MAINTENANCE INTERVALS

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved
 SEBU7899-05
January 2012

Operation and
Maintenance
Manual
C18 Industrial Engine
JDA1-Up (Engine)
GJE1-Up (Engine)
EJG1-Up (Engine)
WJH1-Up (Engine)
WRH1-Up (Engine)

SAFETY.CAT.COM
SEBU7899-05 61
Maintenance Section
Maintenance Interval Schedule

i04760787 Daily
Maintenance Interval Schedule Coolant Level - Check .......................................... 70
Engine Air Cleaner Service Indicator - Inspect ..... 79
(Engines Which Have Deep Oil Engine Air Precleaner - Check/Clean ................... 80
Pans) Engine Oil Level - Check ...................................... 81
Fuel System Primary Filter/Water Separator -
SMCS Code: 1000; 4450; 7500 Drain ................................................................... 88
Fuel Tank Water and Sediment - Drain ................. 90
S/N: GJE1-Up Power Take-Off Clutch - Check ............................ 97
Walk-Around Inspection ........................................ 99
S/N: EJG1-Up
S/N: WJH1-Up Every Week
S/N: WRH1-Up Jacket Water Heater - Check ................................ 94

Ensure that all safety information, warnings, Every 250 Service Hours
and instructions are read and understood before
any operation or any maintenance procedures Battery Electrolyte Level - Check .......................... 66
are performed. The user is responsible for the Coolant Sample (Level 1) - Obtain ....................... 71
performance of all maintenance including the Cooling System Supplemental Coolant Additive
following procedures: all adjustments, the use of (SCA) - Test/Add ................................................. 73
proper lubricants, fluids, filters, and the installation Engine Crankcase Breather - Clean ..................... 80
of new components due to normal wear and aging . Fuel System Primary Filter (Water Separator)
The performance of this product may be diminished if Element - Replace .............................................. 88
proper maintenance intervals and procedures are not Fuel System Secondary Filter - Replace .............. 90
followed. Components may experience accelerated Grounding Stud - Inspect/Clean/Tighten ............... 91
wear if proper maintenance intervals and procedures Hoses and Clamps - Inspect/Replace .................. 92
are not followed. Radiator - Clean .................................................... 97

Note: Use whichever of the following that occurs Initial 500 Service Hours (or at first oil
first in order to determine the maintenance intervals: change)
fuel consumption, service hours, and calendar time
Engine Valve Lash - Check ................................... 85
. Before each consecutive interval is performed, all
maintenance from the previous intervals must be Engine Valve Rotators - Inspect ........................... 85
performed.
Initial 500 Hours (for New Systems, Refilled
Refer to this Operation and Maintenance Manual, Systems, and Converted Systems)
“Refill Capacities” in order to determine the type of
Coolant Sample (Level 2) - Obtain ....................... 72
oil pan with which your Cat C18 Industrial Engine is
equipped.
Every 500 Service Hours
Products that operate in severe operating conditions Belts - Inspect/Adjust/Replace .............................. 67
may require more frequent maintenance. Refer to Engine Oil Sample - Obtain .................................. 82
this Operation and Maintenance Manual, “Severe Engine Oil and Filter - Change ............................. 82
Service Application” to determine if the engine is Starting Motor - Inspect ........................................ 98
operating in a severe service application. Turbocharger - Inspect .......................................... 98
Water Pump - Inspect ......................................... 100
When Required
Battery - Replace .................................................. 65 Every 2000 Service Hours or 1 Year
Battery or Battery Cable - Disconnect .................. 66 Alternator - Inspect ............................................... 65
Coolant - Change .................................................. 68
Coolant Extender (ELC) - Add .............................. 70 Every Year
Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace ........................................ 76 Coolant Sample (Level 2) - Obtain ....................... 72
Engine Oil and Filter - Change ............................. 82
Engine Storage Procedure - Check ...................... 85 Every 3000 Service Hours or 3 Years
Fuel System - Prime ............................................. 86
Aftercooler Core - Clean/Test ............................... 65
Coolant Temperature Regulator - Replace ........... 72
Crankshaft Vibration Damper - Inspect ................. 74
62 SEBU7899-05
Maintenance Section
Maintenance Interval Schedule

Driven Equipment - Check .................................... 75

Electronic Unit Injector - Check/Replace .............. 75
Engine - Clean ...................................................... 76
Engine Mounts - Inspect ....................................... 81
Engine Protective Devices - Check ...................... 84
Engine Valve Lash - Check ................................... 85
Engine Valve Rotators - Inspect ........................... 85
Fan Drive Bearing - Lubricate ............................... 86
Speed Sensor - Clean/Inspect .............................. 98

Every 760,000 L (200,770 US gal) of Fuel

Fan Drive Bearing - Replace ................................ 86
Overhaul Considerations ...................................... 94
SEBU7899-05 63
Maintenance Section
Maintenance Interval Schedule

i04760784 Power Take-Off Clutch - Check ............................ 97

Walk-Around Inspection ........................................ 99
Maintenance Interval Schedule
(Engines Which Have Shallow Every Week
Oil Pans) Jacket Water Heater - Check ................................ 94

SMCS Code: 1000; 4450; 7500 Initial 250 Service Hours (or at first oil
change)
Ensure that all safety information, warnings,
and instructions are read and understood before Engine Valve Lash - Check ................................... 85
any operation or any maintenance procedures Engine Valve Rotators - Inspect ........................... 85
are performed. The user is responsible for the
performance of all maintenance including the Every 250 Service Hours
following procedures: all adjustments, the use of
proper lubricants, fluids, filters, and the installation Battery Electrolyte Level - Check .......................... 66
of new components due to normal wear and aging . Coolant Sample (Level 1) - Obtain ....................... 71
The performance of this product may be diminished if Cooling System Supplemental Coolant Additive
proper maintenance intervals and procedures are not (SCA) - Test/Add ................................................. 73
followed. Components may experience accelerated Engine Crankcase Breather - Clean ..................... 80
wear if proper maintenance intervals and procedures Engine Oil Sample - Obtain .................................. 82
are not followed. Engine Oil and Filter - Change ............................. 82
Fuel System Primary Filter (Water Separator)
Note: Use whichever of the following that occurs Element - Replace .............................................. 88
first in order to determine the maintenance intervals: Fuel System Secondary Filter - Replace .............. 90
fuel consumption, service hours, and calendar time Grounding Stud - Inspect/Clean/Tighten ............... 91
. Before each consecutive interval is performed, all Hoses and Clamps - Inspect/Replace .................. 92
maintenance from the previous intervals must be Radiator - Clean .................................................... 97
performed.
Initial 500 Hours (for New Systems, Refilled
Refer to this Operation and Maintenance Manual, Systems, and Converted Systems)
“Refill Capacities” in order to determine the type of
oil pan with which your Cat C18 Industrial Engine is Coolant Sample (Level 2) - Obtain ....................... 72
equipped.
Every 500 Service Hours
Products that operate in severe operating conditions
Belts - Inspect/Adjust/Replace .............................. 67
may require more frequent maintenance. Refer to
Starting Motor - Inspect ........................................ 98
this Operation and Maintenance Manual, “Severe Turbocharger - Inspect .......................................... 98
Service Application” to determine if the engine is
Water Pump - Inspect ......................................... 100
operating in a severe service application.
Every 2000 Service Hours or 1 Year
When Required
Alternator - Inspect ............................................... 65
Battery - Replace .................................................. 65
Battery or Battery Cable - Disconnect .................. 66
Coolant - Change .................................................. 68 Every Year
Coolant Extender (ELC) - Add .............................. 70 Coolant Sample (Level 2) - Obtain ....................... 72
Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace ........................................ 76 Every 3000 Service Hours or 3 Years
Engine Oil and Filter - Change ............................. 82
Engine Storage Procedure - Check ...................... 85 Aftercooler Core - Clean/Test ............................... 65
Fuel System - Prime ............................................. 86 Coolant Temperature Regulator - Replace ........... 72
Crankshaft Vibration Damper - Inspect ................. 74
Daily Driven Equipment - Check .................................... 75
Electronic Unit Injector - Check/Replace .............. 75
Coolant Level - Check .......................................... 70 Engine - Clean ...................................................... 76
Engine Air Cleaner Service Indicator - Inspect ..... 79 Engine Mounts - Inspect ....................................... 81
Engine Air Precleaner - Check/Clean ................... 80 Engine Protective Devices - Check ...................... 84
Engine Oil Level - Check ...................................... 81 Engine Valve Lash - Check ................................... 85
Fuel System Primary Filter/Water Separator - Engine Valve Rotators - Inspect ........................... 85
Drain ................................................................... 88 Fan Drive Bearing - Lubricate ............................... 86
Fuel Tank Water and Sediment - Drain ................. 90 Speed Sensor - Clean/Inspect .............................. 98
64 SEBU7899-05
Maintenance Section
Maintenance Interval Schedule

Every 760,000 L (200,770 US gal) of Fuel

Fan Drive Bearing - Replace ................................ 86
Overhaul Considerations ...................................... 94
SEBU7899-05 65
Maintenance Section
Aftercooler Core - Clean/Test

i02783957 Note: If parts of the aftercooler system are repaired

or replaced, a leak test is highly recommended.
Aftercooler Core - Clean/Test
(Air-To-Air Aftercooler (If Inspect these items for good condition: welds,
mounting brackets, air lines, connections, clamps,
Equipped)) and seals. Make repairs, if necessary.

SMCS Code: 1064-070; 1064-081 For more detailed information on cleaning and
inspection, see Special Publication, SEBD0518,
Note: Adjust the frequency of cleaning according to “Know Your Cooling System”.
the effects of the operating environment.

Inspect the aftercooler for these items: damaged fins, i02676048

corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the aftercooler, if necessary. Alternator - Inspect
For air-to-air aftercoolers, use the same methods that SMCS Code: 1405-040
are used for cleaning radiators.
Caterpillar recommends a scheduled inspection
of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
Personal injury can result from air pressure. order to ensure proper battery performance and/or
proper performance of the electrical system. Make
Personal injury can result without following prop- repairs, as required.
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing. Check the alternator and the battery charger for
proper operation. If the batteries are properly
Maximum air pressure at the nozzle must be less charged, the ammeter reading should be very near
than 205 kPa (30 psi) for cleaning purposes. zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
Pressurized air is the preferred method for removing the battery will not crank the engine. The battery will
loose debris. Direct the air in the opposite direction not crank the engine, even if the engine is warm.
of the fan's air flow. Hold the nozzle approximately When the engine is not run for long periods of time
6 mm (0.25 inch) away from the fins. The maximum or if the engine is run for short periods, the batteries
air pressure for cleaning purposes must be below may not fully charge. A battery with a low charge will
205 kPa (30 psi) when the air nozzle is deadheaded. freeze more easily than a battery with a full charge.
Slowly move the air nozzle in a direction that is
parallel with the tubes. This will remove debris that is
between the tubes. i01878164

Pressurized water may also be used for cleaning. Battery - Replace

The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized SMCS Code: 1401-510
water in order to soften mud. Clean the core from
both sides.

