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2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt

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SEBU7276-01May 2001

Operation andMaintenance

Manual3054B Industrial Engine

5MF1-Up (Engine)

This Manual Must be Accessible at the Point of Operation

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59Maintenance Section

Maintenance Interval Schedule

i01536402

Maintenance Interval Schedule

SMCS Code: 1000; 7500

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.

There are many operating conditions and typesof lubricants that may require an adjustment tothe normal oil change interval. Refer to Operation

and Maintenance Manual, Engine Oil and Filter -Change for your specific oil change intervals.

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

When Required

Battery - Replace .................................................. 60Battery or Battery Cable - Disconnect .................. 61Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 68Engine Air Cleaner Element (Single Element) -

Replace ............................................................... 72Fuel System - Prime ............................................. 77

Daily

Cooling System Coolant Level - Check ................ 65Driven Equipment - Check .................................... 68Engine Air Cleaner Service Indicator - Inspect ..... 72Engine Oil Level - Check ...................................... 73Walk-Around Inspection ........................................ 85

Every 250 Service Hours or 3 Months

Alternator and Fan Belts - Inspect/Adjust/Replace ............................................................... 60

Battery Electrolyte Level - Check .......................... 61Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 66Engine Oil Sample - Obtain .................................. 73Engine Oil and Filter - Change ............................. 74Fuel Tank Water and Sediment - Drain ................. 80Hoses and Clamps - Inspect/Replace .................. 81Radiator - Clean .................................................... 84

Every 500 Service Hours or 6 Months

Engine Oil and Filter - Change ............................. 74Engine Protective Devices - Check ....................... 75

Fuel Transfer Pump Strainer - Clean .................... 77Fuel System Secondary Filter - Replace .............. 79

Every 1000 Service Hours

Engine Valve Lash - Inspect/Adjust ...................... 76

Every 2000 Service Hours or 1 Year

Engine Mounts - Inspect ....................................... 73Fuel Injection Nozzles - Test/Exchange ................ 76

Every 3000 Service Hours or 2 Years

Alternator - Inspect ............................................... 60Cooling System Coolant (DEAC) - Change .......... 62Cooling System Coolant Extender (ELC) - Add .... 65Cooling System Water Temperature Regulator -

Replace ............................................................... 67Crankshaft Vibration Damper - Inspect ................. 68Starting Motor - Inspect ........................................ 85Water Pump - Inspect ........................................... 86

Overhaul

Overhaul Considerations ...................................... 82

Every 6000 Service Hours or 4 Years

Cooling System Coolant (ELC) - Change ............. 64Engine - Clean ...................................................... 68

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60Maintenance SectionAlternator - Inspect

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 temperature

affects 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.

i01150959

Alternator and Fan Belts -Inspect/Adjust/Replace

SMCS Code: 1357-039

Inspection

To maximize the engine performance, inspect thebelts for wear and for cracking. Replace belts thatare worn or damaged.

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.

If the belts are too loose, vibration causesunnecessary wear on the belts and pulleys. Loosebelts may slip enough to cause overheating.

To check the belt tension, apply 45 N (10 lb ft)of force midway between the pulleys. A correctlyadjusted belt will deflect 10 mm (0.39 inch).

Adjustment

g00285332Illustration 24

Typical example

(1) Adjusting bolt(2) Mounting bolts

1. Loosen mounting bolts (2) and adjusting bolt (1).

2. Move the alternator in order to increase ordecrease the belt tension.

3. Tighten adjusting bolt (1). Tighten mounting bolts(2). Refer to the Operation and MaintenanceManual for the proper torque settings.

If new belts are installed, check the belt tensionagain after 20 hours of engine operation.

ReplacementRefer to the Service Manual for the installationprocedure and the removal procedure for the belt.

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.

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Battery Electrolyte Level - Check

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: 1401-081

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.

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 the1U-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.

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62Maintenance SectionCooling System Coolant (DEAC) - Change

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 that

the 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.

i01196460

Cooling System Coolant

(DEAC) - ChangeSMCS 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 replace

the water pump, the water temperature regulatorand the hoses, if necessary.

