Maintenance Intervals: Operation and Maintenance Manual Excerpt
Maintenance Intervals: Operation and Maintenance Manual Excerpt
Maintenance Intervals: Operation and Maintenance Manual Excerpt
SAFETY.CAT.COM
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When Required
Battery - Replace .................................................. Battery or Battery Cable - Disconnect .................. Engine - Clean ...................................................... Engine Air Cleaner Element (Dual Element) Clean/Replace .................................................... Engine Air Cleaner Element (Single Element) Replace ............................................................... Fuel System - Prime ............................................. 55 56 64 64 67 74
Daily
Alternator and Fan Belts - Inspect/Adjust/ Replace ............................................................... Cooling System Coolant Level - Check ................ Driven Equipment - Check .................................... Engine Air Cleaner Service Indicator - Inspect ..... Engine Oil Level - Check ...................................... Fuel System Primary Filter/Water Separator Drain ................................................................... Walk-Around Inspection ........................................ 54 60 63 67 68 75 83
Overhaul
Engine Crankcase Breather - Clean ..................... 68 Overhaul Considerations ...................................... 80
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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. 8. Dry the core with compressed air. Direct the air in the reverse direction of the normal ow.
Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. 3. Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction of the fan's air ow. Hold the nozzle approximately 6 mm (.25 inch) away from the ns. Slowly move the air nozzle in a direction that is parallel with the tubes. This will remove debris that is between the tubes. 4. Pressurized water may also be used for cleaning. The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean the core from both sides. NOTICE Do not use a high concentration of caustic cleaner to clean the core. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner. 5. Back ush the core with a suitable cleaner. 6. Steam clean the core in order to remove any residue. Flush the ns of the aftercooler core. Remove any other trapped debris. 7. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.
9. Inspect the core in order to ensure cleanliness. Pressure test the core. If necessary, repair the core. 10. Install the core. Refer to the OEM information for the correct procedure. 11. After cleaning, start the engine and accelerate the engine to high idle rpm. This will help in the removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.
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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.
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After cleaning, start the engine and accelerate the engine to high idle rpm. This will help in the removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary. Inspect the ns for damage. Bent ns may be opened with a comb. Note: If parts of the aftercooler system are repaired or 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.
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For applications that require multiple drive belts, replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched. The additional load on the new belt could cause the new belt to break. If the belts are too loose, vibration causes unnecessary wear on the belts and pulleys. Loose belts may slip enough to cause overheating. To accurately check the belt tension, 144-0235 Belt Tension Gauge should be used.
Alternator - Inspect
SMCS Code: 1405-040 Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and proper battery charging. Inspect the ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system. Make repairs, as required. Check the alternator and the battery charger for proper operation. If the batteries are properly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, the battery will not crank the engine. The battery will not crank the engine, even if the engine is warm. When the engine is not run for long periods of time or if the engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge.
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Install the belt tension gauge (1) at the center of the longest free length and check the tension. The correct tension is 535 N (120 lb). If the tension of the belt is below 250 N (56 lb) adjust the belt to 535 N (120 lb). If twin belts are installed, check and adjust the tension on both belts.
Inspection
To maximize the engine performance, inspect the belts for wear and for cracking. Replace belts that are worn or damaged.
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Adjustment
The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting 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 the charger. 3. The NEGATIVE - cable connects the NEGATIVE - battery terminal to the ground plane. Disconnect the cable from the NEGATIVE - battery terminal.
Illustration 28 Typical example
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1. Loosen The alternator pivot bolt (2) and the link bolt (3). 2. Move the alternator in order to increase or decrease the belt tension. Tighten the alternator pivot bolt and the link bolt to 22 Nm (16 lb ft).(1).
4. The POSITIVE + cable connects the POSITIVE + battery terminal to the starting motor. Disconnect the cable from the POSITIVE + battery terminal. Note: Always recycle a battery. Never discard a battery. Return used batteries to an appropriate recycling facility. 5. Remove the used battery. 6. Install the new battery. Note: Before the cables are connected, ensure that the key start switch is OFF. 7. Connect the cable from the starting motor to the POSITIVE + battery terminal. 8. Connect the cable from the ground plane to the NEGATIVE - battery terminal.
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Replacement
Refer to the Disassembly and Assembly Manual for the installation procedure and the removal procedure for the belt.
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Battery - Replace
SMCS Code: 1401-510
Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death. Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced.
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All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries. 1. Remove the ller caps. Maintain the electrolyte level to the FULL mark on the battery. If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use articially softened water. 2. Check the condition of the electrolyte with the 245-5829 Coolant Battery Tester Refractometer. 3. Keep the batteries clean. Clean the battery case with one of the following cleaning solutions:
1. Turn the start switch to the OFF position. Turn the ignition switch (if equipped) to the OFF position and remove the key and all electrical loads. 2. Disconnect the negative battery terminal. Ensure that the cable cannot contact the terminal. When four 12 volt batteries are involved, two negative connection must be disconnected. 3. Remove the positive connection. 4. Clean all disconnected connection and battery terminals. 5. Use a ne grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material can cause the clamps to not t correctly. Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly. 6. Tape the cable connections in order to help prevent accidental starting. 7. Proceed with necessary system repairs. 8. In order to connect the battery, connect the positive connection before the negative connector.
