MAINTENANCE INTERVALS

Operation and Maintenance Manual Excerpt

2010 Caterpillar All Rights Reserved

SEBU7276-01 May 2001

Operation and Maintenance Manual

3054B Industrial Engine
5MF1-Up (Engine)

This Manual Must be Accessible at the Point of Operation

59 Maintenance Section Maintenance Interval Schedule

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Maintenance Interval Schedule

SMCS Code: 1000; 7500 Note: Ensure that the Safety Information, warnings, and instructions are read and understood before operation or maintenance procedures are performed. Note: Use fuel consumption, service hours, or calendar time, whichever occurs first , in order to determine the maintenance intervals. Engines that operate in severe operating conditions may require more frequent maintenance. There are many operating conditions and types of lubricants that may require an adjustment to the 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, all of the maintenance requirements from the previous interval must also be performed.

Fuel Transfer Pump Strainer - Clean .................... 77 Fuel 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 ....................................... 73 Fuel Injection Nozzles - Test/Exchange ................ 76

Every 3000 Service Hours or 2 Years

Alternator - Inspect ............................................... Cooling System Coolant (DEAC) - Change .......... Cooling System Coolant Extender (ELC) - Add .... Cooling System Water Temperature Regulator Replace ............................................................... Crankshaft Vibration Damper - Inspect ................. Starting Motor - Inspect ........................................ Water Pump - Inspect ........................................... 60 62 65 67 68 85 86

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

When Required
Battery - Replace .................................................. Battery or Battery Cable - Disconnect .................. Engine Air Cleaner Element (Dual Element) Clean/Replace .................................................... Engine Air Cleaner Element (Single Element) Replace ............................................................... Fuel System - Prime ............................................. 60 61 68 72 77

Every 6000 Service Hours or 4 Years

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

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

Every 250 Service Hours or 3 Months

Alternator and Fan Belts - Inspect/Adjust/ Replace ............................................................... Battery Electrolyte Level - Check .......................... Cooling System Supplemental Coolant Additive (SCA) - Test/Add ................................................. Engine Oil Sample - Obtain .................................. Engine Oil and Filter - Change ............................. Fuel Tank Water and Sediment - Drain ................. Hoses and Clamps - Inspect/Replace .................. Radiator - Clean .................................................... 60 61 66 73 74 80 81 84

Every 500 Service Hours or 6 Months

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

60 Maintenance Section Alternator - Inspect

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Adjustment

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. Refer to the Service Manual. 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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Illustration 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 or decrease the belt tension. 3. Tighten adjusting bolt (1). Tighten mounting bolts (2). Refer to the Operation and Maintenance Manual for the proper torque settings. If new belts are installed, check the belt tension again after 20 hours of engine operation.

Alternator and Fan Belts Inspect/Adjust/Replace

SMCS Code: 1357-039

Replacement
Refer to the Service Manual for the installation procedure and the removal procedure for the belt.
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Inspection
To maximize the engine performance, inspect the belts for wear and for cracking. Replace belts that are worn or damaged. 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 check the belt tension, apply 45 N (10 lb ft) of force midway between the pulleys. A correctly adjusted belt will deflect 10 mm (0.39 inch).

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.

61 Maintenance Section Battery Electrolyte Level - Check

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. 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.

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 filler 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 artificially softened water. 2. Check the condition of the electrolyte with the 1U-7298 Coolant/Battery Tester (C) or the 1U-7297 Coolant/Battery Tester (F). 3. Keep the batteries clean. Clean the battery case with one of the following cleaning solutions:

A mixture of 0.1 L (0.11 qt) of baking soda and

1 L (1 qt) of clean water

A mixture of 0.1 L (0.11 qt) of ammonia and

1 L (1 qt) of clean water Thoroughly rinse the battery case with clean water. Use a fine 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 fit properly. Coat the clamps and the terminals with 5N-5561 Silicone Lubricant, petroleum jelly or MPGM grease.
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Battery Electrolyte Level Check

SMCS Code: 1401-081 When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing. If batteries are properly charged, ammeter reading should be very near zero.

Battery or Battery Cable Disconnect

SMCS Code: 1402-029

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.

62 Maintenance Section Cooling System Coolant (DEAC) - Change

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 at the battery that goes to the start switch. Ensure that the cable cannot contact the terminal. When four 12 volt batteries are involved, the negative side of two batteries must be disconnected. 3. Tape the leads in order to help prevent accidental starting. 4. Proceed with necessary system repairs. Reverse the steps in order to reconnect all of the cables.
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Cooling System Coolant (DEAC) - Change

SMCS Code: 1350-070; 1395-044 Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist:

The engine overheats frequently. Foaming is observed. The oil has entered the cooling system and the
coolant is contaminated. coolant is contaminated.

Illustration 25 Drain Plugs

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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. 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 Service Technology Group: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL

The fuel has entered the cooling system and the

NOTICE Use of commercially available cooling system cleaners may cause damage to cooling system components. Use only cooling system cleaners that are approved for Caterpillar engines. 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.