Drain

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.


Drain Plugs

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

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 fulldistillation 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 Technology

Group:

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.

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Cooling System Coolant (DEAC) - Change

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theOperation and Maintenance Manual for moreinformation on the proper torques.

NOTICE

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

3. Fill the cooling system with 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 a minimumof 30 minutes with a coolant temperature of atleast 82 C (180 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. Installthe drain plugs. Refer to the Operation andMaintenance Manual, Torque Specifications formore information on the proper torques.

Cooling Systems with Heavy

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


2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theOperation and Maintenance Manual for moreinformation 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 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).

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 for more information on theproper torques.

Fill


1. Fill the cooling system with coolant/antifreeze.

Refer to the Operation and MaintenanceManual for more information on cooling systemspecifications. Do not install the cooling systemfiller cap.

2. Place the transmission in neutral. Start and runthe engine at low idle. Increase the engine rpmto 1500 rpm. Run the engine at 1500 rpm for oneminute in order to purge the air from the cavitiesof 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 level

within 13 mm (0.5 inch) to the proper level on thesight glass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket for the filler cap. If the gasket for the fillercap is damaged, discard the old cooling systemfiller cap and install a new cooling systemfiller cap. If the gasket for the filler cap is notdamaged, use a 9S-8140 Pressurizing Pump inorder to pressure test the cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install a

new cooling system filler cap.

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

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64Maintenance SectionCooling System Coolant (ELC) - Change

i01196510

Cooling System Coolant (ELC)- Change

SMCS Code: 1350-070; 1395-044

When the cooling system is cleaned, only cleanwater is needed when the ELC is drained andreplaced.

Drain

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.


Drain Plugs

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.

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


2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theOperation and Maintenance Manual, TorqueSpecifications for more information on theproper torques.


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 Specifications formore information on the proper torques.

Fill


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Cooling System Coolant Extender (ELC) - Add

1. Fill the cooling system to the top withcoolant/antifreeze. Refer to the Operation andMaintenance Manual for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Place the transmission in neutral. Start and runthe engine at low idle. Increase the engine rpmto 1500 rpm. Run the engine at 1500 rpm for oneminute in order to purge the air from the cavitiesof 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 for the filler cap. If the gasket for the filler

cap is damaged, discard the old cooling systemfiller cap and install a new cooling systemfiller cap. If the gasket for the filler cap is notdamaged, use a 9S-8140 Pressurizing Pump inorder to pressure test the cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install anew 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.

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.


Cooling system filler cap

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. 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.

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66Maintenance SectionCooling System Supplemental Coolant Additive (SCA) - Test/Add


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.

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.

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Cooling System Water Temperature Regulator - Replace

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.

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.

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68Maintenance SectionCrankshaft Vibration Damper - Inspect

i01196868

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.

Removal and InstallationRefer to the Service Manual for the damperremoval procedure and for the damper installationprocedure.

i00174798

Driven Equipment - Check

SMCS Code: 3279-535

Refer to the OEM specifications for more informationon the following maintenance recommendations for

the 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

i01397558

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

SMCS Code: 1054-037; 1054-510

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

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

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

Servicing the Air Cleaner ElementsIf 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 with

clean 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 fordamage. Maintain a supply of suitable air cleanerelements for replacement purposes.

Dual Element Air Cleaners

The dual element air cleaner contains a primaryair cleaner element and a secondary air cleanerelement. The primary air cleaner element can beused up to six times if the element is properly

cleaned and inspected. The primary air cleanerelement should be replaced at least one timeper year. This replacement should be performedregardless 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 requiremore frequent replacement.


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

1. Remove the cover. Remove the primary air

cleaner 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 FilterElements.

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.

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.

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

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. Engine

damage 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 elementalong 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 cleaning

primary 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.

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.

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

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 washing theelement with a process of agitation. Agitation maycause carbon particles to 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. Rinse

the 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 Elements

The 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 cleaner

element 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 damagedpleats, 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.


