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2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt

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SEBU6617-04April 2001

Operation andMaintenance

ManualXQ125 Rental Generator Sets

DED1-Up (Generator Set)9HK1-Up (Engine)

This Manual Must be Accessible at the Point of Operation

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80Maintenance SectionMaintenance Interval Schedule

i01477795

Maintenance Interval Schedule

SMCS Code: 1000; 7500

Before performing any operation or maintenanceprocedures, ensure that the Safety Information,warnings, and instructions are read andunderstood.

To determine the maintenance intervals, use fuelconsumption, service hours, or calendar time, whichever occurs first.

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

Refer to the Operation and Maintenance Manual,

SR4B Generators and Control Panels for allmaintenance information for generators.

When Required

Battery - Replace .................................................. 82Battery or Battery Cable - Disconnect .................. 83Enclosure - Inspect ............................................... 91Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 92Engine Air Cleaner Element (Single Element) -

Inspect/Replace .................................................. 95Fuel System - Prime ........................................... 102Severe Service Application - Check .................... 110Trailer - Inspect ................................................... 112

Daily

Cooling System Coolant Level - Check ................ 88Engine Air Cleaner Service Indicator - Inspect ..... 96Engine Oil Level - Check ...................................... 97Walk-Around Inspection ...................................... 114

Every Week

Battery Charger - Check ....................................... 83

Every 5700 L (1500 US gal) of Fuel or 400Service Hours or 1 Year

Engine Valve Lash - Inspect/Adjust .................... 100

Every 9500 L (2500 US gal) of Fuel or 250Service Hours or Yearly

Alternator and Fan Belts - Inspect/Adjust/Replace ............................................................... 82

Battery Electrolyte Level - Check .......................... 83Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 89Engine Crankcase Breather - Clean ..................... 96Engine Oil Sample - Obtain .................................. 98

Engine Oil and Filter - Change ............................. 98Engine Protective Devices - Check ..................... 100Fan Drive Bearing - Lubricate ............................. 101Fuel System Primary Filter - Clean/Replace ...... 104Fuel Tank Water and Sediment - Drain ............... 105Hoses and Clamps - Inspect/Replace ................ 105

Magnetic Pickups - Clean/Inspect ...................... 106Radiator - Clean .................................................. 110

Every 34 000 L (9000 US gal) of Fuel or 1000Service Hours

Fuel Control Linkage - Check/Lubricate ............. 101

Every 60 000 L (16 000 US gal) of Fuel or2000 Service Hours

Aftercooler Core - Clean/Test ............................... 81Engine Valve Lash - Inspect/Adjust .................... 100Engine Valve Rotators - Inspect .......................... 101

Every 67 000 L (18 000 US gal) of Fuel or2000 Service Hours

Fuel Injection Nozzles - Test/Exchange .............. 102Fuel Ratio Control - Inspect/Adjust ..................... 102

Every 114 000 L (30 000 US gal) of Fuel or3000 Service Hours or 3 Years

Alternator - Inspect ............................................... 81Cooling System Coolant (DEAC) - Change .......... 84Cooling System Coolant Extender (ELC) - Add .... 88Cooling System Water Temperature Regulator -

Replace ............................................................... 90Crankshaft Vibration Damper - Inspect ................. 90Engine Mounts - Inspect ....................................... 97Starting Motor - Inspect ...................................... 112Turbocharger - Inspect ........................................ 113Water Pump - Inspect ......................................... 115

Every 228 000 L (60 000 US gal) of Fuel or6000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 86Standby Generator Set Maintenance

Recommendations ............................................ 111

OverhaulOverhaul Considerations .................................... 107

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81Maintenance Section

Aftercooler Core - Clean/Test

i00744980

Aftercooler Core - Clean/Test

SMCS Code: 1064-070; 1064-081

1. Remove the core. Refer to the Service Manualfor the procedure.

2. Turn the aftercooler core upside-down in orderto remove debris.

NOTICEDo not use a high concentration of caustic cleaner toclean the core. A high concentration of caustic cleanercan attack the internal metals of the core and causeleakage. Only use the recommended concentration ofcleaner.

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Table 33 lists Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 33

Hydrosolv Liquid Cleaners(1)

Description Container

1U-8812 Hydrosolv 4165 4 L (1 US gal)


8T-7570Hydrosolv 4165 208 L (55 US gal)



8T-7571 Hydrosolv 100 208 L (55 US gal)

(1) Use a two to five percent concentration of the cleanerat temperatures up to 93 C (200 F). Refer to ApplicationGuide, NEHS0526 or consult your Caterpillar dealer for moreinformation.

4. Steam clean the core in order to remove anyresidue. Flush the fins of the aftercooler core.Remove any other trapped debris.

5. Wash the core with hot, soapy water. Rinse thecore thoroughly with clean water.

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

6. Dry the core with compressed air. Direct the airin the reverse direction of the normal flow.

7. Inspect the core in order to ensure cleanliness.Pressure test the core. Many shops that serviceradiators are equipped to perform pressure tests.If necessary, repair the core.

8. Install the core. Refer to the Service Manual forthe procedure.

For more information on cleaning the core, consultyour Caterpillar dealer.

i00072207

Alternator - Inspect

SMCS Code: 1405-040

Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and proper battery charging. Inspectthe ammeter (if equipped) during engine operationin order to ensure proper battery performanceand/or proper performance of the electrical system.Make repairs, as required. Refer to the ServiceManual.

Check the alternator and the battery charger forproper operation. If the batteries are properlycharged, the ammeter reading should be very nearzero. All batteries should be kept charged. Thebatteries should be kept warm because temperatureaffects the cranking power. If the battery is too cold,the battery will not crank the engine. The battery willnot crank the engine, even if the engine is warm.When the engine is not run for long periods of timeor if the engine is run for short periods, the batteriesmay not fully charge. A battery with a low charge willfreeze more easily than a battery with a full charge.

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82Maintenance SectionAlternator and Fan Belts - Inspect/Adjust/Replace

i00841051

Alternator and Fan Belts -Inspect/Adjust/Replace

SMCS Code: 1357-039

Inspection

To maximize the engine performance, inspect thebelts for wear and for cracking. Check the belttension. Adjust the belt tension in order to minimizebelt slippage. Belt slippage will decrease the lifeof the belts.

To check the belt tension, apply 110 N (25 lb)of force midway between the pulleys. Acorrectly adjusted belt will deflect 13 to 19 mm(0.50 to 0.75 inch).

Adjustment

If the belts are too loose, the belts will vibrate. Thisvibration is enough to cause unnecessary wear onthe belts and on the pulleys.

If the belts are too tight, unnecessary stresses areplaced upon the pulley bearings and upon thebelts. These stresses will shorten the life of the beltsand of the pulley bearings.

