SEBU7844-25 65

Maintenance Section
Maintenance Interval Schedule

i07076176 “ Engine Air Cleaner Service Indicator - Inspect” . . 92

Maintenance Interval Schedule “ Engine Oil Filter Differential Pressure - Check” . . 94

SMCS Code: 1000; 4450; 7500 “ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 95

Ensure that all safety information, warnings, and “ Fuel Filter Differential Pressure - Check” . . . . . . 102
instructions are read and understood before any
operation or any maintenance procedures are “ Fuel System Primary Filter/Water Separator -
performed. The user is responsible for the Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
performance of maintenance, including all “ Fuel Tank Water and Sediment - Drain” . . . . . . . 106
adjustments, the use of proper lubricants, fluids, and
filters. The user is also responsible for the “ Transmission Oil Level - Check” . . . . . . . . . . . . . 125
replacement of components due to normal wear and
aging. Failure to adhere to proper maintenance “Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . 128
intervals and procedures may result in diminished
performance of the product and/or accelerated wear
of components. Use fuel consumption, service hours,
Initial 250 Service Hours
or calendar time, WHICH EVER OCCURS FIRST, to “ Engine Speed/Timing Sensor - Clean/
determine the maintenance intervals. Products that Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
operate in severe operating conditions may require
more frequent maintenance. Before each “ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 101
consecutive interval is performed, all maintenance
from the previous interval must be performed. “ Fuel Injector - Inspect/Adjust” . . . . . . . . . . . . . . . 102

When Required Every 250 Service Hours

“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 74 “ Battery Electrolyte Level - Check” . . . . . . . . . . . . 75
“ Battery or Battery Cable - Disconnect” . . . . . . . . . 75 “ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 75
“ Centrifugal Oil Filter - Inspect” . . . . . . . . . . . . . . . 76 “ Coolant Sample (Level 1) - Obtain” . . . . . . . . . . . 82
“ Coolant - Change” . . . . . . . . . . . . . . . . . . . . . . . . . 78 “ Cooling System Supplemental Coolant Additive
(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
“ Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . 87 “ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 95
“ Engine Air Cleaner Element (Single Element) - “ Engine Oil and Filter - Change”. . . . . . . . . . . . . . . 96
Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . 89
“ Hoses and Clamps - Inspect/Replace”. . . . . . . . 109
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 102
“ Fuel System Primary Filter/Water Separator - Initial 500 Hours (for New Systems,
Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Refilled Systems, and Converted
“ Fuel System Primary Filter/Water Separator - Systems)
Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
“ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 83
“ Heat Exchanger - Inspect”. . . . . . . . . . . . . . . . . . 107
“Maintenance Recommendations” . . . . . . . . . . . . 112 Every 500 Service Hours
“ Sea Water Strainer - Clean/Inspect”. . . . . . . . . . 124 “ Air Shutoff - Test” . . . . . . . . . . . . . . . . . . . . . . . . . . 68
“ Zinc Rods - Inspect/Replace” . . . . . . . . . . . . . . . 129
Every 1000 Service Hours
Daily
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
“ Air Starting Motor Lubricator Oil Level - Check” . 72 “ Engine Crankcase Breather - Clean” . . . . . . . . . . 93
“ Air Tank Moisture and Sediment - Drain” . . . . . . . 72 “ Engine Protective Devices - Check” . . . . . . . . . . 100
“ Control Panel - Inspect/Test”. . . . . . . . . . . . . . . . . 78
“ Fuel System Primary Filter/Water Separator -
“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . . 81 Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
66 SEBU7844-25
Maintenance Section
Maintenance Interval Schedule

“ Fuel System Secondary Filter - Replace”. . . . . . 104 “ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . 129

Every 2000 Service Hours Every 8000 Service Hours or 3

“ Air Starting Motor Lubricator Bowl - Clean” . . . . . 71
Years
“ Camshaft Roller Followers - Inspect” . . . . . . . . . . 76
“ Crankshaft Vibration Damper - Inspect” . . . . . . . . 85
“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . . 86 Every Year
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 94 “ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 83
“ Turbocharger - Inspect” . . . . . . . . . . . . . . . . . . . . 126
Overhaul
Every 3000 Service Hours “ Aftercooler Core - Inspect/Clean/Test” . . . . . . . . . 67
“ Air Starting Motor - Inspect” . . . . . . . . . . . . . . . . . 71 “Overhaul (Major)” . . . . . . . . . . . . . . . . . . . . . . . . . 116

Every 3000 Service Hours or 3 “Overhaul (Top End)” . . . . . . . . . . . . . . . . . . . . . . . 119

Years “ Overhaul Considerations” . . . . . . . . . . . . . . . . . . 122

“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . . 80

Every 4000 Service Hours

“ Auxiliary Water Pump - Inspect” . . . . . . . . . . . . . . 73
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 101
“ Fuel Injector - Inspect/Adjust” . . . . . . . . . . . . . . . 102

Every 6000 Service Hours

“ Air Shutoff Damper - Remove/Check” . . . . . . . . . 70
“ Coolant Temperature Regulator - Replace” . . . . . 83
“ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . 129

Every 6000 Service Hours or 6

Years
“ Air Shutoff Damper - Remove/Check” . . . . . . . . . 70
“ Coolant Temperature Regulator - Replace” . . . . . 83
“ Engine Speed/Timing Sensor - Clean/
Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
“ Prelube Pump - Inspect” . . . . . . . . . . . . . . . . . . . 124
“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . 124
SEBU7844-25 67
Maintenance Section
Aftercooler Core - Inspect/Clean/Test

i03967390

Aftercooler Core - Inspect/ Personal injury can result from air pressure.
Clean/Test Personal injury can result without following prop-
SMCS Code: 1064-070; 1064-040; 1064-081 er procedure. When using pressure air, wear a
protective face shield and protective clothing.
1. Remove the core. Refer to the Disassembly and
Maximum air pressure at the nozzle must be less
Assembly Manual, “Aftercooler - Remove and than 205 kPa (30 psi) for cleaning purposes.
Install” for the procedure.
2. Place the aftercooler core on one side in order to 8. Dry the core with compressed air. Direct the air in
remove debris. Remove the debris that is the reverse direction of the normal flow.
accessible. 9. Prior to installation, inspect any O-rings or seals for
damage. If necessary, replace the O-rings or
NOTICE seals.
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic 10. Inspect the core for trapped debris and
cleaner can attack the internal metals of the core and cleanliness. If necessary, remove the debris and
cause leakage. Only use the recommended concen-
tration of cleaner. repeat the cleaning procedure.
11. Inspect the core for damage and perform a
3. Back flush the core with cleaner. pressure test in order to detect leaks. Many shops
that service radiators are equipped to perform
Caterpillar recommends the use of Hydrosolv pressure tests.
liquid cleaner. Table 38 lists Hydrosolv liquid
cleaners that are available from your Caterpillar 12. Install the core. Refer to Disassembly and
dealer. Assembly Manual, “Aftercooler - Remove and
Table 38 Install” for the procedure.
Hydrosolv Liquid Cleaners(1) For more information on cleaning the core, consult
your Caterpillar dealer.
Part Number Description Size

1U-5490 Hydrosolv 4165 19 L (5 US gallon)

174-6854 Hydrosolv 100 19 L (5 US gallon)

(1) Use a 2 to 5 percent concentration of the cleaner at tempera-
tures up to 93°C (200°F). Consult your Caterpillar dealer for
more information.

4. Remove the drain plug.

5. Use steam to clean the core in order to remove
any residue. Flush the fins of the aftercooler core.
Remove any other trapped debris from the inside
and from the outside of the core.

Note: Do not use high pressure when the fins are

cleaned. High pressure can damage the fins.

6. Wash the core with hot, soapy water.

7. Flush the core thoroughly in order to remove
residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the
core is clear and free of debris.
68 SEBU7844-25
Maintenance Section
Air Shutoff - Test

i02566367

Air Shutoff - Test

(Engines That Are Equipped with
ADEM II or ADEM III Engine
Control Modules)
SMCS Code: 1078-081

Illustration 39 g01285610
Right hand side air shutoff in the OPEN position

Refer to the Troubleshooting Guide, “Air Shutoff

System” information in your Service Manual for
further information about the electrical system for the
air shutoff system.

Engines That Are Equipped with

ADEM II Engine Control Modules
Note: Do not start the engine. Ensure that the engine
control is in the “OFF” position.

1. Ensure that both air shutoff gates are latched in

the OPEN position and ensure that both air shutoff
switches are connected. Turn on the power to the
engine control panel. Both air shutoff gates should
remain open. If both air shutoff gates do not
remain open, check the wiring for the air shutoff
switches.
2. With the power for the engine control panel in the
Illustration 37 g01285348 ON position, activate the “EMERGENCY STOP”
Typical air shutoffs on a 3500B engine switch. Both of the air shutoff gates should close. If
(1) Air shutoffs both air shutoff gates close, proceed to step 3. If
both air shutoff gates do not close, check the
wiring for the air shutoff switches and check the
wiring for the solenoids. Activate the
“EMERGENCY STOP” switch again. When both
air shutoff gates close, proceed to step 3.
3. Turn the power to the engine control panel to the
OFF position. Ensure that the “EMERGENCY
STOP” switch is in the RUN position. Latch only
the right side air shutoff gate to the OPEN position.
Turn the power for the engine control panel to the
ON position. The right side air shutoff gate should
close. If the right side air shutoff closes, proceed to
step 4. If the right side air shutoff gate does not
close, check the air shutoff switch for the right side
Illustration 38 g01285609 air shutoff and check the wiring for the right side
Left hand side air shutoff in the OPEN position air shutoff . When the right side air shutoff closes,
proceed to step 4.
SEBU7844-25 69
Maintenance Section
Engines That Are Equipped with ADEM II or ADEM III Engine Control Modules

4. Turn the power for the engine control panel to the 4. Reset the “EMERGENCY STOP” switch to the
OFF position. Latch only the left side air shutoff RUN position. Set the power for the engine control
gate to the OPEN position. Turn the power for the panel to the ON position. Activate the
engine control panel to the ON position. The left “EMERGENCY STOP” switch . Both air shutoff
side air shutoff gate should close. If the left side air gates should close. Set power for the engine
shutoff gate closes the test is complete. If the left control panel to the OFF position. Reset the
side air shutoff gate does not close, check the “EMERGENCY STOP” switch to the RUN position.
switch and the wiring for the left side air shutoff . Reset the left side air shutoff to the OPEN
position. Turn the power for the engine control
Note: Testing is only complete when the engine panel to the ON position. Select “START/RUN” on
successfully passes step 1 through step 4.
the engine control panel. The engine should fail
5. Operate the engine normally. Ensure that the air to start. If the engine does not start, proceed to 5.
shutoff gates continue to be latched. If the engine starts, turn off the engine. Check the
left side air shutoff. Check the wiring for the left
side air shutoff. Retest the left side air shutoff.
Engines That Are Equipped with When the procedure in step 4 is followed and the
ADEM III Engine Control Modules engine fails to start, proceed to 5.
Note: Do not start the engine. Ensure that the engine 5. Turn the power for the engine control panel to the
control is in the “OFF” position. ON position. Reset both air shutoffs. Start the
engine. Disconnect only the right side air shutoff.
1. Ensure that both air shutoff gates are latched in Both air shutoff gates should close. The engine
the OPEN position. Ensure that both air shutoff should shut down. If the engine does not shut
switches are connected. Turn the power for the down, use the “EMERGENCY STOP” switch to
engine control panel to the ON position. The air stop the engine. Check the wiring for both air
shutoff gates should remain in the OPEN shutoffs. Use the above procedure in order to
positions. If the air shutoff gates do not remain in retest the right side air shutoff. When the
the OPEN positions, check the wiring for the air procedure in step 5 is followed and results of the
shutoffs. When step 1 has been successfully test are successful, reconnect the right side air
completed, proceed to step 2. shutoff. Reset both air shutoffs.
2. While the power for the engine control panel is in 6. Turn the power for the engine control panel to the
the ON position, activate the “EMERGENCY ON position. Reset both air shutoffs. Start the
STOP” switch . Both air shutoff gates should close. engine. Disconnect only the left side air shutoff.
If the air shutoff gates do not close, check the Both air shutoff gates should close. The engine
wiring for the air shutoffs and the wiring for the should shut down. If the engine does not shut
solenoids. Both air shutoff gates must close before down, use the “EMERGENCY STOP” switch to
proceeding to step 3. stop the engine. Check the wiring for both air
3. Turn the power for the engine control panel to the shutoffs. Use the above procedure in order to
OFF position. Reset the “EMERGENCY STOP” retest the left side air shutoff. When the procedure
switch to the RUN position. Reset the right side air in 6 is followed and the results of the test are
shutoff to the OPEN position. Turn the power for successful, reconnect the right side air shutoff.
the engine control panel to the ON position. Select Reset both air shutoffs.
“Run/Start” on the engine control panel. The 7. Testing is complete only when the engine
engine should fail to start. If the engine does not successfully passes steps 1 through 6.
start, proceed to 4. If the engine starts, turn off the
engine. Check the right side air shutoff. Check the
wiring for the right side air shutoff. Retest the air
shutoff. When the procedure in 3 is followed and
the engine fails to start, proceed to 4.
70 SEBU7844-25
Maintenance Section
Air Shutoff Damper - Remove/Check

8. Reset both air shutoffs. Ensure that the 1. The body of the damper should not be loosened or
“EMERGENCY STOP” switch has been reset. removed from the air shutoff when the plunger is
Operate the engine normally. removed. In order to remove the plunger without
loosening or removing the damper, unscrew the
i02567801 plug with the following tools: a 6.35 mm
(0.25 inch) Allen wrench and an open end wrench
Air Shutoff Damper - Remove/ .
Check 2. Check the seal ring for damage or wear. If
SMCS Code: 1078-535; 1078-011 necessary, replace the seal ring.
3. Inspect the internal parts of the vibration damper
for wear or damage. Clean the components with
138-8440 component cleaner.

Illustration 42 g01286606
Damper plunger

Illustration 40 g01286554 4. Remove the plunger from the spring. Visually

Typical air shutoff (back view) inspect the exposed end of the plunger for dirt,
(1) Air shutoff gate fouling, damage, and wear. If distance “A” is less
(2) Damper assembly than 18.3 mm (0.72 inch) or if a visual inspection
reveals dirt, fouling, damage, or wear on the active
The vibration damper on the air shutoff minimizes the end of the plunger, replace the plunger. Insert the
vibration of the air shutoff gate when the engine is tapered end of a clean, undamaged plunger into
operating and the air shutoff gate is in the LATCHED the spring. Install the open end of the spring into
position. The components of the damper assembly the plug. Apply 9S-3263 thread lock or apply
must be removed in order to ensure correct
performance of the damper. 9S-4030 thread lock onto the threads of the plug.
Screw the assembly into the damper body. The
thread lock should cure for a minimum of 1 hour
before the air shutoff is used.

Illustration 41 g01286567
Damper assembly
(3) Plug
(4) Seal ring
(5) Housing
(6) Spring
(7) Plunger
SEBU7844-25 71
Maintenance Section
Air Starting Motor - Inspect

i07074350

Air Starting Motor - Inspect

SMCS Code: 1451-040

Illustration 44 g03789898
(1) Filler plug
(2) Bowl
(3) Drain valve

2. Slowly loosen filler plug (1) in order to release the

Illustration 43 g06216514
pressure from the lubricator.
Feel under the air starter pilot regulator and
determine if the regulator is leaking. If not, check NOTICE
again at next service interval. If the air starter pilot Care must be taken to ensure that fluids are con-
regulator is leaking, refer to the Service Manual, tained during performance of inspection, mainte-
“Disassembly and Assembly” or consult your nance, testing, adjusting, and repair of the product.
Caterpillar dealer for information about the air starting Be prepared to collect the fluid with suitable contain-
motor. ers before opening any compartment or disassem-
bling any component containing fluids.
i06049302
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
Air Starting Motor Lubricator to collect and contain fluids on Cat products.
Bowl - Clean Dispose of all fluids according to local regulations
SMCS Code: 1451-070 and mandates.

If the engine is equipped with an air starting motor,

use the following procedure: 3. Place a suitable container under bowl (2) and open
drain valve (3) in order to drain the oil from the
bowl.
4. Remove bowl (2). Clean the bowl with warm water.
Personal injury can result from removing hoses
or fittings in a pressure system. 5. Dry the bowl. Inspect the bowl for cracks. If the
bowl is cracked, replace the damaged bowl with a
Failure to relieve pressure can cause personal new bowl. Inspect the gasket. If the gasket is
injury.
damaged, replace the gasket.
Do not disconnect or remove hoses or fittings un- 6. Install the bowl.
til all pressure in the system has been relieved.
7. Make sure that drain valve (3) is closed.
1. Ensure that the air supply to the lubricator is OFF.
8. For instructions on filling the lubricator, see this
Operation and Maintenance Manual, “Air Starting
Motor Lubricator Oil Level - Check” topic.
72 SEBU7844-25
Maintenance Section
Air Starting Motor Lubricator Oil Level - Check

i06049122 4. Install filler plug (4).

Air Starting Motor Lubricator Adjust the Lubricator

Oil Level - Check Note: Adjust the lubricator with a constant rate of air
SMCS Code: 1451-535 flow. After the adjustment, the lubricator will release
oil in proportion to variations of the air flow.
NOTICE
Never allow the lubricator bowl to become empty. 1. Ensure that the fuel supply to the engine is OFF.
The air starting motor will be damaged by a lack of lu-
brication. Ensure that sufficient oil is in the lubricator NOTICE
bowl. 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.

2. Operate the air starting motor. Observe the drops

of oil that are released in dome (1).

Note: Some lubricators have an adjustment screw

rather than a knob.

3. If necessary, adjust the lubricator in order to

release from one to three drops of oil per second.
To increase the rate, turn knob (2)
counterclockwise. To decrease the rate, turn the
knob clockwise.

i04534752

Air Tank Moisture and

Sediment - Drain
SMCS Code: 1466-543-M&S
Moisture and sediment in the air starting system can
Illustration 45 g03789862 cause the following conditions:

1. Observe the oil level in sight gauge (3). If the oil • Freezing
level is less than 1/2, add oil to the lubricator bowl.
• Corrosion of internal parts
• Malfunction of the air starting system
Personal injury can result from removing hoses
or fittings in a pressure system.
Failure to relieve pressure can cause personal When opening the drain valve, wear protective
injury. gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could
Do not disconnect or remove hoses or fittings un- cause debris to be blown and result in personal
til all pressure in the system has been relieved. injury.

2. Ensure that the air supply to the lubricator is OFF.

Slowly loosen filler plug (4) in order to release
pressure from the lubricator bowl.
3. Remove filler plug (4). Pour oil into the lubricator
bowl. Use nondetergent SAE 10W oil for
temperatures that are greater than 0 °C (32 °F).
Use air tool oil for temperatures that are below
0 °C (32 °F).
SEBU7844-25 73
Maintenance Section
Auxiliary Water Pump - Inspect

NOTICE
Pumps with a Cover
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.

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.

i02256018

Auxiliary Water Pump - Inspect

SMCS Code: 1371; 1371-040
Refer to the Disassembly and Assembly Manual for
the engine in order to perform the disassembly of the
auxiliary water pump.
Impellers and seals require periodic inspection. Illustration 46 g01136356
Impellers have a service life that is limited. The (1) Plug
service life depends on the engine operating (2) Bolt
conditions. (3) Cover

Inspect the components more frequently when the 1. Remove plug (1) and drain the water out of the
pump is exposed to debris, sand, or other abrasive pump.
materials. Inspect the components if the pump is
operating at a differential pressure of more than 2. Remove bolts (2) and cover (3).
103 kPa (15 psi).
3. Inspect the priming impeller, the priming impeller
There are different types of pumps. Some pumps will wear plates and the impeller for wear or damage.
have a cover that is bolted to the main pump body. Inspect the pump housing for wear, damage or
Some pumps will have a clamp that holds the front
part of the pump body to the main part of the pump buildup.
body. The cover or the front part of the pump body 4. Inspect the pump shaft and the impeller for
must be removed in order to inspect the pump. excessive axial movement.
74 SEBU7844-25
Maintenance Section
Battery - Replace

5. If wear or damage is found, replace the 6. If wear or damage is found, replace the
components which are worn or damaged. Use the components which are worn or damaged. Use the
proper repair kit for the pump. proper repair kit for the pump.