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

Place the primary air cleaner element into a boxfor storage. For identification, mark the outside of

the box and mark the primary air cleaner element.Include the following information:

Date of 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 andClean Air Filters.

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72Maintenance SectionEngine Air Cleaner Element (Single Element) - Replace

i00619873

Engine Air Cleaner Element(Single Element) - Replace

SMCS Code: 1051; 1054

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


(1) Air cleaner element. (2) Clamp.

1. Loosen clamp (2) which fastens air cleanerelement (1) to the air inlet. Remove the dirty aircleaner element and clamp.

2. Install clamp (2) on new air cleaner element (1).

3. Install new air cleaner element (1) to the air inletand tighten clamp (2). Refer to the Operationand Maintenance Manual for more information ontorque specifications.

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 differentialgauge 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 cleanerelement 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 Mounts - Inspect

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.

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.


(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 personalinjury. Do not allow hot oil or hot components to

contact the skin.

Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In 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 theconsistency 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.

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74Maintenance SectionEngine Oil and Filter - Change

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.

If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposable

tubing 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.

i01536470

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 method

allows 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 todrain 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. Tighten the oil drain plugsto 70 14 Nm (50 10 lb ft).

Replace the Oil Filter

NOTICE

Caterpillar 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. Break apart the pleats and inspect the oilfilter 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 notuncommon 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.

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Engine Protective Devices - Check


Typical filter mounting base and filter gasket

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

is removed.

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

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 that

are 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 Operationand Maintenance Manual for more informationon refill capacities.

NOTICE

If equipped with an auxiliary oil filter or system, extraoil must be added when filling the crankcase. Followthe OEM or filter manufacturers recommendations. Ifthe extra oil is not added, the engine may starve foroil.

NOTICETo help prevent crankshaft or bearing damage, crankengine to fill all filters before starting. Do not crankengine for more than 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 ADDand FULL marks on the oil level gauge.

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 deviceswill 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 shouldperform 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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76Maintenance SectionEngine Valve Lash - Inspect/Adjust

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.

i00626014

Fuel Injection Nozzles -Test/Exchange

SMCS Code: 1254-013; 1254-081

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.

Fuel injection nozzles are subject to tip wear. Tipwear is a result of fuel contamination. Tip wear cancause the following problems:

Increased fuel consumption

Black smoke

Misfire

Rough running

Fuel Injection nozzles should be cleaned, inspected,tested, and replaced, if necessary. Refer to Special

Instruction, SEHS7292 for using the 8S-2245Injection Cleaning Tool Group. Consult yourCaterpillar dealer about cleaning the fuel injectionnozzle and testing the fuel injection nozzle.

NOTICENever wire brush or scrape a fuel injection nozzle.Wire brushing or scraping a fuel injection nozzle willdamage the finely machine orifice. Proper tools forcleaning and testing the fuel injection nozzles can beobtained from Caterpillar dealers.

The following items are symptoms of a malfunction

of the fuel injection nozzle:

Abnormal engine operation

Smoke emission

Engine knock

Each fuel injection nozzle must be isolated one at atime in order to determine the malfunctioning fuelinjection nozzle.

1. Start the engine.

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Fuel Transfer Pump Strainer - Clean

2. Loosen each fuel line nut one at a time at the fuelinjection pump. A cloth or similar material mustbe used in order to prevent fuel from spraying onthe hot exhaust components. Tighten each nutbefore loosening the next nut.

3. A defective fuel injection nozzle may be identifiedwhen a fuel line nut is loosened and the followingconditions are present:

The exhaust smoke is partially eliminated orthe exhaust smoke is completely eliminated.

Engine performance is not affected.

A fuel injection nozzle that is suspected ofbeing defective should be removed. A newfuel injection nozzle should be installed in thecylinder in order to determine if the removed fuelinjection nozzle is defective.