If new belts are installed, check the tension againafter 30 minutes of engine operation at the rated

rpm.

Replacement

For applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new belt tocarry more load because the older belt is stretched.The additional load on the new belt could cause thenew belt to break.

Refer to the Service Manual for more information onthe procedures for the following topics: belt removal

and belt installation procedure.

i01492550

Battery - Replace

SMCS Code: 1401-510

Batteries give off combustible gases which canexplode. A spark can cause the combustible gas-es to ignite. This can result in severe personal in-jury or death.

Ensure proper ventilation for batteries that are inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the key start switch to the OFF position.Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect thecharger.

3. The NEGATIVE - cable connects the NEGATIVE- battery terminal to the ground plane.Disconnect the cable from the NEGATIVE -battery terminal.

4. The POSITIVE + cable connects the POSITIVE+ battery terminal to the starting motor.Disconnect the cable from the POSITIVE +battery terminal.

Note: Always recycle a battery. Never discard abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure thatthe key start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE + battery terminal.

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Battery Electrolyte Level - Check

8. Connect the cable from the ground plane to theNEGATIVE - battery terminal.

i01206348

Battery Electrolyte Level -Check

SMCS Code: 1401-535

When the engine is not run for long periods oftime or when the engine is run for short periods,the batteries may not fully recharge. Ensure a fullcharge in order to help prevent the battery fromfreezing. If batteries are properly charged, ammeterreading should be very near zero.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

1. Remove the filler caps. Maintain the electrolytelevel to the FULL mark on the battery.

If the addition of water is necessary, use distilledwater. If distilled water is not available useclean water that is low in minerals. Do not useartificially softened water.

2. Check the condition of the electrolyte with the1U-7298 Coolant/Battery Tester ( C) or the1U-7297 Coolant/Battery Tester ( F).

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

A mixture of 0.1 L (0.11 qt) of baking soda and1 L (1 qt) of clean water

A mixture of 0.1 L (0.11 qt) of ammonia and1 L (1 qt) of clean water

Thoroughly rinse the battery case with cleanwater.

Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fitproperly. Coat the clamps and the terminals with5N-5561 Silicone Lubricant, petroleum jelly orMPGM grease.

i01501560

Battery or Battery Cable -Disconnect

SMCS Code: 1402-029

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the start switch to the OFF position. Turn the

battery disconnect switch to the OFF positionand remove the key and all electrical loads.

2. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal. When four12 volt batteries are involved, the negative sideof two batteries must be disconnected.

3. Tape the leads in order to help prevent accidentalstarting.

4. Proceed with necessary system repairs. Reversethe steps in order to reconnect all of the cables.

i01039758

Battery Charger - Check

SMCS Code: 1401-535

Checking Before Start-Up

Check the battery charger for proper operation. Ifthe batteries are properly charged, the needle ofthe ammeter will register near 0 (zero).

The battery charger must not produce excessivecurrent during start-up. Alternatively, the chargermust be automatically disconnected for start-up.If the engine has an alternator, the charger mustbe automatically disconnected during start-up andduring engine operation.

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84Maintenance SectionCooling System Coolant (DEAC) - Change

Charging the Battery

Never disconnect any charging unit circuit or bat-tery circuit cable from the battery when the charg-ing unit is operated. A spark can cause an explo-sion from the flammable vapor mixture of hydro-gen and oxygen that is released from the elec-trolyte through the battery outlets. Injury to per-sonnel can be the result.

Perform the following procedure to charge thebattery:

1. Ensure that the charger is turned OFF.

2. Adjust the voltage of the charger in order tomatch the voltage of the battery.

3. Connect the POSITIVE + lead of the chargerto the POSITIVE + battery terminal. Connectthe NEGATIVE - lead of the charger to theNEGATIVE - battery terminal.

4. Turn ON the battery charger.

Overcharging of Batteries

Overcharging reduces the service life of batteries.Use a battery charger that will not overcharge thebattery. DO NOT charge the battery if the meter ofthe battery charger is in the RED zone.

Overcharging is indicated by the followingsymptoms:

The battery is very warm to the touch.

A strong odor of acid is present.

The battery emits smoke or a dense vapor (gas).

Perform one of the following procedures if thebattery shows symptoms of overcharging:

Reduce the rate of charging by a significantamount. Complete the charging at the reducedrate.

Turn OFF the charger.

Table 34 describes the effects of overcharging ondifferent types of batteries.

Table 34

Effects of Overcharging Batteries

Type of Battery Effect

All of the battery cells havea low level of electrolyte.

When the plates of thebattery are inspectedthrough the filler holes, theplates may appear to bewarped. This is caused byan excessive temperature.

Caterpillar General ServiceBatteriesCaterpillar Premium HighOutput Batteries

The battery may not passa load test.

The battery may not accepta charging current.

Caterpillar MaintenanceFree Batteries

The battery may not passa load test.

Checking After Stopping

Ensure that the battery charger is connectedproperly. Observe the meter of the charger. Recordthe amperage.

i01206425

Cooling System Coolant(DEAC) - Change

SMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

The engine overheats frequently.

Foaming is observed.

The oil has entered the cooling system and thecoolant is contaminated.

The fuel has entered the cooling system and thecoolant is contaminated.

NOTICEUse of commercially available cooling system clean-ers may cause damage to cooling system compo-nents. Use only cooling system cleaners that are ap-proved for Caterpillar engines.

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Cooling System Coolant (DEAC) - Change

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulatorand the hoses, if necessary.

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.

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

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The full

distillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Service TechnologyGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush

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

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theOperation and Maintenance Manual, TorqueSpecifications topic (Maintenance Section) formore information on the proper torques.

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

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

4. Start and run the engine at low idle for aminimum of 30 minutes. The coolant temperatureshould be at least 82 C (180 F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling systemdrain plugs. Allow the water to drain. Flush thecooling system with clean water. Close the drainvalve (if equipped). Clean the drain plugs. Installthe drain plugs. Refer to the Operation andMaintenance Manual, Torque Specificationstopic (Maintenance Section) for more informationon the proper torques.

Cooling Systems with HeavyDeposits or Plugging

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


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

Specifications topic (Maintenance Section) formore information on the proper torques.


3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity. Install the cooling system filler cap.

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86Maintenance SectionCooling System Coolant (ELC) - Change

4. Start and run the engine at low idle for aminimum of 90 minutes. The coolant temperatureshould be at least 82 C (180 F).