Drain
1. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.

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

63 Maintenance Section Cooling System Coolant (DEAC) - Change

2. Close the drain valve (if equipped). Clean the drain plugs. Install the drain plugs. Refer to the Operation and Maintenance Manual for more information 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 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 filler cap. 4. Start and run the engine at low idle for a minimum of 30 minutes with a coolant temperature of at least 82C (180F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler 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 Operation and Maintenance Manual, Torque Specifications for more information on the proper torques.

5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler 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 Operation and Maintenance Manual for more information on the proper torques.

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 for more information on cooling system specifications. Do not install the cooling system filler cap. 2. Place the transmission in neutral. Start and run the engine at low idle. Increase the engine rpm to 1500 rpm. Run the engine at 1500 rpm for one minute in order to purge the air from the cavities of the engine block. Stop the engine. 3. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for filling. 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 filler cap. Inspect the gasket for the filler cap. If the gasket for the filler cap is damaged, discard the old cooling system filler cap and install a new cooling system filler cap. If the gasket for the filler cap is not damaged, use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system filler cap. The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not retain the correct pressure, install a new cooling system filler cap. 5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.

Cooling Systems with Heavy Deposits or Plugging

Note: For the following procedure to be effective, there must be some active flow through the cooling system components. 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 Operation and Maintenance Manual for more information 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 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 filler cap. 4. Start and run the engine at low idle for a minimum of 90 minutes. The coolant temperature should be at least 82C (180F).

64 Maintenance Section Cooling System Coolant (ELC) - Change

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Cooling System Coolant (ELC) - Change

SMCS Code: 1350-070; 1395-044 When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced.

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 Service Technology Group: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL Canada: 1-800-523-TOOL

Drain
1. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.

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 Operation and Maintenance Manual, Torque Specifications for more information 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 clean water. Install the cooling system filler cap. 4. Start and run the engine at low idle until the temperature reaches 49 to 66C (120 to 150F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler 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 Operation and Maintenance Manual, Torque Specifications for more information on the proper torques.

Illustration 26 Drain Plugs

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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.

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

65 Maintenance Section Cooling System Coolant Extender (ELC) - Add

1. Fill the cooling system to the top with coolant/antifreeze. Refer to the Operation and Maintenance Manual for more information on cooling system specifications. Do not install the cooling system filler cap. 2. Place the transmission in neutral. Start and run the engine at low idle. Increase the engine rpm to 1500 rpm. Run the engine at 1500 rpm for one minute in order to purge the air from the cavities of the engine block. Stop the engine. 3. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for filling. 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 filler cap. Inspect the gasket for the filler cap. If the gasket for the filler cap is damaged, discard the old cooling system filler cap and install a new cooling system filler cap. If the gasket for the filler cap is not damaged, use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system filler cap. The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not retain the correct pressure, install a new cooling system filler cap. 5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.
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3. Add Extender according to the requirements for your engines cooling system capacity. Refer to the Operation and Maintenance Manual, Refill Capacities in the Maintenance Section for the capacity of the cooling system for your engine. Refer to the Operation and Maintenance Manual, Cooling System Specifications information for the Caterpillar ELC Extender additions. 4. Clean the cooling system filler cap. Inspect the cooling system filler cap gaskets. Replace the cooling system filler cap if the cooling system filler cap gaskets are damaged. Install the cooling system filler cap.
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Cooling System Coolant Level - Check

SMCS Code: 1395-082 Check the coolant level when the engine is stopped and cool.

Cooling System Coolant Extender (ELC) - Add

SMCS Code: 1352-045; 1395-081 Caterpillar Extended Life Coolant (ELC) does not require the frequent Supplemental Coolant Additive (SCA) additions associated with the present conventional coolants. The Extender only needs to be added once. Check the cooling system only when the engine is stopped and cool. 1. Loosen the cooling system filler cap slowly in order to relieve pressure. Remove the cooling system filler cap. 2. It may be necessary to drain enough coolant from the cooling system in order to add the Extender.
Illustration 27 Cooling system filler cap
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Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler 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 filler cap slowly in order to relieve pressure. 2. Maintain the coolant level within 13 mm (0.5 inch) of the bottom of the filler pipe. If the engine is equipped with a sight glass, maintain the coolant level to the proper level in the sight glass.

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

Water and SCA

NOTICE Do not exceed the recommended eight percent supplemental coolant additive concentration. Test the concentration of the SCA with the 8T-5296 Coolant Conditioner Test Kit. Refer to the Operation and Maintenance Manual, Water/Supplemental Coolant Additive (SCA) topic (Maintenance Section). Refer to the Operation and Maintenance Manual, Conventional Coolant/Antifreeze Cooling System Maintenance topic (Maintenance Section).
Illustration 28 Typical filler cap gaskets
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SOS Coolant Analysis

SOS coolant samples can be analyzed at your Caterpillar dealer. SOS Coolant Analysis is a program that is based on periodic samples.

