Usage:
(4)Fan Pulley Bearing
Lubricate 2 fittings.
Check all belts for cracks and wear. Replace belts in sets only to ensure even wear.
(5)Cooling System
 |
Always inspect the cooling system with the engine stopped. |
 |
- 1. Clean radiator fins.
- 2. Inspect condition of the radiator hoses.
- 3. Tighten hose clamps as necessary.
(6)Coolant Conditioner Group Element (If Equipped)
|
Always inspect the cooling system with the engine stopped. Remove the radiator cap slowly to relieve pressure. Steam can cause personal injury. Conditioner contains alkali, avoid contact with skin and eyes to prevent personal injury. Change conditioner group element only when coolant is cold to avoid risk of burns. |
|
| NOTICE |
|---|
All water is corrosive at engine operating temperature. Use either Caterpillar Cooling System Conditioner liquid, or the coolant conditioner group element to treat either plain water or ethylene glycol. NEVER use both the liquid cooling system conditioner and the coolant conditioner element at the same time. Do not use Caterpillar Cooling System Conditioner or Coolant Conditioner Elements with Dowtherm 209 Full-Fill coolant. |
| NOTICE |
|---|
Close both inlet and outlet valves (turn clockwise to close before removing the filter to avoid coolant loss. |
- 1. Close the inlet and outlet valves, if equipped.
- 2. Remove the coolant conditioner element. Discard element.
- 3. Clean the filter mounting base. Make certain all of the old filter gasket material is removed.
- 4. Use only Caterpillar Part Number 9N3368 as a replacement element.
- 5. Coat the seal of the element with a thin film of clean engine oil.
- 6. Install and turn the element until the seal contacts the base, then tighten 3/4 turn more.
- 7. Open the inlet and outlet valves, if equipped.
- 8. Start the engine and check for leaks.
(7)Engine Air Intake
The engine may be equipped with a dry-type or an oil bath air cleaner. Service the air cleaner at regular intervals determined by dust conditions.
| NOTICE |
|---|
NEVER SERVICE AIR INTAKE SYSTEM WITH THE ENGINE RUNNING. |
Dry-type Air Cleaner
- 1. Loosen and remove the retaining bolts and end cover.
- 2. Remove the element.
- 3. Remove any dirt or debris which has accumulated on the bottom or sides of the filter housing. Clean the filter element using one of the methods covered in the topic, CLEANING AIR CLEANER ELEMENTS.
- 4. If the element is damaged, install a new element.
- 5. Install the clean element in the filter housing.
- 6. Install the cover. Tighten the retaining bolts.
Oil Bath-type Air Cleaner
- 1. Loosen the retaining clamp thumb screw and remove the oil pan from the air cleaner.
- 2. Clean the bottom of the oil pan with clean nonflammable solvent. Fill the pan with clean engine oil to the level indicated by the mark on the side of the oil pan.
- 3. Install the oil pan and tighten the retaining clamp.
Cleaning Air Cleaner Elements
|
When using pressure air, wear protective face shield and protective clothing. Use 30 psi (205 kPa) maximum pressure air for cleaning purposes. |
|
| NOTICE |
|---|
Do not clean element by bumping or tapping. Do not use elements with damaged pleats, gaskets or seals. |
Pressure Air - 30 psi (205 kPa) Maximum
- 1. Direct air inside the element along the length of the pleats.
- 2. Direct air outside the element along the length of the pleats. Direct air inside the element along the length of the pleats. Inspect the element.
Water - 40 psi (280 kPa) Maximum
- 1. Direct water inside the element and along the length of the pleats.
- 2. Direct the water outside the element along the length of the pleats. Rinse, air dry thoroughly and inspect the element.
Detergent
- 1. Wash the element in warm water and nonsudsing household detergent.
- 2. Rinse the element with clean water.
- 3. Air dry the element thoroughly and inspect it.
Inspecting Element
- 1. Insert a light inside of the clean and dry element, and inspect it. Discard the element if rips or tears are found.
- 2. Wrap and store good elements in a clean, dry place.