Use a degreaser and steam for removal of oil and Batteries give off combustible gases which can
grease. Clean both sides of the core. Wash the core explode. A spark can cause the combustible gas-
with detergent and hot water. Thoroughly rinse the es to ignite. This can result in severe personal in-
core with clean water. jury or death.
After cleaning, start the engine and accelerate the Ensure proper ventilation for batteries that are in
engine to high idle rpm. This will help in the removal an enclosure. Follow the proper procedures in or-
of debris and drying of the core. Stop the engine. der to help prevent electrical arcs and/or sparks
Use a light bulb behind the core in order to inspect near batteries. Do not smoke when batteries are
the core for cleanliness. Repeat the cleaning, if serviced.
necessary.

Inspect the fins for damage. Bent fins may be opened

with a “comb”.
66 SEBU7899-05
Maintenance Section
Battery Electrolyte Level - Check

The battery cables or the batteries should not be All lead-acid batteries contain sulfuric acid which
removed with the battery cover in place. The bat- can burn the skin and clothing. Always wear a face
tery cover should be removed before any servic- shield and protective clothing when working on or
ing is attempted. near batteries.

Removing the battery cables or the batteries with

1. Remove the filler caps. Maintain the electrolyte
the cover in place may cause a battery explosion
resulting in personal injury. level to the “FULL” mark on the battery.

If the addition of water is necessary, use distilled

1. Switch the engine to the OFF position. Remove water. If distilled water is not available use clean
all electrical loads. water that is low in minerals. Do not use artificially
softened water.
2. Turn off any battery chargers. Disconnect any
battery chargers. 2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the NEGATIVE “-” terminal 3. Keep the batteries clean.
on the starter motor. Disconnect the cable from
the NEGATIVE “-” battery terminal. Clean the battery case with one of the following
cleaning solutions:
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the POSITIVE “+” terminal • A mixture of 0.1 kg (0.2 lb) of baking soda and
on the starting motor. Disconnect the cable from 1 L (1 qt) of clean water
the POSITIVE “+” battery terminal.
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
Note: Always recycle a battery. Never discard a (1 qt) of clean water
battery. Return used batteries to an appropriate
recycling facility. Thoroughly rinse the battery case with clean water.

5. Remove the used battery. Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
6. Install the new battery. until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
Note: Before the cables are connected, ensure that of material can cause the clamps to not fit properly.
the engine start switch is OFF. Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
i01492654

8. Connect the cable from the NEGATIVE “-” terminal

on the starter motor to the NEGATIVE “-” battery
Battery or Battery Cable -
terminal. Disconnect
SMCS Code: 1401; 1402-029
i02601752

Battery Electrolyte Level -

Check The battery cables or the batteries should not be
SMCS Code: 1401-535-FLV removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
When the engine is not run for long periods of time or ing is attempted.
when the engine is run for short periods, the batteries
Removing the battery cables or the batteries with
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. the cover in place may cause a battery explosion
resulting in personal injury.
SEBU7899-05 67
Maintenance Section
Belts - Inspect/Adjust/Replace

1. Turn the start switch to the OFF position. Turn the Alternator Belt Adjustment
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.

2. Disconnect the negative battery terminal at the

battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
two batteries must be disconnected.

3. Tape the leads in order to help prevent accidental

starting.

4. Proceed with necessary system repairs. Reverse

the steps in order to reconnect all of the cables.
g00788814
Illustration 34
i02042962

Belts - Inspect/Adjust/Replace 1. Remove the belt guard.

SMCS Code: 1357-025; 1357-040; 1357-510 2. Loosen mounting bolts (1) and adjusting bolt (2).

3. Move the assembly in order to increase or

Inspection decrease the belt tension.

Inspect the alternator belt and the fan drive belts for 4. Tighten adjusting bolt (2). Tighten mounting bolts
wear and for cracking. Replace the belts if the belts (1).
are not in good condition.
5. Reinstall the belt guard.
Check the belt tension according to the information in
the Service Manual, “Specifications”. If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation
Slippage of loose belts can reduce the efficiency at the rated rpm.
of the driven components. Vibration of loose belts
can cause unnecessary wear on the following
components: Adjustment of the Fan Drive Belt
1. Remove the belt guard.
• Belts
2. Loosen the mounting bolt for the pulley.
• Pulleys
3. Loosen the adjusting nut for the pulley.
• Bearings
If the belts are too tight, unnecessary stress is placed 4. Move the pulley in order to adjust the belt tension.
on the components. This reduces the service life of
the components. 5. Tighten the adjusting nut.

6. Tighten the mounting bolt.

Replacement
7. Reinstall the belt guard.
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing If new drive belts are installed, check the drive belt
one drive belt of a matched set will cause the new tension again after 30 minutes of engine operation
drive belt to carry more load because the older drive at the rated rpm.
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.
68 SEBU7899-05
Maintenance Section
Coolant - Change

i04538352 3. Open the cooling system drain valve (if equipped).

If the cooling system is not equipped with a drain
Coolant - Change valve, remove one of the drain plugs.
SMCS Code: 1350-044; 1352; 1395-044; 1395 Note: If equipped, be sure to drain the heater and
any related supply and return lines.
Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for the correct intervals Allow the coolant to drain.
for changing the coolant.
NOTICE
Clean the cooling system and flush the cooling
Dispose of used engine coolant properly or recycle.
system before the recommended maintenance
Various methods have been proposed to reclaim used
interval if the following conditions exist:
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
• The engine overheats frequently. Caterpillar to reclaim the used coolant.
• Foaming is observed.
For information regarding the disposal and the
• The oil has entered the cooling system and the recycling of used coolant, consult your Cat dealer or
coolant is contaminated. consult Cat Dealer Service Tool Group:

• The fuel has entered the cooling system and the Inside USA: 1-800-542-TOOL
coolant is contaminated. Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Drain the Cooling System International: 1-309-578-7372

Flush

Pressurized System: Hot coolant can cause seri- Systems Filled with Cat ELC, Cat ELI, or a
ous burns. To open the cooling system filler cap, Conventional Coolant that Meets the Cat
stop the engine and wait until the cooling system EC-1 Requirements and the Standards
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
of ASTM D6210
sure.
1. Flush the cooling system with clean water in order
to remove any debris.
NOTICE
Care must be taken to ensure that fluids are contained 2. Close the drain valve (if equipped). Clean the
during performance of inspection, maintenance, test- drain plugs. Install the drain plugs. Refer to
ing, adjusting, and repair of the product. Be prepared the Specifications Manual, SENR3130, “Torque
to collect the fluid with suitable containers before Specifications” for more information on the proper
opening any compartment or disassembling any com- torques.
ponent 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 fluids
on Cat products. 3. Fill the cooling system with clean water. Install the
cooling system filler cap.
Dispose of all fluids according to local regulations and
mandates. 4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the
cooling system is drained.

2. Loosen the cooling system filler cap slowly in

order to relieve any pressure. Remove the cooling
system filler cap.
SEBU7899-05 69
Maintenance Section
Coolant - Change

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

Loosen the cooling system filler cap slowly NOTICE
in order to relieve any pressure. Remove the Improper or incomplete rinsing of the cooling system
cooling system filler cap. Open the drain valve can result in damage to copper and other metal com-
(if equipped) or remove the cooling system drain ponents.
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve To avoid damage to the cooling system, make sure
(if equipped). Clean the drain plugs. Install the to completely flush the cooling system with clear wa-
drain plugs. Refer to the Specifications Manual, ter. Continue to flush the system until all signs of the
SENR3130, “Torque Specifications” for more cleaning agent are gone.
information on the proper torques.
9. Stop the engine and allow the engine to cool.
Systems Filled with Cat DEAC, Loosen the cooling system filler cap slowly
Conventional Coolant which does not in order to relieve any pressure. Remove the
Meet the Cat EC-1 Requirements, or cooling system filler cap. Open the drain valve
Supplemental Coolant Additive (SCA) (if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
and Water system with clean water. If equipped, be sure to
flush the heater and any related supply and return
3. Flush the cooling system with clean water in order lines. Close the drain valve (if equipped). Clean
to remove any debris. the drain plugs. Install the drain plugs. Refer to
the Specifications Manual, SENR3130, “Torque
4. Close the drain valve (if equipped). Clean the Specifications” for more information on the proper
drain plugs. Install the drain plugs. Refer to torques.
the Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques. Fill the Cooling System

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

5. Fill the cooling system with a mixture of clean 1. Fill the cooling system. Refer to this Operation and
water and Cat Fast Acting Cooling System Maintenance Manual, “Fluid Recommendations”
Cleaner. for more information on cooling system
specifications Refer to this Operation and
6. Choose 1 of the following options. Maintenance Manual, “Refill Capacities” for
information about the capacity of the cooling
• Add 0.5 L (1 pint) of cleaner per 15 L (4 US gal) system. Do not install the cooling system filler cap.
of the cooling system capacity.
2. Start and run the engine at low idle. Increase the
• For cooling systems with heavy deposits or engine rpm to high idle. Run the engine at high
plugging, add 0.5 L (1 pint) of cleaner per idle for 1 minute in order to purge the air from the
3.8 to 7.6 L (1 to 2 US gal) of the cooling system cavities of the engine block. Stop the engine.
capacity.
3. Check the coolant level. Maintain the coolant level
7. Install the cooling system filler cap. within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
8. Start and run the engine at low idle for a minimum 13 mm (0.5 inch) to the proper level on the sight
of 30 minutes. For cooling systems with heavy glass (if equipped).
deposits or plugging, run the engine for 90
minutes. The coolant temperature should be at
least 82 °C (180 °F).
70 SEBU7899-05
Maintenance Section
Coolant Extender (ELC) - Add

4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. NOTICE
Only install the used filler cap if the gasket is not Care must be taken to ensure that fluids are contained
damaged. Use a 9S-8140 Pressurizing Pump to during performance of inspection, maintenance, test-
pressure test a reinstalled cooling system filler ing, adjusting, and repair of the product. Be prepared
cap. The correct pressure for the cooling system to collect the fluid with suitable containers before
filler cap is stamped on the face of the cooling opening any compartment or disassembling any com-
system filler cap. If the cooling system filler cap ponent containing fluids.
does not retain the correct pressure, install a new
cooling system filler cap. Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
5. Start the engine. Inspect the cooling system for PECJ0003, “Cat Shop Supplies and Tools Catalog” for
leaks and for proper operating temperature. tools and supplies suitable to collect and contain fluids
on Cat products.
i04445671
Dispose of all fluids according to local regulations and
Coolant Extender (ELC) - Add mandates.

SMCS Code: 1352-544-NL 1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling
Note: Refer to this Operation and Maintenance system filler cap.
Manual, “Fluid Recommendations” (Cooling System)
for the maintenance interval for the addition of the 2. If necessary, drain enough coolant from the
coolant extender. cooling system in order to add the Cat ELC
Extender.
Cat ELC (Extended Life Coolant) and Cat ELI
(Extended Life Inhibitor) do not require the frequent 3. Add Cat ELC Extender according to the
additions of any supplemental cooling additives. The requirements for the cooling system capacity.
Cat ELC Extender will only be added one time. Refer to this Operation and Maintenance Manual,
“Refill Capacities” for the coolant capacity.
Note: Do not use conventional supplemental coolant
additive (SCA) with Cat ELC or with Cat ELI. 4. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace
Check the cooling system only when the engine is the cooling system filler cap if the gaskets are
stopped and cool. damaged. Install the cooling system filler cap.

