Operation and Maintenance Manual: C9.3 Industrial Engine

SEBU9107-03 (en-us)
February 2016
Operation and
Maintenance
Manual
C9.3 Industrial Engine
CS9 1-UP (Engine)
SAFETY.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 re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury 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.
SEBU9107-03 3
Table of Contents
Table of Contents Refill Capacities............................................... 57
Maintenance Recommendations .................... 64

Foreword ........................................................... 4
Maintenance Interval Schedule....................... 67
Safety Section
Maintenance Interval Schedule (Engines With
Safety Messages............................................... 5
Ratings Greater Than 359 hp)....................... 69
Additional Messages ......................................... 8
Warranty Section
General Hazard Information.............................. 8
Warranty Information..................................... 108
Burn Prevention............................................... 12
Reference Information Section
Fire Prevention and Explosion Prevention...... 12
Engine Ratings .............................................. 109
Crushing Prevention and Cutting Prevention.. 14
Customer Service...........................................110
Mounting and Dismounting ............................. 15
Reference Materials .......................................112
Engine Starting................................................ 15
Index Section
Engine Stopping .............................................. 15
Index...............................................................113
Electrical System............................................. 15
Engine Electronics........................................... 17
Product Information Section
General Information ........................................ 18
Product Identification Information ................... 23
Operation Section
Lifting and Storage .......................................... 26
Features and Controls..................................... 31
Engine Diagnostics ......................................... 45
Engine Starting................................................ 46
Engine Operation ............................................ 50
Cold Weather Operation ................................. 53
Engine Stopping .............................................. 55
Maintenance Section
4 SEBU9107-03
Foreword
Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
This manual contains safety, operation instructions, wet or freezing cold operating conditions, more
lubrication and maintenance information. This frequent lubrication and maintenance than is
manual should be stored in or near the engine area in specified in the Maintenance Interval Schedule may
a literature holder or literature storage area. Read, be necessary.
study and keep it with the literature and engine
information. The maintenance schedule items are organized for a
preventive maintenance management program. If the
English is the primary language for all Cat preventive maintenance program is followed, a
publications. The English used facilitates translation periodic tune-up is not required. The implementation
and consistency in electronic media delivery. of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures.
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design Maintenance Intervals
may have caused changes to your engine which are
not included in this manual. Whenever a question Perform maintenance on items at multiples of the
arises regarding your engine, or this manual, please original requirement. Each level and/or individual
consult with your Cat dealer for the latest available items in each level should be shifted ahead or back
information. depending upon your specific maintenance practices,
operation and application. We recommend that the
maintenance schedules be reproduced and
Safety displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
This safety section lists basic safety precautions. In maintained as part of the engine's permanent record.
addition, this section identifies hazardous, warning
situations. Read and understand the basic See the section in the Operation and Maintenance
precautions listed in the safety section before Manual, “Maintenance Records” for information
operating or performing lubrication, maintenance and regarding documents that are generally accepted as
repair on this product. proof of maintenance or repair. Your authorized Cat
dealer can assist you in adjusting your maintenance
schedule to meet the needs of your operating
Operation environment.
Operating techniques outlined in this manual are
basic. They assist with developing the skills and Overhaul
techniques required to operate the engine more
efficiently and economically. Skill and techniques Major engine overhaul details are not covered in the
develop as the operator gains knowledge of the Operation and Maintenance Manual except for the
engine and its capabilities. interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
The operation section is a reference for operators. authorized Cat dealer. Your Cat dealer offers a
variety of options regarding overhaul programs. If you
Photographs and illustrations guide the operator experience a major engine failure, there are also
through procedures of inspecting, starting, operating numerous after failure overhaul options available
and stopping the engine. This section also includes a from your Cat dealer. Consult with your dealer for
discussion of electronic diagnostic information. information regarding these options.
Maintenance California Proposition 65 Warning

The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped Diesel engine exhaust and some of its constituents
by fuel consumption, service hours and/or calendar are known to the State of California to cause cancer,
time maintenance intervals. Items in the maintenance birth defects, and other reproductive harm.
schedule are referenced to detailed instructions that
follow. Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
Use fuel consumption or service hours to determine after handling.
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.
SEBU9107-03 5
Safety Section
Safety Messages
Safety Section
i04022036
Safety Messages
SMCS Code: 1000; 7405
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 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.
6 SEBU9107-03
Safety Section
Safety Messages
Illustration 1 g02199153
View of the left side and view of the right side of a C9.3 Industrial Engine
Universal Warning (1)
One safety message is located on the left side of the

front housing. One safety message is located on the
base for the oil filter, on the right side of the engine.
SEBU9107-03 7
Safety Section
Safety Messages
Do not operate or work on this equipment unless Contact with high pressure fuel may cause fluid
you have read and understand the instructions penetration and burn hazards. High pressure fuel
and warnings in the Operation and Maintenance spray may cause a fire hazard. Failure to follow
Manual. Failure to follow the instructions or heed these inspection, maintenance and service in-
the warnings could result in injury or death. Con- structions may cause personal injury or death.
tact any Caterpillar dealer for replacement man-
uals. Proper care is your responsibility.
Sulfuric Acid Burn (3)
High Pressure (2)
One safety message for high pressure (2) is located

on the bottom of the fuel pump. Two messages are
located on the fuel rail.
The safety message for sulfuric acid burn (3) is

located on top of the exhaust cooler.
8 SEBU9107-03
Safety Section
Additional Messages
This notice is located next to the battery disconnect

switch.
Sulfuric Acid Burn Hazard may cause serious
personal injury or death. NOTICE
Do not turn the battery power disconnect switch off
The exhaust gas cooler may contain a small until indicator lamp has turned off. If the switch is
amount of sulfuric acid. The use of fuel with sul- turned off when the light is illuminated then the DEF
fur levels greater than 15 ppm may increase the system will not purge and DEF could freeze and
amount of sulfuric acid formed. The sulfuric acid cause damage to the pump and lines.
may spill from the cooler during service of the en-
gine. The sulfuric acid will burn the eyes, skin
and clothing on contact. Always wear the appro- i06300340
priate personal protective equipment (PPE) that
is noted on a material safety data sheet (MSDS)
for sulfuric acid. Always follow the directions for General Hazard Information
first aid that are noted on a material safety data SMCS Code: 1000; 4450; 7405
sheet (MSDS) for sulfuric acid.
i05422543
Additional Messages
SMCS Code: 1000; 7405
There are several specific messages on this engine.
The exact location of the messages and the
description of the information are reviewed in this
section. Become familiar with all messages.
Make sure that all of the messages are legible. Clean
the messages or replace the messages if you cannot
read the words. Replace the illustrations if the
illustrations are not legible. When you clean the Illustration 6 g03838041
messages, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean Attach a “Do Not Operate” warning tag to the start
the messages. Solvents, gasoline, or harsh switch or controls before the engine is serviced or
chemicals could loosen the adhesive that secures the repaired. These warning tags (Special Instruction,
messages. Loose adhesive will allow the messages SEHS7332) are available from your Cat dealer.
to fall. Attach the warning tags to the engine and to each
Replace any message that is damaged, or missing. If operator control station. When appropriate,
a message is attached to a part that is replaced, disconnect the starting controls.
install a message on the replacement part. Any Cat Do not allow unauthorized personnel on the engine,
dealer can provide new messages. or around the engine when the engine is being
serviced.
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
Purge notice message
SEBU9107-03 9
Safety Section
General Hazard Information
Use caution when cover plates are removed. • When starting a new engine, make provisions to
Gradually loosen, but do not remove the last two stop the engine if an overspeed occurs. If an
bolts or nuts that are located at opposite ends of the engine has not been started since service has
cover plate or the device. Before removing the last been performed, make provisions to stop the
two bolts or nuts, pry the cover loose in order to engine if an overspeed occurs. Shutting down the
relieve any spring pressure or other pressure. 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

Illustration 7 g00702020 Pressurized air and/or water can cause debris and/or
hot water to be blown out which could result in
• Wear a hard hat, protective glasses, and other personal injury.
protective equipment, as required.
The maximum air pressure for cleaning purposes
• When work is performed around an engine that is must be reduced to 205 kPa (30 psi) when the air
operating, wear protective devices for ears in nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective
order to help prevent damage to hearing. equipment. The maximum water pressure for
• Do not wear loose clothing or jewelry that can cleaning purposes must be below 275 kPa (40 psi).
snag on controls or on other parts of the engine. When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
• Ensure that all protective guards and all covers shoes, and eye protection. Eye protection includes
are secured in place on the engine. goggles or a protective face shield. Always wear eye
protection for cleaning the cooling system.
• 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.
• 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.
10 SEBU9107-03
Safety Section
Avoid direct spraying of water on electrical Static Electricity Hazard when

connectors, connections, and components. When
using air for cleaning, allow the machine to cool to Fueling with Ultra-low Sulfur Diesel
reduce the possibility of fine debris igniting when Fuel
redeposited on hot surfaces.
The removal of sulfur and other compounds in ultra-
Fluid Penetration low 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. Ultra-
Always use a board or cardboard when you check for low sulfur diesel fuel (ULSD fuel) poses a greater
a leak. Leaking fluid that is under pressure can static ignition hazard than earlier diesel formula-
penetrate body tissue. Fluid penetration can cause tions with a higher sulfur contents. Avoid death
serious injury and possible death. A pin hole leak can or serious injury from fire or explosion. Consult
cause severe injury. If fluid is injected into your skin, with your fuel or fuel system supplier to ensure
you must get treatment immediately. Seek treatment the delivery system is in compliance with fueling
from a doctor that is familiar with this type of injury. standards for proper grounding and bonding
practices.
Containing Fluid Spillage
NOTICE Lines, Tubes, and Hoses
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Do not bend or strike high-pressure lines. Do not
nance, testing, adjusting, and repair of the product. install lines, tubes, or hoses that are damaged.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Repair any fuel lines, oil lines, tubes, or hoses that
bling any component containing fluids. are loose or damaged. Leaks can cause fires.
Refer to Special Publication, NENG2500, “Cat Dealer Inspect all lines, tubes, and hoses carefully. Do not
Service Tool Catalog” or refer to Special Publication, use bare hands to check for leaks. Always use a
PECJ0003, “Cat Shop Supplies and Tools Catalog” board or cardboard for checking engine components
for tools and supplies suitable to collect and contain for leaks. Tighten all connections to the
fluids on Cat products. recommended torque.
Dispose of all fluids according to local regulations Check for the following conditions:
and mandates.
• 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
SEBU9107-03 11
Safety Section
Ensure that all of the clamps, the guards, and the • A vacuum cleaner that is equipped with a high
heat shields are installed correctly. Correct efficiency particulate air filter (HEPA) can also be
installation of these components will help to prevent used.
these effects: vibration, rubbing against other parts
and excessive heat during operation. • Use exhaust ventilation on permanent machining
jobs.
Inhalation • 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
Exhaust approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate
Use caution. Exhaust fumes can be hazardous to protective clothing in order to minimize direct contact.
your health. If you operate the equipment in an Use good hygiene practices and wash hands
enclosed area, adequate ventilation is necessary. thoroughly after handling Softwrap material. Do not
smoke until washing hands thoroughly after handling
Asbestos Information Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean
Cat equipment and replacement parts that are up debris.
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.
12 SEBU9107-03
Safety Section
Burn Prevention
Reference: The applicable material safety data Ensure that the filler cap is cool before removing the
sheets can be found at the following web site by filler cap. The filler cap must be cool enough to touch
searching using part number or the name: with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
https://catmsds.cat.com/MSDSSearch/servlet/
cat.cis.ecs. Cooling system conditioner contains alkali. Alkali can
msdsSearch.controller. cause personal injury. Do not allow alkali to contact
UserIdentificationDisplayServlet the skin, the eyes, or the mouth.
Dispose of Waste Properly Oils

Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for
servicing batteries. Wash hands after touching the
batteries and connectors. Use of gloves is
recommended.
i05626649
Illustration 10 g00706404 Fire Prevention and Explosion

Improperly disposing of waste can threaten the Prevention
environment. Potentially harmful fluids should be
disposed of according to local regulations. SMCS Code: 1000; 4450; 7405
Always use leakproof containers when you drain

fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01480768
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
air system, in the hydraulic system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings or related items are
disconnected.
Use of personal protection equipment (PPE) may be
Coolant needed.
When the engine is at operating temperature, the All fuels, most lubricants, and some coolant mixtures
engine coolant is hot. The coolant is also under are flammable.
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
Any contact with hot coolant or with steam can cause product when a fire hazard exists. Contact your Cat
severe burns. Allow cooling system components to dealer for service.
cool before the cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
SEBU9107-03 13
Safety Section
Fire Prevention and Explosion Prevention
Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause a deterioration. Properly route all hoses. The lines and
fire. Fire may cause personal injury and property hoses must have adequate support and secure
damage. clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an Properly install all oil filters and fuel filters. The filter
emergency shutdown. housings must be tightened to the proper torque.
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 Illustration 12 g00704059
containers. Do not smoke in areas that are used for
storing flammable materials. Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not
Do not expose the engine to any flame. refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in a line, a tube, or Avoid static electricity risk when fueling. Ultra Low
a seal failure. Exhaust shields must be installed Sulfur Diesel (ULSD) poses a greater static ignition
correctly. hazard than earlier diesel formulations with a higher
Sulfur content. Avoid death or serious injury from fire
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain or explosion. Consult with your fuel or fuel system
flammable fluid. Clean any such lines or tanks supplier to ensure that the delivery system is in
thoroughly with a nonflammable solvent prior to compliance with fueling standards for proper
welding or flame cutting. grounding and bonding practices.
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.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
14 SEBU9107-03
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 high-
pressure 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
Gases from a battery can explode. Keep any open your bare hand to check for leaks. Use a board or
flames or sparks away from the top of a battery. Do cardboard to check for leaks. Tighten all connections
not smoke in battery charging areas. to the recommended torque.
Never check the battery charge by placing a metal Replace the parts if any of the following conditions
object across the terminal posts. Use a voltmeter or a are present:
hydrometer.
• End fittings are damaged or leaking.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the • Outer coverings are chafed or cut.
Operation Section of this manual for specific
instructions. • Wires are exposed.
Do not charge a frozen battery. Charging a frozen • Outer coverings are ballooning.
battery may result in an explosion.
• Flexible parts of the hoses are kinked.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the • Outer covers have embedded armoring.
recommended cables, connections, and battery box
covers when the engine is operated. • End fittings are displaced.
Fire Extinguisher Make sure that all clamps, guards, and heat shields
are installed correctly in order to prevent vibration,
Make sure that a fire extinguisher is available. Be rubbing against other parts, and excessive heat.
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire i01359666
extinguisher regularly. Obey the recommendations
on the instruction plate. Crushing Prevention and
Ether Cutting Prevention
SMCS Code: 1000; 4450; 7405
Ether is flammable and poisonous.
Support the component properly when work beneath
Use ether in ventilated areas. Do not smoke while the component is performed.
you are replacing an ether cylinder or while you are
using an ether spray. Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
SEBU9107-03 15
Safety Section
Mounting and Dismounting
Stay clear of all rotating parts and of all moving parts. Always start the engine according to the procedure
Leave the guards in place until maintenance is that is described in this Operation and Maintenance
performed. After the maintenance is performed, Manual, “Engine Starting” topic (Operation Section).
reinstall the guards. Knowledge of the correct procedure will help to
prevent major damage to the engine components.
Keep objects away from moving fan blades. The fan Knowledge of the procedure will also help to prevent
blades will throw objects or cut objects. personal injury.
When objects are struck, wear protective glasses in To ensure that the jacket water heater (if equipped)
order to avoid injury to the eyes. and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge and the
Chips or other debris may fly off objects when objects oil temperature gauge during the heater operation.
are struck. Before objects are struck, ensure that no
one will be injured by flying debris. Engine exhaust contains products of combustion that
can be harmful to your health. Always start the
i01372247 engine and operate the engine in a ventilated area. If
the engine is started in an enclosed area, vent the
Mounting and Dismounting engine exhaust to the outside.
SMCS Code: 1000; 4450; 7405 i06299648
Inspect the steps, the handholds, and the work area

before mounting the engine. Keep these items clean Engine Stopping
and keep these items in good repair. SMCS Code: 1000
Mount the engine and dismount the engine only at Do not stop the engine immediately after the machine
locations that have steps and/or handholds. Do not has been operated under load. Stopping the engine
climb on the engine, and do not jump off the engine. immediately can cause overheating and accelerated
wear of engine components.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact After the machine is parked and the parking brake is
with the steps and handholds. Use two feet and one engaged, allow the engine to run at low idle for 5
hand or use one foot and two hands. Do not use any minutes before shutdown. Running the engine allows
controls as handholds. hot areas of the engine to cool gradually.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work i02469632
platform. Secure the climbing equipment so that the
equipment will not move. Electrical System
Do not carry tools or supplies when you mount the SMCS Code: 1000; 1400
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies. 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
i04021433
gases that are produced by some batteries to ignite.
Engine Starting To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
SMCS Code: 1000
negative “−” jump start cable should be connected
If a warning tag is attached to the engine start switch last from the external power source to the negative
or to the controls, DO NOT start the engine or move “−” terminal of the starting motor. If the starting motor
the controls. Consult with the person that attached is not equipped with a negative “−” terminal, connect
the warning tag before the engine is started. the jump start cable to the engine block.
All protective guards and all protective covers must Check the electrical wires daily for wires that are
be installed if the engine must be started in order to loose or frayed. Tighten all loose electrical wires
perform service procedures. To help prevent an before the engine is started. Repair all frayed
accident that is caused by parts in rotation, work electrical wires before the engine is started. Refer to
around the parts carefully. the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.
Start the engine from the operator's compartment or
from the engine start switch.
16 SEBU9107-03
Safety Section
Electrical System
Grounding Practices
Typical example
Alternate Grounding Stud To Battery Ground
Typical example
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.
SEBU9107-03 17
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.
i04021529
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.
The Electronic Control Module (ECM) provides a
comprehensive, programmable engine monitoring
system for this engine. The ECM monitors specific
engine operating parameters in order to detect
abnormal conditions that may develop. The ECM will
generate an event code if a specific engine
parameter exceeds an acceptable range that is
defined by the engine monitoring system. The ECM
will react with an action that is dependent on the
severity of the condition. For information on event
codes, refer to this Operation and Maintenance
Manual, “Event Codes” topic (Operation Section) The
following actions may be initiated by the ECM. These
actions are dependent on the severity of the
condition:
• Illumination of a warning lamp or warning alarm

• Engine derate
• Engine protection shutdown
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.
18 SEBU9107-03
General Information
Product Information
Section
General Information
i04025350
Model View Illustrations

SMCS Code: 1000
SEBU9107-03 19
View of the left side of a typical C9.3 Industrial Engine
(1) Fuel pressure sensor pre-filter (6) Balance valve solenoid (11) Engine control module (ECM)
(2) Fuel pressure sensor post-filter (7) Open crankcase ventilation filter (12) Crankcase pressure sensor
(3) Oil filler (8) Engine crankcase breather (13) Charge air cooler outlet sensor
(4) Fuel rail pressure sensor (9) NRS valve (14) Engine speed sensor
(5) Atmospheric pressure sensor (10) NRS temperature sensor (15) Fuel pump
20 SEBU9107-03
(16) Secondary fuel filter base (17) Fuel temperature sensor
View of the right side of a typical C9.3 Industrial Engine
(18) NRS cooler (19) Turbocharger (20) Oil filter base
SEBU9107-03 21
Product Description
i04135811 (Table 1, contd)

(2) Separate circuit after cooling
Product Description
SMCS Code: 1000; 4450; 4491 Electronic Engine Features
The Caterpillar C9.3 Industrial Engine has the The Caterpillar C9.3 Engine is designed for electronic
following characteristics: controls. The integral on board computer controls the
operation of the engine. Current operating conditions
• Four-stroke cycle are monitored. The Electronic Control Module (ECM)
controls the response of the engine to these
• High pressure common rail fuel system conditions and to the demands of the operator. These
conditions and operator demands determine the
• Turbocharged precise control of fuel injection by the ECM. The
electronic engine control system provides the
Engine Specifications following features:
Note: The front end of the engine is opposite the • Engine speed governor
flywheel end of the engine. The left and the right
• Automatic air/fuel ratio control
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder. • Torque rise shaping
• Injection timing control

• System diagnostics
• Aftertreatment regeneration control

• NOX reduction system control
Additional Features
The following additional features provide increased
engine fuel economy and serviceability:
• Cold starting capability

• Tampering detection
Cylinder and valve location • Diagnostics
(A) Exhaust valve
(B) Inlet valve Common Rail Fuel Injection System
Table 1 The common rail fuel injection system performs the
C-9.3 Engine Specifications following functions:
Arrangement and Cylinders In-Line six cylinder • Pump the fuel.
Bore 115.0 mm (4.53 inch) • Meter the fuel.
Stroke 149.0 mm (5.87 inch)
• Time the fuel injection.
ATAAC(1)
Aspiration
SCAC (2)
Displacement 9.3 L (568 in3)
Firing Order 1-5-3-6-2-4
Rotation (flywheel end) Counterclockwise

(1) Air-to-air aftercooled
(continued)
22 SEBU9107-03
Product Description
The fuel pump pressurizes the fuel. The fuel pump

pumps the fuel to the common fuel rail. The common
rail fuel injectors inject the fuel into the cylinders at a
precise time. The fuel is injected into the cylinders
with the appropriate volume. Electronic sensors on
the engine determine time and volume of fuel
injection.
Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants, and
lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
Expected engine life is predicted by the average
power that is demanded. The average power that is
demanded is based on fuel consumption of the
engine over a time. Reduced hours of operation at
full throttle and/or operating at reduced throttle
settings result in a lower average power demand.
Reduced hours of operation will increase the length
of operating time before an engine overhaul is
required. For more information, refer to the Operation
and Maintenance Manual, “Overhaul Considerations”
topic (Maintenance Section).
Aftermarket Products and

Caterpillar Engines
NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a
four micron[c] absolute high efficiency fuel filter is re-
quired for all Caterpillar common rail fuel systems.
Caterpillar High Efficiency Fuel Filters meet these re-
quirements. Consult your Caterpillar dealer for the
proper part numbers.
When auxiliary devices, accessories, or

consumables (filters, additives, catalysts, etc.) which
are made by other manufacturers are used on
Caterpillar products, the Caterpillar warranty is not
affected simply because of such use.
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.
SEBU9107-03 23
Product Identification Information
Product Identification
Information
i05398496
Plate Locations and Film