(8)Batteries
|
Batteries give off flammable fumes that can explode. Do not smoke when observing electrolyte level. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. |
|
Clean the top of the batteries. Remove the filler caps and inspect the electrolyte level. Maintain the electrolyte level to the bottom of the filler openings. Install the filler caps.
At proper charge rate, batteries will not require more than 1 ounce (30 cc) of water per cell per week.
(9)Alternator And Fan Drive Belts
- 1. Inspect the condition and the adjustment of the alternator belts (A), and the fan drive belts (B).
- 2. Replace the belts in sets if either belt is frayed or cracked.
- 3. Apply 25 lb. (110 N) force midway between the pulleys. Deflection should be 1/2 inch (1 cm).
To Adjust Fan Drive Belts:
- 1. Loosen the idler pulley bolts (A).
- 2. Pry idler pulley (B) until belts have the proper tension.
- 3. Tighten the idler pulley bolts.
To Adjust Alternator Belts:
- 1. Loosen the mounting bolt (A) and the locknut (B).
- 2. Adjust the alternator belts by either tightening or loosening the adjusting nut (C).
- 3. When the alternator is properly adjusted, tighten the locknut (B) and the mounting bolt (A).
(10)Engine Crankcase
|
Hot oil or components can cause personal injury if they contact skin. Use caution when draining oil or changing filters. |
|
The truck must be level, the parking brake applied, engine stopped, and the oil warm.
- 1. Remove the crankcase drain plug and allow the oil to drain.
- 2. Remove and discard the oil filter.
- 3. If equipped with a Brake Saver, remove the drain plug and drain the oil.
- 4. Clean the filter base housing. Be sure all of the old seal is removed.
- 5. Coat the seal of a new element with a clean engine oil.
- 6. Install the new filter by hand. Turn the filter 3/4 turn after the seal contacts the base.
| NOTICE |
|---|
Do not overtighten the filter. |
The filter may have index marks spaced 90° apart. These marks should be used when tightening the new filter an additional 3/4 turn.
- 7. Install the drain plugs. Fill the crankcase to the FULL mark on the dipstick. See the REFILL CAPACITIES CHART in the ENGINE SPECIFICATIONS section.
Remote mounted or auxiliary filters require additional oil. A 13 qt. supplemental oil filtration system extends the normal interval for CD oils to 12,000 miles.
| NOTICE |
|---|
If equipped with auxiliary oil filter, extra oil must be added when filling the crankcase. If the extra oil is not added, the auxiliary oil filter will take priority and the engine will be starved for oil. |
- 8. Start the engine and inspect for leaks.
- 9. Stop the engine and measure the oil level. Maintain oil to the FULL mark on the dipstick.
(11)Cooling System - Add Cooling System Conditioner If Conditioner Element Is Not Available
|
Always inspect the cooling system with the engine stopped. Conditioner contains alkali, avoid contact with skin and eyes to prevent personal injury. Remove the radiator cap slowly to relieve pressure. Steam can cause personal injury. |
|
The truck must be level, the parking brake applied, and the engine stopped.
| NOTICE |
|---|
All water is corrosive at engine operating temperature. Use either Caterpillar Cooling System Conditioner liquid, or the coolant conditioner element to treat either plain water or ethylene glycol antifreeze solution. NEVER use both the liquid cooling system conditioner and the coolant conditioner element at the same time. |
On a new or reconditioned engine: Add enough Caterpillar Cooling System Conditioner, or equivalent, so that the cooling system will have a 3% to 6% concentration of conditioner. Add 1 pint (.50 liters) for each 4 gal. (15.14 liters) of coolant, to obtain a 3% concentration.
Every 12,500 Miles or 250 Service Hours thereafter: Add 1 pint (.50 liters) for each 16 gal. (60.50 liters) of coolant in the system. This will maintain the required 3% concentration of conditioner.
- 1. Loosen the radiator cap slowly to relieve pressure and remove radiator cap.
It may be necessary to drain enough coolant to allow for the addition of conditioner.
- 2. Add Caterpillar Cooling System Conditioner.
| NOTICE |
|---|
Do not use Caterpillar Cooling System Conditioner with Dowtherm 209 coolant. |
- 3. Inspect the radiator cap gaskets. Replace the cap if the gaskets are damaged.
- 4. Install the radiator cap.