For further information, refer to this Operation and

Maintenance Interval, , “Fluid Recommendations”.
Personal injury can result from hot coolant, steam
and alkali. i04156593

At operating temperature, engine coolant is hot Coolant Level - Check

and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or SMCS Code: 1395-082
steam. Any contact can cause severe burns.
Check the coolant level when the engine is stopped
Remove cooling system pressure cap slowly to and cool.
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.

Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
burns.

Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.
SEBU7899-05 71
Maintenance Section
Coolant Sample (Level 1) - Obtain

i04333559

Coolant Sample (Level 1) -

Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Testing the engine coolant is important to ensure

that the engine is protected from internal cavitation
and corrosion. The analysis also tests the ability of
the coolant to protect the engine from boiling and
freezing. S·O·S Systems Coolant Analysis can be
done at your Cat dealer. Cat S·O·S coolant analysis is
the best way to monitor the condition of your coolant
Illustration 35
g00285520 and your cooling system. S·O·S coolant analysis is a
program that is based on periodic samples.
Cooling system filler cap
Note: Obtaining a Coolant Sample (Level 1) is
optional if the cooling system is filled with one of
the following coolants: Cat ELC (Extended Life
Pressurized System: Hot coolant can cause seri- Coolant)., Cat ELI (Extended Life Inhibitor), and
ous burns. To open the cooling system filler cap, Conventional Heavy-Duty Coolant.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system Note: Obtain a Coolant Sample (Level 1) if the
pressure cap slowly in order to relieve the pres- cooling system is filled with any of the following
sure. coolants: Cat DEAC, Cat SCA, and Conventional
Heavy-Duty Coolants.
1. Remove the cooling system filler cap slowly in For additional information about coolant analysis
order to relieve pressure. and about other coolants, see this Operation and
Maintenance Manual, “Fluid Recommendations” or
2. Maintain the coolant level within 13 mm (0.5 inch) consult your Cat dealer.
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass. 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 36
g00103639 • Keep the unused sampling bottles stored in plastic
Typical filler cap gaskets bags.

3. Clean the cooling system filler cap and check the • Obtain coolant samples directly from the coolant
condition of the filler cap gaskets. Replace the sample port. You should not obtain the samples
cooling system filler cap if the filler cap gaskets are from any other location.
damaged. Reinstall the cooling system filler cap.
• Keep the lids on empty sampling bottles until you
4. Inspect the cooling system for leaks. are ready to collect the sample.
72 SEBU7899-05
Maintenance Section
Coolant Sample (Level 2) - Obtain

• Place the sample in the mailing tube immediately i04638756

after obtaining the sample in order to avoid
contamination. Coolant Sample (Level 2) -
Obtain
• Never collect samples from expansion bottles.
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
• Never collect samples from the drain for a system.
An S·O·S Coolant Analysis (Level 2) is a
Timing of the Sampling comprehensive chemical evaluation of the coolant.
This analysis is also a check of the overall condition
Table 19 of the cooling system. The S·O·S Coolant Analysis
Recommended Interval (Level 2) has the following features:

Type of Coolant Level 1 Level 2 • Full coolant analysis (Level 1)

Cat DEAC
Cat SCA • Identification of metal corrosion and contaminants
Conventional Every 250 hours Yearly(1)
Heavy-Duty • Identification of buildup of the impurities that cause
Coolants corrosion and scaling
Cat ELC
Cat ELI • Determination of the possibility of electrolysis
Commercial
Optional(1) Yearly(1) within the cooling system of the engine
EC-1 Coolants
The results are reported and appropriate
(1) The Level 2 Coolant Analysis should be performed sooner if a recommendations are made.
problem is suspected or identified.

Note: Check the SCA (Supplemental Coolant Obtaining the Sample

Additive) of the conventional coolant at every oil
change or at every 250 hours. Perform this check at Refer to Operation and Maintenance Manual,
the interval that occurs first. “Coolant Sample (Level 1) - Obtain” for the guidelines
for proper sampling of the coolant.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order to Submit the sample for Level 2 analysis.
receive the full effect of S·O·S analysis, establish
a consistent trend of data. In order to establish For further information, refer to this Operation and
a pertinent history of data, perform consistent Maintenance Manual, “Fluid Recommendations”.
samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your Cat
i04240223
dealer.
Coolant Temperature
NOTICE
Always use a designated pump for oil sampling, and Regulator - Replace
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may SMCS Code: 1355-510
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor- Replace the water temperature regulator before the
rect interpretation that could lead to concerns by both water temperature regulator fails. Replacing the
dealers and customers. water temperature regulator reduces the chances for
unscheduled downtime.
Submit the sample for Level 1 analysis. A water temperature regulator that fails in a
partially opened position can cause overheating or
Note: Level 1 results may indicate a need for Level overcooling of the engine.
2 Analysis.
SEBU7899-05 73
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

A water temperature regulator that fails in the open i04269112

position will cause the engine operating temperature
to be too low during partial load operation. Low Cooling System Supplemental
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
Coolant Additive (SCA) -
cylinders. This excessive carbon buildup could result Test/Add
in an accelerated wear of the piston rings and wear
of the cylinder liner.
(Systems Which are Filled with
Conventional Coolant)
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive SMCS Code: 1352-045; 1395-081
overheating could result in cracking of the cylinder
head or piston seizure problems. This maintenance procedure is required for
conventional coolants such as DEAC.Do not
perform this maintenance for cooling systems
NOTICE
that are filled with Cat Extended Life Coolant (Cat
Failure to replace your water temperature regulator
ELC) or Cat Extended Life Inhibitor (Cat ELI).
on a regularly scheduled basis could cause severe
engine damage.

Caterpillar engines incorporate a shunt design cooling

system and require operating the engine with a water Cooling system coolant additive contains alkali.
temperature regulator installed. To help prevent personal injury, avoid contact with
the skin and eyes. Do not drink cooling system
If the water temperature regulator is installed incor- coolant additive.
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that NOTICE
the water temperature regulator vent hole is open. Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
Do not use liquid gasket material on the gasket or faces of the cooling system, reducing the engine's
cylinder head surface. heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
NOTICE
Care must be taken to ensure that fluids are contained Excessive supplemental coolant additive concentra-
during performance of inspection, maintenance, test- tion could also result in blockage of the heat exchang-
ing, adjusting, and repair of the product. Be prepared er, overheating, and/or accelerated wear of the water
to collect the fluid with suitable containers before pump seal.
opening any compartment or disassembling any com-
ponent containing fluids. Do not exceed the recommended amount of supple-
mental coolant additive concentration.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” for NOTICE
tools and supplies suitable to collect and contain fluids Do NOT mix brands or types of SCA. Do NOT mix
on Cat products. SCAs and extenders.

Dispose of all fluids according to local regulations and Failure to follow the recommendations can result in
mandates. shortened cooling system component life.

Note: If replacing only the water temperature

regulator, only drain the coolant to a level that is
below the water temperature regulator housing.

Refer to two articles in the Disassembly and

Assembly Manual, “Water Temperature Regulator -
Remove and Water Temperature Regulator - Install”
for the replacement procedure or consult your Cat
dealer.
74 SEBU7899-05
Maintenance Section
Crankshaft Vibration Damper - Inspect

5. Clean the cooling system filler cap. Install the

NOTICE cooling system filler cap.
Use Only Approved SCAs. Conventional coolants
require the maintenance addition of SCA throughout For further information, refer to Special Publication,
their expected life. Do NOT use an SCA with a coolant SEBU6251, “Cat Commercial Diesel Engine Fluids
unless specifically approved by the coolant supplier Recommendations”.
for use with their coolant. It is the responsibility of the
coolant manufacturer to ensure compatibility and ac-
i02933380
ceptable performance.
Crankshaft Vibration Damper
Failure to follow the recommendations can result in
shortened cooling system component life. - Inspect
SMCS Code: 1205-040
NOTICE
Care must be taken to ensure that fluids are contained Damage to the crankshaft vibration damper or failure
during performance of inspection, maintenance, test- of the crankshaft vibration damper can increase
ing, adjusting, and repair of the product. Be prepared torsional vibrations. This can result in damage to
to collect the fluid with suitable containers before the crankshaft and to other engine components. A
opening any compartment or disassembling any com- damper that is damaged can cause excessive gear
ponent containing fluids. train noise at variable points in the speed range.

Refer to Special Publication, NENG2500, “Cat Deal- The damper is mounted to the crankshaft which is
er Service Tool Catalog” and to Special Publication, located behind the belt guard on the front of the
GECJ0003, “Cat Shop Supplies and Tools” for tools engine.
and supplies suitable to collect and contain fluids on
Cat products. Visconic Damper
Dispose of all fluids according to applicable regula- The visconic damper has a weight that is located
tions and mandates. inside a fluid filled case. The weight moves in the
case in order to limit torsional vibration.
Note: Caterpillar recommends that an S·O·S Coolant
Analysis (Level 1) be performed to check the Inspect the damper for evidence of fluid leaks. If
concentration of SCA. a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has
the following characteristics: transparent, viscous,
Maintain the Proper Concentration smooth, and adhering.
of SCA in the Coolant
If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace the crankshaft
seals.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, Inspect the damper and repair or replace the damper
stop the engine and wait until the cooling system for any of the following reasons:
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres- • The damper is dented, cracked, or leaking.
sure.
• The paint on the damper is discolored from heat.
1. Remove the cooling system filler cap slowly. • The engine has had a failure because of a broken
crankshaft.
2. Test the concentration of the SCA with a
286-2578 Nitrite Test Strip or review the results • Analysis of the oil has revealed that the front main
of the S·O·S Coolant Analysis (Level 1). bearing is badly worn.

3. If necessary, drain some coolant in order to allow • There is a large amount of gear train wear that is
space for the addition of the SCA. not caused by a lack of oil.

4. Add the amount of SCA required to maintain a

concentration of 3 percent to 6 percent SCA in
the coolant.
SEBU7899-05 75
Maintenance Section
Driven Equipment - Check

Refer to the Disassembly and Assembly Manual, i04230004

“Vibration Damper and Pulley - Remove and Install”
or consult your Caterpillar dealer for information Electronic Unit Injector -
about damper replacement. Check/Replace
i00934883
SMCS Code: 1251-510; 1251-535; 1290-510;
1290-535
Driven Equipment - Check
SMCS Code: 3279-535
Be sure the engine cannot be started while this
Check the Alignment maintenance is being performed. To prevent pos-
sible injury, do not use the starting motor to turn
To minimize bearing problems and vibration of the the flywheel.
engine crankshaft and the driven equipment, the
alignment between the engine and driven equipment Hot engine components can cause burns. Allow
must be properly maintained. additional time for the engine to cool before mea-
suring/adjusting the unit injectors.
Check the alignment according to the instructions
that are provided by the following manufacturers: The electronic unit injectors use high voltage. Dis-
connect the unit injector enable circuit connector
• Caterpillar in order to prevent personal injury. Do not come
in contact with the injector terminals while the en-
• OEM of the drive coupling gine is running.

