3406e and 3456 industrial engines-maintenance intervals

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3406E and 3456INDUSTRIAL ENGINESMaintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU6959-02-01)

© 2007 CaterpillarAll Rights Reserved

70Maintenance SectionMaintenance Interval Schedule

i01259816

Maintenance Interval ScheduleSMCS Code: 1000; 7500

Note: Ensure that the Safety Information, warnings,and instructions are read and understoodbefore operation or maintenance procedures areperformed.

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

Note: Some maintenance items are for optionalequipment.

When Required

Battery - Replace .................................................. 73Battery or Battery Cable - Disconnect .................. 74Engine Oil Level Gauge - Calibrate ...................... 84Fuel System - Prime ............................................. 89Severe Service Application - Check ...................... 98

Daily

Air Starting Motor Lubricator Oil Level - Check .... 71Air Tank Moisture and Sediment - Drain ............... 72Cooling System Coolant Level - Check ................ 77Driven Equipment - Check .................................... 80Engine Air Cleaner Service Indicator - Inspect ..... 81Engine Air Precleaner - Check/Clean ................... 82Engine Oil Level - Check ...................................... 83Fuel System Primary Filter/Water Separator -Drain ................................................................... 91

Power Take-Off Clutch - Check/Adjust/Lubricate .. 97Walk-Around Inspection ...................................... 100

Every 250 Service Hours

Fuel Tank Breather - Replace ............................... 92

Every 9500 L (2500 US gal) of Fuel or 250Service Hours or 1 Month

Fuel System Secondary Filter - Replace .............. 91

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

Engine Air Cleaner Element (Single Element) -Replace ............................................................... 81

Magnetic Pickups - Clean/Inspect ........................ 94

Every 19 000 L (5000 US gal) of Fuel or 500Service Hours or 3 Months

Fuel System Primary Filter - Clean/Replace ........ 90

Every 114 000 L (30 000 US gal) of Fuel or3000 Service Hours or 2 Years

Engine Protective Devices - Check ....................... 87


Cooling System Coolant (ELC) - Change ............. 76

Overhaul

Overhaul Considerations ...................................... 94

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

Engine Valve Lash - Inspect/Adjust ...................... 88


Cooling System Coolant Extender (ELC) - Add .... 77Cooling System Water Temperature Regulator -Replace ............................................................... 79

Crankshaft Vibration Damper - Inspect ................. 80Engine Mounts - Inspect ....................................... 83Engine Speed/Timing Sensors - Check/Clean/Calibrate .............................................................. 87

Engine Speed/Timing Sensors - Check/Clean/Calibrate .............................................................. 88

Engine Valve Lash - Inspect/Adjust ...................... 88Engine Valve Rotators - Inspect ............................ 89Turbocharger - Inspect .......................................... 99

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

Alternator and Fan Belts - Inspect/Adjust/Replace ............................................................... 72

Battery Electrolyte Level - Check .......................... 73Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 78

Cylinder Head Grounding Stud - Inspect/Clean/Tighten ................................................................ 80

Engine Crankcase Breather - Clean ..................... 82Engine Oil Sample - Obtain .................................. 85Engine Oil and Filter - Change ............................. 85Fan Drive Bearing - Lubricate ............................... 89Fuel Tank Water and Sediment - Drain ................. 92Hoses and Clamps - Inspect/Replace .................. 93Radiator - Clean .................................................... 98

Every 190 000 L (50 000 US gal) of Fuel or5000 Service Hours

Air Compressor - Inspect ...................................... 71Alternator - Inspect ............................................... 72Cooling System Coolant (DEAC) - Change .......... 74Starting Motor - Inspect ........................................ 99Water Pump - Inspect ......................................... 101

71Maintenance Section

Air Compressor - Inspect

i01183385

Air Compressor - InspectSMCS Code: 1803-040

Do not disconnect the air line from the air com-pressor governor without purging the air brakeand the auxiliary air systems. Failure to purge theair brake and the auxiliary air systems before re-moving the air compressor and/or the air linescould cause personal injury.

g00633741Illustration 32

(1) Air compressor pressure relief valve

If the air compressor pressure relief valve that ismounted in the air compressor cylinder head isbypassing compressed air, there is a malfunctionin the air system, possibly ice blockage. Underthese conditions, your engine may have insuffi-cient air for normal brake operation.

Do not operate the engine until the reason for theair bypass is identified and corrected. Failure toheed this warning could lead to property damage,personal injury, or death to the operator or by-standers.

The function of the air compressor pressure reliefvalve is to bypass air when there is a malfunction inthe air compressor system.

The air compressor pressure relief valve releasesair at 1723 kPa (250 psi). It is very important thatall personnel stand clear of the air compressorpressure relief valve when compressed air isreleased. All personnel should also stay clear of theair compressor when the engine is operating andthe air compressor is exposed.

Refer to the Service Manual or refer to the OEMspecifications in order to find information concerningthe air compressor. Consult your Caterpillar dealerfor assistance.

i00805129

Air Starting Motor LubricatorOil Level - Check(If Equipped)SMCS Code: 1451-535

NOTICENever allow the lubricator bowl to become empty. Theair starting motor will be damaged by a lack of lubrica-tion. Ensure that sufficient oil is in the lubricator bowl.


(1) Air valve(2) Lubricator bowl(3) Adjustment knob

1. The vanes of the air starting motor are lubricatedwith a fine mist of oil from the air starting motorlubricator. Check the level of oil in lubricator bowl(2). If the oil level is less than 1/2, add oil to thelubricator bowl.