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The engine overheats frequently. Foaming is observed. The oil has entered the cooling system and the
coolant is contaminated. coolant is contaminated.
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Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water pump, the water temperature regulator and the hoses, if necessary.
NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L (4 US gal) of the cooling system capacity. Install the cooling system ller cap. 4. Start and run the engine at low idle for a minimum of 30 minutes. The coolant temperature should be at least 82 C (180 F). NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely ush the cooling system with clear water. Continue to ush the system until all signs of the cleaning agent are gone. 5. Stop the engine and allow the engine to cool. Loosen the cooling system ller cap slowly in order to relieve any pressure. Remove the cooling system ller cap. Open the drain valve (if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. If equipped, be sure to ush the heater and any related supply and return lines. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Specications Manual, SENR3130, Torque Specications for more information on the proper torques.
Drain
Pressurized System: Hot coolant can cause serious burns. To open the cooling system ller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Stop the engine and allow the engine to cool. Loosen the cooling system ller cap slowly in order to relieve any pressure. Remove the cooling system ller cap. 2. Open the cooling system drain valve (if equipped). If the cooling system is not equipped with a drain valve, remove one of the drain plugs. Note: If equipped, be sure to drain the heater and any related supply and return lines. Allow the coolant to drain. NOTICE Dispose of used engine coolant properly or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant. For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Dealer Service Tool Group: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL
Flush
1. Flush the cooling system with clean water in order to remove any debris. 2. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Specications Manual, SENR3130, Torque Specications for more information on the proper torques.
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NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Add 0.5 L (1 pint) of cleaner per 3.8 to 7.6 L (1 to 2 US gal) of the cooling system capacity. Install the cooling system ller cap. 4. Start and run the engine at low idle for a minimum of 90 minutes. The coolant temperature should be at least 82 C (180 F). NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely ush the cooling system with clear water. Continue to ush the system until all signs of the cleaning agent are gone. 5. Stop the engine and allow the engine to cool. Loosen the cooling system ller cap slowly in order to relieve any pressure. Remove the cooling system ller cap. Open the drain valve (if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Specications Manual, SENR3130, Torque Specications for more information on the proper torques.
3. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for lling. Maintain the coolant level within 13 mm (0.5 inch) to the proper level on the sight glass (if equipped). 4. Clean the cooling system ller cap. Inspect the gasket that is on the cooling system ller cap. If the gasket that is on the cooling system ller cap is damaged, discard the old cooling system ller cap and install a new cooling system ller cap. If the gasket that is on the cooling system ller cap is not damaged, perform a pressure test. A 9S-8140 Pressurizing Pump is used to perform the pressure test. The correct pressure for the cooling system ller cap is stamped on the face of the cooling system ller cap. If the cooling system ller cap does not retain the correct pressure, install a new cooling system ller cap. 5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.
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The engine overheats frequently. Foaming is observed. The oil has entered the cooling system and the
coolant is contaminated. coolant is contaminated.
Fill
NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 1. Fill the cooling system with coolant/antifreeze. Refer to the Operation and Maintenance Manual, Rell Capacitites and Recommendations topic (Maintenance Section) for more information on cooling system specications. Do not install the cooling system ller cap. 2. Start and run the engine at low idle. Increase the engine rpm to 1500 rpm. Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block. Stop the engine.
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Drain
4. Start and run the engine at low idle until the temperature reaches 49 to 66 C (120 to 150 F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system ller cap slowly in order to relieve any pressure. Remove the cooling system ller cap. Open the drain valve (if equipped) or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. For the proper torque, refer to the Specications Manual, SENR3130, Torque Specications.
Pressurized System: Hot coolant can cause serious burns. To open the cooling system ller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Stop the engine and allow the engine to cool. Loosen the cooling system ller cap slowly in order to relieve any pressure. Remove the cooling system ller cap. 2. Open the cooling system drain valve (if equipped). If the cooling system is not equipped with a drain valve, remove the cooling system drain plugs. Allow the coolant to drain. NOTICE Dispose of used engine coolant properly or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant. For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Dealer Service Tool Group: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL
Fill
NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 1. Fill the cooling system with Extended Life Coolant (ELC). See Special Publication, SEBU6385, Caterpillar On-highway Diesel Truck Engine Fluids Recommendations for more information on cooling system specications. Do not install the cooling system ller cap. 2. Start and run the engine at low idle for 5 minutes. Then, increase the engine rpm to high idle. Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block. 3. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for lling. Maintain the coolant level within 13 mm (0.5 inch) to the proper level on the sight glass (if equipped). 4. Clean the cooling system ller cap. Inspect the gasket that is on the cooling system ller cap. If the gasket that is on the cooling system ller cap is damaged, discard the old cooling system ller cap and install a new cooling system ller cap. If the gasket that is on the cooling system ller cap is not damaged, use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system ller cap. The correct pressure for the cooling system ller cap is stamped on the face of the cooling system ller cap. If the cooling system ller cap does not retain the correct pressure, install a new cooling system ller cap. 5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.