NOTICEImproper or incomplete rinsing of the cooling system

can result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling system

drain plugs. Allow the water to drain. Flush thecooling system with clean water. Close the drainvalve (if equipped). Clean the drain plugs. Installthe drain plugs. Refer to the Operation andMaintenance Manual, Torque Specificationstopic (Maintenance Section) for more informationon the proper torques.

Fill


1. Fill the cooling system with coolant/antifreeze.Refer to the Operation and MaintenanceManual, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to 1500 rpm. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolantlevel within 13 mm (0.5 inch) below the bottomof the pipe for filling. Maintain the coolant levelwithin 13 mm (0.5 inch) to the proper level on thesight glass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap.If the gasket that is on the cooling system filler

cap is not damaged, perform a pressure test. A9S-8140 Pressurizing Pump is used to performthe pressure test. The correct pressure for thecooling system filler cap is stamped on the faceof the cooling system filler cap. If the coolingsystem filler cap does not retain the correctpressure, install a new cooling system filler cap.

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

i01206445

Cooling System Coolant (ELC)- Change

SMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

The engine overheats frequently.

Foaming is observed.

The oil has entered the cooling system and the

coolant is contaminated.

The fuel has entered the cooling system and thecoolant is contaminated.

Note: When the cooling system is cleaned, onlyclean water is needed when the ELC is drainedand replaced.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulatorand the hoses, if necessary.

Drain


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Cooling System Coolant (ELC) - Change

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap.

2. Open the cooling system drain valve (if

equipped). If the cooling system is not equippedwith a drain valve, remove the cooling systemdrain plugs.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Service TechnologyGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush


2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theOperation and Maintenance Manual, TorqueSpecifications topic (Maintenance Section) formore information on the proper torques.


3. Fill the cooling system with clean water. Installthe cooling system filler cap.

4. Start and run the engine at low idle until thetemperature reaches 49 to 66 C (120 to 150 F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling systemdrain plugs. Allow the water to drain. Flush the

cooling system with clean water. Close the drainvalve (if equipped). Clean the drain plugs. Installthe drain plugs. Refer to the Operation andMaintenance Manual, Torque Specificationstopic (Maintenance Section) for more informationon the proper torques.

Fill


1. Fill the cooling system with Extended Life Coolant(ELC). Refer to the Operation and MaintenanceManual, Cooling System Specifications topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to high idle. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolantlevel within 13 mm (0.5 inch) below the bottom

of the pipe for filling. Maintain the coolant levelwithin 13 mm (0.5 inch) to the proper level on thesight glass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket that is on the cooling system filler capis not damaged, use a 9S-8140 PressurizingPump in order to pressure test the coolingsystem filler cap. The correct pressure for thecooling system filler cap is stamped on the face

of the cooling system filler cap. If the coolingsystem filler cap does not retain the correctpressure, install a new cooling system filler cap.

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

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88Maintenance SectionCooling System Coolant Extender (ELC) - Add

i00259474

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352-045; 1395-081

Caterpillar Extended Life Coolant (ELC) does notrequire the frequent Supplemental Coolant Additive(SCA) additions associated with the presentconventional coolants. The Extender only needs tobe added once.

Check the cooling system only when the engine isstopped and cool.

1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. It may be necessary to drain enough coolantfrom the cooling system in order to add theExtender.

3. Add Extender according to the requirements foryour engines cooling system capacity. Refer tothe Operation and Maintenance Manual, RefillCapacities in the Maintenance Section for thecapacity of the cooling system for your engine.Refer to the Operation and Maintenance Manual,Cooling System Specifications information forthe Caterpillar ELC Extender additions.

4. Clean the cooling system filler cap. Inspect the

cooling system filler cap gaskets. Replace thecooling system filler cap if the cooling systemfiller cap gaskets are damaged. Install thecooling system filler cap.

i01197583

Cooling System Coolant Level- Check

SMCS Code: 1395-082

Check the coolant level when the engine is stopped

and cool.

g00285520Illustration 57

Cooling system filler cap


1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolant

level to the proper level in the sight glass.


Typical filler cap gaskets

3. Clean the cooling system filler cap and check thecondition of the filler cap gaskets. Replace thecooling system filler cap if the filler cap gasketsare damaged. Reinstall the cooling system fillercap.

4. Inspect the cooling system for leaks.

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

i01463635

Cooling System SupplementalCoolant Additive (SCA) -Test/Add

SMCS Code: 1352-045; 1395-081

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and the eyes. Do not drink cooling systemcoolant additive.

Note: Test the concentration of the SupplementalCoolant Additive (SCA) or test the SCA concentrationas part of an SOS Coolant Analysis.

Test for SCA Concentration

Coolant/Antifreeze and SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Use the 8T-5296 Coolant Conditioner Test Kit oruse the 4C-9301 Coolant Conditioner Test Kit inorder to check the concentration of the SCA. Referto the Operation and Maintenance Manual for more

information.

Water and SCA

NOTICEDo not exceed the recommended eight percent sup-plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Refer to the Operationand Maintenance Manual, Water/SupplementalCoolant Additive (SCA) topic (MaintenanceSection). Refer to the Operation and MaintenanceManual, Conventional Coolant/Antifreeze CoolingSystem Maintenance topic (Maintenance Section).

SOS Coolant Analysis

SOS coolant samples can be analyzed at yourCaterpillar dealer. SOS Coolant Analysis is aprogram that is based on periodic samples.

Level 1

Level 1 is a basic analysis of the coolant. Thefollowing items are tested:

Glycol Concentration

Concentration of SCA

pH

Conductivity

The results are reported, and recommendationsare made according to the results. Consult yourCaterpillar dealer for information on the benefits ofmanaging your equipment with an SOS CoolantAnalysis.

Level 2

This level coolant analysis is recommendedwhen the engine is overhauled. Refer to theOperations and Maintenance Manual, OverhaulConsiderations for further information.

Add the SCA, If Necessary

NOTICEDo not exceed the recommended amount of sup-plemental coolant additive concentration. Excessivesupplemental coolant additive concentration can formdeposits on the higher temperature surfaces of the

cooling system, reducing the engines heat transfercharacteristics. Reduced heat transfer could causecracking of the cylinder head and other high temper-ature components. Excessive supplemental coolantadditive concentration could also result in radiatortube blockage, overheating, and/or accelerated waterpump seal wear. Never use both liquid supplementalcoolant additive and the spin-on element (if equipped)at the same time. The use of those additives togethercould result in supplemental coolant additive concen-tration exceeding the recommended maximum.


1. Slowly loosen the cooling system filler cap inorder to relieve the pressure. Remove the coolingsystem filler cap.

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90Maintenance SectionCooling System Water Temperature Regulator - Replace

Note: Always discard drained fluids according tolocal regulations.