• OEM of the driven equipment The operation of a Cat Engine with an electronic unit
injector which is improperly adjusted may reduce
Torque all of the fasteners to the proper specifications. engine efficiency. This reduced efficiency may result
in excessive fuel usage and/or shortened engine
Inspect the Drive Coupling component life.

Inspect the drive coupling according to the Note: Only qualified service personnel should
instructions that are provided by the OEM of the perform this maintenance.
coupling. For the following service information, see
the literature that is provided by the OEM of the Refer to the Systems Operation, Testing and
coupling: Adjusting, “Electronic Unit Injector - Test” for the test
procedure. Refer to Systems Operation, Testing and
• Lubrication requirements Adjusting, “Electronic Unit Injector - Adjust” for the
adjustment procedure.
• Specifications for the end play
Refer to the Disassembly and Assembly Manual for
• “Reusability Guidelines” the procedure for the removal and replacement of
the injector.
• Replacement instructions
NOTICE
Inspect the Rear Gear Train The camshafts must be correctly timed with the crank-
shaft before an adjustment of the lash for the fuel in-
Inspect the crankshaft gear. If excessive wear is jector is made. The timing pins must be removed from
found, replace the crankshaft gear and the large the camshafts before the crankshaft is turned or dam-
cluster idler. age to the cylinder block will be the result.

If any gear causes damage to other gears through

failure, replace the entire rear gear train.

For the correct parts, see the Parts Manual for the
engine. For removal and replacement instructions,
see the Service Manual, “Disassembly and
Assembly” module. Consult your Caterpillar dealer
for assistance.
76 SEBU7899-05
Maintenance Section
Engine - Clean

i01646701
NOTICE
Engine - Clean Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
SMCS Code: 1000-070

Servicing the Air Cleaner Elements

Personal injury or death can result from high volt- If the air cleaner element becomes plugged, the air
age. can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
Moisture can create paths of electrical conductiv- engine wear. Your Cat dealer has the proper air
ity. cleaner elements for your application. Consult your
Cat dealer for the correct air cleaner element.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “DO • Check the precleaner (if equipped) daily for
NOT OPERATE”. accumulation of dirt and debris. Remove any dirt
and debris, as needed.
NOTICE • Operating conditions (dust, dirt, and debris) may
Accumulated grease and oil on an engine is a fire haz- require more frequent service of the air cleaner
ard. Keep the engine clean. Remove debris and fluid element.
spills whenever a significant quantity accumulates on
the engine. • The air cleaner element may be cleaned up to
six times if the element is properly cleaned and
Periodic cleaning of the engine is recommended. inspected.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following • The air cleaner element should be replaced at least
benefits: one time per year. This replacement should be
performed regardless of the number of cleanings.
• Easy detection of fluid leaks
Replace the dirty paper air cleaner elements with
• Maximum heat transfer characteristics clean air cleaner elements. Before installation,
thoroughly check the air cleaner elements for tears
• Ease of maintenance and/or holes in the filter material. Inspect the gasket
or the seal of the air cleaner element for damage.
Note: Caution must be used in order to prevent Maintain a supply of suitable air cleaner elements
electrical components from being damaged by for replacement purposes.
excessive water when you clean the engine. Avoid
electrical components such as the alternator, the Dual Element Air Cleaners
starter, and the ECM.
The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner
i04322011
element. The primary air cleaner element can be
Engine Air Cleaner used up to six times if the element is properly cleaned
and inspected. The primary air cleaner element
Element (Dual Element) - should be replaced at least one time per year. This
Inspect/Clean/Replace replacement should be performed regardless of the
number of cleanings.
SMCS Code: 1051; 1054-040; 1054-070; 1054-510
The secondary air cleaner element is not serviceable
or washable. The secondary air cleaner element
NOTICE should be removed and discarded for every three
Never run the engine without an air cleaner element cleanings of the primary air cleaner element. When
installed. Never run the engine with a damaged air the engine is operating in environments that are
cleaner element. Do not use air cleaner elements with dusty or dirty, air cleaner elements may require more
damaged pleats, gaskets or seals. Dirt entering the frequent replacement.
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
SEBU7899-05 77
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

Cleaning the Primary Air Cleaner

Elements
NOTICE
Caterpillar recommends certified air filter cleaning ser-
vices that are available at Cat dealers. The Cat clean-
ing process uses proven procedures to assure consis-
tent quality and sufficient filter life.

Observe the following guidelines if you attempt to

clean the filter element:

Do not tap or strike the filter element in order to re-

move dust.
g00736431
Illustration 37
(1) Cover Do not wash the filter element.
(2) Primary air cleaner element
(3) Secondary air cleaner element Use low pressure compressed air in order to remove
(4) Turbocharger air inlet
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
1. Remove the cover. Remove the primary air pleats and down the pleats from the inside of the filter
cleaner element. element. Take extreme care in order to avoid damage
to the pleats.
2. The secondary air cleaner element should be
removed and discarded for every three cleanings Do not use air filters with damaged pleats, gaskets, or
of the primary air cleaner element. seals. Dirt entering the engine will cause damage to
engine components.
Note: Refer to “Cleaning the Primary Air Cleaner
Elements”.
The primary air cleaner element can be used up
3. Cover the turbocharger air inlet with tape in order to six times if the element is properly cleaned and
to keep out dirt. inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
4. Clean the inside of the air cleaner cover and body The primary air cleaner element should be replaced
with a clean, dry cloth. at least one time per year. This replacement should
be performed regardless of the number of cleanings.
5. Remove the tape for the turbocharger air inlet.
Install the secondary air cleaner element. Install a Use clean primary air cleaner elements while dirty
primary air cleaner element that is new or cleaned. elements are being cleaned.

6. Install the air cleaner cover. NOTICE

Do not clean the air cleaner elements by bumping or
7. Reset the air cleaner service indicator. tapping. This could damage the seals. Do not use el-
ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.

Visually inspect the primary air cleaner elements

before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.

There are two common methods that are used to

clean primary air cleaner elements:

• Pressurized air
• Vacuum cleaning
78 SEBU7899-05
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

Pressurized Air Inspecting the Primary Air Cleaner

Elements

Personal injury can result from air pressure.

Personal injury can result without following prop-

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

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Pressurized air can be used to clean primary air

cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
g00281693
deposits of carbon and oil. Use filtered, dry air with a Illustration 39
maximum pressure of 207 kPa (30 psi).
Inspect the clean, dry primary air cleaner element.
Use a 60W blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears
and/or holes. Inspect the primary air cleaner element
for light that may show through the filter material. If
necessary, compare the primary air cleaner element
to a new primary air cleaner element that has the
same part number.

Do not use a primary air cleaner element that has

any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
pleats, gaskets, or seals. Discard damaged primary
g00281692
Illustration 38 air cleaner elements.

Note: When the primary air cleaner elements are Storing Primary Air Cleaner Elements
cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side If a primary air cleaner element that passes inspection
(outside). will not be used, the primary air cleaner element can
be stored for future use.
To help prevent damage to the paper pleats, aim the
hose so that the air flows inside the element along
the length of the filter. Do not aim the stream of air
directly at the primary air cleaner element. Dirt could
be forced further into the pleats.

Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.

Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
g00281694
to vacuum cleaning. Vacuum cleaning will not remove Illustration 40
deposits of carbon and oil.

Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.
SEBU7899-05 79
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Do not use paint, a waterproof cover, or plastic as a Observe the service indicator. The air cleaner
protective covering for storage. An airflow restriction element should be cleaned or the air cleaner element
may result. To protect against dirt and damage, wrap should be replaced when one of the following
the primary air cleaner elements in Volatile Corrosion conditions occur:
Inhibited (VCI) paper.
• The yellow diaphragm enters the red zone.
Place the primary air cleaner element into a box
for storage. For identification, mark the outside of • The red piston locks in the visible position.
the box and mark the primary air cleaner element.
Include the following information: Test the Service Indicator
• Date of cleaning Service indicators are important instruments.
• Number of cleanings • Check for ease of resetting. The service indicator
should reset in less than three pushes.
Store the box in a dry location.
• Check the movement of the yellow core when the
i01900118 engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
Engine Air Cleaner Service greatest vacuum that is attained.
Indicator - Inspect If the service indicator does not reset easily, or if the
(If Equipped) yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
SMCS Code: 7452-040 service indicator will not reset, the hole for the service
indicator may be plugged.
Some engines may be equipped with a different
service indicator. The service indicator may need to be replaced
frequently in environments that are severely dusty, if
Some engines are equipped with a differential gauge necessary. Replace the service indicator annually
for inlet air pressure. The differential gauge for inlet regardless of the operating conditions. Replace the
air pressure displays the difference in the pressure service indicator when the engine is overhauled, and
that is measured before the air cleaner element and whenever major engine components are replaced.
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty, Note: When a new service indicator is installed,
the pressure differential rises. If your engine is excessive force may crack the top of the service
equipped with a different type of service indicator, indicator. Tighten the service indicator to a torque
follow the OEM recommendations in order to service of 2 N·m (18 lb in).
the air cleaner service indicator.

The service indicator may be mounted on the air

cleaner housing or in a remote location.

g00103777
Illustration 41
Typical service indicator
80 SEBU7899-05
Maintenance Section
Engine Air Precleaner - Check/Clean

i02927289

Engine Air Precleaner -

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

g01456410
Illustration 43
View of the left side of a C18 Industrial Engine that is equipped
with two engine crankcase breathers
(1) Hose Clamp
(2) Hose
(3) Valve Cover
g01453058
Illustration 42
Typical engine air precleaner
(1) Wing nut
(2) Cover
(3) Body

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

accumulation of dirt and debris in body (3). Clean the
body, if necessary.

After cleaning the precleaner, install cover (2) and

wing nut (1).

Note: When the engine is operated in dusty

applications, more frequent cleaning is required. Illustration 44
g01786116

View of the left side of a C18 Industrial Engine that is equipped

with one engine crankcase breather
i03435665
(1) Hose Clamp
Engine Crankcase Breather - (2) Hose
(3) Valve Cover
Clean
1. Loosen the hose clamp and remove the hose from
SMCS Code: 1317-070 the valve cover.

NOTICE 2. Remove the valve cover. Refer to Disassembly

Perform this maintenance with the engine stopped. and Assembly, “Valve Mechanism Cover -
Remove and Install”.
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.

Your engine may have one or two crankcase

breathers.
SEBU7899-05 81
Maintenance Section
Engine Mounts - Inspect

g01456434 g01414582
Illustration 45 Illustration 46
Typical installation of the oil level gauge
3. Wash the breather in solvent that is clean and (1) Oil filler cap
nonflammable. Allow the breather to dry before (2) Oil level gauge
installation.

4. Install the valve cover. Refer to Disassembly and

Assembly, “Valve Mechanism Cover - Remove
and Install”.