Pumps with a Clamp i03967451

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 or-
der 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.
4. The POSITIVE “+” cable connects the POSITIVE
Illustration 47 g01136382
“+” battery terminal to the starting motor.
(1) Plug
Disconnect the cable from the POSITIVE “+”
(2) Clamp battery terminal.
(3) Clamp
(4) Front part of the pump body Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
1. Remove plug (1) and drain the water out of the recycling facility.
pump.
5. Remove the used battery.
2. Remove the water line and clamp (2), if necessary.
6. Install the new battery.
3. Loosen clamp (3) and remove the front part of the
pump body (4). Note: Before connecting the cables, ensure that the
key start switch is OFF.
4. Inspect the impeller, the wear plates and the wear
ring for wear or damage. Inspect the pump 7. Connect the cable from the starting motor to the
housing for wear, damage or buildup. POSITIVE “+” battery terminal.
5. Inspect the pump shaft and the impeller for 8. Connect the cable from the ground plane to the
excessive axial movement. NEGATIVE “-” battery terminal.
SEBU7844-25 75
Maintenance Section
Battery Electrolyte Level - Check

i06845102 i06738663

Battery Electrolyte Level - Battery or Battery Cable -

Check Disconnect
SMCS Code: 1401-535-FLV SMCS Code: 1401; 1402-029
When the engine has not run for long or short periods
of time, the batteries may not fully recharge. Ensure a
full charge to help prevent the battery from freezing.
The battery cables or the batteries should not be
In warmer climates, check the electrolyte level more removed with the battery cover in place. The bat-
frequently. tery cover should be removed before any servic-
ing is attempted.
Ensure that the electrolyte level is 13 mm (0.5 inch)
above the top of the separators. Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.

All lead-acid batteries contain sulfuric acid which 1. Turn the start switch to the OFF position. Turn the
can burn the skin and clothing. Always wear a ignition switch (if equipped) to the OFF position
face shield and protective clothing when working
on or near batteries. and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the
1. Remove the filler caps. Maintain the electrolyte battery that goes to the start switch. Ensure that
level to the “FULL” mark on the battery. the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
If the addition of water is necessary, use distilled two batteries must be disconnected.
water. If distilled water is not available, use clean
water that is low in minerals. Do not use artificially 3. Tape the leads in order to help prevent accidental
softened water. starting.
2. Check the condition of the electrolyte with the 4. Proceed with necessary system repairs. Reverse
245-5829 Coolant Battery Tester Refractometer. the steps in order to reconnect all of the cables.
3. Keep the batteries clean.
i06618705
Clean the battery case with one of the following
cleaning solutions: Belts - Inspect/Adjust/Replace
• A mixture of 0.1 kg (0.2 lb) of baking soda and SMCS Code: 1357-025; 1357-040; 1357-510
1 L (1 qt) of clean water
Inspection
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water Inspect the alternator belt and any accessory belts
for wear and for cracking. Replace the belts if the
Thoroughly rinse the battery case with clean belts are not in good condition.
water.
Check the belt tension according to the information in
Use the 1U-9921 Battery Service Tool to clean the Service Manual, “Specifications”.
the battery terminals. Use a wire brush to clean
the cable clamps. Clean the items until the Slippage of loose belts can reduce the efficiency of
surfaces are bright or shiny. DO NOT remove the driven components. Vibration of loose belts can
material excessively. Excessive removal of cause unnecessary wear on the following
material can cause the clamps to fit improperly. components:
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM. • Belts
• Pulleys

• Bearings
76 SEBU7844-25
Maintenance Section
Camshaft Roller Followers - Inspect

If the belts are too tight, unnecessary stress is placed If new drive belts are installed, check the drive belt
on the components. Unnecessary stress reduces the tension again after 30 minutes of engine operation at
service life of the components. the rated rpm. Stop the engine. Use a frequency tool
to check the tension with the alternator guard
installed. Current guard design allows for inspection
Replacement without the drive belt guard removal.
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing i02756549
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive Camshaft Roller Followers -
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail. Inspect
SMCS Code: 1209-040
Alternator Belt Adjustment
For instructions on disassembly and assembly of the
valve lifter group, see the Service Manual,
“Disassembly and Assembly” module.
See Reuse and Salvage Guidelines, SEBF8146,
“Visual Inspection of Camshafts”, and inspect the
following components for wear at each metal to metal
contact point:

• Rollers for the valve lifters

• Camshaft
Inspect each roller for wear, excessive movement,
and end play.
If excessive wear or other signs of deterioration are
found, replace the damaged components.

i05287915

Centrifugal Oil Filter - Inspect

SMCS Code: 1328-040
Illustration 48 g00960176
(1) Adjusting nuts
(2) Mounting bolt
(3) Mounting bolt Hot oil and components can cause personal
(4) Mounting bolt injury.

1. Loosen mounting bolts (2), (3), and (4). Loosen Do not allow hot oil or components to contact
skin.
adjusting nuts (1).
2. Turn adjusting nuts (1) to increase or decrease the
drive belt tension. NOTICE
Keep all parts clean from contaminants.
3. Tighten adjusting nuts (1). Tighten mounting bolts
(2), (3), and (4). Contaminants may cause rapid wear and shortened
component life.
SEBU7844-25 77
Maintenance Section
Centrifugal Oil Filter - Inspect

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.

Table 39
Required Tools

Tool Part Number Part Description Qty

A 185-3630 Strap Wrench Assembly 1

B 8T-0890 Puller Group 1

Illustration 50 g00810333
C 8T-5096 Dial Indicator Group 1
(4) Bearing
(5) Nut
(6) Stiffener plate
(7) Nut
(8) Rotor cover
(9) Cover
(10) Paper liner
(11) Spindle
(12) Stand tube
(13) O-ring
(14) O-ring
(15) Bearing
(16) Clamp
(17) Rotor base
(18) Filter body

1. Close valve (2) to centrifugal oil filter (1).

2. Loosen clamp (16) and nut (5). Remove cover (9)
from filter body (18).
3. Remove O-ring seal (14) from the body.
4. Remove the rotor assembly from spindle (11). Lift
the rotor assembly carefully so the bearings are
not damaged.
Illustration 49 g00810377 5. Use tool (A) to hold the rotor assembly and remove
(1) Centrifugal oil filter nut (7).
(2) Valve
(3) Camshaft cover 6. Remove stiffener plate (6).
7. Use tool (B) to remove rotor cover (8) from rotor
base (17). Remove O-ring seal (13) from the base.
Remove paper liner (10) from the rotor cover.
Properly dispose of the paper liner. Use a plastic
scraper to clean out the inside of rotor cover (8).
8. Remove stand tube (12) from rotor base (17) and
clean the stand tube.
9. Clean the nozzles in rotor base (17). Do not
enlarge the nozzles.
78 SEBU7844-25
Maintenance Section
Control Panel - Inspect/Test

10. Inspect bearings (4) and (15) for excessive wear. i04232973

11. Inspect spindle (11) for excessive wear.

Control Panel - Inspect/Test
12. If there is minimal wear to bearing (4), bearing SMCS Code: 4490-081; 4490-040; 7451-040; 7451-
(15), and spindle (11) go to step 14. If there is 081
considerable wear to bearing (4), bearing (15),
and spindle (11) go to step 13. Inspect the instrument panel for good condition.
Perform the self-test. All of the warning lamps should
13. Use tool (C) to measure the clearances between illuminate. If a warning lamp does not illuminate,
the bearing (4) and bearing (15) and spindle (6). replace the bulb immediately. If the alarm does not
sound, investigate the problem and correct the
The maximum clearance between bearing (4) and problem.
spindle (11) is 0.25 mm (0.010 inch).
Check the condition of all of the gauges. If a gauge is
The maximum clearance between bearing (15) broken, repair the gauge or replace the gauge
and spindle (11) is 0.20 mm (0.008 inch). immediately.
If the rotor bearings and the spindle are not within Frequently monitor the gauges during normal
specifications, replace the parts. operation.

Note: The spindle and the filter body are replaced as Record the data in a log. Compare the new data to
a complete assembly. The rotor assembly is replaced the data that was previously recorded. Comparing
as a complete assembly. the new data to the recorded data will help to
establish the trends of engine performance. A gauge
Before you assemble the centrifugal oil filter, reading that is abnormal may indicate a problem with
thoroughly clean all of the parts and inspect all of operation or a problem with the gauge.
the parts. Replace parts that are damaged or
worn. i04538352

NOTICE
Ensure that all of the rotor components are thor-
Coolant - Change
oughly clean before assembling the rotor. Failure to SMCS Code: 1350-044; 1352; 1395-044; 1395
do so can cause an out of balance condition that can
cause rapid wear to the bearings and the spindle. Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for the correct intervals for
changing the coolant.
14. Install stand tube (12) on rotor base (17).
Clean the cooling system and flush the cooling
15. Install a new paper liner (10) in rotor cover (8). system before the recommended maintenance
Place O-ring seal (13) on rotor base (17). Position interval if the following conditions exist:
rotor cover (8) on rotor base (17).
• The engine overheats frequently.
16. Install stiffener plate (6).
• Foaming is observed.
17. Use tool (A) to hold the rotor assembly and install
nut (7). • The oil has entered the cooling system and the
coolant is contaminated.
18. Install the rotor assembly on spindle (11). Install
the rotor assembly carefully so the bearings are • The fuel has entered the cooling system and the
not damaged. coolant is contaminated.
19. Install O-ring seal (14) on filter body (18).
Drain the Cooling System
20. Install cover (9) and clamp (16) on filter body
(18). Tighten clamp (16) and nut (5).
21. Open valve (2) to centrifugal oil filter (1).
Pressurized System: Hot coolant can cause seri-
22. Check the centrifugal oil filter for leaks. Feel the ous burns. To open the cooling system filler cap,
centrifugal oil filter for excessive vibration. 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.
SEBU7844-25 79
Maintenance Section
Coolant - Change

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

NOTICE
Care must be taken to ensure that fluids are con- plugs. Install the drain plugs. Refer to the
tained during performance of inspection, mainte- Specifications Manual, SENR3130, “Torque
nance, testing, adjusting, and repair of the product. Specifications” for more information on the proper
Be prepared to collect the fluid with suitable contain- torques.
ers before opening any compartment or disassem-
bling any component containing fluids.
NOTICE
Refer to Special Publication, NENG2500, “Cat Dealer Fill the cooling system no faster than 19 L (5 US gal)
Service Tool Catalog” or refer to Special Publication, per minute to avoid air locks.
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain 3. Fill the cooling system with clean water. Install the
fluids on Cat products.
cooling system filler cap.
Dispose of all fluids according to local regulations 4. Start and run the engine at low idle until the
and mandates.
temperature reaches 49 to 66 °C (120 to 150 °F).
5. Stop the engine and allow the engine to cool.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
Ensure that the engine will not start when the
order to relieve any pressure. Remove the cooling
cooling system is drained.
system filler cap. Open the drain valve (if
2. Loosen the cooling system filler cap slowly in order equipped) or remove the cooling system drain
to relieve any pressure. Remove the cooling plugs. Allow the water to drain. Flush the cooling
system filler cap. system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
3. Open the cooling system drain valve (if equipped).
plugs. Refer to the Specifications Manual,
If the cooling system is not equipped with a drain
SENR3130, “Torque Specifications” for more
valve, remove one of the drain plugs.
information on the proper torques.
Note: If equipped, be sure to drain the heater and
any related supply and return lines. Systems Filled with Cat DEAC,
Conventional Coolant which does not
Allow the coolant to drain.
Meet the Cat EC-1 Requirements, or
NOTICE Supplemental Coolant Additive (SCA)
Dispose of used engine coolant properly or recycle. and Water
Various methods have been proposed to reclaim
used coolant for reuse in engine cooling systems.
The full distillation procedure is the only method ac- 3. Flush the cooling system with clean water in order
ceptable by Caterpillar to reclaim the used coolant. to remove any debris.

For information regarding the disposal and the 4. Close the drain valve (if equipped). Clean the drain
recycling of used coolant, consult your Cat dealer or plugs. Install the drain plugs. Refer to the
consult Cat Dealer Service Tool Group: Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
Inside USA 1-800-542-TOOL torques.
Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL NOTICE
International 1-309-578-7372 Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Flush
5. Fill the cooling system with a mixture of clean
Systems Filled with Cat ELC, Cat ELI, or water and Cat Fast Acting Cooling System
a Conventional Coolant that Meets the Cleaner.
Cat EC-1 Requirements and the 6. Choose 1 of the following options.
Standards of ASTM D6210
• Add 0.5 L (1 pint) of cleaner per 15 L
1. Flush the cooling system with clean water in order (4 US gal) of the cooling system capacity.
to remove any debris.
80 SEBU7844-25
Maintenance Section
Coolant Extender (ELC) - Add

• For cooling systems with heavy deposits or 3. Check the coolant level. Maintain the coolant level
plugging, add 0.5 L (1 pint) of cleaner per within 13 mm (0.5 inch) below the bottom of the
3.8 to 7.6 L (1 to 2 US gal) of the cooling pipe for filling. Maintain the coolant level within
system capacity. 13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
7. Install the cooling system filler cap.
4. Clean the cooling system filler cap. Inspect the
8. Start and run the engine at low idle for a minimum gasket that is on the cooling system filler cap. Only
of 30 minutes. For cooling systems with heavy install the used filler cap if the gasket is not
deposits or plugging, run the engine for 90 damaged. Use a 9S-8140 Pressurizing Pump to
minutes. The coolant temperature should be at pressure test a reinstalled cooling system filler
least 82 °C (180 °F). cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
NOTICE system filler cap. If the cooling system filler cap
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal does not retain the correct pressure, install a new
components. cooling system filler cap.

To avoid damage to the cooling system, make sure to 5. Start the engine. Inspect the cooling system for
completely flush the cooling system with clear water. leaks and for proper operating temperature.
Continue to flush the system until all signs of the
cleaning agent are gone. i04745732

9. Stop the engine and allow the engine to cool. Coolant Extender (ELC) - Add
Loosen the cooling system filler cap slowly in SMCS Code: 1352-544-NL
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if Cat ELC (Extended Life Coolant) does not require
the frequent additions of any supplemental cooling
equipped) or remove the cooling system drain
additives which are associated with the present
plugs. Allow the water to drain. Flush the cooling conventional coolants. The Cat ELC Extender will
system with clean water. If equipped, be sure to only be added one time.
flush the heater and any related supply and return
lines. Close the drain valve (if equipped). Clean NOTICE
the drain plugs. Install the drain plugs. Refer to the Use only Cat Extended Life Coolant (ELC) Extender
with Cat ELC.
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper Do NOT use conventional supplemental coolant addi-
torques. tive (SCA) with Cat ELC. Mixing Cat ELC with con-
ventional coolants and/or conventional SCA reduces
the Cat ELC service life.
Fill the Cooling System
Check the cooling system only when the engine is
NOTICE stopped and cool.
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

1. Fill the cooling system. Refer to this Operation and

Maintenance Manual, “Fluid Recommendations”
for more information on cooling system
specifications Refer to this Operation and
Maintenance Manual, “Refill Capacities” for
information about the capacity of the cooling
system. 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 1 minute in order to purge the air from the
cavities of the engine block. Stop the engine.
SEBU7844-25 81
Maintenance Section
Coolant Level - Check

i04233256

Personal injury can result from hot coolant, Coolant Level - Check
steam and alkali. SMCS Code: 1395-082
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns. Climbing equipment may be required to access
this service point. Refer to the Operation and
Remove cooling system pressure cap slowly to Maintenance Manual, “Mounting and Dismount-
relieve pressure only when engine is stopped and ing” topic for safety information.
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when Engines That Are Equipped With a
the coolant is hot, the hose can come off causing
burns. Sight Gauge
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products. Illustration 51 g00750429
(1) Filler cap
Dispose of all fluids according to local regulations (2) Sight gauge
and mandates.
If the engine is equipped with a sight gauge, observe
the position of the coolant in the sight gauge. At
1. Loosen the cooling system filler cap slowly in order normal operating temperature, the proper coolant
to relieve pressure. Remove the cooling system level is in the upper half of the sight gauge. If the
filler cap. coolant level is low, add the proper coolant mixture.
2. If necessary, drain enough coolant from the
cooling system in order to add the Cat ELC Engines That Are Not Equipped
Extender. With a Sight Gauge
3. Add Cat ELC Extender according to the
requirements for the cooling system capacity.
Refer to this Operation and Maintenance Manual,
“Refill Capacities” or to this Operation and Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
Maintenance Manual, “Fluid Recommendations” stop the engine and wait until the cooling system
for more information. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
4. Clean the cooling system filler cap. Inspect the pressure.
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are Check the coolant level when the engine is stopped
damaged. Install the cooling system filler cap. and cool.
82 SEBU7844-25
Maintenance Section
Coolant Sample (Level 1) - Obtain

Remove the cooling system filler cap slowly in order Note: Obtaining a Coolant Sample (Level 1) is
to relieve any pressure. Maintain the coolant within optional if the cooling system is filled with one of
13 mm (0.5 inch) below the bottom of the filler pipe. the following coolants: Cat ELC (Extended Life
Coolant)., Cat ELI (Extended Life Inhibitor) and
Add Coolant Conventional Heavy-Duty Coolant.

Note: For the proper coolant mixture to use, see this Note: Obtain a Coolant Sample (Level 1) if the
Operation and Maintenance Manual, “Fluid cooling system is filled with any of the following
Recommendations”. coolants: Cat DEAC, Cat SCA and Conventional
Heavy-Duty Coolants.
1. Stop the engine. Allow the engine to cool.
For additional information about coolant analysis and
2. Remove the cooling system filler cap slowly in about other coolants, see this Operation and
order to relieve any pressure. Pour the proper Maintenance Manual, “Fluid Recommendations” or
consult your Cat dealer.
coolant mixture into the filler pipe.
Sampling Conditions
If the engine is equipped with a sampling port, the
engine should be running at operating temperature
when the sample is obtained.
If the engine is not equipped with a sampling port, the
coolant should be warm.
Use the following guidelines for proper sampling of
the coolant:

• Complete the information on the label for the

sampling bottle before you begin to take the
samples.

Illustration 52 g00103639
• Keep the unused sampling bottles stored in plastic
bags.
Gaskets
• Obtain coolant samples directly from the coolant
3. Clean the cooling system filler cap. Inspect the sample port. You should not obtain the samples
gaskets of the cooling system filler cap. If the from any other location.
gaskets are damaged, replace the old cooling
system filler cap with a new filler cap. Install the • Keep the lids on empty sampling bottles until you
cooling system filler cap. are ready to collect the sample.

