C11 and C13 Industrial Engines-Maintenance Intervals
C11 and C13 Industrial Engines-Maintenance Intervals
C11 and C13 Industrial Engines-Maintenance Intervals
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© 2007 Caterpillar
All Rights Reserved
SEBU7901-01 51
Maintenance Section
Maintenance Interval Schedule
Ensure that all safety information, warnings, and Every 500 Service Hours
instructions are read and understood before any
operation or any maintenance procedures are Belts - Inspect/Adjust/Replace .............................. 55
performed. Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 61
The user is responsible for the performance of Starting Motor - Inspect ........................................ 86
maintenance, including all adjustments, the use of Turbocharger - Inspect .......................................... 86
proper lubricants, fluids, filters, and the replacement Water Pump - Inspect ........................................... 88
of components due to normal wear and aging. The
performance of this product may be diminished if Every 500 Service Hours or 6 Months
proper maintenance intervals and procedures are not
followed. Components may experience accelerated Engine Protective Devices - Check ...................... 74
wear if proper maintenance intervals and procedures
are not followed. Every 2000 Service Hours or 1 Year
Alternator - Inspect ............................................... 53
Use fuel consumption, service hours, or calendar
time, WHICH EVER OCCURS FIRST, in order to
determine the maintenance intervals. Products that Every Year
operate in severe operating conditions may require Cooling System Coolant Sample (Level 2) -
more frequent maintenance. Obtain ................................................................. 62
Note: Before each consecutive interval is performed, Every 3000 Service Hours or 3 Years
all maintenance from the previous interval must be
performed. Cooling System Coolant (DEAC) - Change .......... 56
Cooling System Coolant Extender (ELC) - Add .... 60
When Required Cooling System Water Temperature Regulator -
Replace ............................................................... 63
Battery - Replace .................................................. 54
Battery or Battery Cable - Disconnect .................. 55
Every 8000 Service Hours or 3 Years
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 66 Driven Equipment - Check .................................... 64
Engine Storage Procedure - Check ...................... 75
Fuel System - Prime ............................................. 76 Every 12 000 Service Hours or 6 Years
Severe Service Application - Check ..................... 85
Cooling System Coolant (ELC) - Change ............. 58
Daily
Every 14 400 L (3750 US gal) of Fuel or 250
Cooling System Coolant Level - Check ................ 61 Service Hours or 1 Year
Engine Air Cleaner Service Indicator - Inspect ..... 69
Engine Oil Level - Check ...................................... 71 Battery Electrolyte Level - Check .......................... 54
Fuel System Primary Filter/Water Separator - Electronics Grounding Stud - Inspect/Clean/
Drain ................................................................... 78 Tighten ................................................................ 65
Power Take-Off Clutch - Check/Adjust/Lubricate .. 84 Engine Crankcase Breather - Clean ..................... 70
Walk-Around Inspection ........................................ 87 Engine Oil Sample - Obtain .................................. 72
Fuel System Primary Filter (Water Separator)
Every Week Element - Replace .............................................. 78
Fuel System Secondary Filter - Replace .............. 79
Fuel Tank Water and Sediment - Drain ................. 80 Hoses and Clamps - Inspect/Replace .................. 81
Jacket Water Heater - Check ................................ 82 Radiator - Clean .................................................... 85
Every 250 Service Hours Every 28 500 L (7500 US gal) of Fuel or 500
Cooling System Supplemental Coolant Additive Service Hours or 1 Year (Deep Sump)
(SCA) - Test/Add ................................................. 62 Engine Oil and Filter - Change ............................. 72
Engine Oil and Filter - Change ............................. 72
Fuel Tank Water and Sediment - Drain ................. 80
52 SEBU7901-01
Maintenance Section
Maintenance Interval Schedule
Overhaul
Fan Drive Bearing - Replace ................................ 76
SEBU7901-01 53
Maintenance Section
Aftercooler Core - Clean/Test
Alternator - Inspect
SMCS Code: 1405-040
Personal injury can result from air pressure.
Caterpillar recommends a scheduled inspection
Personal injury can result without following prop-
of the alternator. Inspect the alternator for loose
er procedure. When using pressure air, wear a pro-
connections and proper battery charging. Inspect the
tective face shield and protective clothing.
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or
Maximum air pressure at the nozzle must be less
proper performance of the electrical system. Make
than 205 kPa (30 psi) for cleaning purposes.
repairs, as required. Refer to the Service Manual.