2. If necessary, drain some coolant from the coolingsystem into a suitable container in order to allowspace for the extra SCA.

3. Add the proper amount of SCA. Refer to theOperation and Maintenance Manual for moreinformation on SCA requirements.

4. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets are damaged, replace the old coolingsystem filler cap with a new cooling system fillercap. Install the cooling system filler cap.

i00912898

Cooling System WaterTemperature Regulator -Replace

SMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime.

A water temperature regulator that fails in apartially opened position can cause overheating orovercooling of the engine.

A water temperature regulator that fails in theclosed position can cause excessive overheating.Excessive overheating could result in cracking ofthe cylinder head or piston seizure problems.

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup insidethe cylinders. This excessive carbon buildup couldresult in an accelerated wear of the piston rings andwear of the cylinder liner.

NOTICEFailure to replace your water temperature regulatoron a regularly scheduled basis could cause severeengine damage.

Caterpillar engines incorporate a shunt design coolingsystem and require operating the engine with a watertemperature regulator installed.

If the water temperature regulator is installed incor-rectly, the engine may overheat, causing cylinder headdamage. Ensure that the new water temperature reg-ulator is installed in the original position. Ensure thatthe water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket orcylinder head surface.

Refer to the Service Manual for the replacementprocedure of the water temperature regulator, orconsult your Caterpillar dealer.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling systemto a level that is below the water temperatureregulator housing.

i00894991

Crankshaft Vibration Damper- Inspect

SMCS Code: 1205-040

Damage to the crankshaft vibration damper orfailure of the crankshaft vibration damper canincrease torsional vibrations. This can result indamage to the crankshaft and to other enginecomponents. A deteriorating damper can causeexcessive gear train noise at variable points in thespeed range.

The damper is mounted to the crankshaft which islocated behind the belt guard on the front of theengine.

Rubber Damper

Your engine may be equipped with a rubberdamper. The rubber damper uses a ring which ismounted in rubber in order to reduce vibrations inthe crankshaft.

Inspect the damper and repair or replace thedamper for any of the following reasons:

There is deterioration and cracking of the rubber.

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Enclosure - Inspect

There is slippage of the outer ring from theoriginal position.

The engine has had a failure because of a brokencrankshaft.

Analysis of the oil has revealed that the front mainbearing is badly worn.

There is a large amount of gear train wear that isnot caused by lack of oil.

Refer to the Service Manual or consult yourCaterpillar dealer for information about damperreplacement.

Visconic Damper

Your engine may be equipped with a visconicdamper. The visconic damper has a weight that islocated inside a fluid filled case. The weight movesin the case in order to limit torsional vibration.

Inspect the damper for evidence of fluid leaks. Ifa fluid leak is found, determine the type of fluid.The fluid in the damper is silicone. Silicone hasthe following characteristics: transparent, viscous,smooth, and difficult to remove from surfaces.

If the fluid leak is oil, inspect the crankshaft seals forleaks. If a leak is observed, replace the crankshaftseals.

Inspect the damper and repair or replace thedamper for any of the following reasons:

The damper is dented, cracked, or leaking.

The paint on the damper is discolored from heat.

The engine has had a failure because of a brokencrankshaft.

Analysis of the oil has revealed that the front mainbearing is badly worn.

There is a large amount of gear train wear that isnot caused by a lack of oil.

Refer to the Service Manual or consult yourCaterpillar dealer for information about damperreplacement.

i01480884

Enclosure - Inspect

SMCS Code: 7263-040; 7274-040

NOTICEDo not spray or splash water into the generator airinlet or exhaust openings. Ensure that the openingsare covered in order to prevent water from enteringthe electrical windings and bearings.

The interior of the enclosure package and theexterior of the enclosure package should be keptclean. Wash the interior of the enclosure packageand the exterior of the enclosure package with soapand water.

Ensure that the air discharge for the exhaust duct

is clear. Clean debris, twigs, and leaves away fromthe enclosure package, as needed.

Lubricate the hinges on the door, as needed. UseCaterpillar Multipurpose Lithium Complex Grease(MPGL). If Caterpillar Multipurpose Lithium ComplexGrease (MPGL) is not available, use a similarmultipurpose grease.

Note: Only chrome hinges require lubrication.Powder black door hinges do not require lubrication.


Screws for the door hinge

Adjust the door hinges, as required. Visually checkthe alignment of the door. Use the following steps toadjust the alignment of the door.

1. Loosen the screws on the door hinge.

2. Reposition the door so that the door is squarewithin the door frame.

3. Tighten the screws on the door hinge.

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92Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

Check the door seal. Adjust the closure fit of thedoor against the gasket seal. Bend the door handlecatch loop inward. This will tighten the door againstthe gasket seal. Bend the door handle catch loopoutward. This will loosen the door against the gasketseal.

The literature pouch is located near the operatorconsole. Ensure that the literature pouch containsa copy of the following literature:

this manual

the Generator Operation and Maintenance Manual

i01397558

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

SMCS Code: 1054-037; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICE

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

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, theair can split the material of the air cleaner element.Unfiltered air will drastically accelerate internalengine wear. Your Caterpillar dealer has the properair cleaner elements for your application. Consultyour Caterpillar dealer for the correct air cleanerelement.

Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

Operating conditions (dust, dirt and debris) mayrequire more frequent service of the air cleanerelement.

The air cleaner element may be cleaned up tosix times if the element is properly cleaned andinspected.

The air cleaner element should be replacedat least one time per year. This replacementshould be performed regardless of the numberof cleanings.

Replace the dirty paper air cleaner elements with

clean air cleaner elements. Before installation, theair cleaner elements should be thoroughly checkedfor tears and/or holes in the filter material. Inspectthe gasket or the seal of the air cleaner element fordamage. Maintain a supply of suitable air cleanerelements for replacement purposes.

Dual Element Air Cleaners

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

element should be replaced at least one timeper year. This replacement should be performedregardless of the number of cleanings.

The secondary air cleaner element is not serviceableor washable. The secondary air cleaner elementshould be removed and discarded for every threecleanings of the primary air cleaner element. Whenthe engine is operating in environments that aredusty or dirty, air cleaner elements may requiremore frequent replacement.


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

1. Remove the cover. Remove the primary aircleaner element.

2. The secondary air cleaner element should beremoved and discarded for every three cleaningsof the primary air cleaner element.

Note: Refer to Cleaning the Primary Air FilterElements.

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

3. Cover the turbocharger air inlet with tape inorder to keep dirt out.

4. Clean the inside of the air cleaner cover andbody with a clean, dry cloth.

5. Remove the tape for the turbocharger air inlet.Install the secondary air cleaner element. Installa primary air cleaner element that is new orcleaned.