4. Start the engine. Inspect the cooling system for • Place the sample in the mailing tube immediately
leaks. after obtaining the sample in order to avoid
contamination.
i04333559
• Never collect samples from expansion bottles.
Coolant Sample (Level 1) - • Never collect samples from the drain for a system.
Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Timing of the Sampling
Table 40
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and Recommended Interval
corrosion. The analysis also tests the ability of the
coolant to protect the engine from boiling and Type of
freezing. S·O·S Systems Coolant Analysis can be Level 1 Level 2
done at your Cat dealer. Cat S·O·S coolant analysis Coolant
is the best way to monitor the condition of your
coolant and your cooling system. S·O·S coolant
analysis is a program that is based on periodic (continued)
samples.
SEBU7844-25 83
Maintenance Section
Coolant Sample (Level 2) - Obtain

(Table 40, contd) The results are reported and appropriate

Cat DEAC
recommendations are made.
Cat SCA
Conventional Heavy-
Every 250 hours Yearly(1)
Obtaining the Sample
Duty Coolants

Cat ELC
Refer to Operation and Maintenance Manual,
Cat ELI
“Coolant Sample (Level 1) - Obtain” for the guidelines
Commercial EC-1
Optional(1) Yearly(1) for proper sampling of the coolant.
Coolants
Submit the sample for Level 2 analysis.
(1) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified. For further information, refer to this Operation and
Maintenance Manual, “Fluid Recommendations”.
Note: Check the SCA (Supplemental Coolant
Additive) of the conventional coolant at every oil i04139169
change or at every 250 hours. Perform this check at
the interval that occurs first. Coolant Temperature
Obtain the sample of the coolant as close as possible Regulator - Replace
to the recommended sampling interval. In order to
receive the full effect of S·O·S analysis, establish a SMCS Code: 1355-510
consistent trend of data. In order to establish a
pertinent history of data, perform consistent Replace the water temperature regulator before the
samplings that are evenly spaced. Supplies for water temperature regulator fails. Replacing the
collecting samples can be obtained from your Cat water temperature regulator is a recommended
dealer. preventive maintenance practice. Replacing the
water temperature regulator reduces the chances for
NOTICE unscheduled downtime. Refer to this Operation and
Always use a designated pump for oil sampling, and Maintenance Manual, “Maintenance Interval
use a separate designated pump for coolant sam- Schedule” for the proper maintenance interval.
pling. Using the same pump for both types of sam- A water temperature regulator that fails in a partially
ples may contaminate the samples that are being opened position can cause overheating or
drawn. This contaminate may cause a false analysis overcooling of the engine.
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers. A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
Submit the sample for Level 1 analysis. overheating could result in cracking of the cylinder
head or piston seizure problems.
Note: Level 1 results may indicate a need for Level 2 A water temperature regulator that fails in the open
Analysis. position will cause the engine operating temperature
to be too low during partial load operation. Low
i04638756 engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
Coolant Sample (Level 2) - cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear of
Obtain the cylinder liner.
SMCS Code: 1350-008; 1395-554; 1395-008; 7542
An S·O·S Coolant Analysis (Level 2) is a
comprehensive chemical evaluation of the coolant.
This analysis is also a check of the overall condition
of the cooling system. The S·O·S Coolant Analysis
(Level 2) has the following features:

• Full coolant analysis (Level 1)

• Identification of metal corrosion and contaminants
• Identification of buildup of the impurities that
cause corrosion and scaling
• Determination of the possibility of electrolysis
within the cooling system of the engine
84 SEBU7844-25
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

NOTICE NOTICE
Failure to replace your water temperature regulator Excessive supplemental coolant additive concentra-
on a regularly scheduled basis could cause severe tion can form deposits on the higher temperature sur-
engine damage. faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer
Caterpillar engines incorporate a shunt design cool- could cause cracking of the cylinder head and other
ing system and require operating the engine with a high temperature components.
water temperature regulator installed.
Excessive supplemental coolant additive concentra-
If the water temperature regulator is installed incor- tion could also result in blockage of the heat ex-
rectly, the engine may overheat, causing cylinder changer, overheating, and/or accelerated wear of the
head damage. Ensure that the new water tempera- water pump seal.
ture regulator is installed in the original position. En-
sure that the water temperature regulator vent hole is Do not exceed the recommended amount of supple-
open. mental coolant additive concentration.
Do not use liquid gasket material on the gasket or cyl-
inder head surface. NOTICE
Do NOT mix brands or types of SCA. Do NOT mix
SCAs and extenders.
Refer to two articles in the Disassembly and
Assembly Manual, “Water Temperature Regulators - Failure to follow the recommendations can result in
Remove and Water Temperature Regulators - Install” shortened cooling system component life.
for the replacement procedure of the water
temperature regulator, or consult your Caterpillar
dealer. NOTICE
Use Only Approved SCAs. Conventional coolants
Note: If the water temperature regulators are require the maintenance addition of SCA throughout
replaced, drain the coolant from the cooling system their expected life. Do NOT use an SCA with a cool-
to a level that is below the water temperature ant unless specifically approved by the coolant sup-
regulator housing. plier for use with their coolant. It is the responsibility
of the coolant manufacturer to ensure compatibility
i04538256 and acceptable performance.

Cooling System Supplemental Failure to follow the recommendations can result in

shortened cooling system component life.
Coolant Additive (SCA) - Test/
Add NOTICE
(Systems Which are Filled with Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
Conventional Coolant or Water/ nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Supplemental Coolant Additive ers before opening any compartment or disassem-
bling any component containing fluids.
(SCA))
Refer to Special Publication, NENG2500, “Cat Dealer
SMCS Code: 1352-045; 1395-081 Service Tool Catalog” and to Special Publication,
This maintenance procedure is required for GECJ0003, “Cat Shop Supplies and Tools” for tools
and supplies suitable to collect and contain fluids on
conventional coolants such as DEAC.Do not
perform this maintenance for cooling systems Cat products.
that are filled with Cat Extended Life Coolant (Cat
Dispose of all fluids according to applicable regula-
ELC) or Cat Extended Life Inhibitor (Cat ELI).
tions and mandates.

Note: Caterpillar recommends the performance of an

Cooling system coolant additive contains alkali. S·O·S Coolant Analysis (Level 1) in order to check
To help prevent personal injury, avoid contact the concentration of the SCA.
with the skin and eyes. Do not drink cooling sys-
tem coolant additive.
SEBU7844-25 85
Maintenance Section
Crankshaft Vibration Damper - Inspect

Maintain the Proper Concentration Damage to the crankshaft vibration damper or failure
of the damper can increase torsional vibrations. This
of SCA in the Coolant or Water/ vibration can result in damage to the crankshaft and
SCA Mixture to other engine components. A deteriorating damper
can cause excessive torsional vibrations.
A damper that is hot may be the result of excessive
torsional vibration, worn bearings, or damage to the
Pressurized System: Hot coolant can cause seri- damper. Use an infrared thermometer to monitor the
ous burns. To open the cooling system filler cap, temperature of the damper during operation. Follow
stop the engine and wait until the cooling system the instructions that are included with the infrared
components are cool. Loosen the cooling system thermometer. If the temperature reaches 100°C
pressure cap slowly in order to relieve the (212 °F), consult your Cat dealer.
pressure.
Inspect the damper for evidence of dents, cracks,
1. Remove the cooling system filler cap slowly. and leaks of the fluid.

2. Use one of the following methods for testing the If a fluid leak is found, determine the type of fluid. The
fluid in the damper is silicone. Silicone has the
concentration of SCA and water or coolant:
following characteristics: transparent, viscous and
a. For cooling systems filled with conventional smooth.
coolant, test the concentration of the SCA with a If the fluid leak is oil, inspect the crankshaft seals for
286-2578 Nitrite Test Strip. leaks. If a leak is observed, replace all of the seals.

b. For cooling systems filled with water and a Inspect the damper and repair or replace the damper
supplemental coolant additive, test the for any of the following reasons.
concentration of SCA with a 298-5311 Nitrite • The damper is dented, cracked, or leaking.
Test Strip.
• The paint on the damper is discolored from heat.
c. Review the results of the S·O·S Coolant
Analysis (Level 1). • The engine has had a failure because of a broken
crankshaft.
3. If necessary, drain some coolant in order to allow
space for the addition of the SCA. • The crankshaft bearings are showing excessive
wear.
4. Add the amount of SCA required to maintain the
correct concentration of SCA: • There is a large amount of gear train wear that is
not caused by a lack of oil.
a. From 3 percent to 6 percent of SCA in the
coolant
b. Up to 8 percent concentration of SCA in water
5. Clean the cooling system filler cap. Install the
cooling system filler cap.
For further information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.

i06194219

Crankshaft Vibration Damper -

Inspect
SMCS Code: 1205-040
The crankshaft vibration damper limits the torsional
vibration of the crankshaft. The visconic damper has
a weight that is located inside a fluid filled case.
86 SEBU7844-25
Maintenance Section
Driven Equipment - Check

Dampers With Sampling Ports • The damper has been operated for 20000 hours.
• The engine is undergoing a major overhaul.

Removal and Installation

Refer to the Disassembly and Assembly Manual,
“Vibration Damper - Remove and Install” article or
consult your Cat dealer for information about damper
replacement.

i00449093

Driven Equipment - Check

SMCS Code: 3279-535
To minimize bearing problems and vibration of the
engine crankshaft and the driven equipment, the
alignment between the engine and driven equipment
must be maintained properly.
Check the alignment according to the instructions
that are provided by the following manufacturers:

• Caterpillar
• OEM of the coupling

• OEM of the driven equipment

i06103535
Illustration 53 g03845581

Some dampers have ports for fluid samples. If the Engine - Clean
damper has no external damage, collect a sample of SMCS Code: 1000-070
the damper fluid. The fluid should be analyzed in
order to check for a loss of viscosity. Use the results
of the analysis to determine if the damper should be
rebuilt or replaced. Kits for fluid samples are
available from the address that follows. Return the Personal injury or death can result from high
kits to the same address for analysis. voltage.

Hasse & Wrede GmbH Moisture can create paths of electrical

Georg-Knorr-Straße 4 conductivity.
12681 Berlin
Make sure that the electrical system is OFF. Lock
Germany out the starting controls and tag the controls “ DO
Phone +49 30 9392-3135 NOT OPERATE”” .
Fax +49 30 9392-7-3135
Alternate phone +49 30 9392-3156
Alternate fax +49 30 9392-7-3156
NOTICE
The typical limit for the degradation of the damper Accumulated grease and oil on an engine is a fire
fluid viscosity that is used by Hasse & Wrede GmbH hazard. Keep the engine clean. Remove debris and
is 20 percent for most applications. The reports from fluid spills whenever a significant quantity accumu-
Hasse & Wrede should indicate that the fluid samples lates on the engine.
meet this viscosity limit.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
Dampers Without Sampling Ports oil and grease. A clean engine provides the following
benefits:
Some dampers do not have a port for a fluid sample.
These dampers must be rebuilt or the dampers must • Easy detection of fluid leaks
be replaced when one of the following criteria has
been met: • Maximum heat transfer characteristics
SEBU7844-25 87
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

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

i04322011 Dual Element Air Cleaners

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

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

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
engine wear. Your Cat dealer has the proper air
cleaner elements for your application. Consult your
Cat dealer for the correct air cleaner element.
Illustration 54 g00736431
• Check the precleaner (if equipped) daily for (1) Cover
accumulation of dirt and debris. Remove any dirt (2) Primary air cleaner element
and debris, as needed. (3) Secondary air cleaner element
(4) Turbocharger air inlet
• Operating conditions (dust, dirt, and debris) may
require more frequent service of the air cleaner 1. Remove the cover. Remove the primary air cleaner
element. element.
• The air cleaner element may be cleaned up to six 2. The secondary air cleaner element should be
times if the element is properly cleaned and removed and discarded for every three cleanings
inspected. of the primary air cleaner element.
• The air cleaner element should be replaced at Note: Refer to “Cleaning the Primary Air Cleaner
least one time per year. This replacement should Elements”.
be performed regardless of the number of
cleanings. 3. Cover the turbocharger air inlet with tape in order
to keep out dirt.
4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
88 SEBU7844-25
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

5. Remove the tape for the turbocharger air inlet. • Vacuum cleaning
Install the secondary air cleaner element. Install a
primary air cleaner element that is new or cleaned. Pressurized Air
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.
Personal injury can result from air pressure.
Cleaning the Primary Air Cleaner Personal injury can result without following prop-
Elements er procedure. When using pressure air, wear a
protective face shield and protective clothing.
NOTICE Maximum air pressure at the nozzle must be less
Caterpillar recommends certified air filter cleaning than 205 kPa (30 psi) for cleaning purposes.
services that are available at Cat dealers. The Cat
cleaning process uses proven procedures to assure Pressurized air can be used to clean primary air
consistent quality and sufficient filter life. cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
Observe the following guidelines if you attempt to deposits of carbon and oil. Use filtered, dry air with a
clean the filter element: maximum pressure of 207 kPa (30 psi).
Do not tap or strike the filter element in order to re-
move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets,
or seals. Dirt entering the engine will cause damage
to engine components.
The primary air cleaner element can be used up to Illustration 55 g00281692
six times if the element is properly cleaned and
inspected. When the primary air cleaner element is Note: When the primary air cleaner elements are
cleaned, check for rips or tears in the filter material. cleaned, always begin with the clean side (inside) in
The primary air cleaner element should be replaced order to force dirt particles toward the dirty side
at least one time per year. This replacement should
(outside).
be performed regardless of the number of cleanings.
To help prevent damage to the paper pleats, aim the
Use clean primary air cleaner elements while dirty
hose so that the air flows inside the element along
elements are being cleaned.
the length of the filter. Do not aim the stream of air
directly at the primary air cleaner element. Dirt could
NOTICE be forced further into the pleats.
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use el- Note: Refer to “Inspecting the Primary Air Cleaner
ements with damaged pleats, gaskets or seals. Dam- Elements”.
aged elements will allow dirt to pass through. Engine
damage could result.
Vacuum Cleaning
Visually inspect the primary air cleaner elements Vacuum cleaning is a good method for cleaning
before cleaning. Inspect the air cleaner elements for primary air cleaner elements which require daily
damage to the seal, the gaskets, and the outer cover. cleaning because of a dry, dusty environment.
Discard any damaged air cleaner elements. Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not
There are two common methods that are used to remove deposits of carbon and oil.
clean primary air cleaner elements:
Note: Refer to “Inspecting the Primary Air Cleaner
• Pressurized air Elements”.
SEBU7844-25 89
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace

Inspecting the Primary Air Cleaner

Elements

Illustration 57 g00281694

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

protective covering for storage. An airflow restriction
Illustration 56 g00281693
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inspect the clean, dry primary air cleaner element. Inhibited (VCI) paper.
Use a 60W blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner Place the primary air cleaner element into a box for
element. Rotate the primary air cleaner element. storage. For identification, mark the outside of the
Inspect the primary air cleaner element for tears and/ box and mark the primary air cleaner element.
or holes. Inspect the primary air cleaner element for Include the following information:
light that may show through the filter material. If
necessary, compare the primary air cleaner element • Date of cleaning
to a new primary air cleaner element that has the
same part number. • Number of cleanings
Do not use a primary air cleaner element that has Store the box in a dry location.
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
i05909507
pleats, gaskets, or seals. Discard damaged primary
air cleaner elements.
Engine Air Cleaner Element
Storing Primary Air Cleaner Elements (Single Element) - Inspect/
If a primary air cleaner element that passes Clean/Replace
inspection will not be used, the primary air cleaner
element can be stored for future use.
(If Equipped)
SMCS Code: 1051; 1054-510; 1054-070; 1054-040

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 pre-
vent 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.
90 SEBU7844-25
Maintenance Section
If Equipped

Servicing the Air Cleaner Elements 3. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element. 4. Remove the tape for the air inlet. Install an air
Unfiltered air will drastically accelerate internal cleaner element that is new or cleaned.
engine wear. Your Caterpillar dealer has the proper
air cleaner elements for your application. Consult 5. Install the air cleaner cover.
your Caterpillar dealer for the correct air cleaner 6. Reset the air cleaner service indicator.
element.

• Check the precleaner (if equipped) daily for Cleaning the Air Cleaner Elements
accumulation of dirt and debris. Remove any dirt
and debris, as needed. NOTICE
Caterpillar recommends certified air filter cleaning
• Operating conditions (dust, dirt, and debris) may services that are available at Cat dealers. The Cat
require more frequent service of the air cleaner cleaning process uses proven procedures to assure
element. consistent quality and sufficient filter life.
• The air cleaner element may be cleaned up to six Observe the following guidelines if you attempt to
times if the air cleaner element is properly cleaned clean the filter element:
and inspected.
Do not tap or strike the filter element in order to re-
• The air cleaner element should be replaced at move dust.
least one time per year. This replacement should Do not wash the filter element.
be performed regardless of the number of
cleanings. Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
Replace the dirty paper air cleaner elements with exceed 207 kPa (30 psi). Direct the air flow up the
clean air cleaner elements. Before installation, pleats and down the pleats from the inside of the filter
thoroughly check the element for tears and/or holes element. Take extreme care in order to avoid damage
in the filter material. Inspect the gasket or the seal of to the pleats.
the air cleaner element for damage. Maintain a
supply of suitable air cleaner elements for Do not use air filters with damaged pleats, gaskets,
replacement purposes. or seals. Dirt entering the engine will cause damage
to engine components.
The air cleaner element can be used up to six times if
the element is properly cleaned and inspected. When
the air cleaner element is cleaned, check for rips or
tears in the filter material. The 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 air cleaner elements while dirty elements
are being cleaned.

NOTICE
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use el-
Illustration 58 g00735127 ements with damaged pleats, gaskets or seals. Dam-
(1) Cover
aged elements will allow dirt to pass through. Engine
(2) Air cleaner element damage could result.
(3) Turbocharger inlet

Visually inspect the air cleaner elements before

1. Remove the air cleaner cover. Remove the air cleaning. Inspect the air cleaner elements for
cleaner element. damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
Note: Refer to “Cleaning the Air Cleaner Elements”.
There are two common methods that are used to
2. Cover the air inlet with tape in order to keep out clean air cleaner elements:
dirt.
• Pressurized air
SEBU7844-25 91
Maintenance Section
If Equipped

• Vacuum cleaning

Primary Air Filter Elements

Caterpillar does not recommend cleaning the air filter
elements. A damaged air filter element can allow dirt
to pass through, resulting in reduced efficiency.
Cleaning the air filter element will result in a
progressive reduction from the original filter capacity
each time the filter is cleaned.
If the air filter must be cleaned, the following steps
should be taken to minimize risks:

• Do not clean the air filter element by bumping or

tapping. Illustration 59 g00281692

• Do not use elements with damaged pleats, Note: When the air cleaner elements are cleaned,
gaskets, or seals. always begin with the clean side (inside) in order to
force dirt particles toward the dirty side (outside).
• Discard damaged elements.
Aim the hose so that the air flows inside the element
• Do not use solvent or water to wash the element. along the length of the filter to prevent damage to the
paper pleats. Do not aim the stream of air directly at
• When cleaning the element, use a maximum air the air cleaner element. Dirt could be forced further
pressure of 207 kPa (30 psi). Minimum distance into the pleats.
and time of using pressurized air is 75 mm
(3 inch) for at least 3 minutes. Note: Refer to “Inspecting the Air Cleaner Elements”.

• Do not aim the high-pressure air stream directly at Vacuum Cleaning

the filter media.
Vacuum cleaning is a good method for cleaning air
• Take precautions during the cleaning procedure to cleaner elements which require daily cleaning
prevent damage to the filter media. because of a dry, dusty environment. Cleaning with
pressurized air is recommended prior to vacuum
• The cleaning procedure can be used for a cleaning. Vacuum cleaning will not remove deposits
maximum of three cleanings before the filter of carbon and oil.
element is replaced.
Note: Refer to “Inspecting the Air Cleaner Elements”.
Secondary Air Filter Element
Caterpillar does not recommend cleaning the
secondary air filter element. The secondary element
is replaced at every third primary air filter element
cleaning.

