CAT CAT C 15 Operation and maintenance manuel Operation

Operation and
Maintenance
Manual

SEBU7902-08 (en-us)

January 2019

C15 Industrial Engines

JRE 1-UP (Engine)
MCW 1-UP (Engine)
JAS 1-UP (Engine)
JKG 1-UP (Engine)
PBN 1-UP (Package)
PDM 1-UP (Package)

PUBLICATIONS.CAT.COM

i06558969

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially
presented.

A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.

The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this
product Caterpillar recommends using Cat re­placement parts.

Failure to follow this warning may lead to pre­mature failures, product damage, personal in­jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.

SEBU7902-08

3

Table of Contents

Table of Contents

Foreword ........................................................... 4

Safety Section

Safety Messages............................................... 6

General Hazard Information.............................. 7

Burn Prevention............................................... 10

Fire Prevention and Explosion Prevention.......11

Crushing Prevention and Cutting Prevention.. 13

Mounting and Dismounting ............................. 13

Before Starting Engine .................................... 13

Engine Starting ................................................ 14

Engine Stopping .............................................. 14

Refill Capacities............................................... 47

Maintenance Recommendations .................... 56

Maintenance Interval Schedule (Engines Which

Have Shallow Sumps) ................................... 59

Maintenance Interval Schedule (Engines Which

Have Deep Sumps) ....................................... 61

Warranty Section

Warranty Information....................................... 98

Reference Information Section

Engine Ratings ................................................ 99

Customer Service.......................................... 100

Reference Materials ...................................... 102

Index Section

Electrical System............................................. 15

Engine Electronics........................................... 16

Product Information Section

General Information ........................................ 17

Product Identification Information ................... 20

Operation Section

Lifting and Storage .......................................... 22

Features and Controls..................................... 25

Engine Diagnostics ......................................... 29

Engine Starting ................................................ 39

Engine Operation ............................................ 42

Cold Weather Operation ................................. 44

Index.............................................................. 105

Engine Stopping .............................................. 46

Maintenance Section

4

Foreword

SEBU7902-08

Foreword

California Proposition 65 Warning

Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.

WARNING – This product can
expose you to chemicals

including ethylene glycol, which

is known to the State of California to
cause birth defects or other reproductive

harm. For more information go to:

www.P65Warnings.ca.gov

Do not ingest this chemical. Wash hands
after handling to avoid incidental
ingestion.

WARNING – This product can
expose you to chemicals

including lead and lead
compounds, which are known to the
State of California to cause cancer, birth

defects, or other reproductive harm. For
more information go to:

www.P65Warnings.ca.gov

Wash hands after handling components
that may contain lead.

Literature Information

This manual contains safety, operation instructions,
lubrication, and maintenance information. This

manual should be stored in or near the engine area in
a literature holder or literature storage area. Read,
study, and keep it with the literature and engine
information.

English is the primary language for all Cat
publications. The English used facilitates translation
and consistency in electronic media delivery.

Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual Whenever a question
arises regarding your engine, or this manual, please
consult with your Cat dealer for the latest available
information.

Safety

This safety section lists basic safety precautions. In
addition, this section identifies hazardous, warning
situations. Read and understand the basic

precautions listed in the safety section before
operating or performing lubrication, maintenance,
and repair on this product.

Operation

Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.

The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating,
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.

Maintenance

The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by fuel consumption, service hours and/or calendar
time maintenance intervals. Items in the maintenance

schedule are referenced to detailed instructions that
follow.

Use fuel consumption or service hours to determine
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals if
they provide more convenient schedules and
approximate the indicated service meter reading.

Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
freezing cold operating conditions, more frequent
lubrication, and maintenance than is specified in the
Maintenance Interval Schedule may be necessary.

SEBU7902-08

The maintenance schedule items are organized for a
preventive maintenance management program. If the
preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.

Maintenance Intervals

Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back

depending upon your specific maintenance practices,
operation, and application. We recommend that the
maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be

maintained as part of the engine's permanent record.

See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information

regarding documents that are accepted as proof of
maintenance or repair. Your authorized Cat dealer
can assist you in adjusting your maintenance
schedule to meet the needs of your operating
environment.

5

Foreword

Overhaul

Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.

Major repairs are best left to trained personnel or an
authorized Cat dealer. Your Cat dealer offers various

options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available
from your Cat dealer. Consult with your dealer for
information regarding these options.

6

Safety Section
Safety Messages

Safety Section

Safety Messages

SMCS Code: 1000; 7405

SEBU7902-08

i02840190

Illustration 1 g01416710

Universal Warning (1)

Do not operate or work on this engine unless you
have read and understand the instructions and

warnings in the Operation and Maintenance Man­ual. Failure to follow the instructions or heed the

warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.

There may be several specific safety messages on
your engine. The exact location and a description of
the safety messages are reviewed in this section.
Please become familiar with all safety messages.

Ensure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and

soap to clean the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off of
the engine.

Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.

The safety messages for the universal warning are
located toward the front of the engine on both sides
of the valve cover base.

SEBU7902-08

Illustration 2 g01105289

Do not operate or work on this engine unless you
have read and understand the instructions and

warnings in the Operation and Maintenance Man­ual. Failure to follow the instructions or heed the

warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.

7

Safety Section

General Hazard Information

Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of the
cover plate or the device. Before removing the last
two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.

i06300340

General Hazard Information

SMCS Code: 1000; 4450; 7405

Illustration 3 g03838041

Attach a “Do Not Operate” warning tag to the start
switch or controls before the engine is serviced or
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each
operator control station. When appropriate,
disconnect the starting controls.

Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.

Illustration 4 g00702020

• Wear a hard hat, protective glasses, and other
protective equipment, as required.

• When work is performed around an engine that is
operating, wear protective devices for ears in
order to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers
are secured in place on the engine.

• Never put maintenance fluids into glass
containers. Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, perform
the maintenance under the following conditions:

• The engine is stopped. Ensure that the engine
cannot be started.

8

Safety Section
General Hazard Information

SEBU7902-08

• The protective locks or the controls are in the
applied position.

• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.

• When starting a new engine, make provisions to
stop the engine if an overspeed occurs. If an
engine has not been started since service has
been performed, make provisions to stop the
engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine.

• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.

• Start the engine with the operator controls. Never
short across the starting motor terminals or the
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the
electrical system could be damaged.

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or
hot water to be blown out which could result in
personal injury.

The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).

When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield. Always wear eye
protection for cleaning the cooling system.

Avoid direct spraying of water on electrical
connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when
redeposited on hot surfaces.

Fluid Penetration

Illustration 5 g00687600

Always use a board or cardboard when you check for
a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.

Containing Fluid Spillage

NOTICE
Care must be taken to ensure that fluids are con­tained during performance of inspection, mainte-

nance, 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.

SEBU7902-08

9

Safety Section

General Hazard Information

Static Electricity Hazard when
Fueling with Ultra-low Sulfur Diesel
Fuel

The removal of sulfur and other compounds in ultra­low sulfur diesel fuel (ULSD fuel) decreases the
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.

Avoid static electricity risk when fueling. Ultra­low sulfur diesel fuel (ULSD fuel) poses a greater
static ignition hazard than earlier diesel formula­tions with a higher sulfur contents. Avoid death
or serious injury from fire or explosion. Consult
with your fuel or fuel system supplier to ensure
the delivery system is in compliance with fueling
standards for proper grounding and bonding
practices.

Lines, Tubes, and Hoses

Do not bend or strike high-pressure lines. Do not
install lines, tubes, or hoses that are damaged.

Repair any fuel lines, oil lines, tubes, or hoses that
are loose or damaged. Leaks can cause fires.

Inspect all lines, tubes, and hoses carefully. Do not
use bare hands to check for leaks. Always use a
board or cardboard for checking engine components
for leaks. Tighten all connections to the
recommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. Correct
installation of these components will help to prevent
these effects: vibration, rubbing against other parts
and excessive heat during operation.

Inhalation

Illustration 6 g02159053

Exhaust

Use caution. Exhaust fumes can be hazardous to
your health. If you operate the equipment in an

enclosed area, adequate ventilation is necessary.

Asbestos Information

Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains

asbestos is generated.

If dust that may contain asbestos is present, there
are several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos

materials.

10

Safety Section
Burn Prevention

SEBU7902-08

• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.

• Use exhaust ventilation on permanent machining
jobs.

• Wear an approved respirator if there is no other
way to control the dust.

• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposal of
asbestos.

• Stay away from areas that might have asbestos
particles in the air.

Softwrap

Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate
protective clothing in order to minimize direct contact.
Use good hygiene practices and wash hands
thoroughly after handling Softwrap material. Do not
smoke until washing hands thoroughly after handling
Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean
up debris.

Reference: The applicable material safety data
sheets can be found at the following web site by
searching using part number or the name:

https://catmsds.cat.com/MSDSSearch/servlet/
cat.cis.ecs.
msdsSearch.controller.
UserIdentificationDisplayServlet

Dispose of Waste Properly

Illustration 7 g00706404

Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.

Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.

i02088921

Burn Prevention

SMCS Code: 1000; 4450; 7405

Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
appropriate system before any lines, fittings or
related items are disconnected.

Coolant

When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.

Allow cooling system components to cool before the
cooling system is drained.

SEBU7902-08

11

Safety Section

Fire Prevention and Explosion Prevention

Check the coolant level after the engine has stopped
and the engine has been allowed to cool. Ensure that
the filler cap is cool before removing the filler cap.
The filler cap must be cool enough to touch with a
bare hand. Remove the filler cap slowly in order to
relieve pressure.

Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.

Oils

Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot
components to contact the skin.

If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.

Batteries

The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.

Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.

Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.

i07254650

Fire Prevention and Explosion
Prevention

SMCS Code: 1000; 4450; 7405

All fuels, most lubricants, and some coolant mixtures
are flammable.

Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
product when a fire hazard exists. Contact your Cat
dealer for service.

Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property
damage.

A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an

emergency shutdown.

Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.

If the application involves the presence of
combustible gases, consult your Cat dealer for
additional information about suitable protection
devices.

Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable

materials to accumulate on the engine.

All fluids that are captured in the fluid spill
containment basin should be cleaned up
immediately. Failure to clean up spilled fluids can
cause a fire. Fire may cause personal injury and
property damage.

Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for

storing flammable materials.

Do not expose the engine to any flame.

Illustration 8 g00704000

Use of personal protection equipment (PPE) may be
needed.

Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in a line, a tube, or
a seal failure. Exhaust shields must be installed

correctly.

Do not weld on lines or tanks that contain flammable
fluids. Do not use flame to cut lines or tanks that
contain flammable fluid. Clean any such lines or

tanks thoroughly with a nonflammable solvent prior to
welding or flame cutting.

Wiring must be kept in good condition. Properly route
and attach all electrical wires. Check all electrical

wires daily. Repair any wires that are loose or frayed
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.

Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.

12

Safety Section
Fire Prevention and Explosion Prevention

Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.

Inspect all lines and hoses for wear or for
deterioration. Properly route all hoses. The lines and
hoses must have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.

Properly install all oil filters and fuel filters. The filter
housings must be tightened to the proper torque.

SEBU7902-08

Illustration 9 g00704059

Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not
refuel an engine near open flames or sparks. Always
stop the engine before refueling.

Avoid static electricity risk when fueling. Ultra Low
Sulfur Diesel (ULSD) poses a greater static ignition
hazard than earlier diesel formulations with a higher
Sulfur content. Avoid death or serious injury from fire
or explosion. Consult with your fuel or fuel system
supplier to ensure that the delivery system is in
compliance with fueling standards for proper
grounding and bonding practices.

Illustration 10 g02298225

Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.

Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a
hydrometer.

Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.

Do not charge a frozen battery. Charging a frozen
battery may result in an explosion.

The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

Ether

Ether is flammable and poisonous.

Use ether in ventilated areas. Do not smoke while
you are replacing an ether cylinder or while you are

using an ether spray.

SEBU7902-08

13

Safety Section

Crushing Prevention and Cutting Prevention

Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49 °C
(120 °F). Keep ether cylinders away from open
flames or sparks.

Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.

Do not spray ether into an engine if the engine is
equipped with a thermal starting aid for cold weather
starting.

Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike high­pressure lines. Do not install any lines that are bent
or damaged.

Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Cat dealer for repair or
for replacement parts.

Check lines, tubes, and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.

Replace the parts if any of the following conditions
are present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
performed. After the maintenance is performed,
reinstall the guards.

Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.

When objects are struck, wear protective glasses in
order to avoid injury to the eyes.

Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.

i01372247

Mounting and Dismounting

SMCS Code: 1000; 4450; 7405

Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.

Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
controls as handholds.

Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.

Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shields
are installed correctly to prevent vibration, rubbing
against other parts, and excessive heat.

i01359666

Crushing Prevention and
Cutting Prevention

SMCS Code: 1000; 4450; 7405

Support the component properly when work beneath
the component is performed.

Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.

i03560601

Before Starting Engine

SMCS Code: 1000

NOTICE

For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.

14

Safety Section
Engine Starting

Engine exhaust contains products of combustion
which may be harmful to your health. Always
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust

to the outside.

Inspect the engine for potential hazards.

Do not start the engine or move any of the controls if
there is a “DO NOT OPERATE” warning tag or similar
warning tag attached to the start switch or to the
controls.

SEBU7902-08

To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge and the
oil temperature gauge during the heater operation.

Engine exhaust contains products of combustion that
can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.

Ether

Ether is poisonous and flammable.

Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.

If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.

All protective guards and all protective covers must
be installed if the engine must be started in order to
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.

Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are

provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.

See the Service Manual for repairs and for
adjustments.

i01103904

Engine Starting

SMCS Code: 1000

If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.

All protective guards and all protective covers must
be installed if the engine must be started in order to
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.

Start the engine from the operator's compartment or
from the engine start switch.

Always start the engine according to the procedure
that is described in this Operation and Maintenance
Manual, “Engine Starting” topic (Operation Section).
Knowing the correct procedure will help to prevent
major damage to the engine components. Knowing
the procedure will also help to prevent personal
injury.

Do not inhale ether, and do not allow ether to contact
the skin. Personal injury could result.

Do not smoke while ether cylinders are changed.

Use ether in well ventilated areas.

Use ether with care in order to avoid fires.

Keep ether cylinders out of the reach of unauthorized
persons.

Store ether cylinders in authorized storage areas
only.

Do not store ether cylinders in direct sunlight or at
temperatures above 49 °C (120 °F).

Discard the ether cylinders in a safe place. Do not
puncture the ether cylinders. Do not burn the ether
cylinders.

i01462046

Engine Stopping

SMCS Code: 1000

Stop the engine according to the procedure in the
Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
the engine components.

Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.

Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled. This may be
accomplished by shutting off the fuel supply to the
engine and/or shutting off the air supply to the
engine.

To stop an electronically controlled engine, cut the
power to the engine.

SEBU7902-08

i02469632

Electrical System

SMCS Code: 1000; 1400

Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” jump start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.

Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. Refer to
the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.

15

Safety Section

Electrical System

Grounding Practices

Illustration 12 g00771487

Typical example
Alternate Grounding Stud To Battery Ground

Proper grounding for the engine electrical system is
necessary for optimum engine performance and
reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.

Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.

Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.

To ensure that the engine and the engine electrical
systems function properly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a starting
motor ground, a starting motor ground to the frame,
or a direct engine ground to the frame.

Illustration 11 g00771448

Typical example
Grounding Stud To Battery Ground

16

Safety Section
Engine Electronics

All grounds should be tight and free of corrosion. The
engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.

i02784356

Engine Electronics

SMCS Code: 1000; 1900

Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.

This engine has a comprehensive, programmable
Engine Monitoring System. The Engine Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.

SEBU7902-08

The following actions are available for engine
monitoring control: WARNING, DERATE and
SHUTDOWN. These engine monitoring modes have
the ability to limit engine speed and/or the engine

power.

Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring
functions. The following parameters can be
monitored as a part of the Engine Monitoring System:

• Operating Altitude

• Engine Coolant Level

• Engine Coolant Temperature

• Engine Oil Pressure

• Engine Speed

• Fuel Temperature

• Intake Manifold Air Temperature

• System Voltage

The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.

Note: Many of the engine control systems and
display modules that are available for Caterpillar
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting
Manual for more information.

SEBU7902-08

Product Information
Section

General Information

Model View Illustrations

SMCS Code: 1000

17

Product Information Section

General Information

i02093819

Illustration 13 g00947237

(1) Inlet air manifold
(2) Lifting eyes
(3) Engine crankcase breather
(4) Water temperature regulator housing

(5) Low pressure turbocharger
(6) High pressure turbocharger
(7) Cooler
(8) Engine oil filter

(9) Water pump
(10) Vibration damper

18

Product Information Section
Product Description

SEBU7902-08

Illustration 14 g00947236

(11) Air compressor (12) Fuel transfer pump (13) Fuel filter

i04250469

Very high injection pressures are produced by
electronically controlled, mechanically actuated unit

Product Description

SMCS Code: 1000; 4450; 4491

Table 1

C15 Engine Specifications

Cylinders and Arrangement In-line six cylinder

Bore

Stroke

Displacement 15.2 L (928 in

Firing Order

Rotation (flywheel end)

The electronic engines that are covered by this
manual have the following characteristics: direct fuel
injection, electronic unit injection that is mechanically
actuated, turbocharged and air-to-air aftercooled
(ATAAC).

The electronic engine control system provides the
following functions: electronic governing, automatic
air to fuel ratio control, torque rise shaping, injection
timing control and system diagnostics.