Pressurized air is the preferred method for removing Check the alternator and the battery charger for
loose debris. Direct the air in the opposite direction proper operation. If the batteries are properly
of the fan’s air flow. Hold the nozzle approximately charged, the ammeter reading should be very near
6 mm (0.25 inch) away from the fins. Slowly move the zero. All batteries should be kept charged. The
air nozzle in a direction that is parallel with the tubes. batteries should be kept warm because temperature
This will remove debris that is between the tubes. affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
Pressurized water may also be used for cleaning. not crank the engine, even if the engine is warm.
The maximum water pressure for cleaning purposes When the engine is not run for long periods of time
must be less than 275 kPa (40 psi). Use pressurized or if the engine is run for short periods, the batteries
water in order to soften mud. Clean the core from may not fully charge. A battery with a low charge will
both sides. freeze more easily than a battery with a full charge.
Removing the battery cables or the batteries with 1. Remove the filler caps. Maintain the electrolyte
the cover in place may cause a battery explosion level to the “FULL” mark on the battery.
resulting in personal injury.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
1. Switch the engine to the OFF position. Remove water that is low in minerals. Do not use artificially
all electrical loads. softened water.
2. Turn off any battery chargers. Disconnect any 2. Check the condition of the electrolyte with the
battery chargers. 245-5829 Coolant Battery Tester Refractometer.
3. The NEGATIVE “-” cable connects the NEGATIVE 3. Keep the batteries clean.
“-” battery terminal to the NEGATIVE “-” terminal
on the starter motor. Disconnect the cable from Clean the battery case with one of the following
the NEGATIVE “-” battery terminal. cleaning solutions:
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the POSITIVE “+” terminal
• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
on the starting motor. Disconnect the cable from
the POSITIVE “+” battery terminal.
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate Thoroughly rinse the battery case with clean water.
recycling facility.
Use a fine grade of sandpaper to clean the
5. Remove the used battery. terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
6. Install the new battery. remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Note: Before the cables are connected, ensure that Coat the clamps and the terminals with 5N-5561
the engine start switch is OFF. Silicone Lubricant, petroleum jelly or MPGM.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
SEBU7901-01 55
Maintenance Section
Battery or Battery Cable - Disconnect
4. Proceed with necessary system repairs. Reverse 1. Remove the belt guard.
the steps in order to reconnect all of the cables.
2. Loosen mounting bolts (1) and adjusting bolt (2).
Inspect the alternator belt and the fan drive belts for If new drive belts are installed, check the drive belt
wear and for cracking. Replace the belts if the belts tension again after 30 minutes of engine operation
are not in good condition. at the rated rpm.
Check the belt tension according to the information in Adjustment of the Fan Drive Belt
the Service Manual, “Specifications”.
1. Remove the belt guard.
Slippage of loose belts can reduce the efficiency
of the driven components. Vibration of loose belts 2. Loosen the mounting bolt for the pulley.
can cause unnecessary wear on the following
components: 3. Loosen the adjusting nut for the pulley.
• Belts 4. Move the pulley in order to adjust the belt tension.
• Pulleys 5. Tighten the adjusting nut.
If new drive belts are installed, check the drive belt NOTICE
tension again after 30 minutes of engine operation Dispose of used engine coolant properly or recycle.
at the rated rpm. Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
i02070334
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
Cooling System Coolant
(DEAC) - Change For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
SMCS Code: 1350-070; 1395-044 dealer or consult Caterpillar Dealer Service Tools:
Clean the cooling system and flush the cooling Outside Illinois: 1-800-542-TOOL
system before the recommended maintenance Inside Illinois: 1-800-541-TOOL
interval if the following conditions exist: Canada: 1-800-523-TOOL
5. Stop the engine and allow the engine to cool. 5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if cooling system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain equipped). Clean the drain plugs. Install the drain
plugs. Refer to the Specifications Manual for your plugs. Refer to the Specifications Manual for your
particular engine for more specific information on particular engine for more specific information on
the proper torques. Refer to the Specifications, the proper torques. Refer to the Specifications,
SENR3130, “Torque Specifications” for more SENR3130, “Torque Specifications” for more
general information on the proper torques. general information on the proper torques.