6. Install the air cleaner cover.

7. Reset the service indicator.

Cleaning the Primary Air CleanerElements

The primary air cleaner element can be used up

to six times if the element is properly cleaned andinspected. When the primary air cleaner element iscleaned, check for rips or tears in the filter material.The primary air cleaner element should be replacedat least one time per year. This replacementshould be performed regardless of the number ofcleanings.

Use clean primary air cleaner elements while dirtyelements are being cleaned.

NOTICEDo not clean the air cleaner elements by bumping ortapping. This could damage the seals. Do not use el-

ements with damaged pleats, gaskets or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air cleaner elementsbefore cleaning. Inspect the air cleaner elementsfor damage to the seal, the gaskets, and the outercover. Discard any damaged air cleaner elements.

There are four common methods that are used toclean primary air cleaner elements:

Pressurized water

Pressurized air

Vacuum cleaning

Washing with nonsudsing detergent

Pressurized Water

Pressurized water will clean the primary air cleanerelement unless carbon and oil have accumulatedon the surface of the primary air cleaner element.The maximum water pressure for cleaning purposes

must be below 275 kPa (40 psi). Do not use aspray nozzle.

Note: When the primary air cleaner element iscleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the water flows inside theelement along the length of the filter in order to helpprevent damage to the paper pleats. Do not aim thestream of water directly at the primary air cleanerelement. Dirt could be forced further into the pleats.

Note: Refer to Drying the Primary Air CleanerElements. Refer to Inspecting the Primary AirCleaner Elements.

Pressurized Air

Pressurized air can be used to clean primary aircleaner elements that have not been cleaned morethan two times. Pressurized air will not removedeposits of carbon and oil. Use filtered, dry air witha maximum pressure of 207 kPa (30 psi).


Note: When the primary air cleaner elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the streamof air directly at the primary air cleaner element. Dirtcould be forced further into the pleats.

Note: Refer to Inspecting the Primary Air CleanerElements.

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94Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningprimary air cleaner elements which require dailycleaning because of a dry, dusty environment.Cleaning with pressurized air is recommended

prior to vacuum cleaning. Vacuum cleaning will notremove deposits of carbon and oil.

Note: Refer to Inspecting the Primary Air CleanerElements.

Washing the Primary Air CleanerElements with Nonsudsing Detergent

Do not wash air cleaner elements in any flammablesolution such as diesel fuel or gasoline. Doing so

can cause fire or an engine runaway and can resultin personal injury.

Washing with nonsudsing detergent is effective forcleaning primary air cleaner elements that havedeposits of carbon or oil. Use a cleaning agent thatis specifically manufactured for cleaning primary aircleaner elements. Cleaning with pressurized water,pressurized air, or a vacuum is recommended priorto washing with nonsudsing detergent.

1. Place the primary air cleaner element into awash tank so that the gasket is up. The wash

tank should be equipped with a rack so that theprimary air cleaner element does not sit on thebottom of the wash tank.

Note: Caterpillar does not recommend washing theelement with a process of agitation. Agitation maycause carbon particles to be distributed.

2. Fill the wash tank with the cleaning agentand warm water to a maximum temperatureof 60 C (140 F). Follow the manufacturersrecommendations for the cleaning agent. Allowthe primary air cleaner element to soak for sixhours.

3. Drain the wash tank. Do not use the cleaningagent more than one time. Remove the primaryair cleaner element from the wash tank. Rinsethe primary air cleaner element with the methodfor using pressurized water.

Note: Refer to Drying the Primary Air CleanerElements. Refer to Inspecting the Primary AirCleaner Elements.

Drying the Primary Air Cleaner Elements

The oven method may be used in order to dryprimary air cleaner elements. If an oven is used,do not expose the primary air cleaner elements totemperatures that exceed 82 C (160 F).

Note: Do not use compressed air in order to dry theprimary air cleaner elements.

Primary air cleaner elements may be allowed toair dry. Allow two days for the primary air cleanerelements to air dry before the elements areinspected and installed.

Inspecting the Primary Air CleanerElements


Inspect the clean, dry primary air cleaner element.Use a 60 watt blue light in a dark room or in asimilar facility. Place the blue light in the primaryair cleaner element. Rotate the primary air cleanerelement. Inspect the primary air cleaner element fortears and/or holes. Inspect the primary air cleanerelement for light that may show through the filtermaterial. If it is necessary in order to confirm theresult, compare the primary air cleaner elementto a new primary air cleaner element that has thesame part number.

Do not use a primary air cleaner element that hasany tears and/or holes in the filter material. Do notuse an primary air cleaner element with damagedpleats, gaskets or seals. Discard damaged primaryair cleaner elements.

Storing Primary Air Cleaner Elements

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

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Engine Air Cleaner Element (Single Element) - Inspect/Replace


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An airflow restrictionmay result. To protect against dirt and damage,

wrap the primary air cleaner elements in VolatileCorrosion Inhibited (VCI) paper.

Place the primary air cleaner element into a boxfor storage. For identification, mark the outside ofthe box and mark the primary air cleaner element.Include the following information:

Date of cleaning

Number of cleanings

Store the box in a dry location.

For more detailed information on cleaning theprimary air cleaner element, refer to SpecialPublication, SEBF8062, Procedure to Inspect andClean Air Filters.

i00708025

Engine Air CleanerElement (Single Element) -Inspect/Replace

SMCS Code: 1054-040; 1054-510

Perform the Operation and Maintenance Manual,Engine Air Cleaner Service Indicator-Inspectprocedure and perform the Operation andMaintenance Manual, Engine Air PrecleanerCheck/Clean procedure (if equipped) beforeperforming the following procedure.

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering the

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

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



1. Remove the air cleaner cover (1) and remove

the element (2).

2. Seal the turbocharger air inlet (3) so that debriscannot enter the air inlet. Tape or a clean clothcan be used to cover the opening.

3. Clean the inside of the air cleaner cover. Cleanthe body that holds the air cleaner element.

4. Inspect the replacement element for the followingitems:damage, dirt, and debris.

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96Maintenance SectionEngine Air Cleaner Service Indicator - Inspect

5. Remove the seal from the opening of theturbocharger inlet.

6. Install a clean, undamaged element.

7. Install the air cleaner cover (1).

8. Reset the service indicator.

i01175055

Engine Air Cleaner ServiceIndicator - Inspect

SMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differentialgauge for inlet air pressure. The differential gaugefor inlet air pressure displays the difference in thepressure that is measured before the air cleanerelement and the pressure that is measured afterthe air cleaner element. As the air cleaner elementbecomes dirty, the pressure differential rises. If yourengine is equipped with a different type of serviceindicator, follow the OEM recommendations in orderto service the air cleaner service indicator.