Flush
1. Flush the cooling system with clean water in order to remove any debris. Note: If equipped, be sure to ush the heater and any related supply and return lines. 2. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. For the proper torque, refer to the Specications Manual, SENR3130, Torque Specications. NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 3. Fill the cooling system with clean water. Install the cooling system ller cap.
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NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 1. Loosen the cooling system ller cap slowly in order to relieve pressure. Remove the cooling system ller cap. 2. It may be necessary to drain enough coolant from the cooling system in order to add the Cat ELC Extender. 3. Add Cat ELC Extender according to the requirements for your engine's cooling system capacity. Refer to the Operation and Maintenance Manual, Rell Capacities and Recommendations article for more information. 4. Clean the cooling system ller cap. Inspect the gaskets on the cooling system ller cap. Replace the cooling system ller cap if the gaskets are damaged. Install the cooling system ller cap.
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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.
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Pressurized System: Hot coolant can cause serious burns. To open the cooling system ller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 2. Loosen ller cap slowly in order to relieve any pressure. Remove the ller cap. 3. Pour the correct coolant mixture into the tank. Refer to the Operation and Maintenance Manual, Rell Capacities for information on the correct mixture and type of coolant. Refer to the Operation and Maintenance Manual, Rell Capacities for the cooling system capacity. Do not ll the coolant recovery tank above COLD FULL mark.
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Pressurized System: Hot coolant can cause serious burns. To open the cooling system ller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Remove the cooling system ller cap slowly in order to relieve pressure. 2. Maintain the coolant level within 13 mm (0.5 inch) of the bottom of the ller pipe. If the engine is equipped with a sight glass, maintain the coolant level to the correct level in the sight glass. 3. Clean the cooling system ller cap and inspect the gasket. If the gasket is damaged, discard the old ller cap and install a new ller cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the ller cap. The correct pressure is stamped on the face of the ller cap. If the ller cap does not retain the correct pressure, install a new ller cap. 4. Inspect the cooling system for leaks.
Illustration 29
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4. Clean ller cap and the receptacle. Reinstall the ller cap and inspect the cooling system for leaks. Note: The coolant will expand as the coolant heats up during normal engine operation. The additional volume will be forced into the coolant recovery tank during engine operation. When the engine is stopped and cool, the coolant will return to the engine.
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Cooling system coolant additive contains alkali. To help prevent personal injury, avoid contact with the skin and the eyes. Do not drink cooling system coolant additive. Note: Test the concentration of the Supplemental Coolant Additive (SCA) or test the SCA concentration as part of an SOS Coolant Analysis.
Level 2
This level coolant analysis is recommended when the engine is overhauled. Refer to this Operations and Maintenance Manual, Overhaul Considerations for further information.
Pressurized System: Hot coolant can cause serious burns. To open the cooling system ller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Slowly loosen the cooling system ller cap in order to relieve the pressure. Remove the cooling system ller cap. Note: Always discard drained uids according to local regulations. 2. If necessary, drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA.
Level 1
Level 1 is a basic analysis of the coolant. The following items are tested:
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3. Add the proper amount of SCA. Refer to the Special Publication, SEBU6251, Caterpillar Commercial Diesel Engines Fluids Recommendations for more information on SCA requirements. 4. Clean the cooling system ller cap. Inspect the gaskets of the cooling system ller cap. If the gaskets are damaged, replace the old cooling system ller cap with a new cooling system ller cap. Install the cooling system ller cap.
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NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage. Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a water temperature regulator installed. If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head damage. Ensure that the new water temperature regulator is installed in the original position. Ensure that the water temperature regulator vent hole is open. Do not use liquid gasket material on the gasket or cylinder head surface. Refer to two articles in the Disassembly and Assembly Manual, Water Temperature Regulators - Remove and Water Temperature Regulators Install for the replacement procedure of the water temperature regulator, or consult your Caterpillar dealer. Note: If only the water temperature regulators are replaced, drain the coolant from the cooling system to a level that is below the water temperature regulator housing.
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Engine - Clean
SMCS Code: 1000-070
Personal injury or death can result from high voltage. Moisture can create paths of electrical conductivity. Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls DO NOT OPERATE. NOTICE Accumulated grease and oil on an engine is a re hazard. Keep the engine clean. Remove debris and uid spills whenever a signicant quantity accumulates on the engine. NOTICE Failure to protect some engine components from washing may make your engine warranty invalid. Allow the engine to cool for one hour before washing the engine. Periodic cleaning of the engine is recommended. Steam cleaning the engine will remove accumulated oil and grease. A clean engine provides the following benets:
accumulation of dirt and debris. Remove any dirt and debris, as needed. require more frequent service of the air cleaner element.