Locations
SMCS Code: 1000; 4450
View of the top of a C9.3 Industrial Engine
The engine information plate is located toward the
rear of the valve cover. The engine information plate
may be read from the right side of the engine.
View of the left side of a C9.3 Industrial Engine
The serial number plate is located on the left side of
the cylinder block. The engine control module will Illustration 22 g01347963
obstruct the view of the serial number plate. Engine information plate
The following information is on the information plate:

engine serial number, engine model, engine
arrangement number, maximum altitude of the
engine that is necessary to achieve the rated power,
horsepower, high idle, full load rpm, fuel settings and
other information
Serial number plate
The following information is stamped on the serial

number plate: engine serial number, engine model
and arrangement number.
24 SEBU9107-03
Plate Locations and Film Locations
View of the exhaust system of a C9.3 Industrial
Engine
The Clean Emission Module (CEM) identification

plate is located on the electronics plate for the CEM.
DEF module
(3) plate location
The DEF module identification plate (3) contains the

following information: part number, serial number and
change level. This information may be needed by the
Cat dealer when inquiries are being made on the
DEF.
CEM plate
The Clean Emission Module (CEM) identification

plate contains the following information: part number,
serial number, change level and configuration ID
code. This information may be needed by the Cat
dealer when inquiries are being made on the CEM.
DEF plate
SEBU9107-03 25
Reference Information
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
Engine full load rpm
Performance specification
number
Engine horsepower
Primary fuel filter part

number
Water separator element
part number
Secondary fuel filter ele-

ment part number
Lubrication oil filter ele-

ment part number
Auxiliary oil filter element

part number
Supplemental coolant ad-

ditive maintenance ele-
ment part number (if
equipped)
Total lubrication system

capacity
Total cooling system

capacity
Engine air cleaner ele-

ment part number
Fan drive belt part

number
Alternator belt part
number
26 SEBU9107-03
Operation Section
Lifting and Storage
Operation Section Engine and Factory Mounted CEM
Lifting and Storage

i05417419
Product Lifting
SMCS Code: 7000; 7002
View of rear lifting locations
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Re-
member that the capacity of an eyebolt is less as the
angle between the supporting members and the ob-
ject 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 View of front lifting location
the weight.
Engines with a factory mounted CEM with or without
Use a hoist to remove heavy components. Use an a factory mounted radiator, can be lifted by the CEM
adjustable lifting beam to lift the engine. All front and rear bracket's load ring (provided) and
supporting members (chains and cables) should be using a certified spreader bar.
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being Refer to the Special Publication, NENG2500, “Cat
lifted. Dealer Service Tool Catalog” for the latest in lifting
devise part numbers. Follow the safety instructions
Some removals require lifting the fixtures in order to for the selected tool to ensure a safe lift. For most
obtain proper balance and safety. packages, the recommended spreader bar is 6V-
6146 set at 142 cm (56 inch) with the lift hook
To remove the engine ONLY, use the lifting eyes that locations set at about 3/4 of the way toward the front
are on the engine. stop (closest to the front engine lift eye).
Lifting eyes are designed and installed for the Remove any ATAAC lines, air cleaners, or other
specific engine arrangement. Alterations to the lifting attachments that would otherwise interfere with the
eyes and/or the engine make the lifting eyes and the lift chains or other lifting devises.
lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided. The engine package center of gravity will change
Consult your Caterpillar dealer for information depending on the engine attachments. Adjust the
regarding fixtures for proper engine lifting. spreader bar and chains as necessary to maintain a
lift within 5 degrees of horizontal in all directions.
SEBU9107-03 27
Operation Section
Product Storage
Remove the front load ring before returning the

engine to service, in order to prevent the last load
ring from rubbing on the fan belt.
Engine and Installed Radiator Only

The engine lifting eyes are rated to lift an engine with
attached radiator, assuming a less than 5 degree tilt
angle can be maintained. Be sure to use an
appropriate spreader set so that lifting chains are
perpendicular to the engine.
Radiator Only
Detach the radiator, and mounting bracket at the
engine front support. Add eyebolts or lifting brackets
to the threaded holes marked for lifting.
Clean Emission Module Lifting
typical example
Side B
Detach the Clean Emission Module (CEM) and use

the lifting eyes attached to the CEM support for lifting.
Care must be taken in order to identify the center of
gravity of the CEM.
NOTICE
Do not attempt to use the radiator or CEM lift points
to aid in the engine package lift.
i05299684
Product Storage
SMCS Code: 7002
Storage (Less Than One Year)
typical example
If an engine is not used, oil can run off the following
Side A 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.
28 SEBU9107-03
Operation Section
Product Storage
2. Remove dirt from the air cleaners. Check all seals, Apply a small amount of oil to the threads on the
gaskets, and the filter element for damage. fuel tank filler neck and install the cap. Seal all
openings to the tank in order to prevent
3. Apply lubricant to all points in this Operation and evaporation of the fuel and as a preservative.
Maintenance Manual, “Maintenance Interval
10. Remove the fuel nozzles or spark plugs. Apply
Schedule”.
30 mL (1 oz) of the mixture of oils (50 percent VCI
4. Drain the crankcase oil. Replace the crankcase oil oil and 50 percent engine oil) into each cylinder.
and change the oil filters. For the proper
procedure, refer to this Operation and Use a bar or a turning tool in order to turn over the
engine slowly. This procedure puts the oil on the
Maintenance Manual. cylinder walls. Install all fuel nozzles or spark plugs
5. If the engine is equipped with an air starting motor, and tighten to the correct torque.
fill the reservoir with the following mixture: 50 11. Spray a thin amount of a mixture of 50 percent
percent volatile corrosion inhibitor oil VCI oil and 50 percent engine oil onto the following
(<nomen>VCI oil</nomen>) and 50 percent components: flywheel, ring gear teeth and starter
engine oil. pinion. Install the covers in order to prevent
6. Add VCI oil to the crankcase oil. The volume of evaporation of the vapors from the VCI oil.
VCI oil in the crankcase oil should be 3 to 4 12. Apply a heavy amount of Cat Multipurpose
percent. Grease (MPGM) to all outside parts that move,
Note: If the engine crankcase is full, drain enough such as rod threads, ball joints, linkage.
engine oil so the mixture can be added. Note: Install all covers. Ensure that tape has been
installed over all openings, air inlets, exhaust
7. Remove the air filter elements. Turn the engine at
openings, the flywheel housing, the crankcase
cranking speed with the throttle control in FUEL breathers, the dipstick tubes.
OFF position. Use a sprayer to add a mixture of 50
percent VCI oil and 50 percent engine oil into the Ensure that all covers are airtight and
air inlet or turbocharger inlet. weatherproof. Use a waterproof weather resistant
tape such as Kendall No. 231 or an equivalent. Do
Note: The mixture of VCI oil can be added to the inlet not use duct tape. Duct tape will only seal for a
by removing the plug for checking turbocharger boost short time.
pressure. The minimum application rate for the VCI 13. Under most conditions, removing the batteries is
oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of
the best procedure. As an alternative, place the
engine displacement.
batteries in storage. As needed, periodically
8. Use a sprayer to apply a mixture of 50 percent VCI charge the batteries while the batteries are in
oil and 50 percent crankcase oil into the exhaust storage.
openings. The minimum application rate for the oil If the batteries are not removed, wash the tops of
mixture is 5.5 mL per L (3 oz per 1000 cu in) of the batteries until the tops are clean. Apply an
engine displacement. Seal the exhaust pipe and electrical charge to the batteries in order to obtain
seal any drain holes in the muffler. a specific gravity of 1.225.
9. Remove the fuel from the secondary fuel filter Disconnect the battery terminals. Place a plastic
housing. Alternately, empty and reinstall the spin- cover over the batteries.
on fuel filter element in order to remove any dirt
Note: For additional information, refer to Special
and water. Drain any sleeve metering fuel pump.
Instruction, SEHS7633, “Battery Test Procedure”.
Clean the primary fuel filter. Fill with calibration
fluid or kerosene. Install the primary fuel filter and 14. Loosen all belts.
operate the priming pump. This procedure will
15. Place a waterproof cover over the engine. Ensure
send clean oil to the secondary filter and the
engine. that the engine cover is secure. The cover should
be loose enough to allow air to circulate around
Open the fuel tank drain valve in order to drain any the engine in order to prevent damage from
water and dirt from the fuel tank. Apply a spray of condensation.
calibration fluid or kerosene at the rate of
30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank 16. Attach a tag with the storage date to the engine.
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.
SEBU9107-03 29
Operation Section
Product Storage
17. Remove the waterproof cover at 2 month or 3 11. Ensure that the cooling system is clean. Ensure
month intervals in order to check the engine for that the system is full. Ensure that the system has
corrosion. If the engine has signs of corrosion, the correct amount of supplemental cooling
repeat the protection procedure. system conditioner.
12. On the first day of operation, check the entire
Coolant System
engine several times for leaks and correct
Completely fill the cooling system before storage. operation.
Refer to this Operation and Maintenance Manual, 13. If the engine was removed from storage in which
“Fluid Recommendations” for more information about temperatures of less than -12°C (10°F) were
coolants. encountered, refer to Service Manual, SEBU5898,
“Cold Weather Recommendations Operation and
Removal from Storage Maintenance”.
1. Remove all outside protective covers. Extended Storage (Engine with

2. Change the oil and filters. DEF Tank)
3. Check the condition of the fan and alternator belts. 1. Ensure a normal shutdown. Allow Delayed Engine
Replace the belts, if necessary. Refer to this Shutdown, or properly cool the engine prior to
Operation and Maintenance Manual, “Belts - shutting down.
Inspect/Adjust/Replace” for the correct procedure.
2. Ensure a proper DEF purge. Do not disconnect the
4. Replace the fuel filter elements. battery disconnect switch within 2 minutes after
5. Remove the plastic covers from the air cleaner key off.
elements. 3. Fill the DEF tank with DEF that meets all
6. Use a bar or a turning tool in order to turn the requirements defined in “ISO 22241-1”.
engine in the normal direction of rotation. The 4. Ensure all DEF lines, and electrical connectors are
procedure ensures that no hydraulic locks or connected prior to prevent crystal from forming.
resistance exist.
5. Ensure that the DEF cap is properly installed.
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
Removal from Extended Storage
order to prevent damage to the mechanism. (Engine with DEF Tank)
8. Pressure-lubricate the engine before starting the If the DEF tank was stored for a duration equal to or
engine. Pressure lubricating the engine ensures exceeding that listed in table 3 at the corresponding
immediate lubrication and prevents damage to the temperature, replace the DEF.
engine during the first few minutes of engine
If the DEF quality is in doubt, test with a
operation. If the engine is not equipped with a refractometer. DEF must be within the required range
prelube pump, contact your Cat dealer for defined in “ISO 22241-1”. For more detailed
information about lubrication of the engine before information about testing DEF quality, contact the
starting the engine. local Caterpillar dealer.
Table 3
9. Check the condition of all rubber hoses. Replace
Temperature Duration
any worn hoses. Replace any damaged hoses.
10° C (50° F) 36 months
10. Before start-up, test the cooling system for a 3
percent to a 6 percent concentration of coolant 25° C (77° F) 18 months
conditioner. Add liquid coolant conditioner or a
30° C (86° F) 12 months
coolant conditioner element, if equipped.
35° C (95° F)(1) 6 months
Test the coolant mixture for proper nitrite level. If
(1) At 35° C, significant degradation can occur. Check every batch
necessary, adjust the coolant mixture.
before use.
Prime the engine with clean diesel fuel before
starting. 1. Drain DEF from the tank, and refill with DEF that
meets all requirements defined in “ISO 22241-1”.
30 SEBU9107-03
Operation Section
Product Storage
2. Replace the DEF filter.

3. Start the engine. If a fault code becomes active,
turn off the engine, allow 2 minutes to purge, then
restart the engine.
4. If a fault code continues to stay active, Refer to
Troubleshooting.
SEBU9107-03 31
Operation Section
Features and Controls
Features and Controls indicator of what level of inducement the engine is in.
The escalating time inducement fault code also
indicates how much time remains until the next level
i06610825 of inducement. There are three inducement
categories (two for European Union) that will trigger
Selective Catalytic Reduction an escalating time inducement fault code.
Warning System
Note: The associated codes for each of the
SMCS Code: 1091-WXX; 7400 escalating time categories can be found in the
The selective catalytic reduction (SCR) system is a Troubleshooting Guide under SCR Warning System
system used to reduce NOx emissions from the Problem.
engine. Diesel exhaust fluid (DEF) is pumped from First occurrence – When an escalating time
the DEF tank and is sprayed into the exhaust stream. inducement fault code becomes active for the first
The DEF reacts with the SCR catalyst to reduce NOx time.
and leaves a nitrogen and water vapor. The Exhaust
Gas Recirculation (EGR) system cools, measures, Repeat occurrence – When any escalating time
and introduces recalculated exhaust gas into the inducement fault code becomes active again within
intake manifold to aid in NOx reduction. 40 hours of the first occurrence. Engine must run for
40 hours without tripping any escalating time
NOTICE inducement fault before returning get back to first
Stopping the engine immediately after the engine has occurrence times.
been working under load can result in overheating of
SCR components. Safe Harbor Mode (Worldwide) – Safe Harbor
Mode is a 20 minute engine run time period. During
Refer to the Operation and Maintenance Manual, the Safe Harbor Mode (European Union) the
“Engine Stopping” procedure to allow the engine to engine can be operated with full power after reaching
cool. Refer to the Operation and Maintenance Man- a level 3 inducement. Once in level 3 inducement, the
ual, “Engine Stopping” procedure to prevent exces- operator can perform a key cycle and the engine will
sive temperatures in the turbocharger housing and enter Safe Harbor Mode. Safe Harbor Mode can only
the DEF injector. be implemented once. Safe Harbor Mode is not
allowed for DEF level inducements with Worldwide
configuration.
NOTICE Safe Harbor Mode (European Union) – Safe
Allow at least 2 minutes after shutting down the en- Harbor Mode is a 30 minute engine run time period.
gine before you turn the battery disconnect switch to During the Safe Harbor Mode (European Union)
OFF. Disconnecting the battery power too soon will the engine can be operated with full power after
prevent purging of the DEF lines after the engine is reaching a level 3 inducement. Once in level 3
shut down. inducement, the operator can perform a key cycle
and the engine will enter Safe Harbor Mode. Safe
Harbor Mode can only be implemented up to three
Definitions times.
Observe the following definitions.

Self-correct – Fault condition no longer exists. An
active fault code will no longer be active.
Notification – Action taken by the system to alert the
operator of pending Inducement.
Inducement – Engine derates, vehicle speed limits,
or other actions intended to prompt the operator to
repair or maintain the emission control system.
Inducement Categories – The Inducements are
separated into categories. DEF Levels have
inducement fault codes separate from the other
inducement categories. DEF level inducements are
based on the DEF level, the other inducement
categories are based on escalating time. The
escalating time inducements will always have an
associated fault code along with the inducement fault
code. The associated fault is the root cause. The
escalating time inducement fault code is just an
32 SEBU9107-03
Operation Section
Selective Catalytic Reduction Warning System
Illustration 32 g03676102 Illustration 34 g03676111

DEF Level Normal
If the DEF level falls below 13.5%, a level 1
inducement event will occur. The check engine lamp
Inducement Strategy for DEF Level and the emissions malfunction indicator lamp will
illuminate. The amber indicator next to the DEF level
(European Union) gauge on the dash will remain lit.
Reduced Performance
If the DEF level falls below 20%, an amber indicator
will illuminate next to the DEF level gauge on the When the ECM is configured to "Reduced
dash. To avoid further inducements, turn the key to Performance" and the DEF level is below 1%, the
the OFF and add DEF to the DEF tank. engine will be in level 2 inducement. The check
engine lamp and emissions malfunction indicator
lamp will illuminate and flash slowly. The DEF level
gauge amber lamp will remain lit. The engine will
have a 50% derate. When the DEF tank has been
emptied of all DEF, the engine will have a 100%
derate. An empty DEF tank also limits the engine to
1000 rpm or low idle, whichever is greater. No further
inducement action will occur for "Reduced
Performance" configuration. Safe Harbor Mode is
allowed for three key cycles.
Reduced Time
When the ECM is configured to “Reduced Time” and
the DEF level is below 7.5%, the engine will be in
level 2 inducement. The check engine lamp and
emissions malfunction indicator lamp will illuminate
and flash slowly. The DEF level gauge amber lamp
will remain lit.
SEBU9107-03 33
Operation Section
The check engine and emissions malfunction

indicator lamp will illuminate for any inducement-
related fault. There are two inducement categories. If
the inducement is a result of a category 1 fault, then a
level 1 inducement will occur for a duration of 36
hours. If the inducement is a result of a category 2
fault, then a level 1 inducement will occur for a
duration of 10 hours. There is no repeat occurrence
for level 1 faults.
Reduced Time
The check engine and emissions malfunction
indicator lamp will illuminate for a level 1 inducement-
related fault. There are two inducement categories. If
the inducement is a result of a category 1 fault, then a
level 1 inducement will occur for a duration of 18
Illustration 36 g03676127 hours. If the inducement is a result of a category 2
fault, then a level 1 inducement will occur for a
Reduced Time duration of 5 hours. There is no repeat occurrence for
level 1 faults.
If the ECM is configured to “Reduced Time” and the
DEF level is 0%, the engine will be in level 3
inducement. The check engine lamp and emissions
malfunction indicator lamp will illuminate and flash at
a fast rate. A red stop lamp will illuminate solid. The
DEF level gauge amber lamp will remain lit. The
engine will have a 100% derate and be limited to
1000 rpm or low idle, whichever is greater. If the final
inducement action in ET is set to “Idle Down” , then
the engine will continue to idle at derated condition. If
set to “Shutdown” , engine will shut down after 5
minutes. Safe Harbor Mode is allowed for three key
cycles. After Safe Harbor Mode is completed, the Reduced Performance
engine will return to idle or shut down. If in shutdown If a fault condition exists for the entire duration of
configuration, the engine may be restarted, but will inducement level 1, the strategy advances to
only run for 5 minutes at derated condition before inducement level 2. The check engine lamp and the
shutting down again. This action will continue until emissions malfunction indicator lamp will illuminate
the issue is resolved. and flash slowly. If the inducement is a result of a
category 1 fault, then a level 2 inducement will occur.
Note: Turn the key to the OFF and add DEF to the The level 2 inducement occurs for a duration of 64
DEF tank to reset the DEF level inducement. hours for first occurrence. For repeat occurrence, a
category 1 level 2 inducement fault will occur for a
Inducement Strategy for Escalating duration of 5 hours.
Time Inducement Faults (European If the inducement is a result of a category 2 fault, then
a level 2 inducement will occur for a duration of 10
Union) hours. For repeat occurrence, a category 2 level 2
inducement fault will occur for a duration of 2 hours.
The engine will have a 50% derate. If the fault is not
corrected before the inducement duration ends, the
engine will become 100% derated. The engine will
also be limited to 1000 rpm or low idle, whichever is
greater. No further inducements will occur for
“Reduced Performance” configuration. Safe Harbor
Mode is allowed for three key cycles.
Reduced Time
Reduced Performance
34 SEBU9107-03
Operation Section
If a fault condition exists for the entire duration of Note: Contact your Cat dealer for repairs if a fault
inducement level 1, the strategy advances to occurs.
inducement level 2. The check engine lamp and the
emissions malfunction indicator lamp will illuminate
and flash slowly. If the inducement is a result of a Inducement Strategy for DEF Level
category 1 fault, then a level 2 inducement will occur. (Worldwide)
The level 2 inducement will occur for a duration of 18
hours for first occurrence. For repeat occurrence, a
duration of 108 minutes.
If the inducement is a result of a category 2 fault, then
hours. For repeat occurrence, a category 2 level 2
inducement fault will occur for a duration of 1 hour.
Reduced Time If the DEF level falls below 20%, an amber indicator
will illuminate next to the DEF level gauge on the
If configured to “Reduced Time” and a fault condition dash. To avoid inducements, turn the key to the OFF
exists for the entire duration of inducement level 2, and add DEF to the DEF tank.
the strategy advances to inducement level 3.
Inducement level 3 has the same actions for all
categories. The check engine lamp and emissions
malfunction indicator lamp will flash at a fast rate. A
red stop lamp will also illuminate solid. The engine
will have a 100% derate and be limited to 1000 rpm
or low idle, whichever is greater. If, the final
inducement action in Cat ET is set to “Idle Down” ,
then engine will continue to idle at derated condition.
If set to “Shutdown” , engine will shut down after 5
minutes. A key cycle will allow safe harbor mode to
initiate. Safe harbor is allowed up to three times. After
safe harbor, the engine will be in level 3 final
inducement. If set to “Shutdown” , the engine may be
restarted, but will only run for 5 minutes at derated
condition before shutting down again. This action will
continue until the issue is resolved. Illustration 41 g03676169
If the DEF level falls below 13.5%, a level 1

inducement event will occur. The check engine lamp
and the emissions malfunction indicator lamp will
illuminate. The amber indicator next to the DEF level
gauge on the dash will remain lit.
SEBU9107-03 35
Operation Section
Note: Turn the key to the OFF and add DEF to the
DEF tank to reset the DEF level inducement.
Inducement Strategy for Escalating

Time Inducement Faults
(Worldwide)
If the DEF level is below 7.5%, a level 2 inducement Illustration 44 g03676215