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

g00103777

Illustration 66Typical service indicator

Observe the service indicator. The air cleanerelement should be cleaned or the air cleanerelement should be replaced when one of thefollowing conditions occur:

The yellow diaphragm enters the red zone.

The red piston locks in the visible position.

Test the Service Indicator

Service indicators are important instruments.

Check for ease of resetting. The service indicatorshould reset in less than three pushes.

Check the movement of the yellow core when theengine is accelerated to the engine rated speed.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If thenew service indicator will not reset, the hole for theservice indicator may be plugged.

The service indicator may need to be replacedfrequently in environments that are severely dusty, if

necessary. Replace the service indicator annuallyregardless of the operating conditions. Replace theservice indicator when the engine is overhauled,and whenever major engine components arereplaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 Nm (18 lb in).

i00972776

Engine Crankcase Breather -Clean

SMCS Code: 1317-070

NOTICEPerform this maintenance with the engine stopped.

If the crankcase breather is not maintained on aregular basis, the crankcase breather will becomeplugged. A plugged crankcase breather will causeexcessive crankcase pressure that may causecrankshaft seal leakage.

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Engine Mounts - Inspect


(1) Bolt(2) Hose clamp(3) Breather assembly(4) Seal

1. Loosen hose clamp (2) and remove the hosefrom breather assembly (3).

2. Remove bolt (1). Remove breather assembly (3)and seal (4).

3. Wash the breather element in solvent that isclean and nonflammable. Allow the breatherelement to dry before installation.

4. Install a breather element that is clean and dry.Install seal (4) and breather assembly (3). Installbolt (1) and tighten. Do not overtighten the bolt.Refer to Specifications for the proper torque.

5. Install the hose. Install hose clamp (2). Refer tothe Operation and Maintenance Manual, TorqueSpecifications topic (Maintenance Section) forthe proper torque.

i00687861

Engine Mounts - Inspect

SMCS Code: 1152-040

Inspect the engine mounts for deterioration and for

proper bolt torque. Engine vibration can be causedby the following conditions:

Improper mounting of the engine

Deterioration of the engine mounts

Any engine mount that shows deterioration shouldbe replaced. Refer to the Service Manual for therecommended torques. Refer to your Caterpillardealer for more information.

i01481250

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.


(1) Oil level gauge(2) Oil filler cap


(Y) ADD mark(X) FULL mark

NOTICEPerform this maintenance with the engine stopped.

1. Maintain the oil level between ADD mark (Y)and FULL mark (X) on oil level gauge (1). Do

not fill the crankcase above FULL mark (X).

NOTICEOperating your engine when the oil level is above theFULL mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oils lubricating char-acteristics and could result in the loss of power.

2. Remove the oil filler cap and add oil, if necessary.Clean the oil filler cap. Install the oil filler cap.

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98Maintenance SectionEngine Oil Sample - Obtain

i01070756

Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1348-554-SM;7542-554-OC, SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using SOS oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine.

Obtain the Sample and the Analysis

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components to

contact the skin.

Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

Engine model

Service hours on the engine

The number of hours that have accumulatedsince the last oil change

The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of theoil in the crankcase, obtain a warm, well mixed oilsample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 8T-9190 Fluid Sampling Bottle Group isrecommended for use with the sampling valve. Thebottle group includes the parts that are neededfor obtaining oil samples. Instructions are alsoprovided.

NOTICEDo not use the same vacuum sampling pump for ex-tracting oil samples that is used for extracting coolantsamples.

A small residue of either type sample may remain inthe pump and may cause a false positive analysis forthe sample being taken.

Always use a designated pump for oil sampling and adesignated pump for coolant sampling.

Failure to do so may cause a false analysis whichcould lead to customer and dealer concerns.

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

tubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEHP6001,How To Take A Good Oil Sample. Consult yourCaterpillar dealer for complete information andassistance in establishing an SOS program foryour engine.

i00652130

Engine Oil and Filter - Change

SMCS Code: 1318-510; 1348-044

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

Do not drain the oil when the engine is cold. Asthe oil cools, suspended waste particles settleon the bottom of the oil pan. The waste particlesare not removed with the draining cold oil. Drainthe crankcase with the engine stopped. Drain thecrankcase with the oil warm. This draining method

allows the waste particles that are suspended in theoil to be drained properly.

Failure to follow this recommended procedure willcause the waste particles to be recirculated throughthe engine lubrication system with the new oil.

Drain the Engine Oil

After the engine has been run at the normaloperating temperature, stop the engine. Use one ofthe following methods to drain the engine crankcaseoil:

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Engine Oil and Filter - Change

If the engine is equipped with a drain valve, turnthe drain valve knob counterclockwise in order todrain the oil. After the oil has drained, turn thedrain valve knob clockwise in order to close thedrain valve.

If the engine is not equipped with a drain valve,remove the oil drain plug in order to allow the oilto drain. If the engine is equipped with a shallowsump, remove the bottom oil drain plugs fromboth ends of the oil pan.

After the oil has drained, the oil drain plugs shouldbe cleaned and installed.

Replace the Oil Filter

NOTICECaterpillar oil filters are built to Caterpillar speci-

fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

1. Remove the oil filter with a 1U-8760 ChainWrench.

2. Cut the oil filter open with a 4C-5084 Oil FilterCutter. Break apart the pleats and inspect the oilfilter for metal debris. An excessive amount ofmetal debris in the oil filter may indicate earlywear or a pending failure.

Use a magnet to differentiate between theferrous metals and the nonferrous metals thatare found in the oil filter element. Ferrous metalsmay indicate wear on the steel and cast ironparts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is notuncommon to find small amounts of debris in theoil filter. Consult your Caterpillar dealer in orderto arrange for a further analysis if an excessiveamount of debris is found in the oil filter.


Typical filter mounting base and filter gasket

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

is removed.

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

NOTICEDo not fill the oil filters with oil before installing them.This oil would not be filtered and could be contaminat-ed. Contaminated oil can cause accelerated wear toengine components.

5. Install the oil filter. Tighten the oil filter until theoil filter gasket contacts the base. Tighten the oilfilter by hand according to the instructions that

are shown on the oil filter. Do not overtighten theoil filter.

Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to the Operationand Maintenance Manual for more information onlubricant specifications. Fill the crankcase withthe proper amount of oil. Refer to the Operationand Maintenance Manual for more informationon refill capacities.

NOTICE

If equipped with an auxiliary oil filter system or a re-mote oil filter system, follow the OEM or filter manu-facturers recommendations. Under filling or overfillingthe crankcase with oil can cause engine damage.

