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2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt

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SEBU6123-06

October 2001

Operation andMaintenance

Manual3114, 3116 and 3126 Industrial andGenerator Set Engines

5EF1-Up (Engine)6AF1-Up (Engine)

1ZG1-Up (Engine)2SG1-Up (Engine)2WG1-Up (Engine)4PG1-Up (Engine)5JG1-Up (Engine)1NJ1-Up (Engine)CKK1-Up (Engine)5EN1-Up (Engine)2MR1-Up (Engine)4KR1-Up (Engine)9ZR1-Up (Engine)6MS1-Up (Engine)

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62Maintenance SectionMaintenance Interval Schedule

i01591075

Maintenance Interval Schedule(3114 Industrial Engines)

SMCS Code: 1000; 7500

S/N: 5EF1-Up

S/N: 6AF1-Up

S/N: 1ZG1-Up

S/N: 5JG1-Up

Note: Ensure that the Safety Information, warnings,and instructions are read and understoodbefore operation or maintenance procedures areperformed.

Note: Use fuel consumption, service hours, or

calendar time, whichever occurs first , in order todetermine the maintenance intervals. Engines thatoperate in severe operating conditions may requiremore frequent maintenance.

Before each consecutive interval is performed, allof the maintenance requirements from the previousinterval must also be performed.

When Required

Battery - Replace .................................................. 66Battery Electrolyte Level - Check .......................... 66Battery or Battery Cable - Disconnect .................. 67

Engine - Clean ...................................................... 74Engine Storage Procedure - Check ...................... 83Ether Starting Aid Cylinder - Replace ................... 83Fuel System - Prime ............................................. 85Severe Service Application - Check ...................... 93

Daily

Cooling System Coolant Level - Check ................ 71Driven Equipment - Check .................................... 74Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 74Engine Air Cleaner Service Indicator - Inspect ..... 78Engine Air Precleaner - Check/Clean ................... 79

Engine Oil Level - Check ...................................... 80Fuel System Water Separator - Drain ................... 88Walk-Around Inspection ........................................ 95

Every 1000 Service Hours

Engine Protective Devices - Check ....................... 82

Every 6000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 69

First 3750 L (1000 US gal) of Fuel or 250Service Hours

Engine Valve Lash - Inspect/Adjust ...................... 83Fuel Injection Timing - Check ............................... 84

PM Level 1 - Every 3750 L (1000 US gal) ofFuel or 250 Service Hours or 6 Months

Aftercooler Core - Clean/Test ............................... 65Alternator - Inspect ............................................... 65Alternator and Fan Belts - Inspect/Adjust/

Replace ............................................................... 65Battery Electrolyte Level - Check .......................... 66Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 71Engine Crankcase Breather - Clean ..................... 79Engine Oil Sample - Obtain .................................. 80Engine Oil and Filter - Change ............................. 81Fan Drive Bearing - Lubricate ............................... 84

Fuel Inlet Screen - Clean/Inspect/Replace ........... 84Fuel System Primary Filter - Clean/Replace ........ 86Fuel System Primary Filter/Water Separator Element

- Replace ............................................................. 86Fuel System Secondary Filter - Replace .............. 87Fuel Tank Water and Sediment - Drain ................. 88Hoses and Clamps - Inspect/Replace .................. 89Radiator - Clean .................................................... 93

PM Level 2 - Every 30 000 L (8000 US gal) ofFuel or 2000 Service Hours or 1 Year


PM Level 3 - Every 45 000 L (12 000 US gal)of Fuel or 3000 Service Hours or 2 Years

Cooling System Coolant (DEAC) - Change .......... 67Cooling System Coolant Extender (ELC) - Add .... 70Cooling System Water Temperature Regulator -

Replace ............................................................... 73Crankshaft Vibration Damper - Inspect ................. 73Engine Mounts - Inspect ....................................... 79

Every 75 000 L (20 000 US gal) of Fuel or5000 Service Hours

Overhaul Considerations ...................................... 90Starting Motor - Inspect ........................................ 94Turbocharger - Inspect/Clean ............................... 94Water Pump - Inspect ........................................... 96

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63Maintenance Section

Maintenance Interval Schedule

i01591089

Maintenance Interval Schedule(3116 and 3126 IndustrialEngines)

SMCS Code: 1000; 7500

S/N: 2SG1-Up

S/N: 2WG1-Up

S/N: 4PG1-Up

S/N: 1NJ1-Up

S/N: CKK1-Up

S/N: 5EN1-Up

S/N: 2MR1-Up

S/N: 9ZR1-Up

S/N: 6MS1-Up

Note: Ensure that the Safety Information, warnings,and instructions are read and understoodbefore operation or maintenance procedures areperformed.

Note: Use fuel consumption, service hours, orcalendar time, whichever occurs first , in order todetermine the maintenance intervals. Engines thatoperate in severe operating conditions may requiremore frequent maintenance.

Before each consecutive interval is performed, allof the maintenance requirements from the previousinterval must also be performed.

When Required

Battery - Replace .................................................. 66Battery Electrolyte Level - Check .......................... 66Battery or Battery Cable - Disconnect .................. 67Engine - Clean ...................................................... 74Engine Storage Procedure - Check ...................... 83Ether Starting Aid Cylinder - Replace ................... 83Fuel System - Prime ............................................. 85

Severe Service Application - Check ...................... 93

Daily

Cooling System Coolant Level - Check ................ 71Driven Equipment - Check .................................... 74Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 74Engine Air Cleaner Service Indicator - Inspect ..... 78Engine Air Precleaner - Check/Clean ................... 79Engine Oil Level - Check ...................................... 80Fuel System Water Separator - Drain ................... 88Walk-Around Inspection ........................................ 95

Every Week

Engine Operation - Test ........................................ 82

Every 1000 Service Hours

Engine Protective Devices - Check ....................... 82

Every 6000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 69

First 5700 L (1500 US gal) of Fuel or 250Service Hours


PM Level 1 - Every 5700 L (1500 US gal) ofFuel or 250 Service Hours or 6 Months

Aftercooler Core - Clean/Test ............................... 65Alternator - Inspect ............................................... 65Alternator and Fan Belts - Inspect/Adjust/

Replace ............................................................... 65Battery Electrolyte Level - Check .......................... 66Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 71Engine Crankcase Breather - Clean ..................... 79Engine Oil Sample - Obtain .................................. 80Engine Oil and Filter - Change ............................. 81Fan Drive Bearing - Lubricate ............................... 84Fuel Inlet Screen - Clean/Inspect/Replace ........... 84Fuel System Primary Filter - Clean/Replace ........ 86Fuel System Primary Filter/Water Separator Element

- Replace ............................................................. 86Fuel System Secondary Filter - Replace .............. 87Fuel Tank Water and Sediment - Drain ................. 88Hoses and Clamps - Inspect/Replace .................. 89Radiator - Clean .................................................... 93

PM Level 2 - Every 45 600 L (12 000 US gal)of Fuel or 2000 Service Hours or 1 Year