An electronic governor controls the output of the unit
injectors in order to maintain the engine rpm that is

137.2 mm (5.4 inch)

171.5 mm (6.8 inch)

3

)

1-5-3-6-2-4

Counterclockwise

injectors. The injectors combine the pumping and the
electronic fuel metering (duration and timing) during
injection. The unit injectors accurately control smoke
limiting, white smoke, and engine acceleration rates.

There is one unit injector per cylinder. Individual unit
injectors meter the fuel. The individual unit injectors
also pump the fuel. The metering and the pumping is
done under high pressure. High injection pressures
help to reduce fuel consumption and emissions. The
use of this type of unit injector provides total
electronic control of injection timing. The injection
timing varies with engine operating conditions. The
engine performance is optimized in the following

areas:

• Starting

• Emissions

• Noise

• Fuel consumption

The timing advance is achieved through precise
control of the injector firing. Engine speed is
controlled by adjusting the firing duration. The
information is provided to the Electronic Control
Module (ECM) by an engine speed/timing sensor.
The information is for detection of cylinder position
and engine speed.

desired. The functions of the governor include a
programmable low idle and a 20 rpm to 200 rpm

governor overrun.

SEBU7902-08

19

Product Information Section

Product Description

The engines have built-in diagnostics in order to
ensure that all of the components are functioning and
operating properly. In the event of a system
component deviation from the programmed limits, the
operator is alerted to the condition by a
DIAGNOSTIC lamp that is mounted on the control
panel. An electronic service tool that is provided by
Cat may be used to read the numerical code of the
diagnostic flash code. There are three types of
diagnostic codes: ACTIVE, LOGGED and EVENT.
These codes are logged and stored in the ECM.
Refer to the Operation and Maintenance Manual,
“Engine Diagnostics” for additional information.

The cooling system consists of the following items: a
centrifugal pump that is driven by a gear, water
temperature regulator, an oil cooler and a radiator
that incorporates a shunt system.

The engine lubricating oil is supplied by a gear type
pump. The engine lubricating oil is cooled and
filtered. Bypass valves provide unrestricted flow of
lubrication oil when the oil viscosity is high or if the oil
cooler or oil filter elements become plugged.

Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to proper
operation and maintenance recommendations
including the use of recommended fuels, coolants,
and lubrication oils.

However, failures that result from the installation
or use of devices, accessories, or consumables
from other manufacturers are NOT Caterpillar

defects. Therefore, the defects are NOT covered
under the Caterpillar warranty.

Welding and Cat Electronic
Engines

NOTICE

Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip­ment or your Cat dealer regarding welding on a chas­sis frame or rail.

To help avoid damage to the electronic controls,
proper welding procedures are necessary. Before
welding on a vehicle that is equipped with an
electronic engine, observe the following precautions:

1. Turn off the engine. Place the key start switch in
the OFF position.

2. If the application has a battery disconnect switch,
open the switch. Otherwise, disconnect the
negative “-” battery cable from the battery of the
vehicle.

Aftermarket Products and Cat
Engines

NOTICE

In order to maximize fuel system life and prevent pre­mature wear out from abrasive particles in the fuel, a
two micron absolute high efficiency fuel filter is re­quired for all Caterpillar Electronic Unit Injectors. Cat­erpillar High Efficiency Fuel Filters meet these
requirements. Consult your Caterpillar dealer for the
proper part numbers.

When auxiliary devices, accessories, or
consumables which are made by other
manufacturers are used on Cat products, the
Caterpillar warranty is not affected simply because of
such use.

Do not ground the welder to electrical components

NOTICE

such as the ECM or sensors. Improper grounding
can cause damage to the drive train bearings, hy­draulic components, electrical components, and oth-

er components.

Clamp the ground cable from the welder to the com­ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos­sibility of damage.

3. Clamp the ground cable from the welder to the
component that will be welded. Place the clamp as
close as possible to the weld.

4. Protect wiring harnesses from welding debris and
from spatter. Use proper welding procedures.

20

Product Information Section
Product Identification Information

SEBU7902-08

Product Identification
Information

Plate Locations and Film
Locations

SMCS Code: 1000; 4450

i02093824

Serial Number Plate (1)

The engine serial number plate is located on the
upper right side of the engine block.

Engine serial number

Engine model

Arrangement number

Information Plate (2)

The engine information plate is located on the valve
cover base near the front of the left side of the

engine.

Engine Serial Number

Engine Arrangement Number

Engine Modification Number

The engine identification plate also contains other
important information about the engine.

i00844066

Illustration 15 g01068240

(1) Serial number plate
(2) Information plate

Caterpillar engines are identified by serial numbers
and by arrangement numbers. These numbers are
shown on the engine serial number plate and on the
engine information plate. Caterpillar dealers need
these numbers in order to determine the components
that were included with the engine. This permits
accurate identification of replacement part numbers.

Emissions Certification Film

SMCS Code: 1000; 7405

Illustration 16 g00284658

EPA Emissions Certification Film

Illustration 17 g00415538

European Emissions Certification Film

SEBU7902-08

21

Product Information Section

Reference Information

The EPA Emissions Certification Film (if equipped)
and/or the European Emissions Certification Film (if
equipped) is located on the side of the engine.

i04128675

Reference Information

SMCS Code: 1000; 4450

Information for the following items may be needed to
order parts. Locate the information for your engine.
Record the information on the appropriate space.
Make a copy of this list for a record. Retain the
information for future reference.

Record for Reference

Table 2

System or Component Information

Chassis serial number

Engine model

Engine serial number

Engine arrangement
number

Modification number

Engine low idle rpm

(Table 2, contd)

Engine air cleaner ele­ment part number

Fan drive belt part
number

Alternator belt part
number

Engine full load rpm

Performance specification
number

Engine horsepower

Primary fuel filter part
number

Water separator element
part number

Secondary fuel filter ele­ment part number

Lubrication oil filter ele­ment part number

Auxiliary oil filter element
part number

Supplemental coolant ad­ditive maintenance ele­ment part number (if
equipped)

Total lubrication system
capacity

Total cooling system
capacity

(continued)

22

Operation Section
Lifting and Storage

SEBU7902-08

Operation Section

Lifting and Storage

i01988813

Product Lifting

SMCS Code: 7000; 7002

Illustration 18 g00103219

i05260537

Product Storage

SMCS Code: 7002

Storage (Less Than One Year)

If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls,
piston rings, main bearings, connecting rod bearings,
crankshaft and gears.

This lack of lubricant allows corrosion to begin to
appear on the metal. This condition is worse in areas
of high humidity.

When the engine is started again, metal to metal
contact will cause wear before the surfaces receive

oil. To minimize this wear, use the starter to turn the
engine with the throttle in the FUEL OFF position.

When oil pressure is shown on the pressure gauge,
start the engine.

1. Clean the engine of any dirt, rust, grease, and oil.
Inspect the exterior. Paint areas that contain paint
damage with a good quality paint.

2. Remove dirt from the air cleaners. Check all seals,
gaskets, and the filter element for damage.

Never bend the eyebolts and the brackets. Only load

NOTICE

the eyebolts and the brackets under tension. Re­member that the capacity of an eyebolt is less as the
angle between the supporting members and the ob­ject becomes less than 90 degrees.

When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.

Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.

Some removals require lifting the fixtures in order to
obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that
are on the engine.

Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting
eyes and/or the engine make the lifting eyes and the
lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Caterpillar dealer for information
regarding fixtures for proper engine lifting.

3. Apply lubricant to all points in this Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.

4. Drain the crankcase oil. Replace the crankcase oil
and change the oil filters. For the proper
procedure, refer to this Operation and
Maintenance Manual.

5. If the engine is equipped with an air starting motor,
fill the reservoir with the following mixture: 50
percent volatile corrosion inhibitor oil
(<nomen>VCI oil</nomen>) and 50 percent
engine oil.

6. Add VCI oil to the crankcase oil. The volume of
VCI oil in the crankcase oil should be 3 to 4
percent.

Note: If the engine crankcase is full, drain enough
engine oil so the mixture can be added.

7. Remove the air filter elements. Turn the engine at
cranking speed with the throttle control in FUEL
OFF position. Use a sprayer to add a mixture of 50
percent VCI oil and 50 percent engine oil into the
air inlet or turbocharger inlet.

SEBU7902-08

23

Operation Section

Product Storage

Note: The mixture of VCI oil can be added to the inlet
by removing the plug for checking turbocharger boost
pressure. The minimum application rate for the VCI
oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of
engine displacement.

8. Use a sprayer to apply a mixture of 50 percent VCI
oil and 50 percent crankcase oil into the exhaust
openings. The minimum application rate for the oil
mixture is 5.5 mL per L (3 oz per 1000 cu in) of
engine displacement. Seal the exhaust pipe and
seal any drain holes in the muffler.

9. Remove the fuel from the secondary fuel filter
housing. Alternately, empty and reinstall the spin­on fuel filter element in order to remove any dirt
and water. Drain any sleeve metering fuel pump.

Clean the primary fuel filter. Fill with calibration
fluid or kerosene. Install the primary fuel filter and
operate the priming pump. This procedure will
send clean oil to the secondary filter and the
engine.

Open the fuel tank drain valve in order to drain any
water and dirt from the fuel tank. Apply a spray of
calibration fluid or kerosene at the rate of
30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank
capacity in order to prevent rust in the fuel tank.
Add 0.15 mL per L (.02 oz per 1 gal US) of
commercial biocide such as Biobor JF to the fuel.

Apply a small amount of oil to the threads on the
fuel tank filler neck and install the cap. Seal all
openings to the tank in order to prevent
evaporation of the fuel and as a preservative.

Ensure that all covers are airtight and
weatherproof. Use a waterproof weather resistant
tape such as Kendall No. 231 or an equivalent. Do
not use duct tape. Duct tape will only seal for a
short time.

13. Under most conditions, removing the batteries is
the best procedure. As an alternative, place the
batteries in storage. As needed, periodically
charge the batteries while the batteries are in
storage.

If the batteries are not removed, wash the tops of
the batteries until the tops are clean. Apply an
electrical charge to the batteries in order to obtain
a specific gravity of 1.225.

Disconnect the battery terminals. Place a plastic
cover over the batteries.

Note: For additional information, refer to Special
Instruction, SEHS7633, “Battery Test Procedure”.

14. Loosen all belts.

15. Place a waterproof cover over the engine. Ensure

that the engine cover is secure. The cover should
be loose enough to allow air to circulate around
the engine in order to prevent damage from
condensation.

16. Attach a tag with the storage date to the engine.

17. Remove the waterproof cover at 2 month or 3

month intervals in order to check the engine for
corrosion. If the engine has signs of corrosion,
repeat the protection procedure.

10. Remove the fuel nozzles or spark plugs. Apply
30 mL (1 oz) of the mixture of oils (50 percent VCI
oil and 50 percent engine oil) into each cylinder.

Use a bar or a turning tool in order to turn over the
engine slowly. This procedure puts the oil on the
cylinder walls. Install all fuel nozzles or spark plugs
and tighten to the correct torque.

11. Spray a thin amount of a mixture of 50 percent
VCI oil and 50 percent engine oil onto the following
components: flywheel, ring gear teeth and starter
pinion. Install the covers in order to prevent
evaporation of the vapors from the VCI oil.

12. Apply a heavy amount of Cat Multipurpose
Grease (MPGM) to all outside parts that move,
such as rod threads, ball joints, linkage.

Note: Install all covers. Ensure that tape has been
installed over all openings, air inlets, exhaust
openings, the flywheel housing, the crankcase
breathers, the dipstick tubes.

Coolant System

Completely fill the cooling system before storage.

Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for more information about

coolants.

Removal from Storage

1. Remove all outside protective covers.

2. Change the oil and filters.

3. Check the condition of the fan and alternator belts.

Replace the belts, if necessary. Refer to this
Operation and Maintenance Manual, “Belts ­Inspect/Adjust/Replace” for the correct procedure.

4. Replace the fuel filter elements.

5. Remove the plastic covers from the air cleaner

elements.

24

Operation Section
Product Storage

6. Use a bar or a turning tool in order to turn the
engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
resistance exist.

7. Before starting the engine, remove the valve cover
or covers. Put a large amount of engine oil on the
camshaft, cam followers, and valve mechanism in
order to prevent damage to the mechanism.

8. Pressure-lubricate the engine before starting the
engine. Pressure lubricating the engine ensures
immediate lubrication and prevents damage to the
engine during the first few minutes of engine
operation. If the engine is not equipped with a
prelube pump, contact your Cat dealer for
information about lubrication of the engine before
starting the engine.

9. Check the condition of all rubber hoses. Replace
any worn hoses. Replace any damaged hoses.

SEBU7902-08

10. Before start-up, test the cooling system for a 3
percent to a 6 percent concentration of coolant
conditioner. Add liquid coolant conditioner or a
coolant conditioner element, if equipped.

Test the coolant mixture for proper nitrite level. If
necessary, adjust the coolant mixture.

Prime the engine with clean diesel fuel before
starting.

11. Ensure that the cooling system is clean. Ensure
that the system is full. Ensure that the system has
the correct amount of supplemental cooling
system conditioner.

12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.

13. If the engine was removed from storage in which
temperatures of less than -12°C (10°F) were
encountered, refer to Service Manual, SEBU5898,
“Cold Weather Recommendations Operation and
Maintenance”.

SEBU7902-08

25

Operation Section

Features and Controls

Features and Controls

i03953970

Monitoring System

(If Equipped)

SMCS Code: 1900; 7400; 7450; 7451

The Monitoring System is designed to alert the
operator to an immediate problem with any of the
engine systems that are monitored. The Monitoring
System is also designed to alert the operator to an
impending problem with any of the engine systems
that are monitored.

Indicators and Gauges

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

Tachometer (3) – This gauge indicates
engine speed (rpm). When the throttle

control lever is moved to the full throttle
position without load, the engine is running at
high idle. The engine is running at the full load
rpm when the throttle control lever is at the full
throttle position with maximum rated load.

NOTICE

To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
damage to the engine. The engine can be operated
at high idle without damage, but should never be al­lowed to exceed high idle rpm.

Note: The high idle rpm and the full load rpm are
stamped on the Information Plate.

Coolant Temperature (4) – When the

coolant temperature is above the normal

operating value, the coolant
temperature gauge will be in the red zone. Refer
to the Messenger display for any additional
information that may be available.

Illustration 19 g01063079

Gauge cluster and indicators

Diagnostic Lamp (1) – The diagnostic
lamp is used to indicate the existence of

a fault by flashing a fault code. For a
more detailed discussion of the diagnostic lamp,
please see this Operation and Maintenance
Manual, “Diagnostic Lamp” topic.

Engine Oil Pressure (2) – The oil

pressure should be greatest after a cold

engine is started. The pressure will
decrease as the engine warms up. The pressure
will increase when the engine rpm is increased.
The pressure will stabilize when the engine rpm
is stable.

A lower oil pressure is normal at low idle. If the load is
stable and the gauge reading changes, perform the
following procedure:

Warning Lamp (5) – There is a general
fault in the engine. Refer to the
Messenger display for any additional

information that may be available.

Fuel Pressure (6) – This gauge indicates
fuel pressure to the fuel injection pump

from the fuel filter. A decrease in fuel
pressure usually indicates a dirty fuel filter or a
plugged fuel filter. As the fuel filter becomes
plugged, there will be a noticeable reduction in
engine performance.

System Voltage (7) – This gauge

indicates the voltage of the electrical

system.

Circuit Breaker (8) – Reset the circuit breaker if a

circuit breaker trips. Press the button in order to reset
the circuit breaker. If the electrical system is working
properly, the button will remain pressed. If the button
does not remain pressed or if the circuit breaker trips
soon after being reset, check the appropriate
electrical circuit. Repair the electrical circuit, if

necessary.

Start Switch (9) – The start switch has three
positions: OFF, RUN and START. When the start
switch is turned clockwise to the RUN position, the
lamps will flash for 5 seconds during the system test.
The lamps will then shut off. In the RUN position, the
ECM and electronic systems are powered up.

26

Operation Section
If Equipped

Idle Speed Switch (10) – When the
switch is in the up position, the engine

speed increases to HIGH IDLE. When
the switch is in the down position, the engine
speed decreases to LOW IDLE.

Maintenance Lamp (11) – The ECM

records data that is related to equipment

maintenance. The ECM will activate the
maintenance indicator lamp when scheduled
maintenance is due. The maintenance indicator
lamp can be reset by actuating the maintenance
clear switch. The maintenance interval may be
based on operating hours or fuel consumption.
The ECM provides information that pertains to
maintenance intervals and the last maintenance
that was performed.

Maintenance Clear Switch (12) – The

maintenance clear switch is required to

reset the maintenance lamp after
maintenance on the engine is performed.

SEBU7902-08

Previous button (16) – Use the previous button to
return to information that was previously shown on
the digital display area.

Scroll up/left button (17) – This button is used to
scroll up through information that is shown on the
display area. The button can also be used to scroll to
the left through information that is shown on the
display area.

Scroll down/right button (18) – This button is used
to scroll down through information that is shown on
the display area. The button can also be used to
scroll to the right through information that is shown on
the display area.

OK button (19) – Use this button to confirm
selections that you have made with the scroll up/left
button and the scroll down/right button.

Totals Display

Shutdown Switch (13) – Use the engine

shutdown switch in order to stop the

engine. Push the shutdown switch in
order to put the switch in the OFF position. After
the engine stops, turn the knob clockwise.
Turning the knob clockwise will reset the engine
shutdown switch to the ON position.

Service Tool Connector (14) – For more information

regarding the use of Cat Electronic Technician (ET)
and the PC requirements for Cat ET, refer to the
documentation.

Caterpillar Messenger Display

Illustration 21 g01054562

Typical totals display

The following information is available through the
display:

CUMULATIVE TOTALS

Service Hours – When you scroll to this option, the

display shows the total amount of service hours that
the engine has accumulated.

