape in
order to keep dirt out.
4. Clean the inside of the air cleaner cover and
body with a clean, dry cloth.

69
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

5. Remove the tape for the turbocharger air inlet.

Install the secondary air cleaner element. Install
a primary air cleaner element that is new or
cleaned.

Note: When the primary air cleaner element is

cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).

6. Install the air cleaner cover.

Aim the hose so that the water flows inside the

element along the length of the filter in order to help
prevent damage to the paper pleats. Do not aim the
stream of water directly at the primary air cleaner
element. Dirt could be forced further into the pleats.

7. Reset the service indicator.

Cleaning the Primary Air Cleaner

Elements
The primary air cleaner element can be used up
to six times if the element is properly cleaned and
inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
The primary air cleaner element should be replaced
at least one time per year. This replacement
should be performed regardless of the number of
cleanings.
Use clean primary air cleaner elements while dirty
elements are being cleaned.

Note: Refer to Drying the Primary Air Cleaner

Elements. Refer to Inspecting the Primary Air
Cleaner Elements.

Pressurized Air
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with
a maximum pressure of 207 kPa (30 psi).

NOTICE
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the primary air cleaner elements
before cleaning. Inspect the air cleaner elements
for damage to the seal, the gaskets, and the outer
cover. Discard any damaged air cleaner elements.
There are four common methods that are used to
clean primary air cleaner elements:

Pressurized water
Pressurized air
Vacuum cleaning
Washing with nonsudsing detergent

Illustration 21

g00281692

Note: When the primary air cleaner elements are

cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
of air directly at the primary air cleaner element. Dirt
could be forced further into the pleats.

Pressurized Water
Pressurized water will clean the primary air cleaner
element unless carbon and oil have accumulated
on the surface of the primary air cleaner element.
The maximum water pressure for cleaning purposes
must be below 275 kPa (40 psi). Do not use a
spray nozzle.

Note: Refer to Inspecting the Primary Air Cleaner

Elements.

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

70
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

Note: Refer to Inspecting the Primary Air Cleaner

Elements.

Washing the Primary Air Cleaner

Elements with Nonsudsing Detergent

Primary air cleaner elements may be allowed to

air dry. Allow two days for the primary air cleaner
elements to air dry before the elements are
inspected and installed.

Inspecting the Primary Air Cleaner

Elements

Do not wash air cleaner elements in any flammable

solution such as diesel fuel or gasoline. Doing so
can cause fire or an engine runaway and can result
in personal injury.
Washing with nonsudsing detergent is effective for
cleaning primary air cleaner elements that have
deposits of carbon or oil. Use a cleaning agent that
is specifically manufactured for cleaning primary air
cleaner elements. Cleaning with pressurized water,
pressurized air, or a vacuum is recommended prior
to washing with nonsudsing detergent.
1. Place the primary air cleaner element into a
wash tank so that the gasket is up. The wash
tank should be equipped with a rack so that the
primary air cleaner element does not sit on the
bottom of the wash tank.
Note: Caterpillar does not recommend a process
for washing the primary air cleaner element which
includes vigorously shaking. By vigorously shaking
the element, carbon particles may be distributed.
2. Fill the wash tank with the cleaning agent
and warm water to a maximum temperature
of 60C (140F). Follow the manufacturers
recommendations for the cleaning agent. Allow
the primary air cleaner element to soak for six
hours.
3. Drain the wash tank. Do not use the cleaning
agent more than one time. Remove the primary
air cleaner element from the wash tank. Rinse
the primary air cleaner element with the method
for using pressurized water.
Note: Refer to Drying the Primary Air Cleaner
Elements. Refer to Inspecting the Primary Air
Cleaner Elements.

Drying the Primary Air Cleaner Elements

The oven method may be used in order to dry
primary air cleaner elements. If an oven is used,
do not expose the primary air cleaner elements to
temperatures that exceed 82C (160F).
Note: Do not use compressed air in order to dry the
primary air cleaner elements.

Illustration 22

g00281693

Inspect the clean, dry primary air cleaner element.

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

Storing Primary Air Cleaner Elements

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

71
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

The service indicator may be mounted on the air

cleaner element or in a remote location.

Illustration 23

g00281694

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

protective covering for storage. Restricted air flow
may result. To protect against dirt and damage,
wrap the primary air cleaner elements in Volalite
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:

Illustration 24

g00103777

Typical service indicator

Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner
element should be replaced when one of the
following conditions occur:

The yellow diaphragm enters the red zone.

The red piston locks in the visible position.

Date of the cleaning

Number of cleanings

Test the Service Indicator

Store the box in a dry location.

Service indicators are important instruments.

For more detailed information on cleaning the

primary air cleaner element, refer to Special
Publication, SEBF8062, Procedure to Inspect and
Clean Air Filters.

Check for ease of resetting. The service indicator

i01175055

Engine Air Cleaner Service

Indicator - Inspect
SMCS Code: 7452-040
Some engines may be equipped with a different
service indicator.
Some engines are equipped with a differential
gauge for inlet air pressure. The differential gauge
for inlet air pressure displays the difference in the
pressure that is measured before the air cleaner
element and the pressure that is measured after
the air cleaner element. As the air cleaner element
becomes dirty, the pressure differential rises. If your
engine is equipped with a different type of service
indicator, follow the OEM recommendations in order
to service the air cleaner service indicator.

should reset in less than three pushes.