Pressurized Air
Pressurized air can be used to clean 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).
92 SEBU7844-25
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Inspecting the Air Cleaner Elements Place the air cleaner element into a box for storage.
For identification, mark the outside of the box and
mark the air cleaner element. Include the following
information:
• Date of cleaning

• Number of cleanings
Store the box in a dry location.

i06194237

Engine Air Cleaner Service

Indicator - Inspect
SMCS Code: 7452-040
Illustration 60 g00281693 A service indicator may be mounted on the air
cleaner element or in a remote location.
Inspect the clean, dry air cleaner element. Use a 60
W blue light in a dark room or in a similar facility.
Place the blue light in the air cleaner element. Rotate
the air cleaner element. Inspect the air cleaner
element for tears and/or holes. Inspect the air cleaner
element for light that may show through the filter
material. If necessary, compare the air cleaner
element to a new air cleaner element that has the
same part number.
Do not use an air cleaner element that has any tears
and/or holes in the filter material. Do not use an air
cleaner element with damaged pleats, gaskets, or
seals. Discard damaged air cleaner elements.

Storing Air Cleaner Elements

Illustration 62 g03845597
If an air cleaner element that passes inspection will
not be used, the air cleaner element can be stored for (1) Service indicator
future use.
Some engines may be equipped with a different
service indicator.
Observe the service indicator. Clean the air cleaner
element or replace the air cleaner element when the
following conditions occur:
• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

• The air restriction reaches 6 kPa
(25 inches of H2O).

Test the Service Indicator

Illustration 61 g00281694
Service indicators are important instruments.

Do not use paint, a waterproof cover, or plastic as a • Check for ease of resetting. The service indicator
protective covering for storage. An air flow restriction should reset in less than three pushes.
may result. To protect against dirt and damage, wrap
the air cleaner elements in Volatile Corrosion • Check the movement of the yellow core when the
Inhibited (VCI) paper. engine is accelerated to the engine rated rpm. The
yellow core should latch approximately at the
greatest vacuum that is attained.
SEBU7844-25 93
Maintenance Section
Engine Crankcase Breather - Clean

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 fitting for the
service indicator may be plugged.

Illustration 64 g03845620

1. Loosen clamp (1). Slide the clamp down on tube

(2).
Illustration 63 g03845603 2. Loosen clamps (3). Remove both breathers as a
Porous filter unit.
A porous filter is part of a fitting that is used for
mounting of the service indicator. Inspect the filter for
cleanliness. Clean the filter, if necessary. Use
compressed air or a clean, nonflammable solvent.
The service indicator may need to be replaced
frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and
whenever major engine components are replaced.

Note: When a new service indicator is installed,

excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque of
2 N·m (18 lb in).
Illustration 65 g00597465
i06194279
3. Remove O-ring seals (4) from the valve covers.
Engine Crankcase Breather - Inspect the O-ring seals for good condition. Obtain
Clean new O-ring seals, if necessary.

SMCS Code: 1317-070

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.
94 SEBU7844-25
Maintenance Section
Engine Mounts - Inspect

i03963084

Engine Mounts - Inspect

SMCS Code: 1152-040; 1152
Misalignment of the engine and the driven equipment
will cause extensive damage. Excessive vibration
can lead to misalignment. Excessive vibration of the
engine and the driven equipment can be caused by
the following conditions:

• Improper mounting
• Loose bolts

• Deterioration of the isolators

Illustration 66 g00597466
Ensure that the mounting bolts are tightened to the
4. Remove two clamps (6). Remove both breathers proper torque. For standard torques, see
(5) from hose tee (7). Specifications, SENR3130, “Torque Specifications”.

Inspect the hose tee for cracks. If the tee is Ensure that the isolators are free of oil and
cracked, discard the old tee and obtain a new tee contamination. Inspect the isolators for deterioration.
for installation. Ensure that the bolts for the isolators are tightened to
the proper torque.
5. Turn the breathers upside-down in order to inspect
the condition of the breather elements. Replace any isolator that shows deterioration. For
more information, see the literature that is provided
Clean the breather elements with clean, by the OEM of the isolators. Also see the Application
nonflammable solvent. If the breather elements and Installation Guide for the engine. Consult your
remain contaminated after the cleaning, discard Cat dealer for assistance.
the breathers and obtain new breathers. Do not
attempt to disassemble the breathers.
i02110431
Allow the breather elements to dry before
installation. Engine Oil Filter Differential
Note: Coat the rubber parts with clean engine oil or Pressure - Check
petroleum jelly in order to make installation easier. SMCS Code: 1308-535
6. Place clamps (6) over the parts of hose tee (7) that Observe the oil filter differential pressure frequently
will receive breathers (5). Install the breathers into during engine operation.
the tee. Tighten the clamps to the torque that is
Oil Filter Differential Pressure
listed in the Service Manual, “Specifications”.
(Restriction) – This gauge indicates the
7. Coat O-ring seals (4) with clean engine oil. Place difference in pressure between the inlet
the O-ring seals on the valve covers. side and the outlet side of the engine oil filters.
As the oil filter elements become plugged, oil
8. Place clamps (3) around the parts of the breathers filter differential pressure will increase.
that will be attached to the valve covers. Install
both breathers as a unit. Tighten the clamps. The nominal oil filter differential pressure during
normal engine operation is approximately 60 kPa
9. Place clamp (1) on the part of the hose tee that will (9 psi).
receive tube (2). Install the tube into the hose tee.
Replace the oil filter elements when the oil filter
Tighten the clamp to the torque that is listed in the
differential pressure reaches 103 kPa (15 psi).
Service Manual, “Specifications”.
For instructions on replacement of the oil filter
elements, see this Operation and Maintenance
Manual, “Engine Oil and Filter - Change” topic.
SEBU7844-25 95
Maintenance Section
Engine Oil Level - Check

i04539043 b. If the engine is operating, reduce the engine

speed to low idle. Remove the engine oil level
Engine Oil Level - Check gauge and observe the engine oil level on
SMCS Code: 1348-535-FLV “ENGINE AT LOW IDLE WITH WARM OIL” side
(4).
The most accurate check of the engine oil level is
obtained when the engine is stopped. The engine oil level should be between “ADD”
mark (5) and “FULL” mark (6).

NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge
(dipstick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers and excessive oil consumption.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
Illustration 67 g01208341 posits in the combustion chamber lead to the follow-
ing problems: guttering of the valves, packing of
(1) Filler cap
(2) Engine oil level gauge (dipstick) carbon under the piston rings and wear of the cylin-
der liner.
1. Remove filler cap (1) in order to ensure that the If the oil level is above the “FULL” mark on the oil lev-
crankcase pressure is equal to the atmospheric el gauge, drain some of the oil immediately.
pressure.
Excess pressure or a slight vacuum will affect 3. If necessary, add engine oil. For the correct engine
engine oil level that is measured. oil to use, refer to this Operation and Maintenance
Manual, “Fluid Recommendations” topic. Do not fill
2. Ensure that engine oil level gauge (2) is seated. the crankcase above the “FULL” mark on the
engine oil level gauge. Clean the filler cap (1).
Install the filler cap.
4. Record the amount of engine oil that is added. For
the next engine oil sample and analysis, include
the total amount of engine oil that has been added
since the previous oil change. This record will help
to provide the most accurate analysis.

i04237495

Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM

Illustration 68 g00735162 In addition to a good preventive maintenance

(3) “ENGINE STOPPED WITH OIL COLD” side program, Caterpillar recommends using S·O·S oil
(4) “ENGINE AT LOW IDLE WITH WARM OIL” side analysis at regularly scheduled intervals. S·O·S oil
(5) “ADD” mark analysis provides infrared analysis, which is required
(6) “FULL” mark for determining nitration and oxidation levels.

a. If the engine is stopped, remove the engine oil

level gauge. Observe the engine oil level on
“ENGINE STOPPED WITH OIL COLD” side (3).
96 SEBU7844-25
Maintenance Section
Engine Oil and Filter - Change

Obtain the Sample and the For instructions, see Special Publication, PEGJ0047,
“How To Take A Good S·O·S Oil Sample”. Consult
Analysis your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.

Hot oil and hot components can cause personal i05362258

injury. Do not allow hot oil or hot components to
contact the skin. Engine Oil and Filter - Change
Before you take the oil sample, complete the Label, SMCS Code: 1318-510
PEEP5031 for identification of the sample. In order to
help obtain the most accurate analysis, provide the If the engine is equipped with duplex oil filters, the
following information: engine oil filter elements can be changed while the
engine is in operation. This feature is useful if the oil
• Engine model filter elements require more frequent replacement
than the engine oil. Refer to “Replacing the Engine
• Service hours on the engine Oil Filters During Engine Operation”.

• The number of hours that have accumulated since The oil change interval can be affected by several
the last oil change factors:

• The amount of oil that has been added since the • Air/fuel ratio
last oil change
• Ambient air conditions
To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, mixed oil sample. • Engine application

To avoid contamination of the oil samples, the tools • Fuel type

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

Caterpillar recommends using the sampling valve in • Size of the oil sump
order to obtain oil samples. The quality and the
consistency of the samples are better when the The S·O·S oil analysis program analyzes used oil in
sampling valve is used. The location of the sampling order to determine if the oil change interval is suitable
valve allows oil that is flowing under pressure to be for your specific engine. In the absence of S·O·S oil
obtained during normal engine operation. analysis, change the engine oil and filters according
to the interval that is listed in Table 41 .
The 169-8373 Fluid Sampling Bottle is Table 41
recommended for use with the sampling valve. The Engine Oil Change Intervals
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are Engine Sump Capacity Oil Change Interval
also provided.
Engines With a Shallow Sump
NOTICE 3508B 104 L (27 US gal) Every 250 Service
Always use a designated pump for oil sampling, and Hours
use a separate designated pump for coolant sam- 3512B 152 L (40 US gal)
pling. Using the same pump for both types of sam- 3512C
ples may contaminate the samples that are being 3516B 204 L (53 US gal)
drawn. This contaminate may cause a false analysis 3516C
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers. Engines With a Standard Sump

3508B 227 L (60 US gal) Every 500 Service

If the engine is not equipped with a sampling valve, Hours
3512B 318 L (84 US gal)
use the 1U-5718 Vacuum Pump. The pump is
3512C
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion into 3516B 405 L (107 US gal)
the sump. 3516C
Engines With a Deep Sump

(continued)
SEBU7844-25 97
Maintenance Section
Engine Oil and Filter - Change

(Table 41, contd)

3508B 443 L (117 US gal) Every 1000 Service a. If the engine does not have a drain valve or a
Hours pump, remove an oil drain plug. Allow the oil to
3512B 625 L (165 US gal) drain. After the oil has drained, clean the drain
3512C
plug and clean the fitting for the drain plug.
3516B 807 L (213 US gal) Install the drain plug. Tighten the drain plug to
3516C
145 ± 15 N·m (105 ± 10 lb ft).

b. If the engine has an oil drain valve, open the

Drain the Oil valve. After the oil has drained, close the valve.

c. If the engine has a pump for removing dirty oil,

connect a hose to the outlet of the pump. Place
Hot oil and components can cause personal the hose in a suitable container. Open the valve
injury. for the drain line. The two marks on the valve
Do not allow hot oil or components to contact must be turned so that one mark points to the
skin. pump and the other points to the drain line.
Operate the pump until the crankcase is empty.
Do not drain the oil when the engine is cold. As the oil Close the valve to the drain line. Disconnect the
cools, waste particles settle on the bottom of the oil hose.
pan. The waste particles are not removed when the
cold oil is drained. Drain the crankcase when the oil d. If the oil drain valve has a “quick connect”
is warm. This method allows proper draining of the
waste particles that are suspended in the oil. coupling, attach the coupling. Open the drain
valve in order to drain the crankcase. After the
Failure to follow this recommended procedure will oil has drained, close the drain valve.
allow the waste particles to be recirculated through Disconnect the coupling.
the engine lubrication system with the new oil.
3. Replace the engine oil filter elements before filling
1. After the engine has been operated at normal the crankcase with new oil.
operating temperature, STOP the engine.
2. Drain the oil according to the equipment on the Replace the Oil Filter Elements
engine.
Replace the engine oil filters when any of the
Note: Drain the oil into a suitable container. DO following conditions occur:
NOT drain the oil into the bilge sump. Dispose of
the oil according to local regulations. • Every oil change
• The engine oil filter differential pressure reaches
103 kPa (15 psi).
• The oil filter elements have been used for 1000
service hours.

Note: Do not attempt to clean the used oil filters.

Used oil filters will retain waste particles. The used oil
filters would not filter the oil properly.
Service tools are available to aid in the service of oil
filters. Consult your Cat dealer for the part names
and the part numbers. Follow the instructions that are
supplied with the service tools. If the service tools are
not used, perform the following appropriate
procedure.
Illustration 69 g00574534
Oil drain plug

Note: If a suction device is used in order to remove

the oil from the oil pan, ensure that the suction
device is clean. Cleanliness helps prevent dirt from
entering into the oil pan. Be careful not to strike the
engine oil suction tubes or the piston cooling jets.
98 SEBU7844-25
Maintenance Section
Engine Oil and Filter - Change

Replacing the Engine Oil Filters With the

Engine Stopped
Personal injury can result from parts and/or cov-
ers under spring pressure.
Spring force will be released when covers are
Hot oil and components can cause personal removed.
injury.
Be prepared to hold spring loaded covers as the
Do not allow hot oil or components to contact bolts are loosened.
skin.
3. Be alert to the spring force. Gradually loosen but
Perform the following procedure after the oil has
do not remove bolts (1). Before removing the
been drained.
bolts, pry cover (2) loose or tap the cover with a
Note: Use this procedure if the engine oil filters do rubber mallet in order to relieve any spring
not have a control valve. pressure.
Section view of the engine oil filter

Illustration 70 g00799719
(1) Bolts
(2) Cover Illustration 71 g00799721
(3) Plug (2) Cover
(4) Drain valve (6) O-ring seal
(5) Drain (7) Spring
(8) Retainer
Note: Drain the oil into a suitable container. Dispose (9) Oil filter element
of the oil according to local regulations.
4. Remove cover (2) and spring (7). Remove O-ring
1. Connect a hose to drain (5). Place the other end of seal (6), retainer (8), and oil filter elements (9).
the hose into a suitable container in order to
5. Clean cover (2), spring (7), O-ring seal (6), and
collect the oil.
retainer (8). Clean the inside of the oil filter
2. Open drain valve (4). Remove plug (3). Allow the housing.
oil to drain. Clean the plug and install the plug.
Close the drain valve. Remove the hose from the NOTICE
drain. Caterpillar oil filters are built to Caterpillar specifica-
tions. Use of an oil filter not recommended by Cater-
Note: Some oil will remain in the housing after the oil pillar could result in severe engine damage to the
has been drained. This oil will pour out of the housing engine bearings, crankshaft, etc., as a result of the
when cover (2) is removed. Prepare to catch the oil in larger waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recom-
a suitable container. Clean up any spilled oil with
mended by Caterpillar.
absorbent pillows or towels. DO NOT use absorbent
particles to clean up the oil.
6. Ensure that the new oil filter elements are in good
condition. Install the new oil filter elements.
SEBU7844-25 99
Maintenance Section
Engine Oil and Filter - Change

7. Inspect the O-ring seal. Ensure that the surfaces 6. Close the “FILL” valve. Rotate the control valve to
for the O-ring seal are clean. Install a new O-ring the “RUN” position for the oil filter that was
seal if the old O-ring seal is damaged or serviced.
deteriorated.
8. Install retainer (8), spring (7) and cover (2). Ensure
Fill the Crankcase
that the retainer and the spring are properly
seated between the oil filter elements and the NOTICE
cover. If the engine is equipped with an auxiliary oil filter sys-
tem, extra oil must be added when filling the crank-
9. Start the engine according to this Operation and case. If equipped with an auxiliary oil filter system
Maintenance Manual, “Starting The Engine” that is not supplied by Caterpillar, follow the recom-
procedure (Operation Section). Check for oil mendations of the OEM.
leaks.
NOTICE
Replacing the Engine Oil Filters During Engine damage can occur if the crankcase is filled
Engine Operation above the “FULL” mark on the oil level gauge
(dipstick).
If the engine is equipped with duplex oil filters, the
engine oil filter elements can be changed while the An overfull crankcase can cause the crankshaft to dip
engine is in operation. This ability is useful if the oil into the oil. This will reduce the power that is devel-
filter elements require more frequent replacement oped and also force air bubbles into the oil. These
than the engine oil. bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers and excessive oil consumption.
This filter contains hot, pressurized oil that can Excessive oil consumption will cause deposits to form
cause burns and fire hazards, which may result in on the pistons and in the combustion chamber. De-
bodily injury or death. Follow the instructions giv- posits in the combustion chamber lead to the follow-
en in this Operation and Maintenance Manual and ing problems: guttering of the valves, packing of
stop the engine if rapid air movement exists to carbon under the piston rings and wear of the cylin-
blow the oil. der liner.
If the oil level is above the “FULL” mark on the oil lev-
1. Open the “FILL” valve for a minimum of 5 minutes el gauge, drain some of the oil immediately.
in order to fill the oil filter elements that will not be
Use the following procedure in order to fill the
serviced. The oil filters that will not be serviced crankcase if the engine oil filters were replaced
must be full of engine oil. Close the FILL valve. during engine operation.
2. Move the control valve to the “AUX RUN” position 1. When the engine oil filters are replaced during
in order to change the main oil filter elements. engine operation, operate the engine at low idle.
Move the selector valve to the “MAIN RUN” Ensure that the oil level is at the “FULL” mark on
position in order to change the auxiliary oil filter the “LOW IDLE” side of the oil level gauge.
elements.
2. Add oil, if necessary. Remove the oil filler cap. Fill
3. Allow the oil pressure gauge for the oil filter that is the crankcase through the oil filler tube only.
being changed to reach a “ZERO” pressure
reading. Use the following procedure in order to fill the
crankcase if the engine oil filters were replaced with
4. Perform Step 1 through Step 8 of “Replacing the the engine stopped.
Engine Oil Filters With the Engine Stopped”.
1. Remove the oil filler cap. Fill the crankcase
5. Open the “FILL” valve for a minimum of 5 minutes through the oil filler tube only. For the amount of oil
in order to fill the new oil filter elements. to use, see this Operation and Maintenance
Manual, “Fluid Recommendations” or this
Operation and Maintenance Manual, “Refill
Capacities and Recommendations”. Clean the oil
filler cap. Install the oil filler cap.
2. Proceed to step 4 if the engine is equipped with a
pre-lube system.
100 SEBU7844-25
Maintenance Section
Engine Protective Devices - Check

Due to normal wear and friction, small amounts of

NOTICE debris may be found in the oil filter element. If an
To prevent crankshaft or bearing damage, crank en- excessive amount of debris is found in the oil filter
gine with fuel off to fill all filters before starting. element, consult your Cat dealer in order to arrange
for further oil analysis.
Do Not crank engine for more than 30 seconds.
i05264151
3. Close the fuel supply line and crank the engine
until the oil pressure gauge indicates 70 kPa Engine Protective Devices -
(10 psi). Open the fuel supply line. Allow the
starting motor to cool for 2 minutes before
Check
cranking again. SMCS Code: 7400-535
4. Start the engine according to this Operation and Alarms and shutoffs must function properly. Alarms
Maintenance Manual, “Starting The Engine” provide timely warning to the operator. Shutoffs help
procedure. Operate the engine at low idle for 2 to prevent damage to the engine. Determining if the
engine protective devices are in good working order
minutes to ensure that the lubrication system has during normal operation is impossible. Malfunctions
oil and that the oil filters are full. Inspect the engine must be simulated in order to test the engine
for oil leaks. Ensure that the oil level is at the protective devices.
“FULL” mark on the “LOW IDLE” side of the oil
level gauge. A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate at
5. Stop the engine and allow the oil to drain back into the setpoints. Ensure that the engine protective
the sump for a minimum of 10 minutes. devices are functioning properly.