Removal and Installation of theFuel Injection Nozzles

For the removal and the installation of fuel injectionnozzles, special tooling is required. Refer to theService Manual for more information. Consult yourCaterpillar dealer for assistance.

i01190897

Fuel Transfer Pump Strainer -

CleanSMCS Code: 1256-070-STR

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.

NOTICE

Do 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.

Cleaning the Strainer and theSediment Chamber for the FuelTransfer Pump

Turn the fuel supply valve to the OFF position beforethe maintenance is performed.


(1) Fuel transfer pump(2) Cover and seal(3) Strainer

1. Remove the cover and seal (2) from the top offuel transfer pump (1). Remove strainer (3).

2. Use nonflammable solvent in order to cleanthe strainer, the cover, and the seal. Carefullywash any sediment from the chamber of the fueltransfer pump.

3. Assemble the clean, dry fuel transfer pump.

NOTICEEnsure that the lift pump cover is secure so that airdoes not enter the fuel system.

4. Turn the fuel supply to the ON position.

5. Prime the fuel system. Refer to the Operationand Maintenance Manual for more information onpriming the fuel system.

i01539174

Fuel System - Prime

SMCS Code: 1258-548

Priming the fuel system fills the fuel filter. Priming

the fuel system removes air bubbles from the fuelsystem. Prime the fuel system under the followingconditions:

Fuel system that is run dry

Storage

Fuel filter maintenance

Disconnecting fuel lines and installing fuel lines

Repair of leaks in the fuel lines

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78Maintenance SectionFuel System - Prime


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


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. Loosen vent (2).

2. Tighten vent (2).

3. Loosen banjo bolt (1).

Note: The priming lever of the fuel transfer pumpcannot be operated if the cam is at the maximumlift position. If this occurs, the crankshaft must berotated one revolution.

4. Operate the priming lever for the fuel transferpump until the flow of fuel from banjo bolt (1) iscontinuous and free of air bubbles.


Priming lever for the fuel transfer pump

Note: The priming lever of the fuel transfer pumpcannot be operated if the cam is at the maximum

lift position. If this occurs, the crankshaft must berotated one revolution.

5. Operate the priming lever for the fuel transferpump until the flow of fuel from the vent iscontinuous and free of air bubbles. Tighten thebolt at the top of the fuel filter.


Nut for the fuel inlet line at the fuel injection pump

6. Loosen the nut for the fuel inlet line at the fuelinjection pump in order to open a vent.

7. Ensure that the manual stop control (if equipped)is in the RUN position. Turn the start switch tothe RUN position. Operate the priming lever forthe fuel transfer pump until the flow of fuel fromthe vent is continuous and free of air bubbles.Tighten the nut for the fuel inlet line.

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Fuel System Secondary Filter - Replace


Fuel line nuts at the fuel injection nozzles

8. Loosen two of the fuel line nuts at two of the fuelinjection nozzles in order to open two vents.

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

9. Ensure that the manual stop control (if equipped)is in the RUN position. Crank the starting motoruntil the flow of fuel from the vents is continuousand free of air bubbles. Tighten the fuel line nuts.

10. Ensure that all fuel line connections are secureand tightened to the proper torque. Ensure that

any spilled fuel is cleaned up.

11. Start the engine. The engine may run rough.Run the engine at low idle until the engine runssmoothly. If the engine will not start, furtherpriming may be necessary. If the engine startsand if the engine continues to misfire or smoke,one or more of the following conditions may bepresent:

The fuel system requires more priming.

There may be an air leak in the fuel system.

i00632067

Fuel System Secondary Filter -Replace

SMCS Code: 1261-510-SE


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.

Turn the fuel supply valve to the OFF position beforeperforming this maintenance. Place a tray under thefuel filter in order to catch any fuel that might spill.Clean up any spilled fuel immediately.


(1) Cap. (2) Locking ring. (3) Element. (4) Drain.

1. Close the fuel supply valve.

2. Clean the outside of the fuel filter assembly.

Open drain (4) and drain the fuel and water fromelement (3) into a suitable container.