Check the movement of the yellow core when the

engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the
new service indicator will not reset, the hole for the
service indicator may be plugged.
The service indicator may need to be replaced
frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled,
and whenever major engine components are
replaced.
Note: When a new service indicator is installed,
excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque
of 2 Nm (18 lb in).

72
Maintenance Section
Engine Air Precleaner - Check/Clean

i00720883

Engine Air Precleaner Check/Clean

SMCS Code: 1055-070; 1055-535

Illustration 26
(1)
(2)
(3)
(4)

Illustration 25

g00287039

g00495506

Bolt
Hose clamp
Breather assembly
Seal

1. Loosen hose clamp (2) and remove the hose

from breather assembly (3).

Typical engine precleaner

2. Remove bolt (1). Remove breather assembly (3)

and seal (4).

(1) Wing nut

(2) Cover
(3) Body

Remove wing nut (1) and cover (2). Check for an

accumulation of dirt and debris in body (3). Clean
the body, if necessary.
After cleaning the precleaner, install cover (2) and
wing nut (1).
Note: When the engine is operated in dusty
applications, more frequent cleaning is required.
i00972776

Engine Crankcase Breather Clean

SMCS Code: 1317-070
NOTICE
Perform this maintenance with the engine stopped.
If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.

3. Wash the breather element in solvent that is

clean and nonflammable. Allow the breather
element to dry before installation.
4. Install a breather element that is clean and dry.
Install seal (4) and breather assembly (3). Install
bolt (1) and tighten. Do not overtighten the bolt.
Refer to Specifications for the proper torque.
5. Install the hose. Install hose clamp (2). Refer to
the Operation and Maintenance Manual, Torque
Specifications topic (Maintenance Section) for
the proper torque.
i00687861

Engine Mounts - Inspect

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

Improper mounting of the engine

Deterioration of the engine mounts
Any engine mount that shows deterioration should
be replaced. Refer to the Service Manual for the
recommended torques. Refer to your Caterpillar
dealer for more information.

73
Maintenance Section
Engine Oil Level - Check

i00985714

i01070756

Engine Oil Level - Check

Engine Oil Sample - Obtain

SMCS Code: 1348-535-FLV

SMCS Code: 1000-008; 1348-554-SM;

7542-554-OC, SM

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.

In addition to a good preventive maintenance

program, Caterpillar recommends using SOS oil
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine.

Obtain the Sample and the Analysis

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
Illustration 27

g00501786

Engine model

(1) Oil filler cap

(2) Oil level gauge

Service hours on the engine

The number of hours that have accumulated
since the last oil change

The amount of oil that has been added since the

last oil change

(Y) ADD mark

(X) FULL mark

To ensure that the sample is representative of the

oil in the crankcase, obtain a warm, well mixed oil
sample.

NOTICE
Perform this maintenance with the engine stopped.

To avoid contamination of the oil samples, the tools

and the supplies that are used for obtaining oil
samples must be clean.

Illustration 28

g00110310

1. Maintain the oil level between ADD mark (Y)

and FULL mark (X) on oil level gauge (2). Do
not fill the crankcase above FULL mark (X).
NOTICE
Operating your engine when the oil level is above the
FULL mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oils lubricating characteristics and could result in the loss of power.
2. Remove oil filler cap (1) and add oil, if necessary.
Clean the oil filler cap. Reinstall the oil filler cap.

Caterpillar recommends using the sampling valve

in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 8T-9190 Fluid Sampling Bottle Group is
recommended for use with the sampling valve. The
bottle group includes the parts that are needed
for obtaining oil samples. Instructions are also
provided.

74
Maintenance Section
Engine Oil and Filter - Change

If the engine is equipped with a drain valve, turn

NOTICE
Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant
samples.
A small residue of either type sample may remain in
the pump and may cause a false positive analysis for
the sample being taken.
Always use a designated pump for oil sampling and a
designated pump for coolant sampling.
Failure to do so may cause a false analysis which
could lead to customer and dealer concerns.

the drain valve knob counterclockwise in order to

drain the oil. After the oil has drained, turn the
drain valve knob clockwise in order to close the
drain valve.

If the engine is not equipped with a drain valve,

remove the oil drain plug in order to allow the oil
to drain. If the engine is equipped with a shallow
sump, remove the bottom oil drain plugs from
both ends of the oil pan.
After the oil has drained, the oil drain plugs should
be cleaned and installed.