Every 114 000 L (30 000 US gal) of Fuel or5000 Service Hours

Overhaul Considerations ...................................... 90Starting Motor - Inspect ........................................ 94Turbocharger - Inspect/Clean ............................... 94Water Pump - Inspect ........................................... 96

PM Level 3 - Every 68 000 L (18 000 US gal)of Fuel or 3000 Service Hours or 2 Years

Cooling System Coolant (DEAC) - Change .......... 67Cooling System Coolant Extender (ELC) - Add .... 70Cooling System Water Temperature Regulator -

Replace ............................................................... 73Crankshaft Vibration Damper - Inspect ................. 73

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64Maintenance SectionMaintenance Interval Schedule

Engine Mounts - Inspect ....................................... 79

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Aftercooler Core - Clean/Test

i01371758

Aftercooler Core - Clean/Test(Air-To-Air Aftercooler)

SMCS Code: 1064-070; 1064-081

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

Inspect the aftercooler for these items: damagedfins, corrosion, dirt, grease, insects, leaves, oil, andother debris. Clean the aftercooler, if necessary.

For air-to-air aftercoolers, use the same methodsthat are used for cleaning radiators.

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 lessthan 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the fans air flow. Hold the nozzle approximately6 mm (0.25 inch) away from the fins. Slowly movethe air nozzle in a direction that is parallel with thetubes. This will remove debris that is between thetubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

Use a degreaser and steam for removal of oil andgrease. Clean both sides of the core. Wash the corewith detergent and hot water. Thoroughly rinse thecore with clean water.

After cleaning, start the engine and accelerate theengine to high idle rpm. This will help in the removalof debris and drying of the core. Stop the engine.Use a light bulb behind the core in order to inspectthe core for cleanliness. Repeat the cleaning, ifnecessary.

Inspect the fins for damage. Bent fins may beopened with a comb.

Note: If parts of the aftercooler system are repairedor replaced, a leak test is highly recommended.

Inspect these items for good condition: welds,mounting brackets, air lines, connections, clamps,and seals. Make repairs, if necessary.

For more detailed information on cleaning andinspection, see Special Publication, SEBD0518,

Know Your Cooling System

.

i00072207

Alternator - Inspect

SMCS Code: 1405-040

Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and proper battery charging. Inspectthe ammeter (if equipped) during engine operationin order to ensure proper battery performanceand/or proper performance of the electrical system.

Make repairs, as required. Refer to the ServiceManual.

Check the alternator and the battery charger forproper operation. If the batteries are properlycharged, the ammeter reading should be very nearzero. All batteries should be kept charged. Thebatteries should be kept warm because temperatureaffects the cranking power. If the battery is too cold,the battery will not crank the engine. The battery willnot crank the engine, even if the engine is warm.When the engine is not run for long periods of timeor if the engine is run for short periods, the batteriesmay not fully charge. A battery with a low charge willfreeze more easily than a battery with a full charge.

i00841051

Alternator and Fan Belts -Inspect/Adjust/Replace

SMCS Code: 1357-039

Inspection

To maximize the engine performance, inspect the

belts for wear and for cracking. Check the belttension. Adjust the belt tension in order to minimizebelt slippage. Belt slippage will decrease the lifeof the belts.

To check the belt tension, apply 110 N (25 lb)of force midway between the pulleys. Acorrectly adjusted belt will deflect 13 to 19 mm(0.50 to 0.75 inch).

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66Maintenance SectionBattery - Replace

Adjustment

If the belts are too loose, the belts will vibrate. Thisvibration is enough to cause unnecessary wear onthe belts and on the pulleys.

If the belts are too tight, unnecessary stresses areplaced upon the pulley bearings and upon thebelts. These stresses will shorten the life of the beltsand of the pulley bearings.

If new belts are installed, check the tension againafter 30 minutes of engine operation at the ratedrpm.

Replacement

For applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new belt tocarry more load because the older belt is stretched.The additional load on the new belt could cause thenew belt to break.

Refer to the Service Manual for more information onthe procedures for the following topics: belt removaland belt installation procedure.

i01492550

Battery - Replace

SMCS Code: 1401-510

Batteries give off combustible gases which canexplode. A spark can cause the combustible gas-es to ignite. This can result in severe personal in-jury or death.

Ensure proper ventilation for batteries that are inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the key start switch to the OFF position.Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect thecharger.

3. The NEGATIVE

-

cable connects the NEGATIVE- battery terminal to the ground plane.Disconnect the cable from the NEGATIVE -battery terminal.

4. The POSITIVE + cable connects the POSITIVE+ battery terminal to the starting motor.Disconnect the cable from the POSITIVE +battery terminal.

Note: Always recycle a battery. Never discard abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure thatthe key start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE + battery terminal.

8. Connect the cable from the ground plane to theNEGATIVE - battery terminal.

i01206348

Battery Electrolyte Level -Check

SMCS Code: 1401-535

When the engine is not run for long periods oftime or when the engine is run for short periods,the batteries may not fully recharge. Ensure a fullcharge in order to help prevent the battery fromfreezing. If batteries are properly charged, ammeterreading should be very near zero.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

1. Remove the filler caps. Maintain the electrolytelevel to the FULL mark on the battery.

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Battery or Battery Cable - Disconnect

If the addition of water is necessary, use distilledwater. If distilled water is not available useclean water that is low in minerals. Do not useartificially softened water.

2. Check the condition of the electrolyte with the

1U-7298 Coolant/Battery Tester (

C) or the1U-7297 Coolant/Battery Tester ( F).

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

A mixture of 0.1 L (0.11 qt) of baking soda and1 L (1 qt) of clean water

A mixture of 0.1 L (0.11 qt) of ammonia and1 L (1 qt) of clean water

Thoroughly rinse the battery case with cleanwater.

Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fitproperly. Coat the clamps and the terminals with5N-5561 Silicone Lubricant, petroleum jelly orMPGM grease.

i01492654

Battery or Battery Cable -Disconnect

SMCS Code: 1402-029

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the start switch to the OFF position. Turn theignition switch (if equipped) to the OFF positionand remove the key and all electrical loads.

2. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal. When four12 volt batteries are involved, the negative sideof two batteries must be disconnected.

3. Tape the leads in order to help prevent accidentalstarting.

4. Proceed with necessary system repairs. Reversethe steps in order to reconnect all of the cables.

i01206425

Cooling System Coolant(DEAC) - Change

SMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

The engine overheats frequently.

Foaming is observed.

The oil has entered the cooling system and thecoolant is contaminated.

The fuel has entered the cooling system and thecoolant is contaminated.

NOTICEUse of commercially available cooling system clean-ers may cause damage to cooling system compo-nents. Use only cooling system cleaners that are ap-proved for Caterpillar engines.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulatorand the hoses, if necessary.

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.

2. Open the cooling system drain valve (ifequipped). If the cooling system is not equippedwith a drain valve, remove one of the drain plugs.