5. Install the hose on the valve cover. Install the hose

clamp.
g00110310
Illustration 47
i02139969 Partial view of the oil level gauge

Engine Mounts - Inspect (Y) “ADD” mark

(X) “FULL” mark

SMCS Code: 1152-040; 1152

NOTICE
Inspect the engine mounts for deterioration and for Perform this maintenance with the engine stopped.
proper bolt torque. Engine vibration can be caused
by the following conditions:
NOTICE
Engine damage can occur if the crankcase is filled
• Improper mounting of the engine above the “FULL” mark on the oil level gauge (dip-
stick).
• Deterioration of the engine mounts
An overfull crankcase can cause the crankshaft to dip
Any engine mount that shows deterioration should
into the oil. This will reduce the power that is devel-
be replaced. Refer to the Specifications Manual,
oped and also force air bubbles into the oil. These
SENR3130, “Torque Specifications”. Refer to your
bubbles (foam) can cause the following problems: re-
Caterpillar dealer for more information.
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
i04339070 crankcase breathers, and excessive oil consumption.

Engine Oil Level - Check Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
SMCS Code: 1348-535-FLV posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.

Hot oil and hot components can cause personal If the oil level is above the “FULL” mark on the oil level
injury. Do not allow hot oil or hot components to gauge, drain some of the oil immediately.
contact the skin.
82 SEBU7899-05
Maintenance Section
Engine Oil Sample - Obtain

1. Remove the oil filler cap and check the oil level. Caterpillar recommends using the sampling valve
Maintain the oil level between the “ADD” mark (Y) in order to obtain oil samples. The quality and the
and the “FULL” mark (X) on the oil level gauge (1). consistency of the samples are better when the
Do not fill the crankcase above “FULL” mark (X). sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
2. In order to choose the correct type of oil for this obtained during normal engine operation.
engine, refer to this Operation and Maintenance
Manual, “Fluid Recommendations”. The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
3. Clean the oil filler cap. Install the oil filler cap. fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
4. Record the amount of oil that is added. For the also provided.
next oil sample and analysis, include the total
amount of oil that has been added since the NOTICE
previous sample in order to provide the most Always use a designated pump for oil sampling, and
accurate oil analysis. use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
i04237495 contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
Engine Oil Sample - Obtain rect interpretation that could lead to concerns by both
dealers and customers.
SMCS Code: 1348-554-SM
If the engine is not equipped with a sampling valve,
In addition to a good preventive maintenance
use the 1U-5718 Vacuum Pump. The pump is
program, Caterpillar recommends using S·O·S oil designed to accept sampling bottles. Disposable
analysis at regularly scheduled intervals. S·O·S oil tubing must be attached to the pump for insertion
analysis provides infrared analysis, which is required
into the sump.
for determining nitration and oxidation levels.
For instructions, see Special Publication, PEGJ0047,
Obtain the Sample and the Analysis “How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to i04268709
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 following information:
Hot oil and hot components can cause personal
• Engine model injury. Do not allow hot oil or hot components to
contact the skin.
• Service hours on the engine
• The number of hours that have accumulated since Do not drain the oil when the engine is cold. As the oil
the last oil change cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed
• The amount of oil that has been added since the with the draining cold oil. Drain the crankcase with
last oil change the engine stopped. Drain the crankcase with the
oil warm. This draining method allows the waste
To ensure that the sample is representative of the oil particles that are suspended in the oil to be drained
in the crankcase, obtain a warm, mixed oil sample. properly.

To avoid contamination of the oil samples, the tools Failure to follow this recommended procedure will
and the supplies that are used for obtaining oil cause the waste particles to be recirculated through
samples must be clean. the engine lubrication system with the new oil.
SEBU7899-05 83
Maintenance Section
Engine Oil and Filter - Change

Interval for Engine Oil and Engine • If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil
Oil Filter Change to drain. If the engine is equipped with a shallow
sump, remove the bottom oil drain plugs from both
Note: The intervals stated in table 20 are only valid
ends of the oil pan.
when preferred lubricants are used. Using fluids
other than the preferred fluids causes the engine to
After the oil has drained, the oil drain plugs should
operate in a severe service application. Refer to this
be cleaned and installed.
Operation and Maintenance Manual, “Severe Service
Application” for information about the effect of using
fluids which are not preferred on the maintenance Replace the Oil Filter
intervals.
NOTICE
Refer to this Operation and Maintenance Manual,
Caterpillar oil filters are built to Caterpillar speci-
“Refill Capacities” before this procedure is started in
fications. Use of an oil filter not recommended by
order to determine the following:
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
• The type of oil pan the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
• The refill capacity for engine oil recommended by Caterpillar.
Table 20
Intervals for Changing the Engine Oil and 1. Remove the oil filter with a 1U-8760 Chain
Engine Oil Filter(1) Wrench.
Every 14200 L
2. Cut the oil filter open with a 175-7546 Oil Filter
Shallow sump (3750 US gal) or 250
service hours or 1 yr Cutter Gp. Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount
Every 28400 L of metal debris in the oil filter may indicate early
Deep sump (7500 US gal) or 500 wear or a pending failure.
service hours or 1 yr
(1) Choose the interval that occurs first. Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
Drain the Engine Oil wear on the steel and cast iron parts of the engine.

NOTICE Nonferrous metals may indicate wear on the

Care must be taken to ensure that fluids are contained aluminum parts, brass parts, or bronze parts of
during performance of inspection, maintenance, test- the engine. Parts that may be affected include
ing, adjusting, and repair of the product. Be prepared the following items: main bearings, rod bearings,
to collect the fluid with suitable containers before turbocharger bearings, and cylinder heads.
opening any compartment or disassembling any com-
ponent containing fluids. Due to normal wear and friction, it is not
uncommon to find small amounts of debris in
Refer to Special Publication, NENG2500, “Cat Dealer the oil filter. Consult your Cat dealer in order to
Service Tool Catalog” or refer to Special Publication, arrange for a further analysis if an excessive
PECJ0003, “Cat Shop Supplies and Tools Catalog” for amount of debris is found in the oil filter.
tools and supplies suitable to collect and contain fluids
on Cat products.

Dispose of all fluids according to local regulations and

mandates.

After the engine has been run at the normal operating

temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:

• If the engine is equipped with a drain valve, turn the

drain valve knob counterclockwise in order to drain
the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.
84 SEBU7899-05
Maintenance Section
Engine Protective Devices - Check

3. Start the engine and run the engine at “LOW

IDLE” for 2 minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.

4. Stop the engine and allow the oil to drain back to

the sump for a minimum of 10 minutes.

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

oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the oil level gauge.

i02861779
g00103713
Illustration 48
Typical filter mounting base and filter gasket
Engine Protective Devices -
Check
3. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket is SMCS Code: 7400-535
removed.

4. Apply clean engine oil to the new oil filter gasket.

Visual Inspection
Visually check the condition of all gauges, sensors
NOTICE and wiring. Look for wiring and components that
Do not fill the oil filters with oil before installing them. are loose, broken, or damaged. Damaged wiring
This oil would not be filtered and could be contaminat- or components should be repaired or replaced
ed. Contaminated oil can cause accelerated wear to immediately.
engine components.
Calibration Check
5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil NOTICE
filter by hand according to the instructions that are During testing, abnormal operating conditions must be
shown on the oil filter. Do not overtighten the oil simulated.
filter.
The tests must be performed correctly in order to pre-
Fill the Engine Crankcase vent possible damage to the engine.

1. Remove the oil filler cap. Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
2. Refer to the Operation and Maintenance Manual, to prevent damage to the engine. It is impossible
“Refill Capacities” for the amount of oil required to to determine if the engine protective devices are
fill the crankcase. Fill the crankcase and replace in good working order during normal operation.
the oil filler cap. Malfunctions must be simulated in order to test the
engine protective devices. To prevent damage to the
NOTICE engine, only authorized service personnel or your
If equipped with an auxiliary oil filter system or a re- Caterpillar dealer should perform the tests.
mote oil filter system, follow the OEM or filter manu-
facturer's recommendations. Under filling or overfilling Consult your Caterpillar dealer or refer to the Service
the crankcase with oil can cause engine damage. Manual for more information.

NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
SEBU7899-05 85
Maintenance Section
Engine Storage Procedure - Check

i01458399 i04242309

Engine Storage Procedure - Engine Valve Lash - Check

Check SMCS Code: 1105-535
SMCS Code: 1000-535
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
The oil change interval may be extended to 12
recommended at the first scheduled oil change. The
months for a vehicle that is operated seasonally
adjustment is necessary due to the initial wear of
and placed in storage for the remainder of the year the valve train components and to the seating of the
by using the required storage procedures and the
valve train components.
required start-up procedures. This extension is
permitted if the following categories for oil change The maintenance is recommended by Caterpillar as
intervals in the Operation and Maintenance Manual,
part of a lubrication and preventive maintenance
“Maintenance Interval Schedule” have not been
schedule to help provide maximum engine life.
reached:
Note: Only qualified service personnel should
• Mileage perform this maintenance. For procedures on
adjusting the valve lash and adjusting the valve
• Operating hours bridge, see System Systems Operation/Testing and
Adjusting, “Engine Valve Lash - Inspect/Adjust”.
• Fuel consumption Consult your Cat dealer for assistance.
If an engine is out of operation and if use of the
engine is not planned, special precautions should
be made. If the engine will be stored for more than
three months, a complete protection procedure is Ensure that the engine can not be started while
recommended. For more detailed information on this maintenance is being performed. To help pre-
engine storage, see Special Instruction, SEHS9031, vent possible injury, do not use the starting motor
“Storage Procedure For Caterpillar Products”. to turn the flywheel.

If the engine will not be started for several weeks, the Hot engine components can cause burns. Allow
lubricating oil will drain from the cylinder walls and additional time for the engine to cool before mea-
from the piston rings. Rust can form on the cylinder suring/adjusting valve lash clearance.
liner surface. Rust on the cylinder liner surface will
cause increased engine wear and a reduction in
engine service life. Caterpillar recommends the i01597115
use of volatile corrosion inhibitor (VCI) oil in order
to prevent internal engine damage due to moisture Engine Valve Rotators - Inspect
during storage. These inhibitors in the VCI oil act by
evaporating inside the engine. The inhibitors then SMCS Code: 1109-040
condense over the inside surfaces of the engine. The
evaporation process and the condensing process
offers full protection to surfaces that cannot be
reached with preservatives. 0.9 L (1.0 qt) of 4C-6792 When inspecting the valve rotators, protective
VCI oil will treat 28.4 L (30.0 qt) of engine oil. This glasses or face shield and protective clothing
will give a 3 percent concentration of VCI oil. The must be worn, to help prevent being burned by
engine must be completely sealed when the engine hot oil or spray.
is stored in order for the VCI oil to function properly.
The VCI oil is easily cleaned from the engine when
you remove the engine from storage. The volatile Engine valve rotators rotate the valves when the
vapors are removed by simply running the engine engine runs. This helps to prevent deposits from
to operating temperature. A mineral oil base is left building up on the valves and the valve seats.
behind after the volatile vapors are removed.
Perform the following steps after the engine valve
lash is set, but before the valve covers are installed:

1. Start the engine according to Operation and

Maintenance Manual, “Engine Starting” (Operation
Section) for the procedure.
86 SEBU7899-05
Maintenance Section
Fan Drive Bearing - Lubricate

2. Operate the engine at low idle. i02053753

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

1. Remove Bearings. Refer to Disassembly and

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

i02075183
If a valve fails to rotate, consult your Caterpillar
dealer. Fuel System - Prime
i02784507
SMCS Code: 1250-548; 1258-548

Fan Drive Bearing - Lubricate The Secondary Fuel Filter Has

SMCS Code: 1359-086-BD Been Replaced
Some of the fan drives have grease fittings and some
of the fan drives do not have grease fittings. If there is
no grease fitting, periodic lubrication is not required.
Fuel leaked or spilled onto hot surfaces or elec-
The fan drive requires grease only if the fan drive
trical components can cause a fire. To help pre-
is equipped with a zerk.
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
g00746166
Illustration 49
Typical location of the grease fitting (if equipped) that is for the fan
Note: Refer to Operation and Maintenance Manual,
drive bearing “Fuel System Secondary Filter - Replace” for
The pulley is shown with the belt guards that have been removed.
information on replacing the filter.