Replace the Oil Filter

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

NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
1. Remove the oil filter with a 1U-8760 Chain
Wrench.

i00652130

Engine Oil and Filter - Change

SMCS Code: 1318-510; 1348-044

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
Do not drain the oil when the engine is cold. As
the oil cools, suspended waste particles settle
on the bottom of the oil pan. The waste particles
are not removed with the draining cold oil. Drain
the crankcase with the engine stopped. Drain the
crankcase with the oil warm. This draining method
allows the waste particles that are suspended in the
oil to be drained 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. Use one of
the following methods to drain the engine crankcase
oil:

2. Cut the oil filter open with a 4C-5084 Oil Filter

Cutter. Break apart the pleats and inspect the oil
filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early
wear or a pending failure.
Use a magnet to differentiate between the
ferrous metals and the nonferrous metals that
are found in the oil filter element. Ferrous metals
may indicate wear on the steel and cast iron
parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive
amount of debris is found in the oil filter.

75
Maintenance Section
Engine Protective Devices - Check

2. Start the engine and run the engine at LOW

IDLE for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
3. Stop the engine and allow the oil to drain back
to the sump for a minimum of ten minutes.
4. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the ADD
and FULL marks on the oil level gauge.
i00626013

Illustration 29

g00103713

Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mounting

base. Ensure that all of the old oil filter gasket
is removed.
4. Apply clean engine oil to the new oil filter gasket.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminated. Contaminated oil can cause accelerated wear to
engine components.
5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that
are shown on the oil filter. Do not overtighten the
oil filter.

Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual for more information on
lubricant specifications. Fill the crankcase with
the proper amount of oil. Refer to the Operation
and Maintenance Manual for more information
on refill capacities.
NOTICE
If equipped with an auxiliary oil filter system or a remote oil filter system, follow the OEM or filter manufacturers recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
NOTICE
To prevent crankshaft bearing damage, crank the engine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.

Engine Protective Devices Check

SMCS Code: 7400-535
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.
A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective
devices are functioning properly.
NOTICE
During testing, abnormal operating conditions must be
simulated.
The tests must be performed correctly in order to prevent possible damage to the engine.
To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
perform the tests.

Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
immediately.

76
Maintenance Section
Engine Valve Lash - Inspect/Adjust

i00869628

Engine Valve Lash Inspect/Adjust

i00937014

Engine Valve Rotators - Inspect

SMCS Code: 1109-040

SMCS Code: 1102-025

The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change.
The adjustment is necessary due to the initial wear
of the valve train components and to the seating of
the valve train components.
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage
and/or shortened engine component life.

When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn, to help prevent being burned by
hot oil or spray.
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
Valve rotators cause the valves to rotate when the
engine runs. This helps to prevent deposits from
building up on the valves and the valve seats.
Perform the following steps after the valve lash is
set, but before the valve covers are installed:
1. Start the engine according to this Operation
and Maintenance Manual, Engine Starting
procedure (Operation Section).

Ensure that the engine can not be started while

this maintenance is being performed. To help prevent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before measuring/adjusting valve lash clearance.
Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance
is performed.
Refer to the Service Manual for more information.

Operate the engine at low idle.

2. Observe the top surface of each valve rotator.
The valve rotators should turn slightly when the
valves close.
If a valve fails to rotate, consult your Caterpillar
dealer.

77
Maintenance Section
Ether Starting Aid Cylinder - Replace

i00805059

Ether Starting Aid Cylinder Replace

(If Equipped)
SMCS Code: 1456-510-CD

Lubricate the fan drive bearing grease fitting with

Bearing Lubricant Special Purpose Grease or the
equivalent.
Inspect the fan drive pulley assembly. If the shaft
is loose, an inspection of the internal components
should be performed. Refer to the Service Manual.
i00705823

Fuel Control Linkage Check/Lubricate

SMCS Code: 1257-086; 1257-535
Check the fuel control linkage for proper operation.
If necessary, adjust the fuel control linkage . Refer to
the Service Manual for the adjustment procedures.

Illustration 30

g00104888

Typical example

1. Loosen the ether cylinder clamp. Unscrew and

remove the empty ether cylinder.
2. Remove the used gasket. Install the new gasket
that is provided with each new ether cylinder.
3. Install the new ether cylinder. Hand tighten the
ether cylinder. Tighten the ether cylinder clamp
securely.

Illustration 32

g00309003

Typical grease fittings on the fuel control linkage

i00175571

Fan Drive Bearing - Lubricate

Some fuel control linkages require lubrication.

Lubricate the grease fittings with 1P-0808
Multipurpose Grease or the equivalent.

SMCS Code: 1359-086-BD

i00626014

Fuel Injection Nozzles Test/Exchange

SMCS Code: 1254-013; 1254-081

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

Illustration 31
Typical Fan Drive Bearing Grease Fitting

g00123252

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.