Easy detection of uid leaks Maximum heat transfer characteristics Ease of maintenance
Note: Caution must be used in order to prevent electrical components from being damaged by excessive water when the engine is cleaned. When a pressure washer or steam cleaner is used to clean the engine, a minimum distance of 300 mm (12 inch) must be maintained between the components of the engine and the jet nozzle of the pressure washer or steam cleaner. Pressure washers and steam cleaners should not be directed at any electrical connectors or the junction of cables into the rear of the connectors. Avoid electrical components such as the alternator and the starter. Protect the fuel injection pump from uids in order to wash the engine.
six times if the element is properly cleaned and inspected. one time per year. This replacement should be performed regardless of the number of cleanings.
Replace the dirty paper air cleaner elements with clean air cleaner elements. Before installation, the air cleaner elements should be thoroughly checked for tears and/or holes in the lter material. Inspect the gasket or the seal of the air cleaner element for damage. Maintain a supply of suitable air cleaner elements for replacement purposes.
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Illustration 31 (1) (2) (3) (4) Cover Primary air cleaner element Secondary air cleaner element Turbocharger air inlet
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1. Remove the cover. Remove the primary air cleaner element. 2. The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element. Note: Refer to Cleaning the Primary Air Cleaner Elements. 3. Cover the turbocharger air inlet with tape in order to keep dirt out. 4. Clean the inside of the air cleaner cover and body with a clean, dry cloth. 5. Remove the tape for the turbocharger air inlet. Install the secondary air cleaner element. Install a primary air cleaner element that is new or cleaned. 6. Install the air cleaner cover. 7. Reset the air cleaner service indicator.
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Pressurized Air
Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times. Pressurized air will not remove deposits of carbon and oil. Use ltered, dry air with a maximum pressure of 207 kPa (30 psi).
Illustration 33
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Illustration 32
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Note: When the primary air cleaner elements are cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). Aim the hose so that the air ows inside the element along the length of the lter in order to help prevent damage to the paper pleats. Do not aim the stream of air directly at the primary air cleaner element. Dirt could be forced further into the pleats. Note: Refer to Inspecting the Primary Air Cleaner Elements.
Inspect the clean, dry primary air cleaner element. Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air cleaner element. Rotate the primary air cleaner element. Inspect the primary air cleaner element for tears and/or holes. Inspect the primary air cleaner element for light that may show through the lter material. If it is necessary in order to conrm the result, compare the primary air cleaner element to a new primary air cleaner element that has the same part number. Do not use a primary air cleaner element that has any tears and/or holes in the lter material. Do not use a primary air cleaner element with damaged pleats, gaskets or seals. Discard damaged primary air cleaner elements.
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning. Vacuum cleaning will not remove deposits of carbon and oil. Note: Refer to Inspecting the Primary Air Cleaner Elements.
Illustration 34
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Do not use paint, a waterproof cover, or plastic as a protective covering for storage. An airow restriction may result. To protect against dirt and damage, wrap the primary air cleaner elements in Volatile Corrosion Inhibited (VCI) paper. Place the primary air cleaner element into a box for storage. For identication, mark the outside of the box and mark the primary air cleaner element. Include the following information:
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1. Loosen clamp (2) which fastens air cleaner element (1) to the air inlet. Remove the dirty air cleaner element and clamp. 2. Install clamp (2) on new air cleaner element (1). 3. Install new air cleaner element (1) to the air inlet and tighten clamp (2). Refer to the Operation and Maintenance Manual for more information on torque specications.
Observe the service indicator. The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur:
The yellow diaphragm enters the red zone. The red piston locks in the visible position.
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engine is accelerated to the engine rated speed. The yellow core should latch approximately at the greatest vacuum that is attained.
If the service indicator does not reset easily, or if the yellow core does not latch at the greatest vacuum, the service indicator should be replaced. If the new service indicator will not reset, the hole for the service indicator may be plugged. The service indicator may need to be replaced frequently in environments that are severely dusty, if necessary. Replace the service indicator annually regardless of the operating conditions. Replace the service indicator when the engine is overhauled, and whenever major engine components are replaced. Note: When a new service indicator is installed, excessive force may crack the top of the service indicator. Tighten the service indicator to a torque of 2 Nm (18 lb in).
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1. The diaphragm for the crankcase breather can be inspected and cleaned. For the correct procedure to remove the diaphragm, refer to Disassembly and Assembly, Crankcase Breather - Remove and Install. For the correct procedure to install the diaphragm, refer to Disassembly and Assembly, Crankcase Breather - Remove and Install. Note: The canister for the crankcase breather is an nonserviceable component. Damage to the canister may occur if the lid of the canister is removed in order to clean the element. Damage to the canister may occur if the element is removed. The canister should be exchanged if the lubricating oil becomes contaminated. The canister should be replaced at an overhaul of the engine.
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Improper mounting of the engine Deterioration of the engine mounts Loose engine mounts
Any engine mount that shows deterioration should be replaced. Refer to the Specications Manual, SENR3130, Torque Specications. Refer to your Caterpillar dealer for more information.
