Maintenance Caterpillar C18

MAINTENANCE INTERVALS
Operation and Maintenance

Manual Excerpt
2010 Caterpillar
All Rights Reserved
SEBU7899-05
January 2012
Operation and
Maintenance
Manual
C18 Industrial Engine
JDA1-Up (Engine)
GJE1-Up (Engine)
EJG1-Up (Engine)
WJH1-Up (Engine)
WRH1-Up (Engine)
SAFETY.CAT.COM
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61
Maintenance Section
Maintenance Interval Schedule
i04760787

(Engines Which Have Deep Oil
Pans)
SMCS Code: 1000; 4450; 7500
S/N: GJE1-Up
S/N: EJG1-Up
Daily
Coolant Level - Check ..........................................
Engine Air Cleaner Service Indicator - Inspect .....
Engine Air Precleaner - Check/Clean ...................
Engine Oil Level - Check ......................................
Fuel System Primary Filter/Water Separator Drain ...................................................................
Fuel Tank Water and Sediment - Drain .................
Power Take-Off Clutch - Check ............................
Walk-Around Inspection ........................................
70
79
80
81
88
90
97
99
S/N: WJH1-Up
Every Week
S/N: WRH1-Up
Jacket Water Heater - Check ................................ 94
Ensure that all safety information, warnings,

and instructions are read and understood before
any operation or any maintenance procedures
are performed. The user is responsible for the
performance of all maintenance including the
following procedures: all adjustments, the use of
proper lubricants, fluids, filters, and the installation
of new components due to normal wear and aging .
The performance of this product may be diminished if
proper maintenance intervals and procedures are not
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures
are not followed.
Every 250 Service Hours
Note: Use whichever of the following that occurs

first in order to determine the maintenance intervals:
fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all
maintenance from the previous intervals must be
performed.
Initial 500 Service Hours (or at first oil

change)
Refer to this Operation and Maintenance Manual,

Refill Capacities in order to determine the type of
oil pan with which your Cat C18 Industrial Engine is
equipped.
Products that operate in severe operating conditions
may require more frequent maintenance. Refer to
this Operation and Maintenance Manual, Severe
Service Application to determine if the engine is
operating in a severe service application.
When Required
Battery - Replace ..................................................
Battery or Battery Cable - Disconnect ..................
Coolant - Change ..................................................
Coolant Extender (ELC) - Add ..............................
Engine Air Cleaner Element (Dual Element) Inspect/Clean/Replace ........................................
Engine Oil and Filter - Change .............................
Engine Storage Procedure - Check ......................
Fuel System - Prime .............................................
65
66
68
70
76
82
85
86
Battery Electrolyte Level - Check ..........................

Coolant Sample (Level 1) - Obtain .......................
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .................................................
Engine Crankcase Breather - Clean .....................
Fuel System Primary Filter (Water Separator)
Element - Replace ..............................................
Fuel System Secondary Filter - Replace ..............
Grounding Stud - Inspect/Clean/Tighten ...............
Hoses and Clamps - Inspect/Replace ..................
Radiator - Clean ....................................................
66
71
73
80
88
90
91
92
97
Engine Valve Lash - Check ................................... 85

Engine Valve Rotators - Inspect ........................... 85
Initial 500 Hours (for New Systems, Refilled

Systems, and Converted Systems)
Coolant Sample (Level 2) - Obtain ....................... 72

Belts - Inspect/Adjust/Replace .............................. 67
Engine Oil Sample - Obtain .................................. 82
Engine Oil and Filter - Change ............................. 82
Starting Motor - Inspect ........................................ 98
Turbocharger - Inspect .......................................... 98
Water Pump - Inspect ......................................... 100
Every 2000 Service Hours or 1 Year

Alternator - Inspect ............................................... 65
Every Year
Every 3000 Service Hours or 3 Years

Aftercooler Core - Clean/Test ............................... 65
Coolant Temperature Regulator - Replace ........... 72
Crankshaft Vibration Damper - Inspect ................. 74
62
Maintenance Section
Driven Equipment - Check ....................................

Electronic Unit Injector - Check/Replace ..............
Engine - Clean ......................................................
Engine Mounts - Inspect .......................................
Engine Protective Devices - Check ......................
Engine Valve Lash - Check ...................................
Engine Valve Rotators - Inspect ...........................
Fan Drive Bearing - Lubricate ...............................
Speed Sensor - Clean/Inspect ..............................
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75
75
76
81
84
85
85
86
98
Every 760,000 L (200,770 US gal) of Fuel

Fan Drive Bearing - Replace ................................ 86
Overhaul Considerations ...................................... 94
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Maintenance Section
i04760784

(Engines Which Have Shallow
Oil Pans)
SMCS Code: 1000; 4450; 7500
Ensure that all safety information, warnings,
and instructions are read and understood before
any operation or any maintenance procedures
are performed. The user is responsible for the
performance of all maintenance including the
following procedures: all adjustments, the use of
proper lubricants, fluids, filters, and the installation
of new components due to normal wear and aging .
The performance of this product may be diminished if
proper maintenance intervals and procedures are not
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures
are not followed.
Note: Use whichever of the following that occurs
first in order to determine the maintenance intervals:
fuel consumption, service hours, and calendar time
. Before each consecutive interval is performed, all
maintenance from the previous intervals must be
performed.
Refill Capacities in order to determine the type of
oil pan with which your Cat C18 Industrial Engine is
equipped.
Products that operate in severe operating conditions
may require more frequent maintenance. Refer to
this Operation and Maintenance Manual, Severe
Service Application to determine if the engine is
operating in a severe service application.
65
66
68
70
76
82
85
86
Daily
Coolant Level - Check ..........................................
Engine Air Cleaner Service Indicator - Inspect .....
Engine Air Precleaner - Check/Clean ...................
Engine Oil Level - Check ......................................
Fuel System Primary Filter/Water Separator Drain ...................................................................
Fuel Tank Water and Sediment - Drain .................
Every Week
Jacket Water Heater - Check ................................ 94
Initial 250 Service Hours (or at first oil

change)
Engine Valve Lash - Check ................................... 85
Engine Valve Rotators - Inspect ........................... 85

Battery Electrolyte Level - Check ..........................
Coolant Sample (Level 1) - Obtain .......................
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .................................................
Engine Crankcase Breather - Clean .....................
Engine Oil Sample - Obtain ..................................
Fuel System Primary Filter (Water Separator)
Element - Replace ..............................................
Fuel System Secondary Filter - Replace ..............
Grounding Stud - Inspect/Clean/Tighten ...............
Hoses and Clamps - Inspect/Replace ..................
Radiator - Clean ....................................................
66
71
73
80
82
82
88
90
91
92
97
Initial 500 Hours (for New Systems, Refilled

Systems, and Converted Systems)

Belts - Inspect/Adjust/Replace .............................. 67
Starting Motor - Inspect ........................................ 98
Turbocharger - Inspect .......................................... 98
Water Pump - Inspect ......................................... 100
Every 2000 Service Hours or 1 Year
When Required
Battery - Replace ..................................................
Battery or Battery Cable - Disconnect ..................
Coolant - Change ..................................................
Coolant Extender (ELC) - Add ..............................
Engine Air Cleaner Element (Dual Element) Inspect/Clean/Replace ........................................
Engine Storage Procedure - Check ......................
Fuel System - Prime .............................................
Power Take-Off Clutch - Check ............................ 97

Walk-Around Inspection ........................................ 99
70
79
80
81
88
90
Alternator - Inspect ............................................... 65
Every Year
Every 3000 Service Hours or 3 Years

Aftercooler Core - Clean/Test ...............................
Coolant Temperature Regulator - Replace ...........
Crankshaft Vibration Damper - Inspect .................
Driven Equipment - Check ....................................
Electronic Unit Injector - Check/Replace ..............
Engine - Clean ......................................................
Engine Mounts - Inspect .......................................
Engine Protective Devices - Check ......................
Engine Valve Lash - Check ...................................
Engine Valve Rotators - Inspect ...........................
Fan Drive Bearing - Lubricate ...............................
Speed Sensor - Clean/Inspect ..............................
65
72
74
75
75
76
81
84
85
85
86
98
64
Maintenance Section
Every 760,000 L (200,770 US gal) of Fuel

Fan Drive Bearing - Replace ................................ 86
Overhaul Considerations ...................................... 94
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65
Maintenance Section
Aftercooler Core - Clean/Test
i02783957
Aftercooler Core - Clean/Test