78
Maintenance Section
Fuel Ratio Control - Inspect/Adjust

Fuel injection nozzles are subject to tip wear. Tip

wear is a result of fuel contamination. Tip wear can
cause the following problems:

Increased fuel consumption

Black smoke
Misfire
Rough running
Fuel Injection nozzles should be cleaned, inspected,
tested, and replaced, if necessary. Refer to Special
Instruction, SEHS7292 for using the 8S-2245
Injection Cleaning Tool Group. Consult your
Caterpillar dealer about cleaning the fuel injection
nozzle and testing the fuel injection nozzle.
NOTICE
Never wire brush or scrape a fuel injection nozzle.
Wire brushing or scraping a fuel injection nozzle will
damage the finely machine orifice. Proper tools for
cleaning and testing the fuel injection nozzles can be
obtained from Caterpillar dealers.
The following items are symptoms of a malfunction
of the fuel injection nozzle:

Abnormal engine operation

Smoke emission
Engine knock
Each fuel injection nozzle must be isolated one at a
time in order to determine the malfunctioning fuel
injection nozzle.
1. Start the engine.
2. Loosen each fuel line nut one at a time at the fuel
injection pump. A cloth or similar material must
be used in order to prevent fuel from spraying on
the hot exhaust components. Tighten each nut
before loosening the next nut.
3. A defective fuel injection nozzle may be identified
when a fuel line nut is loosened and the following
conditions are present:

The exhaust smoke is partially eliminated or

the exhaust smoke is completely eliminated.

Engine performance is not affected.

A fuel injection nozzle that is suspected of

being defective should be removed. A new
fuel injection nozzle should be installed in the
cylinder in order to determine if the removed fuel
injection nozzle is defective.

Removal and Installation of the

Fuel Injection Nozzles
For the removal and the installation of fuel injection
nozzles, special tooling is required. Refer to the
Service Manual for more information. Consult your
Caterpillar dealer for assistance.
i00908934

Fuel Ratio Control Inspect/Adjust

SMCS Code: 1278-025; 1278-040
Slow engine response and low power may indicate
a need for adjustment or repair of the fuel ratio
control. Refer to the Service Manual or your
Caterpillar dealer for the complete adjustment
procedure on the fuel ratio control.
i00976042

Fuel System - Prime

SMCS Code: 1258-548
Prime the fuel system in order to fill dry fuel filters
and purge air from the fuel system. Prime the fuel
system after the following occurrences:

Running the fuel system dry

Removal of the engine from storage
Maintenance of the fuel filter
Disconnecting fuel lines and installing fuel lines
Repair of leaks in the fuel lines

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

79
Maintenance Section
Fuel System - Prime

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
1. Unlock and operate the priming pump plunger
until a resistance is felt. This may require a
considerable number of strokes.
2. Push in and hand tighten the priming pump
plunger.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
3. Start the engine. The engine may run rough.
Run the engine at low idle until the engine runs
smoothly. If the following conditions exist, repeat
Steps 1 through 3:

The engine will not start.

The engine starts but the engine continues to

NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
4. Loosen vent plug (1) on fuel injection pump
housing (2).
5. Unlock and operate the priming pump plunger
until the flow of fuel from the vent valve is
continuous and free of air bubbles.
6. Tighten the vent plug. Clean up any spilled fuel
immediately.
7. Push in and hand tighten the priming pump
plunger.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
8. Start the engine. The engine may run rough.
Run the engine at low idle until the engine runs
smoothly. Proceed to Step 9 if the following
conditions exist:

misfire.

The engine starts but the engine continues to

smoke.

The engine will not start.

The engine starts but the engine continues to
misfire.

If operating problems persist after repeating

Steps 1 through 3, proceed to Step 4.

The engine starts but the engine continues to

smoke.

Illustration 34

Illustration 33
(1) Vent plug
(2) Fuel injection pump housing

g00502366

g00496813

80
Maintenance Section
Fuel System Primary Filter/Water Separator Element - Replace

NOTICE
Do not let the tops of fuel nozzles turn when the fuel
line nuts are loosened or tightened.
The nozzles will be damaged if the top of the nozzle
turns in the body.
The engine will be damaged if a defective fuel injection nozzle is used because the shape of fuel (spray
pattern) that comes out of the nozzles will not be correct.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.

The primary filter/water separator also provides

filtration in order to help extend the life of the
secondary fuel filter. The element should be
changed regularly. The primary filter/water separator
should be changed when the vacuum gauge (if
equipped) registers 50 to 70 kPa (15 to 20 In Hg).

Replace the Element

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

9. Loosen one fuel injection line nut at the fuel

injection nozzle.
10. Unlock and operate the priming pump plunger
until the flow of fuel from the fuel injection line is
continuous and free of air bubbles.
11. Tighten the fuel injection line nut. Refer to
Specifications for the proper torque. Clean up
any spilled fuel immediately.
12. Perform Steps 9 through 11 on each fuel
injection line.
13. Push in and hand tighten the priming pump
plunger.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
14. Start the engine.
i00914347

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 fuel system components
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.

