Marine C7 Service Manual
. MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt ® ® © 2010 Caterpillar All Rights Reserved. SEBU8083-09 March 2009 Operation and Maintenance Manual C7 and C9 On-highway Engines MFF1-Up (Engine) C7S1-Up (Engine) C9S1-Up (Engine) C7W1-Up (Engine) C9W1-Up (Engine) Includes C9 Mass Transit Bus Engines SAFETY.CAT.COM.
Maintenance Section Maintenance Interval Schedule i02871972 Maintenance Interval Schedule (C7 Engines with Shallow Sumps) SMCS Code: 1000; 7500 S/N: C7S1-Up Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. SEBU8083-09 Maintenance Section Maintenance Interval Schedule Daily Cooling System Coolant Level - Check.177 Engine Air Cleaner Service Indicator - Inspect.195 Engine Oil Level - Check.198 Fuel System Water Separator - Check/Drain.224 Walk-Around Inspection. 236 Initial 17 700 km (11 000 miles) or 4150 L (1100 US gal) of Fuel or 250 Service Hours or 6 Months Engine Valve Lash - Inspect/Adjust. SEBU8083-09 Maintenance Section Maintenance Interval Schedule Engine Valve Lash - Inspect/Adjust. 213 Starting Motor - Inspect. 233 Water Pump - Inspect.239 PM Level 3 - Every 483 000 km (300 000 miles) or 190 000 L (50 000 US gal) of Fuel or 6000 Service Hours or 3 Years Turbocharger - Inspect.
Maintenance Section Maintenance Interval Schedule i02871969 Maintenance Interval Schedule (C7 Engines with Deep Sumps) SMCS Code: 1000; 7500 S/N: C7S1-Up Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. SEBU8083-09 Maintenance Section Maintenance Interval Schedule Daily Cooling System Coolant Level - Check.177 Engine Air Cleaner Service Indicator - Inspect.195 Engine Oil Level - Check.198 Fuel System Water Separator - Check/Drain.224 Walk-Around Inspection. 236 Initial 24 000 km (15 000 miles) or 5700 L (1500 US gal) of Fuel or 400 Service Hours or 6 Months Engine Valve Lash - Inspect/Adjust. SEBU8083-09 Maintenance Section Maintenance Interval Schedule Engine Valve Lash - Inspect/Adjust. 213 Starting Motor - Inspect.
233 Water Pump - Inspect.239 PM Level 3 - Every 483 000 km (300 000 miles) or 190 000 L (50 000 US gal) of Fuel or 6000 Service Hours or 3 Years Turbocharger - Inspect. SEBU8083-09 Maintenance Section Maintenance Interval Schedule i02871975 Maintenance Interval Schedule (C9 Engines) SMCS Code: 1000; 7500 S/N: MFF1-Up S/N: C9S1-Up Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.
SEBU8083-09 Maintenance Section Maintenance Interval Schedule Daily Cooling System Coolant Level - Check.177 Engine Air Cleaner Service Indicator - Inspect.195 Engine Oil Level - Check.198 Fuel System Water Separator - Check/Drain.224 Walk-Around Inspection. 236 Initial 24 000 km (15 000 miles) or 7500 L (2000 US gal) of Fuel or 400 Service Hours or 6 Months Compression Brake - Inspect/Adjust. SEBU8083-09 Maintenance Section Maintenance Interval Schedule PM Level 2 - Every 161 000 km (100 000 miles) or 56 850 L (15 000 US gal) of Fuel or 2000 Service Hours or 2 Years Air Compressor - Inspect.159 Alternator - Inspect.
Refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” for information about the types of fuels that may be used in this Caterpillar On-highway Engine. Use the following table to determine the correct interval for cleaning the ARD nozzle. Regeneration Device (ARD) is available at your Caterpillar dealer. The cleaner is already measured into a dispenser.
Contact your authorized Caterpillar dealer for the current part number for the filled bottle. Turn off the engine. Use an allen wrench in order to remove the access plug from the cleaning port. SEBU8083-09 Maintenance Section ARD Nozzle - Clean g01351825 Illustration 36 The cleaning port is located on the left side of the engine to the left of the fuel filter on the C9 Engine. The priming pump that is shown is optional. Note: Remove the red cap from the dispenser immediately before use. SEBU8083-09 Maintenance Section ARD Spark Plug - Inspect/Replace Squeeze the container in order to dispense the fluid.
All of the fluid should be dispensed before the dispenser is removed from the cleaning port. Remove the dispenser and ensure that all of the liquid was dispensed.