6. Remove the oil level gauge and check the oil level. NOTICE
Maintain the oil level to the “FULL” mark on the During testing, abnormal operating conditions must
“ENGINE STOPPED” side of the oil level gauge. be simulated.
The tests must be performed correctly in order to pre-
Inspect the Used Oil Filter vent possible damage to the engine.
Elements
To prevent damage to the engine, only authorized
Cut the used oil filter element open with a utility knife. service personnel or your Cat dealer should perform
Remove the metal wrap. Cut the filter element free the tests.
from the end caps. Spread apart the pleats and
inspect the element for metal debris. An excessive
amount of debris in the element may indicate early Visual Inspection
wear or a pending failure.
Visually check the condition of all gauges, sensors,
Use a magnet to differentiate between the ferrous and wiring. Look for wiring and components that are
metals and the nonferrous metals that are found in loose, broken, or damaged. Damaged wiring or
the element. Ferrous metals may indicate wear on components should be repaired or replaced
the steel and the cast iron parts of the engine. immediately.
Nonferrous metals may indicate wear on the
aluminum parts, the brass parts, or the bronze parts i02209352
of the engine. Parts that may be affected include the
following components: main bearings, rod bearings,
turbocharger bearings and cylinder heads. Engine Speed/Timing Sensor -
Aluminum debris may indicate problems with the
Clean/Inspect
bearings of the front gears. If you find aluminum SMCS Code: 1905-040; 1905-070; 1907-040; 1907-
debris, inspect the crankshaft vibration damper and 070
the idler gear bearings.
An engine speed/timing sensor is mounted in the
flywheel housing. The speed/timing sensor provides
information about engine speed and the position of
the crankshaft to the ECM.
SEBU7844-25 101
Maintenance Section
Engine Valve Lash - Check

c. Coat the threads of the sensor with 4C-5597

Anti-Seize Compound.
Note: The sliphead is designed to contact a tooth
during the first revolution of the speed-timing
wheel. For the maximum allowable clearance
between the sliphead and the tooth, refer to the
engine's Specifications manual.

d. Install the sensor. Tighten the locknut to

40 ± 5 N·m (30 ± 4 lb ft).

i06756693

Illustration 72 g00760464
Engine Valve Lash - Check
1. Remove engine speed/timing sensor (1). Inspect SMCS Code: 1105-535
the condition of the end of the magnet. Look for
signs of wear and contaminants. Note: For procedures on adjusting the valve lash and
adjusting the valve bridge, see System Systems
2. Clean any debris from the face of the magnet. Operation/Testing and Adjusting, “Valve Lash and
Valve Bridge Adjustment”. Consult your Cat dealer
for assistance.
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.

Illustration 73 g01115363

3. Check the tension of the sliphead. Gently extend Ensure that the engine cannot be started while
sliphead (2) for a minimum of 4 mm (0.16 inch). this maintenance is being performed. To help pre-
Then push back the sliphead. vent possible injury, do not use the starting motor
to turn the flywheel.
When the sliphead has the correct tension, at least
22 N (5 lb) of force is required to push in the Hot engine components can cause burns. Allow
sliphead from the extended position. additional time for the engine to cool before
measuring/adjusting valve lash clearance.
NOTICE
The sliphead must be fully extended when the speed/
timing sensor is installed so that the sensor maintains
the correct clearance with the speed-timing wheel. If
the correct clearance is not maintained, the signal
from the sensor will not be generated.
Do not install the sensor between the teeth of the
speed-timing wheel. Damage to the sensor would re-
sult. Before installing the sensor, ensure that a tooth
of the wheel is visible in the mounting hole for the
sensor.

4. Install the engine speed/timing sensor.

a. Ensure that a tooth on the speed-timing wheel is

visible in the mounting hole for the sensor.

b. Extend sliphead (2) by a minimum of 4 mm

(0.16 inch).
102 SEBU7844-25
Maintenance Section
Fuel Filter Differential Pressure - Check

Valve Bridge i01225237

Check the valve bridge and adjust the valve bridge, if Fuel Injector - Inspect/Adjust
necessary. Perform the procedure for both valve
bridges for each cylinder. After the valve bridge is SMCS Code: 1290-025; 1290-040
checked for each cylinder, proceed with the valve
lash adjustment, if necessary. Note: Perform this procedure when the engine valve
lash is inspected.
Engine Valve Lash
NOTICE The Electronic Control module produces high
Only qualified service personnel should perform this voltage. To prevent personal injury make sure the
maintenance. Refer to the Systems Operation/Test- Electronic Control Module is not powered and the
ing and Adjusting Manual, “Valve Lash and Valve unit injector solenoids are disconnected.
Bridge Adjustment” article or consult your Caterpillar
dealer for the complete valve lash adjustment
procedure.
NOTICE
Operation of Caterpillar engines with improper valve The camshafts must be correctly timed with the
adjustments can reduce engine efficiency. This re- crankshaft before an adjustment of the lash for the
duced efficiency could result in excessive fuel usage fuel injector is made. The timing pins must be re-
and/or shortened engine component life. moved from the camshafts before the crankshaft is
turned or damage to the cylinder block will be the
The valve bridge adjustment must be performed result.
before making a valve lash adjustment. If the valve
Inspect the adjustment of the lash for the fuel injector
lash is within the tolerance, an adjustment of the
according to the Systems Operation/Testing And
valve lash is NOT necessary.
Adjusting, “Fuel System” topic. Adjust the lash for the
For the valve lash setting, see the engine fuel injector, if necessary.
Specifications manual. For the procedure to set the
valve lash, see the engine Systems Operation/ i01398238
Testing and Adjusting manual.
Fuel System - Prime
i04206972
SMCS Code: 1250-548; 1258-548
Fuel Filter Differential 1. Open the fuel supply valve. Ensure that the engine
Pressure - Check will not start during the priming procedure. Turn
the start switch to the OFF position.
SMCS Code: 1261-535-PX
Observe the fuel filter differential pressure frequently
during engine operation.
Fuel Filter Differential Pressure (Restriction) –
Indicates the difference in fuel pressure between the
inlet side and the outlet side of the fuel filter. As the
fuel filter element becomes plugged, the difference in
pressure between the two sides of the fuel filter
increases.

The nominal fuel filter differential pressure during

normal engine operation is approximately 60 kPa
(9 psi).
Replace the secondary fuel filter elements when the
fuel filter differential pressure reaches 103 kPa Illustration 74 g00736817
(15 psi).
(1) Fuel priming pump plunger
For instructions on replacement of the secondary fuel
filter elements, see this Operation and Maintenance 2. Turn the fuel priming pump plunger
Manual, “Fuel System Secondary Filter - Replace” counterclockwise in order to release the lock plate
topic. from the retainer.
SEBU7844-25 103
Maintenance Section
Fuel System Primary Filter/Water Separator - Clean/Replace

3. Operate the fuel priming pump until the air in the

NOTICE
fuel system has been pumped through the fuel Use a suitable container to catch any fuel that might
return line back to the fuel tank. spill. Clean up any spilled fuel immediately.
4. Press the fuel priming pump plunger to the locking
position. Turn the fuel priming pump plunger Note: Illustration 75 shows a Caterpillar Primary Fuel
clockwise in order to engage the lock plate in the Filter. If the engine has a different primary filter,
retainer. service the filter according to the instructions that are
provided by the OEM of the filter.
Note: Enable the starting system only after all
maintenance has been completed.

Priming Procedure for Dry Starting

If the air cannot be completely purged from the fuel
system and the engine will not start, see Special
Instruction, SEHS9586, “3500 EUI Fuel Priming
Procedure”.

i01539891

Fuel System Primary Filter/

Water Separator - Clean/
Replace
Illustration 75 g00799801
SMCS Code: 1260-510-PY; 1260-070-PY
(1) Bolt
(2) O-ring seal
(3) Case
(4) Element
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent 4. Remove bolt (1), O-ring seal (2), case (3) and
possible injury, turn the start switch off when element (4).
changing fuel filters or water separator elements.
Clean up fuel spills immediately. 5. Wash the element and the case in clean,
nonflammable solvent.
Inspect the element for good condition. Inspect the
NOTICE O-ring seal for damage and deterioration. Obtain
Do not allow dirt to enter the fuel system. Thoroughly new parts, if necessary.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
NOTICE
Do not fill the fuel filters with fuel before installing
Note: After cleaning or replacing the element, it may them. The fuel would not be filtered and could be con-
be necessary to prime the fuel system before the taminated. Contaminated fuel will cause accelerated
engine will start. See this Operation and Maintenance wear to fuel system parts.
Manual, “Fuel System - Prime” topic (Maintenance
Section).

Primary Filter
1. Stop the engine. Turn the start switch to the “OFF”
position. Disconnect the battery.
2. Shut off the fuel tank supply valve to the engine.
3. If the primary fuel filter is equipped with a drain
valve, open the drain valve in order to drain any
fuel from the filter case. Close the drain valve.
104 SEBU7844-25
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

6. Install the element, the case, the O-ring seal, and

the bolt. Tighten the bolt to 25 ± 5 N·m
(18 ± 4 lb ft). Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent
Water Separator possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Service the water separator according to the Clean up fuel spills immediately.
instructions that are provided by the OEM of the
water separator. Replace the secondary fuel filter elements whenever
the following conditions occur:
i00744357 • The fuel filter differential pressure gauge registers
103 kPa (15 psi).
Fuel System Primary Filter/
• The fuel filters have been used for 1000 service
Water Separator - Drain hours.
SMCS Code: 1260-543; 1263-543
Replacing the Fuel Filter Elements
with the Engine Stopped
Fuel leaked or spilled onto hot surfaces or electri- Canister
cal components can cause a fire.
1. Stop the engine. Ensure that the engine will not
NOTICE start during this procedure.
Use a suitable container to catch any fuel that might 2. Shut off the fuel supply valve to the engine.
spill. Clean up any spilled fuel immediately.

Drain the primary filter/water separator on a daily NOTICE

basis before starting the engine. Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
For specific instructions for draining the primary filter/ will be disconnected. Fit a suitable cover over discon-
water separator, see the service information that is nected fuel system component.
provided by the OEM of the primary filter/water
separator.
NOTICE
NOTICE Use a suitable container to catch any fuel that might
The water separator is under suction during normal spill. Clean up any spilled fuel immediately.
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the
fuel system.

i02828884

Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE

Note: If the engine is equipped with duplex fuel

filters, the fuel filter elements can be changed while
the engine is in operation. Refer to “Replacing the
Fuel Filter Elements During Engine Operation”.
Illustration 76 g01411122
(1) Bolts
(2) Cover
(3) Plug
(4) Drain valve
(5) Drain
SEBU7844-25 105
Maintenance Section
Fuel System Secondary Filter - Replace

3. Connect a hose to drain (5). Place the other end of Spin-On Filter
the hose into a suitable container in order to
collect the fuel. NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
4. Open drain valve (4). Remove plug (3). Allow the
clean the area around a fuel system component that
fuel to drain. Clean the plug and install the plug. will be disconnected. Fit a suitable cover over discon-
Close the drain valve. Remove the hose from the nected fuel system component.
drain.

Note: Some fuel will remain in the housing after the

fuel has been drained. This fuel will pour out of the
housing when cover (2) is removed. Prepare to catch
the fuel in a suitable container. Clean up any spilled
fuel with absorbent towels or pillows. DO NOT use
absorbent particles to clean up the fuel.

Personal injury can result from parts and/or cov-

ers under spring pressure.
Spring force will be released when covers are
removed.
Be prepared to hold spring loaded covers as the Illustration 77 g00425598
bolts are loosened. Secondary fuel filters
5. Be alert to the spring force. Gradually loosen but 1. Remove the used fuel filter with a 1U-8760 Chain
do not remove bolts (1). Before removing bolts (1), Wrench. Discard the used fuel filter.
pry cover (2) loose in order to relieve any spring
pressure. Remove cover (2). Remove the O-ring 2. Clean the gasket sealing surface of the fuel filter
seal on the inside of the cover. Remove the fuel base.
filter elements. Ensure that all of the old gasket is removed.
6. Clean cover (2) and clean the O-ring seal. Clean 3. Apply clean diesel fuel to the new fuel filter gasket.
the inside of the fuel filter housing.
7. Install new fuel filter elements. NOTICE
Do not fill the fuel filters with fuel before installing the
8. Inspect the O-ring seal. Ensure that the surfaces fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
for the O-ring seal are clean. Install a new O-ring ated wear to fuel system parts.
seal if the old O-ring seal is damaged or
deteriorated.
4. Install the new fuel filter.
9. Install cover (2). Ensure that the springs are
seated properly between the cover and the fuel Spin the new fuel filter onto the fuel filter base until
filter elements. the gasket contacts the base. Tighten the fuel filter
by hand by one full turn. Do not overtighten the
10. Open the fuel supply valve. Reconnect the fuel filter. Use the rotation index marks that are on
the fuel filter as a guide for proper tightening.
battery.
5. Prime the fuel system.
11. Prime the fuel system. Refer to this Operation
and Maintenance Manual, “Fuel System - Prime”
topic (Maintenance Section).
106 SEBU7844-25
Maintenance Section
Fuel Tank Water and Sediment - Drain

See this Operation and Maintenance Manual, If the auxiliary filters will be serviced, rotate control
“Fuel System - Prime” topic (Maintenance valve (4) to the “MAIN RUN” position.
Section).
NOTICE
Replacing the Fuel Filter Elements Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
During Engine Operation will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
If the engine is equipped with duplex fuel filters, the
fuel filters can be changed while the engine is in
operation. NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.

If the filter is changed during rapid air movement, 3. See “Replacing the Fuel Filter Elements with the
an explosive vapor may be created. The explosive Engine Stopped”. Perform Step 3 through Step 9
vapor may result in personal injury or in death.
from the “Canister” instructions.
If rapid air movement exists, stop the engine in 4. Open fill valve (5) for a minimum of five minutes in
order to change the filter.
order to fill the new elements. Close the fill valve.
After the new filter elements are full of fuel, either
the main filter or the auxiliary filter may be used.

Filter contains hot pressurized fluid when engine i06104305

is running.
Follow instructions on control valve to avoid per-
Fuel Tank Water and Sediment
sonal injury. - Drain
SMCS Code: 1273-543-M&S
Duplex Fuel Filters
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.

Illustration 78 g01411130
(4) Control valve
(5) Fill valve

1. Open FILL valve (5) for a minimum of five minutes

in order to fill the fuel filters that will not be
serviced. The fuel filters that will not be serviced
must be full of fuel. Close the FILL valve.
2. If the main filter will be serviced, rotate control
valve (4) to the “AUX RUN” position.
SEBU7844-25 107
Maintenance Section
Heat Exchanger - Inspect

Fuel Tank If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to
Fuel quality is critical to the performance and to the settle before filling the engine fuel tank. Internal
service life of the engine. Water in the fuel can cause baffles in the bulk storage tank will also help trap
excessive wear to the fuel system. Condensation sediment. Filtering fuel that is pumped from the
occurs during the heating and cooling of fuel. The storage tank helps to ensure the quality of the fuel.
condensation occurs as the fuel passes through the When possible, water separators should be used.
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining i02259870
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel. The
fuel tank utilizes a fuel tank vent to prevent an air lock Heat Exchanger - Inspect
or vacuum. Ensure that the vent is free of debris and SMCS Code: 1379-040
not damaged.

Drain the Water and the Sediment

Fuel tanks should contain some provision for draining Personal injury can result from hot coolant,
steam and alkali.
water and draining sediment from the bottom of the
fuel tanks. At operating temperature, engine coolant is hot
and under pressure. The heat exchanger and all
Prepare to catch water and sediment in an
lines to heaters or the engine contain hot coolant
appropriate container. Connect a hose (if necessary)
or steam. Any contact can cause severe burns.
to the valve prior to opening the valve.
Remove the filler cap slowly to relieve pressure
Open the drain valve on the bottom of the fuel tank in
order to drain the water and the sediment. Close the only when the engine is stopped and the filler cap
drain valve. for the heat exchanger is cool enough to touch
with your bare hand.
Note: Failure to close the drain properly could result
in fuel leakage, which could have detrimental results Cooling System Conditioner contains alkali.
Avoid contact with skin and eyes.
to performance.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine. Drain NOTICE
the water and sediment from the fuel tank after the Keep all parts clean from contaminants.
fuel tank has been filled. Allow 5 to 10 minutes before
performing this procedure. Contaminants may cause rapid wear and shortened
component life.
Fill the fuel tank after operating the engine in order to
drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel NOTICE
expands as the fuel gets warm. The tank may Care must be taken to ensure that fluids are con-
overflow. tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Some fuel tanks use stand pipes that allow water and Be prepared to collect the fluid with suitable contain-
sediment to settle below the end of the fuel stand ers before opening any compartment or disassem-
pipe. Some fuel tanks use supply lines that take fuel bling any component containing fluids.
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of Refer to Special Publication, NENG2500, “Dealer
the fuel system filter is important. Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Fuel Storage Tanks
Dispose of all fluids according to local regulations
Drain the water and the sediment from the fuel and mandates.
storage tank during the following conditions:

• Weekly Shell and Tube Heat Exchanger

• Refill of the tank The interval for the maintenance of the shell and tube
This procedure will help prevent water or sediment heat exchanger depends on the operating
from being pumped from the storage tank into the environment of the vessel and on the operating time.
engine fuel tank. A four micron(c) absolute filter for The sea water that is circulated through the heat
the breather vent on the fuel tank is also exchanger and the amount of operating time of the
recommended. vessel affects the following items:
108 SEBU7844-25
Maintenance Section
Heat Exchanger - Inspect

• Cleanliness of the tubes for the heat exchanger 5. Steam clean the core in order to remove any
residue. Flush the tubes of the heat exchanger
• Effectiveness of the heat exchanger system core. Remove any other trapped debris.
Operating in water that contains the following will 6. Wash the core with hot, soapy water. Rinse the
adversely affect the heat exchanger system: silt, core thoroughly with clean water.
sediment, salt and algae. In addition, intermittent use
of the vessel will adversely affect the heat exchanger
system.
The following items indicate that the heat exchanger Personal injury can result from air pressure.
may require cleaning:
Personal injury can result without following prop-
• Increased coolant temperature er procedure. When using pressure air, wear a
protective face shield and protective clothing.
• Engine overheating
Maximum air pressure at the nozzle must be less
• Excessive pressure drop between the water inlet than 205 kPa (30 psi) for cleaning purposes.
and the water outlet
7. Dry the core with compressed air. Direct the air in
An operator that is familiar with the normal operating
temperature of the coolant can determine when the the reverse direction of the normal flow.
coolant temperature is out of the normal range. 8. Inspect the core in order to ensure cleanliness.
Inspection and maintenance of the heat exchanger
are required if the engine is overheating. Pressure test the core. Many shops that service
radiators are equipped to perform pressure tests.
Cleaning the Shell and Tube Heat If necessary, repair the core.
Exchanger 9. Install the heat exchanger. Refer to the Service
Manual for the procedure.
Refer to the Disassembly and Assembly Manual for
the engine. For more information on cleaning the core, consult
your Caterpillar dealer.
1. Drain the heat exchanger.
2. Remove the heat exchanger. Plate Type Heat Exchanger
3. Turn the heat exchanger core upside-down in The interval for the maintenance of the plate type
order to remove debris. heat exchanger depends on the operating
environment of the vessel and on the operating time.
NOTICE The sea water that is circulated through the heat
Do not use a high concentration of caustic cleaner to exchanger and the amount of operating time of the
clean the core. A high concentration of caustic vessel affects the following items:
cleaner can attack the internal metals of the core and
cause leakage. Only use the recommended concen- • Cleanliness of the heat exchanger plates
tration of cleaner.
• Effectiveness of the heat exchanger system
4. Back flush the core with cleaner. Operating in water that contains the following will
adversely affect the heat exchanger system: silt,
Caterpillar recommends the use of Hydrosolv sediment, salt and algae. In addition, intermittent use
liquid cleaner. Table 42 lists Hydrosolv liquid of the vessel will adversely affect the heat exchanger
cleaners that are available from your Caterpillar system.
dealer.
Table 42 The following items indicate that the heat exchanger
Hydrosolv Liquid Cleaners(1) may require cleaning:

Part Number Description Size • Increased coolant temperature

1U-5490 Hydrosolv 4165 19 L (5 US gallon) • Engine overheating
174-6854 Hydrosolv 100 19 L (5 US gallon)
• Excessive pressure drop between the water inlet
(1) Use a two to five percent concentration of the cleaner at tem- and the water outlet
peratures up to 93°C (200°F). Refer to Application Guide,
NEHS0526 or consult your Caterpillar dealer for more
information.
SEBU7844-25 109
Maintenance Section
Hoses and Clamps - Inspect/Replace

An operator that is familiar with the normal operating Table 43

temperature of the coolant can determine when the
Problem Source Cleaners(1)
coolant temperature is out of the normal range.
Inspection of the heat exchanger and maintenance of Calcium carbonate
the heat exchanger are required if the engine is Scaling Calcium sulphate
overheating. Silicates

Your Caterpillar dealer has the equipment and the Corrosion products
personnel in order to measure the pressure drop Metal oxides Nitric acid
Sediment(2)
across the heat exchanger. Silt Sulfamic acid
Diatomic organisms Citric acid
Consult your Caterpillar dealer or refer to the Service Phosphoric acid
Seaweed
Manual for service information for the heat Complexing agents
exchanger. Chips of wood and
Gross fouling Sodium
fibers
polyphosphates
Mussels
Cleaning the Plate Type Heat Exchanger Barnacles

Refer to the Disassembly and Assembly Manual for Bacteria

the engine. The heat exchanger must be Biological growth Nematodes
disassembled in order to be cleaned. The Protozoa
Disassembly and Assembly Manual will contain Paraffinic or Naph-
instructions for cleaning the heat exchanger prior to Oily films
tha based solvent
reassembly. The following general guidelines are for Residue Asphalt
such as Kerosene.(3)
cleaning a plate type heat exchanger. Refer to Table Fats (4)
43 for types of cleaners.
(1) Cleaners should be mixed at a maximum concentration of 4
percent by weight. The temperature of the cleaning solution
NOTICE should be less than 60 °C (140 °F).
Do not use hydrochloric acid to clean stainless steel (2) The addition of surfactants to the cleaning solution may ease
plates. cleaning.
(3) Do not mix the solvent with water for cleaning. Dry the plates
Do not use hydrofluoric acid to clean titanium plates. with a cloth or rinse the plates with water.
(4) Gaskets that are made from natural rubber, butyl rubber and
Water that contains more than 300 ppm of chlorine EPDM rubber will swell in these solvents. Do not allow the sol-
should not be used to prepare cleaning solutions. vent to contact the gasket more than half an hour.