2. Ensure that the air supply to the lubricator is OFF.

3. Remove the plug. Pour oil into lubricator bowl(2). Use “10W” oil for temperatures that aregreater than 0� C (32� F). Use air tool oil fortemperatures that are below 0� C (32� F).

4. Install the plug.

Oiler Feed Adjustment

If necessary, adjust the lubricator in order to releaseapproximately two drops of fluid per 30 secondsinto the starting motor air stream.

1. Ensure that the fuel supply to the engine is OFF.

72Maintenance SectionAir Tank Moisture and Sediment - Drain

2. Turn adjustment knob (3) clockwise until theadjustment knob locks.

3. Turn adjustment knob (3) counterclockwise for1/4 turns.

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

4. Crank the starting motor for ten seconds andobserve the exhaust air from the mufflers of thestarting motor. Look for oil mist. A slight oil mistshould be barely visible.

If no mist is observed, or if the mist is excessive,rotate adjustment knob (3) in increments of 1/16 inorder to increase or decrease the oil mist. Repeatthe starting motor cranking and observe until themist is satisfactory.

Note: Drip rates should only be made under anaverage steady flow condition. Once a steadyflow condition is established, the lubricator willautomatically adjust the drip rate in proportion tothe variations in air flow.

i00847451

Air Tank Moisture andSediment - Drain(If Equipped)SMCS Code: 1466-543-M&S

Moisture and sediment in the air starting systemcan cause the following conditions:

• Freezing

• Corrosion of internal parts

• Malfunction of the air starting system

When opening the drain valve, wear protectivegloves, a protective face shield, protective cloth-ing, and protective shoes. Pressurized air couldcause debris to be blown and result in personalinjury.

1. Open the drain valve that is on the bottom ofthe air tank. Allow the moisture and sedimentto drain.

2. Close the drain valve.

3. Check the air supply pressure. The air startingmotor requires a minimum of 620 kPa (90 psi) ofair pressure to operate properly. The maximumair pressure must not exceed 1550 kPa (225 psi).The normal air pressure will be 758 to 965 kPa(110 to 140 psi).

i00072207

Alternator - InspectSMCS 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.

i00841051

Alternator and Fan Belts -Inspect/Adjust/ReplaceSMCS 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).


Battery - Replace

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 ratedrpm.

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 removaland belt installation procedure.

i01179608

Battery - ReplaceSMCS 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.

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.

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

i01206348

Battery Electrolyte Level -CheckSMCS Code: 1401-081

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:

74Maintenance SectionBattery or Battery Cable - Disconnect

• 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.

i00841296

Battery or Battery Cable -DisconnectSMCS Code: 1402-029

1. Turn the start switch to the OFF position. Turn theignition switch (if equipped) to the OFF positionand remove the key and all electrical loads.

2. Disconnect the cable from ground. One cableconnects to the frame and one cable connectsto battery negative. Make sure the cable cannotcontact the surface from where it was removed.

3. 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.

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

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

i01206425

Cooling System Coolant(DEAC) - ChangeSMCS 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.

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 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


Cooling System Coolant (DEAC) - Change

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 Specifications”topic (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.




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.

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 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.


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.

76Maintenance SectionCooling System Coolant (ELC) - Change

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 fillercap 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)- ChangeSMCS 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.

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


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 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




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


Cooling System Coolant Extender (ELC) - Add

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


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 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. 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 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.

i00259474

Cooling System CoolantExtender (ELC) - AddSMCS 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 engine’s 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 thecooling 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- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

78Maintenance SectionCooling System Supplemental Coolant Additive (SCA) - Test/Add


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 coolantlevel 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.

i00992487

Cooling System SupplementalCoolant Additive (SCA) -Test/AddSMCS 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 S·O·S 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 Kitor use the 4C-9301 Coolant Conditioner Test Kitin order to check the concentration of the SCA.Refer to the Operation and Maintenance Manual formore information on conventional coolant/antifreezecooling system maintenance.

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).

S·O·S Coolant Analysis

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


Cooling System Water Temperature Regulator - Replace

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 S·O·S CoolantAnalysis.

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 thecooling system, reducing the engine’s 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.

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 -ReplaceSMCS 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.

80Maintenance SectionCrankshaft Vibration Damper - Inspect

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.

i00072369

Crankshaft Vibration Damper- InspectSMCS 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.

Removal and Installation

Refer to the Service Manual for the damperremoval procedure and for the damper installationprocedure.

Visconic Damper

The visconic damper has a weight that is locatedinside a fluid filled case. The weight moves in thecase in order to limit torsional vibration. Inspectthe damper for evidence of dents, cracks or leaksof the fluid.

Replace the damper if the damper is dented,cracked or leaking. Refer to the Service Manualor consult your Caterpillar dealer for damperreplacement.

i00850065

Cylinder Head Grounding Stud- Inspect/Clean/TightenSMCS Code: 7423-040; 7423-070; 7423-079


Cylinder head grounding stud (side view)

Inspect the OEM harness for good connections.Inspect the condition of the OEM harness.

The cylinder head grounding stud must have a wireground to the battery. Tighten the cylinder headgrounding stud at every oil change. Ground wiresand straps should be combined at engine grounds.All grounds should be tight and free of corrosion.

• Clean the cylinder head grounding stud and theterminals for the cylinder head ground strap witha clean cloth.

• If the connections are corroded, clean theconnections with a solution of baking soda andwater.