Note: If the element is not equipped with a drain,remove cap (1). Remove the nylon insert in order toreduce the level of fuel in the element. A reduction inthe level of fuel in the element will help prevent fuelfrom being spilled when the element is removed.

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80Maintenance SectionFuel Tank Water and Sediment - Drain

NOTICEDo not use a tool in order to remove the fuel filter.Attempting to remove the fuel filter with a filter wrenchor a filter strap could damage the locking ring.

3. Hold element (3) and rotate locking ring (2)counterclockwise. Remove locking ring (2). Theused element should be removed and discarded.

Note: If the element is equipped with a sedimentbowl, remove the sediment bowl from the element.Thoroughly clean the sediment bowl. Inspect theO-ring seals. Install new O-ring seals, if necessary.Install the sediment bowl to the new element. Handtighten the sediment bowl. Hand tightening is theonly method that should be used.

NOTICE

Do not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

4. Ensure that the filter head is clean. Push a newelement fully into the filter head.

5. Hold the element in place. Fit locking ring (2)into position. Rotate the locking ring clockwise inorder to fasten the element to the filter head.

Note: If the nylon insert was removed, install thenylon insert and install cap (1).

6. Prime the fuel system. Refer to the Operationand Maintenance Manual in the MaintenanceSection for more information.

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.

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 may

overflow.

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.

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Hoses and Clamps - Inspect/Replace

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, tubesand 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 hose

will 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.

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

cooling 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 the

cooling 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.

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82Maintenance SectionOverhaul Considerations

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

Oil Consumption as an OverhaulIndicator

Oil consumption, fuel consumption, andmaintenance information can be used to estimatethe total operating cost for your Caterpillar engine.Oil consumption can also be used to estimate

the required capacity of a makeup oil tank that issuitable for the maintenance intervals.

Oil consumption is in proportion to the percentageof the rated engine load. As the percentage of theengine load is increased, the amount of oil that isconsumed per hour also increases.

The oil consumption rate (brake specific oilconsumption) is measured in grams per kW/h(lb per bhp). The brake specific oil consumption(BSOC) depends on the engine load. Consult yourCaterpillar dealer for assistance in determining thetypical oil consumption rate for your engine.

When an engines oil consumption has risen tothree times the original oil consumption rate dueto normal wear, an engine overhaul should bescheduled. There may be a corresponding increasein blowby and a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

A planned overhaul before failure may be the bestvalue for the following reasons:

Costly unplanned downtime can be avoided.

Many original parts can be reused according tothe standards for reusable parts.

The engines service life can be extended without

the risk of a major catastrophe due to enginefailure.

The best cost/value relationship per hour ofextended life can be attained.

After Failure Overhaul

If a major engine failure occurs and the enginemust be removed, many options are available. Anoverhaul should be performed if the engine blockor the crankshaft needs to be repaired.

If the engine block is repairable and/or the

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

This lower cost can be attributed to three aspects:

Specially designed Caterpillar engine features

Caterpillar dealer exchange components

Caterpillar Inc. remanufactured exchangecomponents

Overhaul Recommendation

To minimize downtime, Caterpillar Inc. recommendsa scheduled engine overhaul by your Caterpillardealer before the engine fails. This will provide youwith the best cost/value relationship.

Note: Overhaul programs vary according to theengine application and according to the dealerthat performs the overhaul. Consult your Caterpillardealer for specific information about the availableoverhaul programs and about overhaul services forextending the engine life.

If an overhaul is performed without overhaul servicefrom your Caterpillar dealer, be aware of thefollowing maintenance recommendations.

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Overhaul Considerations

Rebuild or Exchange

Cylinder Head Assembly, Cylinder Packs, OilPump, and Fuel Transfer Pump

These components should be inspected according

to the instructions that are found in variousCaterpillar reusability publications. The SpecialPublication, SEBF8029 lists the reusabilitypublications that are needed for inspecting theengine parts.

If the parts comply with the established inspectionspecifications that are expressed in the reusableparts guideline, the parts should be reused.