Do not use Ketones such as Acetone and 1. Drain the heat exchanger.
Methyletyketone.
2. Disassemble the heat exchanger and remove the
Do not use esters such as Ethylacetate and plates. Keep the plates in order.
Butylacetate.
3. Clean the plates with a cleaning solution and a soft
Do not use Halogenated hydrocarbons such as brush. Pressurized water may also be used. Do
Chlorothene and Carbon Tetrachloride not use steel wool or a wire brush, which may
Do not use Aromatics such as Benzene and Toluene. scratch the plate. Any iron scratches on the plates
can lead to corrosion of the plates. Rinse the
plates with water.
4. Assemble the heat exchanger.

i06825542

Hoses and Clamps - Inspect/

Replace
SMCS Code: 7554-040; 7554-510
Hoses and clamps must be inspected periodically
and replaced at the recommended interval to ensure
safe and continuous operation of the engine. Failure
to replace a fuel hose at the recommended change
interval may result in a hazardous situation. Take
proper safety precautions before inspecting or
replacing hoses and clamps.
110 SEBU7844-25
Maintenance Section
Hoses and Clamps - Inspect/Replace

Note: Always use a board or cardboard when the Due to extreme temperature changes, the hose will
engine components are checked for leaks. Leaking heat set. Heat setting causes hose clamps to loosen
fluid that is under pressure can cause serious injury which can result in leaks. A constant torque hose
or possible death. Leaks that are the size of a pin clamp will help to prevent loose hose clamps.
hole are included. Refer to Operation and
Replace hoses that are cracked or soft. Replace
Maintenance Manual, “General Hazard Information”
hoses that show signs of leakage. Replace hoses
for more information. that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace
Note: Ensure that the hose is compatible with the
hose clamps which are loose.
application.

Inspect Tubes, Hoses, Bellows, and Replace the Hoses and the Clamps
Clamps NOTICE
Care must be taken to ensure that fluids are con-
Inspect all tubes and hoses for leaks that are caused tained during performance of inspection, mainte-
by the following conditions. Replace any tube or hose nance, testing, adjusting, and repair of the product.
which exhibits any of the following conditions. Failure Be prepared to collect the fluid with suitable contain-
to replace a tube or hose which exhibits any of the ers before opening any compartment or disassem-
following conditions may result in a hazardous bling any component containing fluids.
situation.
Refer to Special Publication, NENG2500, “Cat Dealer
• Hoses which are cracked Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
• Hoses which are soft for tools and supplies suitable to collect and contain
fluids on Cat products.
• Outer covering that is chafed or cut
Dispose of all fluids according to local regulations
• Exposed wire that is used for reinforcement and mandates.
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed Cooling System

• Armoring that is embedded in the outer covering

• Exhaust bellows for leaks or damage
Pressurized System: Hot coolant can cause seri-
• Hoses which exhibit signs of leakage which are ous burns. To open the cooling system filler cap,
not the result of loose couplings or clamps stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
Inspect all clamps for the following conditions. pressure cap slowly in order to relieve the
Replace any clamp which exhibits signs of any of the pressure.
following conditions.

• Cracking
• Looseness Personal injury can result from removing hoses
or fittings in a pressure system.
• Damage
Failure to relieve pressure can cause personal
Inspect all couplings for leaks. Replace any coupling injury.
which exhibits signs of leaks.
Do not disconnect or remove hoses or fittings un-
Each installation application can be different. The til all pressure in the system has been relieved.
differences depend on the following factors:

• Type of hose 1. Stop the engine.

• Type of fitting material 2. Allow the engine to cool.

• Anticipated expansion and contraction of the hose 3. Before servicing a coolant hose, slowly loosen the
filler cap for the cooling system to relieve any
• Anticipated expansion and contraction of the pressure.
fittings
4. Remove the filler cap for the cooling system.
SEBU7844-25 111
Maintenance Section
Hoses and Clamps - Inspect/Replace

5. Drain the coolant from the cooling system to a

NOTICE
level that is below the hose that is being replaced. Do not allow dirt to enter the fuel system. Thoroughly
Drain the coolant into a suitable clean container. clean the area around a fuel system component that
The coolant can be reused. will be disconnected. Fit a suitable cover over any
disconnected fuel system components.
6. Remove the hose clamps.
7. Disconnect the old hose.
Note: High-pressure fuel lines may be installed
8. Replace the old hose with a new hose. between the high-pressure fuel pump and the fuel
injectors. High-pressure fuel lines are constantly
9. Install hose clamps which have been inspected or charged with high pressure. Do not check the high-
install new hose clamps. Refer to Specifications, pressure fuel lines with the engine or the starting
SENR3130, “Torque Specifications” “Hose motor in operation. Wait for 10 minutes after the
Clamps” for information about selecting and engine stops before you perform any service or
installing the proper hose clamps. repair on high-pressure fuel lines. Waiting for 10
minutes will allow the pressure to be purged.
10. Refill the cooling system.
1. Drain the fuel from the fuel system to a level that is
11. Clean the coolant filler cap. Inspect the gaskets
below the hose that is being replaced.
on the filler cap. Inspect the gasket seat. Inspect
the vacuum valve and seat for debris or damage. 2. Remove the hose clamps.
Replace the filler cap if the gaskets are damaged.
3. Disconnect the old hose.
Install the filler cap.
12. Start the engine. Inspect the cooling system for Note: When servicing fuel system, use cap/s or
leaks. cover/s as required to protect the system and
maintain fuel system cleanliness.
Fuel System 4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
Personal injury can result from removing hoses SENR3130, “Torque Specifications” “Hose
or fittings in a pressure system. Clamps” for information about selecting and
installing the proper hose clamps.
Failure to relieve pressure can cause personal
injury. 6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
Do not disconnect or remove hoses or fittings un- engine.
til all pressure in the system has been relieved.
Note: Fuel must be added to the fuel system ahead
of the fuel filter.

7. Refill the fuel system. Refer to this Operation and

Contact with high pressure fuel may cause fluid Maintenance Manual, “Fuel System - Prime” for
penetration and burn hazards. High pressure fuel information about priming the engine with fuel.
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in- 8. Start the engine. Inspect the fuel system for leaks.
structions may cause personal injury or death.
Lubrication System
NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and Hot oil and hot components can cause personal
hoses. Leaks can cause fires. Inspect all lines, tubes injury. Do not allow hot oil or hot components to
and hoses carefully. Tighten all connections to the contact the skin.
recommended torque.
1. Drain the oil from the lubrication system to a level
that is below the hose that is being replaced.
2. Remove the hose clamps.
112 SEBU7844-25
Maintenance Section
Maintenance Recommendations

3. Disconnect the old hose. • Operation within acceptable limits

4. Replace the old hose with a new hose. • Engine load
5. Install hose clamps which have been inspected or • Engine speed
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications” “Hose Generally, engines that are operated at a reduced
Clamps” for information about selecting and load and/or speed achieve more service life before
installing the proper hose clamps. an overhaul. However, the engines must be operated
and maintained properly.
6. Refill the lubrication system. Refer to this
Operation and Maintenance Manual, “Engine Oil Other factors must also be considered for
determining a major overhaul:
Level - Check” to ensure that the lubrication
system is filled with the proper amount of engine • The total amount of fuel consumption
oil.
• The service hours of the engine
7. Start the engine. Inspect the lubrication system for
leaks. • An increase of oil consumption

Air System • An increase of crankcase blowby

• The wear metal analysis of the lube oil

1. Remove the hose clamps.
• An increase in the levels of noise and vibration
2. Disconnect the old hose.
An increase of wear metals in the lube oil indicates
3. Replace the old hose with a new hose. that the bearings and the surfaces that wear may
4. Install hose clamps which have been inspected or need serviced. An increase in the levels of noise and
vibration indicates that rotating parts require service.
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications” “Hose Note: Oil analysis may indicate a decrease of wear
Clamps” for information about selecting and metals in the lube oil. The cylinder liners may be
installing the proper hose clamps. worn so that polishing of the bore occurs. Also, the
increased use of lube oil will dilute the wear metals.
Note: The bellows and the V-clamps that are used on
the exhaust bellows should never be reused. Monitor the engine as the engine accumulates
service hours. Consult your Cat dealer about
5. Start the engine. Inspect the air lines for leaks. scheduling a major overhaul.
Note: The driven equipment may also require service
i04605075 when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
Maintenance
Recommendations Using Fuel Consumption For Calculating
SMCS Code: 1000
the Overhaul Intervals
Experience has shown that maintenance intervals
Overhaul Intervals are most accurately based on fuel consumption. Fuel
consumption corresponds more accurately to the
Some factors that are important for determining the engine load. Tables 44 , 45 , and 46 list average
overhaul intervals include the following ranges of fuel consumption and service hours for
considerations: standard displacement engines. These tables are
based on a load factor of approximately 60 percent.
• Performance of preventive maintenance
• Use of recommended lubricants

• Use of recommended coolants

• Use of recommended fuels

• Proper installation
• Operating conditions
SEBU7844-25 113
Maintenance Section
Maintenance Recommendations

Standard Displacement Engines

Table 44
Maintenance Interval Schedule
Service Hours and Fuel Consumption for 3508C Engines, 3508B Engines and 3508 Engines with EUI Option.

Interval Rated Up To 1300 rpm Rated 1301 To 1600 rpm Rated 1601 To 1800 High Performance High Performance
(1) (1) rpm(1) Bhp and Chp Ratings Dhp and Ehp Ratings(2)
(1)

250 Service Hours 22700 L (6000 US gal) 27700 L (7200 US gal) 32000 L 40500 L 29150 L
(8500 US gal) (10,700 US gal) (7600 US gal)

500 Service Hours 45400 L 54400 L (14,400 US gal) 64000 L 81000 L 58300 L
(12,000 US gal) (17,000 US gal) (21,400 US gal) (15,200 US gal)

1000 Service 89000 L 109000 L (28,800 US gal) 128000 L 162000 L 116700 L

Hours (23,500 US gal) (34,000 US gal) (42,800 US gal) (30,800 US gal)

2000 Service 178000 L 218000 L (57,600 US gal) 257000 L 324000 L 233400 L

Hours (47,000 US gal) (68,000 US gal) (85,600 US gal) (61,600 US gal)

3000 Service 267500 L 327500 L (84,000 US gal) 386500 L 485500 L 350000 L

Hours (70,500 US gal) (102,000 US gal) (128,400 US gal) (92,500 US gal)

6000 Service 535000 L 636000 L 774000 L 971000 L 700000 L

Hours (141,000 US gal) (168,000 US gal) (204,000 US gal) (256,250 US gal) (185,000 US gal)

Top End Overhaul 11 000 Service Hours 9000 Service Hours 7500 Service Hours 6000 Service Hours 4500 Service Hours
976000 L (257,500 US gal) 971000 L 525000 L
(256,250 US gal) (135,500 US gal)

Second Top End 22 000 Service Hours 18 000 Service Hours 15 000 Service Hours n/a n/a
Overhaul
1952000 L (515,000 US gal) n/a n/a

Major Overhaul 33000 Service Hours 27000 Service Hours 22500 Service Hours 12000 Service Hours 9000 Service Hours
2928000 L (773,578 US gal) 1942000 L 1050000 L
(512,500 US gal) (275,000 US gal)
(1) Fuel consumption is based on a load factor of approximately 60 percent.
(2) Fuel consumption is based on a load factor of approximately 40 percent.

Table 45
Maintenance Interval Schedule
Service Hours and Fuel Consumption for 3512C Engines, 3512B Engines and 3512 Engines with EUI Option

Interval Rated Up To 1300 rpm Rated 1301 To 1600 Rated 1601 To 1800 High Performance Bhp High Performance
(1) rpm(1) rpm(1) and Chp Ratings(1) Dhp and Ehp Ratings
(2)

250 Service Hours 33400 L (8800 US gal) 41000 L (10,800 US gal) 48500 L 60800 L (16060 US gal) 43750 L
(12,800 US gal) (11,500 US gal)

500 Service Hours 66800 L 82000 L (21,600 US gal) 97000 L 121600 L 87500 L
(17,600 US gal) (25,600 US gal) (32,200 US gal) (23,000 US gal)

1000 Service 133500 L 164000 L 194000 L 243300 L 175000 L

Hours (35,000 US gal) (43,200 US gal) (51,200 US gal) (64,200 US gal) (46,000 US gal)

2000 Service 267000 L 328000 L 388000 L 486600 L 350000 L

Hours (70,000 US gal) (86,400 US gal) (102,400 US gal) (128,400 US gal) (92,000 US gal)

3000 Service 398000 L 491000 L 582000 L 729900 L 525000 L

Hours (105,000 US gal) (129,600 US gal) (153,600 US gal) (192,500 US gal) (138,000 US gal)

(continued)
114 SEBU7844-25
Maintenance Section
Maintenance Recommendations

(Table 45, contd)

6000 Service 796000 L 982000 L 1164000 L 1460000 L 1050000 L
Hours (210,000 US gal) (259,200 US gal) (307,200 US gal) (385,000 US gal) (276,000 US gal)

Top End Overhaul 11 000 Service Hours 9000 Service Hours 7500 Service Hours 6000 Service Hours 4500 Service Hours
1460000 L (385,000 US gal) 787500 L
(206,250 US gal)

Second Top End 22000 Service Hours 18000 Service Hours 15000 Service Hours n/a n/a
Overhaul
2920000 L (770,000 US gal) n/a n/a

Major Overhaul 33000 Service Hours 27000 Service Hours 22500 Service Hours 12000 Service Hours 9000 Service Hours
4380000 L (1,155,000 US gal) 2920000 L 1575000 L
(770,000 US gal) (412,500 US gal)

(1) Fuel consumption is based on a load factor of approximately 60 percent.

(2) Fuel consumption is based on a load factor of approximately 40 percent.

Table 46
Maintenance Interval Schedule
Service Hours and Fuel Consumption for 3516C Engines, 3516B Engines and 3516 Engines with EUI Option

Interval Rated Up To 1300 Rated 1301 To 1600 Rated 1601 To High Performance High Perform- High Performance
rpm(1) rpm(1) 1800 rpm(1) Ahp Rating(2) ance Bhp and Chp Dhp and Ehp Ratings
Ratings(1) (3)

250 Service 44000 L 53000 L 64500 L 97000 L 81000 L 58300 L

Hours (11,600 US gal) (14,000 US gal) (17,000 US gal) (25,600 US gal) (21,400 US gal) (15,200 US gal)

500 Service 88000 L 106000 L 129000 L 194000 L 162000 L 116600 L

Hours (23,200 US gal) (28,000 US gal) (34,000 US gal) (51,300 US gal) (42,800 Us gal) (30,400 US gal)

1000 Service 176000 L 212000 L 258000 L 388000 L 324000 L 233300 L

Hours (46,500 US gal) (56,000 US gal) (68,000 US gal) (102,500 US gal) (85,600 US gal) (61,600 US gal)

2000 Service 352000 L 424000 L 516000 L 777000 L 648000 L 466600 L

Hours (93,000 US gal) (112,000 US gal) (136,000 US gal) (205,300 US gal) (171,200 US gal) (123,200 US gal)

3000 Service 528700 L 636700 L 773000 L 1165000 L 972000 L 700000 L

Hours (139,500 US gal) (168,100 US gal) (204,000 US gal) (308,000 US gal) (257,000 US gal) (185,000 US gal)

6000 Service 1056000 L 1272000 L 1548000 L 2330000 L 1942000 L 1400000 L

Hours (279,000 US gal) (336,000 US gal) (408,000 US gal) (615,500 US gal) (512,500 US gal) (370,000 US gal)

Top End 11000 Service 9000 Service Hours 7500 Service 5000 Service Hours 6000 Service 4500 Service Hours
Overhaul Hours Hours Hours
1942000 L (512,500 US gal) 1050000 L
(275,000 US gal)

Second Top 22000 Service 18000 Service 15000 Service n/a n/a n/a
End Overhaul Hours Hours Hours
3884000 L (1,025,000 US gal) n/a n/a n/a

Major Overhaul 33000 Service 27000 Service 22500 Service 10000 Service 12000 Service 9000 Service Hours
Hours Hours Hours Hours Hours
5826000 L (1,537,500 US gal) 3884000 L (1,025,000 US gal) 2100000 L
(550,000 US gal)
(1) Fuel consumption is based on a load factor of approximately 60 percent.
(2) Fuel consumption is based on a load factor of approximately 80 percent.
(3) Fuel consumption is based on a load factor of approximately 40 percent.
SEBU7844-25 115
Maintenance Section
Maintenance Recommendations

High Displacement Engines (Table 48, contd)

3000 Service 528700 L 636700 L 773000 L
Table 47 Hours (139500 US (168000 US (204000 US
Service Hours and Fuel Consumption for 3512C High Dis- gal) of fuel gal) of fuel gal) of fuel
placement Engines and 3512B High Displacement Engines(1)
6000 Service 1056000 L 1272000 L 1548000 L
Interval Rated Up to Rated 1301 to Rated 1601 to Hours (279000 US (336000 US (408000 US
1300 rpm 1600 rpm 1800 rpm gal) of fuel gal) of fuel gal) of fuel

250 Service 33400 L 41000 L 48500 L Top End 11000 Service 9000 Service 7500 Service
Hours (8800 US gal) (10800 US gal) (12800 US Overhaul Hours Hours Hours
of fuel of fuel gal) of fuel
2000000 L (528000 US gal) of fuel
500 Service 66800 L 82000 L 97000 L
Major Overhaul 22000 Service 18000 Service 15000 Service
Hours (17600 US gal) (21600 US gal) (25600 US
Hours Hours Hours
of fuel of fuel gal) of fuel
4000000 L (1056000 US gal) of fuel
1000 Service 133500 L 164000 L 194000 L
Hours (35000 US gal) (43200 US gal) (51200 US (1) Fuel consumption is based on a load factor of approximately 60
of fuel of fuel gal) of fuel percent.