Total Time – When you scroll to this option, the
display shows the total hours for the engine ECM.

Illustration 20 g01063102

Digital display area (15) – The Messenger system
shows information on the digital display area.

Total Fuel – When you scroll to this option, the
display shows the total amount of fuel that has been
consumed.

SEBU7902-08

27

Operation Section

If Equipped

Settings Display

Illustration 22 g01054565

Typical settings display

The following options are available through the
payload display:

MONITORING SYSTEM

Language – Select this option to change the

language shown on the display.

Units – Select this option to choose the desired
measurement system. The choices are metric or
English.

Adjust Contrast – Select this option to adjust the
contrast of the display in order to improve the visibility
of the information.

Adjust Backlight – Select this option to adjust the
backlighting of the display in order to improve the
visibility of the information.

ENGINE

Equipment ID – Select this option to view the

equipment identification number.

Service Display

Illustration 23 g01054566

Typical service display

DIANOSTICS/EVENTS

The following options are password protected. Enter
a password to change the settings.

View – Select this option to view events logged by
the monitoring system. If you use an authorized
password, you can clear individual events.

Clear All Diagnostics – If you use an authorized
password, you can select this option to clear all
logged events.

SYSTEM PARAMETERS

MONITORING SYSTEM

• Battery Voltage: When you scroll to this option,
the battery voltage is displayed.

• Fuel Level: When you scroll to this option, the
fuel level is displayed.

• Alternator Status: When you scroll to this
option, the alternator status is displayed.

Product ID – Select this option to view the product
identification number.

• Engine Speed: When you scroll to this option,
the engine RPM is displayed.

• Desired Engine Speed: When you scroll to this
option, the desired engine speed is displayed.
This parameter is used by the Automatic Retarder
Control to prevent the engine from overspeeding.
If you have an approved password, you can
change this parameter.

• Throttle Position: When you scroll to this
option, the throttle position is displayed.

• Coolant Temperature: When you scroll to this
option, the coolant temperature is displayed.

28

Operation Section
If Equipped

SEBU7902-08

• Coolant Flow: When you scroll to this option,
the amount of coolant flow is displayed.

• Boost Pressure: When you scroll to this option,
the boost pressure is displayed.

• Atmospheric Pressure: When you scroll to this
option, the atmospheric pressure is displayed.

• Turbo Inlet Pressure: When you scroll to this
option, the turbo inlet pressure is displayed.

• Oil Pressure (Antilock brake system): When
you scroll to this option, the absolute engine oil
pressure is displayed.

• Oil Pressure: When you scroll to this option, the
gauge engine oil pressure is displayed.

• Fuel Temperature: When you scroll to this
option, the fuel temperature is displayed.

SYSTEMS TESTS

SYSTEM SELF TEST

If you select this option, the monitoring system will
initiate the self-test feature. The self test feature is

like the functional test that occurs when you turn the
start switch from the OFF position to the ON position.

TATTLETALE

• Full Tattletale Readout: When you select this
option, all indicators and gauges will display the
maximum values reached during operation.

• Engine Coolant Temperature: When you select
this option, all indicators and will display the
maximum values reached during operation. The
engine coolant temperature gauge will also show
the maximum value reached during operation.

• Tachometer: When you select this option, all
indicators will display the maximum values
reached during operation. The tachometer will
also show the maximum value reached during
operation.

• Fuel Level: When you select this option, all
indicators will display the maximum values
reached during operation. The fuel level gauge will
also show the minimum value reached during
operation.

• Clear: If you have an approved password, you
can clear the maximum values stored by the
monitoring system.

SYSTEM INFORMATION

MONITORING SYSTEM

• Software Part Number: When you scroll to this
option, the software part number is displayed.

• ECM Part Number: When you scroll to this
option, the ECM part number is displayed.

• Software Release Date: When you scroll to this
option, the software release date is displayed.

• Software Description: When you scroll to this
option, the software description is displayed.

ENGINE

• ECM Serial Number: When you scroll to this
option, the ECM serial number is displayed.

• Software Part Number: When you scroll to this
option, the software part number is displayed.

• Software Release Date: When you scroll to this
option, the software release date is displayed.

• Software Description: When you scroll to this
option, the software description is displayed.

• Engine Serial Number: When you scroll to this
option, the engine serial number is displayed.

SEBU7902-08

29

Operation Section

Engine Diagnostics

Engine Diagnostics

i00863835

Self-Diagnostics

SMCS Code: 1000; 1900; 1901; 1902

The electronic control module has some self­diagnostic ability. When an electronic problem with

an input or an output is detected, a diagnostic code is
generated. This indicates the specific problem with
the circuitry.

Diagnostic codes are also generated when an
abnormal engine operating condition is detected. For
example, a diagnostic code will be generated if the
low oil pressure alarm is activated. In this case, the
diagnostic code indicates the symptom of a problem.
This type of diagnostic code is called an event. An
event is triggered by the detection of an abnormal
engine operating condition.

A diagnostic code which represents a problem that
currently exists is called an active code.

A diagnostic code that is stored in memory is called a
logged code. Always service active codes prior to
servicing logged codes. Logged codes may include
the following categories:

• The “DIAGNOSTIC” lamp will turn off for five

seconds.

• The “DIAGNOSTIC” lamp repeats all active

diagnostic codes.

A fault diagnostic code will remain active until the
problem is repaired. The electronic control module
will continue flashing the flash code at five second
intervals until the problem is repaired.

i02496338

Diagnostic Flash Code
Retrieval

SMCS Code: 1000; 1900; 1901; 1902

Problems with the electronic control system are
reported via these types of codes: flash codes, SPN/
FMI codes, diagnostic codes and event codes.

• Intermittent problems

• Recorded events

• Performance history

Logged codes may not indicate that a repair is
needed. The problems may have been repaired since
the logging of the code. Logged codes may be
helpful to troubleshoot intermittent problems.

i01463253

Diagnostic Lamp

SMCS Code: 1000; 1900; 1901; 1902; 7451

The “DIAGNOSTIC” lamp is used to indicate the
existence of an active fault by flashing codes.

When the ignition switch is first turned on, the
“DIAGNOSTIC” lamp will go through the following
procedure:

• The “DIAGNOSTIC” lamp will come on and the
“DIAGNOSTIC” lamp will remain on for five
seconds. This checks the operation of the lamp.

• The “DIAGNOSTIC” lamp will turn off.

• The “DIAGNOSTIC” lamp will come on again and
the “DIAGNOSTIC” lamp will flash codes for any
active diagnostic codes. Not all diagnostic codes
have a unique flash code.

30

Operation Section
Diagnostic Flash Code Retrieval

Table 3

SEBU7902-08

Cross Reference for Diagnostic Codes

Flash Code

N/A

13

21

24

25

26

27

SPN

(1)

/FMI Code

Diagnostic Code

or

Event Code

1387-15

(2)

1387-16

1387-00

0441-15

0441-16

0441-00

626-05

626-06

1835-03 1835-03

1835-04 1835-04

1836-03 1836-03

1836-04 1836-04

111-02 111-02

174-03 174-03

174-04 174-04

678-03 41-03

678-04 41-04

620-03

1079-03

620-04

1079-04

100-03 100-03

100-04 100-04

100-10 100-10

102-03 102-03 Boost Pressure Sensor short to +batt

102-04 102-04

102-10 102-10

108-03 274-03

108-04 274-04

110-03 110-03

110-04 110-04

E443

(2)

E445

545-05

2417-05

545-06

2417-06

262-03

262-04

High Auxiliary Pressure Warning

High Auxiliary Pressure Derate

High Auxiliary Pressure Shutdown

High Auxiliary Temperature Warning

High Auxiliary Temperature Derate

High Auxiliary Temperature Shutdown

Ether Start Relay open/short to +batt

Ether Injection Control Solenoid open/short to +batt

Ether Start Relay short to ground

Ether Injection Control Solenoid short to ground

Auxiliary Pressure Sensor open/short to +batt

Auxiliary Pressure Sensor short to ground

Auxiliary Temperature Sensor open/short to +batt

Auxiliary Temperature Sensor short to ground

Engine Coolant Level Sensor Loss of Signal

Fuel Temperature open/short to +batt

Fuel Temperature short to ground

8 Volt DC Supply short to +batt

8 Volt DC Supply short to ground

5 Volt Sensor DC Power Supply short to +batt

5 Volt Sensor DC Power Supply short to ground

Engine Oil Pressure open/short to +batt

Engine Oil Pressure short to ground

Engine Oil Pressure abnormal rate of change

Boost Pressure Sensor short to ground

Boost Pressure Sensor abnormal rate of change

Atmospheric Pressure open/short to +batt

Atmospheric Pressure short to ground

Engine Coolant Temperature open/short to +batt

Engine Coolant Temperature short to ground

Description of Code

(continued)

SEBU7902-08

(Table 3, contd)

31

Operation Section

Diagnostic Flash Code Retrieval

Cross Reference for Diagnostic Codes

Flash Code

SPN

(1)

/FMI Code

Diagnostic Code

or

Event Code

28 91-13 91-13

32 91-08 91-08

190-08 190-08

34

723-08 342-08

35

190-15

E362

(2)

190-00

94-03 94-03

37

94-04 94-04

105-03 172-03

38

105-04 172-04

42

637-13 261-13

100-17

(2)

46

100-18

E360

100-01

168-00 168-00

51

168-01 168-01

168-02 168-02

56 630-02 268-02

58 639-09 247-09 J1939 Data Link communications

110-15

(2)

61

110-16

E361

110-00

111-17

(2)

62

111-18

E2143

111-01

63 94-15 E096

64

1636-15

1636-00 High Inlet Air Temperature Shutdown

E539

(2)

Throttle Position calibration required

Throttle Position signal abnormal

Engine Speed signal abnormal

Secondary Engine Speed signal abnormal

Engine Overspeed Warning

Engine Overspeed Shutdown

Fuel Pressure open/short to +batt

Fuel Pressure short to ground

Intake Manifold Air Temp open/short to +batt

Intake Manifold Air Temp short to ground

Engine Timing calibration required

Low Engine Oil Pressure Warning

Low Engine Oil Pressure Derate

Low Engine Oil Pressure Shutdown

System Voltage high

System Voltage low

System Voltage intermittent/erratic

Check Programmable Parameters

High Engine Coolant Temperature Warning

High Engine Coolant Temperature Derate

High Engine Coolant Temperature Shutdown

Low Engine Coolant Level Warning

Low Engine Coolant Level Derate

Low Engine Coolant Level Shutdown

High Fuel Pressure Warning

High Inlet Air Temperature Warning

Description of Code

65

71

174-15

174-16

E363

174-00

651-05 001-05

651-06 001-06

High Fuel Temperature Warning

(2)

High Fuel Temperature Derate

High Fuel Temperature Shutdown

Injector Cylinder 1 open circuit

Injector Cylinder 1 short

(continued)

32

Operation Section
Fault Logging

(Table 3, contd)

SEBU7902-08

Cross Reference for Diagnostic Codes

(1)

SPN

Flash Code

72

73

74

75

76

(1)

Suspect Parameter Number

(2)

Caterpillar Electronic Technician (ET) will display the number 1, 2, or 3 after the event code in order to designate a warning, a derate, or a
shutdown.

/FMI Code

651-11 001-11

652-05 002-05

652-06 002-06

652-11 002-11

653-05 003-05

653-06 003-06

653-11 003-11

654-05 004-05

654-06 004-06

654-11 004-11

655-05 005-05

655-06 005-06

655-11 005-11

656-05 006-05

656-06 006-06

656-11 006-11

Diagnostic Code

or

Event Code

Description of Code

Injector Cylinder #1 fault

Injector Cylinder 2 open circuit

Injector Cylinder 2 short

Injector Cylinder #2 fault

Injector Cylinder 3 open circuit

Injector Cylinder 3 short

Injector Cylinder #3 fault

Injector Cylinder 4 open circuit

Injector Cylinder 4 short

Injector Cylinder #4 fault

Injector Cylinder 5 open circuit

Injector Cylinder 5 short

Injector Cylinder #5 fault

Injector Cylinder 6 open circuit

Injector Cylinder 6 short

Injector Cylinder #6 fault

For further information, see the troubleshooting guide
for your engine.

i03840813

Fault Logging

SMCS Code: 1000; 1900; 1901; 1902

The system provides the capability of Fault Logging.
When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will be
logged in the memory of the ECM. The codes that
have been logged in the memory of the ECM can be
retrieved with Caterpillar electronic service tools. The
codes that have been logged can be cleared with
Caterpillar electronic service tools. The codes that
have been logged in the memory of the ECM will be
automatically cleared from the memory after 100
hours. The following faults cannot be cleared from
the memory of the ECM without using a factory
password: overspeed, low engine oil pressure and
high engine coolant temperature.

i01797045

Engine Operation with Active
Diagnostic Codes

SMCS Code: 1000; 1900; 1901; 1902

If a diagnostic lamp illuminates during normal engine
operation, the system has identified a situation that is
not within the specification. Use Caterpillar electronic
service tools to check the active diagnostic codes.

Note: If the customer has selected “DERATE” and if
there is a low oil pressure condition, the Electronic
Control Module (ECM) will limit the engine power
until the problem is corrected. If the oil pressure is
within the normal range, the engine may be operated
at the rated speed and load. However, maintenance
should be performed as soon as possible.

The active diagnostic code should be investigated.
The cause of the problem should be corrected as
soon as possible. If the cause of the active diagnostic
code is repaired and there is only one active
diagnostic code, the diagnostic lamp will turn off.

SEBU7902-08

33

Operation Section

Engine Operation with Intermittent Diagnostic Codes

Operation of the engine and performance of the
engine can be limited as a result of the active
diagnostic code that is generated. Acceleration rates
may be significantly slower. Refer to the
Troubleshooting Guide for more information on the
relationship between these active diagnostic codes
and engine performance.

i01456915

Engine Operation with
Intermittent Diagnostic Codes

SMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp starts to flash codes during
normal engine operation and the diagnostic lamp
shuts off, an intermittent fault may have occurred. If a
fault has occurred, the fault will be logged into the
memory of the Electronic Control Module (ECM).

In most cases, it is not necessary to stop the engine
because of an intermittent code. However, the

operator should retrieve the logged fault codes and
the operator should reference the appropriate
information in order to identify the nature of the event.
The operator should log any observation that could
have caused the lamp to light.

• Low power

• Limits of the engine speed

• Excessive smoke, etc

Parameter Descriptions

““Equipment ID””

“EQUIPMENT ID” allows the customer to enter a

description into the Electronic Control Module (ECM)
in order to identify the machine. A maximum of 17
characters may be entered in the field. This
parameter is only for reference by the customer. This
parameter is not required.

““Engine Serial Number””

Program the “ENGINE SERIAL NUMBER” to match
the engine serial number that is stamped on the
engine information plate. If the ECM is replaced, the
engine serial number from the engine information
plate must be programmed into the new ECM.

Note: When you are requesting factory passwords,
always use the engine serial number that is
programmed in the ECM.

““Rating Number””

The “RATING NUMBER” corresponds to the selected
set of performance maps for the application. This
selected set of performance maps comes out of
several unique sets of maps that are resident in the
flash file. The dealer and/or the OEM will need to

select the appropriate rating tier, if more than one
rating tier is present. The rating tiers are “A” through
“E” .

This information can be useful to help troubleshoot
the situation. The information can also be used for

future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this
engine.

i04250489

Configuration Parameters

SMCS Code: 1000; 1900; 1901; 1902

S/N: JRE1–Up

S/N: PDM1–Up

S/N: PBN1–Up

S/N: JAS1–Up

S/N: MCW1–Up

System configuration parameters are parameters
that affect the emissions and the power of the engine.
Default values for the parameters are programmed at
the factory. Some parameters may be changed by
the customer in order to suit the needs of the specific
application.

Note: Refer to this Operation and Maintenance
Manual, “Engine Rating Definitions” for information.

Factory passwords are required in order to change
the rating number.

34

Operation Section
Configuration Parameters

SEBU7902-08

““Top Engine Limit”” (TEL)

Illustration 24 g00763900

“TEL” is a customer programmable parameter that
defines the maximum allowable engine speed for
maximum power. “TEL” can be programmed up to
the maximum rated engine speed. “TEL” is defined
along the lug curve.

““Engine Accel. Rate””

The engine acceleration rate determines the rate of
change of the engine speed (acceleration or
deceleration) during PTO operation. This rate of
change is also used to achieve intermediate engine
speed.

““Low Idle Speed””

Low speed idle is the minimum allowable operating
speed for the engine. This parameter can be
programmed between 600 and 1400 rpm.

““High Idle Speed””

Illustration 25 g00763900

The high idle speed is the maximum no-load engine
speed when the throttle or the PTO switch is in the
maximum position.

Note: “HIGH IDLE SPEED” cannot be programmed
lower than “TEL” .

““Intermediate Engine Speed””

The intermediate engine speed defines the speed for
the engine when the intermediate engine speed
switch is activated. This parameter can be
programmed to any engine speed between “Low Idle
Speed” and “TEL” . Engine speed will increase or
engine speed will decrease at the rate that is defined
by the programmed value for “ENGINE ACCEL.
RATE” .

““PTO Mode””

“PTO Mode” allows the ECM to be programmed to

either one of the two PTO configurations that are
available.

““Ramp Up/Ramp Down”” – When “PTO Mode” is
programmed to “RAMP UP/RAMP DOWN” , the ECM
allows PTO operation with traditional features.

““Set/Resume”” – When “PTO Mode” is programmed
to “SET/RESUME” , the ECM allows PTO operation
with enhanced features.

