Usage:
Engine Crankcase
Change Oil and Filter
The percentage of sulfur in the fuel will affect the engine oil recommendations. If the fuel has over 0.5% sulfur content, the CD/SE or CD/SF engine oil must have a TBN of 20 times the percentage of fuel sulfur (TBN as measured by the ASTM D-2896 method). If the sulfur content is greater than 1.5% by weight, use an oil with a TBN of 30 and reduce the oil change interval by one half. Your oil supplier should be able to furnish the correct oils.
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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
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Drain the crankcase with the oil warm and the engine stopped.
- 1. Remove the crankcase drain plug and allow the oil to drain. Take sample for analysis.
- 2. Install the crankcase drain plug and tighten it to 70 ± 14 N·m (50 ± 10 lb ft).
- 3. Remove oil filter. Cut filter open using service tool 6V7905 and inspect for foreign material.
- 4. Wipe the sealing surface of the filter element mounting base. Make sure all of the old gaskets are removed.
NOTE: Make sure to use the correct oil filter element for your engine arrangement.
- 5. Apply a small amount of clean engine oil to the new filter element gasket.
- 6. Install the new filter element by hand until the gasket contacts the base. Tighten the filter 3/4 of a turn more. Do not overtighten.
- 7. Fill the crankcase. See "Refill Capacities."
- 8. Before starting the engine, check the oil level. The oil level should be at or above the FULL mark on the dipstick.
- 9. Start and run the engine at low idle for two minutes. Inspect for oil leaks. Stop the engine.
- 10. Wait 10 minutes to allow the oil to drain back into the crankcase. Check the oil level. Maintain the oil level to the FULL mark on the dipstick.
Engine Crankcase Breather (If Equipped)
Clean
- 1. Loosen hose clamps (1) and slide the hose on to the tube.
- 2. Loosen bolt (2), remove breather (3) and seal (4).
- 3. Wash breather (3) in clean, nonflammable solvent and dry it.
- 4. Install a new seal (4) and the clean breather (3). Tighten bolt (2) to 14 ± 3 N·m (10 ± 2 lb ft).
- 5. Slide the hose on to breather (3) and tighten hose clamps (1).
Cooling System
Add Conditioner or Replace Element
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. |
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All water is corrosive at engine operating temperature. Use Caterpillar liquid cooling system conditioner or Caterpillar cooling system conditioner element to treat either plain water or ethylene glycol antifreeze solution. Never use both the liquid cooling system conditioner and the conditioner element at the same time. |
NOTE: See "Know Your Cooling System" Form SEBD0518 and your Caterpillar dealer for more detailed specifications.
Liquid Conditioner
- 1. Loosen the filler cap slowly to relieve pressure and remove the cap.
- 2. It may be necessary to drain enough coolant from the radiator to allow for the addition of the liquid cooling system conditioner.
- 3. Add 0.24 liters (1/2 pint) of Caterpillar liquid cooling system conditioner for every 38 liters (10 U.S. gallons) of cooling system capacity.
NOTE: On a new or rebuilt engine only or when changing the coolant, add enough liquid conditioner for a 3% to 6% concentration of conditioner. Add 0.95 liters (1 quart) for every 30 liters (8 U.S. gallons) of cooling system capacity.
- 4. Inspect the filler cap gaskets. Replace the cap if the gaskets are damaged. Install the filler cap.
Conditioner Element (If Equipped)
- 1. Close the coolant conditioner element inlet and outlet valves. Remove and discard the conditioner element.
- 2. Clean the element mounting base. Make sure all of the old gasket is removed.
- 3. Coat the gasket of a new maintenance conditioner element with a film of engine oil. Install the new conditioner element.
NOTE: On a new or rebuilt engine, use a precharge conditioner element for original fill of the cooling system.
- 4. Open the inlet and outlet valves. Remove the filler cap.
- 5. Start the engine and check for leaks. Allow the coolant level to stabilize.
- 6. Add coolant if necessary to bring the coolant to within 13 mm (1/2 inch) below the bottom of the fill pipe or to the proper level on the sight glass, if so equipped.
- 7. Inspect the filler cap. Replace the cap if the gasket is damaged. Install the cap.
Fuel Filters
Primary Filter (If Equipped)
- 1. Stop the engine.
- 2. Shut off the fuel tank supply valve.
- 3. Loosen bolt (1) on the filter cover and lower filter case (3).
- 4. Remove element (2). Wash the cover and element in clean, nonflammable solvent. Reinstall the element.
Final Fuel Filters
- 1. Remove and discard the fuel filter element.
- 2. Clean the gasket sealing surface of the filter base. Make sure all of the old gasket is removed.
- 3. Lubricate the gasket of the new filter with clean fuel.
- 4. Install the filter and tighten it by hand until gasket contacts base, then tighten 1/2 to 3/4 turn more.
- 5. Prime the fuel system.
