0382796 JOHNSON HOUSING AND RETAINER ASSY.

Walk-Around Inspection
Inspect Engine for Leaks and Loose Connections
For maximum service life of your truck engine, make a thorough under the hood inspection before starting the engine. Look for such items as oil or coolant leaks, loose bolts, worn fan belts, loose connections and trash build-up. Remove trash build-up and have repairs made as needed.Keep a close watch for leaks. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more frequently than the recommended intervals prescribed in this publication. Continue monitoring fluid levels until a leak is found and fixed, or until the suspicion for a leak has been proven to be unwarranted.* Wipe all fittings, caps and plugs before performing maintenance to keep dirt and debris from entering engine components. * Inspect the radiator for leaks and trash build-up. * Inspect the radiator hoses for cracks and loose clamps. * Inspect the fan and accessory drive belts for cracks, breaks or other damage.Belts for multiple groove pulleys must be replaced as matched sets. If only one belt of a 2 or 3 belt set is replaced, it will carry more of a load than the belts not replaced since the older belts are stretched. The additional load on the new belt could cause it to break. * Inspect the water pump for leaks. * Inspect the engine for oil leaks, such as front and rear crankshaft seals, oil pan, oil filters and valve covers. * Inspect the fuel system for leaks, loose fuel line clamps and fittings and loose or worn hoses. * Inspect wiring for loose connections and worn or frayed wires. * Inspect air intake system hoses and elbows for cracks and loose clamps. * Inspect ECM to cylinder head ground strap for good connection and condition.* Inspect engine-to-frame ground strap for good connection and condition.* All guards must be in place. Repair or replace missing or damaged guards.Engine Crankcase
Check Oil Level
Make sure you read and understand the information in the Lubricant Specifications section of this manual before you proceed with maintenance of the crankcase lube oil system.
The vehicle must be parked on a level surface to perform this maintenance procedure.
1. Check the oil level with the engine stopped. 2. Maintain the oil level between the ADD and FULL marks in the FULL RANGE zone on the ENGINE STOPPED side of the dipstick. Do not fill the crankcase above the FULL RANGE zone. Operating your engine when the oil level is above the FULL RANGE zone could cause your crankshaft to dip into the oil. If this happens, the air bubbles created from the crankshaft dipping into the oil will reduce the lubricating characteristics of your oil and would result in the loss of power.If the dipstick does not have a FULL mark in the FULL RANGE zone, refer to Calibrating the oil level gauge in the Dipstick section of this manual or consult your Caterpillar dealer before changing oil and operating the engine. 3. Remove the oil filler cap and add oil if necessary. See Refill Capacities and Lubricant Specifications for the size of your engine crankcase and proper oil to use. Remote mounted or auxiliary filters require additional oil. For all information pertaining to auxiliary filters, refer to the OEM or filter manufacturer's instructions.Cooling System
Check Coolant Level
Make sure you read and understand the information in the "Cooling System Specifications" section of this manual before you proceed with maintenance of the cooling system.
1. Check the coolant level with the engine stopped and cool.2. Remove the filler cap slowly to relieve any pressure.3. Maintain the coolant level within 13 mm (1/2 inch) below the bottom of the fill pipe or to the proper level on the sight glass, if equipped. 4. Inspect the filler cap.Replace the cap if gaskets are damaged. Install the filler cap. 5. Inspect and clean the radiator fins.Engine Air Cleaner
Check Air Cleaner Service Indicator
Typical air cleaner indicator shown.Your engine may be equipped with a different indicator.A service indicator (if equipped) may be mounted on your dashboard or in the engine compartment. A colored piston showing in the window indicates the need for servicing the air cleaner.Observe the air cleaner service indicator. Clean or replace the air cleaner when the yellow diaphragm enters the red zone or the red piston locks in the visible position.As the air cleaner element becomes plugged, the difference of air pressure between the inlet side (dirty side) and the engine side (clean side) will increase.If the air cleaner indicator shows red at any time, clean the filter element or install a new air cleaner element.The primary element (Caterpillar air filters) can be cleaned several times before replacement. The element, when cleaned, should be thoroughly checked for rips or tears in the filter material. Replace the primary element every year even though it has been cleaned.Refer to Guideline for Reusable Parts-Procedures to Inspect and Clean Air Filters, Form SEBF8062 for information on inspecting, cleaning and reusing Caterpillar air filters.Air Cleaner Elements
Clean or replace elements at intervals recommended by the air cleaner OEM or truck manufacturer.Never service the air cleaner with the engine running since this will allow dirt to enter the engine.
Perform maintenance on the air cleaner at regular intervals as determined by the air cleaner OEM or truck manufacturer's recommendations and dust conditions.If your air cleaner element becomes plugged, the air can split the element filter material. This allows unfiltered air into the engine which would drastically accelerate internal engine wear.Your Caterpillar dealer has air filter elements to service most popular makes of trucks. Contact your Caterpillar dealer for the correct filter element to fit your truck.Check the precleaner (if equipped) daily for accumulation of dirt and debris. Remove any dirt and debris as needed.Air-to-Air Aftercooler System
Check
1. Check the front of the air-to-air aftercooler on a daily basis for insects, dirt and other debris.