1. Flush the cooling system with clean water in order Engines that are Equipped with a Coolant
to remove any debris. Recovery Tank
2. Close the drain valve (if equipped). Clean the
NOTICE
drain plugs. Install the drain plugs. Refer to the
Specifications Manual for your particular engine for Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
more specific information on the proper torques.
Refer to the Specifications, SENR3130, “Torque
Specifications” for more general information on 1. Fill the cooling system with coolant/antifreeze.
the proper torques. Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic
NOTICE (Maintenance Section) for more information on
Fill the cooling system no faster than 19 L (5 US gal) cooling system specifications. Do not install the
per minute to avoid air locks. cooling system filler cap.
3. Check the coolant level. Maintain the coolant level Pressurized System: Hot coolant can cause seri-
within 13 mm (.5 inch) below the bottom of the ous burns. To open the cooling system filler cap,
pipe for filling. Maintain the coolant level within stop the engine and wait until the cooling system
13 mm (.5 inch) to the proper level on the sight components are cool. Loosen the cooling system
glass (if equipped). pressure cap slowly in order to relieve the pres-
sure.
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If 1. Stop the engine and allow the engine to cool.
the gasket that is on the cooling system filler cap Loosen the cooling system filler cap slowly in
is damaged, discard the old cooling system filler order to relieve any pressure. Remove the cooling
cap and install a new cooling system filler cap. system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, perform a pressure test. A 2. Open the cooling system drain valve (if equipped).
9S-8140 Pressurizing Pump is used to perform If the cooling system is not equipped with a drain
the pressure test. The correct pressure for the valve, remove the cooling system drain plugs.
cooling system filler cap is stamped on the face of
the cooling system filler cap. If the cooling system Allow the coolant to drain.
filler cap does not retain the correct pressure,
install a new cooling system filler cap. NOTICE
Dispose of used engine coolant properly or recycle.
5. Start the engine. Inspect the cooling system for Various methods have been proposed to reclaim used
leaks and for proper operating temperature. coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
SEBU7901-01 59
Maintenance Section
Cooling System Coolant (ELC) - Change
For information regarding the disposal and the 1. Fill the cooling system with Extended Life Coolant
recycling of used coolant, consult your Caterpillar (ELC). Refer to the Operation and Maintenance
dealer or consult Caterpillar Dealer Service Tools: Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information
Outside Illinois: 1-800-542-TOOL on cooling system specifications. Do not install the
Inside Illinois: 1-800-541-TOOL cooling system filler cap.
Canada: 1-800-523-TOOL
2. Start the engine and operate the engine at low
idle. Increase the engine rpm to high idle. Operate
Flush the engine at high idle for one minute in order to
purge air from the cavities of the engine block.
1. Flush the cooling system with clean water in order
Stop the engine.
to remove any debris.
3. Pour more ELC into the cooling system until the
2. Close the drain valve (if equipped). Clean the
cooling system is full.
drain plugs. Install the drain plugs. Refer to the
Specifications Manual for your particular engine for
4. Clean the cooling system filler cap. Inspect the
more specific information on the proper torques.
gasket that is on the cooling system filler cap. If
Refer to the Specifications, SENR3130, “Torque
Specifications” for more general information on the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
the proper torques.
cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap is
NOTICE not damaged, use a 9S-8140 Pressurizing Pump
Fill the cooling system no faster than 19 L (5 US gal) in order to pressure test the cooling system filler
per minute to avoid air locks. 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
3. Fill the cooling system with clean water. Install the
cooling system filler cap. does not retain the correct pressure, install a new
cooling system filler cap.
4. Start the engine and run the engine at low
idle until the temperature reaches 49 to 66 °C 5. Loosen the cap for the coolant recovery tank
slowly in order to relieve any pressure. Remove
(120 to 150 °F).
the cap for the coolant recovery tank.
5. Stop the engine and allow the engine to cool.
6. Pour Extended Life Coolant (ELC) into the coolant
Loosen the cooling system filler cap slowly
recovery tank until the coolant reaches the “COLD
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if FULL” mark. DO NOT fill the coolant recovery
tank above the “COLD FULL” mark.