SEBU7902-08

35

Operation Section

Configuration Parameters

““Maximum Engine Torque Limit””

Illustration 26 g00817759

“ENGINE TORQUE LIMIT” can be used to limit
torque output to the programmed value when the

torque limit switch is activated.

Note: If an engine overspeed condition occurs and
“AIR SHUTOFF” is programmed to “ENABLED” , the
switched power to the ECM must be cycled and the
air shutoff solenoid must be manually reset before
the engine will restart.

““Maintenance Indicator Mode””

The ECM records data that is related to equipment
maintenance. The ECM will activate the maintenance

indicator lamp when scheduled maintenance is due.
The maintenance indicator lamp can be reset by
actuating the maintenance clear switch. The
maintenance interval may be based on operating
hours or on fuel consumption. The ECM provides
information that pertains to maintenance intervals
and the last maintenance that was performed.

““PM1 Interval””

The PM1 interval allows the customer to define the
maintenance interval if the “MAINTENCE INTERVAL
MODE” is programmed to one of the manual options.

““Throttle Position Sensor””

Program the throttle position sensor to “INSTALLED”
if a throttle position sensor is used for desired speed
control. Otherwise program this parameter to “NOT
INSTALLED” .

““FLS”” (Full Load Setting)

“FLS” is a number representing the adjustment to the

fuel system made at the factory to fine-tune the fuel
system. The correct value for this parameter is
stamped on the engine information plate. Factory
passwords are required in order to change this
parameter.

““FTS”” (Full Torque Setting)

“FTS” is similar to “FLS” . Factory passwords are

required in order to change this parameter.

““Ether Control””

Program the “ETHER CONTROL” to “ENABLED” if
an ether injection system is installed on the engine so
the ECM can control ether injection. If the engine is
not equipped with ether, program this parameter to

“DISABLED” .

““Air Shutoff””

“AIR SHUTOFF” allows the ECM to be programmed

for operation of an air shutoff system. If this
parameter is programmed to “INSTALLED” , the ECM
will activate the air shutoff solenoid in the event of an

engine overspeed condition.

““Coolant Level Sensor””

Program the coolant level sensor to “INSTALLED” if a
coolant level sensor is installed on the engine.
Otherwise program this parameter to “NOT
INSTALLED” .

““Aux Press Sensor Installation Status””

Program “AUX PRESS ENABLE” to “INSTALLED” if
an auxiliary pressure sensor is installed. This will
allow the Cat Messenger Driver Information Display
to monitor the pressure of another system. Program
this parameter to “NOT INSTALLED” if an auxiliary
pressure sensor is not installed.

36

Operation Section
Configuration Parameters

““Aux Temp Sensor Installation Status””

Program “AUX TEMP ENABLE” to “INSTALLED” if
an auxiliary temperature sensor is installed. This will
allow the Cat Messenger Driver Information Display
to monitor the temperature of another system.
Program this parameter to “NOT INSTALLED” if an
auxiliary temperature sensor is not installed.

System Configuration Parameters

Table 4

System Configuration Parameters

SEBU7902-08

Parameter

ECM Identification Parameters

“Equipment ID” 17 alphanumeric characters

“Engine Serial Number”

“ECM Serial Number”

“Software Gp Part Number” Software Dependent Read Only

“Software Gp Release Date” Software Dependent Read Only

Selected Engine Rating

“Rating Number” Software Dependent

“Rated Power”

“Rated Peak Torque” Software Dependent Read Only

“Top Engine Speed Range” Software Dependent Read Only

“Test Spec” Software Dependent Read Only

“Top Engine Limit” Software Dependent

“Engine Governor Primary Mode”

“Engine Accel. Rate”

“Low Idle Speed”

“PTO Mode”

“High Idle Speed”

“Intermediate Engine Speed” Programmed “Low Idle” to “TEL”

“Maximum Engine Torque Limit” Software Dependent

“Customer Password #1”

“Customer Password #2”

“FLS” (Full Load Setting)

“FTS” (Full Torque Setting)

“Ether Control”

Available Range or Options

0XX00000 or XXX00000 0XX00000 None

“Read Only”

Software Dependent Read Only

“Speed Control”

“Min/Max”

50 to 1000 50 None

600 to 1400 700 None

“Ramp Up/Ramp Down”

“Set/Resume”

1800 to 2310

8 alphanumeric characters

8 alphanumeric characters

- 128 to 127

-128 to 127

“No Ether”

“Continuous Flow”

Default

“NOT PROGRAMMED” None

(1)

“Speed Control”

“Ramp Up/Ramp Down”

2310

1100 None

Blank Customer

Blank Customer

0 Factory

0 Factory

“No Ether” None

Required

Password

Customer

Customer

None

None

Customer

None

(1)

(1)

(1)

(1)

(1)

(1)

(continued)

SEBU7902-08

(Table 4, contd)

37

Operation Section

Configuration Parameters

System Configuration Parameters

Parameter

“Air Shutoff”

“Maintenance Indicator Mode”

“PM1 Interval”

“Throttle Position Sensor”

“Coolant Level On”

“Last Tool to change Customer
Parameters”

“Last Tool to change System
Parameters”

“Aux Temp Sensor Installation Status”

“Aux Press Sensor Installation
Status”

“Total Tattletale”

(1)

The parameter can only be viewed. No changes are allowed.

Available Range or Options

3785 to 28390 L (1000 to 7500 US gal)

“Enabled”

“Disabled”

“OFF”

“Auto Fuel”

“Auto Hour”

“Man Fuel”

“Man Hour”

100 to 750 Hours

or

“Installed”

“Not Installed”

“Installed”

“Not Installed”

“On”
“Off”

“On”
“Off”

Read Only

Read Only

Read Only

Default

“Disabled” None

“OFF” None

250 Hours

or

9463 L (2500 US gal)

“Not Installed” None

“Not Installed” None

(1)

(1)

“Off” None

“Off” None

(1)

Required

Password

None

Parameters Worksheet

Note: A mistake in recording this information will

result in incorrect passwords.

Table 5

Engine Parameters

ECM Identification Parameters

“Equipment ID”

“Engine Serial Number”

“ECM Serial Number”

“Software Gp Part Number”

“Software Gp Release Date”

Selected Engine Rating

“Rating Number”

(continued)

(Table 5, contd)

Engine Parameters

“Rated Power”

“Rated Peak Torque”

“Top Engine Speed Range”

“Test Spec”

“Top Engine Limit”

“Engine Accel Rate”

“Low Idle Speed”

“PTO Mode”

“High Idle Speed”

(continued)

38

Operation Section
Configuration Parameters

(Table 5, contd)

Engine Parameters

“Intermediate Engine Speed”

SEBU7902-08

(Table 5, contd)

Injector Code (3)

“Maximum Engine Torque Limit”

“Customer Password #1”

“Customer Password #2”

“FLS”

“FTS”

“Ether Control”

“Air Shutoff”

“Maintenance Indicator Mode”

“PM1 Interval”

“Throttle Position Sensor”

“Coolant Level Sensor”

“Last Tool to change Customer
Parameters”

“Last Tool to change System
Parameters”

“Aux Press Temp Installation
Status”

“Aux Press Sensor Installation
Status”

“Total Tattletale”

Injector Code (4)

Injector Code (5)

Injector Code (6)

Note: Compare the FLS and the FTS from the ECM
with the values that are listed on the engine
information plate. Only change the FLS and the FTS
because of a mechanical change in the engine. The
use of the wrong parameters could cause damage to
the engine. The use of the wrong parameters may
also void the Caterpillar warranty.

Information from Engine Information Plate

“Engine Serial Number”

“FLS”

“FTS”

Injector Code (1)

Injector Code (2)

Injector Codes

(continued)

SEBU7902-08

39

Operation Section

Engine Starting

Engine Starting

i02109067

Before Starting Engine

SMCS Code: 1000; 1400; 1450

Perform the required daily maintenance and other
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can
help prevent major repairs at a later date. Refer to
the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for more

information.

• For the maximum service life of the engine, make
a thorough inspection before the engine is started.
Look for the following items: oil leaks, coolant
leaks, loose bolts and trash buildup. Remove trash
buildup and arrange for repairs, as needed.

• Inspect the aftercooler for loose connections and
for debris buildup.

• Inspect the cooling system hoses for cracks and
for loose clamps.

• Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage.

• Do not start the engine or move any of the controls

if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
to the controls.

• Ensure that the areas around the rotating parts are
clear.

• All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair
any damaged guards. Replace damaged guards
and/or missing guards.

• Disconnect any battery chargers that are not
protected against the high current drain that is
created when the electric starting motor (if
equipped) is engaged. Check electrical cables and
check the battery for poor connections and for
corrosion.

• Reset all of the shutoffs or alarm components.

• Check the engine lubrication oil level. Maintain the
oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.

• Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
the coolant level to the “FULL” mark on the coolant
recovery tank.

• Inspect the wiring for loose connections and for
worn wires or frayed wires.

• Check the fuel supply. Drain water from the water
separator (if equipped). Open the fuel supply
valve.

NOTICE

All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.

If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air may
have entered the filter housing. Also, when fuel filters
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel
system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system.

Engine exhaust contains products of combustion
which may be harmful to your health. Always
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust

to the outside.

• If the engine is not equipped with a coolant
recovery tank 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 in the sight glass.

• Observe the air cleaner service indicator (if
equipped). Service the air cleaner when the yellow
diaphragm enters the red zone, or when the red
piston locks in the visible position.

• Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove
any electrical loads.

i01797227

Cold Weather Starting

SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900

Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.

Startability will be improved at temperatures below

−18 °C (0 °F) from the use of a jacket water heater or

extra battery capacity.

40

Operation Section
Starting the Engine

SEBU7902-08

When No. 2 diesel fuel is used, the following items
provide a means of minimizing starting problems and
fuel problems in cold weather: engine oil pan heaters,
jacket water heaters, fuel heaters and fuel line
insulation.

Use the procedure that follows for cold weather
starting.

Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will
control the engine speed during start-up.

1. Disengage any driven equipment.

2. Turn the keyswitch to the RUN position. Leave the

keyswitch in the RUN position for 20 seconds.

NOTICE

Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.

If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to

allow the starting motor to cool before attempting to
start the engine again.

3. Turn the keyswitch to the START position in order
to engage the starting motor and crank the engine.

4. Allow the keyswitch to return to the RUN position
after the engine starts.

5. Repeat step 2 through step 4 if the engine fails to
start.

6. Allow the engine to idle for three to five minutes, or
allow the engine to idle until the water temperature
indicator begins to rise. The engine should run at
low idle smoothly until speed is gradually
increased to high idle. Allow the white smoke to
disperse before proceeding with normal operation.

7. Operate the engine at low load until all systems
reach operating temperature. Check the gauges
during the warm-up period.

2. Turn the keyswitch to the RUN position. Leave the
keyswitch in the RUN position for 15 seconds.

3. Turn the keyswitch to the START position in order
to engage the electric starting motor and crank the
engine.

NOTICE

Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.

If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to

allow the starting motor to cool before attempting to
start the engine again.

4. Allow the keyswitch to return to the RUN position
after the engine starts.

5. Repeat step 2 through step 4 if the engine fails to
start.

Starting a Warm Engine

1. Disengage any equipment that is driven by the

engine.

2. Turn the keyswitch to the START position in order
to engage the electric starting motor and crank the
engine.

NOTICE

Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.

If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to

allow the starting motor to cool before attempting to
start the engine again.

3. Allow the keyswitch to return to the RUN position
after the engine starts.

4. Repeat step 2 and step 3 if the engine fails to start.

i01903151

Starting the Engine

SMCS Code: 1000; 1450

Note: Do not adjust the engine speed control during

start-up. The electronic control module (ECM) will
control the engine speed during start-up.

Starting a Cold Engine

1. Disengage any equipment that is driven by the

engine.

i04471308

Starting with Jump Start
Cables

SMCS Code: 1000; 1401; 1402; 1900

Improper jump start cable connections can cause
an explosion resulting in personal injury.

Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.

SEBU7902-08

41

Operation Section

After Starting Engine

If the installation is not equipped with a backup
battery system, an external electrical source may be
necessary to start the engine.

NOTICE

Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.

Do not reverse the battery cables. The alternator can
be damaged. Attach the negative cable last and re­move first.

When using an external electrical source to start the
engine, turn the generator set control switch to the
“OFF” position. Turn all electrical accessories OFF
before attaching the jump-start cables.

Ensure that the main power switch is in the OFF posi­tion before attaching the jump-start cables to the en­gine being started.

1. Turn the start switch to the OFF position. Turn off
all accessories.

2. Connect one positive end of the jump-start cable to
the positive cable terminal of the discharged
battery. Connect the other positive end of the
jump-start cable to the positive cable terminal of
the electrical source.

Note: Ensure that the self test for the monitoring
system (if equipped) is completed before operating
the engine under load.

When the engine idles during warm-up, observe the
following conditions:

• Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
possible in some applications.

• Operate the engine at low idle until all systems
achieve operating temperatures. Check all gauges
during the warm-up period.

Note: Gauge readings should be observed and the
data should be recorded frequently while the engine
is operating. Comparing the data over time will help
to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.

3. Connect one negative end of the jump-start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump-start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.

4. Start the engine.

5. Immediately after the stalled engine is started,

disconnect the jump-start cables in reverse order.

Note: If there is a problem with the alternator or the
battery charger, the engine will not continue to run
after starting, unless the power to the engine control
module is supplied by a separate source.

i01646248

After Starting Engine

SMCS Code: 1000

Note: In temperatures from 0 to 60°C (32 to 140°F),

the warm-up time is approximately three minutes. In
temperatures below 0°C (32°F), additional warm-up
time may be required.

42

Operation Section
Engine Operation

SEBU7902-08

Engine Operation

i06545691

Engine Operation

SMCS Code: 1000

Correct operation and maintenance are key factors in
obtaining the maximum life and economy of the
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be

minimized and engine service life can be maximized.

The engine can be operated at the rated rpm after
the engine reaches operating temperature. The
engine will reach normal operating temperature
sooner during a low engine speed (rpm) and during a
low-power demand. This procedure is more effective
than idling the engine at no load. The engine should
reach operating temperature in a few minutes.

Gauge readings should be observed and the data
should be recorded frequently while the engine is
operating. Comparing the data over time will help to
determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.

Minimum Engine Run Time

Changes to the operating cycle may be required
when the engines are applied in a manner that will
result in repeated occurrences of less than one hour
of continuous run time.

In order for the exhaust aftertreatment to function
properly, the engine must complete a DPF

regeneration to 0 percent soot load once in every 24
hours of engine run time.

After this regeneration to 0 percent soot has finished,
an additional 70 minutes of run time is needed for Cat

Regeneration System fuel nozzle maintenance. Both
of these requirements can be run with or without load
on the engine.

Engines rated for constant speed use are allowed to
complete a starting sequence, an operation at a
single constant speed, and a shutdown sequence.
Every time the engine is run, each of these
operations should occur only once. The starting
sequence and shutdown sequence can include a
short period of operation at the low idle speed for
purposes of warming up and cooling down the engine
or driven equipment. The emissions type approval is
not valid for operation of a constant speed engine in
a manner different from that described above.

i01196062

Engaging the Driven
Equipment

SMCS Code: 1000

If the load varies, or if the load is cyclic, the governor
will adjust the engine rpm, as needed.

Extended operation at low idle or extended operation
at a reduced load may cause increased oil
consumption and carbon buildup in the cylinders.
This carbon buildup results in a loss of power and/or
poor performance. When the engine is operated at a
reduced load, the engine should be fully loaded at
every four hours in order to burn excess carbon from
the cylinders.

Industrial Engines

1. When the engine is operating, check the engine

gauges. The engine gauges should be in the
normal range before you engage the driven
equipment.

2. Engage the driven equipment. Begin operating the
engine at low load. Check the gauges and check
the equipment for proper operation. Check the
gauges and check the equipment frequently while
the engine is operating under load.

i05893104

Fuel Conservation Practices

SMCS Code: 1000; 1250

The efficiency of the engine can affect the fuel
economy. The design and technology used
byCaterpillar in manufacturing provides maximum
fuel efficiency in all applications. Follow the
recommended procedures in order to attain optimum
performance for the life of the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.

SEBU7902-08

• Be aware of the properties of the different fuels.
Use only the recommended fuels.

• Avoid unnecessary operation at no load.

Shut off the engine instead of operating the engine at
no load for long periods of time.

• Observe the service indicator for the air cleaner
frequently, if equipped. Keep the air cleaner
elements clean.

• Do not remove the cover for the air cleaner unless
the air filter service indicator indicates the need for
cleaning of the filter.

• Maintain a good electrical system.

One bad battery cell will overwork the alternator. This
will consume excess power and excess fuel.

• Ensure that the belts are properly adjusted. The
belts should be in good condition.

43

Operation Section

Fuel Conservation Practices

• Ensure that all of the connections of the hoses are
tight. The connections should not leak.

• Ensure that the driven equipment is in good
working order.

• Cold engines consume excess fuel. Keep cooling
system components clean and keep cooling
system components in good repair. Never operate
the engine without water temperature regulators.
All of these items will help maintain operating
temperatures.

44

Operation Section
Cold Weather Operation

SEBU7902-08

Cold Weather Operation

i01646447

Radiator Restrictions

SMCS Code: 1353; 1396

Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow

restriction can cause the following conditions:

• High exhaust temperatures

• Power loss

• Excessive fan usage

• Reduction in fuel economy

If an airflow restriction device must be used, the
device should have a permanent opening directly in

line with the fan hub. A centered opening that is
directly in line with the fan hub is specified in order to
prevent an interrupted airflow on the fan blades.
Interrupted airflow on the fan blades could cause a
fan failure.