Illustration 35
(1)
(2)
(3)
(4)
(5)

g00467033

Vent valve
Base
Can
Element
Drain plug

1. Close the main fuel supply valve.

2. Remove drain plug (5). Depress vent valve (1)
in order to start the flow of fuel. Allow the fuel to
drain into a suitable container. Dispose of the
fuel properly.
3. Install the drain plug.
4. Remove can (3) from base (2).
5. Remove element (4) from the can. Dispose of
the used element.
6. Remove the gasket. Clean the following
components:

Can
Gasket
Base

81
Maintenance Section
Fuel System Secondary Filter - Replace

Inspect the gasket for damage and for

deterioration. Replace the gasket, if necessary.
7. Install the gasket. Lubricate the gasket with
clean diesel fuel.
NOTICE
The primary filter/water separator may be prefilled with
fuel to avoid rough running/stalling of the engine due
to air. Do not fill the secondary filter with fuel before
installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
8. Install a new element in the can. The can may
be filled with fuel at this time.
9. Install the can on the base. Tighten the can by
hand. Do not use tools in order to tighten the can.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tightened securely to help prevent air from entering the fuel system.
10. Open the main fuel supply valve.
11. Start the engine and check for leaks. Run the
engine for one minute. Stop the engine and
check for leaks again.
Leaks are difficult to detect while the engine is
running. The primary filter/water separator is
under suction. A leak will allow air to enter the
fuel. The air in the fuel can cause low power due
to aeration of the fuel. If air enters the fuel, ensure
that all components are properly tightened.
i00986685

Fuel System Secondary Filter Replace

SMCS Code: 1261-510-SE

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

Illustration 36

g00502378

(1) Fuel filter

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any disconnected fuel system components.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
NOTICE
Do not loosen fuel lines or fittings at the fuel manifold
or ECM. The engine components may be damaged.
1. Remove the used fuel filter.
2. Clean the gasket sealing surface of the fuel
filter base. Ensure that all of the old gasket is
removed.
3. Apply clean diesel fuel to the new fuel filter
gasket.
NOTICE
Do not fill the secondary fuel filter with fuel before installing. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
4. Install the new fuel filter. Spin the fuel filter onto
the fuel filter base until the gasket contacts the
base. Use the rotation index marks on the filters
as a guide for proper tightening. Tighten the
filter for an additional 3/4 turn by hand. Do not
overtighten the filter.

82
Maintenance Section
Fuel System Water Separator - Drain

i00909035

i00073301

Fuel System Water Separator

- Drain

Fuel Tank Water and Sediment

- Drain

SMCS Code: 1263-543

SMCS Code: 1273-543-M&S

Fuel Tank
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

Fuel quality is critical to the performance and to

the service life of the engine. Water in the fuel can
cause excessive fuel system wear. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through
the fuel system and the fuel returns to the fuel tank.
This causes water to accumulate in fuel tanks.
Draining the fuel tank regularly and obtaining fuel
from reliable sources can help to eliminate water
in the fuel.

Drain the Water and the Sediment

Fuel tanks should contain some provision for
draining water and draining sediment from the
bottom of the fuel tanks.
Illustration 37
(1)
(2)
(3)
(4)
(5)

g00467033

Vent valve
Base
Can
Element
Drain plug

Water in the fuel can cause fuel system components

to fail. Drain the water separator daily. Drain the
water separator more frequently when a large
concentration of water is present in the fuel system.
1. Close the fuel supply valve.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
2. Remove drain plug (5). Depress vent valve (1) in
order to start the flow. Allow the water to drain
into a suitable container. Allow the water to flow
until fuel flows from the drain.

Open the drain valve on the bottom of the fuel tank

in order to drain the water and the sediment. Close
the drain valve.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
Fill the fuel tank after operating the engine in
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important.

3. Install the drain plug. Dispose of the liquid

properly.

Fuel Storage Tanks

4. Open the fuel supply valve.

Drain the water and the sediment from the fuel

storage tank during the following conditions:

NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel
system.

Weekly
Oil change
Refill of the tank

83
Maintenance Section
Hoses and Clamps - Inspect/Replace

This will help prevent water or sediment from being

pumped from the storage tank into the engine fuel
tank.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
i00907072

Hoses and Clamps Inspect/Replace

SMCS Code: 7554-040; 7554-510

Due to extreme temperature changes, the hose

will heat set. Heat setting causes hose clamps to
loosen. This can result in leaks. A constant torque
hose clamp will help to prevent loose hose clamps.
Each installation application can be different. The
differences depend on the following factors:

Type of hose
Type of fitting material
Anticipated expansion and contraction of the
hose

Anticipated expansion and contraction of the

fittings

Replace the Hoses and the Clamps

Inspect all hoses for leaks that are caused by the

following conditions:

Cracking
Softness
Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
NOTICE
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the recommended torque.
Check for the following conditions:

End fittings that are damaged or leaking

Outer covering that is chafed or cut
Exposed wire that is used for reinforcement
Outer covering that is ballooning locally
Flexible part of the hose that is kinked or crushed
Armoring that is embedded in the outer covering
A constant torque hose clamp can be used in
place of any standard hose clamp. Ensure that the
constant torque hose clamp is the same size as
the standard clamp.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
1. Stop the engine. Allow the engine to cool.
2. Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
3. Drain the coolant from the cooling system to
a level that is below the hose that is being
replaced.
4. Remove the hose clamps.
5. Disconnect the old hose.
6. Replace the old hose with a new hose.
Note: For torques on hose clamps, see this
Operation and Maintenance Manual, Torque
Specifications (Maintenance Section).
7. Install the hose clamps with a torque wrench.
Note: For the proper coolant to use, see this
Operation and Maintenance Manual, Coolant
Recommendations (Maintenance Section).
8. Refill the cooling system.