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 7. Clean the cap for the coolant recovery tank. Install
the cap for the coolant recovery tank.
equipped). Clean the drain plugs. Install the drain
plugs. Refer to the Specifications Manual for your
particular engine for more specific information on 8. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
the proper torques. Refer to the Specifications,
SENR3130, “Torque Specifications” for more
general information on the proper torques. Engines that are NOT Equipped with a
Coolant Recovery Tank
Fill
NOTICE
Engines that are Equipped with a Coolant Fill the cooling system no faster than 19 L (5 US gal)
Recovery Tank per minute to avoid air locks.
i01197583 3. Clean the cooling system filler cap and check the
condition of the filler cap gaskets. Replace the
Cooling System Coolant Level cooling system filler cap if the filler cap gaskets are
- Check damaged. Reinstall the cooling system filler cap.
Table 12
Recommended Interval
Pressurized System: Hot coolant can cause seri- Type of Coolant Level 1 Level 2
ous burns. To open the cooling system filler cap, Every 250
stop the engine and wait until the cooling system Cat DEAC Yearly(1)(2)
Hours(1)
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres- Cat ELC Optional(2) Yearly(2)
sure. (1) This is the recommended interval for coolant samples for all
conventional heavy-duty coolant/antifreeze. This is also the
recommended interval for coolant samples of commercial
1. Remove the cooling system filler cap slowly in coolants that meet the Cat EC-1 specification for engine
order to relieve pressure. coolant.
(2) The Level 2 Coolant Analysis should be performed sooner if a
2. Maintain the coolant level within 13 mm (0.5 inch) problem is suspected or identified.
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant • Commercial long life coolants that meet the
level to the proper level in the sight glass. Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
g00103639
Illustration 27
Note: Level 1 results may indicate a need for
Typical filler cap gaskets
Level 2 Analysis.
62 SEBU7901-01
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Obtain the sample of the coolant as close as possible Submit the sample for Level 2 analysis.
to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you For additional information about coolant
must establish a consistent trend of data. In order analysis, see Special Publication, SEBU6251,
to establish a pertinent history of data, perform “Caterpillar Commercial Diesel Engines Fluids
consistent samplings that are evenly spaced. Recommendations” or consult your Caterpillar dealer.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
i02417522
• Never collect samples from expansion bottles. Note: Caterpillar recommends an S·O·S coolant
analysis (Level 1).
• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis. Test the Concentration of the SCA
For additional information about coolant analysis, Coolant/Antifreeze and SCA
see Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids Recommendations” NOTICE
or consult your Caterpillar dealer. Do not exceed the recommended six percent supple-
mental coolant additive concentration.
i01987714
Test the concentration of the SCA with the 8T-5296
Cooling System Coolant Coolant Conditioner Test Kit.
Sample (Level 2) - Obtain
Water and SCA
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
NOTICE Do not exceed the recommended eight percent sup-
Always use a designated pump for oil sampling, and plemental coolant additive concentration.
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This Test the concentration of the SCA with the 8T-5296
contaminate may cause a false analysis and an incor- Coolant Conditioner Test Kit. Use the instructions
rect interpretation that could lead to concerns by both that follow:
dealers and customers.
1. Fill the syringe to the “1.0 ml” mark with the
coolant.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain” 2. Dispense the 1.0 mL coolant sample from the
for the guidelines for proper sampling of the coolant. syringe into the empty mixing bottle.
SEBU7901-01 63
Maintenance Section
Cooling System Water Temperature Regulator - Replace
A water temperature regulator that fails in the open Inspect the damper for evidence of fluid leaks. If
position will cause the engine operating temperature a fluid leak is found, determine the type of fluid.
to be too low during partial load operation. Low The fluid in the damper is silicone. Silicone has
engine operating temperatures during partial loads the following characteristics: transparent, viscous,
could cause an excessive carbon buildup inside the smooth, and difficult to remove from surfaces.
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear If the fluid leak is oil, inspect the crankshaft seals for
of the cylinder liner. leaks. If a leak is observed, replace the crankshaft
seals.
NOTICE
Failure to replace your water temperature regulator Inspect the damper and repair or replace the damper
on a regularly scheduled basis could cause severe for any of the following reasons:
engine damage.
• The damper is dented, cracked, or leaking.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water • The paint on the damper is discolored from heat.
temperature regulator installed.
• The engine has had a failure because of a broken
If the water temperature regulator is installed incor- crankshaft.
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg- • Analysis of the oil has revealed that the front main
ulator is installed in the original position. Ensure that bearing is badly worn.
the water temperature regulator vent hole is open.
• There is a large amount of gear train wear that is
Do not use liquid gasket material on the gasket or not caused by a lack of oil.
cylinder head surface.