Caterpillar recommends a warning device for the inlet
manifold temperature and/or the installation of an
inlet air temperature gauge. The warning device for
the inlet manifold temperature should be set at 75 °C
(167 °F). The inlet manifold air temperature should
not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential
engine damage.

i01872912

There are three major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:

• Lower cloud point

• Lower pour point

• Lower rating of kJ (BTU) per unit volume of fuel

When No. 1 diesel fuel is used, a decrease in power
and in fuel efficiency may be noticed. Other operating
effects should not be experienced.

The cloud point is the temperature when a cloud of
wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is the
temperature when diesel fuel will thicken. The diesel
fuel becomes more resistant to flow through fuel
pumps and through fuel lines.

Be aware of these values when diesel fuel is
purchased. Anticipate the average ambient

temperature for the engine area. Engines that are
fueled in one climate may not operate well if the
engines are moved to another climate. Problems can
result due to changes in temperature.

Before troubleshooting for low power or for poor
performance during cold weather, check the type of
fuel that is being used.

i02010887

Fuel Related Components in
Cold Weather

SMCS Code: 1000; 1250; 1280

Fuel and the Effect from Cold
Weather

SMCS Code: 1000; 1250; 1280

The following fuels are the grades that are available
for Caterpillar engines:

• No. 1

• No. 2

• Blend of No. 1 and No. 2

No. 2 diesel fuel is the most commonly used fuel.
Either No. 1 diesel fuel or a blend of No. 1 and No. 2

is best suited for cold weather operation.

Quantities of No. 1 diesel fuel are limited. No. 1
diesel fuels are usually available during the months

of the winter in the colder climates. During cold
weather operation, if No. 1 diesel fuel is not available,
use No. 2 diesel fuel, if necessary.

Fuel Tanks

Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision for draining
water and sediment from the bottom of the tanks.

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.

SEBU7902-08

Drain the water and sediment from any fuel storage
tank at the following intervals: weekly, oil changes
and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.

Fuel Filters

It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual in the Maintenance Section for more

information on priming the fuel system.

The micron rating and the location of a primary fuel
filter is important in cold weather operation. The
primary fuel filter and the fuel supply line are the most
common components that are affected by cold fuel.

Fuel Heaters

45

Operation Section

Fuel Related Components in Cold Weather

Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in the fuel system before the primary fuel
filter.

The following fuel heaters are recommended for
Caterpillar engines:

• 7C-3557 Fuel Heater Group

• 7C-3558 Heater Kit

For further information on fuel heaters, consult your
Caterpillar dealer.

Disconnect the fuel heater in warm weather.

Note: Fuel heaters that are controlled by the water
temperature regulator or self-regulating fuel heaters
should be used with this engine. Fuel heaters that are
not controlled by the water temperature regulator can
heat the fuel in excess of 65°C (149°F). A loss of
engine power can occur if the fuel supply
temperature exceeds 37°C (100°F).

Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
the fuel in warm weather operation.

46

Operation Section
Engine Stopping

SEBU7902-08

Engine Stopping

i04315380

Manual Stop Procedure

SMCS Code: 1000; 7418

NOTICE

Stopping the engine immediately after it has been
working under load can result in overheating and ac­celerated wear of the engine components.

If the engine has been operating at high rpm and/or
high loads, run at low idle for at least three minutes to
reduce and stabilize internal engine temperature be­fore stopping the engine.

Avoiding hot engine shutdowns will maximize turbo­charger shaft and bearing life.

Note: Individual applications have different control
systems. Ensure that the shutoff procedures are
understood. Use the following general guidelines in
order to stop the engine.

• Fill the fuel tank to prevent accumulation of
moisture in the fuel. Do not overfill the fuel tank.

• Allow the engine to cool. Check the coolant level.
Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling.

Note: Only use coolant that is recommended in this
Operation and Maintenance Manual, “Fluid
Recommendations” article. Failure to do so may
result in engine damage.

• If freezing temperatures are expected, check the
coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.

1. Remove the load from the engine so that the
engine has no more than 30% power.

2. Run the engine at the programmed low idle speed
for at least 3 minutes.

3. After the cool down period, turn the start switch to
the OFF position.

i04137729

After Stopping Engine

SMCS Code: 1000

Note: After operation, allow 10 minutes for the

engine oil to return to the oil pan before checking the
engine oil level.

• Check the crankcase oil level. Maintain the oil
level between the “ADD” mark and the “FULL”
mark on the oil level gauge.

Note: Only use oil that is recommended in this
Operation and Maintenance Manual, “Fluid
Recommendations” article. Failure to do so may
result in engine damage.

• If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.

• Note the service hour meter reading. Perform the
maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.

SEBU7902-08

47

Maintenance Section

Refill Capacities

Maintenance Section

Refill Capacities

i06014408

Refill Capacities

SMCS Code: 1000; 1348; 1395; 7560

Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for information about the

correct fluids for use in your Cat Diesel Engine.

Engine Oil

Illustration 27 g02109595

Shallow sump oil pan
The shallow sump oil pan may be a front sump oil

pan or a rear sump oil pan.

The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will
require additional oil. Refer to the OEM specifications
for the capacity of the auxiliary oil filter.

Table 6

Refill Capacities for a C15 Industrial Engine

Engine crankcase with a shallow sump oil
pan

Engine crankcase with a middle sump oil
pan (deep sump)

Engine crankcase with a flat bottom oil pan
(deep sump)

34 L (36 qt)

60 L (63 qt)

68 L (72 qt)

Coolant

TO properly maintain the cooling system, the total
cooling system capacity must be determined. The
total cooling system capacity varies between
individual installations. The total cooling system
capacity can include the following components:
engine, radiator, piping and heat exchanger.

Refer to the specifications that are provided by
Caterpillar or by the OEM of the installation. Record
the total cooling system capacity in 7 .

Table 7

Approximate Refill Capacities

Illustration 28 g02109596

Deep sump oil pan
The center sump oil pan is a deep sump oil pan.

Illustration 29 g02109598

Deep sump oil pan
The flat bottom oil pan is a deep sump oil pan.

Compartment or System

Cooling System

Liters

Quarts

i04327214

Fluid Recommendations

SMCS Code: 1280; 1348; 1395; 7560

Refer to this Operation and Maintenance Manual,
“Severe Service Application” for information about
operating an engine in a severe service application.

Note: The interval for changing the coolant varies
depending on the type of coolant being replaced.
Refer to this article, “Coolant Recommendations”, for
the intervals for changing the coolant.

Diesel Engine Oil

For more information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.

48

Maintenance Section
Fluid Recommendations

SEBU7902-08

Cat Diesel Engine Oil (Cat DEO)

Cat oils have been developed and tested in order to
provide the full performance and service life that has
been designed and built into Cat engines. Cat oils
are currently used to fill Cat Diesel Engines at the
factory. These oils are offered by Cat dealers for
continued use when the engine oil is changed.
Consult your Cat dealer for more information on
these oils.

Due to significant variations in the quality and in the
performance of commercially available oils,
Caterpillar makes the following recommendations:

Table 8

Cat Lubricants

Diesel Engine

Oil-Ultra Low

Sulfur

Diesel Engine

Oil

Cat DEO-ULS

Cat DEO-ULS SYN SAE 5W-40

Cat Cold Weather

DEO-ULS

Cat DEO

Cat DEO SYN SAE 5W-40

Viscosity Grade

SAE 15W-40

SAE 10W-30

SAE 0W-40

SAE 15W-40

SAE 10W-30

Note: Cat DEO and Cat DEO-ULS multigrade oils
are the preferred oils for use in this Cat Diesel
Engine.

Commercial Oil

(Table 9, contd)

API CI-4 / CI-4 PLUS Oil Category per-

formance requirements

Cat ECF-2

Cat ECF-1-a

Passing standard Cat C13 engine test

per API requirements

Oils of sulfated ash > 1.50 percent are

not allowed

API CH-4 Oil Category performance

requirements

For oils that are between 1.30 percent

and 1.50 percent sulfated ash, passing

one additional Cat 1P SCOTE test

(“ASTM D6681”) is required

Oils of sulfated ash > 1.50 percent are

not allowed

In selecting oil for any engine application, both of the
following must be satisfied: the oil viscosity and the
category of oil performance or the specification for oil
performance . Using only one of these parameters
will not sufficiently define oil for an engine
application.

The proper SAE viscosity grade of oil is determined
by the following temperatures: minimum ambient
temperature during cold engine start-up and
maximum ambient temperature during engine
operation.

Refer to Table 10 (minimum temperature) in order to
determine the required oil viscosity for starting a cold
engine.

Note: Non-Cat commercial oils are second choice
oils for your engine.

NOTICE

Caterpillar does not warrant the quality or perform­ance of non-Cat fluids.

The three current Caterpillar ECF specifications are:
Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each

higher Cat ECF specification provides increased
performance over lower Cat ECF specifications.

A commercial oil must meet the following standards
to be considered an equivalent of a Cat Diesel
Engine Oil:

Table 9

Cat Engine Crankcase Fluids (ECF) Definitions

Cat Performance

Requirement

Cat ECF-3

Cat ECF Specifications Requirements

API CJ-4 Oil Category performance

requirements

(continued)

Refer to Table 10 (maximum temperature) in order to
select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.

Note: Generally, use the highest oil viscosity that is
available to meet the requirement for the temperature
at start-up.

Table 10

Lubricant Viscosities for Ambient Temperatures

Oil Type and Per-

formance

Requirements

Cat ECF-1-a

Cat ECF-2
Cat ECF-3

Cat Cold Weather

DEO-ULS

Cat ECF-1-a

Cat ECF-2
Cat ECF-3

for Cat Diesel Engines

Viscosity

Grade

SAE 0W-30 −40 30 −40 86

SAE 0W-40 −40 40 −40 104

°C °F

Min Max Min Max

(continued)

SEBU7902-08

49

Maintenance Section

Fluid Recommendations

(Table 10, contd)

Lubricant Viscosities for Ambient Temperatures

for Cat Diesel Engines

Cat DEO-ULS

Cat ECF-1-a

Cat ECF-2
Cat ECF-3

Cat DEO-ULS SYN

Cat DEO

Cat ECF-1-a

Cat ECF-2
Cat ECF-3

Cat ECF-1-a

Cat ECF-2
Cat ECF-3

Cat DEO-ULS

Cat DEO

SAE 5W-30 −30 30 −22 86

SAE 5W-40 −30 50 −22 122

SAE 10W-

30

SAE 10W-

40

SAE 15W-

40

−18 40 0 104

−18 50 0 122

−9.5 50 15 122

Note: A cold soaked start occurs when the engine
has not been operated recently, allowing the oil to
become more viscous due to cooler ambient
temperatures. Supplemental heat is recommended
for cold soaked starts below the minimum ambient
temperature. Supplemental heat may be necessary
for cold soaked starts that are above the minimum
temperature depending on factors such as parasitic
load.

Total Base Number (TBN) and Fuel Sulfur
Levels

The use of Cat S·O·S Services oil analysis is
recommended strongly for determining oil life.

The minimum required Total Base Number (TBN) for
oil depends on the fuel sulfur level. The TBN for new
oil is typically determined by the “ASTM D2896”
procedure. For direct injection engines that use
distillate fuel, the following guidelines apply:

Table 11

TBN recommendations for applications in Cat engines

Fuel Sulfur Level per-

cent (ppm)

≤0.05 percent (≤500

ppm)

0. 1- 0.05 percent

(1000-500 ppm)

Above 0.1 percent

(above 1000 ppm)

(2)

(1)

Cat Engine Oils

Cat DEO-ULS

Cat DEO

Cat DEO-ULS

Cat DEO

Cat DEO

(3)

TBN of Com-

mercial Engine

Oils

Min 7

Min 7

Min 10

(Table 11, contd)

(1)

When using fuel with 0.10% sulfur (1000 ppm) or higher, refer
to this Operation and Maintenance Manual, “Severe Service
Application” for more information.

(2)

For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
refer to TBN and engine oil guidelines given in this section.

(3)

Cat DEO-ULS may be used if an oil analysis program is fol­lowed. Base the oil change interval on the analysis.

S·O·S Services Oil Analysis

Caterpillar has developed a maintenance tool that
evaluates oil degradation. the maintenance
management also detects the early signs of wear on
internal components. The Caterpillar tool for oil
analysis is called S·O·S oil analysis and the tool is
part of the S·O·S Services program. S·O·S oil
analysis divides oil analysis into four categories:

• Component wear rate

• Oil condition

• Oil contamination

• Identification of oil

These four types of analysis are used to monitor the
condition of your equipment. The four types of
analysis will also help you identify potential problems.
A properly administered S·O·S oil analysis program
will reduce repair costs and the program will lessen
the impact of downtime.

The S·O·S Oil Analysis program uses a wide range
of tests to determine the condition of the oil and the

crankcase. Guidelines that are based on experience
and a correlation to failures have been established

for these tests. Exceeding one or more of these
guidelines could indicate serious fluid degradation or
a pending component failure. A trained person at
your Cat dealership should make the final analysis.

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.

NOTICE

(continued)

50

Maintenance Section
Fluid Recommendations

SEBU7902-08

Refer to Special Publication, SEBU6251, “Cat
Commercial Diesel Engine Fluids
Recommendations” in order to obtain additional

information about S·O·S Services oil analysis. You
can also contact your local Cat dealer.

Fuel

Note: Caterpillar strongly recommends the filtration

of fuel through a fuel filter with a rating of four
microns(c) absolute or less. This filtration should be
located on the device that dispenses the fuel to the
fuel tank for the engine. This filtration should also be
located on the device that dispenses fuel from the
bulk storage tank. Series filtration is recommended.

NOTICE

In order to meet expected fuel system component life,
4 micron (c) absolute or less secondary fuel filtration
is required for all Cat Diesel Engines that are
equipped with unit injected fuel systems. All current
Cat Diesel Engines are factory equipped with Cat Ad­vanced Efficiency 4 micron(c) absolute fuel filters.

Caterpillar does not warrant the quality or perform­ance of non-Cat fluids and filters.

Diesel engines can burn a wide variety of fuels.
These fuels are divided into two general groups. The
two groups are called the preferred fuels and the
permissible fuels.

Note: The permissible fuels are some crude oils,
some blends of crude oil with distillate fuel, some
biodiesel, and some marine diesel fuel. These fuels
are not suitable for use in all engine applications. The
acceptability of these fuels for use is determined on
an individual basis. A complete fuel analysis is
required.

For more information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations” or consult your Cat dealer for
further information.

Diesel Distillate Fuel

Diesel engines may burn a wide variety of fuels.
These fuels are divided into two general groups. The
two groups are called the preferred fuels and the
permissible fuels.

The preferred fuels provide maximum engine
service life and performance. The preferred fuels

are distillate fuels. These fuels are commonly called
diesel fuel, furnace oil, gas oil, or kerosene. These
fuels must meet the “Cat Specification for Distillate
Diesel Fuel for Off-Highway Diesel Engines” found in
this Special Publication, “Distillate Diesel Fuel”
article.

Note: The permissible fuels are some crude oils,
some blends of crude oil with distillate fuel, some
biodiesel, and some marine diesel fuel. These fuels

are not suitable for use in all engine applications.

The acceptability of these fuels for use is determined
on a case by case basis. A complete fuel analysis is
required. Consult your Cat dealer for further
information.

NOTICE

The footnotes are a key part of the “Caterpillar Speci­fication for Distillate Diesel Fuel for Off-Highway Die­sel Engines” Table. Read ALL of the footnotes.

Table 12

Caterpillar Specification for Distillate Fuel for Nonroad

Specifications Requirements

Aromatics 35% maximum “D1319” “ISO 3837”

Ash

Carbon Residue
on 10% Bottoms

Cetane Number

Cloud Point

Copper Strip
Corrosion

Distillation

Flash Point

Thermal Stability

API Gravity

(2)

Diesel Engines

ASTM

Test ISO Test

0.01% maximum
(weight)

0.35% maximum
(weight)

40 minimum (DI
engines)

(1)

35 minimum (PC
engines)

The cloud point
must not exceed
the lowest ex­pected ambient
temperature.

No. 3 maximum “D130” “ISO 2160”

10% at 282 °C
(540 °F)
maximum

90% at 360 °C
(680 °F)
maximum

legal limit

Minimum of 80%
reflectance after
aging for 180 mi­nutes at 150 °C
(302 °F)

30 minimum

45 maximum

“D482” “ISO 6245”

“D524” “ISO 4262”

“D613”

or

“D6890”

“D2500” “ISO 3015”

“D86” “ISO 3405”

“D93” “ISO 2719”

“D6468”

“D287”

“ISO 5165”

No equiva-

No equiva-

lent test

lent test

(continued)

SEBU7902-08

51

Maintenance Section

Fluid Recommendations

(Table 12, contd)

Caterpillar Specification for Distillate Fuel for Nonroad

Diesel Engines

ASTM

Specifications Requirements

6 °C (10 °F) mini-

Pour Point

Sulfur

Kinematic
Viscosity

Water and
Sediment

Water 0.05% maximum “D6304”

Sediment

Gums and Resins

(6)

Lubricity

(1)

Alternatively, to ensure a minimum cetane number of 35 (PC
engines), and 40 (DI engines), distillate diesel fuel should have
a minimum cetane index of 37.5 (PC engines), and 44.2 (DI en­gines) when the “ASTM D4737-96a” test method is used. A fuel
with a higher cetane number may be required for operation at a
higher altitude or in cold weather.