84
Maintenance Section
Magnetic Pickups - Clean/Inspect

9. Clean the cooling system filler cap. Inspect the

cooling system filler caps gaskets. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
10. Start the engine. Inspect the cooling system for
leaks.
i00906366

Magnetic Pickups Clean/Inspect

SMCS Code: 1907-040; 7400-040; 7400-070

3. Install the magnetic pickup and adjust the

magnetic pickup. Refer to the Service Manual for
the installation procedure.
i00984589

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

Need for preventive maintenance

Quality of the fuel that is being used
Operating conditions
Results of the SOS analysis
Illustration 38

g00293335

Oil Consumption as an Overhaul

Indicator

Typical example
(1) Magnetic pickup
(2) Flywheel housing

Oil consumption, fuel consumption, and

maintenance information can be used to estimate
the total operating cost for your Caterpillar engine.
Oil consumption can also be used to estimate
the required capacity of a makeup oil tank that is
suitable for the maintenance intervals.
Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
consumed per hour also increases.

Illustration 39

g00293337

Typical magnetic pickup

1. Remove magnetic pickup (1) from flywheel

housing (2). Check the condition of the end of
the magnetic pickup. Check for signs of wear
and contaminants.
2. Clean the metal shavings and other debris from
the face of the magnet.

The oil consumption rate (brake specific oil

consumption) is measured in grams per kW/h
(lb per bhp). The brake specific oil consumption
(BSOC) depends on the engine load. Consult your
Caterpillar dealer for assistance in determining the
typical oil consumption rate for your engine.
When an engines oil consumption has risen to
three times the original oil consumption rate due
to normal wear, an engine overhaul should be
scheduled. There may be a corresponding increase
in blowby and a slight increase in fuel consumption.

85
Maintenance Section
Overhaul Considerations

Overhaul Options

Rebuild or Exchange

Before Failure Overhaul

Inspect the following components according to the

instructions that are found in various Caterpillar
reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.

A planned overhaul before failure may be the best

value for the following reasons:

Avoid costly unplanned downtime.

Reuse many original parts according to the
standards for reusable parts.

Extend the engines service life without the risk of

Cylinder head assembly

Connecting rods
Pistons

a major catastrophe due to engine failure.

Attain the best cost/value relationship per hour of

extended life.

Turbocharger
Oil pump

After Failure Overhaul

Fuel ratio control

Many options are available if a major engine failure

occurs. An overhaul should be performed if the
engine block or the crankshaft needs to be repaired.

Cam followers

If the engine block is repairable and/or the

crankshaft is repairable, the overhaul cost should
be between 40 percent and 50 percent of the cost
of a new engine with a similar exchange core.

Timing advance

This lower cost can be attributed to three aspects:

Fuel transfer pump

Valve rotators
If the parts comply with the established inspection
specifications that are expressed in the reusable
parts guideline, the parts should be reused.

Specially designed Caterpillar engine features

Caterpillar dealer exchange components
Caterpillar remanufactured exchange components

Overhaul Recommendation
To minimize downtime, Caterpillar Inc. recommends
a scheduled engine overhaul by your Caterpillar
dealer before the engine fails. This will provide you
with the best cost/value relationship.
Note: Overhaul programs vary according to the
engine application and according to the dealer
that performs the overhaul. Consult your Caterpillar
dealer for specific information about the available
overhaul programs and about overhaul services for
extending the engine life.
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the
following maintenance recommendations.

Parts that are not within the established inspection

specifications should be salvaged, repaired, or
replaced.
Using out-of-spec parts can result in the following
problems:

Unscheduled downtime
Costly repairs
Damage to other engine parts
Reduced engine efficiency
Increased fuel consumption
Reduced engine efficiency and increased fuel
consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts.

Component Replacement
Replace the following components during the
overhaul:

Piston rings

86
Maintenance Section
Overhaul Considerations

Thrust bearings

Excessive wear of the gear train that is not

caused by a lack of lubrication

Main bearings
Connecting rod bearings

Visconic damper that is dented, cracked, or

leaking

Gaskets and seals

Visconic damper that is discolored from heat

Engine mounts

Rubber damper that is deteriorated and cracked

Hoses

Rubber damper with slippage of the outer ring

Inspection

Inspect the gear train for the following conditions:

Inspect the following components according to

the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, Index
of Publications on Reusability or Salvage of Used
Parts.

Worn gear teeth

Unusual fit
Unusual wear
Testing

Camshaft
Camshaft bearings
Crankshaft
Crankshaft vibration damper
Gear train
Inspect the camshaft for damage to the journals
and the lobes. Inspect the camshaft bearings for
signs of wear and/or for signs of fatigue.
Inspect the crankshaft for any of the following
conditions:

Deflection

Test the following components during the overhaul:

Fuel injection nozzles

Fuel injection pump
Governor
Testing the fuel system during the overhaul will
ensure that your engine operates at peak efficiency.
Your Caterpillar dealer can provide these services
and components in order to ensure that your
fuel system is operating within the appropriate
specifications.