Lubricate the grease fitting that is on the fan drive 1. Turn the ignition switch to the “OFF” position.
bearing with High Speed Ball Bearing Grease or the
equivalent.

Inspect the fan drive pulley assembly for wear or for

damage. If the shaft is loose, an inspection of the
internal components should be performed. Refer to
the Systems Operation Testing and Adjusting Manual
for additional information.
SEBU7899-05 87
Maintenance Section
Fuel System - Prime

The Engine Has Been Run Out of

Fuel
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
g00975199
Illustration 50
1. Turn the ignition switch to the “OFF” position.
(1) Fuel priming pump
(2) Air purge screw
(3) Priming valve (If Equipped)
2. Fill the fuel tank(s) with clean diesel fuel.

2. Turn the priming valve (3) (If Equipped) to the

“Closed (Prime)” position in order to prime the fuel
system.

3. Open air purge screw (2) for the fuel filter by three
full turns. Do not remove the air purge screw.

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

4. Start the engine. The engine should start and the g00975199
Illustration 51
engine should run smoothly.
(1) Fuel priming pump
(2) Air purge screw
Note: You may use the fuel priming pump for the fuel (3) Priming valve (If Equipped)
filter (IF EQUIPPED) instead of starting the engine
and running the engine. 3. Turn the priming valve (3) (If Equipped) to the
“Closed (Prime)” position in order to prime the fuel
5. While the engine is running, observe air purge system.
screw (2). When a small drop of fuel appears
at the threads of the air purge screw, close and 4. Open air purge screw (2) for the fuel filter by three
tighten air purge screw (2). full turns. Do not remove the air purge screw.
Note: There may be a noticeable change in the
sound of the running engine when the air purge NOTICE
screw is tightened. The change in the sound of the Do not crank the engine continuously for more than
engine is normal. 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
Note: Failure to tighten all fittings could result in
serious fuel leaks. 5. Crank the engine for 30 seconds. Use a suitable
container to catch the fuel while you crank the
6. Clean any residual fuel from the engine engine. Allow the starter motor to cool for 2
components. minutes.
7. After the engine has operated smoothly for 30 Note: You may use the fuel priming pump (1) (IF
seconds, turn the priming valve (3) to the “Open EQUIPPED) for the fuel filter instead of cranking the
(Run)” position. engine.
Note: Shortened injector life may occur if the priming 6. Crank the engine for 30 seconds. Allow the starter
valve (3) is left in the “Closed (Prime)” position. motor to cool for 2 minutes.
88 SEBU7899-05
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

7. Repeat Step 6 until the engine starts and the

engine runs.

Note: Failure to tighten all fittings could result in

serious fuel leaks.

8. After the engine has operated smoothly for 30

seconds, turn the priming valve (3) to the “Open
(Run)” position.

Note: Shortened injector life may occur if the priming

valve (3) is left in the “Closed (Prime)” position.

9. Clean any residual fuel from the engine

components. g01453091
Illustration 52
(1) Element
i02927285 (2) Bowl
(3) Drain
Fuel System Primary
Filter/Water Separator - Drain Bowl (2) should be monitored daily for signs of water.
If water is present, drain the water from the bowl.
SMCS Code: 1260-543; 1263-543
1. Open drain (3). The drain is a self-ventilated drain.
Catch the draining water in a suitable container.
Dispose of the water properly.

Fuel leaked or spilled onto hot surfaces or elec- 2. Close drain (3).
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
NOTICE
changing fuel filters or water separator elements.
The water separator is under suction during normal
Clean up fuel spills immediately.
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
NOTICE system.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to i02927282
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Fuel System Primary Filter
nent containing fluids. (Water Separator) Element -
Refer to Special Publication, NENG2500, “Caterpillar Replace
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar SMCS Code: 1260-510-FQ; 1263-510-FQ
products.
Water in the fuel can cause the engine to run rough.
Dispose of all fluids according to local regulations and Water in the fuel may cause an electronic unit injector
mandates. to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly The primary filter/water separator also provides
clean the area around a fuel system component that filtration in order to help extend the life of the
will be disconnected. Fit a suitable cover over discon- secondary fuel filter. The element should be changed
nected fuel system component. regularly. If a vacuum gauge is installed, the
primary filter/water separator should be changed at
50 to 70 kPa (15 to 20 inches Hg).
SEBU7899-05 89
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

Replace the Element 4. Remove the O-ring from the gland of the bowl.
Clean the following components:

• Bowl
Fuel leaked or spilled onto hot surfaces or elec- • O-ring
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when • Mounting base
changing fuel filters or water separator elements.
Clean up fuel spills immediately. Inspect the O-ring for damage and for
deterioration. Replace the O-ring, if necessary.
NOTICE
Care must be taken to ensure that fluids are contained 5. Lubricate the O-ring with clean diesel fuel.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 6. Install bowl (2) on a new element. Tighten the
collect the fluid with suitable containers before open- bowl by hand. Do not use tools in order to tighten
ing any compartment or disassembling any compo- the bowl.
nent containing fluids.
NOTICE
Refer to Special Publication, NENG2500, “Caterpillar The primary filter/water separator may be prefilled with
Dealer Service Tool Catalog” for tools and supplies fuel to avoid rough running/stalling of the engine due
suitable to collect and contain fluids on Caterpillar to air. Do not fill the secondary filter with fuel before
products. installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accel-
Dispose of all fluids according to local regulations and erated wear to fuel system parts.
mandates.
7. Lubricate the top seal of element (1) with clean
NOTICE diesel fuel. The element may be filled with fuel at
Do not allow dirt to enter the fuel system. Thoroughly this time. Install the new element on the mounting
clean the area around a fuel system component that base. Tighten the element by hand.
will be disconnected. Fit a suitable cover over discon-
nected fuel system component. NOTICE
The water separator is under suction during normal
1. Close the main fuel supply valve. engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the fu-
el system.

8. Open the main fuel supply valve.

9. Start the engine and check for leaks. Run the

engine for one minute. Stop the engine and check
for leaks again.

Detecting leaks is difficult while the engine is

running. The primary filter/water separator is
under suction. A leak will allow air to enter the fuel.
The air in the fuel can cause low power due to
aeration of the fuel. If air enters the fuel, check the
g01453091
components for overtightening or undertightening.
Illustration 53
(1) Element
(2) Bowl
(3) Drain

2. Remove element (1) from the element mounting

base while bowl (2) is attached.

3. Dispose of the contents of the filter. Remove bowl

(2) from element (1). The bowl is reusable. Do not
discard the bowl. Dispose of the used element.
90 SEBU7899-05
Maintenance Section
Fuel System Secondary Filter - Replace

i03478081
NOTICE
Fuel System Secondary Filter - Do not fill the secondary fuel filter with fuel before in-
Replace stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
SMCS Code: 1261-510-SE ated wear to fuel system parts.

NOTICE
In order to meet expected fuel system component
Fuel leaked or spilled onto hot surfaces or elec- life, 4 micron(c) absolute or less secondary fuel fil-
trical components can cause a fire. To help pre- tration is required for all Caterpillar Diesel Engines
vent possible injury, turn the start switch off when that are equipped with unit injected fuel systems. Note
changing fuel filters or water separator elements. that all current Caterpillar Diesel Engines are factory
Clean up fuel spills immediately. equipped with Caterpillar Advanced Efficiency 4 mi-
cron(c) absolute fuel filters.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly Caterpillar does not warrant the quality or perfor-
mance of non-Caterpillar fluids and filters.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components. 6. Install the new fuel filter. Spin the fuel filter onto
the fuel filter base until the gasket contacts the
base. Use the rotation index marks on the filters
NOTICE as a guide for proper tightening. Tighten the filter
Care must be taken to ensure that fluids are contained according to the instructions that are on the fuel
during performance of inspection, maintenance, test- filter. Do not overtighten the filter.
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- 7. Open the fuel supply valve. The engine will need
ing any compartment or disassembling any compo- to be purged of air. Refer to the Operation and
nent containing fluids. Maintenance Manual, “Fuel System - Prime” topic
(Maintenance Section) for more information.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and i04363480
Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products. Fuel Tank Water and Sediment
- Drain
Dispose of all fluids according to local regulations and
mandates. SMCS Code: 1273-543-M&S

1. Stop the engine. Turn the ignition switch to the NOTICE

OFF position or disconnect the battery. Refer to Care must be taken to ensure that fluids are contained
the Operation and Maintenance Manual, “Battery during performance of inspection, maintenance, test-
or Battery Cable - Disconnect” topic (Maintenance ing, adjusting, and repair of the product. Be prepared
Section) for more information. Shut off the fuel to collect the fluid with suitable containers before
supply valve (if equipped). opening any compartment or disassembling any com-
ponent containing fluids.
2. It may be necessary to relieve residual fuel
pressure from the fuel system before the fuel Refer to Special Publication, NENG2500, “Cat Dealer
filter is removed. Wait for one to five minutes until Service Tool Catalog” or refer to Special Publication,
the fuel pressure has lowered. Use a suitable PECJ0003, “Cat Shop Supplies and Tools Catalog” for
container in order to catch any fuel that may spill. tools and supplies suitable to collect and contain fluids
on Cat products.
3. Remove the used fuel filter and discard the used
fuel filter. Dispose of all fluids according to local regulations and
mandates.
4. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.

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

SEBU7899-05 91
Maintenance Section
Grounding Stud - Inspect/Clean/Tighten

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
i04176149
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel. Grounding Stud -
Drain the Water and the Sediment Inspect/Clean/Tighten
SMCS Code: 7423-040; 7423-070; 7423-079
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.

Open the drain valve on the bottom of the fuel tank The connection of battery cables to a battery and
in order to drain the water and the sediment. Close the disconnection of battery cables from a battery
the drain valve. may cause an explosion which may result in injury
or death. The connection and the disconnection
Note: Failure to properly close the drain can allow air of other electrical equipment may also cause an
into the system, which could have detrimental results explosion which may result in injury or death. The
to performance. procedures for the connection and the disconnec-
tion of battery cables and other electrical equip-
Check the fuel daily. Drain the water and sediment ment should only be performed in a nonexplosive
from the fuel tank after operating the engine or drain atmosphere.
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.