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68Maintenance SectionCooling System Coolant (DEAC) - Change

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The full

distillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Service TechnologyGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush

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

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theOperation and Maintenance Manual, TorqueSpecifications topic (Maintenance Section) formore information on the proper torques.

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

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

4. Start and run the engine at low idle for aminimum of 30 minutes. The coolant temperatureshould be at least 82 C (180 F).

NOTICEImproper or incomplete rinsing of the cooling system

can result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling systemdrain plugs. Allow the water to drain. Flush the

cooling system with clean water. Close the drainvalve (if equipped). Clean the drain plugs. Installthe drain plugs. Refer to the Operation andMaintenance Manual, Torque Specificationstopic (Maintenance Section) for more informationon the proper torques.

Cooling Systems with HeavyDeposits or Plugging

Note: For the following procedure to be effective,there must be some active flow through the coolingsystem components.




3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity. Install the cooling system filler cap.

4. Start and run the engine at low idle for aminimum of 90 minutes. The coolant temperatureshould be at least 82 C (180 F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

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Cooling System Coolant (ELC) - Change

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling systemdrain plugs. Allow the water to drain. Flush the

cooling system with clean water. Close the drainvalve (if equipped). Clean the drain plugs. Installthe drain plugs. Refer to the Operation andMaintenance Manual, Torque Specificationstopic (Maintenance Section) for more informationon the proper torques.

Fill


1. Fill the cooling system with coolant/antifreeze.Refer to the Operation and MaintenanceManual, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to 1500 rpm. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolantlevel within 13 mm (0.5 inch) below the bottom

of the pipe for filling. Maintain the coolant levelwithin 13 mm (0.5 inch) to the proper level on thesight glass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap.If the gasket that is on the cooling system fillercap is not damaged, perform a pressure test. A9S-8140 Pressurizing Pump is used to performthe pressure test. The correct pressure for thecooling system filler cap is stamped on the face

of the cooling system filler cap. If the coolingsystem filler cap does not retain the correctpressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i01206445

Cooling System Coolant (ELC)- Change

SMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

The engine overheats frequently.

Foaming is observed.

The oil has entered the cooling system and thecoolant is contaminated.

The fuel has entered the cooling system and thecoolant is contaminated.

Note: When the cooling system is cleaned, onlyclean water is needed when the ELC is drainedand replaced.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulatorand the hoses, if necessary.

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.

2. Open the cooling system drain valve (ifequipped). If the cooling system is not equippedwith a drain valve, remove the cooling systemdrain plugs.

Allow the coolant to drain.

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70Maintenance SectionCooling System Coolant Extender (ELC) - Add

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable by

Caterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Service TechnologyGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush




3. Fill the cooling system with clean water. Installthe cooling system filler cap.

4. Start and run the engine at low idle until thetemperature reaches 49 to 66 C (120 to 150 F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling systemdrain plugs. Allow the water to drain. Flush thecooling system with clean water. Close the drainvalve (if equipped). Clean the drain plugs. Install

the drain plugs. Refer to the Operation andMaintenance Manual, Torque Specificationstopic (Maintenance Section) for more informationon the proper torques.

Fill


1. Fill the cooling system with Extended Life Coolant(ELC). Refer to the Operation and MaintenanceManual, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to high idle. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolantlevel within 13 mm (0.5 inch) below the bottomof the pipe for filling. Maintain the coolant levelwithin 13 mm (0.5 inch) to the proper level on thesight glass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. If

the gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket that is on the cooling system filler capis not damaged, use a 9S-8140 PressurizingPump in order to pressure test the coolingsystem filler cap. The correct pressure for thecooling system filler cap is stamped on the faceof the cooling system filler cap. If the coolingsystem filler cap does not retain the correctpressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i00259474

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352-045; 1395-081

Caterpillar Extended Life Coolant (ELC) does notrequire the frequent Supplemental Coolant Additive(SCA) additions associated with the presentconventional coolants. The Extender only needs tobe added once.

Check the cooling system only when the engine isstopped and cool.

1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. It may be necessary to drain enough coolantfrom the cooling system in order to add theExtender.

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Cooling System Coolant Level - Check

3. Add Extender according to the requirements foryour engines cooling system capacity. Refer tothe Operation and Maintenance Manual, RefillCapacities in the Maintenance Section for thecapacity of the cooling system for your engine.Refer to the Operation and Maintenance Manual,

Cooling System Specifications

information forthe Caterpillar ELC Extender additions.

4. Clean the cooling system filler cap. Inspect thecooling system filler cap gaskets. Replace thecooling system filler cap if the cooling systemfiller cap gaskets are damaged. Install thecooling system filler cap.

i01197583

Cooling System Coolant Level- Check

SMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

g00285520Illustration 25

Cooling system filler cap


1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel to the proper level in the sight glass.


Typical filler cap gaskets

3. Clean the cooling system filler cap and check thecondition of the filler cap gaskets. Replace the

cooling system filler cap if the filler cap gasketsare damaged. Reinstall the cooling system fillercap.

4. Inspect the cooling system for leaks.

i01463635

Cooling System SupplementalCoolant Additive (SCA) -Test/Add

SMCS Code: 1352-045; 1395-081

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and the eyes. Do not drink cooling systemcoolant additive.

Note: Test the concentration of the SupplementalCoolant Additive (SCA) or test the SCA concentrationas part of an SOS Coolant Analysis.

Test for SCA ConcentrationCoolant/Antifreeze and SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Use the 8T-5296 Coolant Conditioner Test Kit oruse the 4C-9301 Coolant Conditioner Test Kit inorder to check the concentration of the SCA. Referto the Operation and Maintenance Manual for moreinformation.

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72Maintenance SectionCooling System Supplemental Coolant Additive (SCA) - Test/Add

Water and SCA

NOTICEDo not exceed the recommended eight percent sup-plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Refer to the Operationand Maintenance Manual, Water/SupplementalCoolant Additive (SCA) topic (MaintenanceSection). Refer to the Operation and MaintenanceManual, Conventional Coolant/Antifreeze CoolingSystem Maintenance topic (Maintenance Section).

SOS Coolant Analysis

SOS coolant samples can be analyzed at yourCaterpillar dealer. SOS Coolant Analysis is aprogram that is based on periodic samples.

Level 1

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

Glycol Concentration

Concentration of SCA

pH

Conductivity

The results are reported, and recommendationsare made according to the results. Consult yourCaterpillar dealer for information on the benefits ofmanaging your equipment with an SOS CoolantAnalysis.

Level 2

This level coolant analysis is recommendedwhen the engine is overhauled. Refer to theOperations and Maintenance Manual, OverhaulConsiderations for further information.