Cleaning

Damage to the journals

The following components should be cleaned and

pressure tested during the overhaul:

Bearing material that has seized to the journals

Engine oil cooler

Check the journal taper and the profile of the

crankshaft journals. Check these components by
interpreting the wear patterns on the rod bearings
and main bearings.

Aftercooler

Note: If the crankshaft or the camshaft are removed

for any reason, use the magnetic particle inspection
process to check for cracks.
Replace the crankshaft vibration damper if any of
the following conditions are found:

Engine failure due to a broken crankshaft

Excessive wear of the front main bearing

Refer to the Operation and Maintenance Manual,

Aftercooler Core - Inpect/Clean topic (Maintenance
Section) for the cleaning procedure.

Obtain Coolant Analysis

The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits
or with SOS Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine
is overhauled.

87
Maintenance Section
Power Take-Off Clutch - Check/Adjust/Lubricate

For example, considerable deposits are found in the

water jacket areas on the external cooling system,
but the concentrations of coolant additives were
carefully maintained. The coolant water probably
contained minerals that were deposited on the
engine over time.
A coolant analysis can be conducted in order
to verify the condition of the water that is being
used in the cooling system. A full water analysis
can be obtained by consulting your local water
utility company or an agricultural agent. Private
laboratories are also available for water analysis.
Caterpillar Inc. recommends an SOS Coolant
Analysis (Level 2).

Illustration 40

g00108044

(1) Typical instruction plate for the clutch. (2) Typical serial number
plate for the clutch.

SOS Coolant Analysis (Level 2)

An SOS Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An SOS Coolant Analysis (Level 2)
provides the following information:

Complete SOS Coolant Analysis (Level 1)

The clutch adjustment should be checked regularly

after wear in. Heavy-duty applications which
have engagements that are frequent and relatively
long periods of clutch slippage require more
frequent adjustment than light-duty applications.
The operating torque should be measured in order
to determine if a clutch adjustment is required.
Refer to the OEM information and instruction plate
(1) for instructions on the following items: lubrication,
adjustment, and other service recommendations.
Perform the maintenance that is specified on the
instruction plate.

Visual inspection of properties

Identification of metal corrosion
Identification of contaminants
Identification of built up impurities (corrosion and
scale)
SOS Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
recommendations that are based on the analysis.
For more information about coolant analysis, consult
your Caterpillar dealer.

Do not operate the engine with the Instruction

Plate cover removed from the clutch. Personal
injury may result.
If the clutch is damaged to the point of burst failure, expelled pieces can cause personal injury to
anyone in the immediate area. Proper safeguards
must be followed to help prevent accidents.

i00339617

Power Take-Off Clutch Check/Adjust/Lubricate

Radiator - Clean

SMCS Code: 3055-036; 3055-086

SMCS Code: 1353-070

NOTICE
New power take-offs should have the clutch adjustment checked before being placed into service. The
clutch adjustment should be checked again after the
first ten hours of operation. New clutch plates have a
wear in period, and the clutch may require several
adjustments until the new plates are worn in.

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

i01206548

Inspect the radiator for these items: damaged fins,

corrosion, dirt, grease, insects, leaves, oil, and
other debris. Clean the radiator, if necessary.

88
Maintenance Section
Severe Service Application - Check

Performance (power range, speed range, and

fuel consumption)
Personal injury can result from air pressure.

Fuel quality

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

Altitude range

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Oil selection and maintenance

Maintenance intervals

Coolant selection and maintenance

Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
of the fans air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move
the air nozzle in a direction that is parallel with the
tubes. This will remove debris that is between the
tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
Inspect the fins for damage. Bent fins may be
opened with a comb. Inspect these items for
good condition: welds, mounting brackets, air lines,
connections, clamps, and seals. Make repairs, if
necessary.
For more detailed information on cleaning and
inspection, see Special Publication, SEBD0518,
Know Your Cooling System.
i00151038

Severe Service Application Check

SMCS Code: 1000-082
Severe service is an application of an engine
that exceeds current published standards for that
engine. Caterpillar maintains standards for the
following engine parameters:

Environmental qualities
Installation
Refer to the standards for the engine or consult with
your Caterpillar dealer in order to determine if the
engine is operating within the defined parameters.
Severe service operation can accelerate component
wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention
of full service life.
Due to individual applications, it is not possible to
identify all of the factors which can contribute to
severe service operation. Consult your Caterpillar
dealer for the unique maintenance that is necessary
for the engine.
The operating environment, improper operating
procedures and improper maintenance procedures
can be factors which contribute to severe service
conditions.

Environmental Factors
Ambient temperatures The engine may be
exposed to extended operation in extremely
cold environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
cold temperatures. Extremely hot inlet air reduces
engine performance.
Air Quality The engine may be exposed to
extended operation in an environment that is dirty
or dusty, unless the equipment is cleaned regularly.
Mud, dirt and dust can encase components.
Maintenance can be very difficult. The buildup can
contain corrosive chemicals.
Buildup Compounds, elements, corrosive
chemicals and salt can damage some components.