Inspect the cleaning port in order to ensure that no part of the dispenser remains in the cleaning port. SEBU8083-09 Maintenance Section ARD Spark Plug - Inspect/Replace g01308813 Illustration 39 (1) Wiring harness (2) Spark plug 1. Remove wire harness (1) from spark plug (2). Personal injury can result from air pressure. Personal injury can result without following prop- er procedure. ARD Spark Plug - Inspect/Replace 3.
Use a deep well socket and a breaker bar to loosen the spark plug. If necessary, see your Caterpillar dealer for the part number of the socket. After the spark plug has been loosened, use the socket to remove the spark plug by hand in order to detect problems with the threads. SEBU8083-09 Maintenance Section Aftercooler Core - Clean/Test NOTICE Do not overtighten the spark plug. The shell can be cracked and the gasket can be deformed. The met- al can deform and the gasket can be damaged.
The shell can be stretched. This will loosen the seal that is between the shell and the insulator, allowing combus- tion pressure to blow past the seal. SEBU8083-09 Maintenance Section Air Compressor - Inspect g01212654 Illustration 40 Typical example (1) Pressure relief valve If the air compressor pressure relief valve that is mounted in the air compressor cylinder head is bypassing compressed air, there is a malfunction in the air system, possibly ice blockage. SEBU8083-09 Maintenance Section Air Dryer - Check Refer to the Service Manual or refer to the OEM specifications in order to find information concerning the air compressor. Consult your Caterpillar dealer for assistance. I00863920 Air Dryer - Check SMCS Code: 4285-535 Follow the maintenance recommendations that are provided by the OEM or consult your Caterpillar dealer for assistance. SEBU8083-09 Maintenance Section Battery - Replace i02153996 Battery - Replace SMCS Code: 1401-510 Batteries give off combustible gases which can explode.
A spark can cause the combustible gas- es to ignite. This can result in severe personal in- jury or death. Ensure proper ventilation for batteries that are in an enclosure. SEBU8083-09 Maintenance Section Battery - Replace Note: Always recycle a battery. Never discard a battery. Return used batteries to an appropriate recycling facility.
Remove the used battery. Install the new battery. Note: Before the cables are connected, ensure that the key start switch is OFF. SEBU8083-09 Maintenance Section Battery Electrolyte Level - Check i02601752 Battery Electrolyte Level - Check SMCS Code: 1401-535 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. SEBU8083-09 Maintenance Section Battery or Battery Cable - Disconnect i01492654 Battery or Battery Cable - Disconnect SMCS Code: 1402-029 The battery cables or the batteries should not be removed with the battery cover in place. The bat- tery cover should be removed before any servic- ing is attempted. SEBU8083-09 Maintenance Section Belts - Inspect/Adjust/Replace i02719973 Belts - Inspect/Adjust/Replace SMCS Code: 1357-025; 1357-040; 1357-510 g01272337 Illustration 41 Your engine is equipped with a serpentine belt (1). For maximum engine performance and maximum utilization of your engine, inspect the belt for the following conditions: wear, cracks, and damage.
S/N: MFF1-Up S/N: C9S1-Up S/N: C9W1-Up The maintenance of the Caterpillar compression brake should be performed in conjunction with scheduled maintenance of the valve lash. Note: The adjustment of the actuator piston lash must be performed after the engine valve lash adjustment is performed. Make the adjustment of the actuator piston lash while the engine is stopped. Use only cooling system cleaners that are ap- proved for Caterpillar engines. Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained.
C7 Service Manual
This is a good opportunity to replace the water pump, the water temperature regulator and the hoses, if necessary. Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L (4 US gal) of the cooling system capacity. SEBU8083-09 Maintenance Section Cooling System Coolant (DEAC) - Change NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal com- ponents. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear wa- ter.
Maintenance Section Cooling System Coolant (DEAC) - Change 3. Fill the cooling system with a mixture of clean water and Caterpillar Fast Acting Cooling System Cleaner.
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. Install the cooling system filler cap. SEBU8083-09 Maintenance Section Cooling System Coolant (ELC) - Change 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).
Caterpillar to reclaim the used coolant. For information regarding the disposal and the recycling of used coolant, consult your Caterpillar dealer or consult Caterpillar Dealer Service Tool Group: Outside Illinois: 1-800-542-TOOL Inside Illinois: 1-800-541-TOOL. Fill the cooling system with Extended Life Coolant (ELC). See Special Publication, SEBU6385, “Caterpillar On-highway Diesel Truck Engine Fluids Recommendations” for more information on cooling system specifications. Do not install the cooling system filler cap. SEBU8083-09 Maintenance Section Cooling System Coolant Extender (ELC) - Add 4.