3. Clean the cooling system filler cap and check the condition of the filler cap gaskets. Replace the cooling system filler cap if the filler cap gaskets are damaged. Reinstall the cooling system filler cap. 4. Inspect the cooling system for leaks.
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Level 1
Level 1 is a basic analysis of the coolant. The following items are tested:

Glycol Concentration Concentration of SCA pH Conductivity

The results are reported, and recommendations are made according to the results. Consult your Caterpillar dealer for information on the benefits of managing your equipment with an SOS Coolant Analysis.

Cooling System Supplemental Coolant Additive (SCA) Test/Add

SMCS Code: 1352-045; 1395-081

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 the Operations and Maintenance Manual, Overhaul Considerations for further information.

Test for SCA Concentration

Coolant/Antifreeze and SCA
NOTICE Do not exceed the recommended six percent supplemental coolant additive concentration. Use the 8T-5296 Coolant Conditioner Test Kit or use the 4C-9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA. Refer to the Operation and Maintenance Manual for more information.

67 Maintenance Section Cooling System Water Temperature Regulator - Replace

Add the SCA, If Necessary

NOTICE Do not exceed the recommended amount of supplemental coolant additive concentration. Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engines heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. Excessive supplemental coolant additive concentration could also result in radiator tube blockage, overheating, and/or accelerated water pump seal wear. Never use both liquid supplemental coolant additive and the spin-on element (if equipped) at the same time. The use of those additives together could result in supplemental coolant additive concentration exceeding the recommended maximum.

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Cooling System Water Temperature Regulator Replace

SMCS Code: 1355-510 Replace the water temperature regulator before the water temperature regulator fails. This is a recommended preventive maintenance practice. Replacing the water temperature regulator reduces the chances for unscheduled downtime. A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine. A water temperature regulator that fails in the closed position can cause excessive overheating. Excessive overheating could result in cracking of the cylinder head or piston seizure problems. A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation. Low engine operating temperatures during partial loads could cause an excessive carbon buildup inside the cylinders. This excessive carbon buildup could result in an accelerated wear of the piston rings and wear of the cylinder liner. 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 the Service Manual 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.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler 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 filler cap in order to relieve the pressure. Remove the cooling system filler cap. Note: Always discard drained fluids 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. 3. Add the proper amount of SCA. Refer to the Operation and Maintenance Manual for more information on SCA requirements. 4. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets are damaged, replace the old cooling system filler cap with a new cooling system filler cap. Install the cooling system filler cap.

68 Maintenance Section Crankshaft Vibration Damper - Inspect

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Crankshaft Vibration Damper - Inspect

SMCS Code: 1205-040 Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations. This can result in damage to the crankshaft and to other engine components. A deteriorating damper can cause excessive gear train noise at variable points in the speed range. The damper is mounted to the crankshaft which is located behind the belt guard on the front of the engine.

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 Water and/or condensation can cause damage to electrical components. Protect all electrical components from exposure to water. NOTICE Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid spills whenever a significant quantity accumulates on 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 benefits:

Removal and Installation

Refer to the Service Manual for the damper removal procedure and for the damper installation procedure.
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Driven Equipment - Check

SMCS Code: 3279-535 Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment:

Inspection Adjustment Lubrication Other maintenance recommendations

Easy detection of fluid leaks Maximum heat transfer characteristics Ease of maintenance
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Perform any maintenance for the driven equipment which is recommended by the OEM.

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

SMCS Code: 1054-037; 1054-510 NOTICE Never run the engine without an air cleaner element installed. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet.

69 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace

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

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air can split the material of the air cleaner element. Unfiltered air will drastically accelerate internal engine wear. Your Caterpillar dealer has the proper air cleaner elements for your application. Consult your Caterpillar dealer for the correct air cleaner element.

Illustration 29

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Check the precleaner (if equipped) daily for

accumulation of dirt and debris. Remove any dirt and debris, as needed.

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

Operating conditions (dust, dirt and debris) may

require more frequent service of the air cleaner element.

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 Filter 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 service indicator.

The air cleaner element may be cleaned up to

six times if the element is properly cleaned and inspected. at least one time per year. This replacement should be performed regardless of the number of cleanings.

The air cleaner element should be replaced

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 filter 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.

Dual Element Air Cleaners

The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element. The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected. The primary air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings. The secondary air cleaner element is not serviceable or washable. The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element. When the engine is operating in environments that are dusty or dirty, air cleaner elements may require more frequent replacement.

Cleaning the Primary Air Cleaner Elements

The primary air cleaner element can be used up to six times if the element is properly cleaned and inspected. When the primary air cleaner element is cleaned, check for rips or tears in the filter material. The primary air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings. Use clean primary air cleaner elements while dirty elements are being cleaned.