89
Maintenance Section
Starting Motor - Inspect

Altitude Problems can arise when the engine

is operated at altitudes that are higher than the
intended settings for that application. Necessary
adjustments should be made.

Improper Operating Procedures

If the turbocharger fails during engine operation,

damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to
the turbocharger compressor wheel can cause
additional damage to the pistons, the valves, and
the cylinder head.
NOTICE
Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.

Extended operation at low idle

Frequent hot shutdowns
Operating at excessive loads
Operating at excessive speeds
Operating outside the intended application

Improper Maintenance Procedures

Extending the maintenance intervals
Failure to use recommended fuel, lubricants and
coolant/antifreeze
i00651416

Starting Motor - Inspect

SMCS Code: 1451-040; 1453-040
Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
Check the starting motor for proper operation.
Check the electrical connections and clean the
electrical connections. Refer to the Service Manual
for more information on the checking procedure and
for specifications or consult your Caterpillar dealer
for assistance.
i00912946

Minor leakage of a turbocharger housing under extended low idle operation should not cause problems
as long as a turbocharger bearing failure has not occurred.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for
potential damage to other engine parts.
Note: Turbocharger components require precision
clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
Severe Service Applications require more frequent
inspections of the cartridge.

Removal and Installation

For options regarding the removal, installation,
repair and replacement, consult your Caterpillar
dealer. Refer to the Service Manual for this engine
for the procedure and specifications.

Turbocharger - Inspect

Cleaning and Inspecting

SMCS Code: 1052-040

1. Remove the exhaust outlet piping and remove

the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil.

Periodic inspection and cleaning is recommended

for the turbocharger compressor housing (inlet
side). Any fumes from the crankcase are filtered
through the air inlet system. Therefore, by-products
from oil and from combustion can collect in the
turbocharger compressor housing. Over time, this
buildup can contribute to loss of engine power,
increased black smoke and overall loss of engine
efficiency.

2. Turn the compressor wheel and the turbine

wheel by hand. The assembly should turn freely.
Inspect the compressor wheel and the turbine
wheel for contact with the turbocharger housing.
There should not be any visible signs of contact
between the turbine wheel or compressor
wheel and the turbocharger housing. If there is
any indication of contact between the rotating
turbine wheel or the compressor wheel and the
turbocharger housing, the turbocharger must be
reconditioned.

90
Maintenance Section
Walk-Around Inspection

3. Check the compressor wheel for cleanliness.

If only the blade side of the wheel is dirty,
dirt and/or moisture is passing through the air
filtering system. If oil is found only on the back
side of the wheel, there is a possibility of a failed
turbocharger oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
for the inlet air (plugged air filters), which causes
the turbocharger to slobber.
4. Use a dial indicator to check the end clearance
on the shaft. If the measured end play is greater
than the Service Manual specifications, the
turbocharger should be repaired or replaced.
An end play measurement that is less than the
minimum Service Manual specifications could
indicate carbon buildup on the turbine wheel.
The turbocharger should be disassembled for
cleaning and for inspection if the measured end
play is less than the minimum Service Manual
specifications.
5. Inspect the bore of the turbine housing for
corrosion.
6. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.
7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.

Wipe all caps and plugs before the engine is

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

Ensure that cooling lines are properly clamped

and tight. Check for leaks. Check the condition
of all pipes.

Inspect the water pump for coolant leaks.

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

i00632301

Walk-Around Inspection

Inspect the lubrication system for leaks at the

front crankshaft seal, the rear crankshaft seal, the
oil pan, the oil filters and the valve cover.

SMCS Code: 1000-040

Inspect the fuel system for leaks. Look for loose

Inspect the Engine for Leaks and

for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be
avoided.
For maximum engine service life, make a thorough
inspection of the engine compartment before
starting the engine. Look for items such as oil leaks
or coolant leaks, loose bolts, worn belts, loose
connections and trash buildup. Make repairs, as
needed:

The guards must be in the proper place. Repair

damaged guards or replace missing guards.

fuel line clamps.

Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.

Inspect the alternator belt and the accessory

drive belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced
as matched sets. If only one belt is replaced, the
belt will carry more load than the belts that are
not replaced. The older belts are stretched. The
additional load on the new belt could cause the
belt to break.

Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean

fuel enters the fuel system.

91
Maintenance Section
Water Pump - Inspect

Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.

Inspect the ground strap for a good connection

and for good condition.

Inspect the engine-to-frame ground strap for a

good connection and for good condition.

Disconnect any battery chargers that are not

protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.

Check the condition of the gauges. Replace

any gauges which are cracked or can not be
calibrated.
i01057943

Water Pump - Inspect

SMCS Code: 1361-040; 1361
A failed water pump might cause severe engine
overheating problems that could result in the
following conditions:

Cracks in the cylinder head

A piston seizure
Other potential damage to the engine
Visually inspect the water pump for leaks. If any
leaking is observed, replace the water pump
seal or the water pump assembly. Refer to the
Service Manual for the disassembly and assembly
procedure.
Note: Refer to the Service Manual or consult your
Caterpillar dealer if any repair is needed or any
replacement is needed.