• Keep the cylinder head grounding stud and thestrap clean and coated with MPGM grease orpetroleum jelly.

i00174798

Driven Equipment - CheckSMCS Code: 3279-535

Refer to the OEM specifications for more informationon the following maintenance recommendations forthe driven equipment:

• Inspection

• Adjustment

• Lubrication


Engine Air Cleaner Element (Single Element) - Replace

• Other maintenance recommendations

Perform any maintenance for the driven equipmentwhich is recommended by the OEM.

i00851168

Engine Air Cleaner Element(Single Element) - ReplaceSMCS Code: 1051; 1054-510

Perform the Operation and Maintenance Manual,“Engine Air Cleaner Service Indicator-Inspect”procedure 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 theengine 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 removethe 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.

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.

i00831268

Engine Air Cleaner ServiceIndicator - InspectSMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differentialgauge for inlet air pressure. The gauge readsthe difference between inlet air pressure beforethe air cleaner element and after the air cleanerelement. As the air cleaner element becomes dirty,the pressure differential rises. If your engine isequipped with a different type of service indicator,follow the OEM recommendations in order to servicethe air cleaner element.

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

82Maintenance SectionEngine Air Precleaner - Check/Clean

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


Typical service indicator

Observe the service indicator. The air cleanerelement should be cleaned or replaced when theyellow diaphragm enters the red zone or the redpiston locks in the visible position. If the serviceindicator appears red at any time, clean the aircleaner element or install a new air cleaner element.

An air cleaner differential pressure gauge mayeither be located in the engine compartment orlocated on the control panel. The air cleanerdifferential pressure gauge indicates the differenceof the air pressure between the inlet (dirty) sideand the engine (clean) side of the filter element.The pressure difference between the two sidesincreases as the filter becomes plugged.

Replace dirty paper elements with new paperelements. Keep spare filter elements on hand forreplacement. The element should be thoroughlychecked for rips or tears at least every year.A supply of new air filter elements should bemaintained.

• Replace the air cleaner elements at intervals thatare recommended by the air cleaner OEM.

• If operating conditions consist of dust, dirt anddebris, frequent maintenance of air cleanerelements is necessary.

• Service the air cleaner when required by the aircleaner indicator.

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

i00720883

Engine Air Precleaner -Check/CleanSMCS Code: 1055-070; 1055-535


Typical engine precleaner

(1) Wing nut(2) Cover(3) Body

Remove wing nut (1) and cover (2). Check for anaccumulation of dirt and debris in body (3). Cleanthe body, if necessary.

After cleaning the precleaner, install cover (2) andwing nut (1).

Note: When the engine is operated in dustyapplications, more frequent cleaning is required.

i01176301

Engine Crankcase Breather -CleanSMCS 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.


Engine Mounts - Inspect


Typical example

(1) Hose clamp(2) Cover clamp(3) Crankcase breather cover

1. Loosen hose clamp (1) and remove the hosefrom crankcase breather cover (3).

2. Loosen the cover clamp (2). Remove thecrankcase breather cover (3).

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

4. Install a new seal. Install a breather element thatis clean and dry. Install the crankcase breathercover (3) and install the cover clamp (2). Referto the Operation and Maintenance Manual forthe proper torques.

5. Install the hose. Install hose clamp (1). Refer tothe Operation and Maintenance Manual for theproper torques.

i00687861

Engine Mounts - InspectSMCS Code: 1152-040

Inspect the engine mounts for deterioration and forproper 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.

i00837913

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

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


Left side view

(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). Donot fill the crankcase above “FULL” mark (X).

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

2. Remove oil filler cap (2) and add oil, if necessary.Clean the oil filler cap. Reinstall the oil filler cap.

84Maintenance SectionEngine Oil Level Gauge - Calibrate

i00831577

Engine Oil Level Gauge -CalibrateSMCS Code: 1326-524

The angle of the installation and the slant of theinstallation will affect the engine oil level. The angleis the front to back tilt of the engine. The slant is thesideways tilt of the engine.


The engine will be equipped with either dipstick.

(1) Traditional dipstick. (2) Full range dipstick.

Verify that the markings on the engine oil levelgauge are correct. Verify the markings at the firstoil change.

Use the following procedure in order to verify that“ADD” mark is correct. Use the following procedurein order to establish actual “FULL” mark on theengine oil level gauge.

NOTICEThe engine must be on a level surface to perform thismaintenance procedure.

1. Operate the engine until normal operatingtemperature is achieved. Stop the engine.Remove the drain plugs from the enginecrankcase. Allow the engine oil to drain.

NOTICEDo not fill the oil filters with oil before installing them.

This oil would not be filtered and could be contaminat-ed.

Contaminated oil will cause accelerated wear to theengine.

2. Remove the used engine oil filter(s). Install thenew engine oil filter(s). Install the drain plugfor the engine crankcase. Tighten the drainplug for the engine crankcase to 70 ± 14 N·m(50 ± 10 lb ft).

Note: The engine may be equipped with auxiliaryengine oil filters. The oil filters may require adifferent volume than the standard amount. Refer tothe OEM specifications.

3. Pour 26.5 L (28 qt) of engine oil into the enginecrankcase. DO NOT pour oil into the oil filler thatis located on top of the engine. Pour oil into oneof the oil fill locations on the side of the engine.Allow enough time for the engine oil to draininto the engine crankcase. Check the engine oillevel. Wait for a few minutes. Check the engineoil level again. Proceed after the engine oil levelstops changing.