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
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Before you take the oil sample, complete the Label, PEEP5031 for identication of the sample. In order to help obtain the most accurate analysis, provide the following information:
Engine model Service hours on the engine The number of hours that have accumulated since
the last oil change last oil change
To ensure that the sample is representative of the oil in the crankcase, obtain a warm, well mixed oil sample. To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean. Caterpillar recommends using the sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when the sampling valve is used. The location of the sampling valve allows oil that is owing under pressure to be obtained during normal engine operation. The 169-8373 Fluid Sampling Bottle is recommended for use with the sampling valve. The uid sampling bottle includes the parts that are needed for obtaining oil samples. Instructions are also provided. NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. If the engine is not equipped with a sampling valve, use the 1U-5718 Vacuum Pump. The pump is designed to accept sampling bottles. Disposable tubing must be attached to the pump for insertion into the sump. For instructions, see Special Publication, PEgj0047, How To Take A Good SOS Oil Sample. Consult your Caterpillar dealer for complete information and assistance in establishing an SOS program for your engine.
NOTICE Perform this maintenance with the engine stopped. 1. Maintain the oil level between Min mark (Y) and Max mark (X) on oil level gauge (1). Do not ll the crankcase above Max mark (X). NOTICE Operating your engine when the oil level is above the FULL mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into the oil reduces the oil's lubricating characteristics and could result in the loss of power. 2. Remove the oil ller cap and add oil, if necessary. Clean the oil ller cap. Install the oil ller cap.
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
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After the oil has drained, the oil drain plugs should be cleaned and installed. If necessary, renew the O ring seal on the drain plug. Some types of oil pans have oil drain plugs that are on both sides of the oil pan, because of the shape of the pan. This type of oil pan requires the engine oil to be drained from both plugs.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Do not drain the oil when the engine is cold. As the oil cools, suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed with the draining cold oil. Drain the crankcase with the engine stopped. Drain the crankcase with the oil warm. This draining method allows the waste particles that are suspended in the oil to be drained properly. Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil.
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After the engine has been run at the normal operating temperature, stop the engine. Use one of the following methods to drain the engine crankcase oil:
remove the oil drain plug (1) in order to allow the oil to drain. If the engine is equipped with a shallow sump, remove the bottom oil drain plugs from both ends of the oil pan.
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Illustration 40 Typical example (1) Drain plug (2) Square hole (3) Filter bowl
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3. Clean the sealing surface of the oil lter head (2). Ensure that the union (not shown) in the oil lter head is secure. 4. Apply clean engine oil to the O ring seal (3) on the oil lter. NOTICE Do not ll the oil lters with oil before installing them. This oil would not be ltered and could be contaminated. Contaminated oil can cause accelerated wear to engine components. 5. Install the oil lter. Tighten the oil lter by hand according to the instructions that are shown on the oil lter. Do not overtighten the oil lter.
1. Place a suitable container under the oil lter. Remove the drain plug (1) and the seal, from the oil lter. 2. Locate a suitable wrench into the square hole (2) in order to remove the lter bowl (3). 3. Remove the lter bowl (3) and remove the element from the lter bowl. Clean the lter bowl. 4. Cut the oil lter open with a 175-7546 Oil Filter Cutter Gp. Break apart the pleats and inspect the oil lter for metal debris. An excessive amount of metal debris in the oil lter may indicate early wear or a pending failure. Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil lter element. Ferrous metals may indicate wear on the steel and cast iron parts of the engine. Nonferrous metals may indicate wear on the aluminum parts, brass parts or bronze parts of the engine. Parts that may be affected include the following items: main bearings, rod bearings, turbocharger bearings, and cylinder heads. Due to normal wear and friction, it is not uncommon to nd small amounts of debris in the oil lter. Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil lter.
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NOTICE To prevent crankshaft bearing damage, crank the engine with the fuel OFF. This will ll the oil lters before starting the engine. Do not crank the engine for more than 30 seconds. 2. Start the engine and run the engine at LOW IDLE for two minutes. Perform this procedure in order to ensure that the lubrication system has oil and that the oil lters are lled. Inspect the oil lter for oil leaks.
Illustration 41 Typical example (4) O ring seal (5) Element (6) Filter head
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3. Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes.
5. Install a new O ring (4) onto the lter bowl and lubricate the O ring with clean engine oil. Install the lter element (5) into the lter bowl.
Illustration 42
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NOTICE Do not ll the oil lters with oil before installing them. This oil would not be ltered and could be contaminated. Contaminated oil can cause accelerated wear to engine components. 6. Install the lter bowl into the oil lter head (6). Tighten the lter bowl to the following torque 25 Nm (18 lb ft). 7. Install a new seal onto the drain plug (1) and install the drain plug into the oil lter. Tighten the drain plug to the following torque 12 Nm (8 lb ft). Note: Some engines may have a horizontally mounted oil lter. This oil lter has a drain plug that is located in the oil lter head.
4. Remove the oil level gauge in order to check the oil level. Maintain the oil level between the ADD and FULL marks on the oil level gauge.
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To prevent damage to the engine, only authorized service personnel or your Caterpillar dealer should perform the tests.