Clean the cooling system filler cap. Inspect the gasket that is on the cooling system filler cap. If the gasket that is on the cooling system filler cap is damaged, discard the old cooling system filler cap and install a new cooling system filler cap. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.
SEBU8083-09 Maintenance Section Cooling System Coolant Level - Check For more information about Cat ELC Extender, refer to Special Publication, SEBU6385, “Caterpillar On-highway Diesel Engine Fluid Recommendations”. I01197583 Cooling System Coolant Level - Check SMCS Code: 1395-082 Check the coolant level when the engine is stopped and cool.
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 Caterpillar dealer.
Use the following guidelines for proper sampling of the coolant:. Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see this Operation and Maintenance Manual, “Refill Capacities and Recommendations” article or consult with your Caterpillar dealer. Coolant Sample (Level 1) - Obtain” for the guidelines for proper sampling of the coolant. Submit the sample for Level 2 analysis. For additional information about coolant analysis, see Special Publication, SEBU6385, “Caterpillar On-highway Diesel Engines Fluids Recommendations” or consult your Caterpillar dealer. I03085828 Cooling System Supplemental Coolant Additive (SCA) - Test/Add SMCS Code: 1352-045. Do not drink cooling system coolant additive.
Use the 4C-9301 Coolant Conditioner Test Kit in order to check the concentration of the SCA. Refer to the Special Publication, SEBU6385, “Caterpillar On-highway Diesel Engine Fluid Recommendations” for more information. If necessary, drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA. Add the proper amount of SCA. Refer to Special Publication, SEBU6385, “Caterpillar On-highway Diesel Truck Engine Fluid Recommendations” for more information on SCA requirements. SEBU8083-09 Maintenance Section Cooling System Water Temperature Regulator - Replace 4. Clean the cooling system filler cap.
Inspect the gaskets of the cooling system filler cap. If the gaskets are damaged, replace the old cooling system filler cap with a new cooling system filler cap. Install the cooling system filler cap. 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 incor- rectly, the engine may overheat, causing cylinder head damage. SEBU8083-09 Maintenance Section Crankcase Fumes Fitting - Inspect/Clean i02678214 Crankcase Fumes Fitting - Inspect/Clean SMCS Code: 1317-040; 1317-070 g01345683 Illustration 44 (1) Clamps (2) Nut (3) Fitting 1. Loosen the clamps that attach the tube that carries fumes from the engine crankcase breather to the aftertreatment regeneration device (ARD). SEBU8083-09 Maintenance Section Crankcase Fumes Fitting - Inspect/Clean 3.
If fitting (3) is accessible, this procedure may be performed with the fitting on the combustion head. If the fitting is not accessible, remove the fitting and use a vise to hold the fitting. There is a large amount of gear train wear that is not caused by a lack of oil. Refer to the Disassembly and Assembly Manual, “Vibration Damper and Pulley - Remove and Install” or consult your Caterpillar dealer for information about damper replacement.
SEBU8083-09 Maintenance Section Cylinder Head Grounding Stud - Inspect/Clean/Tighten i02370278 Cylinder Head Grounding Stud - Inspect/Clean/Tighten SMCS Code: 7423-040; 7423-070; 7423-079 g01182654 Illustration 45 Cylinder head grounding stud Inspect the OEM harness for good connections and condition. The cylinder head grounding stud must have a wire ground to the battery. Tighten the cylinder head grounding stud at every oil change.
SMCS Code: 1091-070 Note: Caterpillar recommends the use of the Caterpillar ash service tool. Caterpillar does not endorse the use of non-Caterpillar ash service tools.
Improper cleaning or repair of the diesel particulate filter (DPF) can damage the DPF and the engine aftertreatment system. Contact your Caterpillar dealer for more information. SEBU8083-09 Maintenance Section Diesel Particulate Filter - Clean Exceptions to Minimum Maintenance Intervals A number of vehicle applications impose certain restraints on the locations of exhaust system components. These applications are primarily classified as medium service and heavy-duty service. The Environmental Protection Agency has determined that a DPF that has a reduced size may be installed in a vehicle if the DPF is cleaned more frequently.
Any vehicle that has a DPF that is mounted behind the cab and outside of the frame rails Please consult your Caterpillar dealer in order to determine if a DPF with a reduced volume is installed in your vehicle. A DPF with a reduced volume requires a more frequent maintenance interval. SEBU8083-09 Maintenance Section Engine - Clean i01646701 Engine - Clean SMCS Code: 1000-070 Personal injury or death can result from high volt- age. Moisture can create paths of electrical conductiv- ity.
Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls “DO NOT OPERATE”. 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 Caterpillar dealer has the proper air cleaner elements for your application.
Consult your Caterpillar dealer for the correct air cleaner element. SEBU8083-09 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace g00736431 Illustration 46 (1) Cover (2) Primary air cleaner element (3) Secondary air cleaner element (4) Air inlet for the turbocharger 1. Remove the cover. Remove the primary air cleaner element. Maintain a supply of suitable air cleaner elements for replacement purposes.
Your Caterpillar dealer has the proper air cleaner elements for your application. Consult your Caterpillar dealer for the correct air cleaner element or follow the instructions that are provided by the OEM. SEBU8083-09 Maintenance Section Engine Air Cleaner Service Indicator - Inspect 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.
SEBU8083-09 Maintenance Section Engine Air Cleaner Service Indicator - Inspect. Check the movement of the yellow core when the 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. SEBU8083-09 Maintenance Section Engine Crankcase Breather - Clean i02333200 Engine Crankcase Breather - Clean SMCS Code: 1317-070 g01164541 Illustration 48 1. Remove the cover on breather (1).
Remove the breather assembly and the seal. Wash the breather element in solvent that is clean and nonflammable. Allow the breather element to dry before installation. SEBU8083-09 Maintenance Section Engine Oil Level - Check g01182634 Illustration 49 Typical configuration (1) Oil level gauge (2) Oil filler cap g00110310 Illustration 50 (Y) “ADD” mark (X) “FULL” mark NOTICE Perform this maintenance with the engine stopped. Note: Before you perform this maintenance, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. SEBU8083-09 Maintenance Section Engine Oil Level Gauge - Calibrate NOTICE Engine damage can occur if the crankcase is filled above the “FULL” mark on the oil level gauge (dip- stick).
An overfull crankcase can cause the crankshaft to dip into the oil. This will reduce the power that is devel- oped and also force air bubbles into the oil.
20 minutes. Remove the used oil filter(s). Install the new oil filter(s). Install the oil drain plugs and tighten to 70 ± 15 Nm (50 ± 11 lb ft).
Caterpillar recommends the use of Cat Advanced Efficiency oil filters. SEBU8083-09 Maintenance Section Engine Oil Level Gauge - Calibrate 8. Check the oil level on the oil level gauge. The oil level should be at the “FULL” mark. If the oil level is not at the existing “FULL” mark, grind off the “FULL”. Engine Oil Sample - Obtain SMCS Code: 1000-008; 1348-554-SM; 7542-554-OC, SM In addition to a good preventive maintenance program, Caterpillar recommends using SOS oil analysis at regularly scheduled intervals in order to monitor the condition of the engine and the maintenance requirements of the engine. To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean.
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. Dealer Service Tool Catalog” or refer to Special Pub- lication, PECJ0003, “Caterpillar Shop Supplies and Tools Catalog” for tools and supplies suitable to col- lect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. (50 ± 11 lb ft) Replace the Oil Filter NOTICE Caterpillar oil filters are built to Caterpillar speci- fications.
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. Due to normal wear and friction, it is not uncommon to find small amounts of debris in the oil filter. Consult your Caterpillar dealer in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter.
SEBU8083-09 Maintenance Section Engine Oil and Filter - Change 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. Note: The following requirements must be met in order to use table 18.:.
Cat DEO-ULS is used or an oil that meets the requirements of the Caterpillar ECF-3 (Engine Crankcase Fluid specification-3) specification is used. SOS Services oil analysis is performed at 16,100 km (10,000 mile) intervals and all oil change intervals. Engine Oil and Filter - Change Note: Caterpillar cannot guarantee the performance of lubricants or filters that are not sold by Caterpillar. The performance guarantee of any commercially available lubricant is the responsibility of that oil company.
The performance guarantee of any commercially available filter is the responsibility of the filter manufacturer. Maximum Permissible Oil Change Intervals Vehicle Applications Engine Light Medium Heavy Severe Duty Duty Duty Model Service KM (Miles) to Next Oil Change C7 Engine 5 (10800) (8640 ) (6480) (4320) with a Shallow Sump 18 L (19 qt). 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.
The adjustment is necessary due to the initial wear of the valve train components and to the seating of the valve train components. This maintenance is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life.
The belt guards have been removed in this illustration. Note: In some applications, the fan drives are supplied by the OEM. Refer to the OEM specifications if the fan drive is not supplied by Caterpillar. Lubricate the grease fitting that is on the fan drive bearing with Bearing Lubricant or the equivalent. SEBU8083-09 Maintenance Section Fuel System - Prime i02686443 Fuel System - Prime SMCS Code: 1258-548 Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu- el spray may cause a fire hazard. Failure to fol- low these inspection, maintenance and service in- structions may cause personal injury or death.