Add the SCA, If Necessary

NOTICEDo not exceed the recommended amount of sup-plemental coolant additive concentration. Excessivesupplemental coolant additive concentration can formdeposits on the higher temperature surfaces of thecooling system, reducing the engines heat transfercharacteristics. Reduced heat transfer could causecracking of the cylinder head and other high temper-ature components. Excessive supplemental coolantadditive concentration could also result in radiatortube blockage, overheating, and/or accelerated waterpump seal wear. Never use both liquid supplementalcoolant additive and the spin-on element (if equipped)at the same time. The use of those additives togethercould result in supplemental coolant additive concen-tration exceeding the recommended maximum.


1. Slowly loosen the cooling system filler cap inorder to relieve the pressure. Remove the coolingsystem filler cap.

Note: Always discard drained fluids according tolocal regulations.

2. If necessary, drain some coolant from the coolingsystem into a suitable container in order to allowspace for the extra SCA.

3. Add the proper amount of SCA. Refer to theOperation and Maintenance Manual for moreinformation on SCA requirements.

4. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets are damaged, replace the old cooling

system filler cap with a new cooling system fillercap. Install the cooling system filler cap.

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Cooling System Water Temperature Regulator - Replace

i00912898

Cooling System WaterTemperature Regulator -Replace

SMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime.

A water temperature regulator that fails in apartially opened position can cause overheating orovercooling of the engine.

A water temperature regulator that fails in the

closed position can cause excessive overheating.Excessive overheating could result in cracking ofthe cylinder head or piston seizure problems.

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup insidethe cylinders. This excessive carbon buildup couldresult in an accelerated wear of the piston rings andwear of the cylinder liner.

NOTICE

Failure to replace your water temperature regulatoron a regularly scheduled basis could cause severeengine damage.

Caterpillar engines incorporate a shunt design coolingsystem and require operating the engine with a watertemperature regulator installed.

If the water temperature regulator is installed incor-rectly, the engine may overheat, causing cylinder headdamage. Ensure that the new water temperature reg-ulator is installed in the original position. Ensure thatthe water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket orcylinder head surface.

Refer to the Service Manual for the replacementprocedure of the water temperature regulator, orconsult your Caterpillar dealer.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling systemto a level that is below the water temperatureregulator housing.

i00894991

Crankshaft Vibration Damper- Inspect

SMCS Code: 1205-040

Damage to the crankshaft vibration damper orfailure of the crankshaft vibration damper canincrease torsional vibrations. This can result indamage to the crankshaft and to other enginecomponents. A deteriorating damper can causeexcessive gear train noise at variable points in thespeed range.

The damper is mounted to the crankshaft which islocated behind the belt guard on the front of theengine.

Rubber DamperYour engine may be equipped with a rubberdamper. The rubber damper uses a ring which ismounted in rubber in order to reduce vibrations inthe crankshaft.

Inspect the damper and repair or replace thedamper for any of the following reasons:

There is deterioration and cracking of the rubber.

There is slippage of the outer ring from theoriginal position.

The engine has had a failure because of a brokencrankshaft.

Analysis of the oil has revealed that the front mainbearing is badly worn.

There is a large amount of gear train wear that isnot caused by lack of oil.

Refer to the Service Manual or consult yourCaterpillar dealer for information about damperreplacement.

Visconic Damper

Your engine may be equipped with a visconicdamper. The visconic damper has a weight that islocated inside a fluid filled case. The weight movesin the case in order to limit torsional vibration.

Inspect the damper for evidence of fluid leaks. Ifa fluid leak is found, determine the type of fluid.The fluid in the damper is silicone. Silicone hasthe following characteristics: transparent, viscous,smooth, and difficult to remove from surfaces.

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74Maintenance SectionDriven Equipment - Check

If the fluid leak is oil, inspect the crankshaft seals forleaks. If a leak is observed, replace the crankshaftseals.

Inspect the damper and repair or replace thedamper for any of the following reasons:

The damper is dented, cracked, or leaking.

The paint on the damper is discolored from heat.

The engine has had a failure because of a brokencrankshaft.

Analysis of the oil has revealed that the front mainbearing is badly worn.

There is a large amount of gear train wear that isnot caused by a lack of oil.

Refer to the Service Manual or consult yourCaterpillar dealer for information about damperreplacement.

i00174798

Driven Equipment - Check

SMCS Code: 3279-535

Refer to the OEM specifications for more informationon the following maintenance recommendations forthe driven equipment:

Inspection

Adjustment

Lubrication

Other maintenance recommendations

Perform any maintenance for the driven equipmentwhich is recommended by the OEM.

i01239442

Engine - Clean

SMCS Code: 1000-070

Personal injury or death can result from high volt-age.

Moisture can create paths of electrical conductiv-ity.

Make sure that the electrical system is OFF. Lockout the starting controls and tag the controls DONOT OPERATE.

NOTICE

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

NOTICEAccumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Periodic cleaning of the engine is recommended.Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides thefollowing benefits:

Easy detection of fluid leaks

Maximum heat transfer characteristics

Ease of maintenance

i01089660

Engine Air Cleaner Element(Dual Element) - Clean/Replace

SMCS Code: 1054-037; 1054-510

Perform the Operation and Maintenance Manual,Engine Air Cleaner Service Indicator-Inspectprocedure and perform the Operation andMaintenance Manual, Engine Air PrecleanerCheck/Clean procedure (if equipped) beforeperforming the following procedure.

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Engine Air Cleaner Element (Dual Element) - Clean/Replace

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering the

engine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, theair can split the material of the air cleaner element.

Unfiltered air will drastically accelerate internalengine wear. Your Caterpillar dealer has the properair cleaner elements for your application. Consultyour Caterpillar dealer for the correct air cleanerelement.

Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

Operating conditions (dust, dirt and debris) mayrequire more frequent service of the air cleanerelement.

The air cleaner element may be cleaned up tosix times if the element is properly cleaned andinspected.

The air cleaner element should be replacedat least one time per year. This replacementshould be performed regardless of the numberof cleanings.

Replace the dirty paper air cleaner elements withclean air cleaner elements. Before installation, theair cleaner elements should be thoroughly checkedfor tears and/or holes in the filter material. Inspectthe gasket or the seal of the air cleaner element for

damage. Maintain a supply of suitable air cleanerelements for replacement purposes.

Air Cleaners With Dual Elements

An air cleaner with a dual element contains aprimary air cleaner element and a secondary aircleaner element. The primary air cleaner elementcan be used up to six times if the element isproperly cleaned and inspected. The primaryair cleaner element should be replaced at leastone time per year. This replacement should beperformed regardless of the number of cleanings.

The secondary air cleaner element is not serviceableor washable. The secondary air cleaner elementshould be removed and discarded for every threecleanings of the primary air cleaner element. Whenthe engine is operating in environments that aredusty or dirty, air cleaner elements may require

more frequent replacement.


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

1. Remove the cover. Remove the primary aircleaner element.

2. The secondary air cleaner element should beremoved and discarded for every three cleaningsof the primary air cleaner element.

Note: Refer to Cleaning the Primary Air Filter

Elements.