event will occur. The check engine lamp and the
emissions malfunction indicator lamp will illuminate Reduced Performance
and flash slowly. The amber indicator next to the DEF
level gauge on the dash will remain lit. If the ECM is The check engine and emissions malfunction
configured to “Reduced Performance” and the DEF indicator lamp will illuminate for a level 1 inducement-
level has reached 1%, the machine will be limited to related fault. There are three inducement categories.
75% torque. If the inducement is a result of a category 1 fault, then
a level 1 inducement will occur for a duration of 2.5
hours for first occurrence. For repeat occurrence, a
duration of 5 minutes.
hours. There is no repeat occurrence for category 2,
level 1 inducement faults.
hours. There is no repeat occurrence for category 3,
level 1 inducement faults.
Reduced Time The check engine and emissions
malfunction indicator lamp will illuminate for a level 1
Illustration 43 g03676210 inducement-related fault. There are three inducement
categories. If the inducement is a result of a category
If the ECM is configured to “Reduced Performance” 1 fault, then a level 1 inducement will occur for a
duration of 2.5 hours for first occurrence. For repeat
and the DEF tank has been emptied of all DEF, the occurrence, a category 1 level 1 inducement fault will
engine will be in a level 3 final inducement. If the
occur for a duration of 5 minutes.
ECM is configured to “Reduced Time” and the DEF
level is 3%, the engine will be in a level 3 final If the inducement is a result of a category 2 fault, then
inducement. The check engine lamp and the a level 1 inducement will occur for a duration of 5
emissions malfunction indicator lamp will flash at a hours. There is no repeat occurrence for category 2,
fast rate and a red stop lamp will illuminate solid. The level 1 inducement faults.
engine will be taken to low idle or will be shut down.
Once shut down, the engine can be restarted for 5 If the inducement is a result of a category 3 fault, then
minute periods at reduced speed and torque. If set to a level 1 inducement will occur for a duration of 18
idle, the engine will idle indefinitely at reduced torque. hours. There is no repeat occurrence for category 3,
The amber indicator next to the DEF level gauge on level 1 inducement faults.
the dash will remain lit.
36 SEBU9107-03
Operation Section
Reduced Performance If a fault condition exists for If a fault condition exists for the entire duration of
the entire duration of inducement level 1, the strategy inducement level 2, the strategy advances to
advances to inducement level 2. The check engine inducement level 3. Inducement level 3 has the same
and emissions malfunction indicator lamp will actions for all categories. The check engine lamp and
illuminate and flash slowly for a level 2 inducement- the emissions malfunction indicator lamp will flash at
related fault. The engine will have a 50% derate. If a fast rate. A red stop lamp will illuminate solid. The
the inducement is a result of a category 1 fault, then a engine will have a 100% derate and be limited to
level 2 inducement will occur for a duration of 70 1000 rpm or low idle, whichever is greater. If the final
minutes for first occurrence. For repeat occurrence, a inducement action in Cat® ET is set to "Idle Down",
category 1 level 2 inducement fault will occur for a then engine will continue to idle at derated condition.
duration of 5 minutes. If set to "Shutdown" , engine will shut down after 5
minutes. A key cycle will allow safe harbor mode to
If the inducement is a result of a category 2 fault, then initiate. Safe harbor is only allowed once. After safe
a level 2 inducement will occur for a duration of 10 harbor, the engine will be in level 3 final inducement.
hours. For repeat occurrence, a category 2 level 2 If set to "Shutdown", the engine may be restarted, but
inducement fault will occur for a duration of 2 hours. will only run for 5 minutes at derated condition before
If the inducement is a result of a category 3 fault, then shutting down again. This action will continue until
the issue is resolved.
hours. For repeat occurrence, a category 3 level 2
inducement fault will occur for a duration of 5 hours. Note: Contact your Cat dealer for repairs if a fault
occurs.
Reduced Time
If a fault condition exists for the entire duration of Operator Inducement Emergency
inducement level 1, the strategy advances to Override for Cat Engines Equipped
inducement level 2. The check engine and emissions
malfunction indicator lamp will illuminate and flash with Selective Catalytic Reduction
slowly for a level 2 inducement-related fault. If the Systems (If Equipped)
inducement is a result of a category 1 fault, then a
level 2 inducement will occur for a duration of 70 Note: The inducement emergency override will
minutes for first occurrence. For repeat occurrence, a
category 1 level 2 inducement fault will occur for a only be allowed on a select number of engines
duration of 5 minutes. that may be used in emergency situations.
Contact your Cat dealer to find out if your engine
If the inducement is a result of a category 2 fault, then is allowed to have this feature.
hours. For repeat occurrence, a category 2 level 2 The operator Inducement emergency override can
inducement fault will occur for a duration of 1 hour. only be enabled using Caterpillar supplied
passwords. The feature is disabled by default. The
If the inducement is a result of a category 3 fault, then feature will be enabled at the factory if allowed. If the
a level 2 inducement will occur for a duration of 18 customer wants the feature enabled after delivery of
hours. For repeat occurrence, a category 3 level 2 engine, customers need to contact a Cat dealer.
inducement fault will occur for a duration of 108 Operator Inducement emergency override is
minutes.
regulated by the Environmental Protection Agency
(EPA) and only allowed in the United States. The
European Union and Japan do not allow the feature
to be used. For detailed information on activating,
deactivating, or resetting override, contact your Cat
dealer. Before you attempt the procedures
documented below, make sure that you have read
and understand all information in this document.
SEBU9107-03 37
Operation Section
The United States EPA requires the limiting of engine Civil penalties may be assessed per day operated in
speed and/or power (derate) in certain conditions, to violation, and can be severe.
help ensure proper functioning of the engines
emission control system. The EPA allows the Override Activation Method
temporary disabling of these limits (restoration of full
engine speed and power capability) during a qualified The override can be activated using Cat Electronic
emergency situation. The EPA defines a qualified Technician (ET). Commercial applications may have
emergency situation as a significant direct or indirect a switch near the engine, or an electronic display
risk to human life. Below are examples of direct menu to activate the override through. The display
versus indirect risks. menu and switch location may differ by application.
Direct – An emission control condition that inhibits The override will only be available when engine is
performance of an engine being used to rescue a already in inducement (derate). If the override has
person from life-threatening situation. already been enabled by an authorized Cat dealer,
then the operator can turn on the override without
Indirect – An emission control condition that inhibits further input from Caterpillar. Upon activation, the
performance of an engine used to provide electrical amber warning lamp will illuminate to alert the
power to a data center that routes 911 emergency operator that the override is active. A code will also
response communications. become active indicating that the engine emission
operator inducement emergency override is active.
The override must be paused by the operator if the
The emissions-related derate can be disabled for up emergency ends before the 120 hours of override
to 120 hours of engine operation. The temporary operation has expired.
disabling of emissions-related derate is referred to as
“Operator Inducement Emergency Override” and
must be reported to the United States EPA. The Setting the Override through Cat
override must be paused by the operator if the Electronic Technician (ET)
emergency ends before the 120 hours of override
operation has expired. While the override is paused,
the equipment will be subject to derate. The override • Go to “Configuration Parameters”
may only be reactivated if an emergency situation
• Select “Aftertreatment Configuration”
returns prior to reaching an hour threshold of total
engine operation since initially activating the • Select “Operator Inducement Emergency Override
override. This threshold is referred to as the backstop
Activation” to activate the override
timer. This threshold could vary by application, but
will typically be 300 hours. After 120 hours of override
use, or backstop timer threshold met, override will
expire, and the equipment will be subject to derate.
Once the override has expired, a Cat dealer will need
to reset the override to use the override again.
The override can only be enabled or disabled by an
authorized Cat dealer using Caterpillar supplied
passwords. Once enabled, the override can be
activated by the operator using a switch or through
an electronic display menu (if equipped). Upon
activation, the check engine and action lamps will be
illuminated until and the override is reset. A code
indicating that the inducement emergency override is
active will also be active until the override is reset.
The override can only be reset by the engine
manufacturer, Caterpillar. A Cat dealer can reset the
override using Caterpillar supplied passwords.
The following are prohibited under federal regulations
and subject to penalties imposed by the US EPA:
• Improper use of the override

• Failure to deactivate the override when
emergency has ended
• Failure to report use of the override.

38 SEBU9107-03
Operation Section
• The “Value” field should be switched to “Activated” • Contact name, mail and e-mail addresses, and
(to pause the override change the “Value” field to telephone number for the responsible company or
“Not Activated” ) entity
• A description of the emergency situation, the

Setting the Override with Switch location of the engine during the emergency, and
the contact information for an official who can
Commercial applications may choose to install a
switch or jumper harness near the engine for verify the emergency situation (such as a county
activating the override. There is a dedicated STG pin sheriff, fire marshal, or hospital administrator)
on the J1 side of the A5 Electronic Control Module
(ECM) that can be used. Operators must be trained • The reason for the activation of the override during
properly to understand where override switch is the emergency situation, such as the lack of DEF,
located. Operators must be trained properly to or the failure of an emission-related sensor when
understand that there could be severe penalties as the engine was needed to respond to an
mentioned above for misusing the switch. To pause emergency situation
override, simply turn override switch to OFF position
or unplug the jumper harness. A decal will be next to • The engine serial number (or equivalent)
switch or jumper harness stating: “EMERGENCY
USE ONLY. SEE OWNERS MANUAL. PENALTIES • A description of the extent and duration of the
APPLY FOR MISUSE” . engine operation while the override was active,
including a statement describing whether the
Setting the Override through override was manually deactivated (paused) after
the emergency situation ended
Electronic Display Menu
The Override Usage Report may be sent via e-
Some applications may be able to activate or mail or regular mail to one of the following
deactivate the override through an electronic display addresses:
menu. Operators must be trained properly to
understand where override is located and that there Email :
could be severe penalties as mentioned above for
misusing the override. There will be a warning on Emissions_Compliance@cat.com
display stating: “EMERGENCY USE ONLY. SEE
OWNERS MANUAL. PENALTIES APPLY FOR Regular Mail :
MISUSE” .
Resetting the Override

The override needs to be reset through Cat
Electronic Technician (ET) whenever the override
has expired. The override cannot be used again until
the override is reset. The check engine and action
lamps will continue to be illuminated until the override
is reset. The override may be reset at any point after
the initial activation. The override can only be reset
by the engine manufacturer, Caterpillar, or an
authorized Cat dealer using Caterpillar supplied
passwords. Resetting the override will require the
operator to provide the information in the Usage
Report below to the service technician.
Override Usage Report

To comply with federal regulations, the operator must
report usage of the override to Caterpillar Inc. within
60 days of activating the override. Failure to meet this
reporting requirement may subject the operator to
penalties under 40 CFR 1068.101. Caterpillar Inc. will
in turn report override usage annually to the United
States EPA. Although submitted to Caterpillar Inc.,
the override usage reports are deemed to be
submissions to the United States EPA. Federal
regulations prohibit submitting false information. The
following information must be included in the report:
SEBU9107-03 39
Operation Section
Battery Disconnect Switch
Caterpillar Inc. OFF – To deactivate the electrical

P.O. Box 600 system, turn the battery disconnect
Mossville, IL 61552-0600 switch counterclockwise to the OFF
Attention: Emissions Compliance Manager position.
The battery disconnect switch and the engine start
i05422613
switch perform different functions. The entire
electrical system is disabled when you turn the
Battery Disconnect Switch battery disconnect switch to the OFF position. The
(If Equipped) battery remains connected to the electrical system
when you turn the engine start switch to the OFF
SMCS Code: 1411 position.
Turn the battery disconnect switch to the OFF
position and remove the key when you service the
electrical system or any other engine components.
Turn the battery disconnect switch to the OFF
position and remove the disconnect switch key after
you operate the engine. This will prevent the battery
from being discharged. The following problems can
cause battery discharge:
• short circuits
• current draw via some components
• vandalism
Illustration 47 g03422039 i05812500
Monitoring System
NOTICE
Do not turn off the battery disconnect switch until the SMCS Code: 1900; 7400; 7450; 7451
indicator lamp has turned off. If the switch is turned
off when the indicator lamp is illuminated the Diesel The monitoring system is designed to alert the
Exhaust Fluid (DEF) system will not purge the DEF. If operator to an immediate problem with any of the
the DEF does not purge, DEF could freeze and dam- engine systems that are monitored. The Monitoring
age the pump and lines. System is also designed to alert the operator to an
impending problem with any of the engine systems
that are monitored.
NOTICE The monitoring system parameters can be accessed
Never move the battery disconnect switch to the OFF via the Cat ET service tool. Many of the parameters
position while the engine is operating. Serious dam- within the monitoring system can be tailored to suit
age to the electrical system could result. the operation of the engine.
An example of adjustments that may be made within
Battery Disconnect Switch – The battery the monitoring system is changing the setpoint of the
disconnect switch can be used in order engine overspeed indicator from the factory default
to disconnect the battery from the setting.
engines electrical system. The key must be
inserted into the battery disconnect switch
before the battery disconnect switch can be
turned.
ON – To activate the electrical system,
insert the disconnect switch key and
turn the battery disconnect switch
clockwise. The battery disconnect switch must
be turned to the ON position before you start the
engine.
40 SEBU9107-03
Operation Section
Monitoring System
Instrument Panel
Engine Stop (Shutdown) – Turn the key

to this position in order to disable the
delayed engine shutdown (DES). The
engine will be shut down immediately.
Note: Shutting down the engine using this method is
considered a hard shutdown which disables the DES.
Note: A warning message and/or Audible alarm will
be initiated. A fault code will be logged for improper
engine shutdown if exhaust temperature is above
limit.
Note: Overriding delayed engine shutdown may
Illustration 48 g03353026 reduce engine and machine system component life.
Instrument panel
(1) service tool connector
For more information, refer to this Operation and
(2) engine start switch (key) Maintenance Manual, “Delayed Engine Shutdown (If
(3) keypad Equipped)”.
(4) message display
(5) circuit protection OFF – Insert the engine start switch key
only while the start switch is in the OFF
Service Tool Connector (1) position. Remove the engine start
switch key only while the engine start switch is in
For more information about the use of Cat ET and the the OFF position. Turn the engine start switch to
PC requirements for Cat ET, refer to the the OFF position before you attempt to restart the
documentation that accompanies your Cat ET engine. Turn the engine start switch to the OFF
software. position in order to stop the engine.
Engine Start Switch (2) ON – To activate the electrical circuits in

the cab, turn the key clockwise to the
ON position.
NOTICE
The engine start switch must be in the ON position START – To start the tractor engine, turn
and the engine must be running in order to maintain the key clockwise to the START
electrical functions and hydraulic functions. This proposition. After the engine starts, release
cedure must be followed in order to prevent serious
the key. The key will return to the ON position.
machine damage.
Note: If the engine fails to start, return the engine
start switch key to the OFF position. Return the key
to the start position before you attempt to start the
engine again.
SEBU9107-03 41
Operation Section
Monitoring System
Keypad (3) Message Display (4)
Throttle up (6) – This button is used in

order to increase throttle speed.
Force Regeneration (7) – Push and hold

the top switch for 2 seconds in order to Illustration 51 g03353673
start a manual regeneration cycle. Message display screen in “Default” menu
(14) DEF Level
Menu(8) – This button is used to change (15) Indicator Bar
the display screen to other options.
The message display provides for a means to view
Scroll up (9) – This button is used to various types of engine information. The information
navigate through the various screens of that can be viewed is described by menu below.
the . Use the scroll up (9) and scroll down (13) buttons to
navigate through the following menus on the
Throttle down (10) – This button is used message display.
in order to decrease throttle speed.
The DEF level gauge (14), and the Indicator bar (15)
Disable Regeneration (11) – Push and are on the sides of each of the menu screens.
hold the bottom switch for 2 seconds in DEF Level (14) – This gauge is located on the left
order to disable the automatic side of each menu screen, and indicates the level of
regeneration cycle. DEF remaining in the DEF tank.
Enter (12) – This button selects the Indicator Bar (15) – This area is located on the right
currently highlighted menu option. The side of each menu screen. An indicator will illuminate
“ Enter”” button also acknowledges any when the monitoring system senses any of the
Level 1, Level 2, or Level 3 diagnostic message following statuses:
on the display screen.
Check Engine – This indicator
Scroll down (13) – This button is used to illuminates when there is a fault with the
navigate through the various screens of engine or after treatment system.
the .
Alert Indicator – This indicator
illuminates when a Level 2 or Level 3
warning fault has been detected by the
monitoring system.
Diesel Particulate Filter (DPF) – This

indicator will illuminate in order to show
that a regeneration is needed.
42 SEBU9107-03
Operation Section
Monitoring System
Regeneration Active – This indicator will Note: Some applications will configure this option to
illuminate in order to show that the display the time remaining only when regens are
Caterpillar Regeneration System (CRS) disabled. In that case, the display will read “AUTO”
is active. as long as automatic regens are enabled. When
regens are disabled, the time until the next regen is
Regeneration Disabled – This indicator required will be displayed.
will illuminate in order to show that a
regeneration has been disabled. “ Coolant Temp”” – This gauge indicates the current
temperature of the engine coolant.
Emission Malfunction Indicator – This
indicator will illuminate when an “ Oil Pressure”” – This gauge indicates the current
emissions system has failed. Refer to engine oil pressure.
Operation and Maintenance Manual, “Selective “ Fuel Pressure”” – This gauge indicates fuel
Catalytic Reduction Warning System” for more pressure to the fuel injection pump from the fuel filter.
information. A decrease in fuel pressure usually indicates a dirty
fuel filter or a plugged fuel filter. As the fuel filter
Default (Home) Menu becomes plugged, there will be a noticeable
reduction in the performance of the engine.
“ Battery Voltage”” – This gauge indicates the voltage
of the electrical system.
Performance Menu
The following options are displayed in the

“ Default”” menu:
“ Speed (RPM)”” – This gauge indicates engine speed
(rpm). When the throttle control lever is moved to the
full throttle position without load, the engine is Illustration 53 g03353207
running at high idle. The engine is running at the full
load rpm when the throttle control lever is at the full The following options are displayed in the
throttle position with maximum rated load. “ PERFORMANCE”” menu:
“ Percent Load”” – This gauge indicates the “ Engine Requested Speed”” – The display will show
percentage of full load rpm at which the engine is the requested speed of the engine.
operating.
“ Engine Desired Speed”” – The display will show the
“ Time to Regen”” – When you scroll to this option, the desired speed of the engine.
display will show the time remaining until the next
regen is required to run. A forced DPF regeneration “ Speed”” – This gauge indicates engine speed (rpm).
will not be allowed until this timer is less than 8 hours. 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.
SEBU9107-03 43
Operation Section
Monitoring System
“ Percent Load”” – This gauge indicates the “ Engine Hours”” – The display will show the total
percentage of full load rpm at which the engine is number of hours the engine has been operating.
operating.
“ Idle Speed”” – The display will show the low idle
“ Coolant Temp”” – This gauge indicates the current speed setting on the engine.
temperature of the engine coolant.
“ High Idle Speed”” – The display will show the high
“ Intake Manifold Temp”” – The display will show the idle speed setting on the engine.
temperature at the manifold.
“ Turbo Boost Pressure”” – The display will show the Settings Menu
pressure at the intake manifold.
“ Oil Pressure”” – The display will show the engine oil
pressure for engine.
“ Fuel Pressure”” – The display will show the fuel
pressure for the engine.
“ Fuel Rate”” – This gauge shows average fuel
consumption in G/hr.
“ Battery Voltage”” – This gauge indicates the voltage
of the electrical system.
Totals & Configuration Menu
The following options are available in the

“ Settings”” menu:
“ Day Backlight Brightness”” – Select this option in
order to adjust the brightness of the following items:
Message digital display area, switch lights and
instrument panel lights. This will improve the visibility
of the information.
“ TSC1 Enabled”” – This will allow an external throttle
over the “J1939” data link to control engine speed.
When the “TSC1” is in the NO position, only the
control panel throttle will be allowed to change
Illustration 54 g03353210 engine speed.
The following options are displayed in the

“ Totals”” menu:
“ Total Fuel Used”” – The display shows the total
amount of fuel that has been consumed by the
machine.
“ Total ARD Fuel Used”” – The display will show the
amount (in gallons) of fuel burned through the
regeneration system over the life of the engine.
“ Total DEF Used”” – The display shows the total
amount of diesel exhaust fluid that has been
consumed by the system.
44 SEBU9107-03
Operation Section
Monitoring System
Diagnostics Menu Circuit Protection (5)
Scroll to the “ Diagnostics”” menu to view any fault

codes that may be present.
Side view of the instrument panel
(14) circuit breakers
Circuit Breaker (14) – Press the button in order to

reset the circuit breaker if a circuit breaker trips. 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.
SEBU9107-03 45
Operation Section
Engine Diagnostics
Engine Diagnostics i03840813
i01563934
Fault Logging
SMCS Code: 1000; 1900; 1901; 1902
Self-Diagnostics The system provides the capability of Fault Logging.
SMCS Code: 1000; 1900; 1901; 1902 When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will be
Caterpillar Electronic Engines have the capability to logged in the memory of the ECM. The codes that
perform a self-diagnostics test. When the system have been logged in the memory of the ECM can be
detects an active problem, the “DIAGNOSTIC” lamp retrieved with Caterpillar electronic service tools. The
is activated. Diagnostic codes will be stored in codes that have been logged can be cleared with
permanent memory in the Electronic Control Module Caterpillar electronic service tools. The codes that
(ECM). The diagnostic codes can be retrieved by have been logged in the memory of the ECM will be
using the following components: automatically cleared from the memory after 100
hours. The following faults cannot be cleared from
• Caterpillar electronic service tools the memory of the ECM without using a factory
password: overspeed, low engine oil pressure and
• “DIAGNOSTIC” lamp high engine coolant temperature.
Note: The “DIAGNOSTIC” lamp must be installed by
the OEM or by the customer.
Some installations have electronic displays that
provide direct readouts of the engine diagnostic
codes. Refer to the manual that is provided by the
OEM for more information on retrieving engine
diagnostic codes.
Active codes represent problems that currently exist.
These problems should be investigated first. If a code
is active, the “DIAGNOSTIC” lamp will flash the flash
code at five second intervals.
Logged codes represent the following items:
• Intermittent problems
• Recorded events
• Performance history
The problems may have been repaired since the
logging of the code. These codes do not indicate that
a repair is needed. The codes are guides or signals
when a situation exists. Codes may be helpful to
troubleshoot problems.
When the problems have been corrected, the
corresponding logged fault codes should be cleared.
46 SEBU9107-03
Operation Section
Engine Starting
Engine Starting • Ensure that the areas around the rotating parts are
clear.
i02354640 • All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair
Before Starting Engine any damaged guards. Replace damaged guards
and/or missing guards.
SMCS Code: 1000; 1400; 1450
• Disconnect any battery chargers that are not
Perform the required daily maintenance and other
protected against the high current drain that is
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can created when the electric starting motor (if
help prevent major repairs at a later date. equipped) is engaged. Check electrical cables and
check the battery for poor connections and for
• For the maximum service life of the engine, make corrosion.
a thorough inspection before starting the engine.
Look for the following items: oil leaks, coolant • Reset any of the shutoff components or alarm
leaks, loose bolts and trash buildup. Remove trash components.
buildup and arrange for repairs, as needed.
• Check the engine lubrication oil level. Maintain the
• Inspect the cooling system hoses for cracks and oil level between the “ADD” mark and the “FULL”
for loose clamps. mark on the oil level gauge.
• Inspect the alternator and accessory drive belts for • Check the coolant level. Maintain the coolant level
cracks, breaks, and other damage. within 13 mm (0.5 inch) of the bottom of the filler
pipe. If the engine is equipped with a sight glass,
• Inspect the wiring for loose connections and for maintain the coolant level in the sight glass.
worn wires or frayed wires.
• Observe the air cleaner service indicator. Service
• Check the fuel supply. Drain water from the water the air cleaner when the red target locks in the
separator (if equipped). Open the fuel supply visible position.
valve.
• Disengage any driven equipment. Remove any
electrical loads.
NOTICE
All valves in the fuel return line must be open before
i04132731
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage. Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
If the engine has not been run for several weeks, fuel
Startability will be improved at temperatures below
may have drained from the fuel system. Air may have
10°C (50°F) from the use of a cylinder block coolant
entered the filter housing. Also, when fuel filters have
heater or from other means that are used to heat the
been changed, some air space will be left in the crankcase oil. Some engine applications use a jacket
housing. In these instances, prime the fuel system. water heater to improve startability. Use of a jacket
Refer to the Operation and Maintenance Manual, water heater will help reduce white smoke and
“Fuel System - Prime” for more information on misfire during start-up in cold weather.
priming the fuel system.
Note: If the engine has not been run for several
weeks, fuel may have drained. Air may have moved
into the filter housing. Also, when fuel filters have
Engine exhaust contains products of combustion been changed, some air will be left in the filter
which may be harmful to your health. Always housing. Refer to the Operation and Maintenance
start and operate the engine in a well ventilated Manual, “Fuel System - Prime” (Maintenance
area and, if in an enclosed area, vent the exhaust Section) for more information on priming the fuel
to the outside. system.
• 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.
SEBU9107-03 47
Operation Section
Starting the Engine
Ether Injection System (If NOTICE

Equipped) Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
The ether injection system is controlled by the ECM.
The ECM monitors the coolant temperature, intake If the engine fails to start within 30 seconds, release
air temperature, ambient air temperature, and the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
barometric pressure to determine when ether
start the engine again.
injection is needed. At sea level, ether will be used if
any of the temperatures fails to exceed 0° C (32° F).
This temperature is subject to an increase as 3. Push the start button or turn the ignition switch to
barometric pressure increases. the START position in order to crank the engine.
Do not push down or hold the throttle down while
the engine is cranked. The system will
Personal injury or property damage can result automatically provide the correct amount of fuel
from alcohol or starting fluids. that is needed to start the engine.
Alcohol or starting fluids are highly flammable 4. If the engine fails to start within 30 seconds,
and toxic and if improperly stored could result in release the start button, or the ignition switch. Wait
injury or property damage. for 2 minutes in order to allow the starting motor to
cool before attempting to start the engine again.
Follow the procedure in this Operation and
NOTICE
Maintenance Manual, “Starting the Engine”. Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine rpm until the oil
i04032033 pressure gauge indicates normal. If oil pressure is
not indicated on the gauge within 15 seconds, DO
Starting the Engine NOT operate the engine. STOP the engine, investi-
gate and correct the cause.
SMCS Code: 1000; 1450
5. Allow the engine to idle for approximately 3

minutes. Idle the engine until the water
Engine exhaust contains products of combustion temperature gauge has begun to rise. Check all
which may be harmful to your health. Always gauges during the warm-up period.
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust Note: Oil pressures and fuel pressures should be in
to the outside. the normal range on the instrument panel. Engines
that are equipped with “WARNING” lamps do not
have an operating range. The “WARNING and
Starting the Engine DIAGNOSTIC” lamp (if equipped) will flash while the
engine is cranking. The lamp should turn off after
Refer to the Owner's Manual of the OEM for your proper engine oil pressure or fuel pressure is
type of controls. Use the following procedure to start achieved. Do not apply a load to the engine or
the engine. increase engine rpm until the oil pressure gauge
indicates at least normal pressure. Inspect the engine
1. Place the transmission in NEUTRAL. Disengage for leaks and/or unusual noises.
the flywheel clutch in order to allow the engine to
start faster, and to reduce the draining of the If the engine is operated with a low load, the engine
will reach normal operating temperature sooner than
battery. idling the engine with no load. When the engine is
2. Turn the ignition switch to the ON position. idled in cold weather, increase the engine rpm to
approximately 1000 to 1200 rpm in order to warm up
During the key on, the diagnostic lamp, warning the engine more quickly. Do not exceed the
lamp, regeneration lamps, and DPF disabled lamp recommended rpm in order to increase the speed of
will be checked for proper bulb operation. If any of the warm-up. Limit unnecessary idle time to 10
the lamps do not illuminate, replace the bulb. minutes.
Starting Problems
An occasional starting problem may be caused by
one of the following items:
48 SEBU9107-03
Operation Section
Starting with Jump Start Cables
• Low battery charge 3. Start the engine. If the engine does not start,
consult the nearest Caterpillar dealer for
• Lack of fuel assistance.
• Problem with the wiring harness
i05428473
If the engine fuel system has been run dry, fill the fuel
tank and prime the fuel system. Refer to the Starting with Jump Start
Operation and Maintenance Manual, “Fuel System -
Prime” topic (Maintenance Section). Cables
If the other problems are suspected, perform the (Do Not Use This Procedure in
appropriate procedure in order to start the engine. Hazardous Locations that have
Problems with the Wiring Harness Explosive Atmospheres)
SMCS Code: 1000; 1401; 1402; 1900
If the installation is not equipped with a backup
battery system, starting the engine from an external
electrical source may be necessary.
First, determine the reason that starting the engine
from an external electrical source is necessary. Refer
to Troubleshooting, UENR0978, “C9.3 Engines”.
Many batteries which are considered unusable are
still rechargeable. After jump starting, the alternator
may not be able to recharge batteries that are
severely discharged. The batteries must be charged
to the proper voltage with a battery charger. For
information on testing and charging, refer to the
Special Instruction, SEHS7633, “Battery Test
Procedure”.
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
ECM Connector J2/P2 be damaged. Attach ground cable last and remove
Locate the ECM. Check the connector in order to first.
ensure that the connector is secure. Lightly pull each When using an external electrical source to start the
of the wires in the chassis harness. engine, turn the generator set control switch to the
1. Pull each wire with approximately 4.5 kg (10 lb) of “OFF” position. Turn all electrical accessories OFF
before attaching the jump start cables.
force. The wire should remain in the connector.
2. If a wire is loose, push the wire back into the Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
connector. Pull the wire again in order to ensure gine being started.
that the wire is secure.
1. Turn the start switch on the stalled engine to OFF.