4. The oil level should be at the “ADD” mark. If theoil is not at the “ADD” mark, grind off the existing“ADD” mark. Mark the new level as “ADD” usingan engraving pen.

5. Pour 5.7 L (6 qt) of engine oil into the enginecrankcase. Allow enough time for the engineoil to drain into the engine crankcase. Allow aminimum of five minutes.

6. Install the oil level gauge. Remove the gaugeand note the oil level on the gauge. This is thenew “FULL” mark on the dipstick. If the oil is notat the “FULL” mark, grind off the existing “FULL”mark. Mark the new level as “FULL” using anengraving pen.

7. Pour 5.7 L (6 qt) of engine oil into the enginecrankcase for the filter or filters and margin.

8. Start the engine. Ensure that the lubricationsystem is filled. Inspect the lubrication systemfor leaks.

9. Stop the engine and allow enough time for theengine oil to drain into the engine crankcase.Allow a minimum of five minutes.

10. Check the engine oil level on the engine oillevel gauge. If the engine oil level is not at thecalibrated “FULL” mark, fill the sump to thecalibrated “FULL” mark. Record the amount ofoil that is added. This additional engine oil isthe system capacity plus the 38 L (40 qt) in thesump. This additional engine oil is the amount ofengine oil that is required when the engine oil ischanged. Record the engine oil capacity for thesystem for future changes of the engine oil.


Engine Oil Sample - Obtain

i00831483

Engine Oil Sample - ObtainSMCS Code: 1000-008; 1348-554-SM;

7542-554-OC, SM


Obtain the Sample and the Analysis

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

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

Obtain the S·O·S Sample

Use one of the following methods in order to obtainan S·O·S sample:


Typical oil sampling valve

• Use the oil sampling valve (if equipped).

• Use a 1U-5758 Vacuum Pump or use anequivalent pump that is inserted into the sump.

Caterpillar recommends using a sampling valvein order to obtain oil samples. The quality andthe consistency of the samples is better when thesampling valve is used. The location of the samplingvalve must allow oil that is flowing under pressureto be obtained during normal engine operation.

If the engine is not equipped with a sampling valve,the use of a 1U-5758 Vacuum Pump is preferred.

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

Table 29

S·O·S Interval Chart

Compartment Interval

Engine Crankcase Every 250 Hours

For more information, see Special Publication,PEHP6001, “How To Take A Good Oil Sample”.Consult your Caterpillar dealer for completeinformation and assistance in establishing an S·O·Sprogram for your engine.

i00838597

Engine Oil and Filter - ChangeSMCS Code: 1318-510; 1348-044


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 methodallows 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:

• 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.

86Maintenance SectionEngine Oil and Filter - Change

• 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.


Front view

(1) Oil filler(2) Oil level gauge(3) Oil drain plugs(4) Oil filter

1. Remove the oil filter with a 2P-8250 StrapWrench Assembly.

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 gasketis 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 thatare shown on the oil filter. Do not overtighten theoil filter.


Engine Protective Devices - Check

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.

NOTICEIf equipped with an auxiliary oil filter system or a re-mote oil filter system, follow the OEM or filter manu-facturer’s 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.

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 “ADD”and “FULL” marks on the oil level gauge.

i00626013

Engine Protective Devices -CheckSMCS 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.

i00864325

Engine Speed/Timing Sensors- Check/Clean/CalibrateSMCS Code: 1912-040; 1912-070; 1912-524


Left side view

(1) Speed-timing sensor

88Maintenance SectionEngine Speed/Timing Sensors - Check/Clean/Calibrate


Right side view

(2) Backup speed-timing sensor

1. Remove the speed-timing sensors from the fronthousing. Check the condition of the plastic endof the speed-timing sensors for wear and/orcontaminants.

2. Clean the metal shavings and other debris fromthe face of the speed-timing sensors. Use theprocedure in the Service Manual in order tocalibrate the speed-timing sensors.

Refer to the Service Manual for more information onthe speed-timing sensors.

i01161856

Engine Speed/Timing Sensors- Check/Clean/CalibrateSMCS Code: 1912-040; 1912-070; 1912-524

S/N: 3LW1-Up


Left side view

(1) Primary speed/timing sensor(2) Secondary speed/timing sensor

1. Remove the speed/timing sensors from the fronthousing. Check the condition of the plastic endof the speed/timing sensors for wear and/orcontaminants.

2. Clean the metal shavings and other debris fromthe face of the speed/timing sensors. Use theprocedure in the Service Manual in order tocalibrate the speed/timing sensors.

Refer to the Service Manual for more information onthe speed/timing sensors.

i00869413

Engine Valve Lash -Inspect/AdjustSMCS Code: 1102-025

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

Adjustment of the Electronic UnitInjector

Adjust the electronic unit injector (preload) at thesame interval as the valve lash adjustment. Theoperation of Caterpillar engines with improper valveadjustments and with improper adjustments of theelectronic unit injector can reduce engine efficiency.This reduced efficiency could result in excessivefuel usage and/or shortened engine component life.

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.


Engine Valve Rotators - Inspect

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.

i00937014

Engine Valve Rotators - InspectSMCS 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 pistonand 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 Starting”procedure (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.

i00175571

Fan Drive Bearing - LubricateSMCS Code: 1359-086-BD


Typical Fan Drive Bearing Grease Fitting

Lubricate the fan drive bearing grease fitting withBearing Lubricant Special Purpose Grease or theequivalent.