(2)

Via standards tables, the equivalent kg/m3(kilograms per cubic
meter) using the “ASTM D287” test method temperature of

15.56° C (60° F) for the minimum API gravity of 30 is 875.7 kg/

3

m

, and for the maximum API gravity of 45 is 801.3 kg/m3.

(3)

ULSD 0.0015% (<15 ppm S) is required by law for Tier 4 en­gines and engines with aftertreatment devices.

(4)

Certain Cat fuel systems and engine components can operate
on fuel with a maximum sulfur content of 3%. Contact your Cat
dealer for guidance about appropriate maintenance intervals
and fluids for engines operating on fuel with sulfur levels be­tween 0.1% and 3%.

(5)

An engine which operates on fuel with 0.1% (1000 ppm) of sul­fur or more is operating in a severe service application. Refer to
this Operation and Maintenance Manual, “Severe Service Ap­plication” for information about operating an engine in a severe
service application.

(6)

Follow the test conditions and procedures for gasoline (motor).

mum below ambi­ent temperature

(3)(4)(5)

1.4 cSt minimum
and 20.0 cSt max­imum as delivered
to the fuel injec­tion pumps

1.4 cSt minimum
and 4.5 cSt maxi­mum as delivered
to the rotary fuel
injection pumps

0.05% maximum

0.05% maximum
(weight)

10 mg per 100 mL
maximum

0.52 mm
(0.0205 inch)
maximum at 60 °C
(140 °F)

Test ISO Test

“D97” “ISO 3016”

“D5453”

or

“D2622”

“D1796”

or

“D2709”

“D473” “ISO 3735”

“D381” “ISO 6246”

“D6079”

ISO 20846

or

ISO 20884

- -

“ISO 3734”

No equiva-

lent test

No equiva-

lent test

Biodiesel

A biodiesel blend of up to 20 percent may be used in
the engine when the fuel blend meets the
recommendations in table 13 and meets the

recommendations in Special Publication, SEBU6251,
“Biodiesel”.

Note: A complete Cat S·O·S Services oil analysis
program is recommended strongly when using
biodiesel blends above 5 percent.

Table 13

Biodiesel Blends for Cat Commercial Diesel Engines

Biodiesel blend stock Final blend

Caterpillar biodiesel

specification, “ASTM

D6751” or “EN14214”

B20: “ASTM

D7467” and “API”

gravity 30-45

Distillate diesel fuel

used for blend

Caterpillar distillate

diesel fuel specifica-

tion, “ASTM D975” or

“EN590”

Fuel Additives

Cat Diesel Fuel Conditioner

Cat Diesel Fuel Conditioner is a proprietary
formulation that has been extensively tested for use
with distillate diesel fuels for use in Cat Diesel

Engines. Cat Diesel Fuel Conditioner is a high
performance diesel fuel conditioner for use with lower
quality fuels that do not meet the minimum
requirements of any of the following:

• “Caterpillar Specification for Distillate Diesel Fuel”

• National Conference on Weights and Measures
(NCWM) Premium Diesel definition (refer to the
2004 or newer National Institute of Standards &
Technology (NIST) Handbook).

• EN590 (non-arctic)

• ASTM D975

Cat Diesel Fuel Conditioner is the only fuel
conditioner/additive available to the end user that is

tested and approved by Caterpillar for use in Cat
Diesel Engines.

Refer to Special Publication, SEBU6251, “Cat
Commercial Diesel Engine Fluids
Recommendations” for information about the use of

Cat Diesel Fuel Conditioner.

Cat Diesel Fuel System Cleaner

Note: Cat Diesel Fuel System Cleaner is the only fuel

system cleaner available to the end user that is
tested and approved by Caterpillar for use in Cat
Diesel Engines.

52

Maintenance Section
Fluid Recommendations

Cat Diesel Fuel System Cleaner is a proven high
performance detergent product designed specifically
for cleaning deposits that form in the fuel system.
Deposits in the fuel system reduce system
performance and can increase fuel consumption. Cat
Diesel Fuel System Cleaner addresses the deposits
formed due to the use of degraded diesel fuel, poor
quality diesel fuel, and diesel fuel containing high
quantities of high molecular weight compounds. Cat
Diesel Fuel System Cleaner addresses deposits
formed due to the use of biodiesel, biodiesel blends,

and biodiesel that does not meet the appropriate
quality specifications. Continued use of Cat Diesel
Fuel System Cleaner is proven to inhibit the growth of
new deposits.

SEBU7902-08

The cooling system operates under pressure
which is controlled by the radiator pressure cap.
Removing the cap while the system is hot may al­low the escape of hot coolant and steam, causing
serious burns.

Before you remove the radiator cap, allow the
system to cool. Use a thick cloth and turn the ra­diator cap slowly to the first stop to allow pres­sure to escape before fully removing the cap.

Avoid contact with coolant.

Caterpillar strongly recommends that Cat Diesel
Fuel System Cleaner be used with biodiesel and
biodiesel blends. Cat Diesel Fuel System Cleaner is
suitable for use with biodiesel/biodiesel blends that

meet Caterpillar biodiesel recommendations and
requirements. Not all fuel cleaners are suitable for
use with biodiesel/biodiesel blends. Read and follow

all applicable label usage instructions. Also, refer to
Special Publication, SEBU6251, “Cat Commercial
Diesel Engine Fluids Recommendations” “Distillate
Diesel Fuel”, article and also refer to the “Biodiesel”

article, which includes Caterpillar biodiesel
recommendations and requirements.

Aftermarket Fuel Additives

There are many different types of fuel additives that
are available to use. Caterpillar does not generally
recommend the use of fuel additives.

In special circumstances, Caterpillar recognizes the
need for fuel additives. Use fuel additives with

caution. The additive may not be compatible with the
fuel. Some additives may precipitate. This action
causes deposits in the fuel system. The deposits may
cause seizure. Some additives may plug fuel filters.
Some additives may be corrosive, and some
additives may be harmful to the elastomers in the fuel
system. Some additives may damage emission
control systems. Some additives may raise fuel sulfur
levels above the maximum levels that are allowed by
the following agencies: EPA and other regulatory
agencies. Contact your fuel supplier for those
circumstances when fuel additives are required. Your
fuel supplier can make recommendations for
additives to use and for the proper level of treatment.

Never add coolant to an overheated engine. Engine

NOTICE

damage could result. Allow the engine to cool first.

NOTICE

If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside tem­perature or drained completely in order to prevent
damage caused by freezing coolant.

Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system
problems can develop without water temperature
regulators. Removing the regulators allows some
coolant to bypass the radiator, potentially causing
overheating.

Coolant Recommendations

Note: A Cat Diesel Engine equipped with air-to-air

aftercooling (ATAAC) requires a minimum of 30
percent glycol to help prevent water pump cavitation.

Note: For best results, your fuel supplier should treat
the fuel when additives are needed.

Cooling System

Note: Refer to Special Publication , SEBU6251, “Cat

Commercial Diesel Engine Fluids
Recommendations” for complete information about
the proper fluids for use in the cooling system.

SEBU7902-08

Table 14

53

Maintenance Section

Fluid Recommendations

Coolant Recommendations for use in Cat Diesel Engines

Recommendations Product

Cat ELC (Cat Extended Life Coolant)

Preferred

Cat ELI (Cat Extended Life Inhibitor)

Organic Additive Technology (OAT) based on a combination of a

Min requirements

Nitrite: minimum typical concentration of 500 ppm in new coolants

Acceptable Cat DEAC (Cat Diesel Engine Antifreeze/Coolant)

Min requirements for fully

formulated Heavy Duty

Commercial coolants

Min requirements for Com-

mercial coolants requiring

SCA precharge

(1)

New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets
Reagent 4 “ASTM D1193” requirements.

(2)

Maintain the in-service coolant at the given limits.

(3)

When referring to the service hours, use the interval that occurs first. These coolant change intervals are only achievable with annual S·O·S
Services Level 2 coolant sampling analysis.

Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US

Silicon concentration: minimum of 100 ppm and maximum of 275

Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US

Silicon concentration: minimum of 100 ppm and maximum of 275

Cat EC-1 specification and “ASTM D6210” and

monocarboxylic acid and a dicarboxylic acid

Phosphate, borate, and silicate free

Tolyltriazole: minimum typical concnetration of 900 ppm

“ASTM D6210” and

gal) and maximum of 2400 ppm (140 grains/US gal)

ppm

“ASTM D4985” and(1)

gal) and maximum of 2400 ppm (140 grains/US gal)

ppm

Service Hours

(1)(2)(3)

12000 hours or

6 years

12000 hours or

6 years

6000 hours or 6

years

3000 hours or 3

years

3000 hours or 2

years

3000 hours or 1

year

Required Maintenance

Add Cat ELC Extender at

6000 service hours or
one half of service life

Add Cat ELC Extender at

6000 service hours or
one half of service life

Add Extender at 3000

service hours or one half

of service life

SCA (Supplemental cool-

ant additive) at mainte-

nance intervals

SCA at maintenance

intervals

SCA at initial fill and SCA

at maintenance intervals

Table 15

Cat C7-C32 Marine Engines with heat exchangers

Cat diesel engines equipped with air-to-air aftercooling (ATAAC)

Special Requirements

Minimum of 30% glycol is required. 50% Glycol is recommended.

Water alone or water with SCA or with ELI is NOT allowed.

54

Maintenance Section
Fluid Recommendations

SEBU7902-08

Use Only Approved SCAs and Extenders

NOTICE

Conventional coolants require the maintenance addi­tion of SCA throughout the expected life of the cool­ants. Do NOT use an SCA with a coolant unless

approved specifically by the coolant supplier. The
coolant manufacturer is responsible for ensuring
compatibility and acceptable performance.

To help ensure expected performance, EC-1 coolants
require the one time maintenance addition of an ex­tender at coolant service mid-life. Do not use an ex-

tender with a coolant unless the extender has been
approved specifically for use by the coolant manufac-

turer. The coolant manufacturer is responsible for en­suring compatibility and acceptable performance.

Failure to follow these recommendations can result in
shortened cooling system component life.

Cat ELC can be recycled into conventional coolants.

For more information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.

S·O·S Services Coolant Analysis

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. S·O·S coolant analysis can be done at your
Cat dealer. Cat S·O·S coolant analysis is the best
way to monitor the condition of your coolant and your
cooling system. S·O·S coolant analysis is a program
that is based on periodic samples.

Table 16

Recommended Interval

Type of

Coolant

Cat DEAC

Conventional Heavy-

Duty Coolants

Cat ELC

Cat ELI

Commercial EC-1

Coolants

(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.

S·O·S Services Coolant Analysis (Level 1)

A coolant analysis (Level 1) is a test of the properties
of the coolant.

Level 1 Level 2

Every 250 hours Yearly

Optional Yearly

(1)

(1)

The following properties of the coolant are tested:

• Glycol concentration for freeze protection and boil
protection

• Ability to protect from erosion and corrosion

• pH

• Conductivity

• Visual analysis

• Odor analysis

The results are reported, and appropriate
recommendations are made.

S·O·S Services Coolant Analysis (Level 2)

A 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 S·O·S coolant analysis (Level 2) has the
following features:

• Full coolant analysis (Level 1)

• Identification of metal corrosion and of
contaminants

• Identification of buildup of the impurities that
cause corrosion

• Identification of buildup of the impurities that
cause scaling

• Determination of the possibility of electrolysis
within the cooling system of the engine

The results are reported, and appropriate
recommendations are made.

For more information on S·O·S coolant analysis,
consult your Cat dealer.

Greases

If it is necessary to choose a single grease, always
choose a grease that meets or exceeds the
requirements of the most demanding application.
Remember that the products which barely meet the
minimum performance requirements can be
expected to barely produce the minimum lives of your
parts. False economy is being used if a grease is
purchased with the lowest cost as the only
consideration. Instead, use the grease that yields the
lowest total operating cost. The cost should be based
on an analysis that includes the costs of parts, labor,
downtime, and the cost of the amount of grease that
is required.

SEBU7902-08

For more information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.

55

Maintenance Section

Fluid Recommendations

56

Maintenance Section
Maintenance Recommendations

SEBU7902-08

Maintenance
Recommendations

i02909163

System Pressure Release

SMCS Code: 1250; 1300; 1350; 5050

Coolant System

Pressurized system: Hot coolant can cause seri­ous burn. To open cap, stop engine, wait until ra­diator is cool. Then loosen cap slowly to relieve
the pressure.

To relieve the pressure from the coolant system, turn
off the engine. Allow the cooling system pressure cap
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure.

Fuel System

To relieve the pressure from the fuel system, turn off
the engine.

High Pressure Fuel Lines (If Equipped)

Do not loosen the high pressure fuel lines in order to
remove air pressure from the fuel system.

Engine Oil

To relieve pressure from the lubricating system, turn
off the engine.

i05909227

Welding on Engines with
Electronic Controls

SMCS Code: 1000

NOTICE

Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip­ment or your Cat dealer regarding welding on a chas­sis frame or rail.

Proper welding procedures are necessary in order to
avoid damage to the engine ECM, sensors, and
associated components. When possible, remove the
component from the unit and then weld the
component. If removal of the component is not
possible, the correct procedure must be followed.
When welding on a unit that is equipped with a Cat
Electronic Engine, the following is considered to be
the safest procedure:

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.

The high pressure fuel lines are the fuel lines that are
between the high pressure fuel pump and the high
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel

systems.

This is because of the following differences:

• The high pressure fuel lines are constantly
charged with high pressure.

• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system.

Before any service or repair is performed on the
engine fuel lines, perform the following tasks:

1. Stop the engine.

2. Wait for ten minutes.

Do not ground the welder to electrical components

NOTICE

such as the ECM or sensors. Improper grounding
can cause damage to the drive train, the bearings,
hydraulic components, electrical components, and
other components.

Do not ground the welder across the centerline of the
package. Improper grounding could cause damage
to the bearings, the crankshaft, the rotor shaft, and
other components.

Clamp the ground cable from the welder to the com­ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos­sibility of damage.

Note: Perform the welding in areas that are free from
explosive hazards.

1. Stop the engine. Turn the switched power to the
OFF position.

2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
open the switch.

SEBU7902-08

57

Maintenance Section

Severe Service Application

3. Disconnect the J1/P1 and J2/P2 connectors from
the ECM. Move the harness to a position that will
not allow the harness to move back accidentally,
and contact any of the ECM pins.

4. Disconnect any component with a microprocessor
from the engine harness, such as:

• Engine ECM

• Product Link

• Cell/Sat Radio

• DOC Identity Modules

5. Connect the welding ground cable directly to the
part that will be welded. Place the ground cable as
close as possible to the weld. This location will
reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
components, and ground straps.

Note: If electrical/electronic components are used as
a ground for the welder, current flow from the welder
could severely damage the component. Current flow
from the welder could also severely damage
electrical/electronic components that are located
between the welder ground and the weld.

6. Protect the wiring harness from welding debris and
spatter.

7. Use standard welding practices to weld the
materials.

i05083249

Severe Service Application

SMCS Code: 1000

An engine which operates outside of normal
conditions is operating in a severe service
application.

Illustration 30 g01075639

Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage any associated components.

(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being

welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder

An engine that operates in a severe service
application may need more frequent maintenance
intervals in order to maximize the following
conditions:

• Reliability

• Service life

The number of individual applications cause the
impossibility of identifying all of the factors which may
contribute to severe service operation. Consult your
Caterpillar dealer for the unique maintenance that
may be necessary for your engine.

An application is a severe service application if any of
the following conditions apply:

Severe Environmental Factors

• Frequent operation in dirty air

• Frequent operation at an altitude which is above
1525 m (5000 ft)

• Frequent operation in ambient temperatures which
are above 32° C (90° F)

58

Maintenance Section
Severe Service Application

SEBU7902-08

• Frequent operation in ambient temperatures which
are below 0° C (32° F)

Severe Operating Conditions

• Frequent operation with inlet air which has a
corrosive content

• Operation with inlet air which has a combustible
content

• Operation which is outside of the intended
application

• Operation with a plugged fuel filter

• Extended operation at low idle (more than 20% of
hours)

• Frequent cold starts at temperatures below 0° C
(32° F)

• Frequent dry starts (starting after more than 72
hours of shutdown)

• Frequent hot shutdowns (shutting down the
engine without the minimum of 2 minutes to 5
minutes of cool down time)

• Extending maintenance intervals for changing the
engine oil and engine coolant without S·O·S
validation

• Extending maintenance intervals for changing air
filters, oil filters, and fuel filters

• Failure to use a water separator

• Using filters which are not recommended by
Special Publication, PEWJ0074, “2008 Cat Filter
and Fluid Application Guide”

• Storing the engine for more than 3 months but less
than 1 yr (For information about engine storage,
refer to Special Publication, SEHS9031, “Storage
Procedure for Caterpillar Products”)

• Storing the engine for 1 yr to 2 years (For
information about engine storage, refer to Special
Instruction, REHS5001, “The Long Term Storage
and Recovery of Certain Commercial Engines”)

• Operation above the engine rated speed

• Operation below the peak torque speed

• Operating with fuel which does not meet the
standards for distillate diesel fuel as stated in
Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids
Recommendations” “Distillate Diesel Fuel”

• Operating with fuel which contains greater than
1000 ppm (0.1%) sulfur

• Operating with a blend of distillate fuel which
contains more than 5 percent biodiesel

Improper Maintenance Procedures
(Maintenance Procedures Which
May Contribute to a Severe Service
Application)

• Inadequate maintenance of fuel storage tanks
from causes such as excessive water, sediment,
and microorganism growth.