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

NOTICE Do not clean the air cleaner elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine damage could result. Visually inspect the primary air cleaner elements before cleaning. Inspect the air cleaner elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged air cleaner elements. There are four common methods that are used to clean primary air cleaner elements:
Illustration 30
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Pressurized water Pressurized air Vacuum cleaning Washing with nonsudsing detergent Pressurized Water
Pressurized water will clean the primary air cleaner element unless carbon and oil have accumulated on the surface of the primary air cleaner element. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi). Do not use a spray nozzle. Note: When the primary air cleaner element is 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 water flows inside the element along the length of the filter in order to help prevent damage to the paper pleats. Do not aim the stream of water directly at the primary air cleaner element. Dirt could be forced further into the pleats. Note: Refer to Drying the Primary Air Cleaner Elements. Refer to Inspecting the Primary Air Cleaner Elements.

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 flows inside the element along the length of the filter 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.

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.

Washing the Primary Air Cleaner Elements with Nonsudsing Detergent

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 filtered, dry air with a maximum pressure of 207 kPa (30 psi).

Do not wash air cleaner elements in any flammable solution such as diesel fuel or gasoline. Doing so can cause fire or an engine runaway and can result in personal injury. Washing with nonsudsing detergent is effective for cleaning primary air cleaner elements that have deposits of carbon or oil. Use a cleaning agent that is specifically manufactured for cleaning primary air cleaner elements. Cleaning with pressurized water, pressurized air, or a vacuum is recommended prior to washing with nonsudsing detergent.

71 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace

1. Place the primary air cleaner element into a wash tank so that the gasket is up. The wash tank should be equipped with a rack so that the primary air cleaner element does not sit on the bottom of the wash tank. Note: Caterpillar does not recommend washing the element with a process of agitation. Agitation may cause carbon particles to be distributed. 2. Fill the wash tank with the cleaning agent and warm water to a maximum temperature of 60 C (140 F). Follow the manufacturers recommendations for the cleaning agent. Allow the primary air cleaner element to soak for six hours. 3. Drain the wash tank. Do not use the cleaning agent more than one time. Remove the primary air cleaner element from the wash tank. Rinse the primary air cleaner element with the method for using pressurized water. Note: Refer to Drying the Primary Air Cleaner Elements. 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 filter material. If it is necessary in order to confirm 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 filter material. Do not use an primary air cleaner element with damaged pleats, gaskets or seals. Discard damaged primary air cleaner elements.

Storing Primary Air Cleaner Elements

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

Drying the Primary Air Cleaner Elements

The oven method may be used in order to dry primary air cleaner elements. If an oven is used, do not expose the primary air cleaner elements to temperatures that exceed 82 C (160 F). Note: Do not use compressed air in order to dry the primary air cleaner elements. Primary air cleaner elements may be allowed to air dry. Allow two days for the primary air cleaner elements to air dry before the elements are inspected and installed.
Illustration 32
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Inspecting the Primary Air Cleaner Elements

Do not use paint, a waterproof cover, or plastic as a protective covering for storage. An airflow 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 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 the primary air cleaner element, refer to Special Publication, SEBF8062, Procedure to Inspect and Clean Air Filters.

Illustration 31

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72 Maintenance Section Engine Air Cleaner Element (Single Element) - Replace

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Engine Air Cleaner Element (Single Element) - Replace

SMCS Code: 1051; 1054 NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.

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

Illustration 34 Typical service indicator

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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:
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The yellow diaphragm enters the red zone. The red piston locks in the visible position.

Illustration 33 (1) Air cleaner element. (2) Clamp.

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 specifications.
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Test the Service Indicator

Service indicators are important instruments.

Check for ease of resetting. The service indicator

should reset in less than three pushes.

Check the movement of the yellow core when the

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).

Engine Air Cleaner Service Indicator - Inspect

SMCS Code: 7452-040 Some engines may be equipped with a different service indicator. Some engines are equipped with a differential gauge for inlet air pressure. The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element. As the air cleaner element becomes dirty, the pressure differential rises. If your engine is equipped with a different type of service indicator, follow the OEM recommendations in order to service the air cleaner service indicator.

73 Maintenance Section Engine Mounts - Inspect

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Engine Mounts - Inspect

SMCS Code: 1152-040 Inspect the engine mounts for deterioration and for proper bolt torque. Engine vibration can be caused by the following conditions:

Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1348-554-SM; 7542-554-OC, SM In addition to a good preventive maintenance program, Caterpillar recommends using SOS oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine.

Improper mounting of the engine Deterioration of the engine mounts

Any engine mount that shows deterioration should be replaced. Refer to the Service Manual for the recommended torques. Refer to the OEM recommendations for more information.
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Obtain the Sample and the Analysis

Hot oil and hot components can cause personal injury. 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 order to help obtain the most accurate analysis, provide the following information:

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

Engine model Service hours on the engine The number of hours that have accumulated
since the last oil change

The amount of oil that has been added since the

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 flowing under pressure to be obtained during normal engine operation. The 169-8373 Fluid Sampling Bottle is recommended for use with the sampling valve. The fluid sampling bottle includes the parts that are needed for obtaining oil samples. Instructions are also provided.