Inspect the fan drive pulley assembly. If the shaftis loose, an inspection of the internal componentsshould be performed. Refer to the Service Manual.

i00838960

Fuel System - PrimeSMCS Code: 1258-548

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.

Priming the fuel system fills the fuel filters. Primingthe fuel system also removes air from the fuelsystem. This procedure is used primarily when theengine runs out of fuel.

Note: DO NOT remove the fitting in the fuel filterbase in order to release air from the fuel systemduring periodic service of the fuel filter. Periodicremoval of the fitting will result in increased wear ofthe threads in the fuel filter base. This can lead tofuel leakage. However, the fitting in the fuel filterbase can be used to purge air from the fuel systemif the engine runs out of fuel.

90Maintenance SectionFuel System Primary Filter - Clean/Replace

1. Loosen the fuel filter air purge plug two full turns.Unlock and operate the priming pump until fuelappears at the fitting. This procedure will requireconsiderable strokes. Use a cloth or a containerto catch the excess fuel.

2. Tighten the fuel filter air purge plug. Open fuelpriming pump and operate the fuel priming pumpuntil a strong pressure is felt on the fuel primingpump. Push the priming pump plunger inward.Tighten the plunger by hand, and promptlycontinue with the next step.

3. Crank the engine after pressurizing the system.

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

4. If the engine will not start, allow the starting motorto cool for 2 minutes. Repeat Steps 2 and 3 inorder to start the engine. Further priming may benecessary to help purge the fuel lines of air, if:

• The engine starts, but runs rough.

• The engine started, but continues to misfireor smoke.

5. Run the engine at low idle until the engine runssmoothly.

i01250642

Fuel System Primary Filter -Clean/ReplaceSMCS Code: 1260-070; 1260-510


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.

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


5. Remove the fuel filter bowl (1) and wash the fuelfilter bowl with clean diesel fuel.

6. Remove the fuel filter (2).

7. Clean the gasket sealing surface of the fuelfilter base. Ensure that all of the old gasket isremoved.

8. Apply clean diesel fuel to the new fuel filtergasket.

NOTICEIn order to maximize fuel system life and prevent pre-mature wear out from abrasive particles in the fuel,use Caterpillar fuel filters.

Consult your Caterpillar dealer for proper part num-bers.

9. Install the new fuel filter. Spin the fuel filter ontothe fuel filter base until the gasket contacts thebase. Use the rotation index marks on the filtersas a guide for proper tightening. Tighten thefilter for an additional 3/4 turn by hand. Do notovertighten the filter.

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.

10. Install the clean fuel filter bowl on the new fuelfilter.

11. Open the fuel tank supply valve.


Fuel System Primary Filter/Water Separator - Drain

i01254694

Fuel System PrimaryFilter/Water Separator - DrainSMCS Code: 1260-543; 1263-543


(1) Bowl(2) Element(3) Drain

Bowl (1) should be monitored daily for signs ofwater. If water is present, drain the water from thebowl.

1. Open drain (3). The drain is a self-ventilateddrain. Catch the draining water in a suitablecontainer. Dispose of the water properly.

2. Close drain (3).

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering the fuelsystem.

i01250684

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE



(1) Fuel priming pump(2) Fuel filter(3) Fuel block(4) Fuel filter air purge plug

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over any dis-connected fuel system components.

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

1. It may be necessary to relieve residual fuelpressure from the fuel system before removingthe fuel filter.

Loosen the fuel filter air purge plug (4) in orderto purge any residual pressure.

NOTICEDo not loosen fuel lines or fittings at the fuel manifoldor ECM. The engine components may be damaged.

2. Remove the used fuel filter.

3. Clean the gasket sealing surface of the fuelfilter base. Ensure that all of the old gasket isremoved.

4. Apply clean diesel fuel to the new fuel filtergasket.

92Maintenance SectionFuel Tank Breather - Replace

NOTICEIn order to maximize fuel system life and preventpremature wear out from abrasive particles in thefuel, a two micron absolute high efficiency fuel filteris required for all Caterpillar Electronic Unit Injectors.Caterpillar High Efficiency Fuel Filters meet theserequirements. Consult your Caterpillar dealer for theproper part numbers.

NOTICEDo not fill the secondary fuel filter with fuel before in-stalling. The fuel would not be filtered and could becontaminated. Contaminated fuel will cause acceler-ated wear to fuel system parts.

5. Install the new fuel filter. Spin the fuel filter ontothe fuel filter base until the gasket contacts thebase. Use the rotation index marks on the filtersas a guide for proper tightening. Tighten thefilter for an additional 3/4 turn by hand. Do notovertighten the filter.

6. Open the fuel tank supply valve and prime thefuel system.

i01258873

Fuel Tank Breather - ReplaceSMCS Code: 1273-510-BRE


1. Remove the old fuel tank breather filter.

2. Install new fuel tank breather filter.

i00073301

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S

Fuel Tank

Fuel 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 Sediment

Fuel 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 minutesbefore 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


Hoses and Clamps - Inspect/Replace

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

i00907072

Hoses and Clamps -Inspect/ReplaceSMCS 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

• 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 theconstant 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


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.

94Maintenance SectionMagnetic Pickups - Clean/Inspect

9. Clean the cooling system filler cap. Inspect thecooling system filler cap’s 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.

i00850920

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


(1) Magnetic pickup. (2) Flywheel housing.


Typical magnetic pickup

1. Remove the magnetic pickup (1) from theflywheel housing. Check the condition of the endof the magnetic pickup. Check for signs of wearand contaminants.

