SEBU7125-13 107

Maintenance Section
Battery - Replace

To check the belt tension, apply 110 N (25 lb) of

force midway between the pulleys. A correctly
adjusted belt will deflect 13 to 19 mm The battery cables or the batteries should not be
(0.50 to 0.75 inch). removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
Adjustment ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.

Note: Always recycle a battery. Never discard a

battery. Return used batteries to an appropriate
recycling facility.

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
Illustration 95 g00290209 “-” battery terminal to the ground plane.
Typical illustration: (1) Adjusting nuts. (2) Mounting Disconnect the cable from the NEGATIVE “-”
bolts. battery terminal.

1. Loosen mounting bolts (2) and adjusting bolt (1). 4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the starting motor.
2. Move the alternator in order to increase or Disconnect the cable from the POSITIVE “+”
decrease the belt tension. battery terminal.
3. Tighten adjusting bolt (1). Tighten mounting bolts 5. Remove the used battery.
(2). Refer to the Service Manual for the proper
torques. 6. Install the new battery.
If new belts are installed, check the belt tension again Note: Before the cables are connected, ensure that
after 20 hours of engine operation.
the key start switch is OFF.
Replacement 7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
Refer to the Service Manual for more information on
the procedures for the following topics: belt removal 8. Connect the cable from the ground plane to the
and belt installation procedure. NEGATIVE “-” battery terminal.

i06103470 i06064262

Battery - Replace Battery Electrolyte Level -

SMCS Code: 1401-510 Check
SMCS Code: 1401-535
When the engine has not run for long or short periods
Batteries give off combustible gases which can of time, the batteries may not fully recharge. Ensure a
explode. A spark can cause the combustible full charge in order to help prevent the battery from
gases to ignite. This can result in severe personal freezing.
injury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
108 SEBU7125-13
Maintenance Section
Battery or Battery Cable - Disconnect

2. Disconnect the negative battery terminal at the

battery that goes to the start switch. Ensure that
All lead-acid batteries contain sulfuric acid which the cable cannot contact the terminal. When four
can burn the skin and clothing. Always wear a 12 volt batteries are involved, the negative side of
face shield and protective clothing when working two batteries must be disconnected.
on or near batteries.
3. Tape the leads in order to help prevent accidental
starting.
1. Remove the filler caps. Maintain the electrolyte
level to the “FULL” mark on the battery. 4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.
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 i05793911
softened water.
Cooling System Coolant
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer. (DEAC) - Change
3. Keep the batteries clean. SMCS Code: 1350-070; 1395-044

Clean the battery case with one of the following Clean the cooling system and flush the cooling
cleaning solutions: system before the recommended maintenance
interval if the following conditions exist:
• A mixture of 0.1 kg (0.2 lb) of baking soda and • The engine overheats frequently.
1 L (1 qt) of clean water
• Foaming is observed.
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water • The oil has entered the cooling system and the
coolant is contaminated.
Thoroughly rinse the battery case with clean
water. • The fuel has entered the cooling system and the
coolant is contaminated.
Use the 1U-9921 Battery Service Tool to clean
the battery terminals. Use a wire brush to clean
the cable clamps. Clean the items until the NOTICE
surfaces are bright or shiny. DO NOT remove Use of commercially available cooling system
material excessively. Excessive removal of cleaners may cause damage to cooling system com-
material can cause the clamps to fit improperly. ponents. Use only cooling system cleaners that are
Coat the clamps and the terminals with 5N-5561 approved for Caterpillar engines.
Silicone Lubricant, petroleum jelly or MPGM.

i01492654
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
Battery or Battery Cable - been drained. This procedure is a good opportunity
to replace the water pump, the water temperature
Disconnect regulator, and the hoses, if necessary.
SMCS Code: 1402-029
Drain

The battery cables or the batteries should not be

removed with the battery cover in place. The bat- Pressurized System: Hot coolant can cause seri-
tery cover should be removed before any servic- ous burns. To open the cooling system filler cap,
ing is attempted. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
Removing the battery cables or the batteries with pressure cap slowly in order to relieve the
the cover in place may cause a battery explosion pressure.
resulting in personal injury.
1. Stop the engine and allow the engine to cool.
1. Turn the start switch to the OFF position. Turn the Loosen the cooling system filler cap slowly in
ignition switch (if equipped) to the OFF position order to relieve any pressure. Remove the cooling
and remove the key and all electrical loads. system filler cap.
SEBU7125-13 109
Maintenance Section
Cooling System Coolant (DEAC) - Change

2. Open the cooling system drain valve (if equipped). 5. Stop the engine and allow the engine to cool.
If the cooling system is not equipped with a drain Loosen the cooling system filler cap slowly in
valve, remove one of the drain plugs. order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if
Note: If equipped, be sure to drain the heater and equipped) or remove the cooling system drain
any related supply and return lines. plugs. Allow the water to drain. Flush the cooling
Allow the coolant to drain. system with clean water. If equipped, be sure to
flush the heater and any related supply and return
NOTICE lines. Close the drain valve (if equipped). Clean
Dispose of used engine coolant properly or recycle. the drain plugs. Install the drain plugs. Refer to the
Various methods have been proposed to reclaim Specifications Manual, SENR3130, “Torque
used coolant for reuse in engine cooling systems.
Specifications” for more information on the proper
The full distillation procedure is the only method ac-
ceptable by Caterpillar to reclaim the used coolant. torques.