Refer to the Service Manual or consult your
Caterpillar dealer for information about damper
Refer to the Service Manual for the replacement replacement.
procedure of the water temperature regulator, or
consult your Caterpillar dealer.
i00934883
Visconic Damper
The visconic damper has a weight that is located
inside a fluid filled case. The weight moves in the
case in order to limit torsional vibration.
SEBU7901-01 65
Maintenance Section
Electronic Unit Injector - Inspect/Adjust
Inspect the Drive Coupling The operation of Caterpillar engines with improper
adjustments of the electronic unit injector can reduce
Inspect the drive coupling according to the engine efficiency. This reduced efficiency could result
instructions that are provided by the OEM of the in excessive fuel usage and/or shortened engine
coupling. For the following service information, see component life.
the literature that is provided by the OEM of the
coupling: Only qualified service personnel should perform
this maintenance. Refer to the following topics
• Lubrication requirements for your engine for the correct procedure: Refer
to the Systems Operation, Testing and Adjusting,
• Specifications for the end play “Electronic Unit Injector - Test” for the test procedure,
and Systems Operation, Testing and Adjusting,
• “Reusability Guidelines” “Electronic Unit Injector - Adjust” for the correct
procedure for adjusting the injectors.
• Replacement instructions
NOTICE
Inspect the Rear Gear Train The camshafts must be correctly timed with the crank-
shaft before an adjustment of the lash for the fuel in-
Inspect the crankshaft gear. If excessive wear is jector is made. The timing pins must be removed from
found, replace the crankshaft gear and the large the camshafts before the crankshaft is turned or dam-
cluster idler. age to the cylinder block will be the result.
For the correct parts, see the Parts Manual for the Electronics Grounding Stud -
engine. For removal and replacement instructions,
see the Service Manual, “Disassembly and
Inspect/Clean/Tighten
Assembly” module. Consult your Caterpillar dealer SMCS Code: 7423-040; 7423-070; 7423-079
for assistance.
i02070777
i01646701
Engine - Clean
SMCS Code: 1000-070
NOTICE
Accumulated grease and oil on an engine is a fire haz-
Illustration 28
g00765094 ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
Electronics grounding stud (side view)
the engine.
Inspect the OEM harness for good connections.
Inspect the condition of the OEM harness. Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
The electronics grounding stud must have a wire oil and grease. A clean engine provides the following
ground to the battery. Tighten the electronics benefits:
grounding stud at every oil change. Ground wires
and straps should be combined at engine grounds. • Easy detection of fluid leaks
All grounds should be tight and free of corrosion.
• Maximum heat transfer characteristics
• Clean the electronics grounding stud and the
terminals for the electronics ground strap with a • Ease of maintenance
clean cloth.
Note: Caution must be used in order to prevent
• If the connections are corroded, clean the electrical components from being damaged by
connections with a solution of baking soda and excessive water when you clean the engine. Avoid
water. electrical components such as the alternator, the
starter, and the ECM.
• Keep the electronics grounding stud and the strap
clean and coated with MPGM grease or petroleum
jelly. i01553486
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 air-
borne debris from entering the air inlet.
SEBU7901-01 67
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.
• The air cleaner element may be cleaned up to 2. The secondary air cleaner element should be
six times if the element is properly cleaned and removed and discarded for every three cleanings
inspected. of the primary air cleaner element.
• The air cleaner element should be replaced at least Note: Refer to “Cleaning the Primary Air Cleaner
one time per year. This replacement should be Elements”.
performed regardless of the number of cleanings.
3. Cover the turbocharger air inlet with tape in order
Replace the dirty paper air cleaner elements with to keep dirt out.
clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked 4. Clean the inside of the air cleaner cover and body
for tears and/or holes in the filter material. Inspect with a clean, dry cloth.
the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner 5. Remove the tape for the turbocharger air inlet.
elements for replacement purposes. Install the secondary air cleaner element. Install a
primary air cleaner element that is new or cleaned.
Dual Element Air Cleaners
6. Install the air cleaner cover.
The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner 7. Reset the air cleaner service indicator.