2. Clean the metal shavings and other debris fromthe face of the magnet.

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

i01136294

Overhaul ConsiderationsSMCS Code: 7595-043

Reduced hours of operation at full load will resultin a lower average power demand. A decreasedaverage 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 S·O·S 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 engine’s 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:


Overhaul Considerations

• Costly unplanned downtime can be avoided.

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

• The engine service life can be extended withoutthe risk of a major catastrophe due to enginefailure.

• 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, many options are available. Anoverhaul should be performed if the engine blockor the crankshaft needs to be repaired.

If the engine block is repairable and/or thecrankshaft is repairable, the overhaul cost shouldbe 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, a scheduled engine overhaulby your Caterpillar dealer is recommended. This willprovide you with 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.

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

Unit Fuel Injector

Clean the fuel injector body and replace theO-rings. Replace the O-rings and the gasket on theinjector sleeve. Clean the area around the injectorseating in the injector sleeve. Refer to the ServiceManual for the complete procedure, or consult withyour Caterpillar dealer for assistance.

Rebuild or Exchange

Cylinder Head Assembly, Connecting Rods,Pistons, Cylinder Liners, Turbocharger, CylinderPacks, Oil Pump, 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 within the established inspectionspecifications should be dealt with in one of thefollowing manners:

• Salvaging

• Repairing

• Replacing

Using out-of-spec parts can result in the followingproblems:

• Unscheduled downtime

• Costly repairs

• Damage to other engine parts

• Reduced engine efficiency

• Increased fuel consumption

Reduced engine efficiency and increased fuelconsumption translates into higher operating costs.Therefore, Caterpillar Inc. recommends repairingout-of-spec parts or replacing out-of-spec parts.

Inspection and/or Replacement

Piston Rings, Crankshaft Bearings, ValveRotators, and Crankshaft Seals

The following components may not last until thesecond overhaul.

• Thrust bearings

• Main bearings

• Rod bearings

• Valve rotators

96Maintenance SectionOverhaul Considerations

• Crankshaft seals

Caterpillar Inc. recommends the installation of newparts at each overhaul period.

Inspect these parts while the engine is disassembledfor an overhaul.

Inspect the crankshaft for any of the followingconditions:

• Deflection

• Damage to the journals

• Bearing material that has seized to the journals

Check the journal taper and the profile of thecrankshaft journals. Check these components byinterpreting the wear patterns on the followingcomponents:

• Rod bearing

• Main bearings

Note: If the crankshaft is removed for any reason,use the magnetic particle inspection process tocheck for cracks in the crankshaft.

Inspect the camshaft for damage to the journalsand to the lobes.

Note: If the camshaft is removed for any reason, usethe magnetic particle inspection process to checkfor cracks in the camshaft.

Inspect the following components for signs of wearor for signs of scuffing:

• Camshaft bearings

• Camshaft followers

Caterpillar Inc. recommends replacing thecrankshaft vibration damper.

Oil Cooler Core and Aftercooler Core

During an overhaul, the removal of the oil coolercore and the aftercooler core is recommended. Theoil cooler core and the aftercooler core should becleaned and pressure tested.

NOTICEDo not use caustic cleaners to clean the core.

Caustic cleaners can attack the internal metals of thecore and cause leakage.

Note: Use this cleaning procedure to clean the oilcooler core and the aftercooler core.

1. Remove the oil cooler core and the aftercoolercore.

2. Remove any debris from the oil cooler core andthe aftercooler core. To remove debris from theoil cooler core, turn the oil cooler core onto oneend. To remove debris from the aftercooler core,turn the aftercooler core upside-down.

3. Flush the oil cooler core and the aftercooler coreinternally with cleaner in order to loosen foreignsubstances. This will also help to remove oil fromthe oil cooler core and the aftercooler core.

Note: The use of Hydrosolv Liquid Cleaners isrecommended. Table 30 lists the Hydrosolv LiquidCleaners that are available from your Caterpillardealer.

Table 30

HydrosolvLiquid Cleaners

PartNumber Description Size

1U-8812 4 L (1 US gallon)

1U-5490 19 L (5 US gallon)

8T-7570

Hydrosolv4165

208 L (55 US gallon)

1U-8804 4 L (1 US gallon)

1U-5492 19 L (5 US gallon)

8T-5571

Hydrosolv100

208 L (55 US gallon)

4. Use steam to clean the oil cooler core and theaftercooler core. This removes any remainingresidue from the cleaner. Flush the fins of the oilcooler core and the aftercooler core. Removeany other trapped debris.

5. Wash the oil cooler core and the aftercooler corewith hot, soapy water. Rinse the oil cooler coreand the aftercooler core thoroughly with cleanwater.


Power Take-Off Clutch - Check/Adjust/Lubricate

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 oil cooler core and the aftercooler corewith compressed air. Direct the air in the reversedirection of the normal flow.

7. Inspect the components in order to ensurecleanliness. The oil cooler core and theaftercooler core should be pressure tested.Repair the oil cooler core and the aftercoolercore, if necessary. Install the oil cooler core andthe aftercooler core.

For more information about cleaning the cores,consult your Caterpillar dealer.

Obtain Coolant Analysis

The concentration of supplemental coolant additive(SCA) should be checked regularly with test kitsor with S·O·S Coolant Analysis (Level 1). Furthercoolant analysis is recommended when the engineis overhauled.