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.
SEBU9107-03 49
Operation Section
After Starting Engine
3. Connect one negative end of the jump-start cable Extended Idle at Cold Ambient
to the negative cable terminal of the electrical Temperature
source. Connect the other negative end of the
jump-start cable to the engine block or to the The engine may automatically change speeds when
chassis ground. This procedure helps to prevent the engine is idling in cold ambient temperatures
potential sparks from igniting combustible gases (typically less than 0° C (32° F) for extended periods.
that are produced by some batteries. The purpose of the automatic speed change is
threefold: to maintain the desired operation of the
4. Charge the batteries. The engine will not continue NOx reduction system, to maintain the desired
to run after starting if the batteries have not been operation of the regeneration system and to keep the
charged. engine coolant warm. The engine speed may rise to
1600 rpm for as long as 20 minutes.
5. Start the engine.
The high exhaust system temperature lamp may
6. Immediately after the stalled engine is started, illuminate during extended idling conditions. This
disconnect the jump-start cables in reverse order. illumination signals that a diesel particulate filter
(DPF) regeneration is in progress. Regenerations
Refer to the Electrical Schematic for your engine. during cold ambient extended idling may only last up
Consult your Caterpillar dealer for more information. to 10 minutes.
i05359363
After Starting Engine

SMCS Code: 1000
Note: In temperatures from 0 to 60°C (32 to 140°F),

the warm-up time is approximately 3 minutes. In
temperatures below 0°C (32°F), additional warm-up
time may be required.
When the engine is idling during warm-up, observe
the following conditions:
• Check for fluid or air leaks at idle rpm and at one-
half full rpm (no load on the engine) before
operating the engine under load. Operating the
engine at idle and at one-half full rpm with no load
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.
50 SEBU9107-03
Operation Section
Engine Operation
Engine Operation i05813053
i06545704
Diesel Particulate Filter
Regeneration
Engine Operation SMCS Code: 108F
SMCS Code: 1000
Proper operation and maintenance are key factors in
Regeneration
obtaining the maximum life and economy of the Regeneration is to increase the exhaust temperature
engine. If the directions in the Operation and for a given time. The Caterpillar Regeneration
Maintenance Manual are followed, costs can be System (CRS) is used to remove soot from the DPF,
minimized and engine service life can be maximized.
and warm up the Selective Catalyst Reduction (SCR)
The time that is needed for the engine to reach system. The DPF traps both soot and ash. The ash is
normal operating temperature can be less than the removed through a manual cleaning process. Refer
time needed for a walk-around inspection of the to Operation and Maintenance Manual, “Diesel
engine. Particulate Filter - Clean” for more information on the
service of the DPF.
After the engine is started and after the engine
reaches normal operating temperature, the engine Regeneration Indicators
can be operated at the rated rpm. The engine will
reach normal operating temperature faster when the Regeneration Active – When
engine is at rated speed. The engine will reach illuminated, this indicator shows that
normal operating temperature faster when the engine the system is active. This indicator
is at low-power demand. This procedure is more
shows that elevated emission temperatures are
effective than idling the engine at no load. The engine
should reach operating temperature in a few minutes. possible. This indicator will turn off when
regeneration is complete.
Gauge readings should be observed and the data
should be recorded frequently while the engine is DPF – This indicator will illuminate in
operating. Comparing the data over time will help to order to show that a regeneration is
determine normal readings for each gauge. required. This indicator will illuminate
Comparing data over time will also help detect when “ Time to Regen”” is less than a pre-
abnormal operating developments. Significant determined amount of time.
changes in the readings should be investigated.
Regeneration Disabled – This indicator
Engines rated for constant speed use are allowed to will illuminate in order to show that a
complete a starting sequence, an operation at a regeneration has been disabled.
single constant speed, and a shutdown sequence.
Every time the engine is run, each of these
operations should occur only once. The starting Regeneration Switch
sequence and shutdown sequence can include a
short period of operation at the low idle speed for Force Regeneration – Press in the top
purposes of warming up and cooling down the engine switch for 2 seconds in order to begin
or driven equipment. The emissions type approval is regeneration.
not valid for operation of a constant speed engine in
a manner different from that described above. Disable Regeneration – Press in the
bottom switch for 2 seconds in order to
disable regeneration.
Note: If equipped with a rocker style switch, the

MIDDLE position of the regeneration switch is the
default position for automatic regeneration.
Note: If the engine start switch key is cycled or the

“Force Regeneration” switch is pressed for longer
than 2 seconds the system will no longer be disabled.
When the “Force Regeneration” switch is pressed
and “Time to Regen” is less than 8 hours,
regeneration will begin if the machine is at low idle
and is parked.
SEBU9107-03 51
Operation Section
Diesel Particulate Filter Regeneration
Note: If the engine start switch key is cycled while Start-Up Regeneration: A start-up regeneration is
the regeneration system is disabled via the “Disable initiated by the ECM after a cold engine start. This
Regeneration” switch, press and hold the “Disable regeneration is performed to heat the system to a
Regeneration” switch for 2 seconds to reinitiate. required temperature for Diesel Exhaust Fluid (DEF)
dosing to begin.
Modes of Regeneration SCR Maintenance: A regeneration is performed to
maintain the SCR system.
Automatic: The Electronic Control Module (ECM)
uses multiple inputs from the engine and the machine ARD Maintenance: A regeneration is performed to
to determine the best time to perform an automatic maintain the CRS system.
regeneration. Automatic regenerations can take
place throughout the operating cycle of the engine. Regeneration System Warning
The regeneration active indicator will be illuminated
when a regeneration is being performed. Indicators
Interruptions of the regeneration are acceptable. If a
regeneration is in progress and needs to be stopped,
it is permissible to press the “Disable Regeneration”
switch.
Note: Automatic adjustments of engine speed may
be noticed during regenerations. If a regeneration is
taking place and the engine is taken to low idle, the
engine speed may remain elevated in order to
maintain the regeneration.
Note: If the machine returns to work while an
automatic regeneration is active, the regeneration The DPF Indicator will illuminate solid when a
may be stopped. The ECM will continue to monitor regeneration is required. A regeneration should be
inputs to determine the best time to restart the performed as soon as possible.
regeneration. Note: In some situations, the DPF indicator may stay
Manual: A manual regeneration is initiated by illuminated after a regeneration ends. The illuminated
pressing the “Force Regeneration” switch. A manual DPF indicator indicates that a complete regeneration
regeneration will only be allowed if the “Time to has not been performed. A complete regeneration is
Regen” is less than 8 hours. If the “Force when the soot has been depleted or all of the criteria
Regeneration” switch is pressed before “Time to for one of the other regeneration types have been
Regen” is less than 8 hours, then “Regen not met. If the DPF indicator stays illuminated, perform a
Required” will be displayed. The machine must be regeneration without interruption. The DPF indicator
stationary, the parking brake must be applied, and will shut off when a regeneration is complete.
the engine must be at low idle in order to perform a
manual regeneration. If the soot load is above a threshold or “Time to
Regen” is 0 hours, then a regeneration is required.
Disabled: When the regeneration system is in The DPF indicator will illuminate and flash slowly.
disabled mode, automatic regenerations will not be Engine power will be slightly derated. If the machine
performed. The DPF indicator will illuminate if a continues to operate without a regeneration, derate
manual regeneration is required. The “Time to will eventually reach 100%. Stop the machine and
Regen” displayed on the performance screen will apply the parking brake. With the engine at low idle,
indicate the time until the next regeneration will be initiate a manual regeneration.
required. However, the DPF indicator may illuminate
with time remaining on the display. When the DPF
indicator illuminates, the operator must perform a
manual regeneration.
Regeneration Triggers
A regeneration may be required for the following
reasons:
Soot: The DPF will collect soot produced by the
engine. An automatic regeneration will become Once the amount of soot collected in the DPF has
active to reduce soot level. reached a threshold or “Time to Regen” has been at
0 hours for a pre-determined time, the DPF indicator
will illuminate and flash at a fast rate. A red stop lamp
will illuminate solid.
52 SEBU9107-03
Operation Section
Engaging the Driven Equipment
10 minutes after the illumination of the DPF indicator i01136207

and red stop lamp the engine will shut down. The
engine can be restarted by cycling the engine start
switch key. The engine will return to the previous
Fuel Conservation Practices
derate state before shutdown. SMCS Code: 1000; 1250
Once the amount of soot collected reaches a The efficiency of the engine can affect the fuel
threshold level or 6.4 hours of run time has passed economy. Caterpillar's design and technology in
since the red stop lamp was illuminated without a manufacturing provides maximum fuel efficiency in
successful regeneration, the engine will have a 100% all applications. Follow the recommended procedures
derate. in order to attain optimum performance for the life of
the engine.
Once the amount of soot collected reaches a critical
threshold level, the regeneration will be locked out. At
this time, a regeneration can only be done through • Avoid spilling fuel.
Cat Electronic Technician (ET), by an authorized Cat Fuel expands when the fuel is warmed up. The fuel
dealer. The engine may be restarted, but will only run may overflow from the fuel tank. Inspect fuel lines for
for 3 minutes before shutting down again. leaks. Repair the fuel lines, as needed.
i04038637 • Be aware of the properties of the different fuels.
Use only the recommended fuels.
Engaging the Driven
• Avoid unnecessary idling.
Equipment
Shut off the engine rather than idle for long periods of
SMCS Code: 1000 time.
1. Operate the engine at one-half of the rated rpm, • Observe the service indicator frequently. Keep the
when possible. air cleaner elements clean.
2. Engage the driven equipment without a load on the • Ensure that the turbochargers are operating
equipment, when possible. correctly so that the proper air/fuel ratio is
maintained. Clean exhaust indicates proper
Interrupted starts put excessive stress on the drive functioning.
train. Interrupted starts also waste fuel. To get the
driven equipment in motion, engage the clutch • Maintain a good electrical system.
smoothly with no load on the equipment. This
method should produce a start that is smooth and One faulty battery cell will overwork the alternator.
easy. The engine rpm should not increase and the This will consume excess power and excess fuel.
clutch should not slip.
3. Ensure that the ranges of the gauges are normal • Ensure that the belts are properly adjusted. The
belts should be in good condition.
when the engine is operating at one-half of the
rated rpm. Ensure that all gauges operate • Ensure that all of the connections of the hoses are
properly. tight. The connections should not leak.
4. Increase the engine rpm to the rated rpm. Always • Ensure that the driven equipment is in good
increase the engine rpm to the rated rpm before working order.
the load is applied.
• Cold engines consume excess fuel. Utilize heat
5. Apply the load. Begin operating the engine at low from the jacket water system and the exhaust
load. Check the gauges and equipment for proper system, when possible. Keep cooling system
operation. After normal oil pressure is reached and components clean and keep cooling system
the temperature gauge begins to move, the engine components in good repair. Never operate the
may be operated at full load. Check the gauges engine without water temperature regulators. All of
and equipment frequently when the engine is these items will help maintain operating
operated under load. temperatures.
Extended operation at low idle or at 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.
SEBU9107-03 53
Operation Section
Cold Weather Operation
Cold Weather Operation There are three major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
i03729720
• Lower cloud point
Radiator Restrictions • Lower pour point
SMCS Code: 1353; 1396
• Lower rating of kJ (BTU) per unit volume of fuel
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow When No. 1 diesel fuel is used, a decrease in power
restriction can cause the following conditions: and in fuel efficiency may be noticed. Other operating
effects should not be experienced.
• High exhaust temperatures
The cloud point is the temperature when a cloud of
• Power loss wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is the
• Excessive fan usage temperature when diesel fuel will thicken. The diesel
fuel becomes more resistant to flow through fuel
• Reduction in fuel economy pumps and through fuel lines.
If an airflow restriction device must be used, the Be aware of these values when diesel fuel is
device should have a permanent opening directly in purchased. Anticipate the average ambient
line with the fan hub. The device must have a temperature of the area. Engines that are fueled in
minimum opening dimension of at least 770 cm2 one climate may not operate well if the engines are
(120 in2). moved to another climate. Problems can result due to
changes in temperature.
A centered opening that is directly in line with the fan
hub is specified in order to prevent an interrupted Before troubleshooting for low power or for poor
airflow on the fan blades. Interrupted airflow on the performance in the winter, check the type of fuel that
fan blades could cause a fan failure. is being used.
Caterpillar recommends a warning device for the inlet When No. 2 diesel fuel is used the following
manifold temperature and/or the installation of an components provide a means of minimizing problems
inlet air temperature gauge. The warning device for in cold weather:
the inlet manifold temperature should be set at 90° C
(194° F). The inlet manifold air temperature should • Starting aids
not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential • Engine oil pan heaters
engine damage.
• Engine coolant heaters
i05264084
• Fuel heaters
Fuel and the Effect from Cold • Fuel line insulation
Weather For more information on cold-weather operation, see
SMCS Code: 1000; 1250; 1280 Special Publication, SEBU5898, “Cold Weather
Recommendations”.
The following fuels are the grades that are available
for Cat engines: i03728501
• No. 1
Fuel Related Components in
• No. 2 Cold Weather
• Blend of No. 1 and No. 2 SMCS Code: 1000; 1250; 1280
No. 2 diesel fuel is the most commonly used fuel.
Either No. 1 diesel fuel or a blend of No. 1 and No. 2 Fuel Tanks
is best suited for cold-weather operation.
Condensation can form in partially filled fuel tanks.
Quantities of No. 1 diesel fuel are limited. No. 1 Top off the fuel tanks after operating the engine.
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.
54 SEBU9107-03
Operation Section
Fuel Related Components in Cold Weather
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.
Drain the water and sediment from any fuel storage
tank at the following intervals:
• Weekly
• Oil changes
• 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 Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in order for the fuel to be heated before
the fuel enters the primary fuel filter.
Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater
with a large heating surface. The fuel heater should
be practical in size. Small heaters can be too hot due
to the limited surface area.
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.
For further information on fuel heaters, consult your
Caterpillar dealer.
SEBU9107-03 55
Operation Section
Engine Stopping
Engine Stopping
Leaving the machine unattended when the engine
i05798719
is running may result in personal injury or death.
Before leaving the machine operator station, neu-
Stopping the Engine tralize the travel controls, lower the work tools to
the ground and deactivate all work tools, and
SMCS Code: 1000 place the lever for the hydraulic lockout control
in the LOCKED position.
NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and ac- Note: Leaving the engine unattended while running
celerated wear of the engine components. may result in property damage in the event of a
malfunction.
See the following stopping procedure, to allow the
engine to cool, and to prevent excessive tempera- Turn the engine start switch to the OFF position.
tures in the turbocharger center housing, which could
cause oil coking problems. Delayed Engine Shutdown – The
delayed engine shutdown indicator will
illuminate or the following text will be
1. While the machine is stopped, run the engine for 5 displayed, ENGINE COOLDOWN ACTIVE.
minutes at low idle. Idling the engine allows hot
areas of the engine to cool gradually. Delayed engine shutdown will run whenever the
exhaust temperature is above a threshold at engine
Note: If the “Regen Active” indicator is illuminated, shutdown. Delayed engine shutdown will run for a
do not shut off the engine. Refer to Operation and minimum of 76 seconds and will continue to run until
Maintenance Manual, “Monitoring System” for more the engine and system components are cooled. The
information on indicators. (if equipped) default maximum run time is 7 minutes.
2. Turn the engine start switch to the OFF position Note: An authorized dealer can change the
maximum run time value up to 30 minutes, but the
and remove the key.
default setting is 7 minutes.
Note: The engine may delay before completely
Note: To override delayed engine shutdown and stop
shutting down. Delayed engine shutdowns aid in
the engine, turn the engine start switch to the STOP
cooling the engine and after-treatment (if equipped)
position. Overriding delayed engine shutdown may
components.
reduce engine and system component life. A warning
message and/or audible alarm will be initiated and a
Delayed Engine Shutdown (If fault code will be logged for improper engine
Enabled) shutdown.
The Delayed Engine Shutdown allows the engine to

run for a time after the engine start switch key is
turned to the OFF position to cool the engine and
system components. The engine start switch key
may be removed.
Note: The DEF purge process will run for 2 minutes

once the engine is shut down and must complete.
The purge process may occur during delayed engine
shutdown. Do not turn off battery disconnect switch
during the purge process. Do not turn off the battery
power disconnect switch until the battery disconnect
switch indicator lamp has turned off. If the purge
process does not complete, a diagnostic code will
become active.
Note: There may be regulations that define the
requirements for the operator and/or support
personnel to be present when the engine is running.
56 SEBU9107-03
Operation Section
Manual Stop Procedure
i01465494
After Stopping Engine

SMCS Code: 1000
Note: Before you check the engine oil, do not

operate the engine for at least 10 minutes in order to
allow the engine oil to return to the oil pan.
• Check the crankcase oil level. Maintain the oil

level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• If necessary, perform minor adjustments. Repair

any leaks and tighten any loose bolts.
• Note the service hour meter reading. Perform the
Note: At any time during a delayed engine shutdown, maintenance that is in the Operation and
the engine start switch may be turned to the ON Maintenance Manual, “Maintenance Interval
position. The engine may be placed back into Schedule”.
service.
• Fill the fuel tank in order to help prevent
i05812522 accumulation of moisture in the fuel. Do not overfill
the fuel tank.
Manual Stop Procedure
SMCS Code: 1000; 7418 NOTICE
Only use antifreeze/coolant mixtures recommended
in the Coolant Specifications that are in the Operation
NOTICE and Maintenance Manual. Failure to do so can cause
Stopping the engine immediately after it has been engine damage.
working under load can result in overheating and ac-
celerated wear of the engine components.
• Allow the engine to cool. Check the coolant level.
If the engine has been operating at high rpm and/or
high loads, run at low idle for at least three minutes to • If freezing temperatures are expected, check the
reduce and stabilize internal engine temperature be- coolant for proper antifreeze protection. The
fore stopping the engine. cooling system must be protected against freezing
to the lowest expected outside temperature. Add
Avoiding hot engine shutdowns will maximize turbo- the proper coolant/water mixture, if necessary.
charger shaft and bearing life.
• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
Note: Individual applications have different control the instructions from the OEM.
systems. Ensure that the shutoff procedures are
understood. Use the following general guidelines in
order to stop the engine.
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.
SEBU9107-03 57
Maintenance Section
Refill Capacities
Maintenance Section (Table 5, contd)

(1) The total cooling system capacity includes the following compo-
nents:the engine block, the radiator and all coolant hoses and
lines.
Refill Capacities
i05268614
i04133869
Fluid Recommendations
Refill Capacities SMCS Code: 1280; 1348; 1395; 7560
SMCS Code: 1000; 1348; 1395; 7560
NOTICE
Refer to this Operation and Maintenance Manual, Every attempt is made to provide accurate, up-to-
“Fluid Recommendations” for information about the date information. By the use of this document, you
fluids which are acceptable for this engine. agree that Caterpillar Inc. is not responsible for errors
or omissions.
Refer to Special Publication, SEBU6251, “Caterpillar
Commercial Engine Fluids Recommendations” for
additional information.
NOTICE
These recommendations are subject to change with-
Lubricant Refill Capacities out prior notice. Contact your Caterpillar dealer for
the most up to date recommendations.
The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump Refer to Special Publication, SEBU6251, “Cat
plus standard oil filters. Auxiliary oil filter systems will Commercial Diesel Engine Fluids
require additional oil. Refer to the OEM specifications Recommendations” for additional information.
for the capacity of the auxiliary oil filter.
Refer to this Operation and Maintenance Manual,
Table 4 “Severe Service Application” for information about
C9.3 Industrial Engine operating an engine in a severe service application.
Approximate Refill Capacities
Note: Instructions for the installation of the filter are
System Liters Quarts printed on the side of each Cat spin-on filter. For
filters that are not Cat filters, refer to the installation
Oil Sump(1) 32 33.8 instructions that are provided by the supplier of the
(1)
filter.
These values are approximate capacities for the crankcase oil
sump which include the standard oil filters that are installed at
the factory. Engines with auxiliary oil filters will require addition- Diesel Engine Oil
al oil. Refer to the OEM specifications for the capacity of the
auxiliary oil filter.
Cat DEO (Diesel Engine Oil)
Coolant Refill Capacities Due to significant variations in the quality and in the
performance of commercially available oils,
To maintain the cooling system, the total cooling Caterpillar makes the following recommendations:
system capacity must be known. The capacity of the
total cooling system will vary. The capacity will • Cat DEO-ULS (Diesel Engine Oil Ultra Low
depend on the size of the radiator (capacity). Table 5 Sulfur) (SAE 5W-40)
should be completed by the customer for the
maintenance of the cooling system. • Cat DEO-ULS (Diesel Engine Oil Ultra Low
Table 5 Sulfur) (SAE 10W-30)
Approximate Capacity of the Cooling System
• Cat DEO-ULS (Diesel Engine Oil Ultra Low
Compartment or Sulfur) (SAE 15W-40)
Liters Quarts
System
Engine Oil
Total Cooling Sys-
tem(1)
Cat oils have been developed and tested in order to
provide the full performance and life that has been
designed and built into Cat engines.
(continued)
58 SEBU9107-03
Maintenance Section
Cat DEO-ULS or oils that meet the Cat ECF-3

specification and the API CJ-4 are required for use in
the applications listed below. Cat DEO-ULS and oils
meeting Cat ECF-3 specification and the API CJ-4
and ACEA E9 oil categories have been developed
with limited sulfated ash, phosphorus, and sulfur.
These chemical limits are designed to maintain the
expected aftertreatment devices life, performance,
and service interval. If oils meeting the Cat ECF-3
specification and the API CJ-4 specifications are not
available, oils meeting ACEA E9 may be used. ACEA
E9 oils meet the chemical limits designed to maintain
aftertreatment device life. ACEA E9 oils are validated
using some but not all ECF-3 and API CJ-4 standard
engine performance tests. Consult your oil supplier
when considering use of an oil that is not Cat ECF-3
or API CJ-4 qualified.
Failure to meet the listed requirements will damage
aftertreatment-equipped engines and can negatively
impact the performance of the aftertreatment
devices. The Diesel Particulate Filter (DPF) will plug
sooner and require more frequent DPF ash service
intervals.
Typical aftertreatment systems include the following:
• Diesel Particulate Filters (DPF)
• Diesel Oxidation Catalysts (DOC)

• Selective Catalytic Reduction (SCR)
• Lean NOx Traps (LNT)

Other systems may apply.
Table 6
Lubricant Viscosities for Ambient Temperatures
Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat DEO-ULS Cold Weather SAE 0W-40 −40 40 −40 104
Engine Crankcase Cat DEO-ULS SAE 10W-30 −18 40 0 104
Cat DEO-ULS SAE 15W-40 −9.5 50 15 122
Caterpillar has developed a maintenance tool that

NOTICE evaluates oil degradation. the maintenance
Oil Renewal systems should not be used in engines
equipped with aftertreatment systems. Reduced life management also detects the early signs of wear on
or damage to the aftertreatment may occur. internal components. The Cat 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:
S·O·S Services Oil Analysis
• Component wear rate
NOTICE • Oil condition
These recommendations are subject to change with-
out prior notice. Contact your Caterpillar dealer for • Oil contamination
the most up to date recommendations.
• Identification of oil
SEBU9107-03 59
Maintenance Section
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
lubricated compartment. 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.
NOTICE EAME Film
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam- Diesel fuel must meet “Cat Specification for Distillate
pling. Using the same pump for both types of sam- Fuel” and the latest versions of “ASTM D975” or “EN
ples may contaminate the samples that are being 590” in order to ensure optimum engine performance.
drawn. This contaminate may cause a false analysis Refer to Special Publication, SEBU6251, “Cat
and an incorrect interpretation that could lead to con- Commercial Diesel Engine Fluids
cerns by both dealers and customers. Recommendations” for the latest fuel information and
for Cat fuel specification. This manual may be found
on the Web at Safety.Cat.com.
Refer to Special Publication, SEBU6251, “Cat
Commercial Diesel Engine Fluids NOTICE
Recommendations” in order to obtain additional Ultra Low Sulfur Diesel (ULSD) fuel 0.0015 percent
information about S·O·S Services oil analysis. You (≤15 ppm (mg/kg)) sulfur is required by regulation for
can also contact your local Cat dealer in order to use in engines certified to nonroad Tier 4 standards
obtain additional information about the S·O·S (U.S. EPA Tier 4 certified) and that are equipped with
Services Oil Analysis program.
exhaust aftertreatment systems.
Diesel Fuel Recommendations European ULSD 0.0010 percent (≤10ppm (mg/kg))
sulfur fuel is required by regulation for use in engines
certified to European nonroad Stage IIIB and newer
standards and are equipped with exhaust aftertreat-
ment systems.
Misfueling with fuels of higher sulfur level can

have the following negative effects:
• Shorten the time interval between

aftertreatment device service intervals (cause
the need for more frequent service intervals)
• Adversely impact the performance and life of

aftertreatment devices (cause loss of
performance)
• Reduce regeneration intervals of
aftertreatment devices
NACD Film
• Reduce engine efficiency and durability.
• Increase the wear.
• Increase the corrosion.