Parts that are not within the established inspectionspecifications should be dealt with in one of thefollowing manners:

Salvaging

Repairing

Replacing

Using out-of-spec parts can result in the followingproblems:

Unscheduled downtime

Costly repairs

Damage to other engine parts

Reduced engine efficiency

Increased fuel consumption

Reduced engine efficiency and increased fuelconsumption translates into higher operating costs.Therefore, Caterpillar Inc. recommends repairingout-of-spec parts or replacing out-of-spec parts.

Inspection and/or Replacement

Crankshaft Bearings, Valve Rotators, andCrankshaft Seals

The following components may not last until thesecond overhaul.

Thrust bearings

Main bearings

Rod bearings

Valve rotators

Crankshaft seals

Caterpillar Inc. recommends the installation of newparts at each overhaul period.

Inspect these parts while the engine is disassembledfor an overhaul.

Inspect the crankshaft for any of the followingconditions:

Deflection

Damage to the journals

Bearing material that has seized to the journals

Check the journal taper and the profile of thecrankshaft journals. Check these components byinterpreting the wear patterns on the followingcomponents:

Rod bearing

Main bearings

Inspect the camshaft for damage to the journalsand to the lobes.

Note: If the camshaft is removed for any reason, usethe magnetic particle inspection process to checkfor cracks in the camshaft.

Inspect the following components for signs of wearor for signs of scuffing:

Camshaft bearings

Camshaft followers

Caterpillar Inc. recommends replacing thecrankshaft vibration damper.

Oil Cooler Core

During an overhaul, Caterpillar Inc. recommendsthe removal of the oil cooler core. Clean the oilcooler core. Then, pressure test the oil cooler core.

NOTICEDo not use caustic cleaners to clean the core.

Caustic cleaners can attack the internal metals of thecore and cause leakage.

Note: Use this cleaning procedure to clean the oilcooler core.

1. Remove the oil cooler core.

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84Maintenance SectionRadiator - Clean

2. Remove any debris from the oil cooler core. Toremove debris from the oil cooler core, turn theoil cooler core onto one end.

3. Flush the oil cooler core internally with cleaner inorder to loosen foreign substances. This will also

help to remove oil from the oil cooler core.

Note: Caterpillar Inc. recommends the use ofHydrosolv Liquid Cleaners. Table 33 lists theHydrosolv Liquid Cleaners that are available fromyour Caterpillar dealer.

Table 33

HydrosolvLiquid Cleaners

PartNumber

Description Size

1U-8812 4 L (1 US gallon)

1U-549019 L (5 US gallon)

8T-7570

Hydrosolv4165208 L (55 US gallon)

1U-8804 4 L (1 US gallon)

1U-5492 19 L (5 US gallon)

8T-5571

Hydrosolv100

208 L (55 US gallon)

4. Use steam to clean the oil cooler core. Thisremoves any remaining residue from the cleaner.Flush the fins of the oil cooler core. Remove anyother trapped debris.

5. Wash the oil cooler core with hot, soapy water.

Rinse the oil cooler core thoroughly with cleanwater.

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.

6. Dry the oil cooler core with compressed air.Direct the air in the reverse direction of thenormal flow.

7. Inspect the components in order to ensurecleanliness. The oil cooler core should bepressure tested. Repair the oil cooler core, ifnecessary. Install the oil cooler core.

For more information about cleaning the cores,consult your Caterpillar dealer.

Obtain Coolant Analysis

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

is overhauled.

For example, considerable deposits are found in thewater jacket areas on the external cooling system,but the concentrations of coolant additives werecarefully maintained. The coolant water probablycontained minerals that were deposited on theengine over time.

A coolant analysis can be conducted in orderto verify the condition of the water that is beingused in the cooling system. A full water analysiscan be obtained by consulting your local waterutility company or an agricultural agent. Private

laboratories are also available for water analysis.

Caterpillar Inc. recommends an SOS CoolantAnalysis (Level 2).