For information regarding the disposal and the Cooling Systems with Heavy
recycling of used coolant, consult your Cat dealer or
consult Cat Dealer Service Tool Group: Deposits or Plugging
Outside Illinois 1-800-542-TOOL Note: For the following procedure to be effective,
Inside Illinois 1-800-541-TOOL there must be some active flow through the cooling
Canada 1-800-523-TOOL system components.

1. Flush the cooling system with clean water in order

Flush to remove any debris.
1. Flush the cooling system with clean water in order Note: If equipped, be sure to flush the heater and
to remove any debris. any related supply and return lines.
2. Close the drain valve (if equipped). Clean the drain
2. Close the drain valve (if equipped). Clean the drain
plugs. Install the drain plugs. Refer to the
plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, “Torque
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
Specifications” for more information on the proper
torques.
torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) NOTICE
per minute to avoid air locks. 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

3. Fill the cooling system with a mixture of clean
water and Cat Quick Flush cooling system cleaner.
water and Cat Fast Acting Cooling System
Refer to the directions for the cleaner. For
Cleaner. Add 0.5 L (1 pt) of cleaner per
additional information on cooling system cleaners,
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
refer to the One Safe Source catalog. Install the
capacity. Install the cooling system filler cap.
cooling system filler cap.
4. Start and run the engine at low idle for a minimum
4. Start and run the engine at low idle for a minimum
of 90 minutes. The coolant temperature should be
of 30 minutes. The coolant temperature should be
at least 82 °C (180 °F).
at least 82 °C (180 °F).
NOTICE
NOTICE Improper or incomplete rinsing of the cooling system
Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal
can result in damage to copper and other metal components.
components.
To avoid damage to the cooling system, make sure to
To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water.
completely flush the cooling system with clear water. Continue to flush the system until all signs of the
Continue to flush the system until all signs of the cleaning agent are gone.
cleaning agent are gone.
110 SEBU7125-13
Maintenance Section
Cooling System Coolant (ELC) - Change

5. Stop the engine and allow the engine to cool. 5. Start the engine. Inspect the cooling system for
Loosen the cooling system filler cap slowly in leaks and for proper operating temperature.
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if i03292691
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling Cooling System Coolant (ELC)
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
- Change
plugs. Refer to the Specifications Manual, SMCS Code: 1350-070; 1395-044
SENR3130, “Torque Specifications” for more Clean the cooling system and flush the cooling
information on the proper torques. system before the recommended maintenance
interval if the following conditions exist:
Fill
• The engine overheats frequently.

NOTICE • Foaming is observed.

Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks. • The oil has entered the cooling system and the
coolant is contaminated.
1. Fill the cooling system with coolant/antifreeze. • The fuel has entered the cooling system and the
Refer to the Operation and Maintenance Manual, coolant is contaminated.
“Refill Capacities and Recommendations” topic
(Maintenance Section) for more information on Note: When the cooling system is cleaned, only
cooling system specifications. Do not install the clean water is needed when the ELC is drained and
cooling system filler cap. replaced.

2. Start and run the engine at low idle. Increase the Note: Inspect the water pump and the water
engine rpm to 1500 rpm. Run the engine at high temperature regulator after the cooling system has
idle for 1 minute in order to purge the air from the been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
cavities of the engine block. Stop the engine.
the hoses, if necessary.
3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the Drain
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
Pressurized System: Hot coolant can cause seri-
4. Clean the cooling system filler cap. Inspect the ous burns. To open the cooling system filler cap,
gasket that is on the cooling system filler cap. If stop the engine and wait until the cooling system
the gasket that is on the cooling system filler cap is components are cool. Loosen the cooling system
damaged, discard the cap and install a new pressure cap slowly in order to relieve the
cooling system filler cap. If the gasket that is on pressure.
the cooling system filler cap is not damaged,
perform a pressure test. A 9S-8140 Pressurizing 1. Stop the engine and allow the engine to cool.
Pump is used to perform the pressure test. The Loosen the cooling system filler cap slowly in
correct pressure for the cooling system filler cap is order to relieve any pressure. Remove the cooling
stamped on the face of the cooling system filler system filler cap.
cap. If the cooling system filler cap does not retain
the correct pressure, install a new cooling system 2. Open the cooling system drain valve (if equipped).
filler cap. If the cooling system is not equipped with a drain
valve, remove the cooling system drain plugs.
Allow the coolant to drain.