3. Cover the turbocharger air inlet with tape inorder to keep dirt out.

4. Clean the inside of the air cleaner cover andbody with a clean, dry cloth.

5. Remove the tape for the turbocharger air inlet.Install the secondary air cleaner element. Installa primary air cleaner element that is new orcleaned.

6. Install the air cleaner cover.

7. Reset the service indicator.

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76Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

Cleaning the Primary Air CleanerElements

The primary air cleaner element can be used upto six times if the element is properly cleaned andinspected. When the primary air cleaner element iscleaned, check for rips or tears in the filter material.The primary air cleaner element should be replacedat least one time per year. This replacementshould be performed regardless of the number ofcleanings.

Use clean primary air cleaner elements while dirtyelements are being cleaned.

NOTICEDo not clean the air cleaner elements by bumping ortapping. 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. Enginedamage could result.

Visually inspect the primary air cleaner elementsbefore cleaning. Inspect the air cleaner elementsfor damage to the seal, the gaskets, and the outercover. Discard any damaged air cleaner elements.

There are four common methods that are used toclean primary air cleaner elements:

Pressurized water

Pressurized air

Vacuum cleaning

Washing with nonsudsing detergent

Pressurized Water

Pressurized water will clean the primary air cleanerelement unless carbon and oil have accumulatedon the surface of the primary air cleaner element.The maximum water pressure for cleaning purposesmust be below 275 kPa (40 psi). Do not use aspray nozzle.

Note: When the primary air cleaner element iscleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the water flows inside theelement along the length of the filter in order to helpprevent damage to the paper pleats. Do not aim thestream of water directly at the primary air cleanerelement. Dirt could be forced further into the pleats.

Note: Refer to Drying the Primary Air CleanerElements. Refer to Inspecting the Primary AirCleaner Elements.

Pressurized Air

Pressurized air can be used to clean primary aircleaner elements that have not been cleaned morethan two times. Pressurized air will not removedeposits of carbon and oil. Use filtered, dry air witha maximum pressure of 207 kPa (30 psi).


Note: When the primary air cleaner elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the element

along the length of the filter in order to help preventdamage to the paper pleats. Do not aim the streamof air directly at the primary air cleaner element. Dirtcould be forced further into the pleats.

Note: Refer to Inspecting the Primary Air CleanerElements.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningprimary air cleaner elements which require dailycleaning because of a dry, dusty environment.Cleaning with pressurized air is recommendedprior to vacuum cleaning. Vacuum cleaning will notremove deposits of carbon and oil.

Note: Refer to Inspecting the Primary Air CleanerElements.

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Engine Air Cleaner Element (Dual Element) - Clean/Replace

Washing the Primary Air CleanerElements with Nonsudsing Detergent

Do not wash air cleaner elements in any flammablesolution such as diesel fuel or gasoline. Doing socan cause fire or an engine runaway and can resultin personal injury.

Washing with nonsudsing detergent is effective forcleaning primary air cleaner elements that havedeposits of carbon or oil. Use a cleaning agent thatis specifically manufactured for cleaning primary aircleaner elements. Cleaning with pressurized water,pressurized air, or a vacuum is recommended priorto washing with nonsudsing detergent.

1. Place the primary air cleaner element into awash tank so that the gasket is up. The washtank should be equipped with a rack so that theprimary air cleaner element does not sit on thebottom of the wash tank.

Note: Caterpillar does not recommend a processfor washing the primary air cleaner element whichincludes vigorously shaking. By vigorously shakingthe element, carbon particles may be distributed.

2. Fill the wash tank with the cleaning agentand warm water to a maximum temperatureof 60 C (140 F). Follow the manufacturersrecommendations for the cleaning agent. Allowthe primary air cleaner element to soak for sixhours.

3. Drain the wash tank. Do not use the cleaningagent more than one time. Remove the primaryair cleaner element from the wash tank. Rinsethe primary air cleaner element with the methodfor using pressurized water.

Note: Refer to Drying the Primary Air CleanerElements. Refer to Inspecting the Primary AirCleaner Elements.

Drying the Primary Air Cleaner ElementsThe oven method may be used in order to dryprimary air cleaner elements. If an oven is used,do not expose the primary air cleaner elements totemperatures that exceed 82 C (160 F).

Note: Do not use compressed air in order to dry theprimary air cleaner elements.

Primary air cleaner elements may be allowed toair dry. Allow two days for the primary air cleanerelements to air dry before the elements areinspected and installed.

Inspecting the Primary Air CleanerElements


Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in asimilar facility. Place the blue light in the primaryair cleaner element. Rotate the primary air cleanerelement. Inspect the primary air cleaner element fortears and/or holes. Inspect the primary air cleanerelement for light that may show through the filtermaterial. If it is necessary in order to confirm theresult, compare the primary air cleaner elementto a new primary air cleaner element that has thesame part number.

Do not use a primary air cleaner element that hasany tears and/or holes in the filter material. Do notuse an primary air cleaner element with damaged

pleats, gaskets or seals. Discard damaged primaryair cleaner elements.

Storing Primary Air Cleaner Elements

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


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78Maintenance SectionEngine Air Cleaner Service Indicator - Inspect

Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. Restricted air flowmay result. To protect against dirt and damage,wrap the primary air cleaner elements in VolaliteCorrosion Inhibited (VCI) paper.

Place the primary air cleaner element into a boxfor storage. For identification, mark the outside ofthe box and mark the primary air cleaner element.Include the following information:

Date of the cleaning

Number of cleanings

Store the box in a dry location.

For more detailed information on cleaning theprimary air cleaner element, refer to SpecialPublication, SEBF8062, Procedure to Inspect and

Clean Air Filters.

i01175055

Engine Air Cleaner ServiceIndicator - Inspect

SMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differential

gauge for inlet air pressure. The differential gaugefor inlet air pressure displays the difference in thepressure that is measured before the air cleanerelement and the pressure that is measured afterthe air cleaner element. As the air cleaner elementbecomes dirty, the pressure differential rises. If yourengine is equipped with a different type of serviceindicator, follow the OEM recommendations in orderto service the air cleaner service indicator.

The service indicator may be mounted on the aircleaner element or in a remote location.


Typical service indicator

Observe the service indicator. The air cleanerelement should be cleaned or the air cleaner

element should be replaced when one of thefollowing conditions occur:

The yellow diaphragm enters the red zone.

The red piston locks in the visible position.

Test the Service Indicator

Service indicators are important instruments.

Check for ease of resetting. The service indicatorshould reset in less than three pushes.

Check the movement of the yellow core when theengine is accelerated to the engine rated speed.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If thenew service indicator will not reset, the hole for theservice indicator may be plugged.

The service indicator may need to be replacedfrequently in environments that are severely dusty, ifnecessary. Replace the service indicator annuallyregardless of the operating conditions. Replace theservice indicator when the engine is overhauled,and whenever major engine components arereplaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 Nm (18 lb in).