SOS Coolant Analysis (Level 2)

An SOS Coolant Analysis (Level 2) is acomprehensive coolant analysis which completelyanalyzes the coolant and the effects on the coolingsystem. An SOS Coolant Analysis (Level 2)provides the following information:

Complete SOS Coolant Analysis (Level 1)

Visual inspection of properties

Identification of metal corrosion

Identification of contaminants

Identification of built up impurities (corrosion andscale)

SOS Coolant Analysis (Level 2) provides a report ofthe results of both the analysis and the maintenancerecommendations.

For more information about coolant analysis, seeyour Caterpillar dealer.

i01206548

Radiator - Clean

SMCS Code: 1353-070

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

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Starting Motor - Inspect

Inspect the radiator for these items: damaged fins,corrosion, dirt, grease, insects, leaves, oil, andother debris. Clean the radiator, if necessary.

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 move

the 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. Inspect these items forgood condition: welds, mounting brackets, air lines,connections, clamps, and seals. Make repairs, ifnecessary.

For more detailed information on cleaning andinspection, see Special Publication, SEBD0518,Know Your Cooling System.

i00651416

Starting Motor - Inspect

SMCS Code: 1451-040; 1453-040

Caterpillar Inc. recommends a scheduled inspectionof the starting motor. If the starting motor fails, theengine may not start in an emergency situation.

Check the starting motor for proper operation.Check the electrical connections and clean theelectrical connections. Refer to the Service Manualfor more information on the checking procedure andfor specifications or consult your Caterpillar dealerfor assistance.

i00632301

Walk-Around Inspection

SMCS Code: 1000-040

Inspect the Engine for Leaks andfor Loose Connections

A walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can be

avoided.

For maximum engine service life, make a thoroughinspection of the engine compartment beforestarting the engine. Look for items such as oil leaksor coolant leaks, loose bolts, worn belts, looseconnections and trash buildup. Make repairs, asneeded:

The guards must be in the proper place. Repairdamaged guards or replace missing guards.

Wipe all caps and plugs before the engine isserviced in order to reduce the chance of system

contamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICEAccumulated grease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaning

or high pressure water.

Ensure that cooling lines are properly clampedand tight. Check for leaks. Check the conditionof all pipes.

Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by coolantin the cooling system. It is normal for a small amountof leakage to occur as the engine cools down andthe parts contract.

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86Maintenance SectionWater Pump - Inspect

Excessive coolant leakage may indicate the needto replace the water pump seal. For the removalof water pump and the installation of water pumpand/or seals, refer to the Service Manual for theengine or consult your Caterpillar dealer.

Inspect the lubrication system for leaks at thefront crankshaft seal, the rear crankshaft seal, theoil pan, the oil filters and the valve cover.

Inspect the fuel system for leaks. Look for loosefuel line clamps.

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

Inspect the alternator belt and the accessorydrive belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced

as matched sets. If only one belt is replaced, thebelt will carry more load than the belts that arenot replaced. The older belts are stretched. Theadditional load on the new belt could cause thebelt to break.

Drain the water and the sediment from fuel tankson a daily basis in order to ensure that only cleanfuel enters the fuel system.

Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

Inspect the ground strap for a good connectionand for good condition.

Inspect the engine-to-frame ground strap for agood connection and for good condition.

Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolytelevel of the batteries, unless the engine isequipped with a maintenance free battery.

Check the condition of the gauges. Replaceany gauges which are cracked or can not be

calibrated.

i01057943

Water Pump - Inspect

SMCS Code: 1361-040; 1361

A failed water pump might cause severe engineoverheating problems that could result in thef ll i di i

A piston seizure

Other potential damage to the engine

Visually inspect the water pump for leaks. If anyleaking is observed, replace the water pump

seal or the water pump assembly. Refer to theService Manual for the disassembly and assemblyprocedure.

Note: Refer to the Service Manual or consult yourCaterpillar dealer if any repair is needed or anyreplacement is needed.

SEBU7276-01 M

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