• Extending maintenance intervals beyond the
recommended intervals

• Using fluids which are not recommended in
Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids
Recommendations”

SEBU7902-08

59

Maintenance Section

Maintenance Interval Schedule

i05757049

Maintenance Interval Schedule

(Engines Which Have Shallow
Sumps)

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:
service hours and calendar time . Before each
consecutive interval is performed, all maintenance
from the previous intervals must be performed.

“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 78

“ Fuel System Primary Filter/Water Separator - Drain”

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

“ Fuel Tank Water and Sediment - Drain” . . . . . . . . .

“Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 96

Initial 250 Service Hours (or at first
oil change)

“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . . .

“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . . 83

Every 250 Service Hours

“ Battery Electrolyte Level - Check” . . . . . . . . . . . . . .

“ Coolant Sample (Level 1) - Obtain” . . . . . . . . . . . 69

“ Cooling System Supplemental Coolant Additive

(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . 71

“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 79

“ Engine Oil and Filter - Change” . . . . . . . . . . . . . . 80

Refer to this Operation and Maintenance Manual,
“Refill Capacities” to determine the type of oil pan
with which your engine is equipped.

Products that operate in severe operating conditions
may require more frequent maintenance. Refer to
this Operation and Maintenance Manual, “Severe
Service Applications” to determine if the engine is
operating in a severe service application.

When Required

“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 63

“ Battery or Battery Cable - Disconnect” . . . . . . . . . .

“ Coolant - Change” . . . . . . . . . . . . . . . . . . . . . . . . . 65

“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . 67

“ Engine Air Cleaner Element (Dual Element) -

Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . 73

“ Engine Oil and Filter - Change” . . . . . . . . . . . . . . 80

“ Engine Storage Procedure - Check” . . . . . . . . . . 82

“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 84

“ Fuel System Primary Filter (Water Separator)

Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 86

“ Fuel System Secondary Filter - Replace” . . . . . . 87

“Grounding Stud - Inspect/Clean/Tighten” . . . . . . . 89

“ Hoses and Clamps - Inspect/Replace” . . . . . . . . . .

“ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 94

“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 95

Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
Systems)

“ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 70

Every 500 Service Hours

“ Belts - Inspect/Adjust/Replace” . . . . . . . . . . . . . . 65

“ Turbocharger - Inspect” . . . . . . . . . . . . . . . . . . . . . .

Daily

“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . . 68

“ Engine Air Cleaner Service Indicator - Inspect” . . .

“ Engine Air Precleaner - Check/Clean” . . . . . . . . . 77

60

Maintenance Section
Engines Which Have Shallow Sumps

“ Water Pump - Inspect” . . . . . . . . . . . . . . . . . . . . . 97

Every 1000 Service Hours

“ Engine Crankcase Breather - Clean” . . . . . . . . . . 77

Every Year

“ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 70

Every 3000 Service Hours or 3
Years

“ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . . 63

“ Coolant Temperature Regulator - Replace” . . . . 70

“ Crankshaft Vibration Damper - Inspect” . . . . . . . 72

“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . 72

SEBU7902-08

“ Electronic Unit Injector - Check/Replace” . . . . . . . .

“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 78

“ Engine Protective Devices - Check” . . . . . . . . . . 82

“ Engine Speed/Timing Sensor - Clean/Inspect” . . 82

“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . . .

“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . . 83

“ Fan Drive Bearing - Lubricate” . . . . . . . . . . . . . . . 84

Every 585,000 L (154,540 US gal) of
Fuel

“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . 92

Overhaul

“ Fan Drive Bearing - Replace” . . . . . . . . . . . . . . . . 84

SEBU7902-08

61

Maintenance Section

Maintenance Interval Schedule

i05757058

Maintenance Interval Schedule

(Engines Which Have Deep
Sumps)

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:
service hours and calendar time . Before each
consecutive interval is performed, all maintenance
from the previous intervals must be performed.

Refer to this Operation and Maintenance Manual,
“Refill Capacities” to determine the type of oil pan
with which your engine is equipped.

Products that operate in severe operating conditions
may require more frequent maintenance. Refer to
this Operation and Maintenance Manual, “Severe
Service Applications” to determine if the engine is
operating in a severe service application.

When Required

“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 63

“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 78

“ Fuel System Primary Filter/Water Separator - Drain”

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

“ Fuel Tank Water and Sediment - Drain” . . . . . . . . .

“Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 96

Every 250 Service Hours

“ Battery Electrolyte Level - Check” . . . . . . . . . . . . . .

“ Coolant Sample (Level 1) - Obtain” . . . . . . . . . . . 69

“ Cooling System Supplemental Coolant Additive

(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . 71

“ Fuel System Primary Filter (Water Separator)

Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 86

“ Fuel System Secondary Filter - Replace” . . . . . . 87

“Grounding Stud - Inspect/Clean/Tighten” . . . . . . . 89

“ Hoses and Clamps - Inspect/Replace” . . . . . . . . . .

“ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 94

“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 95

Initial 500 Service Hours (or at first
oil change)

“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . . .

“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . . 83

Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
Systems)

“ Battery or Battery Cable - Disconnect” . . . . . . . . . .

“ Coolant - Change” . . . . . . . . . . . . . . . . . . . . . . . . . 65

“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . 67

“ Engine Air Cleaner Element (Dual Element) -

Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . 73

“ Engine Oil and Filter - Change” . . . . . . . . . . . . . . 80

“ Engine Storage Procedure - Check” . . . . . . . . . . 82

“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 84

Daily

“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . . 68

“ Engine Air Cleaner Service Indicator - Inspect” . . .

“ Engine Air Precleaner - Check/Clean” . . . . . . . . . 77

“ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 70

Every 500 Service Hours

“ Belts - Inspect/Adjust/Replace” . . . . . . . . . . . . . . 65

“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 79

“ Engine Oil and Filter - Change” . . . . . . . . . . . . . . 80

“ Turbocharger - Inspect” . . . . . . . . . . . . . . . . . . . . . .

62

Maintenance Section
Engines Which Have Deep Sumps

“ Water Pump - Inspect” . . . . . . . . . . . . . . . . . . . . . 97

Every 1000 Service Hours

“ Engine Crankcase Breather - Clean” . . . . . . . . . . 77

Every Year

“ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 70

Every 3000 Service Hours or 3
Years

“ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . . 63

“ Coolant Temperature Regulator - Replace” . . . . 70

“ Crankshaft Vibration Damper - Inspect” . . . . . . . 72

“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . 72

SEBU7902-08

“ Electronic Unit Injector - Check/Replace” . . . . . . . .

“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 78

“ Engine Protective Devices - Check” . . . . . . . . . . 82

“ Engine Speed/Timing Sensor - Clean/Inspect” . . 82

“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . . .

“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . . 83

“ Fan Drive Bearing - Lubricate” . . . . . . . . . . . . . . . 84

Every 585,000 L (154,540 US gal) of
Fuel

“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . 92

Overhaul

“ Fan Drive Bearing - Replace” . . . . . . . . . . . . . . . . 84

SEBU7902-08

63

Maintenance Section

Aftercooler Core - Clean/Test

i02783957

Aftercooler Core - Clean/Test

(Air-To-Air Aftercooler (If
Equipped))

SMCS Code: 1064-081; 1064-070

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.

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”.

i01878164

Battery - Replace

SMCS Code: 1401-510

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.

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.

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.

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.

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.

Inspect the fins for damage. Bent fins may be opened
with a “comb”.

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.

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.

Note: If parts of the aftercooler system are repaired
or replaced, a leak test is highly recommended.

5. Remove the used battery.

6. Install the new battery.

64

Maintenance Section
Battery Electrolyte Level - Check

SEBU7902-08

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.

i07419560

Battery Electrolyte Level ­Check

SMCS Code: 1401-535-FLV

When the engine has not run for long or short periods
of time, the batteries may not fully recharge. Ensure a
full charge to help prevent the battery from freezing.

In warmer climates, check the electrolyte level more
frequently.

Ensure that the electrolyte level is 13 mm (0.5 inch)
above the top of the separators.

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.

Use the 1U-9921 Battery Service Tool to clean
the battery terminals. Use a wire brush to clean
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 fit improperly.
Coat the clamps and the terminals with the Loctite

®

product listed below, petroleum jelly or MPGM.

• For Americas North - Loctite LB8632

• For Europe and Africa, Middle East, CIS
(AMEC) - Loctite LB8104

• For Asia Pacific - Loctite LB8801

• For Americas South - Loctite LB Superlube

For ordering the products listed above, go to the
following address.

http://www.loctite.com/en/meta/meta-nav/
location-selector.html

Battery or Battery Cable ­Disconnect

SMCS Code: 1401; 1402-029

i06738663

1. Remove the filler caps. Maintain the electrolyte

level to the “FULL” mark on the battery.

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.

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.

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.

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.

SEBU7902-08

65

Maintenance Section

Belts - Inspect/Adjust/Replace

i02042962

Belts - Inspect/Adjust/Replace

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

Inspection

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.

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:

• Belts

• Pulleys

• Bearings

If the belts are too tight, unnecessary stress is placed
on the components. This reduces the service life of
the components.

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.

Alternator Belt Adjustment

3. Move the assembly in order to increase or

decrease the belt tension.

4. Tighten adjusting bolt (2). Tighten mounting bolts
(1).

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

1. Remove the belt guard.

2. Loosen the mounting bolt for the pulley.

3. Loosen the adjusting nut for the pulley.

4. Move the pulley in order to adjust the belt tension.

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.

i04538352

Coolant - Change

SMCS Code: 1350-044; 1352; 1395; 1395-044

Refer to this Operation and Maintenance Manual,
“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:

Illustration 31 g00788814

1. Remove the belt guard.

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

• 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.

66

Maintenance Section
Coolant - Change

SEBU7902-08

Drain the Cooling System

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, mainte-

nance, 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.

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.

Inside USA 1-800-542-TOOL
Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL
International 1-309-578-7372

Flush

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).

5. Stop the engine and allow the engine to cool.
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.

Dispose of used engine coolant properly or recycle.

NOTICE

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:

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 the
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques.

SEBU7902-08

67

Maintenance Section

Coolant Extender (ELC) - Add

Fill the cooling system no faster than 19 L (5 US gal)

NOTICE

per minute to avoid air locks.

5. Fill the cooling system with a mixture of clean
water and Cat Fast Acting Cooling System
Cleaner.

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).

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.

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.

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).

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
cooling system filler cap.

5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.

i04862631

9. Stop the engine and allow the engine to cool.
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 the
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques.

Fill the Cooling System

NOTICE

Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

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.

68

Maintenance Section
Coolant Level - Check

SEBU7902-08

i04156593

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.

NOTICE
Care must be taken to ensure that fluids are con­tained during performance of inspection, mainte-

nance, 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.

Coolant Level - Check

SMCS Code: 1395-082

Check the coolant level when the engine is stopped
and cool.

Illustration 32 g00285520

Cooling system filler cap

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.

Dispose of all fluids according to local regulations
and 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.
Refer to this Operation and Maintenance Manual,
“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 Manual, , “Fluid Recommendations”.

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.

Illustration 33 g00103639

Typical filler cap gaskets

SEBU7902-08

69

Maintenance Section

Coolant Sample (Level 1) - Obtain

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.

i04333559

Coolant Sample (Level 1) ­Obtain

SMCS Code: 1350-008; 1395-554; 1395-008; 7542

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. S·O·S Systems Coolant Analysis can be
done at your Cat dealer. Cat S·O·S coolant analysis
is the best way to monitor the condition of your
coolant and your cooling system. S·O·S 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.

• Keep the lids on empty sampling bottles until you
are ready to collect the sample.

• 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.

Timing of the Sampling

Table 17

Recommended Interval

Type of

Coolant

Cat DEAC

Cat SCA

Conventional Heavy-

Duty Coolants

Cat ELC

Cat ELI

Commercial EC-1

Coolants

(1)

The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.

Level 1 Level 2

Every 250 hours Yearly

Optional

(1)

Yearly

(1)

(1)

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.

• Keep the unused sampling bottles stored in plastic
bags.

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 S·O·S 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.

• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.

70

Maintenance Section
Coolant Sample (Level 2) - Obtain

SEBU7902-08

Note: Level 1 results may indicate a need for Level 2
Analysis.

i04638756

Coolant Sample (Level 2) ­Obtain

SMCS Code: 1350-008; 1395-554; 1395-008; 7542

An S·O·S 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 S·O·S Coolant Analysis
(Level 2) has the following features:

• Full coolant analysis (Level 1)

• Identification of metal corrosion and contaminants

• Identification of buildup of the impurities that
cause corrosion and scaling

• 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”.

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
Care must be taken to ensure that fluids are con­tained during performance of inspection, mainte-

nance, 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.

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.

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.

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.

SEBU7902-08

71

Maintenance Section

Cooling System Supplemental Coolant Additive (SCA) - Test/Add

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.

Care must be taken to ensure that fluids are con-

NOTICE

tained 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” and to Special Publication,
GECJ0003, “Cat Shop Supplies and Tools” for tools
and supplies suitable to collect and contain fluids on
Cat products.

Dispose of all fluids according to applicable regula­tions and mandates.

Note: Caterpillar recommends that an S·O·S Coolant
Analysis (Level 1) be performed to check the
concentration of SCA.

Maintain the Proper Concentration
of SCA in the Coolant

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.

1. Remove the cooling system filler cap slowly.

2. Test the concentration of the SCA with a

286-2578 Nitrite Test Strip or review the results
of the S·O·S Coolant Analysis (Level 1).

3. If necessary, drain some coolant in order to allow

space for the addition of the SCA.

4. Add the amount of SCA required to maintain a

concentration of 3 percent to 6 percent SCA in the
coolant.

5. Clean the cooling system filler cap. Install the

cooling system filler cap.

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.

NOTICE

72

Maintenance Section
Crankshaft Vibration Damper - Inspect

SEBU7902-08

For further information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.

i05264144

Crankshaft Vibration Damper ­Inspect

SMCS Code: 1205-040

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.

The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the
engine.

Visconic Damper

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.

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.

• Analysis of the oil has revealed that the front main
bearing is badly worn.

• 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 Cat dealer for information about
damper replacement.

i00934883

Driven Equipment - Check

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.

SEBU7902-08

73

Maintenance Section

Electronic Unit Injector - Check/Replace

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.

i06826449

Electronic Unit Injector ­Check/Replace

SMCS Code: 1251-510; 1251-535; 1290-510; 1290-

535

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.

i06103535

Engine - Clean

SMCS Code: 1000-070

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

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, “Engine Valve Lash — Inspect/Adjust” for
the adjustment procedure.

Refer to the Disassembly and Assembly Manual for
the procedure applicable 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.

• 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.

74

Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

SEBU7902-08

Never service the air cleaner element with the engine

NOTICE

running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

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.

Illustration 34 g00736431

(1) Cover
(2) Primary air cleaner element
(3) Secondary air cleaner element
(4) 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”.

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.

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.

SEBU7902-08

75

Maintenance Section

Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

7. Reset the air cleaner service indicator.

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:

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.

Pressurized Air

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 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).

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

Illustration 35 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.

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”.

76

Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Inspecting the Primary Air Cleaner
Elements

Illustration 36 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.

SEBU7902-08

Illustration 37 g00281694

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

• Number of cleanings

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.

Store the box in a dry location.

i06103548

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 and 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 clean
side of the air cleaner housing or in a remote
location.

SEBU7902-08

Illustration 38 g00103777

Typical service indicator

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:

77

Maintenance Section

Engine Air Precleaner - Check/Clean

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 N·m (18 lb in).

i02927289

Engine Air Precleaner - Check/
Clean

SMCS Code: 1055-070; 1055-535

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service Indicator

Service indicators are important instruments.

• Check for ease of resetting. The service indicator
should reset in less than three pushes.

• Check the movement of the service indicator core
when the engine is run at full load speed. The core
should latch approximately at the greatest vacuum
that is attained.

If the service indicator does not reset easily, or if the
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.

If necessary, replace the service indicator more
frequently in environments that are severely dusty.
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.

Illustration 39 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.

i02489863

Engine Crankcase Breather ­Clean

SMCS Code: 1317-070

Perform this maintenance with the engine stopped.

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.

NOTICE

78

Maintenance Section
Engine Mounts - Inspect

SEBU7902-08

5. Install hose (2) on valve cover (3). Install hose
clamp (1).

i02139969

Engine Mounts - Inspect

SMCS Code: 1152; 1152-040

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.

Illustration 40 g00908595

1. Loosen hose clamp (1) and remove hose (2) from
valve cover (3).

2. Remove the valve cover (3). Refer to the
Disassembly and Assembly Manual.

i04285621

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.

Illustration 41 g00908611

3. Wash breather (4) in solvent that is clean and
nonflammable. Allow the breather to dry before
installation.

4. Install the valve cover (3). Refer to the
Disassembly and Assembly Manual.

Illustration 42 g01456636

(1) Oil level gauge
(2) Oil filler cap

SEBU7902-08

Illustration 43 g00110310

(Y) “ADD” mark
(X) “FULL” mark

NOTICE

Perform this maintenance with the engine stopped.

1. Maintain the oil level between the “ADD” mark (Y)
and the “FULL” mark (X) on the oil level gauge .
Do not fill the crankcase above the “FULL” mark
(X).

79

Maintenance Section

Engine Oil Sample - Obtain

i04237495

Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM

In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.

Obtain the Sample and the
Analysis

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.

Engine damage can occur if the crankcase is filled

NOTICE

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.

2. Remove the oil filler cap and add oil, if necessary.
For the correct oil to use, see this Operation and
Maintenance Manual, “Fluid Recommendations”
topic. Do not fill the crankcase above the “FULL”
mark (X) on the oil level gauge. Clean the oil filler
cap. Install the oil filler cap.

3. 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. This will help to provide the most
accurate oil analysis.