A coolant analysis can be conducted in orderto verify the condition of the water that is beingused in the cooling system. A full water analysiscan be obtained by consulting your local waterutility company or an agricultural agent. Privatelaboratories are also available for water analysis.

Caterpillar Inc. recommends an S·O·S CoolantAnalysis (Level 2).

S·O·S Coolant Analysis (Level 2)

An S·O·S Coolant Analysis (Level 2) is acomprehensive coolant analysis which completelyanalyzes the coolant and the effects on the coolingsystem. An S·O·S Coolant Analysis (Level 2)provides the following information:

• Complete S·O·S Coolant Analysis (Level 2)

• Visual inspection of properties

• Identification of metal corrosion

• Identification of contaminants

• Identification of built up impurities (corrosion andscale)

S·O·S Coolant Analysis (Level 2) provides a report ofthe results of both the analysis and the maintenancerecommendations.

For more information about coolant analysis, consultyour Caterpillar dealer.

i00339617

Power Take-Off Clutch -Check/Adjust/LubricateSMCS Code: 3055-036; 3055-086

NOTICENew power take-offs should have the clutch adjust-ment checked before being placed into service. Theclutch adjustment should be checked again after thefirst ten hours of operation. New clutch plates have a“wear in” period, and the clutch may require severaladjustments until the new plates are “worn in”.


(1) Typical instruction plate for the clutch. (2) Typical serial numberplate for the clutch.

The clutch adjustment should be checked regularlyafter “wear in”. Heavy-duty applications whichhave engagements that are frequent and relativelylong periods of clutch slippage require morefrequent adjustment than light-duty applications.The operating torque should be measured in orderto determine if a clutch adjustment is required.

Refer to the OEM information and instruction plate(1) for instructions on the following items: lubrication,adjustment, and other service recommendations.Perform the maintenance that is specified on theinstruction plate.

98Maintenance SectionRadiator - Clean

Do not operate the engine with the InstructionPlate cover removed from the clutch. Personalinjury may result.

If the clutch is damaged to the point of burst fail-ure, expelled pieces can cause personal injury toanyone in the immediate area. Proper safeguardsmust be followed to help prevent accidents.

i01206548

Radiator - CleanSMCS Code: 1353-070

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

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

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.

Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the fan’s air flow. Hold the nozzle approximately6 mm (0.25 inch) away from the fins. Slowly movethe air nozzle in a direction that is parallel with thetubes. This will remove debris that is between thetubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

Use a degreaser and steam for removal of oil andgrease. Clean both sides of the core. Wash the corewith detergent and hot water. Thoroughly rinse thecore with clean water.

After cleaning, start the engine and accelerate theengine to high idle rpm. This will help in the removalof debris and drying of the core. Stop the engine.Use a light bulb behind the core in order to inspectthe core for cleanliness. Repeat the cleaning, ifnecessary.

Inspect the fins for damage. Bent fins may beopened with a “comb”. Inspect these items forgood condition: welds, mounting brackets, air lines,connections, clamps, and seals. Make repairs, ifnecessary.

For more detailed information on cleaning andinspection, see Special Publication, SEBD0518,“Know Your Cooling System”.

i00151038

Severe Service Application -CheckSMCS Code: 1000-082

Severe service is an application of an enginethat exceeds current published standards for thatengine. Caterpillar maintains standards for thefollowing engine parameters:

• Performance (power range, speed range, andfuel consumption)

• Fuel quality

• Altitude range

• Maintenance intervals

• Oil selection and maintenance

• Coolant selection and maintenance

• Environmental qualities

• Installation

Refer to the standards for the engine or consult withyour Caterpillar dealer in order to determine if theengine is operating within the defined parameters.

Severe service operation can accelerate componentwear. Engines that operate under severe conditionsmay need more frequent maintenance intervals inorder to ensure maximum reliability and retentionof full service life.

Due to individual applications, it is not possible toidentify all of the factors which can contribute tosevere service operation. Consult your Caterpillardealer for the unique maintenance that is necessaryfor the engine.


Starting Motor - Inspect

The operating environment, improper operatingprocedures and improper maintenance procedurescan be factors which contribute to severe serviceconditions.

Environmental Factors

Ambient temperatures – The engine may beexposed to extended operation in extremelycold environments or hot environments. Valvecomponents can be damaged by carbon buildup ifthe engine is frequently started and stopped in verycold temperatures. Extremely hot inlet air reducesengine performance.

Air Quality – The engine may be exposed toextended operation in an environment that is dirtyor dusty, unless the equipment is cleaned regularly.Mud, dirt and dust can encase components.Maintenance can be very difficult. The buildup cancontain corrosive chemicals.

Buildup – Compounds, elements, corrosivechemicals and salt can damage some components.

Altitude – Problems can arise when the engineis operated at altitudes that are higher than theintended settings for that application. Necessaryadjustments should be made.

Improper Operating Procedures

• Extended operation at low idle

• Frequent hot shutdowns

• Operating at excessive loads

• Operating at excessive speeds

• Operating outside the intended application

Improper Maintenance Procedures

• Extending the maintenance intervals

• Failure to use recommended fuel, lubricants andcoolant/antifreeze

i00651416

Starting Motor - InspectSMCS Code: 1451-040; 1453-040

Caterpillar Inc. recommends a scheduled inspectionof the starting motor. If the starting motor fails, theengine may not start in an emergency situation.