NOTICETo prevent crankshaft bearing damage, crank the en-gine with the fuel OFF. This will fill the oil filters beforestarting the engine. Do not crank the engine for morethan 30 seconds.

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100Maintenance SectionEngine Protective Devices - Check

2. Start the engine and run the engine at LOWIDLE for two minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain backto the sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the ADDand FULL marks on the oil level gauge.

i00626013

Engine Protective Devices -Check

SMCS Code: 7400-535

Alarms and shutoffs must function properly. Alarmsprovide timely warning to the operator. Shutoffs helpto prevent damage to the engine. It is impossibleto determine if the engine protective devices arein good working order during normal operation.Malfunctions must be simulated in order to test theengine protective devices.

A calibration check of the engine protective deviceswill ensure that the alarms and shutoffs activateat the setpoints. Ensure that the engine protectivedevices are functioning properly.

NOTICEDuring testing, abnormal operating conditions must besimulated.

The tests must be performed correctly in order to pre-vent possible damage to the engine.

To prevent damage to the engine, only authorizedservice personnel or your Caterpillar dealer shouldperform the tests.

Visual Inspection

Visually check the condition of all gauges, sensorsand wiring. Look for wiring and components thatare loose, broken, or damaged. Damaged wiringor components should be repaired or replacedimmediately.

i00869628

Engine Valve Lash -Inspect/Adjust

SMCS Code: 1102-025

The initial valve lash adjustment on new engines,rebuilt engines, or remanufactured engines isrecommended at the first scheduled oil change.The adjustment is necessary due to the initial wearof the valve train components and to the seating ofthe valve train components.

This maintenance is recommended by Caterpillaras part of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuringthe valve lash. To obtain an accurate measurement,allow the valves to cool before this maintenanceis performed.

Refer to the Service Manual for more information.

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Engine Valve Rotators - Inspect

i00937014

Engine Valve Rotators - Inspect

SMCS Code: 1109-040

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to help prevent being burned byhot oil or spray.

NOTICEA valve rotator which does not operate properly willaccelerate valve face wear and valve seat wear andshorten valve life. If a damaged rotator is not replaced,valve face guttering could result and cause pieces ofthe valve to fall into the cylinder. This can cause piston

and cylinder head damage.

Valve rotators cause the valves to rotate when theengine runs. This helps to prevent deposits frombuilding up on the valves and the valve seats.

Perform the following steps after the valve lash isset, but before the valve covers are installed:

1. Start the engine according to this Operationand Maintenance Manual, Engine Startingprocedure (Operation Section).

Operate the engine at low idle.

2. Observe the top surface of each valve rotator.The valve rotators should turn slightly when thevalves close.

If a valve fails to rotate, consult your Caterpillardealer.

i01423301

Fan Drive Bearing - Lubricate

SMCS Code: 1359-086-BD


Typical location of the grease fitting that is for the fan drive bearing

The pulley is shown with the belt guards removed

Lubricate the grease fitting that is on the fan drivebearing with Bearing Lubricant or the equivalent.

Inspect the fan drive pulley assembly for wear or fordamage. If the shaft is loose, an inspection of theinternal components should be performed. Refer tothe Service Manual for additional information.

i00705823

Fuel Control Linkage -Check/Lubricate

SMCS Code: 1257-086; 1257-535

Check the fuel control linkage for proper operation.If necessary, adjust the fuel control linkage . Refer tothe Service Manual for the adjustment procedures.


Typical grease fittings on the fuel control linkage

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102Maintenance SectionFuel Injection Nozzles - Test/Exchange

Some fuel control linkages require lubrication.Lubricate the grease fittings with 1P-0808Multipurpose Grease or the equivalent.

i00626014

Fuel Injection Nozzles -Test/Exchange

SMCS Code: 1254-013; 1254-081

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

NOTICEDo not allow dirt to enter the fuel system. Thoroughly

clean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

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

Increased fuel consumption

Black smoke

Misfire

Rough running

Fuel Injection nozzles should be cleaned, inspected,tested, and replaced, if necessary. Refer to SpecialInstruction, SEHS7292 for using the 8S-2245Injection Cleaning Tool Group. Consult yourCaterpillar dealer about cleaning the fuel injectionnozzle and testing the fuel injection nozzle.

NOTICENever wire brush or scrape a fuel injection nozzle.Wire brushing or scraping a fuel injection nozzle willdamage the finely machine orifice. Proper tools for

cleaning and testing the fuel injection nozzles can beobtained from Caterpillar dealers.

The following items are symptoms of a malfunctionof the fuel injection nozzle:

Abnormal engine operation

Smoke emission

Engine knock

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

1. Start the engine.

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

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

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

Engine performance is not affected.

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

Removal and Installation of theFuel Injection Nozzles

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

Caterpillar dealer for assistance.

i00908934

Fuel Ratio Control -Inspect/Adjust

SMCS Code: 1278-025; 1278-040

Slow engine response and low power may indicatea need for adjustment or repair of the fuel ratiocontrol. Refer to the Service Manual or yourCaterpillar dealer for the complete adjustment

procedure on the fuel ratio control.

i00976042

Fuel System - Prime

SMCS Code: 1258-548

Prime the fuel system in order to fill dry fuel filtersand purge air from the fuel system. Prime the fuelsystem after the following occurrences:

Running the fuel system dry

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103Maintenance SectionFuel System - Prime

Removal of the engine from storage

Maintenance of the fuel filter

Disconnecting fuel lines and installing fuel lines

Repair of leaks in the fuel lines

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component that

will be disconnected. Fit a suitable cover over discon-nected fuel system component.

1. Unlock and operate the priming pump plungeruntil a resistance is felt. This may require aconsiderable number of strokes.

2. Push in and hand tighten the priming pumpplunger.

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

3. Start the engine. The engine may run rough.Run the engine at low idle until the engine runssmoothly. If the following conditions exist, repeatSteps 1 through 3:

The engine will not start.

The engine starts but the engine continues tomisfire.

The engine starts but the engine continues to

smoke.

If operating problems persist after repeatingSteps 1 through 3, proceed to Step 4.


(1) Vent plug(2) Fuel injection pump housing

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

4. Loosen vent plug (1) on fuel injection pumphousing (2).

5. Unlock and operate the priming pump plunger

until the flow of fuel from the vent valve iscontinuous and free of air bubbles.

6. Tighten the vent plug. Clean up any spilled fuelimmediately.



8. Start the engine. The engine may run rough.Run the engine at low idle until the engine runssmoothly. Proceed to Step 9 if the followingconditions exist:

The engine will not start.

The engine starts but the engine continues tomisfire.

The engine starts but the engine continues tosmoke.