(Air-To-Air Aftercooler (If
Equipped))
SMCS Code: 1064-070; 1064-081
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the aftercooler for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the aftercooler, if necessary.
For air-to-air aftercoolers, use the same methods that
are used for cleaning radiators.
Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
of the fan's air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. The maximum
air pressure for cleaning purposes must be below
205 kPa (30 psi) when the air nozzle is deadheaded.
Slowly move the air nozzle in a direction that is
parallel with the tubes. This will remove debris that is
between the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Note: If parts of the aftercooler system are repaired

or replaced, a leak test is highly recommended.
Inspect these items for good condition: welds,
mounting brackets, air lines, connections, clamps,
and seals. Make repairs, if necessary.
For more detailed information on cleaning and
inspection, see Special Publication, SEBD0518,
Know Your Cooling System.
i02676048
Alternator - Inspect
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection
of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or
proper performance of the electrical system. Make
repairs, as required.
Check the alternator and the battery charger for
proper operation. If the batteries are properly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time
or if the engine is run for short periods, the batteries
may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
i01878164
Battery - Replace
SMCS Code: 1401-510
Use a degreaser and steam for removal of oil and

grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
Batteries give off combustible gases which can

explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death.
After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
Ensure proper ventilation for batteries that are in

an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
Inspect the fins for damage. Bent fins may be opened

with a comb.
66
Maintenance Section
Battery Electrolyte Level - Check
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The battery cables or the batteries should not be

removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.
All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
Removing the battery cables or the batteries with

the cover in place may cause a battery explosion
resulting in personal injury.
1. Remove the filler caps. Maintain the electrolyte

level to the FULL mark on the battery.
1. Switch the engine to the OFF position. Remove

all electrical loads.
2. Turn off any battery chargers. Disconnect any
battery chargers.
3. The NEGATIVE - cable connects the NEGATIVE
- battery terminal to the NEGATIVE - terminal
on the starter motor. Disconnect the cable from
the NEGATIVE - battery terminal.
4. The POSITIVE + cable connects the POSITIVE
+ battery terminal to the POSITIVE + terminal
on the starting motor. Disconnect the cable from
the POSITIVE + battery terminal.
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that
the engine start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE + battery terminal.
8. Connect the cable from the NEGATIVE - terminal
on the starter motor to the NEGATIVE - battery
terminal.
i02601752
Battery Electrolyte Level Check

SMCS Code: 1401-535-FLV
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing.
If the addition of water is necessary, use distilled

water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
3. Keep the batteries clean.
Clean the battery case with one of the following
cleaning solutions:
A mixture of 0.1 kg (0.2 lb) of baking soda and

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

(1 qt) of clean water
Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
i01492654
Battery or Battery Cable Disconnect

SMCS Code: 1401; 1402-029
The battery cables or the batteries should not be

removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
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67
Maintenance Section
Belts - Inspect/Adjust/Replace
1. Turn the start switch to the OFF position. Turn the

ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
Alternator Belt Adjustment
2. Disconnect the negative battery terminal at the

battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
two batteries must be disconnected.
3. Tape the leads in order to help prevent accidental
starting.
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.
i02042962
Illustration 34
g00788814
Belts - Inspect/Adjust/Replace
1. Remove the belt guard.
SMCS Code: 1357-025; 1357-040; 1357-510
2. Loosen mounting bolts (1) and adjusting bolt (2).
Inspection
3. Move the assembly in order to increase or

decrease the belt tension.
Inspect the alternator belt and the fan drive belts for
wear and for cracking. Replace the belts if the belts
are not in good condition.
4. Tighten adjusting bolt (2). Tighten mounting bolts

(1).
Check the belt tension according to the information in

the Service Manual, Specifications.
Slippage of loose belts can reduce the efficiency
of the driven components. Vibration of loose belts
can cause unnecessary wear on the following
components:
5. Reinstall the belt guard.

If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation
at the rated rpm.
Adjustment of the Fan Drive Belt
Belts
1. Remove the belt guard.
Pulleys
2. Loosen the mounting bolt for the pulley.
Bearings
3. Loosen the adjusting nut for the pulley.
If the belts are too tight, unnecessary stress is placed

on the components. This reduces the service life of
the components.
4. Move the pulley in order to adjust the belt tension.
Replacement
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.
5. Tighten the adjusting nut.

6. Tighten the mounting bolt.
7. Reinstall the belt guard.
If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation
at the rated rpm.
68
Maintenance Section
Coolant - Change
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i04538352
Coolant - Change
SMCS Code: 1350-044; 1352; 1395-044; 1395
Fluid Recommendations for the correct intervals
for changing the coolant.
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
The engine overheats frequently.

Foaming is observed.
The oil has entered the cooling system and the
coolant is contaminated.
The fuel has entered the cooling system and the

coolant is contaminated.
Drain the Cooling System
3. Open the cooling system drain valve (if equipped).

If the cooling system is not equipped with a drain
valve, remove one of the drain plugs.
Note: If equipped, be sure to drain the heater and
any related supply and return lines.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Cat dealer or
consult Cat Dealer Service Tool Group:
Inside USA: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
International: 1-309-578-7372
Flush
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Cat Dealer
Service Tool Catalog or refer to Special Publication,
PECJ0003, Cat Shop Supplies and Tools Catalog for
tools and supplies suitable to collect and contain fluids
on Cat products.
Dispose of all fluids according to local regulations and
mandates.
1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the
cooling system is drained.
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
Systems Filled with Cat ELC, Cat ELI, or a

Conventional Coolant that Meets the Cat
EC-1 Requirements and the Standards
of ASTM D6210
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to
the Specifications Manual, SENR3130, Torque
Specifications for more information on the proper
torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with clean water. Install the
cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 C (120 to 150 F).
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Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve
(if equipped). Clean the drain plugs. Install the
drain plugs. Refer to the Specifications Manual,
SENR3130, Torque Specifications for more
information on the proper torques.
Systems Filled with Cat DEAC,

Conventional Coolant which does not
Meet the Cat EC-1 Requirements, or
Supplemental Coolant Additive (SCA)
and Water
3. Flush the cooling system with clean water in order
to remove any debris.
4. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to
torques.
69
Maintenance Section
Coolant - Change
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal components.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear water. Continue to flush the system until all signs of the
cleaning agent are gone.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. If equipped, be sure to
flush the heater and any related supply and return
lines. Close the drain valve (if equipped). Clean
the drain plugs. Install the drain plugs. Refer to
torques.
Fill the Cooling System
NOTICE
NOTICE
5. Fill the cooling system with a mixture of clean

water and Cat Fast Acting Cooling System
Cleaner.
1. Fill the cooling system. Refer to this Operation and

Maintenance Manual, Fluid Recommendations
for more information on cooling system
specifications Refer to this Operation and
Maintenance Manual, Refill Capacities for
information about the capacity of the cooling
system. Do not install the cooling system filler cap.
6. Choose 1 of the following options.
Add 0.5 L (1 pint) of cleaner per 15 L (4 US gal)

of the cooling system capacity.
For cooling systems with heavy deposits or
plugging, add 0.5 L (1 pint) of cleaner per

3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity.
7. Install the cooling system filler cap.

8. Start and run the engine at low idle for a minimum
of 30 minutes. For cooling systems with heavy
deposits or plugging, run the engine for 90
minutes. The coolant temperature should be at
least 82 C (180 F).
2. Start and run the engine at low idle. Increase the

engine rpm to high idle. Run the engine at high
idle for 1 minute in order to purge the air from the
cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
70
Maintenance Section
Coolant Extender (ELC) - Add
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4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap.
Only install the used filler cap if the gasket is not
damaged. Use a 9S-8140 Pressurizing Pump to
pressure test a reinstalled cooling system filler
cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i04445671
Coolant Extender (ELC) - Add

SMCS Code: 1352-544-NL
Note: Refer to this Operation and Maintenance
Manual, Fluid Recommendations (Cooling System)
for the maintenance interval for the addition of the
coolant extender.
Cat ELC (Extended Life Coolant) and Cat ELI
(Extended Life Inhibitor) do not require the frequent
additions of any supplemental cooling additives. The
Cat ELC Extender will only be added one time.
Note: Do not use conventional supplemental coolant
additive (SCA) with Cat ELC or with Cat ELI.
Check the cooling system only when the engine is
stopped and cool.
NOTICE
on Cat products.
mandates.
1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling
system filler cap.
2. If necessary, drain enough coolant from the
cooling system in order to add the Cat ELC
Extender.
3. Add Cat ELC Extender according to the
requirements for the cooling system capacity.
Refill Capacities for the coolant capacity.
4. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
For further information, refer to this Operation and
Maintenance Interval, , Fluid Recommendations.
Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
i04156593
Coolant Level - Check

SMCS Code: 1395-082
Check the coolant level when the engine is stopped
and cool.
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Maintenance Section
Coolant Sample (Level 1) - Obtain
i04333559
Coolant Sample (Level 1) Obtain

SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Illustration 35
g00285520
Cooling system filler cap
1. Remove the cooling system filler cap slowly in
order to relieve pressure.
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
Testing the engine coolant is important to ensure

that the engine is protected from internal cavitation
and corrosion. The analysis also tests the ability of
the coolant to protect the engine from boiling and
freezing. SOS Systems Coolant Analysis can be
done at your Cat dealer. Cat SOS coolant analysis is
the best way to monitor the condition of your coolant
and your cooling system. SOS coolant analysis is a
program that is based on periodic samples.
Note: Obtaining a Coolant Sample (Level 1) is
optional if the cooling system is filled with one of
the following coolants: Cat ELC (Extended Life
Coolant)., Cat ELI (Extended Life Inhibitor), and
Conventional Heavy-Duty Coolant.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any of the following
coolants: Cat DEAC, Cat SCA, and Conventional
Heavy-Duty Coolants.
For additional information about coolant analysis
and about other coolants, see this Operation and
Maintenance Manual, Fluid Recommendations or
consult your Cat dealer.
Sampling Conditions
If the engine is equipped with a sampling port, the
engine should be running at operating temperature
when the sample is obtained.
If the engine is not equipped with a sampling port, the
coolant should be warm.
Use the following guidelines for proper sampling of
the coolant:
Complete the information on the label for the

sampling bottle before you begin to take the
samples.
Illustration 36
g00103639
Typical filler cap gaskets
3. Clean the cooling system filler cap and check the

condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.
4. Inspect the cooling system for leaks.
Keep the unused sampling bottles stored in plastic

bags.
Obtain coolant samples directly from the coolant

sample port. You should not obtain the samples
from any other location.
Keep the lids on empty sampling bottles until you

are ready to collect the sample.
72
Maintenance Section
Coolant Sample (Level 2) - Obtain
SEBU7899-05
Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
contamination.
Never collect samples from expansion bottles.

Never collect samples from the drain for a system.
Coolant Sample (Level 2) Obtain

SMCS Code: 1350-008; 1395-008; 1395-554; 7542
An SOS Coolant Analysis (Level 2) is a
comprehensive chemical evaluation of the coolant.
This analysis is also a check of the overall condition
of the cooling system. The SOS Coolant Analysis
(Level 2) has the following features:
Timing of the Sampling

Table 19
Recommended Interval
Type of Coolant
Level 1
Level 2
Cat DEAC
Cat SCA
Conventional
Heavy-Duty
Coolants
Every 250 hours
Yearly(1)
Cat ELC
Cat ELI
Commercial
EC-1 Coolants
Optional(1)
(1)
i04638756
Full coolant analysis (Level 1)

Identification of metal corrosion and contaminants
Identification of buildup of the impurities that cause
corrosion and scaling
Yearly(1)
The Level 2 Coolant Analysis should be performed sooner if a

problem is suspected or identified.
Note: Check the SCA (Supplemental Coolant

Additive) of the conventional coolant at every oil
change or at every 250 hours. Perform this check at
the interval that occurs first.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order to
receive the full effect of SOS analysis, establish
a consistent trend of data. In order to establish
a pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your Cat
dealer.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
Submit the sample for Level 1 analysis.
Note: Level 1 results may indicate a need for Level
2 Analysis.
Determination of the possibility of electrolysis

within the cooling system of the engine
The results are reported and appropriate

recommendations are made.
Obtaining the Sample

Refer to Operation and Maintenance Manual,
Coolant Sample (Level 1) - Obtain for the guidelines
for proper sampling of the coolant.
Submit the sample for Level 2 analysis.
For further information, refer to this Operation and
Maintenance Manual, Fluid Recommendations.
i04240223
Coolant Temperature
Regulator - Replace
SMCS Code: 1355-510
Replace the water temperature regulator before the
water temperature regulator fails. Replacing the
water temperature regulator reduces the chances for
unscheduled downtime.
A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine.
SEBU7899-05
73
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
A water temperature regulator that fails in the open

position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water
temperature regulator installed.
If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature regulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or
cylinder head surface.
NOTICE
on Cat products.
mandates.
Note: If replacing only the water temperature
regulator, only drain the coolant to a level that is
below the water temperature regulator housing.
Refer to two articles in the Disassembly and
Assembly Manual, Water Temperature Regulator Remove and Water Temperature Regulator - Install
for the replacement procedure or consult your Cat
dealer.
i04269112
Cooling System Supplemental

Coolant Additive (SCA) Test/Add
(Systems Which are Filled with
Conventional Coolant)
SMCS Code: 1352-045; 1395-081
This maintenance procedure is required for
conventional coolants such as DEAC.Do not
perform this maintenance for cooling systems
that are filled with Cat Extended Life Coolant (Cat
ELC) or Cat Extended Life Inhibitor (Cat ELI).
Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact with
the skin and eyes. Do not drink cooling system
coolant additive.
NOTICE
Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger, overheating, and/or accelerated wear of the water
pump seal.
Do not exceed the recommended amount of supplemental coolant additive concentration.
NOTICE
Do NOT mix brands or types of SCA. Do NOT mix
SCAs and extenders.
Failure to follow the recommendations can result in
shortened cooling system component life.
74
Maintenance Section
Crankshaft Vibration Damper - Inspect
NOTICE
Use Only Approved SCAs. Conventional coolants
require the maintenance addition of SCA throughout
their expected life. Do NOT use an SCA with a coolant
unless specifically approved by the coolant supplier
for use with their coolant. It is the responsibility of the
coolant manufacturer to ensure compatibility and acceptable performance.
Failure to follow the recommendations can result in
shortened cooling system component life.
SEBU7899-05
5. Clean the cooling system filler cap. Install the

For further information, refer to Special Publication,
SEBU6251, Cat Commercial Diesel Engine Fluids
Recommendations.
i02933380
Crankshaft Vibration Damper

- Inspect
SMCS Code: 1205-040
NOTICE
Damage to the crankshaft vibration damper or failure

of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to
the crankshaft and to other engine components. A
damper that is damaged can cause excessive gear
train noise at variable points in the speed range.
Refer to Special Publication, NENG2500, Cat Dealer Service Tool Catalog and to Special Publication,
GECJ0003, Cat Shop Supplies and Tools for tools
and supplies suitable to collect and contain fluids on
Cat products.
The damper is mounted to the crankshaft which is

located behind the belt guard on the front of the
engine.
Dispose of all fluids according to applicable regulations and mandates.
The visconic damper has a weight that is located

inside a fluid filled case. The weight moves in the
case in order to limit torsional vibration.
Note: Caterpillar recommends that an SOS Coolant

Analysis (Level 1) be performed to check the
concentration of SCA.
Maintain the Proper Concentration

of SCA in the Coolant
1. Remove the cooling system filler cap slowly.
Visconic Damper
Inspect the damper for evidence of fluid leaks. If

a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has
the following characteristics: transparent, viscous,
smooth, and adhering.
If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace the crankshaft
seals.
Inspect the damper and repair or replace the damper
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 broken
crankshaft.
2. Test the concentration of the SCA with a

286-2578 Nitrite Test Strip or review the results
of the SOS Coolant Analysis (Level 1).
Analysis of the oil has revealed that the front main
3. If necessary, drain some coolant in order to allow

space for the addition of the SCA.
There is a large amount of gear train wear that is
4. Add the amount of SCA required to maintain a

concentration of 3 percent to 6 percent SCA in
the coolant.
bearing is badly worn.
not caused by a lack of oil.
SEBU7899-05
75
Maintenance Section
Driven Equipment - Check
Refer to the Disassembly and Assembly Manual,

Vibration Damper and Pulley - Remove and Install
or consult your Caterpillar dealer for information
about damper replacement.
i00934883
Driven Equipment - Check
i04230004
Electronic Unit Injector Check/Replace

SMCS Code: 1251-510; 1251-535; 1290-510;
1290-535
SMCS Code: 3279-535
Check the Alignment

To minimize bearing problems and vibration of the
engine crankshaft and the driven equipment, the
alignment between the engine and driven equipment
must be properly maintained.
Check the alignment according to the instructions
that are provided by the following manufacturers:
Caterpillar
OEM of the drive coupling
OEM of the driven equipment
Torque all of the fasteners to the proper specifications.
Inspect the Drive Coupling

Inspect the drive coupling according to the
instructions that are provided by the OEM of the
coupling. For the following service information, see
the literature that is provided by the OEM of the
coupling:
Lubrication requirements
Specifications for the end play
Reusability Guidelines
Replacement instructions
Inspect the Rear Gear Train