Priming the System
- 1. Move the governor control to the OFF position.
- 2. Open the vent valve (if equipped) on the fuel injection pump housing.
- 3. Operate the priming pump until the flow of fuel from the vent valve is continuous, and free of air bubbles.
- 4. Close the vent valve (if equipped) and lock the fuel priming pump.
| NOTICE |
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The fuel injection nozzles can be permanently damaged by twisting if only one wrench is used to loosen or tighten the fuel line nuts. Use one wrench to hold the nozzle and another to loosen the nut. |
- 5. Start the engine. If the engine continues to misfire or smoke, further bleeding is necessary.
- 6. Loosen the fuel lines at the cylinder head.
- 7. If the engine is equipped with a fuel priming pump, put the governor control lever in the OFF fuel position. Operate the priming pump until fuel flows free of air bubbles at the cylinder head.
- 8. If the engine does not have a fuel priming pump, crank the engine until fuel flows free of air bubbles. Do not crank the engine for more than 30 seconds at a time without letting the electric starting motor cool for a minimum of two minutes between cranking periods.
- 9. Tighten the fuel line nuts to 40 ± 7 N·m (30 ± 5 lb ft).
Air Cleaner
Clean or Replace
A service indicator may be mounted on the information panel or in the engine compartment. A colored piston showing in the window indicates the need for servicing the air cleaner. Replace the filter element at least once a year.
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Never service the air cleaner with the engine running. |
Changing Air Cleaner Elements
- 1. Loosen the retaining bolts and remove the end cover on the air cleaner housing.
- 2. Remove and inspect the element for damaged pleats, gaskets or seals. Replace the element if damaged.
- 3. Clean the inside of the housing.
- 4. Install a new or cleaned element in the air cleaner housing.
- 5. Install the end cover on the air cleaner housing.
- 6. Reset the service indicator by pushing on the piston plunger.
Cleaning Air Cleaner Elements
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Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. |
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Do not clean filter elements by bumping or tapping. Do not use filter elements with damaged pleats, gaskets or seals. |
NOTE: Air cleaner filter elements can be cleaned with either air, water or detergent. Have spare elements on hand to use while cleaning used elements.
Pressure Air - 205 kPa (30 psi) Maximum Pressure
- 1. Direct air inside of the element along the length of the pleats.
- 2. Direct air on the outside of the element along the length of the pleats. Direct air on the inside along the pleats. Inspect the element for any rips, tears or damage.
Pressure Water - 280 kPa (40 psi) Maximum Pressure
- 1. Direct water on the inside of the element, along the length of the pleats.
- 2. Direct water on the outside of the element along the length of the pleats. Air dry thoroughly before using and inspect the element.
Detergent
- 1. Wash the element in warm water and nonsudsing detergent.
- 2. Rinse the element with clean water. See instruction for cleaning with water.
- 3. Air dry it thoroughly before using and inspect the element.
Inspecting Element
- 1. Insert a light inside of the cleaned and dry element. Inspect it for rips and tears. Discard the element if damaged.
- 2. Wrap and store good cleaned elements in a clean, dry place.
Batteries
Clean - Check Electrolyte Level
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Batteries give off flammable fumes that can explode. Do not smoke when observing the battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. Always wear protective glasses when working with batteries. |
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- 1. Clean the top of the batteries.
- 2. Remove the filler caps. Maintain the electrolyte level to the bottom of the filler openings. If an addition of water is necessary, use distilled water. If not available, use clean water, low in minerals. Do not use artificially softened water.
At proper charging rate, batteries should not require more than 30 cc (1 ounce) of water per cell per week.
- 3. Install filler caps.
Alternator, Fan and Accessory Drive Belts
Inspect - Adjust
- 1. Inspect the condition and adjustment of the belts.
- 2. To check the belt tension, apply 110 N (25 lbs) of force midway between the pulleys. Correctly adjusted belts will deflect 13 to 19 mm (1/2 to 3/4 inch).
To Adjust Alternator Belts
- 1. To adjust the alternator drive belt, loosen mounting bolt (1) and the adjusting bracket bolt (2).
- 2. Loosen bolt (3). Move the alternator in or out as required to obtain the correct adjustment. Tighten bolt (3).
- 3. Tighten bolts (1) and (2).
- 4. If new belts are installed, check belt adjustment again after 30 minutes of engine operation.
Clutch Bearings
Lubricate Fittings
Lubricate the clutch bearings with grease, one or two strokes each fitting.
- 1. Lubricate shift-collar bearings (1) sparingly. One fitting at top left of center.
- 2. Lubricate main shaft bearing (2). One fitting located above the output shaft on the bearing cage.
- 3. Lubricate shift lever bearings (3). One fitting on each side of the clutch housing.
- 4. Lubricate pilot bearing. One fitting at end of shaft (4). If this fitting is not accessible, remove the plug located on the circumference on the shaft near the rear of the housing and install a fitting.