Illustration 35 (Y) ADD mark. (X) FULL mark.

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NOTICE Perform this maintenance with the engine stopped. 1. Maintain the oil level between ADD mark (Y) and FULL mark (X) on oil level gauge (1). Do not fill the crankcase above FULL 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 oils lubricating characteristics 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.

74 Maintenance Section Engine Oil and Filter - Change

If the engine is equipped with a drain valve, turn

NOTICE Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant samples. A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken. Always use a designated pump for oil sampling and a designated pump for coolant sampling. Failure to do so may cause a false analysis which could lead to customer and dealer concerns. 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, PEHP6001, How To Take A Good Oil Sample. Consult your Caterpillar dealer for complete information and assistance in establishing an SOS program for your engine.
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the drain valve knob counterclockwise in order to drain the oil. After the oil has drained, turn the drain valve knob clockwise in order to close the drain valve.

If the engine is not equipped with a drain valve,

remove the oil drain plug 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. After the oil has drained, the oil drain plugs should be cleaned and installed. Tighten the oil drain plugs to 70 14 Nm (50 10 lb ft).

Replace the Oil Filter

NOTICE Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by Caterpillar could result in severe engine damage to the engine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubricating system. Only use oil filters recommended by Caterpillar. 1. Remove the oil filter with a 1U-8760 Chain Wrench. 2. Cut the oil filter open with a 175-7546 Oil Filter Cutter. Break apart the pleats and inspect the oil filter for metal debris. An excessive amount of metal debris in the oil filter 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 filter 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 find small amounts of debris in the oil filter. Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter.

Engine Oil and Filter - Change

SMCS Code: 1318-510; 1348-044

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.

Drain the Engine Oil

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:

75 Maintenance Section Engine Protective Devices - Check

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 filters are filled. Inspect the oil filter for oil leaks. 3. Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes. 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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Illustration 36 Typical filter mounting base and filter gasket

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3. Clean the sealing surface of the filter mounting base. Ensure that all of the old oil filter gasket is removed. 4. Apply clean engine oil to the new oil filter gasket. NOTICE Do not fill the oil filters with oil before installing them. This oil would not be filtered and could be contaminated. Contaminated oil can cause accelerated wear to engine components. 5. Install the oil filter. Tighten the oil filter until the oil filter gasket contacts the base. Tighten the oil filter by hand according to the instructions that are shown on the oil filter. Do not overtighten the oil filter.

Engine Protective Devices Check

SMCS Code: 7400-535 Alarms and shutoffs must function properly. Alarms provide timely warning to the operator. Shutoffs help to prevent damage to the engine. It is impossible to determine if the engine protective devices are in good working order during normal operation. Malfunctions must be simulated in order to test the engine protective devices. A calibration check of the engine protective devices will ensure that the alarms and shutoffs activate at the setpoints. Ensure that the engine protective devices are functioning properly. NOTICE During testing, abnormal operating conditions must be simulated. The tests must be performed correctly in order to prevent possible damage to the engine. To prevent damage to the engine, only authorized service personnel or your Caterpillar dealer should perform the tests.

Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to the Operation and Maintenance Manual for more information on lubricant specifications. Fill the crankcase with the proper amount of oil. Refer to the Operation and Maintenance Manual for more information on refill capacities. NOTICE If equipped with an auxiliary oil filter or system, extra oil must be added when filling the crankcase. Follow the OEM or filter manufacturers recommendations. If the extra oil is not added, the engine may starve for oil. NOTICE To help prevent crankshaft or bearing damage, crank engine to fill all filters before starting. Do not crank engine for more than 30 seconds.

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.

76 Maintenance Section Engine Valve Lash - Inspect/Adjust

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Engine Valve Lash Inspect/Adjust

SMCS Code: 1102-025 The initial valve lash adjustment on new engines, rebuilt engines, or remanufactured engines is recommended at the first scheduled oil change. The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components. This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life. NOTICE Only qualified service personnel should perform this maintenance. Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjustment procedure. Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.

Fuel Injection Nozzles Test/Exchange

SMCS Code: 1254-013; 1254-081

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. 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:

Increased fuel consumption Black smoke Misfire Rough running

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 flywheel. 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 the Service Manual for more information.

Fuel Injection nozzles should be cleaned, inspected, tested, and replaced, if necessary. Refer to Special Instruction, SEHS7292 for using the 8S-2245 Injection Cleaning Tool Group. Consult your Caterpillar dealer about cleaning the fuel injection nozzle and testing the fuel injection nozzle. NOTICE Never wire brush or scrape a fuel injection nozzle. Wire brushing or scraping a fuel injection nozzle will damage the finely machine orifice. Proper tools for cleaning and testing the fuel injection nozzles can be obtained 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 a time in order to determine the malfunctioning fuel injection nozzle. 1. Start the engine.

77 Maintenance Section Fuel Transfer Pump Strainer - Clean

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 identified when a fuel line nut is loosened and the following conditions are present:

The exhaust smoke is partially eliminated or

the exhaust smoke is completely eliminated.