2000 Service 267000 L 328000 L 388000 L • Overhaul intervals are guidelines and are
Hours (70000 US gal) (86400 US gal) (102400 US
dependent on the maintenance and usage factors
of fuel of fuel gal) of fuel
described in this Operation and Maintenance
3000 Service 398000 L 491000 L 582000 L Manual.
Hours (105000 US (129600 US (153600 US
gal) of fuel gal) of fuel gal) of fuel • Maintenance intervals must be reduced for
engines that operate in a severe service
6000 Service 796000 L 982000 L 1164000 L
application. Maintenance intervals must also be
Hours (210000 US (259200 US (307200 US
gal) of fuel gal) of fuel gal) of fuel
reduced for engines that operate in excess of the
engine rating definition.
Top End 11000 Service 9000 Service 7500 Service
Overhaul Hours Hours Hours Oil Consumption as an Overhaul
1500000 L (395000 US gal) of fuel Indicator
Major Overhaul 22000 Service 18000 Service 15000 Service Oil consumption, fuel consumption, and maintenance
Hours Hours Hours information can be used to estimate the total
3000000 L (790000 US gal) of fuel operating cost for your Cat engine. Oil consumption
can also be used to estimate the required capacity of
(1) Fuel consumption is based on a load factor of approximately 60 a makeup oil tank that is suitable for the maintenance
percent. intervals.
Table 48 Oil consumption is in proportion to the percentage of
Service Hours and Fuel Consumption for 3516C High Dis- the rated engine load. As the percentage of the
placement Engines and 3516B High Displacement Engines(1) engine load is increased, the amount of oil that is
consumed per hour also increases.
Interval Rated Up to Rated 1301 to Rated 1601 to
1300 rpm 1600 rpm 1800 rpm The oil consumption rate (brake-specific oil
consumption) is measured in grams per kW/h (lb per
250 Service 44000 L 53000 L 64500 L bhp). The brake-specific oil consumption (BSOC)
Hours (11600 US gal) (14000 US gal) (17000 US depends on the engine load. Consult your Cat dealer
of fuel of fuel gal) of fuel for assistance in determining the typical oil
500 Service 88000 L 106000 L 129000 L consumption rate for your engine.
Hours (23200 US gal) (28000 US gal) (34000 US
of fuel of fuel gal) of fuel

1000 Service 176000 L 212000 L 258000 L

Hours (46500 US gal) (56000 US gal) (68000 US
of fuel of fuel gal) of fuel

2000 Service 352000 L 424000 L 516000 L

Hours (93000 US gal) (112000 US (136000 US
of fuel gal) of fuel gal) of fuel

(continued)
116 SEBU7844-25
Maintenance Section
Overhaul (Major)

When the oil consumption of an engine has risen Note: See this Operation and Maintenance Manual,
to three times the original oil consumption rate, “Cold Weather Operation” topic (Operation Section),
an engine overhaul should be scheduled. There or see Special Publication, SEBU5898, “Cold
may be a corresponding increase in blowby and a Weather Recommendations”.
slight increase in fuel consumption.
Cleanliness
Severe Operation Unless the equipment is cleaned regularly, extended
Severe operation is the use of an engine that operation in a dirty environment and in a dusty
environment can damage components. Built up mud,
exceeds current published standards for that engine.
dirt, and dust can encase components and make
Caterpillar maintains standards for the following
maintenance difficult. The buildup can contain
engine parameters:
corrosive chemicals. Corrosive chemicals and salt
can damage some components.
• Horsepower
• Range of rpm Improper Operating Procedures
• Fuel consumption • Extended operation at low idle

• Fuel quality • Minimum cool down periods after high load factor
operation
• Altitude
• Operating the engine beyond the guidelines for
• Maintenance intervals the engine rating
• Selection of oil • Operating the engine at loads that are greater than
the rated load
• Selection of coolant
• Operating the engine at speeds that are greater
• Environmental qualities than the rated speed
• Installation • Use of the engine for an application that is not
Refer to the standards for your engine or consult your approved
Cat dealer in order to determine if your engine is
operating within the defined parameters. Improper Maintenance Practices
Severe operation can accelerate component wear. • Extension of maintenance intervals
Engines that are operating under severe conditions
may need more frequent maintenance intervals for • Not using recommended fuel, lubricants, and
the following reasons: coolant
• Maximum reliability i02624456

• Retention of full service life

Overhaul (Major)
Because of individual applications, all of the factors
which can contribute to severe operation cannot be SMCS Code: 7595-020-MJ
identified. Consult your Cat dealer about the Refer to this Operation and Maintenance Manual,
maintenance that is needed for your specific engine. “Maintenance Recommendations” in order to
determine the maintenance interval for a major
The following factors can contribute to severe overhaul.
operation: environment, improper operating
procedures and improper maintenance practices. The need for a major overhaul is determined by
several factors.
Environmental Factors
• An increase of oil consumption
Extreme Ambient Temperatures
• An increase of crankcase blowby
Extended operation in environments that are too cold
or too hot can damage components. Valve • The total amount of fuel consumption
components can be damaged by carbon buildup if
the engine is frequently started and stopped in • The service hours of the engine
temperatures that are too cold. Inlet air that is too hot • The wear metal analysis of the lube oil
reduces the performance capabilities of the engine.
SEBU7844-25 117
Maintenance Section
Overhaul (Major)

• An increase in the levels of noise and vibration • Piston rings

An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may Inspection, Reconditioning or
need to be serviced. An increase in the levels of
noise and vibration indicates that rotating parts
Exchanging of Components
require service.
Inspect the following components according to the
Note: It is possible for oil analysis to indicate a instructions that are in Caterpillar reusability
decrease of wear metals in the lube oil. The cylinder publications. Refer to Guidelines for Reusable Parts
liners may be worn so that polishing of the bore and Salvage Operations, SEBF8029, “Index of
Publications on Reusability or Salvage of Used
occurs. Also, the increased use of lube oil will dilute
Parts”.
the wear metals.
Recondition the worn components or exchange the
Monitor the engine as the engine accumulates components, if necessary. Your Caterpillar dealer can
service hours. Consult your Caterpillar dealer about provide these services and components.
scheduling a major overhaul.
• Camshaft followers
Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature • Camshaft thrust washers
that is provided by the OEM of the driven equipment.
• Connecting rods
A major overhaul includes all of the work that is done
for the top end overhaul. A major overhaul includes • Crankshaft vibration damper
additional parts and labor. Additional parts and labor
are required in order to completely rebuild the • Cylinder head assembly
engine.
• Cylinder liners
For the major overhaul, all of the bearings, seals,
gaskets, and components that wear are • Engine mounts
disassembled. The parts are cleaned and inspected.
If necessary, the parts are replaced. The crankshaft • Scavenge oil pump
is measured for wear. The crankshaft may require
regrinding. Alternatively, the crankshaft may be • Engine wiring harness
replaced with a Caterpillar replacement part.
• Exhaust manifold seals
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure • Exhaust manifold bellows
that the components are operating within the
appropriate specifications. • Fuel pressure regulating valve

Replacement of Components • Fuel priming pump

• Fuel transfer pump
Replace the following components during the major
overhaul: • Inlet manifold gaskets
• Camshaft bearings • Inlet manifold seals
• Connecting rod bearings • Oil cooler core
• Crankshaft seals • Oil pump
• Crankshaft thrust washers • Pistons
• Electronic unit injectors • Piston pins
• Gear train bushings • Prelube pump
• Gear train bearings • Pushrods
• Main bearings • Rocker arms

• Spacer plate
• Software update
118 SEBU7844-25
Maintenance Section
Overhaul (Major)

• Turbocharger • Excessive wear of the gear train that is not caused

by a lack of lubrication
Inspection of Components Inspect the gears of the gear train and inspect the
gear train bushings for the following conditions:
Inspect the following components according to the
instructions that are in Caterpillar reusability • Worn gear teeth
publications. Refer to Guidelines for Reusable Parts
and Salvage Operations, SEBF8029, “Index of • Unusual fit
Publications on Reusability or Salvage of Used
Parts”. • Unusual wear
• Aftercooler core In addition to the inspection of components, inspect
the alignment of the driven equipment. See the
• Camshaft Application and Installation Guide for the engine or
see the literature that is provided by the OEM of the
• Crankshaft driven equipment.
• Driven equipment (alignment)
Cleaning of Components
• Engine cylinder block
Clean the oil cooler core and the aftercooler core.
• Engine control module Then, pressure test both of these cores. For
instructions on cleaning the cores, see this Operation
• Exhaust bellow shields and Maintenance Manual, “Aftercooler Core -
Inspect/Clean” topic.
• Flywheel
Clean the oil suction screen. Also, remove side
• Front gear train (gears) covers in order to clean the oil sump. For instructions
on removal and installation of components, see the
• Oil suction screen Service Manual, “Disassembly and Assembly”
module.
• Rear gear train
Obtain a Coolant Analysis
Inspect the camshaft for damage to the journals and
the lobes. For conventional heavy-duty coolant/antifreeze,
Inspect the crankshaft for any of the following check the concentration of supplemental coolant
conditions: additive (SCA) regularly. The concentration of SCA
can be checked with an S·O·S coolant analysis
• Deflection (Level I). A more detailed coolant analysis is
recommended periodically.
• Damage to the journals
For example, considerable deposits are found in the
• Bearing material that has seized to the journals water jacket areas on the external cooling system,
but the concentrations of coolant additives were
Check the journal taper and the profile of the carefully maintained. The coolant water probably
crankshaft journals. Check these components by contained minerals which were deposited on the
interpreting the wear patterns on the following engine over time.
components:
A coolant analysis can be conducted in order to verify
• Rod bearing the condition of the water that is being used in the
cooling system. A full water analysis may be obtained
• Main bearings from the following sources:

Note: If the crankshaft or the camshaft are removed • Caterpillar dealer

for any reason, use the magnetic particle inspection
• Local water utility company
process to check for cracks.
Replace the crankshaft vibration damper if any of the • Agricultural agent
following conditions occur:
• Independent laboratory
• Engine failure due to a broken crankshaft
• Excessive wear of the front bearing for the
crankshaft
SEBU7844-25 119
Maintenance Section
Overhaul (Top End)

Caterpillar recommends an S·O·S coolant analysis Cylinder Head Assembly

(Level II). This is a comprehensive chemical
evaluation of the coolant. This analysis is also a Inspect the cylinder head assembly according to the
check of the overall condition of the inside of the instructions that are in Caterpillar reusability
cooling system. The following services are provided: publications. Refer to Guidelines for Reusable Parts
and Salvage Operations, SEBF8029, “Index of
• Full Level I analysis Publications on Reusability or Salvage of Used
Parts”.
• Identification of the source of metal corrosion and
of contaminants Your Cat dealer can provide these services and
components. Your Cat dealer can ensure that the
• Identification of buildup of the impurities that components are operating within the appropriate
cause corrosion specifications.
• Identification of buildup of the impurities that The use of out-of-spec parts will cause unscheduled
cause scaling downtime and/or costly repairs.

• Determination of possible electrolysis within the Unit Injectors

engines' cooling system
Replace the unit injectors. Consult your Cat dealer
A report of the results of the analysis is provided. about exchanging the unit injectors. Your Cat dealer
Maintenance recommendations are based on the can provide these services and components.
results.
For more information about S·O·S coolant analysis, The wear of unit injectors is affected by the following
consult your Caterpillar dealer. considerations:

• Quality of the fuel

i04538552
• Quality of the filtration of the fuel
Overhaul (Top End) The wear of the unit injectors can result in elevated
SMCS Code: 7595-020-TE levels of exhaust emissions and/or poor engine
performance. The misfire of a single cylinder is not
Refer to this Operation and Maintenance Manual, typically attributed to normal wear. This condition can
“Maintenance Recommendations” in order to be repaired by replacing the faulty unit injector.
determine the maintenance interval for a top end
overhaul. The following lists of circumstances indicate that the
A top end overhaul involves the removal, the unit injectors should be inspected more frequently:
inspection, and the rework of the cylinder head
• Use of fuels that are not recommended in this
components. Some additional components are
replaced and serviced. Operation and Maintenance Manual, “Fluid
Recommendations”
Your Cat dealer can provide these services and
components. Your Cat dealer can ensure that the • Extreme ambient temperatures that reduce the
components are operating within the appropriate ability of the fuel to provide lubrication
specifications.
• Frequent plugging of the fuel filters
Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature • Insufficient maintenance of the fuel tank or the fuel
that is provided by the OEM of the driven equipment. storage tank that can allow excessive water,
sediment, and other foreign matter.
First Top End Overhaul • Insufficient maintenance of the fuel filters
If you elect to perform an overhaul without the Oil Suction Screen
services of a Cat dealer, be aware of the following
recommendations. Clean the oil suction screen after the oil has been
drained.

Note: Approximately 1 L (1 qt) of oil will remain in

the oil housing after the sump has been drained. This
oil will pour out of the oil housing when the cover is
removed. Prepare to catch the oil in a pan. Clean up
any spilled oil with absorbent towels or pillows. DO
NOT use absorbent particles to clean up the oil.
120 SEBU7844-25
Maintenance Section
Overhaul (Top End)

1. Remove the cover. • Inlet manifold gaskets

2. Remove the screen assembly according to the • Inlet manifold seals
instructions in the Service Manual, “Disassembly
and Assembly” module. Discard the used O-ring • Oil pump
seals.
• Prelube pump
3. Inspect the screen assembly. Obtain a new screen
assembly, if necessary. • Pushrods

4. Wash the screen assembly in clean nonflammable • Rocker arms

solvent. Allow the screen assembly to dry before
• Spacer plate
installation.
5. Install the screen assembly and install new O-ring • Software update
seals according to the instructions in the Service • Turbocharger
Manual, “Disassembly and Assembly” module.
6. Install the cover. Inspection of Components
7. Remove side covers in order to gain access to the Inspect the following components according to the
sump. Clean the bottom of the sump with instructions that are in Caterpillar reusability
absorbent towels or pillows. When the bottom of publications. Refer to Guidelines for Reusable Parts
the sump is clean, install the side covers. and Salvage Operations, SEBF8029, “Index of
Publications on Reusability or Salvage of Used
Parts”.
Replacement of Components
• Aftercooler core
Replace the following components during the top end
overhaul: • Camshaft
• Electronic unit injectors • Driven equipment (alignment)

Inspection, Reconditioning, or • Engine control module

Exchanging of Components • Exhaust bellow shields
Inspect the following components according to the • Oil suction screen
instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Parts
and Salvage Operations, SEBF8029, “Index of Top End Overhaul (Second)
Publications on Reusability or Salvage of Used
Parts”. If you elect to perform an overhaul without the
services of a Cat dealer, be aware of the following
Recondition the worn components or exchange the recommendations.
components, if necessary. Your Cat dealer can
provide these services and components. Cylinder Head Assembly
• Camshaft followers Inspect the cylinder head assembly according to the
• Cylinder head assembly instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Parts
• Scavenge oil pump and Salvage Operations, SEBF8029, “Index of
Publications on Reusability or Salvage of Used
• Engine wiring harness Parts”.
Your Cat dealer can provide these services and
• Exhaust manifold seals components. Your Cat dealer can ensure that the
components are operating within the appropriate
• Exhaust manifold bellows
specifications.
• Fuel pressure regulating valve The use of out-of-spec parts will cause unscheduled
downtime and/or costly repairs.
• Fuel priming pump

• Fuel transfer pump

SEBU7844-25 121
Maintenance Section
Overhaul (Top End)

Unit Injectors 4. Inspect the screen assembly for good condition.

Obtain a new screen assembly, if necessary.
Replace the unit injectors. Consult your Cat dealer Install the screen assembly. Install new O-ring
about exchanging the unit injectors. Your Cat dealer seals.
can provide these services and components.
The wear of unit injectors is affected by the following Replacement of Components
considerations:
Replace the following components during the top end
• Quality of the fuel overhaul:

• Quality of the filtration of the fuel • Electronic unit injectors

The wear of the unit injectors can result in elevated Inspection, Reconditioning, or
levels of exhaust emissions and/or poor engine
performance. The misfire of a single cylinder is not Exchanging of Components
typically attributed to normal wear. This condition can
be repaired by replacing the faulty unit injector. Inspect the following components according to the
instructions that are in Caterpillar reusability
The following lists of circumstances indicate that the publications. Refer to Guidelines for Reusable Parts
unit injectors should be inspected more frequently: and Salvage Operations, SEBF8029, “Index of
Publications on Reusability or Salvage of Used
• Use of fuels that are not recommended in this Parts”.
Operation and Maintenance Manual, “Fluid
Recondition the worn components or exchange the
Recommendations”
components, if necessary. Your Cat dealer can
• Extreme ambient temperatures that reduce the provide these services and components.
ability of the fuel to provide lubrication • Camshaft followers
• Frequent plugging of the fuel filters • Connecting rods
• Insufficient maintenance of the fuel tank or the fuel • Connecting rod bearings
storage tank that can allow excessive water,
sediment, and other foreign matter. • Cylinder head assembly
• Insufficient maintenance of the fuel filters • Cylinder liners

Oil Suction Screen • Scavenge oil pump

Clean the oil suction screen after the oil has been • Engine wiring harness
drained.
• Exhaust manifold seals
Note: Approximately 1 L (1 qt) of oil will remain in
the housing after the sump has been drained. This oil • Exhaust manifold bellows
will pour out of the housing when cover (1) is
removed. Prepare to catch the oil in a pan. Clean up • Fuel pressure regulating valve
any spilled oil with absorbent towels or pillows. DO
NOT use absorbent particles to clean up the oil. • Fuel priming pump
• Fuel transfer pump
1. Remove the screen assembly according to the
instructions in the Service Manual, “Disassembly • Inlet manifold gaskets
and Assembly” module. Discard the used O-ring
seals. • Inlet manifold seals
2. Wash the screen assembly in clean nonflammable • Oil pump
solvent. Allow the screen assembly to dry before
installation. • Pistons

3. Remove side covers in order to gain access to the • Piston pins

sump. Clean the bottom of the sump with
• Prelube pump
absorbent towels or pillows. When the bottom of
the sump is clean, install the side covers. • Pushrods
• Rocker arms
122 SEBU7844-25
Maintenance Section
Overhaul Considerations

• Spacer plate • Installation

• Software update Refer to the standards for your engine or consult your
Caterpillar dealer in order to determine if your engine
• Turbocharger is operating within the defined parameters.

Inspection of Components Severe operation can accelerate component wear.

Engines that are operating under severe conditions
may need more frequent maintenance intervals for
Inspect the following components according to the the following reasons:
instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable Parts • Maximum reliability
and Salvage Operations, SEBF8029, “Index of
Publications on Reusability or Salvage of Used • Retention of full service life
Parts”.
Because of individual applications, it is not possible
• Aftercooler core to identify all of the factors which can contribute to
severe operation. Consult your Caterpillar dealer
• Camshaft about the maintenance that is needed for your
specific engine.
• Crankshaft
The following factors can contribute to severe
• Driven equipment (alignment) operation: environment, improper operating
procedures and improper maintenance practices.
• Engine control module

• Exhaust bellow shields

Environmental Factors

• Oil suction screen Extreme Ambient Temperatures

Note: Inspect only two of the components from each Extended operation in environments that are
cylinder bank. Inspecting only two components will extremely cold or hot can damage components.
provide an adequate example of the condition of the Valve components can be damaged by carbon
other components. buildup if the engine is frequently started and
stopped in very cold temperatures. Extremely hot
inlet air reduces the performance capabilities of the
i03101741 engine.