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 primary air cleaner element can be used up Aim the hose so that the air flows inside the element
to six times if the element is properly cleaned and along the length of the filter in order to help prevent
inspected. When the primary air cleaner element is damage to the paper pleats. Do not aim the stream
cleaned, check for rips or tears in the filter material. of air directly at the primary air cleaner element. Dirt
The primary air cleaner element should be replaced could be forced further into the pleats.
at least one time per year. This replacement should
be performed regardless of the number of cleanings. Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
Use clean primary air cleaner elements while dirty
elements are being cleaned. Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
NOTICE
primary air cleaner elements which require daily
Do not clean the air cleaner elements by bumping or
cleaning because of a dry, dusty environment.
tapping. This could damage the seals. Do not use el-
Cleaning with pressurized air is recommended prior
ements with damaged pleats, gaskets or seals. Dam-
to vacuum cleaning. Vacuum cleaning will not remove
aged elements will allow dirt to pass through. Engine
deposits of carbon and oil.
damage could result.
Note: Refer to “Inspecting the Primary Air Cleaner
Visually inspect the primary air cleaner elements 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.
• Pressurized air
• Vacuum cleaning
SEBU7901-01 69
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Inspecting the Primary Air Cleaner Do not use paint, a waterproof cover, or plastic as a
Elements 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.
• Date of cleaning
• Number of cleanings
Store the box in a dry location.
g00281693
Illustration 31
i01900118
g00281694
Illustration 32
g00103777
Illustration 33
Typical service indicator
70 SEBU7901-01
Maintenance Section
Engine Crankcase Breather - Clean
Note: When a new service indicator is installed, 1. Loosen hose clamp (2) and remove the hose from
excessive force may crack the top of the service breather cover (3).
indicator. Tighten the service indicator to a torque
of 2 N·m (18 lb in). 2. Loosen four bolts (1) for the breather cover and
remove breather cover (3).
i02139969
If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately.
Illustration 35
g00622328 3. Record the amount of oil that is added. For the
(1) Oil level gauge
next oil sample and analysis, include the total
(2) Oil filler cap amount of oil that has been added since the
previous sample. This will help to provide the most
accurate oil analysis.
72 SEBU7901-01
Maintenance Section
Engine Oil Sample - Obtain
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NOTICE
Engine Oil Sample - Obtain Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
SMCS Code: 1000-008; 1348-554-SM;
Using the same pump for both types of samples may
7542-554-OC, SM
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
In addition to a good preventive maintenance
rect interpretation that could lead to concerns by both
program, Caterpillar recommends using S·O·S oil
dealers and customers.
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine. S·O·S oil If the engine is not equipped with a sampling valve,
analysis provides infrared analysis, which is required use the 1U-5718 Vacuum Pump. The pump is
for determining nitration and oxidation levels. designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
Obtain the Sample and the Analysis
For instructions, see Special Publication, PEHP6001,
“How To Take A Good Oil Sample”. Consult your
Caterpillar dealer for complete information and
Hot oil and hot components can cause personal assistance in establishing an S·O·S program for your
injury. Do not allow hot oil or hot components to engine.
contact the skin.
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Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order Engine Oil and Filter - Change
to help obtain the most accurate analysis, provide
the following information: SMCS Code: 1318-510; 1348-044
• Engine model
• Service hours on the engine Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
• The number of hours that have accumulated since contact the skin.
the last oil change
• The amount of oil that has been added since the Do not drain the oil when the engine is cold. As the oil
last oil change cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed
To ensure that the sample is representative of the with the draining cold oil. Drain the crankcase with
oil in the crankcase, obtain a warm, well mixed oil the engine stopped. Drain the crankcase with the
sample. oil warm. This draining method allows the waste
particles that are suspended in the oil to be drained
To avoid contamination of the oil samples, the tools properly.
and the supplies that are used for obtaining oil
samples must be clean. Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
Caterpillar recommends using the sampling valve the engine lubrication system with the new oil.
in order to obtain oil samples. The quality and the
consistency of the samples are better when the Drain the Engine Oil
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be After the engine has been run at the normal operating
obtained during normal engine operation. temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The • If the engine is equipped with a drain valve, turn the
fluid sampling bottle includes the parts that are drain valve knob counterclockwise in order to drain
needed for obtaining oil samples. Instructions are the oil. After the oil has drained, turn the drain valve
also provided. knob clockwise in order to close the drain valve.
SEBU7901-01 73
Maintenance Section
Engine Oil and Filter - Change
After the oil has drained, the oil drain plugs should
be cleaned and installed.