SEBU8083-09 Maintenance Section Fuel System - Prime After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments.
SEBU8083-09 Maintenance Section Fuel System - Prime 1. Check that the fuel supply valve (if equipped) is in the “ON” position. Open the fuel priming pump and operate the fuel priming pump until a strong pressure is felt.
This procedure will require considerable strokes. If the fuel has been contaminated with water, the element should be changed before the regularly scheduled interval. Note: Caterpillar requires the use of a 10 micron(c) absolute primary fuel filter with a water separator. Fuel leaked or spilled onto hot surfaces or elec- trical components can cause a fire. Dealer Service Tool Catalog” or refer to Special Pub- lication, PECJ0003, “Caterpillar Shop Supplies and Tools Catalog” for tools and supplies suitable to col- lect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.
SEBU8083-09 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 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. SEBU8083-09 Maintenance Section Fuel System Secondary Filter - Replace Primary Fuel Filter and Water Separator which are Provided by an OEM 1. Close the main fuel supply valve. In order to replace the primary fuel filter, use the instructions which are provided by the OEM.
Dealer Service Tool Catalog” or refer to Special Pub- lication, PECJ0003, “Caterpillar Shop Supplies and Tools Catalog” for tools and supplies suitable to col- lect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Install the new fuel filter. Spin the fuel filter onto the fuel filter base until the gasket contacts the base. Instructions for the installation of the filter are printed on the side of each Caterpillar spin-on filter.
For non-Caterpillar filters, refer to the installation instructions that are provided by the supplier of the filter. Dealer Service Tool Catalog” or refer to Special Pub- lication, PECJ0003, “Caterpillar Shop Supplies and Tools Catalog” for tools and supplies suitable to col- lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates. Dealer Service Tool Catalog” or refer to Special Pub- lication, PECJ0003, “Caterpillar Shop Supplies and Tools Catalog” for tools and supplies suitable to col- lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates. SEBU8083-09 Maintenance Section Fuel Tank Water and Sediment - Drain 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. SEBU8083-09 Maintenance Section Hoses and Clamps - Inspect/Replace i02357283 Hoses and Clamps - Inspect/Replace SMCS Code: 7554-040; 7554-510 Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu- el spray may cause a fire hazard.
Failure to fol- low these inspection, maintenance and service in- structions may cause personal injury or death. SEBU8083-09 Maintenance Section Hoses and Clamps - Inspect/Replace. Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp. Ensure that the constant torque hose clamp is the same size as the standard clamp. SEBU8083-09 Maintenance Section Radiator - Clean 5. Disconnect the old hose.
Replace the old hose with a new hose. Install the hose clamps with a torque wrench. Note: Refer to the Specifications, SENR3130, “Torque Specifications” in order to locate the proper torques.
SEBU8083-09 Maintenance Section Severe Service Application - Check 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. Slowly move the air nozzle in a direction that is parallel with the tubes. (1)(2) Average Average Average Gross Vehicle Miles Kilometer liters per Engine Model Weight per Liter 100 km Gallon C7 On-highway 22680 kg 23.5 Engine (50000 lb) 27215 kg 29.4 C9 On-highway Engine (60000 lb) 27215 kg 58.8 C9 On-highway Engine (Urban. Extending maintenance beyond the recommended maintenance intervals. Use of fuels, coolants or lubricants that are not specified by Caterpillar in Special Publication, SEBU6385, “Caterpillar On-highway Diesel Truck Engine Fluids Recommendations”.
Frequent operation at low idle (more than 20%). 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. Check the starting motor for proper operation. Check the electrical connections and clean the electrical connections.
SEBU8083-09 Maintenance Section Turbocharger - Inspect A risk of corrosion exists for the compressor side of the turbocharger if ultralow sulfur diesel fuel is not used. A risk of corrosion exists for the compressor side of the turbocharger if unfiltered air intake occurs. If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Dispose of all fluids according to local regulations and mandates.
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. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.
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. Check the engine oil level. 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. SEBU8083-09 Maintenance Section Walk-Around Inspection. Check the water separator (if equipped) for water on a daily basis. Drain any water from the water separator.
If necessary, drain the water and the sediment from fuel tanks in order to ensure that only clean fuel enters the fuel system. Removal and Installation Refer to the Service Manual for more information on the removal and installation of the water pump, or consult your Caterpillar dealer for assistance.
Inspect the Bearing for the Water Pump Pulley Inspect the water pump pulley for unusual noise, excessive looseness and/or vibration of the bearings.