Inspect the crankshaft gear. If excessive wear is
found, replace the crankshaft gear and the large
cluster idler.
If any gear causes damage to other gears through
failure, replace the entire rear gear train.
For the correct parts, see the Parts Manual for the
engine. For removal and replacement instructions,
see the Service Manual, Disassembly and
Assembly module. Consult your Caterpillar dealer
for assistance.
Be sure the engine cannot be started while this

maintenance is being performed. To prevent possible injury, do not use the starting motor to turn
the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before measuring/adjusting the unit injectors.
The electronic unit injectors use high voltage. Disconnect the unit injector enable circuit connector
in order to prevent personal injury. Do not come
in contact with the injector terminals while the engine is running.
The operation of a Cat Engine with an electronic unit
injector which is improperly adjusted may reduce
engine efficiency. This reduced efficiency may result
in excessive fuel usage and/or shortened engine
component life.
Note: Only qualified service personnel should
perform this maintenance.
Refer to the Systems Operation, Testing and
Adjusting, Electronic Unit Injector - Test for the test
procedure. Refer to Systems Operation, Testing and
Adjusting, Electronic Unit Injector - Adjust for the
adjustment procedure.
Refer to the Disassembly and Assembly Manual for
the procedure for the removal and replacement of
the injector.
NOTICE
The camshafts must be correctly timed with the crankshaft before an adjustment of the lash for the fuel injector is made. The timing pins must be removed from
the camshafts before the crankshaft is turned or damage to the cylinder block will be the result.
76
Maintenance Section
Engine - Clean
SEBU7899-05
i01646701
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Engine - Clean
SMCS Code: 1000-070
Servicing the Air Cleaner Elements

Personal injury or death can result from high voltage.
Moisture can create paths of electrical conductivity.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls DO
NOT OPERATE.
NOTICE
Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
Easy detection of fluid leaks

Maximum heat transfer characteristics
Ease of maintenance
Note: Caution must be used in order to prevent
electrical components from being damaged by
excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
starter, and the ECM.
i04322011
Engine Air Cleaner

Element (Dual Element) Inspect/Clean/Replace
SMCS Code: 1051; 1054-040; 1054-070; 1054-510
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
If the air cleaner element becomes plugged, the air

can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
engine wear. Your Cat dealer has the proper air
cleaner elements for your application. Consult your
Cat dealer for the correct air cleaner element.
Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt

and debris, as needed.
Operating conditions (dust, dirt, and debris) may

require more frequent service of the air cleaner
element.
The air cleaner element may be cleaned up to
six times if the element is properly cleaned and

inspected.
The air cleaner element should be replaced at least

one time per year. This replacement should be
performed regardless of the number of cleanings.
Replace the dirty paper air cleaner elements with

clean air cleaner elements. Before installation,
thoroughly check the air cleaner elements for tears
and/or holes in the filter material. Inspect the gasket
or the seal of the air cleaner element for damage.
Maintain a supply of suitable air cleaner elements
for replacement purposes.
Dual Element Air Cleaners

The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner
element. The primary air cleaner element can be
used up to six times if the element is properly cleaned
and inspected. The primary air cleaner element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.
The secondary air cleaner element is not serviceable
or washable. The secondary air cleaner element
should be removed and discarded for every three
cleanings of the primary air cleaner element. When
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more
frequent replacement.
SEBU7899-05
77
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
Cleaning the Primary Air Cleaner

Elements
NOTICE
Caterpillar recommends certified air filter cleaning services that are available at Cat dealers. The Cat cleaning process uses proven procedures to assure consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to
clean the filter element:
Illustration 37
(1)
(2)
(3)
(4)
g00736431
Cover
Primary air cleaner element
Secondary air cleaner element
Turbocharger air inlet
1. Remove the cover. Remove the primary air

cleaner element.
2. The secondary air cleaner element should be
removed and discarded for every three cleanings
of the primary air cleaner element.
Note: Refer to Cleaning the Primary Air Cleaner
Elements.
3. Cover the turbocharger air inlet with tape in order
to keep out dirt.
4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
5. Remove the tape for the turbocharger air inlet.
Install the secondary air cleaner element. Install a
primary air cleaner element that is new or cleaned.
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.
Do not tap or strike the filter element in order to remove dust.

Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
The primary air cleaner element can be used up
to six times if the element is properly cleaned and
inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
The primary air cleaner element should be replaced
at least one time per year. This replacement should
be performed regardless of the number of cleanings.
Use clean primary air cleaner elements while dirty
elements are being cleaned.
NOTICE
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the primary air cleaner elements
before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
There are two common methods that are used to
clean primary air cleaner elements:
Pressurized air
Vacuum cleaning
78
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
SEBU7899-05
Inspecting the Primary Air Cleaner

Elements
Pressurized Air

Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
Illustration 39
g00281693
Inspect the clean, dry primary air cleaner element.

Use a 60W blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears
and/or holes. Inspect the primary air cleaner element
for light that may show through the filter material. If
necessary, compare the primary air cleaner element
to a new primary air cleaner element that has the
same part number.
Illustration 38
g00281692
Note: When the primary air cleaner elements are

cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).
To help prevent damage to the paper pleats, aim the
hose so that the air flows inside the element along
the length of the filter. Do not aim the stream of air
directly at the primary air cleaner element. Dirt could
be forced further into the pleats.
Do not use a primary air cleaner element that has

any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
pleats, gaskets, or seals. Discard damaged primary
air cleaner elements.
Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes inspection
will not be used, the primary air cleaner element can
be stored for future use.
Note: Refer to Inspecting the Primary Air Cleaner

Elements.
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not remove
deposits of carbon and oil.
Note: Refer to Inspecting the Primary Air Cleaner
Elements.
Illustration 40
g00281694
SEBU7899-05
79
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air cleaner element into a box
for storage. For identification, mark the outside of
the box and mark the primary air cleaner element.
Include the following information:
Date of cleaning
Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner element
should be replaced when one of the following
conditions occur:
The yellow diaphragm enters the red zone.

The red piston locks in the visible position.
Test the Service Indicator

Service indicators are important instruments.
Number of cleanings
Check for ease of resetting. The service indicator

should reset in less than three pushes.
Store the box in a dry location.
Check the movement of the yellow core when the

i01900118
Engine Air Cleaner Service

Indicator - Inspect
(If Equipped)
SMCS Code: 7452-040
Some engines may be equipped with a different
service indicator.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner housing or in a remote location.
Illustration 41
Typical service indicator
g00103777
engine is accelerated to the engine rated speed.

The yellow core should latch approximately at the
greatest vacuum that is attained.
If the service indicator does not reset easily, or if the

yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be plugged.
The service indicator may need to be replaced
frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and
whenever major engine components are replaced.
Note: When a new service indicator is installed,
excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque
of 2 Nm (18 lb in).
80
Maintenance Section
Engine Air Precleaner - Check/Clean
SEBU7899-05
i02927289
Engine Air Precleaner Check/Clean

SMCS Code: 1055-070; 1055-535
Illustration 43
g01456410
View of the left side of a C18 Industrial Engine that is equipped

with two engine crankcase breathers
(1) Hose Clamp
(2) Hose
(3) Valve Cover
Illustration 42
g01453058
Typical engine air precleaner

(1) Wing nut
(2) Cover
(3) Body
Remove wing nut (1) and cover (2). Check for an

accumulation of dirt and debris in body (3). Clean the
body, if necessary.
After cleaning the precleaner, install cover (2) and
wing nut (1).
Note: When the engine is operated in dusty
applications, more frequent cleaning is required.
i03435665
Engine Crankcase Breather Clean
Illustration 44
g01786116
View of the left side of a C18 Industrial Engine that is equipped

with one engine crankcase breather
(1) Hose Clamp
(2) Hose
(3) Valve Cover
SMCS Code: 1317-070
1. Loosen the hose clamp and remove the hose from

the valve cover.
NOTICE
Perform this maintenance with the engine stopped.
2. Remove the valve cover. Refer to Disassembly

and Assembly, Valve Mechanism Cover Remove and Install.
If the crankcase breather is not maintained on a

regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.
Your engine may have one or two crankcase
breathers.
SEBU7899-05
Illustration 45
81
Maintenance Section
Engine Mounts - Inspect
g01456434
3. Wash the breather in solvent that is clean and

nonflammable. Allow the breather to dry before
installation.
Illustration 46
g01414582
Typical installation of the oil level gauge

(1) Oil filler cap
(2) Oil level gauge
4. Install the valve cover. Refer to Disassembly and

Assembly, Valve Mechanism Cover - Remove
and Install.
5. Install the hose on the valve cover. Install the hose
clamp.
Illustration 47
i02139969
Engine Mounts - Inspect
g00110310
Partial view of the oil level gauge

(Y) ADD mark
(X) FULL mark
SMCS Code: 1152-040; 1152

Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused
by the following conditions:
Improper mounting of the engine

Deterioration of the engine mounts
Any engine mount that shows deterioration should
be replaced. Refer to the Specifications Manual,
SENR3130, Torque Specifications. Refer to your
Caterpillar dealer for more information.
i04339070
Engine Oil Level - Check