Engine performance is not affected.

A fuel injection nozzle that is suspected of being defective should be removed. A new fuel injection nozzle should be installed in the cylinder in order to determine if the removed fuel injection nozzle is defective.
Illustration 37 (1) Fuel transfer pump (2) Cover and seal (3) Strainer
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Removal and Installation of the Fuel Injection Nozzles

For the removal and the installation of fuel injection nozzles, special tooling is required. Refer to the Service Manual for more information. Consult your Caterpillar dealer for assistance.
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1. Remove the cover and seal (2) from the top of fuel transfer pump (1). Remove strainer (3). 2. Use nonflammable solvent in order to clean the strainer, the cover, and the seal. Carefully wash any sediment from the chamber of the fuel transfer pump. 3. Assemble the clean, dry fuel transfer pump. NOTICE Ensure that the lift pump cover is secure so that air does not enter the fuel system. 4. Turn the fuel supply to the ON position. 5. Prime the fuel system. Refer to the Operation and Maintenance Manual for more information on priming the fuel system.
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Fuel Transfer Pump Strainer Clean

SMCS Code: 1256-070-STR

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters 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.

Fuel System - Prime

SMCS Code: 1258-548 Priming the fuel system fills the fuel filter. Priming the fuel system removes air bubbles from the fuel system. Prime the fuel system under the following conditions:

Fuel system that is run dry

Cleaning the Strainer and the Sediment Chamber for the Fuel Transfer Pump
Turn the fuel supply valve to the OFF position before the maintenance is performed.

Storage Fuel filter maintenance Disconnecting fuel lines and installing fuel lines Repair of leaks in the fuel lines

78 Maintenance Section Fuel System - Prime

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. NOTICE Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.

Illustration 39 Priming lever for the fuel transfer pump

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Note: The priming lever of the fuel transfer pump cannot be operated if the cam is at the maximum lift position. If this occurs, the crankshaft must be rotated one revolution. 5. Operate the priming lever for the fuel transfer pump until the flow of fuel from the vent is continuous and free of air bubbles. Tighten the bolt at the top of the fuel filter.
Illustration 38
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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. 1. Loosen vent (2). 2. Tighten vent (2). 3. Loosen banjo bolt (1). Note: The priming lever of the fuel transfer pump cannot be operated if the cam is at the maximum lift position. If this occurs, the crankshaft must be rotated one revolution. 4. Operate the priming lever for the fuel transfer pump until the flow of fuel from banjo bolt (1) is continuous and free of air bubbles.
Illustration 40 Nut for the fuel inlet line at the fuel injection pump
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6. Loosen the nut for the fuel inlet line at the fuel injection 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 to the RUN position. Operate the priming lever for the fuel transfer pump until the flow of fuel from the vent is continuous and free of air bubbles. Tighten the nut for the fuel inlet line.

79 Maintenance Section Fuel System Secondary Filter - Replace

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Fuel System Secondary Filter Replace

SMCS Code: 1261-510-SE

Illustration 41 Fuel line nuts at the fuel injection nozzles

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Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters 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. Turn the fuel supply valve to the OFF position before performing this maintenance. Place a tray under the fuel filter in order to catch any fuel that might spill. Clean up any spilled fuel immediately.

8. Loosen two of the fuel line nuts at two of the fuel injection nozzles in order to open two vents. 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. 9. Ensure that the manual stop control (if equipped) is in the RUN position. Crank the starting motor until the flow of fuel from the vents is continuous and free of air bubbles. Tighten the fuel line nuts. 10. Ensure that all fuel line connections are secure and 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 runs smoothly. If the engine will not start, further priming may be necessary. If the engine starts and if the engine continues to misfire or smoke, one or more of the following conditions may be present:

Illustration 42 (1) Cap. (2) Locking ring. (3) Element. (4) Drain.

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The fuel system requires more priming. There may be an air leak in the fuel system.

1. Close the fuel supply valve. 2. Clean the outside of the fuel filter assembly. Open drain (4) and drain the fuel and water from element (3) into a suitable container. Note: If the element is not equipped with a drain, remove cap (1). Remove the nylon insert in order to reduce the level of fuel in the element. A reduction in the level of fuel in the element will help prevent fuel from being spilled when the element is removed.