2. Cut the oil filter open with a 175-7546 Oil Filter NOTICE
Cutter Gp. Break apart the pleats and inspect the Do not fill the oil filters with oil before installing them.
oil filter for metal debris. An excessive amount This oil would not be filtered and could be contaminat-
of metal debris in the oil filter may indicate early ed. Contaminated oil can cause accelerated wear to
wear or a pending failure. engine components.
Use a magnet to differentiate between the ferrous 5. Install the oil filter. Tighten the oil filter until the
metals and the nonferrous metals that are found in oil filter gasket contacts the base. Tighten the oil
the oil filter element. Ferrous metals may indicate filter by hand according to the instructions that are
wear on the steel and cast iron parts of the engine. shown on the oil filter. Do not overtighten the oil
filter.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include Fill the Engine Crankcase
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads. 1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual, “Refill Capacities and
Due to normal wear and friction, it is not Recommendations” for more information.
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order NOTICE
to arrange for a further analysis if an excessive If equipped with an auxiliary oil filter system or a re-
amount of debris is found in the oil filter. mote oil filter system, follow the OEM or filter manu-
facturer’s recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
3. Stop the engine and allow the oil to drain back to i01464654
the sump for a minimum of ten minutes.
Engine Speed/Timing Sensors
4. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the “ADD”
- Check/Clean/Calibrate
and “FULL” marks on the oil level gauge. SMCS Code: 1912-040; 1912-070; 1912-524
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The oil change interval may be extended to 12 The initial valve lash adjustment on new engines,
months for a vehicle that is operated seasonally rebuilt engines, or remanufactured engines is
and placed in storage for the remainder of the year recommended at the first scheduled oil change. The
by using the required storage procedures and the adjustment is necessary due to the initial wear of
required start-up procedures. This extension is the valve train components and to the seating of the
permitted if the following categories for oil change valve train components.
intervals in the Operation and Maintenance Manual,
“Maintenance Interval Schedule” have not been This maintenance is recommended by Caterpillar
reached: as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
• Mileage life.
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NOTICE
Fan Drive Bearing - Replace
A valve rotator which does not operate properly will SMCS Code: 1359-510-BD
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced, 1. Remove Bearings. Refer to Disassembly and
valve face guttering could result and cause pieces of Assembly, “Bearing Removal”.
the valve to fall into the cylinder. This can cause piston
and cylinder head damage. 2. Measure the bearing housings for roundness and
for proper size.
If a valve fails to rotate, consult your Caterpillar
dealer. 3. Replace the bearings.
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Some of the fan drives have grease fittings and some The Secondary Fuel Filter Has
of the fan drives do not have grease fittings. If there is
no grease fitting, periodic lubrication is not required. Been Replaced
The fan drive requires grease only if the fan drive
is equipped with a zerk.
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 discon-
nected fuel system component.
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Illustration 40
(1) Fuel priming pump 1. Turn the ignition switch to the “OFF” position.
(2) Air purge screw
(3) Priming valve (If Equipped) 2. Fill the fuel tank(s) with clean diesel fuel.
2. Turn the priming valve (3) (If Equipped) to the
“Closed (Prime)” position in order to prime the fuel
system.
3. Open air purge screw (2) for the fuel filter by three
full turns. Do not remove the air purge screw.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Open air purge screw (2) for the fuel filter by three
full turns. Do not remove the air purge screw. NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
NOTICE clean the area around a fuel system component that
Do not crank the engine continuously for more than will be disconnected. Fit a suitable cover over discon-
30 seconds. Allow the starting motor to cool for two nected fuel system component.
minutes before cranking the engine again.
Note: You may use the fuel priming pump (1) (IF
EQUIPPED) for the fuel filter instead of cranking the
engine.
NOTICE
1. Close the main fuel supply valve.
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the fu-
el system.
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NOTICE
Use a suitable container to catch any fuel that might
Fuel Tank Water and Sediment
spill. Clean up any spilled fuel immediately. - Drain
SMCS Code: 1273-543-M&S
1. Stop the engine. Turn the ignition switch to the
OFF position or disconnect the battery. Refer to
the Operation and Maintenance Manual, “Battery NOTICE
or Battery Cable - Disconnect” topic (Maintenance Care must be taken to ensure that fluids are contained
Section) for more information. Shut off the fuel during performance of inspection, maintenance, test-
supply valve (if equipped). ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
2. It may be necessary to relieve residual fuel ing any compartment or disassembling any compo-
pressure from the fuel system before the fuel nent containing fluids.
filter is removed. Wait for one to five minutes until
the fuel pressure has lowered. Use a suitable Refer to Special Publication, NENG2500, “Caterpillar
container in order to catch any fuel that may spill. Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
3. Remove the used fuel filter and discard the used products.
fuel filter.