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Engine Air Precleaner - Check/Clean

i00720883

Engine Air Precleaner -Check/Clean

SMCS Code: 1055-070; 1055-535


Typical engine precleaner

(1) Wing nut(2) Cover(3) Body

Remove wing nut (1) and cover (2). Check for anaccumulation of dirt and debris in body (3). Cleanthe body, if necessary.

After cleaning the precleaner, install cover (2) andwing nut (1).

Note: When the engine is operated in dustyapplications, more frequent cleaning is required.

i01007514

Engine Crankcase Breather -Clean

SMCS Code: 1317-070

NOTICEPerform this maintenance with the engine stopped.

If the crankcase breather is not maintained on aregular basis, the crankcase breather will becomeplugged. A plugged crankcase breather will causeexcessive crankcase pressure that may causecrankshaft seal leakage.


(1) Hose clamp(2) Breather assembly(3) Seal

1. Loosen hose clamp (1) and remove the hosefrom breather assembly (2).

2. Remove breather assembly (2) and seal (3).

3. Wash the breather element in solvent that isclean and nonflammable. Allow the breatherelement to dry before installation.

4. Install a breather element that is clean and dry.Install seal (3) and breather assembly (2).

5. Install the hose. Install hose clamp (1). Refer tothe Operation and Maintenance Manual, TorqueSpecifications topic (Maintenance Section) forthe proper torque.

i00259257

Engine Mounts - Inspect

SMCS Code: 1152-040

Inspect the engine mounts for deterioration and forproper bolt torque. Engine vibration can be causedby the following conditions:

Improper mounting of the engine

Deterioration of the engine mounts

Any engine mount that shows deterioration shouldbe replaced. Refer to the Service Manual forthe recommended torques. Refer to the OEMrecommendations for more information.

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80Maintenance SectionEngine Oil Level - Check

i00623423

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

g00110310

Illustration 34(Y) ADD mark. (X) FULL mark.

NOTICEPerform this maintenance with the engine stopped.

1. Maintain the oil level between ADD mark (Y)and FULL mark (X) on oil level gauge (1). Donot fill the crankcase above FULL mark (X).

NOTICEOperating your engine when the oil level is above theFULL mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oils lubricating char-acteristics and could result in the loss of power.

2. Remove the oil filler cap and add oil, if necessary.Clean the oil filler cap. Install the oil filler cap.

i01534451

Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1348-554-SM;7542-554-OC, SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using SOS oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine.

Obtain the Sample and the Analysis

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components tocontact the skin.

Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

Engine model

Service hours on the engine

The number of hours that have accumulatedsince the last oil change

The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of theoil in the crankcase, obtain a warm, well mixed oilsample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and the

consistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.

NOTICEDo not use the same vacuum sampling pump for ex-

tracting oil samples that is used for extracting coolantsamples.

A small residue of either type sample may remain inthe pump and may cause a false positive analysis forthe sample being taken.

Always use a designated pump for oil sampling and adesignated pump for coolant sampling.

Failure to do so may cause a false analysis whichcould lead to customer and dealer concerns.

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Engine Oil and Filter - Change

If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEHP6001,How To Take A Good Oil Sample. Consult yourCaterpillar dealer for complete information andassistance in establishing an SOS program foryour engine.

i01591548

Engine Oil and Filter - Change

SMCS Code: 1318-510; 1348-044

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

Do not drain the oil when the engine is cold. Asthe oil cools, suspended waste particles settleon the bottom of the oil pan. The waste particlesare not removed with the draining cold oil. Drainthe crankcase with the engine stopped. Drain thecrankcase with the oil warm. This draining methodallows the waste particles that are suspended in theoil to be drained properly.

Failure to follow this recommended procedure willcause the waste particles to be recirculated throughthe engine lubrication system with the new oil.

Drain the Engine Oil

After the engine has been run at the normaloperating temperature, stop the engine. Use one ofthe following methods to drain the engine crankcaseoil:

If the engine is equipped with a drain valve, turnthe drain valve knob counterclockwise in order to

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

If the engine is not equipped with a drain valve,remove the oil drain plug in order to allow the oilto drain. If the engine is equipped with a shallowsump, remove the bottom oil drain plugs fromboth ends of the oil pan.

After the oil has drained, the oil drain plugs shouldbe cleaned and installed.

Replace the Oil Filter

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

1. Remove the oil filter with a 1U-8760 ChainWrench.

2. Cut the oil filter open with a 175-7546 Oil FilterCutter Gp. Break apart the pleats and inspect theoil filter for metal debris. An excessive amount ofmetal debris in the oil filter may indicate earlywear or a pending failure.

Use a magnet to differentiate between theferrous metals and the nonferrous metals thatare found in the oil filter element. Ferrous metalsmay indicate wear on the steel and cast ironparts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is not

uncommon to find small amounts of debris in theoil filter. Consult your Caterpillar dealer in orderto arrange for a further analysis if an excessiveamount of debris is found in the oil filter.


Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mountingbase. Ensure that all of the old oil filter gasketis removed.

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

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82Maintenance SectionEngine Operation - Test

NOTICEDo not fill the oil filters with oil before installing them.This oil would not be filtered and could be contaminat-ed. Contaminated oil can cause accelerated wear toengine components.

5. Install the oil filter. Tighten the oil filter until theoil filter gasket contacts the base. Tighten the oilfilter by hand according to the instructions thatare shown on the oil filter. Do not overtighten theoil filter.

Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to the Operationand Maintenance Manual for more information onlubricant specifications. Fill the crankcase withthe proper amount of oil. Refer to the Operation

and Maintenance Manual for more informationon refill capacities.

NOTICEIf equipped with an auxiliary oil filter system or a re-mote oil filter system, follow the OEM or filter manu-facturers recommendations. Under filling or overfillingthe crankcase with oil can cause engine damage.

NOTICETo prevent crankshaft bearing damage, crank the en-gine with the fuel OFF. This will fill the oil filters beforestarting the engine. Do not crank the engine for morethan 30 seconds.

2. Start the engine and run the engine at LOWIDLE for two minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain backto the sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the ADD

and FULL marks on the oil level gauge.

i01592900

Engine Operation - Test

SMCS Code: 1000-081

S/N: CKK1-Up

In accordance with NFPA-20, start the engine andrun the engine for a minimum of 30 minutes in orderto attain normal operating temperature.

Automatic Operation

The basic function of a fire pump controller isautomatically starting the engine. The fire pumpcontroller will start the engine upon a drop inpressure in the water supply or from a number

of other demand signals. The controller providesautomatic cycled cranking and the controllerprovides alarm protection for various engine failures.After the demand period is terminated, The enginemay be manually stopped or the engine may beautomatically stopped.

Recommended ambient room temperature is 20 C(68 F). The jacket water coolant temperature mustbe maintained at a minimum of 49 C (120 F).

i00626013

Engine Protective Devices -Check

SMCS Code: 7400-535

Alarms and shutoffs must function properly. Alarmsprovide timely warning to the operator. Shutoffs helpto prevent damage to the engine. It is impossibleto determine if the engine protective devices arein good working order during normal operation.Malfunctions must be simulated in order to test theengine protective devices.