• Increase the deposits.
• Lower fuel economy

60 SEBU9107-03
Maintenance Section
• Shorten the time period between oil drain intervals Note: Purge all of the old grease from a joint before
(more frequent oil drain intervals). you change from one type of grease to another type
of grease. Some greases are not chemically
• Increase overall operating costs. compatible with other greases. Consult your supplier
in order to determine if the greases are compatible.
Failures that result from the use of improper fuels are
not Cat factory defects. Therefore the cost of repairs If you are not certain that the old grease is
would not be covered by a Cat warranty. compatible with the new grease, purge the old
grease from the system before applying the new
Cat does not require the use of ULSD in off road and grease.
machine applications that are not Tier 4/Stage IIIB
certified engines. ULSD is not required in engines Note: All Cat greases are chemically compatible with
that are not equipped with after treatment devices. each other. Mixing of Cat greases does not result in
For Tier 4/Stage IIIB/Stage IV certified engines an adverse chemical reaction. However, mixing of
always follow operating instructions. Fuel tank inlet Cat greases may result in reduced performance.
labels are installed in order to ensure that the correct
fuels are used. Non-Cat commercial greases are as a group second
Refer to Special Publication, SEBU6251, “Cat choice greases. Within this grouping of second
Commercial Diesel Engine Fluids choice greases, there are tiered levels of
Recommendations” for more details about fuels, performance. For more information, refer to Special
lubricants, and Tier 4 requirements. This manual may Publication, SEBU6251, “Cat Commercial Diesel
be found on the Web at Safety.Cat.com. Engines Fluids Recommendations”.
Lubricating Grease Coolant
NOTICE NOTICE
These recommendations are subject to change with- These recommendations are subject to change with-
out prior notice. Contact your Caterpillar dealer for out prior notice. Contact your Caterpillar dealer for
the most up to date recommendations. the most up to date recommendations.
Cat provides various greases that vary in

performance from a moderate performance to high NOTICE
performance. Cat greases service the entire line of Never add coolant to an overheated engine. Engine
Cat products in the wide variety of climates damage could result. Allow the engine to cool first.
throughout the world. From this variety of Cat grease
products, you can find a Cat grease that will meet or
exceed the performance requirements of most NOTICE
engines. Frequently check the specific gravity of the coolant
for proper freeze protection or for anti-boil protection.
The performance requirements of your engine must
be determined before you select any Cat grease.
Consult the recommendations for greases that are NOTICE
made by the OEM for the equipment. Then, consult Never operate an engine without water temperature
with your Cat dealer for a list of greases that have the regulators in the cooling system. Water temperature
performance specifications and the available sizes of regulators help to maintain the engine coolant at the
containers. proper operating temperature. Cooling system prob-
lems can develop without water temperature
Note: Always choose grease that meets or exceeds regulators.
the recommendations that are specified by the
equipment manufacturer for the application. The following two coolants are used in Cat Diesel
Engines:
If it is necessary to choose a single grease to use for
all of the equipment at one site, always choose a Preferred – Cat ELC (Extended Life Coolant) or a
grease that meets or exceeds the requirements of commercial extended life coolant that meets the Cat
the most demanding application. Remember that the Engine Coolant -1 (EC-1) specification.
products which barely meet the minimum
performance requirements can be expected to
produce the minimum lives of your parts. False Acceptable – Cat DEAC (Diesel Engine Antifreeze/
economy is being used if a grease is purchased with Coolant) or a commercial heavy-duty coolant that
the lowest cost as the only consideration. Instead, meets “ASTM D4985”, or “ASTM D6210”
use the grease that yields the lowest total operating specifications
cost. This 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.
SEBU9107-03 61
Maintenance Section
Note: Cat DEAC does not require a treatment with a Testing the engine coolant is important to ensure that
Supplemental Coolant Additive (SCA) at the initial fill. the engine is protected from internal cavitation and
However, a commercial heavy-duty coolant that only from corrosion. The analysis also tests the ability of
meets the “ASTM D4985” specification will require a the coolant to protect the engine from boiling and
treatment with an SCA at the initial fill. A commercial from freezing. The S·O·S Coolant Analysis can be
heavy-duty coolant that meets the “ASTM D6210” performed at your Cat dealer. Cat S·O·S Coolant
specification will not require a treatment with an SCA Analysis is the best way to monitor the condition of
at the initial fill. Read the label or the instructions that your coolant and your cooling system. S·O·S Coolant
Analysis is a program that is based on periodic
are provided by the manufacturer of the commercial
samples.
heavy-duty coolant.
Note: These coolants will require a treatment with a NOTICE
supplemental coolant additive on a maintenance Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
basis. pling. Using the same pump for both types of sam-
Table 7 ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
Service Life Before Flushing and Before Refilling
and an incorrect interpretation that could lead to con-
Coolant Service Life(1) cerns by both dealers and customers.
Cat ELC 12,000 hours, or 6 years
For more information, refer to Special Publication,
Commercial coolant that meets the 6000 hours, or 6 years SEBU6251, “Cat Commercial Diesel Engines Fluids
Cat EC-1 specification Recommendations”
Cat DEAC 3000 hours, or 3 years
Diesel Exhaust Fluid
Commercial Heavy-Duty Coolant
that meets “ASTM D4985” or 3000 hours, or 1 year
“ASTM D6210” General Information
(1) Use the interval that occurs first. Diesel Exhaust Fluid (DEF) is a liquid that is injected
into the exhaust system of engines equipped with
Note: Add the Cat ELC Extender at the halfway point Selective Catalytic Reduction (SCR) systems. SCR
of the coolant change interval. reduces emissions of nitrogen oxides (NOx) in diesel
engine exhaust.
Note: These coolant change intervals are only
possible with annual S·O·S Services Level 2 coolant Diesel Exhaust Fluid (DEF) is also known under
sampling and analysis. other names including Aqueous Urea Solution (AUS)
32, AdBlue, or generically referred to as urea.
S·O·S Services Coolant Analysis
In engines equipped with SCR emissions reduction
Table 8
system, DEF is injected in controlled amounts into
the engine exhaust stream. At the elevated exhaust
Recommended Interval temperature, urea in DEF is converted to ammonia.
The ammonia chemically reacts with NOx in diesel
Type of exhaust in the presence of the SCR catalyst. The
Level 1 Level 2 reaction converts NOx into harmless nitrogen (N2)
Coolant and water (H2O).
Every 500 Hours(1) Every 2000 Hours
DEAC (2) or Yearly(1) (3) DEF Recommendations
ELC Optional(3) Yearly(3) For use in Cat engines, DEF must meet all the
(1) This interval is recommended for the sampling of all conven- requirements defined by “ISO 22241-1”
tional heavy-duty coolant. Requirements.
(2) This interval is also recommended for the sampling of a com-
mercial coolant that meets the Cat (Engine Coolant specifica- Caterpillar recommends the use of DEF available
tion - 1) requirement. through the Cat parts ordering system for use in Cat
(3) The Level 2 coolant analysis should be performed sooner if a engines equipped with SCR systems. Refer to Table
problem is suspected or identified.
9 for part number information:
Table 9
Cat Part Number Container Size
350-8733 2.5 gal bottle
350-8734 1000-L tote

62 SEBU9107-03
Maintenance Section
In North America, commercial DEF that is API Stainless Steels:

approved and meets all the requirements defined in
“ISO 22241-1” may be used in Cat engines that are • 304 (S30400)
equipped with SCR systems.
• 304L (S30403)
Outside of North America, commercial DEF that
meets all requirements defined in “ISO 22241-1” may • 316 (S31600)
be used in Cat engines that are equipped with SCR
systems. • 316L (S31603)
The supplier should provide documentation to prove Alloys and metals:
the DEF is compliant with the requirements of “ISO
22241-1”. • Chromium Nickel (CrNi)
NOTICE • Chromium Nickel Molybdenum (CrNiMo)

Cat does not warrant the quality or performance of
non-Cat fluids. • Titanium
Non-metallic materials:
NOTICE • Polyethylene
Do not use agriculture grade urea solutions. Do
not use any fluids that do not meet “ISO 22241-1” Re- • Polypropylene
quirements in SCR emissions reduction systems.
Use of these fluids can result in numerous problems • Polyisobutylene
including damage to SCR equipment and a reduction
in NOx conversion efficiency. • Teflon (PFA)
• Polyfluoroethylene (PFE)
DEF is a solution of solid urea that is dissolved in
demineralized water to produce a final concentration • Polyvinylidene fluoride (PVDF)
of 32.5% urea. DEF concentration of 32.5% is
optimal for use in SCR systems. DEF solution of • Polytetrafluoroethylene (PTFE)
32.5% urea has the lowest attainable freeze point of
−11.5° C (11.3° F). DEF concentrations that are Materials NOT compatible with DEF solutions include
higher or lower than 32.5% have higher freeze Aluminum, Magnesium, Zinc, Nickel coatings, Silver
points. DEF dosing systems and “ISO 22241-1” and Carbon steel and Solders containing any of the
specifications are designed for a solution that is above. Unexpected reactions may occur if DEF
approximately 32.5%. solutions come in contact with any non-compatible
material or unknown materials.
Caterpillar offers a refractometer, Cat part number
360-0774, that can be used to measure DEF Bulk storage
concentration. Follow the instructions provided with
the instrument. Appropriate commercial portable
refractometers can be used to determine urea Follow all local regulations covering bulk storage
concentration. Follow the instructions from the tanks. Follow proper tank construction guidelines.
manufacturer. Tank volume typically should be 110% of planned
capacity. Appropriately vent indoor tanks. Plan for
DEF Guidelines control of overflow of the tank. Heat tanks that
dispense DEF in cold climates.
DEF solution is typically colorless and clear. Changes Bulk tank breathers should be fitted with filtration to
to color or clarity are indicators of quality issues. keep airborne debris from entering the tank.
Quality of DEF can degrade when stored and Desiccant breathers should not be used because
handled inappropriately or if DEF is not protected water will be absorbed, which potentially can alter
from contamination. Details are provided below. DEF concentration.
If quality issues are suspected, testing of DEF should Handling
focus on urea percentage, alkalinity as NH3 and
biuret content. DEF that does not pass all these tests Follow all local regulations covering transport and
or that is no longer clear should not be used. handling. DEF transport temperature is
recommended to be −5° C (23° F) to 25° C (77° F).
Materials compatibility All transfer equipment and intermediate containers
should be used exclusively for DEF. Containers
DEF is corrosive. Due to the corrosion caused, DEF should not be reused for any other fluids. Ensure that
must be stored in tanks constructed of approved transfer equipment is made from DEF-compatible
materials. Recommended storage materials: materials. Recommended material for hoses and
other non-metallic transfer equipment include:
SEBU9107-03 63
Maintenance Section
• Nitrile Rubber (NBR) Note: Dispose of all fluids according to applicable

regulations and mandates.
• Fluoroelastomer (FKM)
• Ethylene Propylene Diene Monomer (EPDM) Fuel Additives

The condition of hoses and other nonmetallics that Cat Diesel Fuel Conditioner and Cat Fuel System
are used with DEF should be monitored for signs of Cleaner are available for use when needed. These
degradation. DEF leaks are easily recognizable by products are applicable to diesel and biodiesel fuels.
white urea crystals that accumulate at the site of the Consult your Cat dealer for availability.
leak. Solid urea can be corrosive to galvanized or
unalloyed steel, aluminum, copper, and brass. Leaks Biodiesel
should be repaired immediately to avoid damage to
surrounding hardware. Biodiesel is a fuel that can be made from various
renewable resources that include vegetable oils,
Cleanliness animal fat, and waste cooking oil. Soybean oil and
rapeseed oil are the primary vegetable oil sources. In
Contaminants can degrade the quality and life of order to use any of these oils or fats as fuel, the oils
DEF. Filtering DEF is recommended when dispensed or fats are chemically processed (esterified). The
into the DEF tank. Filters should be compatible with water and contaminants are removed.
DEF and should be used exclusively with DEF.
Check with the filter supplier to confirm compatibility U.S. distillate diesel fuel specification “ASTM D975-
with DEF before using. Mesh-type filters using 09a” includes up to B5 (5 percent) biodiesel.
compatible metals, such as stainless steel, are Currently, any diesel fuel in the U.S. may contain up
recommended. Paper (cellulose) media and some to B5 biodiesel fuel.
synthetic filter media are not recommended because
of degradation during use. European distillate diesel fuel specification “EN 590”
includes up to B5 (5 percent) and in some regions up
Care should be taken when dispensing DEF. Spills to B7 (7 percent) biodiesel. Any diesel fuel in Europe
should be cleaned immediately. Machine or engine may contain up to B5 or in some regions up to B7
surfaces should be wiped clean and rinsed with biodiesel fuel.
water. Caution should be used when dispensing DEF
near an engine that has recently been running. Note: The diesel portion used in the biodiesel blend
Spilling DEF onto hot components will cause harmful must be Ultra Low Sulfur Diesel (15 ppm sulfur or
vapors. less, per “ASTM D975”). In Europe the diesel fuel
portion used in the biodiesel blend must be sulfur free
Stability diesel (10 ppm sulfur or less, per “EN 590”). The final
blend must have 15 ppm sulfur or less.
DEF fluid is stable when stored and handled properly.
The quality of DEF rapidly degrades when stored at When biodiesel fuel is used, certain guidelines must
high temperatures. The ideal storage temperature for be followed. Biodiesel fuel can influence the engine
DEF is between −9° C (15.8° F) and 25° C (77° F). oil, aftertreatment devices, non-metallic, fuel system
DEF that is stored above 35° C (95° F) for longer components, and others. Biodiesel fuel has limited
than 1 month must be tested before use. Testing storage life and has limited oxidation stability. Follow
should evaluate Urea Percentage, Alkalinity as NH3 the guidelines and requirements for engines that are
and Biuret content. seasonally operated.
The length of storage of DEF is listed in the following In order to reduce the risks associated with the use of
table: biodiesel, the final biodiesel blend and the biodiesel
Table 10 fuel used must meet specific blending requirements.
Storage Temperature Expected DEF Life All the guidelines and requirements are provided in
the latest revision of Special Publication, SEBU6251,
Below 25° C (77° F) 18 months “Cat Commercial Diesel Engine Fluids
25° C (77° F) to 30° C (86° F) 12 months Recommendations”. This manual may be found on
the Web at Safety.Cat.com.
30° C (86° F) to 35° C (95° F) 6 months
Above 35° C (95° F) test quality before use
Refer to “ISO 22241” document series for more

information about DEF quality control.
64 SEBU9107-03
Maintenance Section
Maintenance Recommendations
Maintenance Do not loosen the high pressure fuel lines in order to

remove air pressure from the fuel system.
Recommendations
Engine Oil
i02909163
To relieve pressure from the lubricating system, turn
System Pressure Release off the engine.
SMCS Code: 1250; 1300; 1350; 5050 i05182568
Coolant System Welding on Engines with

Electronic Controls
SMCS Code: 1000
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra- NOTICE
diator is cool. Then loosen cap slowly to relieve Because the strength of the frame may decrease,
the pressure. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Cat dealer regarding welding on a chas-
off the engine. Allow the cooling system pressure cap sis frame or rail.
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure. Proper welding procedures are necessary in order to
avoid damage to the engine Electronic Control
Fuel System Module (ECM), Clean Emissions Module (CEM),
sensors, and associated components. When
possible, remove the component from the unit and
To relieve the pressure from the fuel system, turn off
then weld the component. If removal of the
the engine.
component is not possible, the following procedure
must be followed when you weld on a unit that is
High Pressure Fuel Lines (If Equipped) equipped with a Caterpillar Electronic Engine. The
following procedure is considered to be the safest
procedure to weld on a component. This procedure
should provide a minimum risk of damage to
electronic components.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow NOTICE
these inspection, maintenance and service in- Do not ground the welder to electrical components
structions may cause personal injury or death. such as the ECM or sensors. Improper grounding
can cause damage to the drive train, the bearings,
The high pressure fuel lines are the fuel lines that are hydraulic components, electrical components, and
between the high pressure fuel pump and the high other components.
pressure fuel manifold and the fuel lines that are Do not ground the welder across the centerline of the
between the fuel manifold and cylinder head. These package. Improper grounding could cause damage
fuel lines are different from fuel lines on other fuel to the bearings, the crankshaft, the rotor shaft, and
systems.
other components.
This is because of the following differences:
Clamp the ground cable from the welder to the com-
• The high pressure fuel lines are constantly ponent that will be welded. Place the clamp as close
charged with high pressure. as possible to the weld. This will help reduce the pos-
sibility of damage.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system.
Note: Perform the welding in areas that are free from
Before any service or repair is performed on the explosive hazards.
engine fuel lines, perform the following tasks:
1. Stop the engine. Turn the switched power to the
1. Stop the engine. OFF position.
2. Wait for ten minutes. 2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
open the switch.
SEBU9107-03 65
Maintenance Section
Severe Service Application
3. Disconnect the J1/P1 and J2/P2 connectors from Note: If electrical/electronic components are used as
the ECM and. Disconnect the wiring from the a ground for the welder, or electrical/electronic
CEM. Move the harnesses to a position that will components are located between the welder ground
not allow the harnesses to contact with any of the and the weld, current flow from the welder could
ECM, CEM, or pins accidentally. severely damage the component.
5. Protect the wiring harness from welding debris and

spatter.
6. Use standard welding practices to weld the
materials.
i04889860

SMCS Code: 1000
An engine which operates outside of normal
conditions is operating in a severe service
application.
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
Cat dealer for the unique maintenance that may be
necessary for your engine.
Illustration 64 g01075639 An application is a severe service application if any of
Use the example above. The current flow from the the following conditions apply:
welder to the ground clamp of the welder will not
damage any associated components. Severe Environmental Factors
(1) Engine
(2) Welding electrode • Frequent operation in dirty air
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables • Frequent operation at an altitude which is above
(6) Battery 1525 m (5000 ft)
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being • Frequent operation in ambient temperatures which
welded and any electrical/electronic component are above 32° C (90° F)
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
• Frequent operation in ambient temperatures which
are below 0° C (32° F)
4. Connect the welding ground cable directly to the
part that will be welded. Place the ground cable as Severe Operating Conditions
close as possible to the weld in order to reduce the
• Frequent operation with inlet air which has a
possibility of welding current damage to bearings,
corrosive content
hydraulic components, electrical components, and
ground straps. • Operation with inlet air which has a combustible
content
• Operation which is outside of the intended
application
66 SEBU9107-03
Maintenance Section
• 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)
• 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, “Cat Commercial
Diesel Engine Fluids Recommendations”
“Distillate Diesel Fuel”
• Operating with a blend of distillate fuel which
contains more than 20 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, “Cat Commercial
Diesel Engine Fluids Recommendations”
• 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”
SEBU9107-03 67
Maintenance Section
Maintenance Interval Schedule
i06612738 “ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 89
Maintenance Interval Schedule “ Fuel System Primary Filter/Water Separator -

Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
SMCS Code: 1000; 4450; 7500
“ Power Take-Off Clutch - Check” . . . . . . . . . . . . . 104
The user is responsible for the performance of
maintenance, all adjustments, use of proper “Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . 106
lubricants, fluids, filters, and replacement of
components due to normal wear and aging. Failure to Every 6000 Service Hours or 3
adhere to proper maintenance intervals and
procedures may result in diminished performance of Years
the product and/or accelerated wear of components.
“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . . 79
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, to Every 340 500 L (90 000 US gal) of
determine the maintenance intervals. Products that
operate in severe operating conditions may require Fuel
more frequent maintenance.
“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . 102
Before each consecutive interval is performed, all
maintenance from the previous intervals must be Every 10 000 Service Hours
performed.
Choose the interval that occurs first to determine the “ DEF Manifold Filters - Replace” . . . . . . . . . . . . . . 84
correct maintenance interval: fuel consumption ,
service hours, and calendar time. Products that Every 12 000 Service Hours or 6
operate in severe operating conditions may require
more frequent maintenance. Years
Note: Ensure that all safety information, warnings, “ Coolant (ELC) - Change”. . . . . . . . . . . . . . . . . . . . 78
and instructions are read and understood before any
operation or any maintenance procedures are Every 250 Service Hours
performed.
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 90
When Required
“Grounding Stud - Inspect/Clean/Tighten” . . . . . . . 98
“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . . 73
Every 500 Service Hours
“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 73
“ Air Shutoff - Test” . . . . . . . . . . . . . . . . . . . . . . . . . . 72
“ Battery or Battery Cable - Disconnect” . . . . . . . . . 74
“ Battery Electrolyte Level - Check” . . . . . . . . . . . . 74
“ DEF Filler Screen - Clean” . . . . . . . . . . . . . . . . . . 84
“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 74
“ Diesel Exhaust Fluid - Fill”. . . . . . . . . . . . . . . . . . . 86
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 “ Coolant Sample (Level 1) - Obtain” . . . . . . . . . . . 81
“ Engine Storage Procedure - Check”. . . . . . . . . . . 93 “ Cooling System Supplemental Coolant Additive