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Visual Inspection
Visually check the condition of all gauges, sensors and wiring. Look for wiring and components that are loose, broken, or damaged. Damaged wiring or components should be repaired or replaced immediately.
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Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component. Fuel injection nozzles are subject to tip wear. Tip wear is a result of fuel contamination. Tip wear can cause the following problems:
Ensure that the engine can not be started while this maintenance is being performed. To help prevent possible injury, do not use the starting motor to turn the ywheel. Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting valve lash clearance. Ensure that the engine is stopped before measuring the valve lash. To obtain an accurate measurement, allow the valves to cool before this maintenance is performed. Refer to Systems Operation, Testing and Adjusting, Engine Valve Lash - Inspect/Adjust for more information.
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2. Loosen each fuel line nut one at a time at the fuel injection pump. A cloth or similar material must be used in order to prevent fuel from spraying on the hot exhaust components. Tighten each nut before loosening the next nut. 3. A defective fuel injection nozzle may be identied when a fuel line nut is loosened and the following conditions are present:
2. Crank the engine with the throttle lever in the CLOSED position until the engine starts. Note: If necessary, loosen the union nuts (1) on the fuel injection lines at the connection with the fuel injector until fuel is evident. Stop cranking the engine. Tighten the union nuts (1) to a torque of 30 Nm (22 lb ft). 3. Start the engine and run the engine at idle for one minute. NOTICE Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again. 4. Cycle the throttle lever from the low idle position to the high idle position three times. The cycle time for the throttle lever is one second to six seconds for one complete cycle. Note: In order to purge air from the fuel injection pump on engines with a xed throttle, the engine should be run at full load for thirty seconds. The load should then be decreased until the engine is at high idle. This should be repeated three times. This will assist in removing trapped air from the fuel injection pump. 5. Check for leaks in the fuel system.
The low pressure fuel lines are disconnected. A leak exists in the low pressure fuel system. The fuel lter is replaced.
Use the following procedure in order to remove air from the fuel system: 1. Turn the keyswitch to the RUN position. Leave the keyswitch in the RUN position for three minutes. If a manual purging screw is installed, the purging screw should be slackened during priming the fuel system.
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75 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace
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2. Place a suitable container under the water separator. Clean the outside of the water separator. 3. Open the drain (5). Allow the uid to drain into the container. 4. Tighten the drain (5) by hand pressure only. 5. Hold the element (2) and remove the screw (1). Remove the element and the glass bowl (3) from the base. Discard the old element. 6. Clean the glass bowl (4). Clean the bottom cover (6). 7. Install the new O ring seal. Install the bottom cover onto the new element. Install the assembly onto the base. 8. Install the screw (1) and tighten the screw to a torque of 8 Nm (6 lb ft). 9. Remove the container and dispose of the fuel safely. 10. Open the fuel supply valve. 11. Prime the fuel system. Refer to Operation and Maintenance Manual, Fuel System - Prime for more information.
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Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. To help prevent possible injury, turn the start switch off when changing fuel lters or water separator elements. Clean up fuel spills immediately. NOTICE Ensure that the engine is stopped before any servicing or repair is performed.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. To help prevent possible injury, turn the start switch off when changing fuel lters or water separator elements. Clean up fuel spills immediately.
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Illustration 44 Typical example (1) (2) (3) (4) (5) (6) Screw Element Glass bowl Sensor connection Drain Bottom cover
NOTICE The water separator is not a lter. The water separator separates water from the fuel. The engine should never be allowed to run with the water separator more than half full. Engine damage may result. NOTICE The water separator is under suction during normal engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system.
1. Turn the fuel supply valve (if equipped) to the OFF position.
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Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. To help prevent possible injury, turn the start switch off when changing fuel lters or water separator elements. Clean up fuel spills immediately. NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
Element lter
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Illustration 45 Typical example (1) (2) (3) (4) (5) (6) Screw Element Glass bowl Sensor connection Drain Bottom cover
Turn the valves for the fuel lines (if equipped) to the OFF position before performing this maintenance. Place a tray under the fuel lter in order to catch any fuel that might spill. Clean up any spilled fuel immediately.
1. Place a suitable container below the water separator. 2. Open the drain (5). Allow the uid to drain into the container. 3. When clean fuel drains from the water separator close the drain (5). Tighten the drain by hand pressure only. Dispose of the drained uid correctly.
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2. Clean the outside of the fuel lter assembly. Open the fuel drain (1) and drain the fuel into a suitable container.
Spin-on lter
Turn the valves for the fuel lines (if equipped) to the OFF position before performing this maintenance. Place a tray under the fuel lter in order to catch any fuel that might spill. Clean up any spilled fuel immediately.
Illustration 47 Typical example (3) O ring seal (4) Element (5) Filter head
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3. Remove the lter bowl (2) from the lter head (5). Press on the element (4). Rotate the element counterclockwise in order to release the element for the lter bowl and remove the element from the bowl. Discard the used element.