SMCS Code: 1348-535-FLV
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
Perform this maintenance with the engine stopped.
NOTICE
Engine damage can occur if the crankcase is filled
above the FULL mark on the oil level gauge (dipstick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is developed and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: reduction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. Deposits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
If the oil level is above the FULL mark on the oil level
gauge, drain some of the oil immediately.
82
Maintenance Section
Engine Oil Sample - Obtain
SEBU7899-05
1. Remove the oil filler cap and check the oil level.
Maintain the oil level between the ADD mark (Y)
and the FULL mark (X) on the oil level gauge (1).
Do not fill the crankcase above FULL mark (X).
2. In order to choose the correct type of oil for this
engine, refer to this Operation and Maintenance
Manual, Fluid Recommendations.
3. Clean the oil filler cap. Install the oil filler cap.
4. Record the amount of oil that is added. For the
next oil sample and analysis, include the total
amount of oil that has been added since the
previous sample in order to provide the most
accurate oil analysis.
i04237495
Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM
In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil
analysis at regularly scheduled intervals. SOS oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
Obtain the Sample and the Analysis

contact the skin.
Caterpillar recommends using the sampling valve

in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
For instructions, see Special Publication, PEGJ0047,
How To Take A Good SOS Oil Sample. Consult
your Cat dealer for complete information and
assistance in establishing an SOS program for your
engine.
i04268709
Engine Oil and Filter - Change
Before you take the oil sample, complete the Label,

PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
SMCS Code: 1318-510
Engine model

contact the skin.
Service hours on the engine

The number of hours that have accumulated since
To ensure that the sample is representative of the oil

in the crankcase, obtain a warm, mixed oil sample.
Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed
with the draining cold oil. Drain the crankcase with
the engine stopped. Drain the crankcase with the
oil warm. This draining method allows the waste
particles that are suspended in the oil to be drained
properly.
To avoid contamination of the oil samples, the tools

and the supplies that are used for obtaining oil
samples must be clean.
Failure to follow this recommended procedure will

cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
the last oil change
The amount of oil that has been added since the

last oil change
SEBU7899-05
83
Maintenance Section
Engine Oil and Filter - Change
Interval for Engine Oil and Engine

Oil Filter Change
Note: The intervals stated in table 20 are only valid
when preferred lubricants are used. Using fluids
other than the preferred fluids causes the engine to
operate in a severe service application. Refer to this
Operation and Maintenance Manual, Severe Service
Application for information about the effect of using
fluids which are not preferred on the maintenance
intervals.
Refill Capacities before this procedure is started in
order to determine the following:
The type of oil pan

The refill capacity for engine oil
If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil

to drain. If the engine is equipped with a shallow
sump, remove the bottom oil drain plugs from both
ends of the oil pan.
After the oil has drained, the oil drain plugs should
be cleaned and installed.
Replace the Oil Filter

NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
Table 20
Intervals for Changing the Engine Oil and

Engine Oil Filter(1)
(1)
Shallow sump
Every 14200 L
(3750 US gal) or 250
service hours or 1 yr
Deep sump
Every 28400 L
(7500 US gal) or 500
service hours or 1 yr
Choose the interval that occurs first.
Drain the Engine Oil

NOTICE
on Cat products.
mandates.
After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
If the engine is equipped with a drain valve, turn the

drain valve knob counterclockwise in order to drain
the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.
1. Remove the oil filter with a 1U-8760 Chain

Wrench.
2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount
of metal debris in the oil filter may indicate early
wear or a pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts, or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in
the oil filter. Consult your Cat dealer in order to
arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
84
Maintenance Section
Engine Protective Devices - Check
SEBU7899-05
3. Start the engine and run the engine at LOW

IDLE for 2 minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
4. Stop the engine and allow the oil to drain back to
the sump for a minimum of 10 minutes.
5. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the ADD
and FULL marks on the oil level gauge.
Illustration 48
g00103713
Typical filter mounting base and filter gasket
3. Clean the sealing surface of the filter mounting

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

1. Remove the oil filler cap.
2. Refer to the Operation and Maintenance Manual,
Refill Capacities for the amount of oil required to
fill the crankcase. Fill the crankcase and replace
the oil filler cap.
NOTICE
If equipped with an auxiliary oil filter system or a remote oil filter system, follow the OEM or filter manufacturer's recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
NOTICE
To prevent crankshaft bearing damage, crank the engine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
i02861779
Engine Protective Devices Check

SMCS Code: 7400-535
Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
immediately.
Calibration Check
NOTICE
During testing, abnormal operating conditions must be
simulated.
The tests must be performed correctly in order to prevent possible damage to the engine.
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices. To prevent damage to the
engine, only authorized service personnel or your
Caterpillar dealer should perform the tests.
Consult your Caterpillar dealer or refer to the Service
Manual for more information.
SEBU7899-05
85
Maintenance Section
Engine Storage Procedure - Check
i01458399
i04242309
Engine Storage Procedure Check
Engine Valve Lash - Check
SMCS Code: 1000-535
The initial valve lash adjustment on new engines,

rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of
the valve train components and to the seating of the
valve train components.
The oil change interval may be extended to 12

months for a vehicle that is operated seasonally
and placed in storage for the remainder of the year
by using the required storage procedures and the
required start-up procedures. This extension is
permitted if the following categories for oil change
intervals in the Operation and Maintenance Manual,
Maintenance Interval Schedule have not been
reached:
SMCS Code: 1105-535
The maintenance is recommended by Caterpillar as

part of a lubrication and preventive maintenance
schedule to help provide maximum engine life.
Fuel consumption
Note: Only qualified service personnel should

perform this maintenance. For procedures on
adjusting the valve lash and adjusting the valve
bridge, see System Systems Operation/Testing and
Adjusting, Engine Valve Lash - Inspect/Adjust.
Consult your Cat dealer for assistance.
If an engine is out of operation and if use of the

engine is not planned, special precautions should
be made. If the engine will be stored for more than
three months, a complete protection procedure is
recommended. For more detailed information on
engine storage, see Special Instruction, SEHS9031,
Storage Procedure For Caterpillar Products.
Ensure that the engine can not be started while

this maintenance is being performed. To help prevent possible injury, do not use the starting motor
to turn the flywheel.
Mileage
Operating hours
If the engine will not be started for several weeks, the

lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface. Rust on the cylinder liner surface will
cause increased engine wear and a reduction in
engine service life. Caterpillar recommends the
use of volatile corrosion inhibitor (VCI) oil in order
to prevent internal engine damage due to moisture
during storage. These inhibitors in the VCI oil act by
evaporating inside the engine. The inhibitors then
condense over the inside surfaces of the engine. The
evaporation process and the condensing process
offers full protection to surfaces that cannot be
reached with preservatives. 0.9 L (1.0 qt) of 4C-6792
VCI oil will treat 28.4 L (30.0 qt) of engine oil. This
will give a 3 percent concentration of VCI oil. The
engine must be completely sealed when the engine
is stored in order for the VCI oil to function properly.
The VCI oil is easily cleaned from the engine when
you remove the engine from storage. The volatile
vapors are removed by simply running the engine
to operating temperature. A mineral oil base is left
behind after the volatile vapors are removed.
Hot engine components can cause burns. Allow

additional time for the engine to cool before measuring/adjusting valve lash clearance.
i01597115
Engine Valve Rotators - Inspect

SMCS Code: 1109-040
When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn, to help prevent being burned by
hot oil or spray.
Engine valve rotators rotate the valves when the
engine runs. This helps to prevent deposits from
building up on the valves and the valve seats.
Perform the following steps after the engine valve
lash is set, but before the valve covers are installed:
1. Start the engine according to Operation and
Maintenance Manual, Engine Starting (Operation
Section) for the procedure.
86
Maintenance Section
Fan Drive Bearing - Lubricate
SEBU7899-05
2. Operate the engine at low idle.
i02053753
3. Observe the top surface of each valve rotator. The

valve rotators should turn slightly when the valves
close.
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
If a valve fails to rotate, consult your Caterpillar
dealer.
i02784507
Fan Drive Bearing - Lubricate

SMCS Code: 1359-086-BD
Some of the fan drives have grease fittings and some
of the fan drives do not have grease fittings. If there is
no grease fitting, periodic lubrication is not required.
The fan drive requires grease only if the fan drive
is equipped with a zerk.
Fan Drive Bearing - Replace

SMCS Code: 1359-510-BD
1. Remove Bearings. Refer to Disassembly and
Assembly, Bearing Removal.
2. Measure the bearing housings for roundness and
for proper size.
3. Replace the bearings.
i02075183
Fuel System - Prime

SMCS Code: 1250-548; 1258-548
The Secondary Fuel Filter Has

Been Replaced
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
Illustration 49
g00746166
Typical location of the grease fitting (if equipped) that is for the fan
drive bearing
The pulley is shown with the belt guards that have been removed.
Lubricate the grease fitting that is on the fan drive

bearing with High Speed Ball Bearing Grease or the
equivalent.
Inspect the fan drive pulley assembly for wear or for
damage. If the shaft is loose, an inspection of the
internal components should be performed. Refer to
the Systems Operation Testing and Adjusting Manual
for additional information.
Note: Refer to Operation and Maintenance Manual,

Fuel System Secondary Filter - Replace for
information on replacing the filter.
1. Turn the ignition switch to the OFF position.
SEBU7899-05
87
Maintenance Section
Fuel System - Prime
The Engine Has Been Run Out of

Fuel
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
NOTICE
Illustration 50
g00975199
(1) Fuel priming pump

(2) Air purge screw
(3) Priming valve (If Equipped)
1. Turn the ignition switch to the OFF position.