(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . . 94
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . . 91
“ Fuel Tank Water and Sediment - Drain” . . . . . . . . 97
“ Fuel System Primary Filter (Water Separator)
“ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . 105 Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 95
“ Fuel System Secondary Filter - Replace”. . . . . . . 96
Daily
“ Hoses and Clamps - Inspect/Replace”. . . . . . . . . 98
“ Air Tank Moisture and Sediment - Drain” . . . . . . . 73
“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . . 80 Every 2000 Service Hours or 1 Year
“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . . 88 “ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 81
“ Engine Air Cleaner Service Indicator - Inspect” . . 89
68 SEBU9107-03
Maintenance Section
“ Fumes Disposal Filter Element - Replace”. . . . . . 97

“ Compression Brake - Inspect/Adjust/Replace” . . 76
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . 93
Every 3000 Service Hours or 3

Years
“ Coolant (DEAC) - Change” . . . . . . . . . . . . . . . . . . 76
“ Coolant Temperature Regulator - Replace” . . . . . 82

“ Air Compressor - Check”. . . . . . . . . . . . . . . . . . . . 72
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 89

Years
“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . 105

“ ARD Spark Plug - Clean”. . . . . . . . . . . . . . . . . . . . 71
“ Diesel Exhaust Fluid Filter - Replace” . . . . . . . . . 87
“ Diesel Particulate Filter - Clean” . . . . . . . . . . . . . . 88
“ Injector (Diesel Exhaust Fluid) - Replace” . . . . . 101
SEBU9107-03 69
Maintenance Section
i06612739 “ Driven Equipment - Check” . . . . . . . . . . . . . . . . . . 88
Maintenance Interval Schedule “ Engine Air Cleaner Service Indicator - Inspect” . . 89
(Engines With Ratings Greater “ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 89
Than 359 hp) “ Fuel System Primary Filter/Water Separator -

Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
SMCS Code: 1000; 4450; 7500
“ Power Take-Off Clutch - Check” . . . . . . . . . . . . . 104
The user is responsible for the performance of
maintenance, all adjustments, use of proper “Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . 106
lubricants, fluids, filters, and replacement of
components due to normal wear and aging. Failure to Every 6000 Service Hours or 3
adhere to proper maintenance intervals and
procedures may result in diminished performance of Years
the product and/or accelerated wear of components.
“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . . 79
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, to Every 340 500 L (90 000 US gal) of
determine the maintenance intervals. Products that
operate in severe operating conditions may require Fuel
more frequent maintenance.
“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . 102
Before each consecutive interval is performed, all
maintenance from the previous intervals must be
performed. Every 10 000 Service Hours
Choose the interval that occurs first to determine the “ DEF Manifold Filters - Replace” . . . . . . . . . . . . . . 84
correct maintenance interval: fuel consumption ,
service hours, and calendar time. Products that
operate in severe operating conditions may require Every 12 000 Service Hours or 6
more frequent maintenance. Years
Ensure that all safety information, warnings, and “ Coolant (ELC) - Change”. . . . . . . . . . . . . . . . . . . . 78
instructions are read and understood before any
operation or any maintenance procedures are
performed. Every 250 Service Hours
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 90
When Required
“Grounding Stud - Inspect/Clean/Tighten” . . . . . . . 98
“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . . 73
“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 73 Initial 500 Service Hours
“ Battery or Battery Cable - Disconnect” . . . . . . . . . 74 “ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . 93
“ DEF Filler Screen - Clean” . . . . . . . . . . . . . . . . . . 84 Every 500 Service Hours

“ Diesel Exhaust Fluid - Fill”. . . . . . . . . . . . . . . . . . . 86
“ Air Shutoff - Test” . . . . . . . . . . . . . . . . . . . . . . . . . . 72
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
“ Battery Electrolyte Level - Check” . . . . . . . . . . . . 74
“ Engine Storage Procedure - Check”. . . . . . . . . . . 93
“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 74
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . . 94
“ Coolant Sample (Level 1) - Obtain” . . . . . . . . . . . 81
“ Fuel Tank Water and Sediment - Drain” . . . . . . . . 97
“ Cooling System Supplemental Coolant Additive
“ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . 105 (SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . . 91
Daily
“ Fuel System Primary Filter (Water Separator)
“ Air Tank Moisture and Sediment - Drain” . . . . . . . 73 Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 95
“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . . 80 “ Fuel System Secondary Filter - Replace”. . . . . . . 96
70 SEBU9107-03
Maintenance Section
Engines With Ratings Greater Than 359 hp
“ Hoses and Clamps - Inspect/Replace”. . . . . . . . . 98
Every 2000 Service Hours or 1 Year

“ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 81

“ Compression Brake - Inspect/Adjust/Replace” . . 76
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . 93

Years
“ Coolant (DEAC) - Change” . . . . . . . . . . . . . . . . . . 76
“ Coolant Temperature Regulator - Replace” . . . . . 82

“ Air Compressor - Check”. . . . . . . . . . . . . . . . . . . . 72
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 89

Years
“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . 105

“ ARD Spark Plug - Clean”. . . . . . . . . . . . . . . . . . . . 71
“ Diesel Exhaust Fluid Filter - Replace” . . . . . . . . . 87
“ Diesel Particulate Filter - Clean” . . . . . . . . . . . . . . 88
“ Injector (Diesel Exhaust Fluid) - Replace” . . . . . 101
SEBU9107-03 71
Maintenance Section
ARD Spark Plug - Clean
i05379868 3. Use a deep well socket and a breaker bar to

loosen the spark plug. If necessary, see your
ARD Spark Plug - Clean Caterpillar dealer for the part number of the
SMCS Code: 1555-070 socket. After the spark plug has been loosened,
use the socket to remove the spark plug by hand
in order to detect problems with the threads. After
Removing the Spark Plug the spark plug has been removed, inspect the
used spark plug and the gasket.
NOTICE
If the engine is running or the key is in the ON posi- 4. After removing the spark plug, clean the ground
tion the ARD plug will continue to fire. Turn the key to probe inside the ARD combustion head by running
the OFF position before servicing the ARD plug. a 305-2389 Plug Bore Brush through the hole in
the ARD combustion head. This tool scrapes
debris from the seat and from the threads. Run the
brush through the hole several times.
5. Carefully clean the spark plug using a nonmetallic
cleaning pad. If the probe appears to be bent,
replace the spark plug. Otherwise, install the
original spark plug. Refer to Specifications manual
for the correct torque value.
Note: The spark plug may be damaged if the spark

plug is dropped. Do not install a spark plug that has
been dropped.
NOTICE
Do not use a thread tap. A thread tap will remove
metal unnecessarily. The threads could be stripped
and the combustion group could be damaged.
Installing the Spark Plug

Note: Do not use anti-seize compound on the spark
plug. Most of the heat is transferred through the
(1) Wiring harness threads and the seat area of the spark plug. Contact
(2) Spark plug
of the metal surfaces must be maintained in order to
provide the heat transfer that is required.
1. Remove wire harness (1) from spark plug (2).
1. Ensure that the spark plug is clean and free of dirt
and oil.
Personal injury can result from air pressure. NOTICE

Do not overtighten the spark plug. The shell can be
Personal injury can result without following prop- cracked and the gasket can be deformed. The metal
er procedure. When using pressure air, wear a can deform and the gasket can be damaged. The
protective face shield and protective clothing. shell can be stretched. This will loosen the seal that
is between the shell and the insulator, allowing com-
The maximum air pressure for cleaning purposes bustion pressure to blow past the seal. Serious dam-
must be reduced to 205 kPa (30 psi) when the air age to the engine can occur.
nozzle is deadheaded.
Use the proper torque.
2. Debris may have collected in the spark plug well.
Thoroughly remove any debris. Use compressed
2. Install the spark plug by hand until the spark plug
air. The maximum air pressure for cleaning
contacts the ARD. Torque the spark plug to the
purposes must be below 205 kPa (30 psi). Ensure
proper specification. Refer to Specifications,
that the area around the spark plug is clean and
“Spark Plug” for the proper torque specification.
free of dirt and debris.
72 SEBU9107-03
Maintenance Section
Air Compressor - Check
3. Connect the wiring harness. The pressure relief valve for the air compressor
releases air at 1723 kPa (250 psi). If the pressure
i03966490 relief valve for the air compressor exhausts, all
personnel should be at a safe distance away from the
air compressor. All personnel should also stay clear
Air Compressor - Check of the air compressor when the engine is operating
(If equipped) and the air compressor is exposed.
SMCS Code: 1803-535 Refer to the Service Manual or refer to the OEM
specifications in order to find information concerning
the air compressor. Consult your Caterpillar dealer
for assistance.
Do not disconnect the air line from the air com-
i05427169
pressor governor without purging the air brake
and the auxiliary air systems. Failure to purge the
air brake and the auxiliary air systems before re- Air Shutoff - Test
moving the air compressor and/or the air lines
could cause personal injury. (If Equipped)
SMCS Code: 1078-081
To ensure that the air shutoff valve always shuts
down when the engine ingests gaseous fumes,
perform the test below at each oil change. A test
failure can indicate wear in the block off plate to valve
body interface and/or the bearing system.
1. Place engine at low idle speed. Ensure all
accessories that are normally used for the
application are in use, like a fan, or power takeoffs.
2. Actuate the air shutoff manually. On electrical
operator air shutoffs, utilize an applicable power
supply or jumper cables from the battery to
energize the air shut-off solenoid. Ensure that the
solenoid receives only a momentary signal to
prevent overheating. On hydraulic operator air
Typical example
shutoffs, found on some hazardous location units,
(1) Pressure relief valve
actuate by pulling the emergency stop handle.
3. Ensure that air shutoff was actuated and that the
engine comes to a complete stop.
If the air compressor pressure relief valve that is
mounted in the air compressor cylinder head is Note: As every application has different parasitic
bypassing compressed air, there is a malfunction loads and inertia, the duration for the problem to
in the air system, possibly ice blockage. Under occur cannot be specified. However, if the engine
these conditions, your engine may have insuffi- stumbles or attempts to continue running, these
cient air for normal brake operation. symptoms may be an indication that worn
components may need replacement.
Do not operate the engine until the reason for the
air bypass is identified and corrected. Failure to If additional help is needed, contact the Dealer
heed this warning could lead to property damage, Solution Network.
personal injury, or death to the operator or
bystanders. NOTICE
Actuating the air shutoff valve may result in oil leak-
The function of the pressure relief valve is to bypass age past the shaft seal in some cases. Repeated ac-
air when there is a malfunction in the system for the tuation of the air shutoff valve during loaded
air compressor. operation of the engine can result in mechanical
damage to the turbocharger and reduce turbocharger
life.
SEBU9107-03 73
Maintenance Section
Air Tank Moisture and Sediment - Drain
i00847451 i06103470
Air Tank Moisture and Battery - Replace

Sediment - Drain SMCS Code: 1401-510
(If Equipped)
SMCS Code: 1466-543-M&S
Batteries give off combustible gases which can
Moisture and sediment in the air starting system can explode. A spark can cause the combustible
cause the following conditions: gases to ignite. This can result in severe personal
injury or death.
• Freezing
Ensure proper ventilation for batteries that are in
• Corrosion of internal parts an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
• Malfunction of the air starting system near batteries. Do not smoke when batteries are
serviced.
When opening the drain valve, wear protective

gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could The battery cables or the batteries should not be
cause debris to be blown and result in personal removed with the battery cover in place. The bat-
injury. tery cover should be removed before any servic-
ing is attempted.
1. Open the drain valve that is on the bottom of the Removing the battery cables or the batteries with
air tank. Allow the moisture and sediment to drain. the cover in place may cause a battery explosion
resulting in personal injury.
2. Close the drain valve.
3. Check the air supply pressure. The air starting Note: Always recycle a battery. Never discard a
motor requires a minimum of 620 kPa (90 psi) of battery. Return used batteries to an appropriate
air pressure to operate properly. The maximum air recycling facility.
pressure must not exceed 1550 kPa (225 psi).
The normal air pressure will be 758 to 965 kPa 1. Turn the key start switch to the OFF position.
(110 to 140 psi). Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the
i02039199
charger.
Battery - Recycle 3. The NEGATIVE “-” cable connects the NEGATIVE
SMCS Code: 1401-535; 1401; 1401-510; 1401-005; “-” battery terminal to the ground plane.
1401-561 Disconnect the cable from the NEGATIVE “-”
battery terminal.
Always recycle a battery. Never discard a battery.
Return used batteries to one of the following 4. The POSITIVE “+” cable connects the POSITIVE
locations: “+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+”
• A battery supplier battery terminal.
• An authorized battery collection facility 5. Remove the used battery.
• A recycling facility 6. Install the new battery.
Note: Before the cables are connected, ensure that

the key start switch is OFF.
7. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.
8. Connect the cable from the ground plane to the
NEGATIVE “-” battery terminal.
74 SEBU9107-03
Maintenance Section
Battery Electrolyte Level - Check
i06064262 i02039603
Battery Electrolyte Level - Battery or Battery Cable -

Check Disconnect
SMCS Code: 1401-535-FLV SMCS Code: 1401; 1402-029
When the engine has not run for long or short periods
of time, the batteries may not fully recharge. Ensure a
full charge in order to help prevent the battery from
freezing. 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 in-
jury or death. The connection and the disconnec-
tion of other electrical equipment may also cause
All lead-acid batteries contain sulfuric acid which an explosion which may result in injury or death.
can burn the skin and clothing. Always wear a The procedures for the connection and the dis-
face shield and protective clothing when working connection of battery cables and other electrical
on or near batteries. equipment should only be performed in a nonex-
plosive atmosphere.
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 The battery cables or the batteries should not be
water that is low in minerals. Do not use artificially removed with the battery cover in place. The bat-
softened water. tery cover should be removed before any servic-
ing is attempted.
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer. Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
3. Keep the batteries clean. resulting in personal injury.
Clean the battery case with one of the following
cleaning solutions: 1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position
• A mixture of 0.1 kg (0.2 lb) of baking soda and and remove the key and all electrical loads.
1 L (1 qt) of clean water
2. Disconnect the negative battery terminal at the
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L battery that goes to the start switch. Ensure that
(1 qt) of clean water the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
Thoroughly rinse the battery case with clean
water. two batteries must be disconnected.
Use the 1U-9921 Battery Service Tool to clean 3. Tape the leads in order to help prevent accidental
the battery terminals. Use a wire brush to clean starting.
the cable clamps. Clean the items until the
surfaces are bright or shiny. DO NOT remove 4. Proceed with necessary system repairs. Reverse
material excessively. Excessive removal of the steps in order to reconnect all of the cables.
material can cause the clamps to fit improperly.
Coat the clamps and the terminals with 5N-5561 i04024237
Silicone Lubricant, petroleum jelly or MPGM.
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Inspection
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.
SEBU9107-03 75
Maintenance Section
Belts - Inspect/Adjust/Replace
For applications that require multiple drive belts, If new belts are installed, check the belt tension again
replace the belts in matched sets. Replacing only one after 30 minutes of engine operation at the rated rpm.
belt of a matched set will cause the new belt to carry
more load because the older belt is stretched. The Drive Belt for the Air Compressor
additional load on the new belt could cause the new
belt to break. (If Equipped)
If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
If the belts are too tight, unnecessary stresses are
placed on the pulley bearings and on the belts.
Unnecessary stress may shorten the service life of
the components.
Inspect the condition and adjustment of the alternator
belts and accessory drive belts (if equipped).
To check the belt tension, apply 110 N (25 lb ft) of
force midway between the pulleys. A correctly
adjusted belt will deflect 9 mm (0.35 inch) to 15 mm
(0.59 inch).
Alternator Belt Illustration 68 g01389673

(4) Drive belt for the air compressor
(5) Mounting bolts
Loosen the four mounting bolts from the bracket that

holds the air compressor.
Typical alternator mounting
(1) Adjusting nuts
(2) Mounting bolt
(3) Mounting bolts
1. Slightly loosen mounting bolt (2) and mounting bolt

(3). Slightly loosen adjusting nut (1).
2. Move the pulley in order to adjust the belt tension.
3. Tighten the following: adjusting nuts (1), mounting
bolt (2) and mounting bolt (3). Refer to the Side view of the air compressor and pulley
Specifications, SENR3130 for the proper torques. (6) Bolt
(7) Adjusting bolt
4. Install the belt guard. Refer to the Specifications,
SENR3130 for the proper torques. Loosen bolt 6. Loosen bolt 7. Slide the air
compressor closer to the pulley. Remove the old belt.
Install a new belt.
Slide the air compressor into position. Tighten bolt 7.
Refer to Specification, SENR3130, “Torque
Specifications” for the correct torque.
76 SEBU9107-03
Maintenance Section
Compression Brake - Inspect/Adjust/Replace
Tension the belt. 1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
Tighten the four mounting bolts (5). Refer to
Specification, SENR3130, “Torque Specifications” for order to relieve any pressure. Remove the cooling
the correct torque. system filler cap.
2. Open the cooling system drain valve (if equipped).
i03965390 If the cooling system is not equipped with a drain
valve, remove one of the drain plugs.
Compression Brake - Inspect/
Adjust/Replace Note: If equipped, be sure to drain the heater and
any related supply and return lines.
SMCS Code: 1129-040; 1129-025; 1129-510
Allow the coolant to drain.
Contact your Cat dealer for the proper procedure.
NOTICE
i03841934 Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim
Coolant (DEAC) - Change used coolant for reuse in engine cooling systems.
The full distillation procedure is the only method ac-
SMCS Code: 1350-070; 1395-044 ceptable by Caterpillar to reclaim the used coolant.
Clean the cooling system and flush the cooling For information regarding the disposal and the
system before the recommended maintenance recycling of used coolant, consult your Caterpillar
interval if the following conditions exist: dealer or consult Caterpillar Dealer Service Tool
Group:
• The engine overheats frequently.
Outside Illinois 1-800-542-TOOL
• Foaming is observed. Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL
• The oil has entered the cooling system and the
coolant is contaminated.
Flush
• The fuel has entered the cooling system and the
coolant is contaminated. 1. Flush the cooling system with clean water in order
to remove any debris.
NOTICE 2. Close the drain valve (if equipped). Clean the drain
Use of commercially available cooling system
plugs. Install the drain plugs. Refer to the
cleaners may cause damage to cooling system com-
ponents. Use only cooling system cleaners that are Specifications Manual, SENR3130, “Torque
approved for Caterpillar engines. Specifications” for more information on the proper
torques.
Note: Inspect the water pump and the water NOTICE

temperature regulator after the cooling system has Fill the cooling system no faster than 19 L (5 US gal)
been drained. This is a good opportunity to replace per minute to avoid air locks.
the water pump, the water temperature regulator and
the hoses, if necessary.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Drain Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
Pressurized System: Hot coolant can cause seri- 4. Start and run the engine at low idle for a minimum
ous burns. To open the cooling system filler cap, of 30 minutes. The coolant temperature should be
stop the engine and wait until the cooling system at least 82 °C (180 °F).
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
SEBU9107-03 77
Maintenance Section
Coolant (DEAC) - Change
NOTICE NOTICE
Improper or incomplete rinsing of the cooling system Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal can result in damage to copper and other metal
components. components.
To avoid damage to the cooling system, make sure to To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water. completely flush the cooling system with clear water.
Continue to flush the system until all signs of the Continue to flush the system until all signs of the
cleaning agent are gone. cleaning agent are gone.
5. Stop the engine and allow the engine to cool. 5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling plugs. Allow the water to drain. Flush the cooling
system with clean water. If equipped, be sure to system with clean water. Close the drain valve (if
flush the heater and any related supply and return equipped). Clean the drain plugs. Install the drain
lines. Close the drain valve (if equipped). Clean plugs. Refer to the Specifications Manual,
the drain plugs. Install the drain plugs. Refer to the SENR3130, “Torque Specifications” for more
Specifications Manual, SENR3130, “Torque information on the proper torques.
Specifications” for more information on the proper
torques. Fill
Cooling Systems with Heavy NOTICE
Deposits or Plugging Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Note: For the following procedure to be effective,
there must be some active flow through the cooling 1. Fill the cooling system with an antifreeze/coolant
system components. solution. Refer to the Operation and Maintenance
1. Flush the cooling system with clean water in order Manual, “Refill Capacitites and
to remove any debris. Recommendations” topic (Maintenance Section)
for more information on cooling system
Note: If equipped, be sure to flush the heater and specifications. Do not install the cooling system
any related supply and return lines. filler cap.
2. Close the drain valve (if equipped). Clean the drain 2. Start and run the engine at low idle. Increase the
plugs. Install the drain plugs. Refer to the engine rpm to 1500 rpm. Run the engine at high
Specifications Manual, SENR3130, “Torque idle for one minute in order to purge the air from
Specifications” for more information on the proper the cavities of the engine block. Stop the engine.
torques. 3. Check the coolant level. Maintain the coolant level
within 13 mm (0.5 inch) below the bottom of the
NOTICE pipe for filling. Maintain the coolant level within
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks. 13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the cooling system filler cap.
4. Start and run the engine at low idle for a minimum
of 90 minutes. The coolant temperature should be
at least 82 °C (180 °F).
78 SEBU9107-03
Maintenance Section
Coolant (ELC) - Change
4. Clean the cooling system filler cap. Inspect the 1. Stop the engine and allow the engine to cool.
gasket that is on the cooling system filler cap. If Loosen the cooling system filler cap slowly in
the gasket that is on the cooling system filler cap is order to relieve any pressure. Remove the cooling
damaged, discard the old cooling system filler cap system filler cap.
and install a new cooling system filler cap. If the
2. Open the cooling system drain valve (if equipped).
gasket that is on the cooling system filler cap is not
If the cooling system is not equipped with a drain
damaged, perform a pressure test. A 9S-8140
valve, remove the cooling system drain plugs.
Pressurizing Pump is used to perform the
pressure test. The correct pressure for the cooling Allow the coolant to drain.
system filler cap is stamped on the face of the
cooling system filler cap. If the cooling system filler NOTICE
cap does not retain the correct pressure, install a Dispose of used engine coolant properly or recycle.
new cooling system filler cap. Various methods have been proposed to reclaim
used coolant for reuse in engine cooling systems.
5. Start the engine. Inspect the cooling system for The full distillation procedure is the only method ac-
leaks and for proper operating temperature. ceptable by Caterpillar to reclaim the used coolant.
For information regarding the disposal and the

i03842431 recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tool
Coolant (ELC) - Change Group:
SMCS Code: 1350-070; 1395-044 Outside Illinois 1-800-542-TOOL
Clean the cooling system and flush the cooling Inside Illinois 1-800-541-TOOL
system before the recommended maintenance Canada 1-800-523-TOOL
interval if the following conditions exist:
Flush
• The engine overheats frequently.
1. Flush the cooling system with clean water in order
• Foaming is observed.
to remove any debris.
• The oil has entered the cooling system and the 2. Close the drain valve (if equipped). Clean the drain
coolant is contaminated. plugs. Install the drain plugs. Refer to the
• The fuel has entered the cooling system and the Specifications Manual, SENR3130, “Torque
coolant is contaminated. Specifications” for more information on the proper
torques.
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and NOTICE
replaced. Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace 3. Fill the cooling system with clean water. Install the
the water pump, the water temperature regulator and cooling system filler cap.
the hoses, if necessary. 4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
Drain
Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
pressure.
SEBU9107-03 79
Maintenance Section
Coolant Extender (ELC) - Add
5. Stop the engine and allow the engine to cool. 5. Start the engine. Inspect the cooling system for
Loosen the cooling system filler cap slowly in leaks and for proper operating temperature.
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if i04745732
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling Coolant Extender (ELC) - Add
system with clean water. Close the drain valve (if SMCS Code: 1352-544-NL
equipped). Clean the drain plugs. Install the drain
plugs. Refer to the Specifications Manual, Cat ELC (Extended Life Coolant) does not require
SENR3130, “Torque Specifications” for more the frequent additions of any supplemental cooling
information on the proper torques. additives which are associated with the present
conventional coolants. The Cat ELC Extender will
only be added one time.
Fill
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender
NOTICE with Cat ELC.
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks. Do NOT use conventional supplemental coolant addi-
tive (SCA) with Cat ELC. Mixing Cat ELC with con-
ventional coolants and/or conventional SCA reduces
1. Fill the cooling system with Extended Life Coolant the Cat ELC service life.
(ELC). Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information Check the cooling system only when the engine is
on cooling system specifications. Do not install the stopped and cool.
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 Personal injury can result from hot coolant,
idle for one minute in order to purge the air from steam and alkali.
the cavities of the engine block. Stop the engine. At operating temperature, engine coolant is hot
3. Check the coolant level. Maintain the coolant level and under pressure. The radiator and all lines to
within 13 mm (0.5 inch) below the bottom of the heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight Remove cooling system pressure cap slowly to
glass (if equipped). relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
4. Clean the cooling system filler cap. Inspect the touch with your bare hand.
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap is Do not attempt to tighten hose connections when
damaged, discard the old cooling system filler cap the coolant is hot, the hose can come off causing
burns.
and install a new cooling system filler cap. If the
gasket that is on the cooling system filler cap is not Cooling System Coolant Additive contains alkali.
damaged, use a 9S-8140 Pressurizing Pump in Avoid contact with skin and eyes.
order to pressure test the 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.
80 SEBU9107-03
Maintenance Section
Coolant Level - Check
NOTICE
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
ers before opening any compartment or disassem-
bling 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.
Cooling system filler cap
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 Pressurized System: Hot coolant can cause seri-
cooling system in order to add the Cat ELC ous burns. To open the cooling system filler cap,
Extender. stop the engine and wait until the cooling system
3. Add Cat ELC Extender according to the pressure cap slowly in order to relieve the
requirements for the cooling system capacity. pressure.
“Refill Capacities” or to this Operation and 1. Remove the cooling system filler cap slowly in
Maintenance Manual, “Fluid Recommendations” order to relieve pressure.
for more information.
2. Maintain the coolant level within 13 mm (0.5 inch)
4. Clean the cooling system filler cap. Inspect the of the bottom of the filler pipe. If the engine is
gaskets on the cooling system filler cap. Replace equipped with a sight glass, maintain the coolant
the cooling system filler cap if the gaskets are level to the proper level in the sight glass.
damaged. Install the cooling system filler cap.
i03842450
Coolant Level - Check