Dispose of all fluids according to local regulations and
4. Clean the gasket sealing surface of the fuel filter mandates.
base. Ensure that all of the old gasket is removed.
5. Apply clean diesel fuel to the new fuel filter gasket. Fuel Tank
Fuel quality is critical to the performance and to the
NOTICE service life of the engine. Water in the fuel can cause
Do not fill the secondary fuel filter with fuel before in- excessive wear to the fuel system. Condensation
stalling. The fuel would not be filtered and could be occurs during the heating and cooling of fuel. The
contaminated. Contaminated fuel will cause acceler- condensation occurs as the fuel passes through the
ated wear to fuel system parts. 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
NOTICE sources can help to eliminate water in the fuel.
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a
two micron high efficiency fuel filter is required for all Drain the Water and the Sediment
Caterpillar Electronic Unit Injectors. Caterpillar High
Efficiency Fuel Filters meet these requirements. Con- Fuel tanks should contain some provision for draining
sult your Caterpillar dealer for the proper part num- water and draining sediment from the bottom of the
bers. fuel tanks.
Some fuel tanks use supply pipes that allow water Check for the following conditions:
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that • End fittings that are damaged or leaking
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular • Outer covering that is chafed or cut
maintenance of the fuel system filter is important.
• Exposed wire that is used for reinforcement
Fuel Storage Tanks
• Outer covering that is ballooning locally
Drain the water and the sediment from the fuel
storage tank during the following conditions: • Flexible part of the hose that is kinked or crushed
Inspect all hoses for leaks that are caused by the Pressurized System: Hot coolant can cause seri-
following conditions: ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
• Cracking components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
• Softness sure.
Jacket Water Heater - Check When an engine’s oil consumption has risen to three
times the original oil consumption rate due to normal
SMCS Code: 1383-535 wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
Jacket water heaters help to improve startability in and a slight increase in fuel consumption.
ambient temperatures that are below 21 °C (70 °F).
All installations that require automatic starting should Overhaul Options
have jacket water heaters.
Before Failure Overhaul
Check the operation of the jacket water heater. For
an ambient temperature of 0 °C (32 °F), the heater A planned overhaul before failure may be the best
should maintain the jacket water coolant temperature value for the following reasons:
at approximately 32 °C (90 °F).
• Costly unplanned downtime can be avoided.
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• Many original parts can be reused according to the
Overhaul Considerations standards for reusable parts.
SMCS Code: 7595-043 • The engine service life can be extended without the
risk of a major catastrophe due to engine failure.
Reduced hours of operation at full load will result in a
lower average power demand. A decreased average • The best cost/value relationship per hour of
power demand should increase both the engine extended life can be attained.
service life and the overhaul interval.
After Failure Overhaul
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power. If a major engine failure occurs and the engine
must be removed, many options are available. An
The following factors are important when a decision overhaul should be performed if the engine block or
is being made on the proper time for an engine the crankshaft needs to be repaired.
overhaul:
If the engine block is repairable and/or the crankshaft
• The need for preventive maintenance is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine
• The quality of the fuel that is being used with a similar exchange core.
• The operating conditions This lower cost can be attributed to three aspects:
• The results of the S·O·S analysis • Specially designed Caterpillar engine features
SEBU7901-01 83
Maintenance Section
Overhaul Considerations
Inspect the camshaft for damage to the journals and • Identification of metal corrosion
to the lobes.
• Identification of contaminants
Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check for • Identification of built up impurities (corrosion and
cracks in the camshaft. scale)
Inspect the following components for signs of wear or S·O·S Coolant Analysis (Level 2) provides a report of
for signs of scuffing: the results of both the analysis and the maintenance
recommendations.
• Camshaft bearings
For more information about coolant analysis, consult
• Camshaft followers your Caterpillar dealer.
• Inspect the fuel system for leaks. Look for loose Note: Refer to the Service Manual or consult your
fuel line clamps or for loose fuel line tie-wraps. Caterpillar dealer if any repair is needed or any
replacement is needed.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
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