2. Fill the fuel tank(s) with clean diesel fuel.
2. Turn the priming valve (3) (If Equipped) to the

Closed (Prime) position in order to prime the fuel
system.
3. Open air purge screw (2) for the fuel filter by three
full turns. Do not remove the air purge screw.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Start the engine. The engine should start and the
engine should run smoothly.
Note: You may use the fuel priming pump for the fuel
filter (IF EQUIPPED) instead of starting the engine
and running the engine.
5. While the engine is running, observe air purge
screw (2). When a small drop of fuel appears
at the threads of the air purge screw, close and
tighten air purge screw (2).
Note: There may be a noticeable change in the
sound of the running engine when the air purge
screw is tightened. The change in the sound of the
engine is normal.
Note: Failure to tighten all fittings could result in
serious fuel leaks.
Illustration 51
g00975199
(1) Fuel priming pump

(2) Air purge screw
(3) Priming valve (If Equipped)
3. Turn the priming valve (3) (If Equipped) to the

Closed (Prime) position in order to prime the fuel
system.
4. Open air purge screw (2) for the fuel filter by three
full turns. Do not remove the air purge screw.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
6. Clean any residual fuel from the engine

components.
5. Crank the engine for 30 seconds. Use a suitable

container to catch the fuel while you crank the
engine. Allow the starter motor to cool for 2
minutes.
7. After the engine has operated smoothly for 30

seconds, turn the priming valve (3) to the Open
(Run) position.
Note: You may use the fuel priming pump (1) (IF
EQUIPPED) for the fuel filter instead of cranking the
engine.
Note: Shortened injector life may occur if the priming

valve (3) is left in the Closed (Prime) position.
6. Crank the engine for 30 seconds. Allow the starter

motor to cool for 2 minutes.
88
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
SEBU7899-05
7. Repeat Step 6 until the engine starts and the

engine runs.
Note: Failure to tighten all fittings could result in
serious fuel leaks.
8. After the engine has operated smoothly for 30
seconds, turn the priming valve (3) to the Open
(Run) position.
Note: Shortened injector life may occur if the priming
valve (3) is left in the Closed (Prime) position.
9. Clean any residual fuel from the engine
components.
Illustration 52
i02927285
Fuel System Primary

Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543
NOTICE
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
mandates.
NOTICE
g01453091
(1) Element
(2) Bowl
(3) Drain
Bowl (2) should be monitored daily for signs of water.

If water is present, drain the water from the bowl.
1. Open drain (3). The drain is a self-ventilated drain.
Catch the draining water in a suitable container.
Dispose of the water properly.
2. Close drain (3).
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel
system.
i02927282
Fuel System Primary Filter

(Water Separator) Element Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.
The primary filter/water separator also provides
filtration in order to help extend the life of the
secondary fuel filter. The element should be changed
regularly. If a vacuum gauge is installed, the
primary filter/water separator should be changed at
50 to 70 kPa (15 to 20 inches Hg).
SEBU7899-05
89
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
Replace the Element
4. Remove the O-ring from the gland of the bowl.

Clean the following components:
Bowl
NOTICE
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
mandates.
NOTICE
1. Close the main fuel supply valve.
O-ring
Mounting base
Inspect the O-ring for damage and for
deterioration. Replace the O-ring, if necessary.
5. Lubricate the O-ring with clean diesel fuel.
6. Install bowl (2) on a new element. Tighten the
bowl by hand. Do not use tools in order to tighten
the bowl.
NOTICE
The primary filter/water separator may be prefilled with
fuel to avoid rough running/stalling of the engine due
to air. Do not fill the secondary filter with fuel before
installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
7. Lubricate the top seal of element (1) with clean
diesel fuel. The element may be filled with fuel at
this time. Install the new element on the mounting
base. Tighten the element by hand.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tightened securely to help prevent air from entering the fuel system.
8. Open the main fuel supply valve.
9. Start the engine and check for leaks. Run the
engine for one minute. Stop the engine and check
for leaks again.
Illustration 53
g01453091
(1) Element
(2) Bowl
(3) Drain
2. Remove element (1) from the element mounting

base while bowl (2) is attached.
3. Dispose of the contents of the filter. Remove bowl
(2) from element (1). The bowl is reusable. Do not
discard the bowl. Dispose of the used element.
Detecting leaks is difficult while the engine is

running. The primary filter/water separator is
under suction. A leak will allow air to enter the fuel.
The air in the fuel can cause low power due to
aeration of the fuel. If air enters the fuel, check the
components for overtightening or undertightening.
90
Maintenance Section
Fuel System Secondary Filter - Replace
SEBU7899-05
i03478081
Fuel System Secondary Filter Replace

SMCS Code: 1261-510-SE
NOTICE
will be disconnected. Fit a suitable cover over any disconnected fuel system components.
NOTICE
Dealer Service Tool Catalog or refer to Special Publication, PECJ0003, Caterpillar Shop Supplies and
Tools Catalog for tools and supplies suitable to collect and contain fluids on Caterpillar products.
mandates.
1. Stop the engine. Turn the ignition switch to the
OFF position or disconnect the battery. Refer to
the Operation and Maintenance Manual, Battery
or Battery Cable - Disconnect topic (Maintenance
Section) for more information. Shut off the fuel
supply valve (if equipped).
2. It may be necessary to relieve residual fuel
pressure from the fuel system before the fuel
filter is removed. Wait for one to five minutes until
the fuel pressure has lowered. Use a suitable
container in order to catch any fuel that may spill.
3. Remove the used fuel filter and discard the used
fuel filter.
4. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.
5. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
Do not fill the secondary fuel filter with fuel before installing. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
NOTICE
In order to meet expected fuel system component
life, 4 micron(c) absolute or less secondary fuel filtration is required for all Caterpillar Diesel Engines
that are equipped with unit injected fuel systems. Note
that all current Caterpillar Diesel Engines are factory
equipped with Caterpillar Advanced Efficiency 4 micron(c) absolute fuel filters.
Caterpillar does not warrant the quality or performance of non-Caterpillar fluids and filters.
6. Install the new fuel filter. Spin the fuel filter onto
the fuel filter base until the gasket contacts the
base. Use the rotation index marks on the filters
as a guide for proper tightening. Tighten the filter
according to the instructions that are on the fuel
filter. Do not overtighten the filter.
7. Open the fuel supply valve. The engine will need
to be purged of air. Refer to the Operation and
Maintenance Manual, Fuel System - Prime topic
(Maintenance Section) for more information.
i04363480
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
NOTICE
on Cat products.
mandates.
SEBU7899-05
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
Drain the Water and the Sediment

Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
Note: Failure to properly close the drain can allow air
into the system, which could have detrimental results
to performance.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
91
Maintenance Section
Grounding Stud - Inspect/Clean/Tighten
If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
i04176149
Grounding Stud Inspect/Clean/Tighten

SMCS Code: 7423-040; 7423-070; 7423-079
The connection of battery cables to a battery and

the disconnection of battery cables from a battery
may cause an explosion which may result in injury
or death. The connection and the disconnection
of other electrical equipment may also cause an
explosion which may result in injury or death. The
procedures for the connection and the disconnection of battery cables and other electrical equipment should only be performed in a nonexplosive
atmosphere.
Fill the fuel tank after operating the engine in

order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Fuel Storage Tanks

Drain the water and the sediment from the fuel
storage tank during the following conditions:
Weekly
Illustration 54
g00765094
Typical example
Oil change
Electronics grounding stud (side view)
Refill of the tank
Inspect the OEM harness for good connections.