Fill the fuel tank after operating the engine in

order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.

Some fuel tanks use supply pipes that allow water

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

Fuel Storage Tanks

Drain the water and the sediment from the fuel
storage tank during the following conditions:
g00765094
Illustration 54
• Weekly Typical example
Electronics grounding stud (side view)
• Oil change
• Refill of the tank Inspect the OEM harness for good connections.
Inspect the condition of the OEM harness.
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank. A four micron(c) absolute filter for the breather
vent on the fuel tank is also recommended.
92 SEBU7899-05
Maintenance Section
Hoses and Clamps - Inspect/Replace

The electronics grounding stud must have a wire • Hoses which exhibit signs of leakage which are not
ground to the battery. Tighten the electronics the result of loose couplings or clamps
grounding stud at every oil change. Ground wires
and straps should be combined at engine grounds. Inspect all clamps for the following conditions.
All grounds should be tight and free of corrosion. Replace any clamp which exhibits signs of any of the
following conditions.
• Clean the electronics grounding stud and the
terminals for the electronics ground strap with a • Cracking
clean cloth.
• Looseness
• If the connections are corroded, clean the
connections with a solution of baking soda and • Damage
water.
Inspect all couplings for leaks. Replace any coupling
• Keep the electronics grounding stud and the strap which exhibits signs of leaks.
clean and coated with MPGM grease or petroleum
jelly. Each installation application can be different. The
differences depend on the following factors:
i04301694
• Type of hose
Hoses and Clamps -
• Type of fitting material
Inspect/Replace
• Anticipated expansion and contraction of the hose
SMCS Code: 7554-040; 7554-510
• Anticipated expansion and contraction of the
Hoses and clamps must be inspected periodically fittings
in order to ensure safe operation and continuous
operation of the engine. Take proper safety Due to extreme temperature changes, the hose will
precautions before inspecting or replacing hoses and heat set. Heat setting causes hose clamps to loosen
clamps. which can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
Note: Always use a board or cardboard when the
engine components are checked for leaks. Leaking Replace hoses that are cracked or soft. Replace
fluid that is under pressure can cause serious hoses that show signs of leakage. Replace hoses
injury or possible death. Leaks that are the size that show signs of damage. Replace hose clamps
of a pin hole are included. Refer to Operation and that are cracked or damaged. Tighten or replace
Maintenance Manual, “General Hazard Information” hose clamps which are loose.
for more information.
Replace the Hoses and the Clamps
Inspect the Hoses and the Clamps
Inspect all hoses for leaks that are caused by the NOTICE
following conditions. Replace any hose which exhibits Care must be taken to ensure that fluids are contained
any of the following conditions. Failure to replace a during performance of inspection, maintenance, test-
hose which exhibits any of the following conditions ing, adjusting, and repair of the product. Be prepared
may result in a hazardous situation. to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
• Hoses which are cracked
Refer to Special Publication, NENG2500, “Cat Dealer
• Hoses which are soft Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” for
• Outer covering that is chafed or cut tools and supplies suitable to collect and contain fluids
on Cat products.
• Exposed wire that is used for reinforcement
Dispose of all fluids according to local regulations and
• Outer covering that is ballooning locally mandates.
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
SEBU7899-05 93
Maintenance Section
Hoses and Clamps - Inspect/Replace

Cooling System Fuel System

Pressurized System: Hot coolant can cause seri- Personal injury can result from removing hoses or
ous burns. To open the cooling system filler cap, fittings in a pressure system.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system Failure to relieve pressure can cause personal in-
pressure cap slowly in order to relieve the pres- jury.
sure.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.

Personal injury can result from removing hoses or

fittings in a pressure system.
Contact with high pressure fuel may cause fluid
Failure to relieve pressure can cause personal in- penetration and burn hazards. High pressure fu-
jury. el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
Do not disconnect or remove hoses or fittings un- structions may cause personal injury or death.
til all pressure in the system has been relieved.
NOTICE
1. Stop the engine. Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
2. Allow the engine to cool. any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
3. Before servicing a coolant hose, slowly loosen the and hoses carefully. Tighten all connections to the rec-
filler cap for the cooling system in order to relieve ommended torque.
any pressure.

4. Remove the filler cap for the cooling system. NOTICE

Do not allow dirt to enter the fuel system. Thoroughly
5. Drain the coolant from the cooling system to a clean the area around a fuel system component that
level that is below the hose that is being replaced. will be disconnected. Fit a suitable cover over any dis-
Drain the coolant into a suitable clean container. connected fuel system components.
The coolant can be reused.

6. Remove the hose clamps. Note: High-pressure fuel lines may be installed
between the high-pressure fuel pump and the fuel
7. Disconnect the old hose. injectors. High-pressure fuel lines are constantly
charged with high pressure. Do not check the
8. Replace the old hose with a new hose. high-pressure fuel lines with the engine or the starting
motor in operation. Wait for 10 minutes after the
9. Install hose clamps which have been inspected or engine stops before you perform any service or repair
install new hose clamps. Refer to Specifications, on high-pressure fuel lines. Waiting for 10 minutes
SENR3130, “Torque Specifications”, “Hose will to allow the pressure to be purged.
Clamps” for information about selecting and
installing the proper hose clamps. 1. Drain the fuel from the fuel system to a level that
is below the hose that is being replaced.
10. Refill the cooling system.
2. Remove the hose clamps.
11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap 3. Disconnect the old hose.
if the gaskets are damaged. Install the filler cap.
4. Replace the old hose with a new hose.
12. Start the engine. Inspect the cooling system for
leaks.
94 SEBU7899-05
Maintenance Section
Jacket Water Heater - Check

5. Install hose clamps which have been inspected or 4. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications, install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose SENR3130, “Torque Specifications”, “Hose
Clamps” for information about selecting and Clamps” for information about selecting and
installing the proper hose clamps. installing the proper hose clamps.

6. Carefully inspect the engine for any spilled fuel. Note: The bellows and the V-clamps that are used
Make sure that no fuel remains on or close to the on the bellows should never be reused.
engine.
5. Start the engine. Inspect the air lines for leaks.
Note: Fuel must be added to the fuel system ahead
of the fuel filter.
i03230758

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

Maintenance Manual, “Fuel System - Prime” for
Jacket Water Heater - Check
information about priming the engine with fuel. SMCS Code: 1383-535
8. Start the engine. Inspect the fuel system for leaks. Jacket water heaters help to improve startability in
ambient temperatures that are below 21 °C (70 °F).
Lubrication System All installations that require automatic starting should
have jacket water heaters.

Check the operation of the jacket water heater. Check

the operation of the circulation pump, if equipped. For
Hot oil and hot components can cause personal
an ambient temperature of 0 °C (32 °F), the heater
injury. Do not allow hot oil or hot components to
should maintain the jacket water coolant temperature
contact the skin.
at approximately 32 °C (90 °F).

1. Drain the oil from the lubrication system to a level

i01848653
that is below the hose that is being replaced.

2. Remove the hose clamps.

Overhaul Considerations
SMCS Code: 7595-043
3. Disconnect the old hose.
Reduced hours of operation at full load will result in a
4. Replace the old hose with a new hose. lower average power demand. A decreased average
power demand should increase both the engine
5. Install hose clamps which have been inspected or service life and the overhaul interval.
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications”, “Hose The need for an overhaul is generally indicated by
Clamps” for information about selecting and increased fuel consumption and by reduced power.
installing the proper hose clamps.
The following factors are important when a decision
6. Refill the lubrication system. Refer to this is being made on the proper time for an engine
Operation and Maintenance Manual, “Engine overhaul:
Oil Level - Check” in order to ensure that the
lubrication system is filled with the proper amount • The need for preventive maintenance
of engine oil.
• The quality of the fuel that is being used
7. Start the engine. Inspect the lubrication system
for leaks. • The operating conditions
Air System • The results of the S·O·S analysis
1. Remove the hose clamps.

2. Disconnect the old hose.

3. Replace the old hose with a new hose.

SEBU7899-05 95
Maintenance Section
Overhaul Considerations

Oil Consumption as an Overhaul • Caterpillar dealer exchange components

Indicator • Caterpillar Inc. remanufactured exchange
components
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil Overhaul Recommendation
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable To minimize downtime, a scheduled engine overhaul
for the maintenance intervals. by your Caterpillar dealer is recommended. This will
provide you with the best cost/value relationship.
Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the Note: Overhaul programs vary according to the
engine load is increased, the amount of oil that is engine application and according to the dealer that
consumed per hour also increases. performs the overhaul. Consult your Caterpillar
dealer for specific information about the available
The oil consumption rate (brake specific oil overhaul programs and about overhaul services for
consumption) is measured in grams per kW/h (lb per extending the engine life.
bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar If an overhaul is performed without overhaul service
dealer for assistance in determining the typical oil from your Caterpillar dealer, be aware of the following
consumption rate for your engine. maintenance recommendations.

When an engine's oil consumption has risen to three Unit Fuel Injector
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled. Clean the fuel injector body and replace the O-rings.
There may be a corresponding increase in blowby Replace the O-rings and the gasket on the injector
and a slight increase in fuel consumption. sleeve. Clean the area around the injector seating
in the injector sleeve. Refer to the Service Manual
Overhaul Options for the complete procedure, or consult with your
Caterpillar dealer for assistance.
Before Failure Overhaul
Rebuild or Exchange
A planned overhaul before failure may be the best
value for the following reasons: Cylinder Head Assembly, Connecting Rods,
Pistons, Cylinder Liners, Turbocharger, Cylinder
• Costly unplanned downtime can be avoided. Packs, Oil Pump, and Fuel Transfer Pump

• Many original parts can be reused according to the These components should be inspected according to
standards for reusable parts. the instructions that are found in various Caterpillar
reusability publications. The Special Publication,
• The engine service life can be extended without the SEBF8029 lists the reusability publications that are
risk of a major catastrophe due to engine failure. needed for inspecting the engine parts.

• The best cost/value relationship per hour of If the parts comply with the established inspection
extended life can be attained. specifications that are expressed in the reusable
parts guideline, the parts should be reused.
After Failure Overhaul
Parts that are not within the established inspection
If a major engine failure occurs and the engine specifications should be dealt with in one of the
must be removed, many options are available. An following manners:
overhaul should be performed if the engine block or
the crankshaft needs to be repaired. • Salvaging
If the engine block is repairable and/or the crankshaft • Repairing
is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine • Replacing
with a similar exchange core.
Parts that do not comply with the established
This lower cost can be attributed to three aspects: inspection specifications can result in the following
problems:
• Specially designed Caterpillar engine features
96 SEBU7899-05
Maintenance Section
Overhaul Considerations

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

Reduced engine efficiency and increased fuel • Camshaft bearings

consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing • Camshaft followers
out-of-spec parts or replacing out-of-spec parts.
Caterpillar Inc. recommends replacing the crankshaft
Inspection and/or Replacement vibration damper.