SMCS Code: 1395-082
Check the coolant level when the engine is stopped
and cool.
Typical filler cap gaskets
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.
SEBU9107-03 81
Maintenance Section
Coolant Sample (Level 1) - Obtain
i04956993 Use the following guidelines for proper sampling of

the coolant:
Coolant Sample (Level 1) - • Complete the information on the label for the
Obtain sampling bottle before you begin to take the
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 samples.
• Keep the unused sampling bottles stored in plastic

Note: Obtaining a Coolant Sample (Level 1) is
bags.
optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems • Obtain coolant samples directly from the coolant
filled with Cat ELC should have a Coolant Sample sample port. You should not obtain the samples
(Level 2) that is obtained at the recommended from any other location.
interval as stated in the maintenance interval
schedule. • Keep the lids on empty sampling bottles until you
are ready to collect the sample.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant • Place the sample in the mailing tube immediately
instead of Cat ELC including the following after obtaining the sample in order to avoid
coolants: contamination.
• Commercial long life coolants that meet the • Never collect samples from expansion bottles.
Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1) • Never collect samples from the drain for a system.
• Cat DEAC (Diesel Engine Antifreeze/Coolant) Submit the sample for Level 1 analysis.
• Commercial heavy-duty coolant/antifreeze For additional information about coolant analysis, see
this Operation and Maintenance Manual, “Fluid
Table 11 Recommendations” or consult your Caterpillar dealer.
Recommended Interval
i05378320
Type of Coolant Level 1 Level 2
Cat DEAC Coolant Sample (Level 2) -

Every 250 service 2000 Hours or Every
Conventional heavy hours year(1) Obtain
duty-coolant
SMCS Code: 1350-008; 1395-554; 1395-008; 7542
Cat ELC or conven- 2000 Hours or Every
Optional
tional EC-1 coolant year(1)
NOTICE
(1) The Level 2 Coolant Analysis should be performed sooner if a Always use a designated pump for oil sampling, and
problem is suspected or identified. use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
NOTICE drawn. This contaminate may cause a false analysis
use a separate designated pump for coolant sam- and an incorrect interpretation that could lead to con-
pling. Using the same pump for both types of sam- cerns by both dealers and customers.
cerns by both dealers and customers.
Note: Level 1 results may indicate a need for

Level 2 Analysis.
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
Caterpillar dealer.
82 SEBU9107-03
Maintenance Section
Coolant Temperature Regulator - Replace
NOTICE NOTICE
Care must be taken to ensure that fluids are con- Failure to replace your water temperature regulator
tained during performance of inspection, mainte- on a regularly scheduled basis could cause severe
nance, testing, adjusting, and repair of the product. engine damage.
ers before opening any compartment or disassem- Caterpillar engines incorporate a shunt design cool-
bling any component containing fluids. ing system and require operating the engine with a
water temperature regulator installed.
Service Tool Catalog” or refer to Special Publication, If the water temperature regulator is installed incor-
PECJ0003, “Cat Shop Supplies and Tools Catalog” rectly, the engine may overheat, causing cylinder
for tools and supplies suitable to collect and contain head damage. Ensure that the new water tempera-
fluids on Cat products. ture regulator is installed in the original position. En-
sure that the water temperature regulator vent hole is
Dispose of all fluids according to local regulations open.
and mandates.
Do not use liquid gasket material on the gasket or cyl-
Refer to Operation and Maintenance Manual, inder head surface.
“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for a proper sampling of the
coolant. Refer to two articles in the Disassembly and
Assembly Manual, “Water Temperature Regulators -
Submit the sample for Level 2 analysis. Remove and Water Temperature Regulators - Install”
for the replacement procedure of the water
For additional information about coolant analysis, see temperature regulator, or consult your Caterpillar
Special Publication, SEBU7003, “Cat 3600 Series dealer.
and C280 Series Diesel Engine Fluids
Recommendations” or consult your Cat dealer. Note: If the water temperature regulators are
replaced, drain the coolant from the cooling system
i04139169 to a level that is below the water temperature
regulator housing.
Coolant Temperature
i05264140
Regulator - Replace
SMCS Code: 1355-510 Cooling System Supplemental
Replace the water temperature regulator before the Coolant Additive (SCA) - Test/
water temperature regulator fails. Replacing the
water temperature regulator is a recommended
Add
preventive maintenance practice. Replacing the SMCS Code: 1352-045; 1395-081
water temperature regulator reduces the chances for
unscheduled downtime. Refer to this Operation and
Maintenance Manual, “Maintenance Interval
Schedule” for the proper maintenance interval.
Cooling system coolant additive contains alkali.
A water temperature regulator that fails in a partially To help prevent personal injury, avoid contact
opened position can cause overheating or with the skin and eyes. Do not drink cooling sys-
overcooling of the engine. tem coolant additive.
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.
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.
SEBU9107-03 83
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
NOTICE
Add the SCA, If Necessary
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer Pressurized System: Hot coolant can cause seri-
could cause cracking of the cylinder head and other
high temperature components. ous burns. To open the cooling system filler cap,
Excessive supplemental coolant additive concentra- components are cool. Loosen the cooling system
tion could also result in blockage of the heat ex- pressure cap slowly in order to relieve the
pressure.
changer, overheating, and/or accelerated wear of the
water pump seal.
1. Remove the cooling system filler cap slowly.
Do not exceed the recommended amount of supple-
mental coolant additive concentration. 2. If necessary, drain some coolant in order to allow
space for the addition of the SCA.
NOTICE 3. Add the proper amount of SCA. For the proper
Care must be taken to ensure that fluids are con- amount of SCA, refer to this Operation and
tained during performance of inspection, mainte- Maintenance Manual, “Refill Capacities and
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain- Recommendations” topic. The proper
ers before opening any compartment or disassem- concentration of SCA depends on the type of
bling any component containing fluids. coolant that is used. For the proper concentration
of SCA, refer to Special Publication, SEBU6251,
Refer to Special Publication, NENG2500, “Cat Dealer “Cat Commercial Diesel Engine Fluids
Service Tool Catalog” and to Special Publication,
Recommendations”.
GECJ0003, “Cat Shop Supplies and Tools” for tools
and supplies suitable to collect and contain fluids on 4. Clean the cooling system filler cap. Install the
Cat products. cooling system filler cap.
Dispose of all fluids according to applicable regula-
tions and mandates. Cooling Systems that Use Water
and SCA
Note: Caterpillar recommends an S·O·S coolant
analysis (Level 1). Test the Concentration of the SCA
Test the concentration of the SCA with a 298-5311
Cooling Systems that Use Coolant Nitrite Test Kit for SCA or perform an S·O·S
Conventional Coolant Coolant Analysis. The test kit includes the following
items: a tool for the testing, 30 ampoules for testing
This maintenance procedure is required for nitrite, instructions and a case. 294-7420 Test Kit
conventional coolants such as DEAC.This contains the refill ampoules for the 298-5311
maintenance is NOT required for cooling systems Coolant Nitrite Test Kit. Use the instructions that are
that are filled with Extended Life Coolant. included with the test kit in order to properly conduct
the testing.
Test the Concentration of the SCA Refer to this Operation and Maintenance Manual,
“Maintenance Interval Schedule” for the times at
which the procedures should be conducted. Test the
NOTICE concentration of the SCA more frequently if more
Do not exceed the recommended six percent supple-
mental coolant additive concentration. frequent testing is indicated by the results of the
S·O·S Coolant Analysis.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. NOTICE
Do not exceed the recommended eight percent sup-
plemental coolant additive concentration.
84 SEBU9107-03
Maintenance Section
DEF Filler Screen - Clean
Add the SCA, If Necessary
Pressurized System: Hot coolant can cause seri-

pressure.
1. Remove the cooling system filler cap slowly.

2. If necessary, drain some coolant in order to allow
space for the addition of the SCA.
3. Add the proper amount of SCA. For the proper
amount of SCA, refer to this Operation and
Maintenance Manual, “Refill Capacities and
Recommendations” topic. For the proper
concentration of SCA, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids Illustration 72 g03618438
Recommendations”.
1. Use a screwdriver or pick to press the tabs (1).
4. Clean the cooling system filler cap. Install the
cooling system filler cap. 2. Pull the screen assembly (2) upward from both
sides and remove from the fill neck adapter
i05698174
3. Use water or compressed air to clean out the filter
screen (3). If there is any debris inside, let dry and
DEF Filler Screen - Clean remove the debris by turning the screen upside
SMCS Code: 108K-070-Z3 down and dumping debris out. If the debris cannot
be removed or the filter screen is damaged,
NOTICE replace the filler neck adapter filter screen.
Ensure that the engine is stopped before any servic-
ing or repair is performed. i05830613
DEF Manifold Filters - Replace

NOTICE
Care must be taken to ensure that fluids are con- SMCS Code: 108K-510-FI
Be prepared to collect the fluid with suitable contain- NOTICE
Ensure that the engine is stopped before any servic-
ers before opening any compartment or disassem- ing or repair is performed.
and mandates.
The filler neck adapter filter screen in the diesel

exhaust fluid tank will need to be cleaned or replaced
if contaminated.
SEBU9107-03 85
Maintenance Section
DEF Manifold Filters - Replace
NOTICE
and mandates.
Note: Refer to Special Instruction, REHS8231, 3. Remove bolts (6), plate (7), tank manifold (8), and
“Removal Procedures for Diesel Exhaust Fluid (DEF) gasket (not shown).
Connectors” for the correct removal procedure of
hose assemblies (1) and (5).
Illustration 73 g03662693 4. Unscrew the band clamp (9) and remove the band
clamp from the filter base (10).
1. Clamp off hoses (1).
2. Remove clips (2) and (3). Disconnect harness
assemblies (4). Remove hose assemblies (1) and
(5).
86 SEBU9107-03
Maintenance Section
Diesel Exhaust Fluid - Fill
7. Install new filter by pulling filter over the manifold

coils up to the bottom of the assembled filter base.
8. Tighten the band clamp 4.5 ± 0.7 N·m

(40 ± 6 lb in), ensuring that the band clamp is
aligned, as shown in illustration 78 , to the flat spot
on the base. Ensure that the filter does not bunch
when tightening the band clamp.
9. Install the tank manifold following steps 3 through
5 in reverse order with a new gasket.
10. Tighten bolts (6) in an alternating sequence to
5 ± 1 N·m (44 ± 9 lb in). Tighten bolts (6) a second
time in an alternating sequence to 5 ± 1 N·m
(44 ± 9 lb in). Apply rubber lubricant to the o-ring
seal inside of hose assemblies (1).
i05379743
5. Remove the filter (11) from the filter base. Diesel Exhaust Fluid - Fill
SMCS Code: 108K-544
NOTICE
nance, testing, adjusting, and repair of the machine.
and mandates.
Reference: See Operation and Maintenance

Manual, “Capacities (Refill)” for the capacity of the
Diesel Exhaust Fluid (DEF) tank for your engine.
6. Remove the suction filter (12) at the bottom of the
header coils by pulling tabs (13). Replace with a
new suction filter.
SEBU9107-03 87
Maintenance Section
Diesel Exhaust Fluid Filter - Replace
i05806161
Diesel Exhaust Fluid Filter -

Replace
SMCS Code: 108K-510-FI
The Diesel Exhaust Fluid (DEF) filter is located on
the DEF tank. The DEF tank is located in the tool box
on the right side of the machine.
DEF Tank Filler Cap
Typical Example
NOTICE
1. Clean blue DEF tank filler cap (1) and the Ensure that the engine is stopped before any servic-
surrounding area. ing or repair is performed.
2. Remove the blue DEF tank filler cap.
3. Fill the tank with diesel exhaust fluid (DEF). NOTICE
Note: Do not fill the DEF tank from a tained during performance of inspection, mainte-
contaminated container or funnel.
Note: Do not over fill the tank. DEF can freeze and ers before opening any compartment or disassem-
needs room for expansion.
4. Install the blue DEF tank filler cap. Service Tool Catalog” or refer to Special Publication,
Refer to Operation and Maintenance Manual, PECJ0003, “Cat Shop Supplies and Tools Catalog”
“Lubricant Viscosities” for more information on diesel for tools and supplies suitable to collect and contain
exhaust fluid (DEF) guidelines. fluids on Cat products.
and mandates.
1. Remove the diesel exhaust fluid (DEF) filter cap

(3) with a 27 mm (1.06 inch) wrench.
2. Remove the rubber cone insert (2) from the DEF
filter (1).
88 SEBU9107-03
Maintenance Section
Diesel Particulate Filter - Clean
Note: In order to maintain emissions documentation,

the DPF that is removed from the engine when the
DPF is cleaned must be reinstalled on the same
engine.
Note: A specific ash service regeneration must be
performed before removing a DPF that will be
cleaned. All three scenarios listed above require a
reset of the ash monitoring system in the engine
ECM.
i00174798
Driven Equipment - Check

SMCS Code: 3279-535
Refer to the OEM specifications for more information
on the following maintenance recommendations for
the driven equipment:
• Inspection
Illustration 82 g03332637 • Adjustment
Typical Example
• Lubrication
3. Insert the DEF filter removal tool (4) into the DEF • Other maintenance recommendations
filter (1) and remove the DEF filter (1).
Perform any maintenance for the driven equipment
Note: Wear gloves when you handle the DEF filter which is recommended by the OEM.
removal tool (4).
i06103535
4. Clean the area around the filter housing.
5. Apply a thin coat of 207-1601 Lubricant to the Engine - Clean
seals of the new DEF filter (1). SMCS Code: 1000-070
6. Install new DEF filter (1) and rubber cone insert.
Torque the filter to 20 ± 5 N·m (14.8 ± 3.7 lb ft)
with a 27 mm (1.06 inch) wrench.
Personal injury or death can result from high
voltage.
i05400525
Moisture can create paths of electrical
Diesel Particulate Filter - Clean conductivity.
SMCS Code: 108F-070 Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “ DO
Consult your Cat dealer when the DPF needs to be NOT OPERATE”” .
cleaned.
The approved Caterpillar DPF maintenance
procedure requires that one of the following actions NOTICE
be taken when the DPF needs to be cleaned: Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and
• The DPF from your engine can be replaced with a fluid spills whenever a significant quantity accumu-
new DPF lates on the engine.
• The DPF from your engine can be replaced with a Periodic cleaning of the engine is recommended.
remanufactured DPF Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
• The DPF from your engine can be cleaned by your benefits:
local authorized Cat dealer, or a Caterpillar
approved DPF cleaning machine, and reinstalled • Easy detection of fluid leaks
• Maximum heat transfer characteristics

SEBU9107-03 89
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
• Ease of maintenance • Check for ease of resetting. The service indicator

should reset in less than three pushes.
Note: Caution must be used in order to prevent
electrical components from being damaged by • Check the movement of the service indicator core
excessive water when you clean the engine. Avoid when the engine is run at full load speed. The core
electrical components such as the alternator, the should latch approximately at the greatest vacuum
starter, and the ECM. that is attained.
If the service indicator does not reset easily, or if the
i06103548
core does not latch at the greatest vacuum, the
service indicator should be replaced. If the new
Engine Air Cleaner Service service indicator will not reset, the hole for the service
indicator may be plugged.
Indicator - Inspect
(If Equipped) If necessary, replace the service indicator more
frequently in environments that are severely dusty.
SMCS Code: 7452-040 Replace the service indicator annually regardless of
the operating conditions. Replace the service
Some engines may be equipped with a different indicator when the engine is overhauled, and
service indicator. whenever major engine components are replaced.
Some engines are equipped with a differential gauge Note: When a new service indicator is installed,
for inlet air pressure. The differential gauge for inlet excessive force may crack the top of the service
air pressure displays the difference in the pressure indicator. Tighten the service indicator to a torque of
that is measured before and after the air cleaner
element. As the air cleaner element becomes dirty, 2 N·m (18 lb in).
the pressure differential rises. If your engine is
equipped with a different type of service indicator, i02436689
follow the OEM recommendations in order to service
the air cleaner service indicator. Engine Mounts - Inspect
The service indicator may be mounted on the clean SMCS Code: 1152-040; 1152
side of the air cleaner housing or in a remote
location. 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

• Loose mounting bolts
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.
i04369322
Illustration 83 g00103777 Engine Oil Level - Check

Typical service indicator
SMCS Code: 1348-535-FLV
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: Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
• The yellow diaphragm enters the red zone. contact the skin.
• The red piston locks in the visible position.
Test the Service Indicator

Service indicators are important instruments.
90 SEBU9107-03
Maintenance Section
Engine Oil Sample - Obtain
2. Remove the oil filler cap and add oil, if necessary.

For information about choosing the correct oil for
the engine, refer to one of the following articles:
Operation and Maintenance Manual, “Refill
Capacities and Recommendations” or Operation
and Maintenance Manual, “Fluid
Recommendations”. Do not fill the crankcase
above “FULL” mark (X) on the oil level gauge.
Clean the oil filler cap. Install the oil filler cap.
(Y) “ADD” mark
(X) “FULL” mark 3. Record the amount of oil that is added. For the
next oil sample and analysis, include the total
NOTICE amount of oil that has been added since the
Perform this maintenance with the engine stopped. previous sample. This information will help to
provide the most accurate oil analysis.
NOTICE i04237495
nance, testing, adjusting, and repair of the product. Engine Oil Sample - Obtain
Be prepared to collect the fluid with suitable contain- SMCS Code: 1348-554-SM
bling any component containing fluids. In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
Refer to Special Publication, NENG2500, “Cat Dealer analysis at regularly scheduled intervals. S·O·S oil
Service Tool Catalog” or refer to Special Publication, analysis provides infrared analysis, which is required
PECJ0003, “Cat Shop Supplies and Tools Catalog” for determining nitration and oxidation levels.
Obtain the Sample and the
Dispose of all fluids according to local regulations Analysis
and mandates.
1. Maintain the oil level between “ADD” mark (Y) and

“FULL” mark (X) on the oil level gauge. Do not fill Hot oil and hot components can cause personal
the crankcase above “FULL” mark (X). injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
Engine damage can occur if the crankcase is filled Before you take the oil sample, complete the Label,
above the “FULL” mark on the oil level gauge PEEP5031 for identification of the sample. In order to
(dipstick). help obtain the most accurate analysis, provide the
following information:
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel- • Engine model
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re- • Service hours on the engine
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the • The number of hours that have accumulated since
crankcase breathers and excessive oil consumption. the last oil change
Excessive oil consumption will cause deposits to form • The amount of oil that has been added since the
on the pistons and in the combustion chamber. De- last oil change
posits in the combustion chamber lead to the follow-
ing problems: guttering of the valves, packing of To ensure that the sample is representative of the oil
carbon under the piston rings and wear of the cylin- in the crankcase, obtain a warm, mixed oil sample.
der liner.
To avoid contamination of the oil samples, the tools
If the oil level is above the “FULL” mark on the oil lev- and the supplies that are used for obtaining oil
el gauge, drain some of the oil immediately. samples must be clean.
SEBU9107-03 91
Maintenance Section
Engine Oil and Filter - Change
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.
NOTICE
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
cerns 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.
i04024367

SMCS Code: 1318-510
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
Selection of Oil Change Interval

“Refill Capacities and Recommendations” for further
information about oils that may be used in Caterpillar
engines.
“Severe Service Application - Check” to determine if
oil change interval should be reduced from the
normal change interval. If operating in any of the
conditions or environments outlined in the Severe
Service Application, use S·O·S Services oil analysis
to determine the best oil change interval. If S·O·S
Services oil analysis S is not being used, oil change
interval should be reduced to 250 hrs.
92 SEBU9107-03
Maintenance Section
Table 12
Oil Change Interval for C9.3 Industrial Engine (1)
Multigrade Oil Type Operating Conditions
Normal Severe Service Application
Cat DEO 500 hr 250 hr

or Cat DEO-ULS
Preferred
Oil meeting the requirements of the Cat ECF-3 500 hr 250 hr
Specification or the API CJ-4 classification
8 minimum TBN
Preferred
Oil meeting the requirements of the ACEA C9/ 500 hr 250 hr
E6 Specification
TBN below 10.4
(1) The standard oil change interval in this engine is 500 hours, if the operating conditions and recommended oil types that are listed in this table
are met. If the type of oil, the quality of the oil and the operating conditions fail to meet certain standards, the oil change intervals must be de-
creased to 250 hours. Refer to Special Publication, PEHJ0192, “Optimizing Oil Change Intervals” in order to determine whether the oil
change interval should be reduced to 250 hours.
Drain the Engine Oil 2. After the oil has drained, the oil drain plug should
be cleaned and installed.
After the engine has been run at the normal
operating temperature, stop the engine. Attach a “DO Replace the Oil Filter
NOT OPERATE” or a similar warning tag to the
ignition keyswitch before the engine is serviced.
NOTICE
NOTICE Caterpillar oil filters are built to Caterpillar specifica-
Care must be taken to ensure that fluids are con- tions. Use of an oil filter not recommended by Cater-
tained during performance of inspection, mainte- pillar could result in severe engine damage to the
nance, testing, adjusting, and repair of the product. engine bearings, crankshaft, etc., as a result of the
Be prepared to collect the fluid with suitable contain- larger waste particles from unfiltered oil entering the
ers before opening any compartment or disassem- engine lubricating system. Only use oil filters recom-
bling any component containing fluids. mended by Caterpillar.
and mandates.
1. Remove the oil drain plug in order to allow the oil

to drain.
Typical filter mounting base and filter gasket
1. Remove the oil filter with a 185-3630 Strap