Check the starting motor for proper operation.Check the electrical connections and clean theelectrical connections. Refer to the Service Manualfor more information on the checking procedure andfor specifications or consult your Caterpillar dealerfor assistance.

i00912946

Turbocharger - InspectSMCS Code: 1052-040

Periodic inspection and cleaning is recommendedfor the turbocharger compressor housing (inletside). Any fumes from the crankcase are filteredthrough the air inlet system. Therefore, by-productsfrom oil and from combustion can collect in theturbocharger compressor housing. Over time, thisbuildup can contribute to loss of engine power,increased black smoke and overall loss of engineefficiency.

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage tothe turbocharger compressor wheel can causeadditional damage to the pistons, the valves, andthe cylinder head.

NOTICETurbocharger bearing failures can cause large quan-tities of oil to enter the air inlet and exhaust systems.Loss of engine lubricant can result in serious enginedamage.

Minor leakage of a turbocharger housing under ex-tended low idle operation should not cause problemsas long as a turbocharger bearing failure has not oc-curred.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is repaired orreplaced.

An inspection of the turbocharger can minimizeunscheduled downtime. An inspection of theturbocharger can also reduce the chance forpotential damage to other engine parts.

Note: Turbocharger components require precisionclearances. The turbocharger cartridge mustbe balanced due to high rpm. Severe ServiceApplications can accelerate component wear.Severe Service Applications require more frequentinspections of the cartridge.

100Maintenance SectionWalk-Around Inspection

Removal and Installation

For options regarding the removal, installation,repair and replacement, consult your Caterpillardealer. Refer to the Service Manual for this enginefor the procedure and specifications.

Cleaning and Inspecting

1. Remove the exhaust outlet piping and removethe air inlet piping from the turbocharger. Visuallyinspect the piping for the presence of oil.

2. Turn the compressor wheel and the turbinewheel by hand. The assembly should turn freely.Inspect the compressor wheel and the turbinewheel for contact with the turbocharger housing.There should not be any visible signs of contactbetween the turbine wheel or compressorwheel and the turbocharger housing. If there isany indication of contact between the rotatingturbine wheel or the compressor wheel and theturbocharger housing, the turbocharger must bereconditioned.

3. Check the compressor wheel for cleanliness.If only the blade side of the wheel is dirty,dirt and/or moisture is passing through the airfiltering system. If oil is found only on the backside of the wheel, there is a possibility of a failedturbocharger oil seal.

The presence of oil may be the result of extendedengine operation at low idle. The presence of oilmay also be the result of a restriction of the linefor the inlet air (plugged air filters), which causesthe turbocharger to slobber.

4. Use a dial indicator to check the end clearanceon the shaft. If the measured end play is greaterthan the Service Manual specifications, theturbocharger should be repaired or replaced.An end play measurement that is less than theminimum Service Manual specifications couldindicate carbon buildup on the turbine wheel.The turbocharger should be disassembled forcleaning and for inspection if the measured endplay is less than the minimum Service Manualspecifications.

5. Inspect the bore of the turbine housing forcorrosion.

6. Clean the turbocharger housing with standardshop solvents and a soft bristle brush.

7. Fasten the air inlet piping and the exhaust outletpiping to the turbocharger housing.

i01185304

Walk-Around InspectionSMCS Code: 1000-040

Inspect the Engine for Leaks andfor Loose Connections

A walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can beavoided.

For maximum engine service life, make a thoroughinspection of the engine compartment beforestarting the engine. Look for items such as oil leaksor coolant leaks, loose bolts, worn belts, looseconnections and trash buildup. Make repairs, asneeded:

• The guards must be in the proper place. Repairdamaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICEAccumulated grease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaningor high pressure water.

• Ensure that the cooling lines are properly clampedand that the cooling lines are tight. Check forleaks. Check the condition of all pipes.

• Inspect the water pumps for coolant leaks.

Note: The water pump seal is lubricated by coolantin the cooling system. It is normal for a small amountof leakage to occur as the engine cools down andthe parts contract.

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


Water Pump - Inspect

• Inspect the lubrication system for leaks at thefront crankshaft seal, the rear crankshaft seal, theoil pan, the oil filters and the valve cover.

• Inspect the fuel system for leaks. Look for loosefuel line clamps or for loose fuel line tie-wraps.

• Inspect the piping for the air inlet system and theelbows for cracks and for loose clamps. Ensurethat hoses and tubes are not contacting otherhoses, tubes, wiring harnesses, etc.

• Inspect the alternator belt and the accessorydrive belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replacedas matched sets. If only one belt is replaced, thebelt will carry more load than the belts that arenot replaced. The older belts are stretched. Theadditional load on the new belt could cause thebelt to break.

• Drain the water and the sediment from fuel tankson a daily basis in order to ensure that only cleanfuel enters the fuel system.

• Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

• Inspect the ground strap for a good connectionand for good condition.

• Inspect the ECM to the cylinder head groundstrap for a good connection and for goodcondition.

• Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolytelevel of the batteries, unless the engine isequipped with a maintenance free battery.

• Check the condition of the gauges. Replace anygauges that are cracked. Replace any gauge thatcan not be calibrated.

i01057943

Water Pump - InspectSMCS Code: 1361-040; 1361

A failed water pump might cause severe engineoverheating problems that could result in thefollowing conditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

Visually inspect the water pump for leaks. If anyleaking is observed, replace the water pumpseal or the water pump assembly. Refer to theService Manual for the disassembly and assemblyprocedure.

Note: Refer to the Service Manual or consult yourCaterpillar dealer if any repair is needed or anyreplacement is needed.

3406e and 3456 industrial engines-maintenance intervals

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