A calibration check of the engine protective devices

will ensure that the alarms and shutoffs activateat the setpoints. Ensure that the engine protectivedevices are functioning properly.

NOTICEDuring testing, abnormal operating conditions must besimulated.

The tests must be performed correctly in order to pre-vent possible damage to the engine.

To prevent damage to the engine, only authorizedservice personnel or your Caterpillar dealer should

perform the tests.

Visual Inspection

Visually check the condition of all gauges, sensorsand wiring. Look for wiring and components thatare loose, broken, or damaged. Damaged wiringor components should be repaired or replacedimmediately.

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Engine Storage Procedure - Check

i01430860

Engine Storage Procedure -Check

SMCS Code: 1000-535

Caterpillar requires all engines that are stored formore than 3 months to follow storage proceduresand start-up procedures. These procedures providemaximum protection to internal engine components.Refer to Special Instruction, SEHS9031, StorageProcedure For Caterpillar Products for informationon these procedures.

An extension of the oil change interval to 12months is permitted if you follow the requiredprocedures for storage and start-up. This extensionis permitted if the following intervals in the Operationand Maintenance Manual, Maintenance Interval

Schedule have not been reached:

Operating hours

Fuel consumption

i00869628

Engine Valve Lash -Inspect/Adjust

SMCS Code: 1102-025

The initial valve lash adjustment on new engines,rebuilt engines, or remanufactured engines isrecommended at the first scheduled oil change.The adjustment is necessary due to the initial wearof the valve train components and to the seating ofthe valve train components.

This maintenance is recommended by Caterpillaras part of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuringthe valve lash. To obtain an accurate measurement,allow the valves to cool before this maintenanceis performed.

Refer to the Service Manual for more information.

i00805059

Ether Starting Aid Cylinder -Replace(If Equipped)

SMCS Code: 1456-510-CD


Typical example

1. Loosen the ether cylinder clamp. Unscrew andremove the empty ether cylinder.

2. Remove the used gasket. Install the new gasketthat is provided with each new ether cylinder.

3. Install the new ether cylinder. Hand tighten theether cylinder. Tighten the ether cylinder clampsecurely.

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84Maintenance SectionFan Drive Bearing - Lubricate

i01602288

Fan Drive Bearing - Lubricate(If Equipped)

SMCS Code: 1359-086-BD


Typical grease fitting for the fan drive bearing

Lubricate the fan drive bearing with BearingLubricant Special Purpose Grease or the equivalent.

Inspect the fan drive pulley assembly. If the shaftis loose, an inspection of the internal componentsshould be performed. Refer to the Service Manual.

i00850658

Fuel Injection Timing - CheckSMCS Code: 1251-036-TM; 1290-036-TM

Note: The correct fuel timing specification isfound on the Engine Information Plate. Fueltiming specifications may vary for different engineapplications and/or for different power ratings.

A qualified mechanic should adjust the fuel injectortiming because special tools and training arerequired.

Refer to your Caterpillar dealer for the complete

adjustment procedure for the fuel injector timing.

i01534632

Fuel Inlet Screen -Clean/Inspect/Replace

SMCS Code: 1250-510-Z3; 1250-571-Z3;

1252-040-Z3; 1252-070-Z3; 1252-510-Z3;1252-571; 1252-571-Z3; 1252; 1256-040-Z3;1256-070-Z3; 1256-510-Z3; 1256

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.


1. Disconnect the fuel supply line.

2. Remove the fuel inlet screen.

3. Clean the fuel inlet screen with a nonflammablesolvent.

4. Install the fuel inlet screen.

5. Connect the fuel supply line.

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85Maintenance SectionFuel System - Prime

i01007661

Fuel System - Prime

SMCS Code: 1258-548

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

Prime the fuel system in order to fill the fuel filter.Prime the fuel system in order to purge trappedair. The fuel system should be primed under thefollowing conditions:

Running out of fuel

Storage

Replacement of the fuel filter

Engines that are Equipped with aFuel Priming Pump


(1) Select knob(2) Plunger

1. Turn select knob (1) counterclockwise until theindicator is in line with the body of the primingpump.

2. Unlock the plunger and operate the plunger untila resistance is felt. A considerable number ofpump strokes may be required.

3. Push in plunger (2) and tighten by hand.

4. Turn select knob (1) clockwise until the indicatoris in line with the fuel outlet.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

5. Promptly start the engine. If the engine runsrough, increase the engine rpm to one half ofthe rated rpm.

Note: If the engine will not start, further priming maybe necessary. If the engine continues to misfireor smoke after starting, further priming may benecessary.

Engines that are Not Equipped witha Fuel Priming Pump

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over any dis-connected fuel system components.

If the engine is not equipped with a fuel primingpump, it may be necessary to fill the fuel filter withclean fuel. The following procedure will only allowfiltered fuel to enter the fuel system.


(1) Plug

(2) Fuel filter

1. Remove plug (1) in order to fill fuel filter (2).Ensure that air is able to vent from the fitting ofthe plug while the fuel filter is being filled. Cleanup any spilled fuel immediately. Clean plug (1).Install plug (1).

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

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86Maintenance SectionFuel System Primary Filter - Clean/Replace

2. Start the engine and immediately increase theengine rpm to one half of the rated rpm.

3. Maintain the engine rpm until the engine operatessmoothly.

4. Reduce the engine rpm to low idle.

i00951418

Fuel System Primary Filter -Clean/Replace

SMCS Code: 1260-070; 1260-510


1. Stop the engine.

2. Turn the start switch to the OFF position.Disconnect the battery.

3. Shut off the fuel tank supply valve to the engine.

4. If the primary fuel filter is equipped with a drainvalve, open the drain valve in order to drain any

fuel from the filter case. Close the drain valve.

NOTICEUse a suitable container to catch any fuel that mightspill. Clean up any spilled fuel immediately.


(1) Bolt(2) Element(3) Case

5. Loosen the bolt (1) that is on the filter housing.Remove the filter case (3).

6. Remove the element (2) and wash the elementin clean, nonflammable solvent.

NOTICEDo not fill the fuel filters with fuel before installing them.The fuel would not be filtered and could be contami-

nated. Contaminated fuel will cause accelerated wearto fuel system parts.

7. Install the element (2) and the filter case (3).Tighten the bolt (1) to a torque of 24 4 Nm(18 3 lb ft).

i00914347

Fuel System PrimaryFilter/Water Separator Element- Replace

SMCS Code: 1260-510-FQ; 1263-510-FQ

Water in the fuel can cause the engine to run rough.Water in the fuel may cause fuel system componentsto fail. If the fuel has been contaminated with water,the element should be changed before the regularlyscheduled interval.

The primary filter/water separator also providesfiltration in order to help extend the life of thesecondary fuel filter. The element should bechanged regularly. The primary filter/water separatorshould be changed when the vacuum gauge (ifequipped) registers 50 to 70 kPa (15 to 20 In Hg).