Overhaul Considerations Note: See this Operation and Maintenance Manual,

“Cold Weather Operation” topic (Operation Section),
SMCS Code: 7595-043 or see Supplement, SEBU5898, “Cold Weather
Recommendations”.
Severe Operation
Cleanliness
Severe operation is the use of an engine that
exceeds current published standards for that engine. Unless the equipment is cleaned regularly, extended
Caterpillar maintains standards for the following operation in a dirty environment and in a dusty
engine parameters: environment can damage components. Built up mud,
dirt, and dust can encase components. This can
• Horsepower make maintenance difficult. The buildup can contain
corrosive chemicals. Corrosive chemicals and salt
• Range of rpm can damage some components.

• Fuel consumption Improper Operating Procedures

• Fuel quality • Extended operation at low idle
• Altitude • Minimum cool down periods after high load factor
operation
• Maintenance intervals
• Operating the engine beyond the guidelines for
• Selection of oil the engine rating
• Selection of coolant • Operating the engine at loads that are greater than
the rated load
• Environmental qualities
SEBU7844-25 123
Maintenance Section
Overhaul Considerations

• Operating the engine at speeds that are greater Line (2) represents the maintenance and repair costs
than the rated speed for an owner that chose to operate beyond the
recommended intervals. The initial cost of the “repair-
• Use of the engine for an application that is not after-failure” philosophy is lower. Also, the first
approved overhaul was delayed. However, the peaks are
significantly higher than the peaks for the customer
Improper Maintenance Practices that used the “repair-before-failure” philosophy.
The higher peaks result from two key factors:
• Extension of maintenance intervals
• Delaying an overhaul until a breakdown increases
• Not using recommended fuel, lubricants, and
the chance of a catastrophic failure. This type of
coolant/antifreeze
failure requires more parts, labor, and cleanup.
Overhaul Information • Excessive wear means that fewer components will
be reusable. More labor may be required for
An overhaul is replacing the major worn components salvage or repair of the components.
of the engine. An overhaul interval is a maintenance
interval that is planned. The engine is rebuilt with When all of the costs are considered, “repair-before-
certain rebuilt parts or new parts that replace the failure” is the least expensive alternative for most
worn parts. components and engines.
An overhaul also includes the following maintenance: It is not practical to wait until the engine exhibits
symptoms of excessive wear or failure. It is not less
• Inspection of all the parts that are visible during costly to wait. A planned overhaul before failure may
the disassembly be the best value for the following reasons:
• Replacement of the seals and gaskets that are • Costly unplanned downtime can be avoided.
removed
• Many original parts can be reused according to the
• Cleaning of the internal passages of the engine guidelines for reusable parts.
and the engine block
• The service life of the engine can be extended
• Inspecting the alignment of the driven equipment without the risk of a major catastrophe due to
engine failure.
Most owners will save money by overhauling the
engine at the intervals that are recommended in this • Achieve the best cost/value relationship per hour
Operation and Maintenance Manual. Consider the of extended service life.
graph in Illustration 79 .
Overhaul Inspection
Refer to the Service Manual for the disassembly and
assembly procedures that are necessary in order to
perform the required maintenance on the items that
are listed. Consult your Caterpillar dealer for
assistance.
To determine the reusability publications that are
needed to inspect the engine, refer to Guidelines for
Reusable Parts and Salvage Operations, SEBF8029,
“Index of Publications on Reusability or Salvage of
Used Parts”.
The Guidelines For Reusable Parts and Salvage
Operations is part of an established Caterpillar parts
Illustration 79 g00745964 reusability program. These guidelines were
(Y) Cost developed in order to assist Caterpillar dealers and
(X) Time customers reduce costs by avoiding unnecessary
(1) Cost of maintenance and repair that is planned expenditures for new parts. If the engine parts
(2) Cost of maintenance and repair that is not planned comply with the established inspection specifications,
the parts can be reused.
In Illustration 79 , line (1) represents the maintenance
and repair costs for an owner that followed the
recommendations for inspection, maintenance, and
repair. The peaks represent overhauls.
124 SEBU7844-25
Maintenance Section
Prelube Pump - Inspect

The use of out-of-spec parts could result in • Pin holes

unscheduled downtime and/or costly repairs. The
use of out-of-spec parts can also contribute to • Proper operation
increased fuel consumption and reduction of engine
efficiency. New parts are not necessary if the old • Wear
parts can be reused, repaired, or salvaged.
Otherwise, the old parts can be replaced or Perform a pressure check on the prelube pump.
exchanged.
Inspect the hoses and the fittings for leaks.
Your Caterpillar dealer can provide the parts that are
Inspect the prelube pump for leaks. Replace all of the
needed to rebuild the engine at the least possible
cost. seals if a leak is observed.
Inspect the wiring for the following conditions:
Overhaul Programs
• Damage
An economical way to obtain most of the parts that
are needed for overhauls is to use Caterpillar • Fraying
remanufactured parts. Caterpillar remanufactured
parts are available at a fraction of the cost of new Ensure that the wiring is in good condition.
parts. These parts have been rebuilt by Caterpillar
and certified for use. The following components are Inspect the electrical connections. Ensure that the
examples of the remanufactured parts: electrical connections are secure.
Inspect the brushes. Replace the brushes, if
• Cylinder heads necessary.
• Oil Pumps If repair or replacement is necessary, see the Service
Manual or see literature that is provided by the OEM
• Turbochargers of the pump. Consult your Caterpillar dealer for
assistance.
• Water pumps
i02259851
Consult your Caterpillar dealer for details and for a
list of the remanufactured parts that are available.
Sea Water Strainer - Clean/
Your Caterpillar dealer may be offering a variety of
overhaul options. Inspect
SMCS Code: 1371-070; 1371-040
A Flat Rate Overhaul guarantees the maximum price
that you will pay for an overhaul. Flat rate prices on The sea water strainer must be clean in order to
preventive maintenance programs or major repair allow proper engine cooling. Check the sea water
options are available from many servicing dealers for strainer for plugging. Inspect the sea water strainer
all Caterpillar engines. Consult your Caterpillar more frequently if the vessel is being operated in
dealer in order to schedule a before failure overhaul. water which is shallow or dirty. Refer to the OEM
recommendations for more information about
Overhaul Recommendation inspecting and cleaning the sea water strainer.
Caterpillar recommends a scheduled overhaul in i05264216
order to minimize downtime. A scheduled overhaul
will provide the lowest cost and the greatest value.
Schedule an overhaul with your Caterpillar dealer. Starting Motor - Inspect
Overhaul programs vary between dealers. To obtain (If equipped)
specific information about the types of overhaul SMCS Code: 1451-040; 1453-040
programs and services, consult your Caterpillar
dealer.
Air Starting Motor
i01879911
If the starting motor fails, the engine may not start in
Prelube Pump - Inspect an emergency situation. A scheduled inspection of
the starting motor is recommended.
SMCS Code: 1319-040
Inspect the prelube pump for the following conditions:
• Cracks
SEBU7844-25 125
Maintenance Section
Transmission Oil Level - Check

The starting motor pinion and the flywheel ring gear Inspect the electrical system for the following
must be in good condition in order for the engine to conditions:
start properly. The engine will not start if the starting
motor pinion does not engage the flywheel ring gear. • Loose connections
The teeth of the starting motor pinion and the
flywheel ring gear can be damaged because of • Corrosion
irregular engagement.
• Wires that are worn or frayed
Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the • Cleanliness
teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth. Removal and Installation of the
Look for teeth that are broken or chipped. If damaged
teeth are found, the starting motor pinion and the Starting Motor
flywheel ring gear must be replaced.
Refer to the Service Manual, “Disassembly and
Assembly” module for information on removing the
starting motor and installing the starting motor.
Personal injury or death can result from improp- Consult your Cat dealer for assistance and/or for
erly checking for a leak. options on replacement of the starting motor.
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure, i04237689
even a pin-hole size leak, can penetrate body tis-
sue causing serious injury, and possible death. Transmission Oil Level - Check
If fluid is injected into your skin, it must be SMCS Code: 3030-535-FLV
treated immediately by a doctor familiar with this
Check the marine transmission oil level according to
type of injury.
the instructions that are provided by the OEM of the
transmission or the OEM of the vessel.
Inspect all of the components in the air circuit for the For the lubrication requirements of the transmission,
starting motor. Inspect all of the air lines and refer to the recommendations on the nameplate or
connections for leaks. the service information for the transmission.
If damaged teeth are found, the air circuit for the
starting motor must be examined in order to Marine Transmission Operation,
determine the cause of the problem.
Maintenance, Warranty, and Parts
Electric Starting Motor Support
If the starting motor fails, the engine may not start in For information on maintenance and operation of the
an emergency situation. A scheduled inspection of marine transmission, consult your Cat dealer and/or
the starting motor is recommended. the OEM dealer of the transmission.

The starting motor pinion and the flywheel ring gear

must be in good condition in order for the engine to
start properly. The engine will not start if the starting
motor pinion does not engage the flywheel ring gear.
The teeth of the starting motor pinion and the
flywheel ring gear can be damaged because of
irregular engagement.
Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth.
Look for teeth that are broken or chipped. If damaged
teeth are found, the starting motor pinion and the
flywheel ring gear must be replaced.
Problems with the electric starting motor can be
caused by the following conditions: malfunction of the
solenoid and malfunction of the electric starting
system.
126 SEBU7844-25
Maintenance Section
Turbocharger - Inspect

All support for the warranty of the transmission will be Note: Turbocharger components require clearances
the responsibility of the OEM. All parts support for the that are precise. The turbocharger cartridge must be
transmission will be the responsibility of the OEM. balanced due to high rpm. Severe service
This parts support includes both the installation of applications can accelerate the wear of the
parts and the resolution of any service problems. components. Severe service applications may
require more frequent inspections of the
i02349288 turbocharger.

Turbocharger - Inspect Removal and Installation

SMCS Code: 1052-040
For options regarding the removal, installation, repair
and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine or consult
your Caterpillar dealer for the procedure and
Avoid contact with hot surfaces. Exhaust piping specifications.
and engine components become hot during en-
gine operation and cool slowly after engine shut- Cleaning and Inspecting
down. Any contact with hot surfaces can cause
severe burns.
1. Remove the exhaust outlet piping and remove the
Periodic inspection and cleaning is recommended for air inlet piping from the turbocharger. Visually
the turbocharger compressor housing (inlet side). inspect the piping for the presence of oil.
Fouling of the compressor can contribute to loss of 2. Turn the compressor wheel and the turbine wheel
engine power, increased black smoke and overall by hand. The assembly should turn freely. Inspect
loss of engine efficiency. the compressor wheel and the turbine wheel for
If the turbocharger fails during engine operation, contact with the turbocharger housing. There
damage to the turbocharger compressor wheel and/ should not be any visible signs of contact between
or to the engine may occur. Damage to the the turbine wheel or compressor wheel and the
turbocharger compressor wheel could allow parts turbocharger housing. If there is any indication of
from the compressor wheel to enter an engine contact between the rotating turbine wheel or the
cylinder. This can cause additional damage to the turbocharger wheel and the turbocharger housing,
pistons, the valves, and the cylinder head.
the turbocharger should be reconditioned or
replaced.
NOTICE
Turbocharger bearing failures can cause large quan- 3. Check the compressor wheel for cleanliness. If
tities of oil to enter the air inlet and exhaust systems.
only the blade side of the wheel is dirty, dirt and/or
Loss of engine lubricant can result in serious engine
damage. moisture is passing through the air filtering
system. If oil is found only on the back side of the
Minor leakage of a turbocharger housing under ex- wheel, there is a possibility of a failed turbocharger
tended low idle operation should not cause problems oil seal.
as long as a turbocharger bearing failure has not
occurred. The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
When a turbocharger bearing failure is accompanied may also be the result of a restriction of the line for
by a significant engine performance loss (exhaust the inlet air (plugged air filters), which causes the
smoke or engine rpm up at no load), do not continue turbocharger to slobber.
engine operation until the turbocharger is repaired or
replaced. 4. Inspect the bore of the turbine housing for
corrosion.
An inspection of the turbocharger can minimize 5. Clean the turbocharger housing with standard
unscheduled downtime. An inspection of the shop solvents and a soft bristle brush.
turbocharger can also reduce the chance for potential
damage to other engine parts.
SEBU7844-25 127
Maintenance Section
Turbocharger - Inspect

6. Fasten the air inlet piping and the exhaust outlet

piping to the turbocharger housing.

Inspect the Exhaust Bypass

The exhaust bypass is a wear component that is
sensitive to the load cycles of the engine.
Replacement of the exhaust bypass is predicted at
the top end overhaul for a general “C” or “D” load
profile. Applications that have frequent cycling of the
engine will increase the wear rate of the valve in the
exhaust bypass. Applications that have extended
periods of operation at the opening position of the
valve will increase the wear rate of the valve. The
valve stem should be inspected periodically for wear
of the valve stem. A reduced service interval may be
required if the inspection reveals heavy wear of the
valve. This will ensure proper operation of the
exhaust bypass. Use the following steps in order to
inspect the exhaust bypass.

Illustration 80 g01174063
Pressurized System: Hot coolant can cause seri- (1) Exhaust bypass
ous burns. To open the cooling system filler cap, (2) Boost line
stop the engine and wait until the cooling system (3) Coolant line
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the 2. Disconnect the boost line (2) and the two coolant
pressure. lines (3) from the exhaust bypass (1). The coolant
lines (3) attach to both sides of the exhaust bypass
1. Drain the cooling system to a sufficient level below
(1).
the exhaust bypass in order to remove the cooling
lines that attach to the exhaust bypass. Refer to
the maintenance section of this Operation and
Maintenance Manual, “Cooling System Coolant -
Change” for instructions on draining the cooling
system.

Illustration 81 g01173813
(1) Exhaust Bypass
(4) Nut
(5) Housing

3. Remove the nuts (4) that fasten the exhaust

bypass (1) to the housing (5).
128 SEBU7844-25
Maintenance Section
Walk-Around Inspection

4. Remove the exhaust bypass (1) from the housing

NOTICE
(5). 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 flu-
id 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 clean-
ing or high pressure water.

Note: Use care when you use steam cleaning. Use

care when you use high-pressure water. Direct spray
to rotating electrics or electronic components can
cause nonfixable damage.

NOTICE
Water and/or condensation can cause damage to
electrical components. Protect all electrical compo-
nents from exposure to water.

Illustration 82 g01173915
• Ensure that the cooling lines are clamped properly
5. Inspect the valve stem (6) for heavy wear. and ensure that the cooling lines are tight. Check
for leaks. Check the condition of all pipes.
6. Replace the exhaust bypass (1) if the valve stem is
excessively worn. • Inspect the water pumps for coolant leaks.
Note: The water pump seal is lubricated by coolant in
i06584122
the cooling system. When the engine cools and the
parts contract, a small amount of leakage is normal.
Walk-Around Inspection
SMCS Code: 1000-040 Excessive coolant leakage may indicate the need to
replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/
Inspect the Engine for Leaks and or seals, refer to the Disassembly and Assembly
Manual, “Water Pump - Remove and Water Pump -
for Loose Connections Install” or consult your Cat dealer.
A walk-around inspection should only take a few
• Inspect the lubrication system for leaks at the
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided. following locations: front crankshaft seal, rear
crankshaft seal, oil pan, oil filters, valve cover,
For maximum engine service life, thoroughly inspect turbocharger, external oil lines, and connections.
the engine compartment before starting the engine.
Look for items such as leaks, loose bolts, loose • Inspect the fuel system for leaks. Look for loose
connections, and trash buildup. Make repairs, as fuel line clamps or connections.
needed.
• Inspect the piping for the air inlet system and the
• The guards must be in the proper place. Repair elbows for cracks and for loose clamps.
damaged guards or replace missing guards.
• Drain the water and the sediment from fuel tanks
• Wipe all caps and plugs before the engine is daily to ensure that only clean fuel enters the fuel
serviced to reduce the chance of system system.
contamination.
• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
SEBU7844-25 129
Maintenance Section
Water Pump - Inspect

• Inspect the ground strap for a good connection Zinc rods are installed in the sea water cooling
and for good condition. system of the engine in order to help prevent the
corrosive oxidation that is caused by sea water.
• Inspect the closed crankcase ventilation (CCV) Electrical current is conducted through the contact of
filter, if equipped. If the restriction indicator is the zinc rods with the cooling system components.
visible, service the CCV. The zinc rods oxidize rather than the cooling system
components. Rapid deterioration of zinc rods may
• Check the condition of the gauges. Replace any indicate the presence of uncontrolled electrical
gauge that is damaged. Replace any gauge that currents from improperly installed electrical
cannot be calibrated. attachments or improperly grounded electrical
attachments.
• Inspect the exhaust system for leaks. Inspect the
gaskets and the exhaust bellows joint. If a leak is The engineer for the operation must determine the
interval for inspecting the zinc rods. The interval for
found, make repairs. inspecting the zinc rods will depend on the size of the
• Ensure that sensors are not covered with zinc rods and the number of zinc rods that are
installed.
insulation. The insulation would trap heat in the Table 49
sensor body and cable. This heat may cause
sensor failure. Locations of the Zinc Rods

Location Quantity
i04342954
Elbow of the Auxiliary Water Pump 1
Water Pump - Inspect Elbow of the Aftercooler 1
SMCS Code: 1361-040
A failed water pump might cause severe engine Inspect the Zinc Rods
overheating problems. Severe overheating problems
could result in cracks in the cylinder head, a piston 1. Remove the zinc rod.
seizure, or other potential damage to the engine.
2. Inspect the zinc rod.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of Ensure that the zinc rod will remain effective until
the water pump seals. Refer to two articles in the the next scheduled inspection.
Disassembly and Assembly Manual, “Water Pump -
Disassemble and Water Pump - Assemble” for the a. If the zinc rod has deteriorated excessively,
procedure. If removal of the water pump is install a new zinc rod.
necessary, refer to two articles in the Disassembly
and Assembly Manual, “Water Pump - Remove and
Water Pump - Install”.
Inspect the water pump for wear, cracks, pin holes,
and proper operation. Refer to the Parts Manual for
the correct part numbers for your engine or consult
your Cat dealer if repair is needed or replacement is
needed.

i03028045

Zinc Rods - Inspect/Replace

SMCS Code: 1388-040; 1388-510
Corrosion in sea water circuits can result in the Illustration 83 g00481100
following issues: premature deterioration of cooling
system components, leaks and possible cooling
system contamination. The corrosion may be caused b. Tap the zinc rod lightly with a hammer. If the
by the lack of zinc rods in the sea water system. zinc rod breaks, install a new zinc rod.
130 SEBU7844-25
Maintenance Section
Zinc Rods - Inspect/Replace

3. If the zinc rod will be reused, scrape the layer of

oxidation from the zinc rod before installation. The
layer of oxidation reduces the effectiveness of the
zinc rod.

Replace the Zinc Rods

1. Use pliers to unscrew the old zinc rod from the
plug.
If not enough material remains or the zinc rod has
broken off, drill the zinc from the plug.
2. Clean the plug.

Illustration 84 g00748510
(1) Shoulder
(2) Threads
(3) External threads of the plug

Note: Do not apply adhesive or sealant to the

threads of the zinc rod (2).

3. Apply 9S-3263 Thread Lock Compound to the

shoulder (1) of a new zinc rod. Apply the
compound only to the shoulder of the zinc rod.
Install the zinc rod onto the plug.
4. Coat the external threads of the plug (3) with
5P-3413 Pipe Sealant. Install the zinc rod. See
Specifications, SENR3130, “Torque
Specifications” for the torque for the plug.