Inspect the condition of the OEM harness.
This will help prevent water or sediment from being

pumped from the storage tank into the engine fuel
tank. A four micron(c) absolute filter for the breather
vent on the fuel tank is also recommended.
92
Maintenance Section
Hoses and Clamps - Inspect/Replace
SEBU7899-05
The electronics grounding stud must have a wire

ground to the battery. Tighten the electronics
grounding stud at every oil change. Ground wires
and straps should be combined at engine grounds.
All grounds should be tight and free of corrosion.
Clean the electronics grounding stud and the
terminals for the electronics ground strap with a

clean cloth.
If the connections are corroded, clean the
connections with a solution of baking soda and

water.
Keep the electronics grounding stud and the strap
clean and coated with MPGM grease or petroleum

jelly.
i04301694
Hoses and Clamps Inspect/Replace

SMCS Code: 7554-040; 7554-510
Hoses and clamps must be inspected periodically
in order to ensure safe operation and continuous
operation of the engine. Take proper safety
precautions before inspecting or replacing hoses and
clamps.
Note: Always use a board or cardboard when the
engine components are checked for leaks. Leaking
fluid that is under pressure can cause serious
injury or possible death. Leaks that are the size
of a pin hole are included. Refer to Operation and
Maintenance Manual, General Hazard Information
for more information.
Inspect the Hoses and the Clamps

Inspect all hoses for leaks that are caused by the
following conditions. Replace any hose which exhibits
any of the following conditions. Failure to replace a
hose which exhibits any of the following conditions
may result in a hazardous situation.
Hoses which are cracked

Hoses which are soft
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
Hoses which exhibit signs of leakage which are not

the result of loose couplings or clamps
Inspect all clamps for the following conditions.

Replace any clamp which exhibits signs of any of the
following conditions.
Cracking
Looseness
Damage
Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.
Each installation application can be different. The
differences depend on the following factors:
Type of hose
Type of fitting material
Anticipated expansion and contraction of the hose
Anticipated expansion and contraction of the
fittings
Due to extreme temperature changes, the hose will

heat set. Heat setting causes hose clamps to loosen
which can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
Replace hoses that are cracked or soft. Replace
hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace
hose clamps which are loose.
Replace the Hoses and the Clamps

NOTICE
on Cat products.
mandates.
SEBU7899-05
93
Maintenance Section
Hoses and Clamps - Inspect/Replace
Cooling System
Fuel System
Personal injury can result from removing hoses or

fittings in a pressure system.
Personal injury can result from removing hoses or

fittings in a pressure system.
Failure to relieve pressure can cause personal injury.
Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
1. Stop the engine.
2. Allow the engine to cool.
3. Before servicing a coolant hose, slowly loosen the
filler cap for the cooling system in order to relieve
any pressure.
4. Remove the filler cap for the cooling system.
5. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
Drain the coolant into a suitable clean container.
The coolant can be reused.
6. Remove the hose clamps.
7. Disconnect the old hose.
8. Replace the old hose with a new hose.
9. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
SENR3130, Torque Specifications, Hose
Clamps for information about selecting and
installing the proper hose clamps.
10. Refill the cooling system.
11. Clean the filler cap for the cooling system. Inspect
the gaskets on the filler cap. Replace the filler cap
if the gaskets are damaged. Install the filler cap.
12. Start the engine. Inspect the cooling system for
leaks.
Failure to relieve pressure can cause personal injury.

Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
NOTICE
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the recommended torque.
NOTICE
will be disconnected. Fit a suitable cover over any disconnected fuel system components.
Note: High-pressure fuel lines may be installed
between the high-pressure fuel pump and the fuel
injectors. High-pressure fuel lines are constantly
charged with high pressure. Do not check the
high-pressure fuel lines with the engine or the starting
motor in operation. Wait for 10 minutes after the
engine stops before you perform any service or repair
on high-pressure fuel lines. Waiting for 10 minutes
will to allow the pressure to be purged.
1. Drain the fuel from the fuel system to a level that
is below the hose that is being replaced.
94
Maintenance Section
Jacket Water Heater - Check
SEBU7899-05


6. Carefully inspect the engine for any spilled fuel.

Make sure that no fuel remains on or close to the
engine.
Note: The bellows and the V-clamps that are used

on the bellows should never be reused.
Note: Fuel must be added to the fuel system ahead

of the fuel filter.
5. Start the engine. Inspect the air lines for leaks.

i03230758
7. Refill the fuel system. Refer to this Operation and

Maintenance Manual, Fuel System - Prime for
information about priming the engine with fuel.
Jacket Water Heater - Check
8. Start the engine. Inspect the fuel system for leaks.
Jacket water heaters help to improve startability in

ambient temperatures that are below 21 C (70 F).
All installations that require automatic starting should
have jacket water heaters.
Lubrication System

contact the skin.
1. Drain the oil from the lubrication system to a level
that is below the hose that is being replaced.
6. Refill the lubrication system. Refer to this
Operation and Maintenance Manual, Engine
Oil Level - Check in order to ensure that the
lubrication system is filled with the proper amount
of engine oil.
7. Start the engine. Inspect the lubrication system
for leaks.
Air System
SMCS Code: 1383-535
Check the operation of the jacket water heater. Check

the operation of the circulation pump, if equipped. For
an ambient temperature of 0 C (32 F), the heater
should maintain the jacket water coolant temperature
at approximately 32 C (90 F).
i01848653
Overhaul Considerations
SMCS Code: 7595-043
Reduced hours of operation at full load will result in a
lower average power demand. A decreased average
power demand should increase both the engine
service life and the overhaul interval.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
The following factors are important when a decision
is being made on the proper time for an engine
overhaul:
The need for preventive maintenance

The quality of the fuel that is being used
The operating conditions
The results of the SOS analysis
SEBU7899-05
Oil Consumption as an Overhaul

Indicator
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
for the maintenance intervals.
Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
consumed per hour also increases.
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
consumption rate for your engine.
When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
Overhaul Options
95
Maintenance Section
Caterpillar dealer exchange components

Caterpillar Inc. remanufactured exchange
components
Overhaul Recommendation
To minimize downtime, a scheduled engine overhaul
by your Caterpillar dealer is recommended. This will
provide you with the best cost/value relationship.
Note: Overhaul programs vary according to the
engine application and according to the dealer that
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available
overhaul programs and about overhaul services for
extending the engine life.
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the following
maintenance recommendations.
Unit Fuel Injector

Clean the fuel injector body and replace the O-rings.
Replace the O-rings and the gasket on the injector
sleeve. Clean the area around the injector seating
in the injector sleeve. Refer to the Service Manual
for the complete procedure, or consult with your
Caterpillar dealer for assistance.
Before Failure Overhaul

A planned overhaul before failure may be the best
value for the following reasons:
Costly unplanned downtime can be avoided.

Many original parts can be reused according to the
standards for reusable parts.
The engine service life can be extended without the

risk of a major catastrophe due to engine failure.
The best cost/value relationship per hour of

extended life can be attained.
After Failure Overhaul

If a major engine failure occurs and the engine
must be removed, many options are available. An
overhaul should be performed if the engine block or
the crankshaft needs to be repaired.
If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine
with a similar exchange core.
This lower cost can be attributed to three aspects:
Specially designed Caterpillar engine features
Rebuild or Exchange
Cylinder Head Assembly, Connecting Rods,
Pistons, Cylinder Liners, Turbocharger, Cylinder
Packs, Oil Pump, and Fuel Transfer Pump
These components should be inspected according to
the instructions that are found in various Caterpillar
reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
If the parts comply with the established inspection
specifications that are expressed in the reusable
parts guideline, the parts should be reused.
Parts that are not within the established inspection
specifications should be dealt with in one of the
following manners:
Salvaging
Repairing
Replacing
Parts that do not comply with the established
inspection specifications can result in the following
problems:
96
Maintenance Section
Unscheduled downtime
Costly repairs
Damage to other engine parts
Reduced engine efficiency
Increased fuel consumption
Reduced engine efficiency and increased fuel
consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts.
Inspection and/or Replacement

Piston Rings, Crankshaft Bearings, Valve
Rotators, and Crankshaft Seals
The following components may not last until the
second overhaul.
Thrust bearings
Main bearings
Rod bearings
Valve rotators
SEBU7899-05
Inspect the camshaft for damage to the journals and

to the lobes.
Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check for
cracks in the camshaft.
Inspect the following components for signs of wear or
for signs of scuffing:
Camshaft bearings
Camshaft followers
Caterpillar Inc. recommends replacing the crankshaft
vibration damper.
Oil Cooler Core and Aftercooler Core
During an overhaul, the removal of the oil cooler
core and the aftercooler core is recommended. The
oil cooler core and the aftercooler core should be
cleaned and pressure tested.
NOTICE
Do not use caustic cleaners to clean the core.
Caustic cleaners can attack the internal metals of the
core and cause leakage.
Crankshaft seals
Obtain Coolant Analysis
Caterpillar Inc. recommends the installation of new

parts at each overhaul period.
The concentration of supplemental coolant additive

(SCA) should be checked regularly with test kits
or with SOS Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine
is overhauled.
Inspect these parts while the engine is disassembled

for an overhaul.
Inspect the crankshaft for any of the following
conditions:
Deflection
Damage to the journals
Bearing material that has seized to the journals
Check the journal taper and the profile of the
crankshaft journals. Check these components by
interpreting the wear patterns on the following
components:
Rod bearing
Main bearings
Note: If the crankshaft is removed for any reason,
use the magnetic particle inspection process to check
for cracks in the crankshaft.
A coolant analysis can be conducted in order to verify

the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
by consulting your local water utility company or
an agricultural agent. Private laboratories are also
available for water analysis.
Caterpillar Inc. recommends an SOS Coolant
Analysis (Level 2).
SOS Coolant Analysis (Level 2)
An SOS Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An SOS Coolant Analysis (Level 2) provides
the following information:
Complete SOS Coolant Analysis (Level 2)