Replace the Element


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Fuel System Secondary Filter - Replace


(1) Vent valve(2) Base(3) Can(4) Element(5) Drain plug

1. Close the main fuel supply valve.

2. Remove drain plug (5). Depress vent valve (1)in order to start the flow of fuel. Allow the fuel todrain into a suitable container. Dispose of thefuel properly.

3. Install the drain plug.

4. Remove can (3) from base (2).

5. Remove element (4) from the can. Dispose ofthe used element.

6. Remove the gasket. Clean the followingcomponents:

Can

Gasket

Base

Inspect the gasket for damage and fordeterioration. Replace the gasket, if necessary.

7. Install the gasket. Lubricate the gasket with

clean diesel fuel.

NOTICEThe primary filter/water separator may be prefilled withfuel to avoid rough running/stalling of the engine dueto air. Do not fill the secondary filter with fuel beforeinstallation. The fuel would not be filtered and couldbe contaminated. Contaminated fuel will cause accel-erated wear to fuel system parts.

8. Install a new element in the can. The can maybe filled with fuel at this time.

9. Install the can on the base. Tighten the can byhand. Do not use tools in order to tighten the can.

NOTICEThe water separator is under suction during normalengine operation. Ensure that the vent plug is tight-

ened securely to help prevent air from entering the fu-el system.

10. Open the main fuel supply valve.

11. Start the engine and check for leaks. Run theengine for one minute. Stop the engine andcheck for leaks again.

Leaks are difficult to detect while the engine isrunning. The primary filter/water separator isunder suction. A leak will allow air to enter thefuel. The air in the fuel can cause low power due

to aeration of the fuel. If air enters the fuel, ensurethat all components are properly tightened.

i01007602

Fuel System Secondary Filter -Replace

SMCS Code: 1261-510-SE


1. Stop the engine.

2. Turn off the start switch, or disconnect the battery(starting motor) when maintenance is performedon fuel filters.

3. Shut off the fuel tank supply valve to the engine.


4. Unlock the fuel priming pump (if equipped). Thisrelieves any residual pressure in the fuel system.

5. Remove the used fuel filter. Use a cloth, or use acontainer to catch excess fuel.

6. Clean the gasket sealing surface of the fuelfilter base. Ensure that all of the old gasket isremoved.

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88Maintenance SectionFuel System Water Separator - Drain

7. Apply clean diesel fuel to the new fuel filtergasket.

NOTICEDo not fill the secondary fuel filter with fuel before in-stalling. The fuel would not be filtered and could be

contaminated. Contaminated fuel will cause acceler-ated wear to fuel system parts.

8. Install a new fuel filter, and tighten the fuel filteruntil the gasket contacts the base.

9. Tighten the fuel filter by hand according to theinstructions that are shown on the fuel filter.

Do not overtighten the fuel filter.

10. Lock the fuel priming pump (if equipped). Openthe fuel tank supply valve.

11. If the engine stalls, refer to the Operation andMaintenance Manual, Fuel System - Prime topic(Maintenance Section) for more information.

i00909035

Fuel System Water Separator- Drain

SMCS Code: 1263-543

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.


(1) Vent valve(2) Base(3) Can(4) Element(5) Drain plug

Water in the fuel can cause fuel system componentsto fail. Drain the water separator daily. Drain thewater separator more frequently when a largeconcentration of water is present in the fuel system.

1. Close the fuel supply valve.


2. Remove drain plug (5). Depress vent valve (1) inorder to start the flow. Allow the water to draininto a suitable container. Allow the water to flowuntil fuel flows from the drain.

3. Install the drain plug. Dispose of the liquidproperly.

4. Open the fuel supply valve.

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering the fuelsystem.

i00073301

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S

Fuel Tank

Fuel quality is critical to the performance and tothe service life of the engine. Water in the fuel cancause excessive fuel system wear. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes throughthe fuel system and the fuel returns to the fuel tank.This causes water to accumulate in fuel tanks.Draining the fuel tank regularly and obtaining fuelfrom reliable sources can help to eliminate waterin the fuel.

Drain the Water and the Sediment

Fuel tanks should contain some provision fordraining water and draining sediment from thebottom of the fuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

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Hoses and Clamps - Inspect/Replace

Check the fuel daily. Drain the water and sedimentfrom the fuel tank after operating the engine or drainthe water and sediment from the fuel tank after thefuel tank has been filled. Allow five to ten minutesbefore performing this procedure.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayoverflow.

Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel directly from the bottom of the tank. Ifthe engine is equipped with this system, regularmaintenance of the fuel system filter is important.

Fuel Storage Tanks

Drain the water and the sediment from the fuelstorage tank during the following conditions:

Weekly

Oil change

Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank.

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaffles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from thestorage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

i00907072

Hoses and Clamps -Inspect/Replace

SMCS Code: 7554-040; 7554-510

Inspect all hoses for leaks that are caused by thefollowing conditions:

Cracking

Softness

Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubes

and hoses carefully. Tighten all connections to the rec-ommended torque.

Check for the following conditions:

End fittings that are damaged or leaking

Outer covering that is chafed or cut

Exposed wire that is used for reinforcement

Outer covering that is ballooning locally

Flexible part of the hose that is kinked or crushed

Armoring that is embedded in the outer covering

A constant torque hose clamp can be used inplace of any standard hose clamp. Ensure that theconstant torque hose clamp is the same size asthe standard clamp.

Due to extreme temperature changes, the hosewill heat set. Heat setting causes hose clamps toloosen. This can result in leaks. A constant torquehose clamp will help to prevent loose hose clamps.

Each installation application can be different. Thedifferences depend on the following factors:

Type of hose

Type of fitting material

Anticipated expansion and contraction of thehose

Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps


1. Stop the engine. Allow the engine to cool.

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90Maintenance SectionOverhaul Considerations

2. Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.

Note: Drain the coolant into a suitable, cleancontainer. The coolant can be reused.

3. Drain the coolant from the cooling system toa level that is below the hose that is beingreplaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

Note: For torques on hose clamps, see thisOperation and Maintenance Manual, TorqueSpecifications (Maintenance Section).

7. Install the hose clamps with a torque wrench.

Note: For the proper coolant to use, see thisOperation and Maintenance Manual, CoolantRecommendations (Maintenance Section).

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler caps gaskets. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

10. Start the engine. Inspect the cooling system forleaks.

i01452713

Overhaul Considerations

SMCS Code: 7595-043

Reduced hours of operation at full load will resultin a lower average power demand. A decreasedaverage power demand should increase both theengine service life and the overhaul interval.

The need for an overhaul is generally indicated byincreased fuel consumption and by reduced power.

The following factors are important when a decisionis being made on the proper time for an engineoverhaul:

The need for preventive maintenance

The quality of the fuel that is being used

The operating conditions

The results of the SOS analysis

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