80 Maintenance Section Fuel Tank Water and Sediment - Drain

Drain the Water and the Sediment

NOTICE Do not use a tool in order to remove the fuel filter. Attempting to remove the fuel filter with a filter wrench or a filter strap could damage the locking ring. 3. Hold element (3) and rotate locking ring (2) counterclockwise. Remove locking ring (2). The used element should be removed and discarded. Note: If the element is equipped with a sediment bowl, remove the sediment bowl from the element. Thoroughly clean the sediment bowl. Inspect the O-ring seals. Install new O-ring seals, if necessary. Install the sediment bowl to the new element. Hand tighten the sediment bowl. Hand tightening is the only method that should be used. NOTICE Do not fill fuel filters with fuel before installing them. Contaminated fuel will cause accelerated wear to fuel system parts. 4. Ensure that the filter head is clean. Push a new element fully into the filter head. 5. Hold the element in place. Fit locking ring (2) into position. Rotate the locking ring clockwise in order to fasten the element to the filter head. Note: If the nylon insert was removed, install the nylon insert and install cap (1). 6. Prime the fuel system. Refer to the Operation and Maintenance Manual in the Maintenance Section for more information.
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Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks. Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the drain valve. Check the fuel daily. Drain the water and sediment from the fuel tank after operating the engine or drain the water and sediment from the fuel tank after the fuel tank has been filled. Allow five to ten minutes before performing this procedure. Fill the fuel tank after operating the engine in order to drive out moist air. This will help prevent condensation. Do not fill the tank to the top. The fuel expands as the fuel gets warm. The tank may overflow. Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system filter is important.

Fuel Storage Tanks

Drain the water and the sediment from the fuel storage tank during the following conditions:

Weekly Oil change Refill of the tank

Fuel Tank Water and Sediment - Drain

SMCS Code: 1273-543-M&S

This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank. If a bulk storage tank has been refilled or moved recently, allow adequate time for the sediment to settle before filling the engine fuel tank. Internal baffles 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.

Fuel Tank
Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel can cause excessive fuel system wear. 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.

81 Maintenance Section Hoses and Clamps - Inspect/Replace

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Anticipated expansion and contraction of the

fittings

Hoses and Clamps Inspect/Replace

SMCS Code: 7554-040; 7554-510 Inspect all hoses for leaks that are caused by the following conditions:

Replace the Hoses and the Clamps

Cracking Softness Loose clamps

Replace hoses that are cracked or soft. Tighten any loose clamps. NOTICE Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque. Check for the following conditions:

Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler 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 filler cap slowly in order to relieve any pressure. Remove the cooling system filler 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. Note: For torques on hose clamps, see this Operation and Maintenance Manual, Torque Specifications (Maintenance Section). 7. Install the hose clamps with a torque wrench. Note: For the proper coolant to use, see this Operation and Maintenance Manual, Coolant Recommendations (Maintenance Section). 8. Refill the cooling system. 9. Clean the cooling system filler cap. Inspect the cooling system filler caps gaskets. Replace the cooling system filler cap if the gaskets are damaged. Install the cooling system filler cap. 10. Start the engine. Inspect the cooling system for leaks.

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 in place of any standard hose clamp. Ensure that the constant torque hose clamp is the same size as the standard clamp. 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 fitting material Anticipated expansion and contraction of the
hose

82 Maintenance Section Overhaul Considerations

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Costly unplanned downtime can be avoided. Many original parts can be reused according to
the standards for reusable parts.

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:

The engines service life can be extended without

the risk of a major catastrophe due to engine failure. extended life can be attained. After Failure Overhaul If a major engine failure occurs and the engine must be removed, many options are available. An overhaul should be performed if the engine block or the crankshaft needs to be repaired. If the engine block is repairable and/or the crankshaft is repairable, the overhaul cost should be between 40 percent and 50 percent of the cost of a new engine with a similar exchange core. This lower cost can be attributed to three aspects:

The best cost/value relationship per hour of

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 Overhaul Indicator

Oil consumption, fuel consumption, and maintenance information can be used to estimate the total operating cost for your Caterpillar engine. Oil consumption can also be used to estimate the required capacity of a makeup oil tank that is suitable for the maintenance intervals. Oil consumption is in proportion to the percentage of the rated engine load. As the percentage of the engine load is increased, the amount of oil that is consumed per hour also increases. The oil consumption rate (brake specific oil consumption) is measured in grams per kW/h (lb per bhp). The brake specific oil consumption (BSOC) depends on the engine load. Consult your Caterpillar dealer for assistance in determining the typical oil consumption rate for your engine. When an engines oil consumption has risen to three times the original oil consumption rate due to normal wear, an engine overhaul should be scheduled. There may be a corresponding increase in blowby and a slight increase in fuel consumption.

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 specific 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.

Overhaul Options
Before Failure Overhaul A planned overhaul before failure may be the best value for the following reasons:

83 Maintenance Section Overhaul Considerations

Rebuild or Exchange
Cylinder Head Assembly, Cylinder Packs, 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 specifications that are expressed in the reusable parts guideline, the parts should be reused. Parts that are not within the established inspection specifications should be dealt with in one of the following manners:

Caterpillar Inc. recommends the installation of new parts at each overhaul period. Inspect these parts while the engine is disassembled for an overhaul. Inspect the crankshaft for any of the following conditions:

Deflection Damage to the journals Bearing material that has seized to the journals
Check the journal taper and the profile of the crankshaft journals. Check these components by interpreting the wear patterns on the following components:

Salvaging Repairing Replacing

Using out-of-spec parts can result in the following problems:

Rod bearing Main bearings

Inspect the camshaft for damage to the journals and to the lobes. Note: If the camshaft is removed for any reason, use the magnetic particle inspection process to check for cracks in the camshaft. Inspect the following components for signs of wear or for signs of scuffing:

Unscheduled downtime Costly repairs Damage to other engine parts Reduced engine efficiency Increased fuel consumption
Reduced engine efficiency and increased fuel consumption translates into higher operating costs. Therefore, Caterpillar Inc. recommends repairing out-of-spec parts or replacing out-of-spec parts.