Illustration 48
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4. Remove the O ring (3) from the lter bowl and clean the lter bowl. Check that the threads of the lter bowl are not damaged. 5. Install a new O ring seal (3) to the lter bowl (2). 6. Locate a new lter element (4) into the lter bowl. Press on the element and rotate the element clockwise in order to lock the element into the lter bowl. 7. Install the lter bowl (4) into the top of the lter head (5). 8. Tighten the lter bowl by hand until the lter bowl contacts the lter head. Rotate the lter bowl through 90 degrees. Note: Do not use a tool to tighten the lter bowl. 9. Open the valves for the fuel lines (if equipped).
Typical example (1) Filter Head (2) Spin-on lter (3) Drain
1. Clean the outside of the fuel lter assembly. Open the fuel drain (3) and drain the fuel into a suitable container. 2. Use a suitable tool in order to remove the spin-on lter (2) from the lter head (1). 3. Ensure that the fuel drain (3) on the new spin-on lter is closed.
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Fuel Tank
Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel can cause excessive wear to the fuel system. Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel.
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4. Lubricate the sealing ring (4) with clean fuel oil. 5. Install the spin-on lter (2) into the top of the lter head (1). 6. Tighten the spin-on lter by hand until the sealing ring contacts the lter head. Rotate the spin-on lter through 90 degrees. 7. Prime the fuel system. Refer to Operation and Maintenance Manual, Fuel System - Prime.
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This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank. A four micron(c) absolute lter for the breather vent on the fuel tank is also recommended. Refer to Special Publication, SENR9620, Improving Fuel System Durablity. If a bulk storage tank has been relled or moved recently, allow adequate time for the sediment to settle before lling the engine fuel tank. Internal bafes in the bulk storage tank will also help trap sediment. Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel. When possible, water separators should be used.
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Due to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen. This can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps. Each installation application can be different. The differences depend on the following factors:
Type of hose Type of tting material Anticipated expansion and contraction of the hose Anticipated expansion and contraction of the
ttings
Pressurized System: Hot coolant can cause serious burns. To open the cooling system ller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. 1. Stop the engine. Allow the engine to cool. 2. Loosen the cooling system ller cap slowly in order to relieve any pressure. Remove the cooling system ller cap. Note: Drain the coolant into a suitable, clean container. The coolant can be reused. 3. Drain the coolant from the cooling system to a level that is below the hose that is being replaced. 4. Remove the hose clamps. 5. Disconnect the old hose. 6. Replace the old hose with a new hose. 7. Install the hose clamps with a torque wrench. Note: Refer to the Specications, SENR3130, Torque Specications in order to locate the proper torques. 8. Rell the cooling system. 9. Clean the cooling system ller cap. Inspect the cooling system ller cap's gaskets. Replace the cooling system ller cap if the gaskets are damaged. Install the cooling system ller cap.
End ttings that are damaged or leaking Outer covering that is chafed or cut Exposed wire that is used for reinforcement Outer covering that is ballooning locally Flexible part of the hose that is kinked or crushed Armoring that is embedded in the outer covering
A constant torque hose clamp can be used in place of any standard hose clamp. Ensure that the constant torque hose clamp is the same size as the standard clamp.
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10. Start the engine. Inspect the cooling system for leaks.
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Overhaul Options
Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons:
Overhaul Considerations
SMCS Code: 7595-043 Reduced hours of operation at full load will result in a lower average power demand. A decreased average power demand should increase both the engine service life and the overhaul interval. The need for an overhaul is generally indicated by increased fuel consumption and by reduced power. The following factors are important when a decision is being made on the proper time for an engine overhaul:
Costly unplanned downtime can be avoided. Many original parts can be reused according to the
standards for reusable parts.
The need for preventive maintenance The quality of the fuel that is being used The operating conditions The results of the SOS analysis
Specially designed Caterpillar engine features Caterpillar dealer exchange components Caterpillar Inc. remanufactured exchange
components
Overhaul Recommendation
To minimize downtime, Caterpillar Inc. recommends a scheduled engine overhaul by your Caterpillar dealer before the engine fails. This will provide you with the best cost/value relationship. Note: Overhaul programs vary according to the engine application and according to the dealer that performs the overhaul. Consult your Caterpillar dealer for specic information about the available overhaul programs and about overhaul services for extending the engine life. If an overhaul is performed without overhaul service from your Caterpillar dealer, be aware of the following maintenance recommendations.
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Rebuild or Exchange
Cylinder Head Assembly, Oil Pump, and Fuel Transfer Pump These components should be inspected according to the instructions that are found in various Caterpillar reusability publications. The Special Publication, SEBF8029 lists the reusability publications that are needed for inspecting the engine parts. If the parts comply with the established inspection specications that are expressed in the reusable parts guideline, the parts should be reused. Parts that are not within the established inspection specications should be dealt with in one of the following manners:
Inspect these parts while the engine is disassembled for an overhaul. Inspect the crankshaft for any of the following conditions:
Deection Damage to the journals Bearing material that has seized to the journals
Check the journal taper and the prole of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:
Unscheduled downtime Costly repairs Damage to other engine parts Reduced engine efciency Increased fuel consumption
Reduced engine efciency and increased fuel consumption translates into higher operating costs. Therefore, Caterpillar Inc. recommends repairing out-of-spec parts or replacing out-of-spec parts.