Visual inspection of properties
SEBU7899-05
97
Maintenance Section
Power Take-Off Clutch - Check
Identification of metal corrosion

Identification of contaminants
Identification of built up impurities (corrosion and
scale)
SOS Coolant Analysis (Level 2) provides a report of

the results of both the analysis and the maintenance
recommendations.
Do not operate the engine with the Instruction

Plate cover removed from the clutch. Personal
injury may result.
If the clutch is damaged to the point of burst failure, expelled pieces can cause personal injury to
anyone in the immediate area. Proper safeguards
must be followed to help prevent accidents.
For more information about coolant analysis, consult

your Caterpillar dealer.
i03901481
Power Take-Off Clutch - Check

SMCS Code: 3055-535
i04020194
Radiator - Clean
SMCS Code: 1353-070
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
NOTICE
New power take-offs should have the clutch adjustment checked before being placed into service. The
clutch adjustment should be checked again after the
first ten hours of operation. New clutch plates have a
wear in period, and the clutch may require several
adjustments until the new plates are worn in.
Inspect the radiator for these items: damaged fins,

corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.

The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
Illustration 55
g00781502
(1) Instruction plate

(2) Serial number plate
Check the clutch adjustment regularly after wear in.

Heavy-duty applications which have engagements
that are frequent and relatively long periods of
clutch slippage require more frequent adjustment
than light-duty applications. The operating torque
should be measured in order to determine if a clutch
adjustment is required.
Refer to the OEM information and instruction plate
(1) for instructions on lubrication, adjustment, and
other recommendations for service. Perform the
maintenance that is specified on the instruction plate.
Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction
of the air flow. Hold the nozzle approximately 6 mm
(0.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes.
This movement will remove debris that is between
the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
98
Maintenance Section
Speed Sensor - Clean/Inspect
SEBU7899-05
After cleaning, start the engine and accelerate the

engine to high idle rpm. This procedure will help in
the removal of debris and drying of the core. Stop the
engine. Use a light bulb behind the core in order to
inspect the core for cleanliness. Repeat the cleaning,
if necessary.
Inspect the fins for damage. Bent fins may be opened
with a comb. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
Check the starting motor for proper operation. Check

the electrical connections and clean the electrical
connections. Refer to the Service Manual for more
information on the checking procedure and for
specifications or consult your Caterpillar dealer for
assistance.
i01539769
Turbocharger - Inspect
SMCS Code: 1052-040
i03397657
Speed Sensor - Clean/Inspect

SMCS Code: 1907-040; 1907-070
Periodic inspection and cleaning is recommended

for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through
the air inlet system. Therefore, by-products from oil
and from combustion can collect in the turbocharger
compressor housing. Over time, this buildup can
contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder
head.
Illustration 56
g01453018
Left side view

(1) Secondary speed/timing sensor
(2) Primary speed/timing sensor
1. Remove the speed/timing sensors. Refer to

Disassembly and Assembly, Speed/Timing
Sensor - Remove and Install for the removal
procedure. Check the condition of the plastic
end of the speed/timing sensors for wear and/or
contaminants.
2. Clean the metal shavings and other debris from
the face of the speed/timing sensors.
3. Install the speed/timing sensors. Refer to
Disassembly and Assembly, Speed/Timing
Sensor - Remove and Install for the installation
procedure.
i00651416
Starting Motor - Inspect

SMCS Code: 1451-040; 1453-040
Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
NOTICE
Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
Minor leakage of a turbocharger housing under extended low idle operation should not cause problems
as long as a turbocharger bearing failure has not occurred.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
Note: Turbocharger components require precision
clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
Severe Service Applications require more frequent
inspections of the cartridge.
SEBU7899-05
99
Maintenance Section
Walk-Around Inspection
Removal and Installation

For options regarding the removal, installation, repair
and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine for the
procedure and specifications.
Cleaning and Inspecting

1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt
from entering during reassembly.
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned.
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 air filtering
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the
turbocharger to slobber.
4. Use a dial indicator to check the end clearance
on the shaft. If the measured end play is greater
than the Service Manual specifications, the
turbocharger should be repaired or replaced.
An end play measurement that is less than the
minimum Service Manual specifications could
indicate carbon buildup on the turbine wheel. The
turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less
than the minimum Service Manual specifications.
5. Inspect the bore of the turbine housing for
corrosion.
6. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.
7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
i01185304
Walk-Around Inspection
SMCS Code: 1000-040
Inspect the Engine for Leaks and

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

damaged guards or replace missing guards.
Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system

contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
Ensure that the cooling lines are properly clamped
and that the cooling lines are tight. Check for leaks.
Check the condition of all pipes.
Inspect the water pumps for coolant leaks.

Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
the parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer.
Inspect the lubrication system for leaks at the front

crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
100
Maintenance Section
Water Pump - Inspect
SEBU7899-05
Inspect the fuel system for leaks. Look for loose

fuel line clamps or for loose fuel line tie-wraps.
Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
Inspect the alternator belt and the accessory drive

belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced as

matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
Drain the water and the sediment from fuel tanks
on a daily basis in order to ensure that only clean

fuel enters the fuel system.
Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed

wires.
Inspect the ground strap for a good connection and

for good condition.
Inspect the ECM to the cylinder head ground strap

for a good connection and for good condition.
Disconnect any battery chargers that are not
protected against the current drain of the starting

motor. Check the condition and the electrolyte level
of the batteries, unless the engine is equipped with
a maintenance free battery.
Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauge that

can not be calibrated.
i03543200
Water Pump - Inspect

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

A piston seizure
Other potential damage to the engine
A failed water pump might cause severe engine
overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential
damage to the engine.
Visually inspect the water pump for leaks. If leaking

of the water pump seals is observed, replace all of
the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, Water Pump
- Disassemble and Water Pump - Assemble for
the disassembly and assembly procedure. If it is
necessary to remove the water pump, refer to two
articles in the Disassembly and Assembly Manual,
Water Pump - Remove and Water Pump - Install.
Inspect the water pump for wear, cracks, pin holes
and proper operation. Refer to the Parts Manual
for the correct part numbers for your engine or
consult your Caterpillar dealer if repair is needed or
replacement is needed.

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MAINTENANCE INTERVALS

Operation and Maintenance

Maintenance Interval Schedule

Jacket Water Heater - Check ................................ 94

Ensure that all safety information, warnings,

Every 250 Service Hours

Note: Use whichever of the following that occurs

Initial 500 Service Hours (or at first oil

Refer to this Operation and Maintenance Manual,

Battery Electrolyte Level - Check ..........................

Engine Valve Lash - Check ................................... 85

Initial 500 Hours (for New Systems, Refilled

Every 500 Service Hours

Every 2000 Service Hours or 1 Year

Every 3000 Service Hours or 3 Years

Driven Equipment - Check ....................................

Every 760,000 L (200,770 US gal) of Fuel

Maintenance Interval Schedule

Initial 250 Service Hours (or at first oil

Every 250 Service Hours

Initial 500 Hours (for New Systems, Refilled

Every 500 Service Hours

Every 2000 Service Hours or 1 Year

Power Take-Off Clutch - Check ............................ 97

Alternator - Inspect ............................................... 65

Every 3000 Service Hours or 3 Years

Every 760,000 L (200,770 US gal) of Fuel

Aftercooler Core - Clean/Test

Personal injury can result from air pressure.

Note: If parts of the aftercooler system are repaired

Use a degreaser and steam for removal of oil and

Batteries give off combustible gases which can

After cleaning, start the engine and accelerate the

Ensure proper ventilation for batteries that are in

Inspect the fins for damage. Bent fins may be opened

The battery cables or the batteries should not be

All lead-acid batteries contain sulfuric acid which

Removing the battery cables or the batteries with

1. Remove the filler caps. Maintain the electrolyte

1. Switch the engine to the OFF position. Remove

Battery Electrolyte Level Check

If the addition of water is necessary, use distilled

A mixture of 0.1 kg (0.2 lb) of baking soda and

A mixture of 0.1 L (0.11 qt) of ammonia and 1 L

Thoroughly rinse the battery case with clean water.

Battery or Battery Cable Disconnect

The battery cables or the batteries should not be

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

Alternator Belt Adjustment

2. Disconnect the negative battery terminal at the

1. Remove the belt guard.

SMCS Code: 1357-025; 1357-040; 1357-510

2. Loosen mounting bolts (1) and adjusting bolt (2).

3. Move the assembly in order to increase or

4. Tighten adjusting bolt (2). Tighten mounting bolts

Check the belt tension according to the information in