Piston Rings, Crankshaft Bearings, Valve Oil Cooler Core and Aftercooler Core
Rotators, and Crankshaft Seals
During an overhaul, the removal of the oil cooler
The following components may not last until the core and the aftercooler core is recommended. The
second overhaul. oil cooler core and the aftercooler core should be
cleaned and pressure tested.
• Thrust bearings
NOTICE
• Main bearings Do not use caustic cleaners to clean the core.

• Rod bearings Caustic cleaners can attack the internal metals of the
core and cause leakage.
• Valve rotators
• Crankshaft seals Obtain Coolant Analysis
Caterpillar Inc. recommends the installation of new The concentration of supplemental coolant additive
parts at each overhaul period. (SCA) should be checked regularly with test kits
or with S·O·S Coolant Analysis (Level 1). Further
Inspect these parts while the engine is disassembled coolant analysis is recommended when the engine
for an overhaul. is overhauled.

Inspect the crankshaft for any of the following A coolant analysis can be conducted in order to verify
conditions: the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
• Deflection by consulting your local water utility company or
an agricultural agent. Private laboratories are also
• Damage to the journals available for water analysis.

• Bearing material that has seized to the journals Caterpillar Inc. recommends an S·O·S Coolant
Analysis (Level 2).
Check the journal taper and the profile of the
crankshaft journals. Check these components by S·O·S Coolant Analysis (Level 2)
interpreting the wear patterns on the following
components: An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
• Rod bearing analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level 2) provides
• Main bearings the following information:

Note: If the crankshaft is removed for any reason, • Complete S·O·S Coolant Analysis (Level 2)
use the magnetic particle inspection process to check
for cracks in the crankshaft. • Visual inspection of properties
SEBU7899-05 97
Maintenance Section
Power Take-Off Clutch - Check

• Identification of metal corrosion

• Identification of contaminants Do not operate the engine with the Instruction
Plate cover removed from the clutch. Personal
• Identification of built up impurities (corrosion and injury may result.
scale)
If the clutch is damaged to the point of burst fail-
S·O·S Coolant Analysis (Level 2) provides a report of
ure, expelled pieces can cause personal injury to
the results of both the analysis and the maintenance
anyone in the immediate area. Proper safeguards
recommendations.
must be followed to help prevent accidents.
For more information about coolant analysis, consult
your Caterpillar dealer.
i04020194

i03901481 Radiator - Clean

Power Take-Off Clutch - Check SMCS Code: 1353-070

SMCS Code: 3055-535 Note: Adjust the frequency of cleaning according to

the effects of the operating environment.
NOTICE
New power take-offs should have the clutch adjust- Inspect the radiator for these items: damaged fins,
ment checked before being placed into service. The corrosion, dirt, grease, insects, leaves, oil, and other
clutch adjustment should be checked again after the debris. Clean the radiator, if necessary.
first ten hours of operation. New clutch plates have a
“wear in” period, and the clutch may require several
adjustments until the new plates are “worn in”.
Personal injury can result from air pressure.

Personal injury can result without following prop-

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

The maximum air pressure for cleaning purposes

must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.

Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction
of the air flow. Hold the nozzle approximately 6 mm
(0.25 inch) away from the fins. Slowly move the air
Illustration 55
g00781502 nozzle in a direction that is parallel with the tubes.
This movement will remove debris that is between
(1) Instruction plate
(2) Serial number plate
the tubes.

Check the clutch adjustment regularly after “wear in”. Pressurized water may also be used for cleaning.
Heavy-duty applications which have engagements The maximum water pressure for cleaning purposes
that are frequent and relatively long periods of must be less than 275 kPa (40 psi). Use pressurized
clutch slippage require more frequent adjustment water in order to soften mud. Clean the core from
than light-duty applications. The operating torque both sides.
should be measured in order to determine if a clutch
adjustment is required. Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
Refer to the OEM information and instruction plate with detergent and hot water. Thoroughly rinse the
(1) for instructions on lubrication, adjustment, and core with clean water.
other recommendations for service. Perform the
maintenance that is specified on the instruction plate.
98 SEBU7899-05
Maintenance Section
Speed Sensor - Clean/Inspect

After cleaning, start the engine and accelerate the Check the starting motor for proper operation. Check
engine to high idle rpm. This procedure will help in the electrical connections and clean the electrical
the removal of debris and drying of the core. Stop the connections. Refer to the Service Manual for more
engine. Use a light bulb behind the core in order to information on the checking procedure and for
inspect the core for cleanliness. Repeat the cleaning, specifications or consult your Caterpillar dealer for
if necessary. assistance.

Inspect the fins for damage. Bent fins may be opened

i01539769
with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
Turbocharger - Inspect
SMCS Code: 1052-040
i03397657
Periodic inspection and cleaning is recommended
Speed Sensor - Clean/Inspect for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through
SMCS Code: 1907-040; 1907-070 the air inlet system. Therefore, by-products from oil
and from combustion can collect in the turbocharger
compressor housing. Over time, this buildup can
contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.

If the turbocharger fails during engine operation,

damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder
head.

NOTICE
Turbocharger bearing failures can cause large quan-
g01453018 tities of oil to enter the air inlet and exhaust systems.
Illustration 56
Loss of engine lubricant can result in serious engine
Left side view damage.
(1) Secondary speed/timing sensor
(2) Primary speed/timing sensor Minor leakage of a turbocharger housing under ex-
tended low idle operation should not cause problems
1. Remove the speed/timing sensors. Refer to as long as a turbocharger bearing failure has not oc-
Disassembly and Assembly, “Speed/Timing curred.
Sensor - Remove and Install” for the removal
procedure. Check the condition of the plastic When a turbocharger bearing failure is accompanied
end of the speed/timing sensors for wear and/or by a significant engine performance loss (exhaust
contaminants. smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
2. Clean the metal shavings and other debris from replaced.
the face of the speed/timing sensors.

3. Install the speed/timing sensors. Refer to An inspection of the turbocharger can minimize
Disassembly and Assembly, “Speed/Timing unscheduled downtime. An inspection of the
Sensor - Remove and Install” for the installation turbocharger can also reduce the chance for potential
procedure. damage to other engine parts.

Note: Turbocharger components require precision

i00651416 clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Starting Motor - Inspect Applications can accelerate component wear.
Severe Service Applications require more frequent
SMCS Code: 1451-040; 1453-040 inspections of the cartridge.
Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
SEBU7899-05 99
Maintenance Section
Walk-Around Inspection

Removal and Installation i01185304

For options regarding the removal, installation, repair Walk-Around Inspection

and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine for the SMCS Code: 1000-040
procedure and specifications.
Inspect the Engine for Leaks and
Cleaning and Inspecting for Loose Connections
1. Remove the exhaust outlet piping and remove A walk-around inspection should only take a few
the air inlet piping from the turbocharger. Visually minutes. When the time is taken to perform these
inspect the piping for the presence of oil. Clean checks, costly repairs and accidents can be avoided.
the interior of the pipes in order to prevent dirt
from entering during reassembly. For maximum engine service life, make a thorough
inspection of the engine compartment before starting
2. Turn the compressor wheel and the turbine wheel the engine. Look for items such as oil leaks or coolant
by hand. The assembly should turn freely. Inspect leaks, loose bolts, worn belts, loose connections and
the compressor wheel and the turbine wheel for trash buildup. Make repairs, as needed:
contact with the turbocharger housing. There
should not be any visible signs of contact between • The guards must be in the proper place. Repair
the turbine wheel or compressor wheel and the damaged guards or replace missing guards.
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the • Wipe all caps and plugs before the engine is
compressor wheel and the turbocharger housing, serviced in order to reduce the chance of system
the turbocharger must be reconditioned. contamination.

3. Check the compressor wheel for cleanliness. NOTICE

If only the blade side of the wheel is dirty, dirt For any type of leak (coolant, lube, or fuel) clean up the
and/or moisture is passing through the air filtering fluid. If leaking is observed, find the source and correct
system. If oil is found only on the back side of the the leak. If leaking is suspected, check the fluid levels
wheel, there is a possibility of a failed turbocharger more often than recommended until the leak is found
oil seal. or fixed, or until the suspicion of a leak is proved to be
unwarranted.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line for NOTICE
the inlet air (plugged air filters), which causes the Accumulated grease and/or oil on an engine or deck is
turbocharger to slobber. a fire hazard. Remove this debris with steam cleaning
or high pressure water.
4. Use a dial indicator to check the end clearance
on the shaft. If the measured end play is greater
than the Service Manual specifications, the • Ensure that the cooling lines are properly clamped
turbocharger should be repaired or replaced. and that the cooling lines are tight. Check for leaks.
An end play measurement that is less than the Check the condition of all pipes.
minimum Service Manual specifications could
indicate carbon buildup on the turbine wheel. The • Inspect the water pumps for coolant leaks.
turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less Note: The water pump seal is lubricated by coolant
than the minimum Service Manual specifications. in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
5. Inspect the bore of the turbine housing for the parts contract.
corrosion.
Excessive coolant leakage may indicate the need
6. Clean the turbocharger housing with standard to replace the water pump seal. For the removal of
shop solvents and a soft bristle brush. water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
7. Fasten the air inlet piping and the exhaust outlet engine or consult your Caterpillar dealer.
piping to the turbocharger housing.
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
100 SEBU7899-05
Maintenance Section
Water Pump - Inspect

• Inspect the fuel system for leaks. Look for loose Visually inspect the water pump for leaks. If leaking
fuel line clamps or for loose fuel line tie-wraps. of the water pump seals is observed, replace all of
the water pump seals. Refer to two articles in the
• Inspect the piping for the air inlet system and the Disassembly and Assembly Manual, “Water Pump
elbows for cracks and for loose clamps. Ensure - Disassemble and Water Pump - Assemble” for
that hoses and tubes are not contacting other the disassembly and assembly procedure. If it is
hoses, tubes, wiring harnesses, etc. necessary to remove the water pump, refer to two
articles in the Disassembly and Assembly Manual,
• Inspect the alternator belt and the accessory drive “Water Pump - Remove and Water Pump - Install”.
belts for cracks, breaks or other damage.
Inspect the water pump for wear, cracks, pin holes
Belts for multiple groove pulleys must be replaced as and proper operation. Refer to the Parts Manual
matched sets. If only one belt is replaced, the belt will for the correct part numbers for your engine or
carry more load than the belts that are not replaced. consult your Caterpillar dealer if repair is needed or
The older belts are stretched. The additional load on replacement is needed.
the new belt could cause the belt to break.

• Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.

• Inspect the ground strap for a good connection and

for good condition.

• Inspect the ECM to the cylinder head ground strap

for a good connection and for good condition.

• Disconnect any battery chargers that are not

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

• Check the condition of the gauges. Replace any

gauges that are cracked. Replace any gauge that
can not be calibrated.

i03543200

Water Pump - Inspect

SMCS Code: 1361-040

A failed water pump might cause severe engine

overheating problems that could result in the following
conditions:

• Cracks in the cylinder head

• A piston seizure
• Other potential damage to the engine
A failed water pump might cause severe engine
overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential
damage to the engine.