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:

• Engine model

• Service hours on the engine

• The number of hours that have accumulated since
the last oil change

• The amount of oil that has been added since the
last oil change

To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, mixed oil sample.

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. 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.

80

Maintenance Section
Engine Oil and Filter - Change

SEBU7902-08

Always use a designated pump for oil sampling, and

NOTICE

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 S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.

i04268709

Engine Oil and Filter - Change

SMCS Code: 1318-510

• The type of oil pan

• The refill capacity for engine oil

Table 18

Intervals for Changing the Engine Oil and Engine Oil Filter

Shallow sump

Deep sump

(1)

Choose the interval that occurs first.

Every 14200 L (3750 US gal) or

250 service hours or 1 yr

Every 28400 L (7500 US gal) or

500 service hours or 1 yr

(1)

Drain the Engine Oil

Care must be taken to ensure that fluids are con­tained during performance of inspection, mainte-

nance, 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.

NOTICE

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.

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.

Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.

Interval for Engine Oil and Engine
Oil Filter Change

Note: The intervals stated in table 18 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.

Dispose of all fluids according to local regulations
and 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.

• 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.

Refer to this Operation and Maintenance Manual,
“Refill Capacities” before this procedure is started in
order to determine the following:

SEBU7902-08

81

Maintenance Section

Engine Oil and Filter - Change

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.

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.

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 contami-

nated. 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.

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.

Illustration 44 g00103713

Typical filter mounting base and filter gasket

To prevent crankshaft bearing damage, crank the en-

NOTICE

gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.

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.

82

Maintenance Section
Engine Protective Devices - Check

SEBU7902-08

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.

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.

i04230693

Engine Speed/Timing Sensor ­Clean/Inspect

SMCS Code: 1905-040; 1905-070; 1907-040; 1907-

070

Illustration 45 g02407038

Left side view

(1) Secondary speed/timing sensor
(2) Primary speed/timing sensor

1. Remove the speed/timing sensors from the front
housing. 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. Install the
sensors into the front housing.

i01458399

Engine Storage Procedure ­Check

SMCS Code: 1000-535

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:

• Mileage

• Operating hours

SEBU7902-08

• Fuel consumption

83

Maintenance Section

Engine Valve Lash - Check

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”.

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.

i07139300

Engine Valve Lash - Check

SMCS Code: 1105-535

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 maintenance is recommended by Caterpillar as
part of a lubrication and preventive maintenance
schedule to help provide maximum engine life.

Note: Only qualified service personnel should
perform this maintenance. For procedures on
adjusting the valve lash and adjusting the valve
bridge, see Systems Operation/Testing and
Adjusting, “Engine Valve Lash - Inspect/Adjust”.
Consult your Cat dealer for assistance.

Ensure that the engine cannot be started while
this maintenance is being performed. To help 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 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.

2. Operate the engine at low idle.

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.

Note: For information on adjusting the unit injector
refer to Testing and Adjusting, RENR1232, Unit
Injector Adjustment.

84

Maintenance Section
Fan Drive Bearing - Lubricate

SEBU7902-08

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.

Illustration 46 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.

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 discon-

nected fuel system component.

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.

i02053753

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.

Illustration 47 g00975199

(1) Fuel priming pump
(2) Air purge screw
(3) Priming valve (If Equipped)

2. Turn the priming valve (3) (If Equipped) to the

“Closed (Prime)” position in order to prime the fuel
system.

SEBU7902-08

3. Open air purge screw (2) for the fuel filter by three
full turns. Do not remove the air purge screw.

85

Maintenance Section

Fuel System - Prime

Do not crank the engine continuously for more than

NOTICE

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.

6. Clean any residual fuel from the engine
components.

7. 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.

Illustration 48 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.

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.

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

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 discon-

nected fuel system component.

1. Turn the ignition switch to the “OFF” position.

2. Fill the fuel tank(s) with clean diesel fuel.

Note: You may use the fuel priming pump (1) (IF

EQUIPPED) for the fuel filter instead of cranking the
engine.

6. Crank the engine for 30 seconds. Allow the starter
motor to cool for 2 minutes.

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.

86

Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

SEBU7902-08

9. Clean any residual fuel from the engine
components.

i05354209

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).

Replace the Element

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
Care must be taken to ensure that fluids are con­tained during performance of inspection, mainte-

nance, 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.

Do not fill fuel filters with fuel before installing

NOTICE

them. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause ac­celerated wear to fuel system parts. The fuel sys-

tem should be primed prior to starting the engine.

1. Close the main fuel supply valve.

Illustration 49 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.

4. Remove the O-ring from the gland of the bowl.
Clean the following components:

• Bowl

• O-ring

Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations
and mandates.

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 discon-

nected fuel system component.

• 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.

7. Lubricate the top seal of element (1) with clean
diesel fuel. Install the new element on the
mounting base. Tighten the element by hand.

SEBU7902-08

87

Maintenance Section

Fuel System Primary Filter/Water Separator - Drain

The water separator is under suction during normal

NOTICE

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 1 minute. Stop the engine and check for
leaks again.

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. Ensure that the components are
correctly installed to prevent air from entering the
fuel system.

i02927285

Fuel System Primary Filter/
Water Separator - Drain

SMCS Code: 1260-543; 1263-543

Illustration 50 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).

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
Care must be taken to ensure that fluids are con­tained during performance of inspection, mainte-

nance, 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, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations
and mandates.

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 discon-

nected fuel system component.

The water separator is under suction during normal

NOTICE

engine operation. Ensure that the drain valve is tight­ened securely to help prevent air from entering the
fuel system.

i03478081

Fuel System Secondary Filter ­Replace

SMCS Code: 1261-510-SE

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

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 any
disconnected fuel system components.

88

Maintenance Section
Fuel Tank Water and Sediment - Drain

SEBU7902-08

Care must be taken to ensure that fluids are con-

NOTICE

tained 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. 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.

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.

i06104305

Fuel Tank Water and Sediment

- Drain

SMCS Code: 1273-543-M&S

NOTICE
Care must be taken to ensure that fluids are con­tained during performance of inspection, mainte-

nance, 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.

Do not fill the secondary fuel filter with fuel before in-

NOTICE

stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-

ated 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 Cat Diesel Engines that are
equipped with unit injected fuel systems. All current
Cat Diesel Engines are factory equipped with Cat Ad­vanced Efficiency 4 micron(c) absolute fuel filters.

Caterpillar does not warrant the quality or perform­ance of non-Cat fluids and filters.

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. The
fuel tank utilizes a fuel tank vent to prevent an air lock
or vacuum. Ensure that the vent is free of debris and

not damaged.

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.

Prepare to catch water and sediment in an
appropriate container. Connect a hose (if necessary)
to the valve prior to opening the valve.

SEBU7902-08

89

Maintenance Section

Grounding Stud - Inspect/Clean/Tighten

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 close the drain properly could result
in fuel leakage, which could have detrimental results
to performance.

Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the

fuel tank has been filled. Allow 5 to 10 minutes before
performing this procedure.

Fill the fuel tank after operating the engine in order to
drive out moist air. This procedure 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 stand pipes that allow water and
sediment to settle below the end of the fuel stand

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:

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: 7423-070; 7423-079; 7423-040

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.

• Weekly

• Refill of the tank

This procedure 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.

Illustration 51 g00765094

Typical example
Electronics grounding stud (side view)

Inspect the OEM harness for good connections.
Inspect the condition of the OEM harness.

90

Maintenance Section
Hoses and Clamps - Inspect/Replace

SEBU7902-08

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.

i06825542

Hoses and Clamps - Inspect/
Replace

SMCS Code: 7554-040; 7554-510

Hoses and clamps must be inspected periodically
and replaced at the recommended interval to ensure
safe and continuous operation of the engine. Failure
to replace a fuel hose at the recommended change
interval may result in a hazardous situation. 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.

Note: Ensure that the hose is compatible with the
application.

Inspect Tubes, Hoses, Bellows, and
Clamps

Inspect all tubes and hoses for leaks that are caused
by the following conditions. Replace any tube or hose
which exhibits any of the following conditions. Failure
to replace a tube or 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

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

• Exhaust bellows for leaks or damage

• 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
Care must be taken to ensure that fluids are con­tained during performance of inspection, mainte-

nance, 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.

• Outer covering that is ballooning locally

SEBU7902-08

91

Maintenance Section

Hoses and Clamps - Inspect/Replace

Cooling System

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.

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 to relieve any
pressure.

Fuel 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.

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 in-

stall 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.

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 coolant filler cap. Inspect the gaskets

on the filler cap. Inspect the gasket seat. Inspect
the vacuum valve and seat for debris or damage.
Replace the filler cap if the gaskets are damaged.
Install the filler cap.

12. Start the engine. Inspect the cooling system for
leaks.

Do not allow dirt to enter the fuel system. Thoroughly

NOTICE

clean the area around a fuel system component that
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 high­pressure 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 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.

2. Remove the hose clamps.

3. Disconnect the old hose.

Note: When servicing fuel system, use cap/s or

cover/s as required to protect the system and
maintain fuel system cleanliness.

4. Replace the old hose with a new hose.

92

Maintenance Section
Overhaul Considerations

SEBU7902-08

5. 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.

6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
engine.

Note: Fuel must be added to the fuel system ahead
of the fuel filter.

7. Refill the fuel system. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime” for
information about priming the engine with fuel.

8. Start the engine. Inspect the fuel system for leaks.

Lubrication System

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.

4. 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.

Note: The bellows and the V-clamps that are used on
the exhaust bellows should never be reused.

5. Start the engine. Inspect the air lines for leaks.

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:

1. Drain the oil from the lubrication system to a level
that is below the hose that is being replaced.

2. Remove the hose clamps.

3. Disconnect the old hose.

4. Replace the old hose with a new hose.

5. 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.

6. Refill the lubrication system. Refer to this
Operation and Maintenance Manual, “Engine Oil
Level - Check” 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

1. Remove the hose clamps.

2. Disconnect the old hose.

3. Replace the old hose with a new hose.

• The need for preventive maintenance

• The quality of the fuel that is being used

• The operating conditions

• The results of the S·O·S analysis

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.

SEBU7902-08

93

Maintenance Section

Overhaul Considerations

Overhaul Options

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

• 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.

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:

• 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 out­of-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

94

Maintenance Section
Radiator - Clean

SEBU7902-08

• Rod bearings

• Valve rotators

• Crankshaft seals

Caterpillar Inc. recommends the installation of new
parts at each overhaul period.

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.

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.

Obtain Coolant Analysis

The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits or
with S·O·S Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine is
overhauled.

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 S·O·S Coolant
Analysis (Level 2).

S·O·S Coolant Analysis (Level 2)

An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level 2)
provides the following information:

• Complete S·O·S Coolant Analysis (Level 2)

• Visual inspection of properties

• Identification of metal corrosion

• Identification of contaminants

• Identification of built up impurities (corrosion and
scale)

S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
recommendations.

For more information about coolant analysis, consult
your Caterpillar dealer.

i04020194

Radiator - Clean

SMCS Code: 1353-070

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary.

Caustic cleaners can attack the internal metals of the
core and cause leakage.

SEBU7902-08

95

Maintenance Section

Starting Motor - Inspect

i05965726

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.

The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.

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.

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.

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.

Turbocharger - Inspect

SMCS Code: 1052-040

Periodic inspection and cleaning are 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.

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.

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.

96

Maintenance Section
Walk-Around Inspection

SEBU7902-08

Removal and Installation

For options regarding the removal, installation, repair,
and replacement, consult your Cat 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.

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 clean-

ing or high pressure water.

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. Inspect the bore of the turbine housing for
corrosion.

5. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.

6. 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

• 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.

• 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.

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.

SEBU7902-08

97

Maintenance Section

Water Pump - Inspect

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.

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 Cat dealer if repair is needed or replacement is
needed.

i05264233

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. Overheating 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 necessary
to remove the water pump, refer to two articles in the
Disassembly and Assembly Manual, “Water Pump ­Remove and Water Pump - Install”.

98

Warranty Section
Warranty Information

SEBU7902-08

Warranty Section

Warranty Information

i06112217

Emissions Warranty
Information

SMCS Code: 1000

The certifying engine manufacturer warrants to the
ultimate purchaser and each subsequent purchaser
that:

1. New non-road diesel engines and stationary diesel

engines less than 10 liters per cylinder (including
Tier 1 and Tier 2 marine engines < 37 kW, but
excluding locomotive and other marine engines)
operated and serviced in the United States and
Canada, including all parts of their emission
control systems (“emission related components”),
are:

a. Designed, built, and equipped so as to conform,

at the time of sale, with applicable emission
standards prescribed by the United States
Environmental Protection Agency (EPA) by way
of regulation.

3. New non-road diesel engines installed in
construction machines conforming to the South
Korean regulations for construction machines
manufactured after January 1, 2015, and operated
and serviced in South Korea, including all parts of
their emission control systems (“emission related
components”), are:

a. Designed, built, and equipped so as to conform,

at the time of sale, with applicable emission
standards prescribed in the Enforcement Rule
of the Clean Air Conservation Act promulgated
by South Korea MOE.

b. Free from defects in materials and

workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.

A detailed explanation of the Emission Control
Warranty that is applicable to new non-road and
stationary diesel engines, including the components
covered and the warranty period, is found in a
supplemental Special Publication. Consult your
authorized Cat dealer to determine if your engine is
subject to an Emission Control Warranty and to
obtain a copy of the applicable Special Publication.

b. Free from defects in materials and

workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.

2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission related components”),
are:

a. Designed, built, and equipped so as to conform,

at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
(ARB).

b. Free from defects in materials and

workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the engine manufacturer's
application for certification for the warranty
period.

SEBU7902-08

99

Reference Information Section

Engine Ratings

Reference Information
Section

Engine Ratings

i01097462

Engine Rating Conditions

SMCS Code: 1000

All engine ratings are based on“SAE J1349”.

Ratings relate to the standard conditions of
“AS1501”, of “ISO3046/1”, of “DIN6271”, and of

“BS5514”.

The engine ratings are gross output ratings.

Gross Output Ratings – The total output capability
of the engine that is equipped with standard
accessories.

Standard accessories include the following
components:

• Oil pumps

• Fuel pumps

Table 19

Engine Rating Information

hour

(1)

Examples of
Applications

Pipe line
pumping
Ventilation

Irrigation pumps
Drilling
applications
Plant air
compressors

Fire pumps
Chippers
Rock crushers
Portable air
compressors

Snowgroomer
Snowblowers
Cranes
Water well drills

Standby centrifu­gal pumps
Oil well servicing

Perform­ance
Rating

(1)

Both the overall time at rated load and the time the engine is
operated in any one instance must be considered.

Load
Factor

A 100% 100% n/a

B 85% 75% n/a

C 70% 50%

D 50% 10%

E 35% 5%

Time at Rated Load

Overall

Any One

Instance

Less than1

Less than 30

minutes

Less than 15

minutes

• Water pumps

Subtract the power that is required to drive auxiliary
components from the gross output. This will produce
the net power that is available for the external load
(flywheel).

i03880100

Engine Rating Definitions

SMCS Code: 1000

In selecting a rating for a specific application, the
most important consideration is the time that is spent
at full throttle. These rating definitions identify the
percent of time at full throttle. The definitions also
identify the corresponding times below rated rpm.
Refer to this Operation and Maintenance Manual,
“Configuration Parameters” for information about the
rating for this engine.

Note: The examples of the applications are only for
reference. For an exact determination of the
appropriate rating, follow the OEM specifications or
consult your Caterpillar dealer.

Operating engines above the rating definitions can

NOTICE

result in shorter service life before overhaul.

100

Reference Information Section
Customer Service

SEBU7902-08

Customer Service

i07240427

Customer Assistance

SMCS Code: 1000; 4450

USA and Canada

When a problem arises concerning the operation or
the service of an engine, the problem will normally be
managed by the dealer in your area.

Your satisfaction is a primary concern to Caterpillar
and to Caterpillar dealers. If you have a problem that
has not been handled to your complete satisfaction,
follow these steps:

1. Discuss your problem with a manager from the
dealership.

2. If your problem cannot be resolved at the dealer
level, use the phone number that is listed below to
talk with a Field Service Coordinator:

1-800-447-4986

The normal hours are from 8:00 to 4:30 Monday
through Friday Central Standard Time.

3. If your needs have not been met still, submit the
matter in writing to the following address:

Designated Compliance Officer Heavy-Duty and
Nonroad Engine Group 6403-J,
US Ave, NW, Washington,
DC 20460
Email address: [e-mail].

Please keep in mind: probably, your problem will
ultimately be solved at the dealership, using the
dealership facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a
problem is experienced.

Europe, Africa, and Middle East
Caterpillar Overseas S.A.
76 Route de Frontenex
P.O. Box 6000
CH-1211 Geneva 6
Switzerland
Phone: [phone]
Fax: [phone]

Far East
Caterpillar Asia Pte. Ltd.
7 Tractor Road
Jurong, Singapore 627968
Republic of Singapore
Phone: [phone]
Fax: [phone]

China
Caterpillar China Ltd.
37/F., The Lee Gardens
33 Hysan Avenue
Causeway Bay
G.P.O. Box 3069
Hong Kong
Phone: [phone]
Fax: [phone]

Japan
Shin Caterpillar Mitsubishi Ltd.
SBS Tower
10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
Japan
Phone: [phone]
Fax: [phone]

Japan
Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Phone: [phone]
Fax: [phone]

Outside of the USA and of Canada

If a problem arises outside the USA and outside
Canada, and if the problem cannot be resolved at the
dealer level, consult the appropriate Caterpillar office.

Latin America, Mexico, Carribean
Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: [phone]
Fax: [phone]