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104Maintenance SectionFuel System Primary Filter - Clean/Replace


NOTICEDo not let the tops of fuel nozzles turn when the fuelline nuts are loosened or tightened.

The nozzles will be damaged if the top of the nozzleturns in the body.

The engine will be damaged if a defective fuel injec-tion nozzle is used because the shape of fuel (spraypattern) that comes out of the nozzles will not be cor-rect.


9. Loosen one fuel injection line nut at the fuelinjection nozzle.

10. Unlock and operate the priming pump plungeruntil the flow of fuel from the fuel injection line iscontinuous and free of air bubbles.

11. Tighten the fuel injection line nut. Refer toSpecifications for the proper torque. Clean upany spilled fuel immediately.

12. Perform Steps 9 through 11 on each fuelinjection line.



14. Start the engine.

i00951418

Fuel System Primary Filter -Clean/Replace

SMCS Code: 1260-070; 1260-510

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

1. Stop the engine.

2. Turn the start switch to the OFF position.Disconnect the battery.

3. Shut off the fuel tank supply valve to the engine.

4. If the primary fuel filter is equipped with a drainvalve, open the drain valve in order to drain anyfuel from the filter case. Close the drain valve.



(1) Bolt

(2) Element(3) Case

5. Loosen the bolt (1) that is on the filter housing.Remove the filter case (3).

6. Remove the element (2) and wash the elementin clean, nonflammable solvent.

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Fuel Tank Water and Sediment - Drain

NOTICEDo not fill the fuel filters with fuel before installing them.The fuel would not be filtered and could be contami-nated. Contaminated fuel will cause accelerated wearto fuel system parts.

7. Install the element (2) and the filter case (3).Tighten the bolt (1) to a torque of 24 4 Nm(18 3 lb ft).

i00073301

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S

Fuel TankFuel quality is critical to the performance and tothe service life of the engine. Water in the fuel cancause excessive fuel system wear. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes throughthe fuel system and the fuel returns to the fuel tank.This causes water to accumulate in fuel tanks.Draining the fuel tank regularly and obtaining fuelfrom reliable sources can help to eliminate waterin the fuel.

Drain the Water and the SedimentFuel tanks should contain some provision fordraining water and draining sediment from thebottom of the fuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

Check the fuel daily. Drain the water and sedimentfrom the fuel tank after operating the engine or drainthe water and sediment from the fuel tank after thefuel tank has been filled. Allow five to ten minutes

before performing this procedure.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayoverflow.

Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel directly from the bottom of the tank. Ifthe engine is equipped with this system, regularmaintenance of the fuel system filter is important.

Fuel Storage Tanks

Drain the water and the sediment from the fuelstorage tank during the following conditions:

Weekly

Oil change

Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank.

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaffles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from the

storage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

i00907072

Hoses and Clamps -Inspect/Replace

SMCS Code: 7554-040; 7554-510

Inspect all hoses for leaks that are caused by thefollowing conditions:

Cracking

Softness

Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubesand hoses carefully. Tighten all connections to the rec-ommended torque.

Check for the following conditions:

End fittings that are damaged or leaking

Outer covering that is chafed or cut

Exposed wire that is used for reinforcement

Outer covering that is ballooning locally

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106Maintenance SectionMagnetic Pickups - Clean/Inspect

Flexible part of the hose that is kinked or crushed

Armoring that is embedded in the outer covering

A constant torque hose clamp can be used inplace of any standard hose clamp. Ensure that the

constant torque hose clamp is the same size asthe standard clamp.

Due to extreme temperature changes, the hosewill heat set. Heat setting causes hose clamps toloosen. This can result in leaks. A constant torquehose clamp will help to prevent loose hose clamps.

Each installation application can be different. Thedifferences depend on the following factors:

Type of hose

Type of fitting material

Anticipated expansion and contraction of thehose

Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Stop the engine. Allow the engine to cool.

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

Note: Drain the coolant into a suitable, cleancontainer. The coolant can be reused.

3. Drain the coolant from the cooling system toa level that is below the hose that is beingreplaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

Note: For torques on hose clamps, see thisOperation and Maintenance Manual, TorqueSpecifications (Maintenance Section).

7. Install the hose clamps with a torque wrench.

Note: For the proper coolant to use, see thisOperation and Maintenance Manual, CoolantRecommendations (Maintenance Section).

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler caps gaskets. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

10. Start the engine. Inspect the cooling system forleaks.

i00906366

Magnetic Pickups -

Clean/InspectSMCS Code: 1907-040; 7400-040; 7400-070


Typical example

(1) Magnetic pickup(2) Flywheel housing


Typical magnetic pickup

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Overhaul Considerations

1. Remove magnetic pickup (1) from flywheelhousing (2). Check the condition of the end ofthe magnetic pickup. Check for signs of wearand contaminants.

2. Clean the metal shavings and other debris from

the face of the magnet.

3. Install the magnetic pickup and adjust themagnetic pickup. Refer to the Service Manual forthe installation procedure.

i01090308

Overhaul Considerations

SMCS Code: 7595-043

Reduced hours of operation at full load will resultin a lower average power demand. A decreased

average power demand should increase both theengine service life and the overhaul interval.

The need for an overhaul is generally indicated byincreased fuel consumption and by reduced power.

The following factors are important when a decisionis being made on the proper time for an engineoverhaul:

The need for preventive maintenance

The quality of the fuel that is being used

The operating conditions

The results of the SOS analysis

Oil Consumption as an OverhaulIndicator

Oil consumption, fuel consumption, andmaintenance information can be used to estimatethe total operating cost for your Caterpillar engine.Oil consumption can also be used to estimatethe required capacity of a makeup oil tank that issuitable for the maintenance intervals.

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

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

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

Overhaul Options

Before Failure Overhaul

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

Costly unplanned downtime can be avoided.

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

The engines service life can be extended withoutthe risk of a major catastrophe due to engine

failure.

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

After Failure Overhaul

If a major engine failure occurs and the enginemust be removed from the hull, many options areavailable. An overhaul should be performed if theengine block or the crankshaft needs to be repaired.

If the engine block is repairable and/or thecrankshaft is repairable, the overhaul cost should

be between 40 percent and 50 percent of the costof a new engine with a similar exchange core.

This lower cost can be attributed to three aspects:

Specially designed Caterpillar engine features

Caterpillar dealer exchange components

Caterpillar Inc. remanufactured exchangecomponents

Overhaul Recommendation

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

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

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108Maintenance SectionOverhaul Considerations

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

Rebuild or Exchange

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

These components should be inspected accordingto the instructions that are found in variousCaterpillar reusability publications. The SpecialPublication, SEBF8029 lists the reusabilitypublications that are needed for inspecting theengine parts.

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

Parts that are not wi

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