Camshaft bearings Camshaft followers

Caterpillar Inc. recommends replacing the crankshaft vibration damper. Oil Cooler Core During an overhaul, Caterpillar Inc. recommends the removal of the oil cooler core. Clean the oil cooler core. Then, pressure test the oil cooler core. NOTICE Do not use caustic cleaners to clean the core. Caustic cleaners can attack the internal metals of the core and cause leakage. Note: Use this cleaning procedure to clean the oil cooler core. 1. Remove the oil cooler core.

Inspection and/or Replacement

Crankshaft Bearings, Valve Rotators, and Crankshaft Seals The following components may not last until the second overhaul.

Thrust bearings Main bearings Rod bearings Valve rotators Crankshaft seals

84 Maintenance Section Radiator - Clean

2. Remove any debris from the oil cooler core. To remove debris from the oil cooler core, turn the oil cooler core onto one end. 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 33 lists the Hydrosolv Liquid Cleaners that are available from your Caterpillar dealer.
Table 33

Obtain Coolant Analysis

The concentration of supplemental coolant additive (SCA) should be checked regularly with test kits or with SOS Coolant Analysis (Level 1). Further coolant analysis is recommended when the engine is overhauled. 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:

HydrosolvLiquid Cleaners Part Number 1U-8812 1U-5490 8T-7570 1U-8804 1U-5492 8T-5571 Hydrosolv100 Hydrosolv4165 Description Size 4 L (1 US gallon) 19 L (5 US gallon) 208 L (55 US gallon) 4 L (1 US gallon) 19 L (5 US gallon) 208 L (55 US gallon)

4. Use steam to clean the oil cooler core. This removes any remaining residue from the cleaner. Flush the fins 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 Identification 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 flow. 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.

Identification of contaminants Identification of built up impurities (corrosion and

scale) SOS Coolant Analysis (Level 2) provides a report of the results of both the analysis and the maintenance recommendations. For more information about coolant analysis, see your Caterpillar dealer.
i01206548

Radiator - Clean
SMCS Code: 1353-070 Note: Adjust the frequency of cleaning according to the effects of the operating environment.

85 Maintenance Section Starting Motor - Inspect

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

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 specifications or consult your Caterpillar dealer for assistance.
i00632301

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. Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction of the fans air flow. Hold the nozzle approximately 6 mm (0.25 inch) away from the fins. 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 fins for damage. Bent fins 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, see Special Publication, SEBD0518, Know Your Cooling System.
i00651416

Walk-Around Inspection
SMCS Code: 1000-040

Inspect the Engine for Leaks and for Loose Connections

A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided. For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections and trash buildup. Make repairs, as needed:

The guards must be in the proper place. Repair

damaged guards or replace missing guards.

Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system contamination. NOTICE For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted. NOTICE Accumulated grease and/or oil on an engine or deck is a fire hazard. Remove this debris with steam cleaning or high pressure water.

Ensure that cooling lines are properly clamped

and tight. Check for leaks. Check the condition of all pipes.

Starting Motor - Inspect

SMCS Code: 1451-040; 1453-040 Caterpillar Inc. recommends a scheduled inspection of the starting motor. If the starting motor fails, the engine may not start in an emergency situation.

Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and the parts contract.

86 Maintenance Section Water Pump - Inspect

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

A piston seizure Other potential damage to the engine

Visually inspect the water pump for leaks. If any leaking is observed, replace the water pump seal or the water pump assembly. Refer to the Service Manual for the disassembly and assembly procedure. Note: Refer to the Service Manual or consult your Caterpillar dealer if any repair is needed or any replacement is needed.

Inspect the lubrication system for leaks at the

front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters and the valve cover.

Inspect the fuel system for leaks. Look for loose

fuel line clamps.

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

Inspect the alternator belt and the accessory

drive belts for cracks, breaks or other damage. Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belts are stretched. The additional load on the new belt could cause the belt to break.

Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean fuel enters the fuel system. loose connections and for worn wires or frayed wires.

Inspect the wiring and the wiring harnesses for

Inspect the ground strap for a good connection

and for good condition.

Inspect the engine-to-frame ground strap for a

good connection and for good condition.

Disconnect any battery chargers that are not

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

Check the condition of the gauges. Replace

any gauges which are cracked or can not be calibrated.
i01057943

Water Pump - Inspect

SMCS Code: 1361-040; 1361 A failed water pump might cause severe engine overheating problems that could result in the following conditions:

Cracks in the cylinder head