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3. Flush the oil cooler core internally with cleaner in order to loosen foreign substances. This will also help to remove oil from the oil cooler core. Note: Caterpillar Inc. recommends the use of Hydrosolv Liquid Cleaners. Table 26 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer.
Table 26
For example, considerable deposits are found in the water jacket areas on the external cooling system, but the concentrations of coolant additives were carefully maintained. The coolant water probably contained minerals that were deposited on the engine over time. A coolant analysis can be conducted in order to verify the condition of the water that is being used in the cooling system. A full water analysis can be obtained by consulting your local water utility company or an agricultural agent. Private laboratories are also available for water analysis. Caterpillar Inc. recommends an SOS Coolant Analysis (Level 2). SOS Coolant Analysis (Level 2) An SOS Coolant Analysis (Level 2) is a comprehensive coolant analysis which completely analyzes the coolant and the effects on the cooling system. An SOS Coolant Analysis (Level 2) provides the following information:
Hydrosolv Liquid Cleaners Part Number 1U-5490 1U-5492 Description Hydrosolv4165 Hydrosolv100 Size 19 L (5 US gal) 19 L (5 US gallon)
4. Use steam to clean the oil cooler core. This removes any remaining residue from the cleaner. Flush the ns of the oil cooler core. Remove any other trapped debris. 5. Wash the oil cooler core with hot, soapy water. Rinse the oil cooler core thoroughly with clean water.
Complete SOS Coolant Analysis (Level 1) Visual inspection of properties Identication of metal corrosion
Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes. 6. Dry the oil cooler core with compressed air. Direct the air in the reverse direction of the normal ow. 7. Inspect the components in order to ensure cleanliness. The oil cooler core should be pressure tested. Repair the oil cooler core, if necessary. Install the oil cooler core. For more information about cleaning the cores, consult your Caterpillar dealer.
Radiator - Clean
SMCS Code: 1353-070 Note: Adjust the frequency of cleaning according to the effects of the operating environment. Inspect the radiator for these items: damaged ns, corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the radiator, if necessary.
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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded. Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction of the fan's air ow. Hold the nozzle approximately 6 mm (0.25 inch) away from the ns. Slowly move the air nozzle in a direction that is parallel with the tubes. This will remove debris that is between the tubes. Pressurized water may also be used for cleaning. The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean the core from both sides. Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water. After cleaning, start the engine and accelerate the engine to high idle rpm. This will help in the removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary. Inspect the ns for damage. Bent ns may be opened with a comb. Inspect these items for good condition: welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary. For more detailed information on cleaning and inspection, refer to Special Publication, SEBD0518, Know Your Cooling System.
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Check the starting motor for proper operation. Check the electrical connections and clean the electrical connections. Refer to the Service Manual for more information on the checking procedure and for specications or consult your Caterpillar dealer for assistance.
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Walk-Around Inspection
SMCS Code: 1000-040
NOTICE For any type of leak (coolant, lube, or fuel) clean up the uid. If leaking is observed, nd the source and correct the leak. If leaking is suspected, check the uid levels more often than recommended until the leak is found or xed, or until the suspicion of a leak is proved to be unwarranted. NOTICE Accumulated grease and/or oil on an engine or deck is a re hazard. Remove this debris with steam cleaning or high pressure water.
and that the cooling lines are tight. Check for leaks. Check the condition of all pipes.
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Excessive coolant leakage may indicate the need to replace the water pump seal. For the removal of water pumps and the installation of water pumps and/or seals, refer to the Service Manual for the engine or consult your Caterpillar dealer.
Cracks in the cylinder head A piston seizure Other potential damage to the engine
A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head, a piston seizure or other potential damage to the engine. Visually inspect the water pump for leaks. If leaking of the water pump seals is observed, replace all of the water pump seals. Refer to two articles in the Disassembly and Assembly Manual, Water Pump - Disassemble and Water Pump - Assemble for the disassembly and assembly procedure. If it is necessary to remove the water pump, refer to two articles in the Disassembly and Assembly Manual, Water Pump - Remove and Water Pump - Install. Inspect the water pump for wear, cracks, pin holes and proper operation. Refer to the Parts Manual for the correct part numbers for your engine or consult your Caterpillar dealer if repair is needed or replacement is needed.
Inspect the fuel system for leaks. Look for loose Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure that hoses and tubes are not contacting other hoses, tubes, wiring harnesses, etc. belts for cracks, breaks or other damage.
on a daily basis in order to ensure that only clean fuel enters the fuel system. loose connections and for worn wires or frayed wires. for good condition.
Inspect the ground strap for a good connection and Inspect the ECM to the cylinder head ground strap
for a good connection and for good condition.
protected against the current drain of the starting motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintenance free battery. gauges that are cracked. Replace any gauge that can not be calibrated.
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