Wrench.
2. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket is
removed.
SEBU9107-03 93
Maintenance Section
Engine Storage Procedure - Check
3. Apply clean engine oil to the new oil filter gasket. 4. Remove the oil level gauge in order to check the oil
level. Maintain the oil level between the “ADD” and
NOTICE “FULL” marks on the “ENGINE STOPPED” side of
Do not fill the oil filters with oil before installing them. the oil level gauge.
This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear
to engine components. i02703023
4. Install the oil filter. Tighten the oil filter until the oil
Engine Storage Procedure -
filter gasket contacts the base. Tighten the oil filter Check
by hand according to the instructions that are SMCS Code: 1000-535
shown on the oil filter. Do not overtighten the oil
filter. Caterpillar recommends storage procedures and
start-up procedures for all engines that are stored for
more than 1 month. These procedures provide
Fill the Engine Crankcase maximum protection to internal engine components.
Refer to Special Instruction, SEHS9031, “Storage
1. Remove the oil filler cap. Fill the crankcase with Procedure For Caterpillar Products” for information
the proper amount of oil. Refer to the Operation on these procedures.
and Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section) An extension of the oil change interval to 12 months
is permitted if you follow the required procedures for
for more information. storage and start-up. This extension is permitted if
the following intervals in the Operation and
NOTICE Maintenance Manual, “Maintenance Interval
If equipped with an auxiliary oil filter or system, extra Schedule” have not been reached:
oil must be added when filling the crankcase. Follow
the OEM or filter manufacturer's recommendations. If • Operating hours
the extra oil is not added, the engine may starve for
oil. • Fuel consumption
i03964791
NOTICE
To help prevent crankshaft or bearing damage, crank
engine to fill all filters before starting. Do not crank Engine Valve Lash - Check
engine for more than 30 seconds. SMCS Code: 1105-535
Note: Procedures for adjusting the valve lash can be

2. Start the engine and run the engine at “LOW IDLE”
found in Systems Operation/Testing and Adjusting,
for 2 minutes. Perform this procedure in order to “Valve Lash Adjustment”. Consult your Cat dealer for
ensure that the lubrication system has oil and that assistance.
the oil filters are filled. Inspect the oil filter for oil
leaks.
3. Stop the engine and allow the oil to drain back to
the sump for a minimum of 10 minutes. Ensure that the engine cannot be started while
this maintenance is being performed. To help pre-
vent 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.
94 SEBU9107-03
Maintenance Section
Fuel System - Prime
i04036726 3. Attempt to start the engine. If engine starts and

runs rough or misfires, operate at low idle until the
Fuel System - Prime engine is running smoothly. If the engine cannot
SMCS Code: 1250-548; 1258-548 be started, continue to prime the fuel system for 30
more seconds.
NOTICE i04370506
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- Fuel System Primary Filter/
nected fuel system component.
Water Separator - Drain
SMCS Code: 1260-543; 1263-543
Key-on Priming (if equipped)
1. Turn the engine start switch to the ON position.
Leave the engine start switch in the ON position Fuel leaked or spilled onto hot surfaces or electri-
for 2 minutes. cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
2. Verify that the water separator is full of fuel. changing fuel filters or water separator elements.
Clean up fuel spills immediately.
3. If the water separator is not full of fuel, turn the
engine start switch OFF and then turn the engine
start switch ON. Turning the switch OFF, then ON
will cycle the fuel priming pump again.
4. When the water separator is full of fuel, attempt to
start the engine. If the engine starts and the
engine runs rough or the engine misfires, operate
at low idle until the engine is running smoothly. If
the engine cannot be started, or if the engine
continues to misfire or smoke, repeat Step 1.
Manual Switch Priming (if

equipped)
The manual switch is located on the primary filter Illustration 86 g01453091
base/electric priming pump assembly. Typical primary fuel filter/water separator
1. Hold the manual switch in the up position until fuel (1) Primary fuel filter element
has filled the water separator. (2) Collection bowl for the water separator
(3) Drain for the water separator
2. Continue to hold the switch for 30 seconds after
the water separator is full. The bowl should be monitored daily for signs of
water. If water is present, drain the water from the
bowl.
SEBU9107-03 95
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
NOTICE NOTICE
Care must be taken to ensure that fluids are con- Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain- Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- ers before opening any compartment or disassem-
bling any component containing fluids. bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer Refer to Special Publication, NENG2500, “Caterpillar
Service Tool Catalog” or refer to Special Publication, Dealer Service Tool Catalog” guide for tools and sup-
PECJ0003, “Cat Shop Supplies and Tools Catalog” plies suitable to collect and contain fluids on Caterpil-
for tools and supplies suitable to collect and contain lar products.
Dispose of all fluids according to local regulations and mandates.
and mandates.
1. Turn the start switch to the OFF position or
1. Open the drain. The drain is a self-ventilated drain. disconnect the battery (starting motor) when
Catch the draining water in a suitable container. maintenance is performed on a fuel filter.
Dispose of the water properly.
2. Shut off the fuel supply.
2. Close the drain.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the
fuel system.
i02349031
Fuel System Primary Filter

(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ Illustration 87 g00104012
(1) filter body
(2) bowl
(3) drain valve
Personal injury or death may result from failure
to adhere to the following procedures. Note: Refer to this Operation and Maintenance
Manual, “General Hazard Information” that pertains
Fuel leaked or spilled onto hot surfaces or electri- to containing fluid spillage.
cal components can cause a fire.
3. Turn drain valve (3) counterclockwise in order to
Clean up all leaked or spilled fuel. Do not smoke open. The drain valve is located on the bottom of
while working on the fuel system.
the water separator.
Turn the disconnect switch OFF or disconnect 4. Drain the water and sediment into a suitable
the battery when changing fuel filters.
container. Dispose of the drained fluids and used
filters according to local regulations.
NOTICE 5. Close the drain valve.
Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be 6. Hold the bottom of the filter while you loosen the
contaminated. Contaminated fuel will cause acceler- bowl. Remove the bowl.
ated wear to fuel system parts.
7. Turn the filter counterclockwise in order to loosen
the filter. If the filter will not turn, use a strap
wrench to loosen the filter.
96 SEBU9107-03
Maintenance Section
Fuel System Secondary Filter - Replace
8. Remove the filter and discard the filter. Clean the

bottom of the filter mounting base. Make sure that
all of the old filter seal is removed from the bottom
groove of the opening in the base.
9. Clean the water separator bowl and clean the
groove for the seal. Inspect the seal. If the seal is
worn or damaged, replace the seal.
10. Lubricate the seal with clean diesel fuel or
lubricate the seal with clean motor oil. Place the
seal in the groove on the water separator bowl.
11. Install the water separator bowl onto the new fuel
filter by hand. Tighten the bowl assembly to 15
15 N·m (11 lb ft). Illustration 88 g02145531
12. Apply clean diesel fuel to the seal of the new (1) Fuel supply connections
(2) Fuel filters
filter.
13. Install the new filter onto the base. Tighten the NOTICE
filter by hand until the seal contacts the filter base. Do not allow dirt to enter the fuel system. Thoroughly
Additionally tighten the filter by 1/3 to 1/2 rotation. clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
14. Open the fuel shutoff valve. disconnected fuel system components.
15. Reconnect the battery, if necessary.
16. Purge the air from the fuel system. See this NOTICE
Operation and Maintenance Manual, “Fuel System Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
- Prime” for further instructions.
17. Stop the engine and check for leaks.
1. It may be necessary to relieve residual fuel
Note: The secondary fuel filter should also be pressure from the fuel system before removing the
replaced at this time. See this Operation and fuel filter.
Maintenance Manual, “Fuel System Secondary Filter
Loosen one of the fuel supply connections (1) in
- Replace” for further information.
order to purge any residual pressure.
i04036723
NOTICE
Do not loosen fuel lines or fittings at the fuel manifold
Fuel System Secondary Filter - or ECM. The engine components may be damaged.
Replace
SMCS Code: 1261-510-SE 2. Remove the used fuel filter.
3. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.
Fuel leaked or spilled onto hot surfaces or electri- 4. Apply clean diesel fuel to the new fuel filter gasket.
cal components can cause a fire. To help prevent
possible injury, turn the start switch off when NOTICE
changing fuel filters or water separator elements. Do not fill the secondary fuel filter with fuel before in-
Clean up fuel spills immediately. stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
5. 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 for an
additional 3/4 turn by hand. Do not overtighten the
filter.
SEBU9107-03 97
Maintenance Section
Fuel Tank Water and Sediment - Drain
i06104305 Fill the fuel tank after operating the engine in order to
drive out moist air. This procedure will help prevent
Fuel Tank Water and Sediment condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
- Drain overflow.
SMCS Code: 1273-543-M&S 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
NOTICE directly from the bottom of the tank. If the engine is
tained during performance of inspection, mainte- equipped with this system, regular maintenance of
nance, testing, adjusting, and repair of the product. the fuel system filter is important.
ers before opening any compartment or disassem- Fuel Storage Tanks
Drain the water and the sediment from the fuel
Refer to Special Publication, NENG2500, “Cat Dealer storage tank during the following conditions:
PECJ0003, “Cat Shop Supplies and Tools Catalog” • Weekly
fluids on Cat products. • Refill of the tank
Dispose of all fluids according to local regulations This procedure will help prevent water or sediment
and mandates. 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.
Fuel Tank
If a bulk storage tank has been refilled or moved
Fuel quality is critical to the performance and to the recently, allow adequate time for the sediment to
service life of the engine. Water in the fuel can cause settle before filling the engine fuel tank. Internal
excessive wear to the fuel system. Condensation baffles in the bulk storage tank will also help trap
occurs during the heating and cooling of fuel. The sediment. Filtering fuel that is pumped from the
condensation occurs as the fuel passes through the storage tank helps to ensure the quality of the fuel.
fuel system and the fuel returns to the fuel tank. This When possible, water separators should be used.
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
i05226716
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 Fumes Disposal Filter Element
not damaged.
- Replace
Drain the Water and the Sediment SMCS Code: 1074
Fuel tanks should contain some provision for draining The filter for the open crankcase ventilation system
water and draining sediment from the bottom of the (OCV) may be located toward the front or toward the
fuel tanks. rear of the left side of the engine. A filter that has
been used may contain a small amount of engine oil.
Prepare to catch water and sediment in an
appropriate container. Connect a hose (if necessary) NOTICE
to the valve prior to opening the valve. Care must be taken to ensure that fluids are con-
Open the drain valve on the bottom of the fuel tank in nance, testing, adjusting and repair of the machine.
order to drain the water and the sediment. Close the Be prepared to collect the fluid with suitable contain-
drain valve. ers before opening any compartment or disassem-
Note: Failure to close the drain properly could result
in fuel leakage, which could have detrimental results Refer to Special Publication, NENG2500, “Caterpillar
to performance. Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpil-
Check the fuel daily. Drain the water and sediment lar machines.
from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the Dispose of all fluids according to local regulations
fuel tank has been filled. Allow 5 to 10 minutes before and mandates.
performing this procedure.
98 SEBU9107-03
Maintenance Section
Grounding Stud - Inspect/Clean/Tighten
i03965989
NOTICE
Failure to perform this maintenance procedure at less
than 1500 service hours will not void the emissions- Grounding Stud - Inspect/
related warranty.
Clean/Tighten
SMCS Code: 7423-070; 7423-079; 7423-040
The grounding stud is located on the upper left corner
of the engine control module.
Inspect the OEM harness for good connections.

Illustration 89 g02021434 Inspect the condition of the OEM harness.
(1) Cap
(2) Housing for the filter element
The grounding stud must have a wire ground to the
(3) Filter element battery. Tighten the grounding stud at every oil
(4) Cup change. Ground wires and straps should be
combined at engine grounds. All grounds should be
Remove either the cap or the cup from the housing tight and free of corrosion.
for the OCV filter. Remove the OCV filter. The filter
may not be used again. Dispose of the filter. Place a • Clean the grounding stud and the terminals for the
new OCV filter inside the filter housing. If the cap was ground strap with a clean cloth.
removed, replace the cap. If the cup was removed,
replace the cup. Tighten hand tight. • If the connections are corroded, clean the
connections with a solution of baking soda and
Note: Caterpillar will not be held liable for an engine water.
that does not comply with EPA emissions standards
due to modification of the OCV filter or due to the use • Keep the grounding stud and the strap clean and
of a filter that is not approved by Caterpillar. coated with MPGM grease or petroleum jelly.
i06104329
Hoses and Clamps - Inspect/

Replace
SMCS Code: 7554-510; 7554-040
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.
SEBU9107-03 99
Maintenance Section
Hoses and Clamps - Inspect/Replace
Note: Always use a board or cardboard when the Replace hoses that are cracked or soft. Replace
engine components are checked for leaks. Leaking hoses that show signs of leakage. Replace hoses
fluid that is under pressure can cause serious injury that show signs of damage. Replace hose clamps
or possible death. Leaks that are the size of a pin that are cracked or damaged. Tighten or replace
hole are included. Refer to Operation and hose clamps which are loose.
Maintenance Manual, “General Hazard Information”
for more information. Replace the Hoses and the Clamps
Note: Ensure that the hose is compatible with the
application. NOTICE
Inspect the Hoses and the Clamps nance, testing, adjusting, and repair of the product.
Inspect all hoses for leaks that are caused by the ers before opening any compartment or disassem-
following conditions. Replace any hose which bling any component containing fluids.
exhibits any of the following conditions. Failure to
replace a hose which exhibits any of the following Refer to Special Publication, NENG2500, “Cat Dealer
conditions may result in a hazardous situation. Service Tool Catalog” or refer to Special Publication,
• Hoses which are cracked for tools and supplies suitable to collect and contain
• Hoses which are soft
• Outer covering that is chafed or cut and mandates.
• Exposed wire that is used for reinforcement

Cooling System
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering Pressurized System: Hot coolant can cause seri-
• Hoses which exhibit signs of leakage which are stop the engine and wait until the cooling system
not the result of loose couplings or clamps components are cool. Loosen the cooling system
Inspect all clamps for the following conditions. pressure.
Replace any clamp which exhibits signs of any of the
following conditions.
• Cracking
• Looseness Personal injury can result from removing hoses
or fittings in a pressure system.
• Damage
Failure to relieve pressure can cause personal
Inspect all couplings for leaks. Replace any coupling injury.
which exhibits signs of leaks.
Do not disconnect or remove hoses or fittings un-
Each installation application can be different. The til all pressure in the system has been relieved.
differences depend on the following factors:
• Type of hose 1. Stop the engine.
2. Allow the engine to cool.
• Type of fitting material
3. Before servicing a coolant hose, slowly loosen the
• Anticipated expansion and contraction of the hose filler cap for the cooling system in order to relieve
• Anticipated expansion and contraction of the any pressure.
fittings 4. Remove the filler cap for the cooling system.
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.
100 SEBU9107-03
Maintenance Section
Hoses and Clamps - Inspect/Replace
5. Drain the coolant from the cooling system to a

NOTICE
level that is below the hose that is being replaced. Do not allow dirt to enter the fuel system. Thoroughly
Drain the coolant into a suitable clean container. clean the area around a fuel system component that
The coolant can be reused. will be disconnected. Fit a suitable cover over any
disconnected fuel system components.
6. Remove the hose clamps.
7. Disconnect the old hose.
Note: High-pressure fuel lines may be installed
8. Replace the old hose with a new hose. between the high-pressure fuel pump and the fuel
injectors. High-pressure fuel lines are constantly
9. Install hose clamps which have been inspected or charged with high pressure. Do not check the high-
install new hose clamps. Refer to Specifications, pressure fuel lines with the engine or the starting
SENR3130, “Torque Specifications” “Hose motor in operation. Wait for 10 minutes after the
Clamps” for information about selecting and engine stops before you perform any service or
installing the proper hose clamps. repair on high-pressure fuel lines. Waiting for 10
minutes will to allow the pressure to be purged.
10. Refill the cooling system.
1. Drain the fuel from the fuel system to a level that is
11. Clean the coolant filler cap. Inspect the gaskets
below the hose that is being replaced.
on the filler cap. Inspect the gasket seat. Inspect
the vacuum valve and seat for debris or damage. 2. Remove the hose clamps.
Replace the filler cap if the gaskets are damaged.
Install the filler cap.
12. Start the engine. Inspect the cooling system for Note: When servicing fuel system, use cap/s or
leaks. cover/s as required to protect the system and
maintain fuel system cleanliness.
Fuel System 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,
Personal injury can result from removing hoses SENR3130, “Torque Specifications” “Hose
or fittings in a pressure system. Clamps” for information about selecting and
installing the proper hose clamps.
Failure to relieve pressure can cause personal
injury. 6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
Do not disconnect or remove hoses or fittings un- engine.
til all pressure in the system has been relieved.
Note: Fuel must be added to the fuel system ahead
of the fuel filter.
7. Refill the fuel system. Refer to this Operation and

Contact with high pressure fuel may cause fluid Maintenance Manual, “Fuel System - Prime” for
penetration and burn hazards. High pressure fuel information about priming the engine with fuel.
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in- 8. Start the engine. Inspect the fuel system for leaks.
structions may cause personal injury or death.
Lubrication System
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 Hot oil and hot components can cause personal
hoses. Leaks can cause fires. Inspect all lines, tubes injury. Do not allow hot oil or hot components to
and hoses carefully. Tighten all connections to the contact the skin.
recommended torque.
1. Drain the oil from the lubrication system to a level
that is below the hose that is being replaced.
SEBU9107-03 101
Maintenance Section
Injector (Diesel Exhaust Fluid) - Replace
3. Disconnect the old hose. 5. Start the engine. Inspect the air lines for leaks.
4. Replace the old hose with a new hose.
i05389715
install new hose clamps. Refer to Specifications, Injector (Diesel Exhaust Fluid)
SENR3130, “Torque Specifications” “Hose
Clamps” for information about selecting and
- Replace
installing the proper hose clamps. SMCS Code: 108I-510
6. Refill the lubrication system. Refer to this

Operation and Maintenance Manual, “Engine Oil
Level - Check” in order 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
3. Replace the old hose with a new hose.
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 Typical example shown
the exhaust bellows should never be reused.
1. Remove the diesel exhaust fluid (DEF) line (1)
from the injector (4).
2. Remove the coolant lines (2) from the injector.
3. Remove the electrical connector (3) from the
injector.
4. Remove the bolts from the injector and remove the
injector.
5. Replace gasket. The steel side of the gasket
should face towards diesel particulate filter (DPF)
outlet.
6. Replace the injector.
7. Apply anti-seize to bolt threads.
8. Torque the bolts of the injector to 5 N·m (3.7 lb ft).
Retighten all bolts to 5 N·m (3.7 lb ft), then turn
90°.
9. Connect the electrical connector.
10. Connect the coolant lines.
11. Connect the DEF line.
102 SEBU9107-03
Maintenance Section
Overhaul Considerations
i04631403 Overhaul Options

Overhaul Considerations Before Failure Overhaul
SMCS Code: 7595-043 A planned overhaul before failure may be the best
value for the following reasons:
Reduced hours of operation at full load will result in a
lower average power demand and reduced fuel • Costly unplanned downtime can be avoided.
consumption. A decreased average power demand
should increase both the engine service life and the • Many original parts can be reused according to the
overhaul interval. standards for reusable parts.
The need for an overhaul is indicated by increased
• The service life of the engine can be extended
fuel consumption, increased oil consumption,
excessive engine blowby, and reduced power. Arctic without the risk of a major catastrophe due to
temperatures, extreme high temperatures, corrosive engine failure.
environments, or extreme dusty conditions contribute
to premature wear and the need for an overhaul. • The best cost/value relationship per hour of
extended life can be attained.
The following factors are important when a decision
is being made on the proper time for an engine After Failure Overhaul
overhaul:
If a major engine failure occurs and the engine must
• The need for preventive maintenance be removed, many options are available. An overhaul
should be performed if the engine block or the
• The quality of the fuel that is being used crankshaft needs to be repaired.
• The operating conditions If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
• The results of the S·O·S analysis percent and 50 percent of the cost of a new engine
with a similar exchange core.
Note: The aftertreatment system can be expected to
function properly for the useful life of the engine This lower cost can be attributed to three aspects:
(emissions durability period), as defined by
• Specially designed Cat engine features
regulation, subject to prescribed maintenance
requirements being followed. • Cat dealer exchange components
Oil Consumption as an Overhaul • Caterpillar remanufactured exchange components

Indicator
Overhaul Recommendation
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total To minimize downtime, Caterpillar recommends a
operating cost for your Cat engine. Oil consumption scheduled engine overhaul by your Cat dealer before
can also be used to estimate the required capacity of the engine fails. A scheduled engine overhaul will
a makeup oil tank that is suitable for the maintenance provide you with the best cost/value relationship.
intervals.
Note: Overhaul programs vary according to the
Oil consumption is in proportion to the percentage of engine application and according to the dealer that
the rated engine load. As the percentage of the performs the overhaul. Consult your Cat dealer for
engine load is increased, the amount of oil that is specific information about the available overhaul
consumed per hour also increases. programs and about overhaul services for extending
the engine life.
The oil consumption rate (brake-specific oil
consumption) is measured in grams per kW/h (lb per If an overhaul is performed without overhaul service
bhp). The brake-specific oil consumption (BSOC) from your Cat dealer, be aware of the following
depends on the engine load. Consult your Cat dealer maintenance recommendations.
for assistance in determining the typical oil
consumption rate for your engine.
When the oil consumption of an engine 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.
SEBU9107-03 103
Maintenance Section
Overhaul Considerations
Rebuild or Exchange Inspect the crankshaft for any of the following

conditions:
Cylinder Head Assembly, Cylinder Packs, Oil
Pump, and Fuel Transfer Pump • Deflection
These components should be inspected according to • Damage to the journals

the instructions that are found in various Cat
reusability publications. The Special Publication, • Bearing material that has seized to the journals
SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts. Check the journal taper and the profile of the
crankshaft journals. Check these components by
If the parts comply with the established inspection interpreting the wear patterns on the following
specifications that are expressed in the reusable components:
parts guideline, the parts should be reused.
• Rod bearing
Parts that are not within the established inspection
specifications should be dealt with in one of the • Main bearings
following manners:
Inspect the camshaft for damage to the journals and
• Salvaging to the lobes.
• Repairing Note: If the camshaft is removed for any reason, use

the magnetic particle inspection process to check for
• Replacing cracks in the camshaft.
Using out-of-spec parts can result in the following Inspect the following components for signs of wear or
problems: for signs of scuffing:
• Unscheduled downtime • Camshaft bearings
• Costly repairs • Camshaft followers

Caterpillar recommends replacing the crankshaft
• Damage to other engine parts
vibration damper.
• Reduced engine efficiency
Oil Cooler Core
• Increased fuel consumption
During an overhaul, Caterpillar recommends the
Reduced engine efficiency and increased fuel removal of the oil cooler core. Clean the oil cooler
consumption translates into higher operating costs. core. Then, pressure test the oil cooler core.
Therefore, Caterpillar recommends repairing out-of-
spec parts or replacing out-of-spec parts. NOTICE
Do not use caustic cleaners to clean the core.
Inspection and/or Replacement Caustic cleaners can attack the internal metals of the
core and cause leakage.
Crankshaft Bearings, Valve Rotators, and
Crankshaft Seals
Note: Use this cleaning procedure to clean the oil
The following components may not last until the cooler core.
second overhaul.
1. Remove the oil cooler core.
• Thrust bearings
2. Remove any debris from the oil cooler core. To
• Main bearings remove debris from the oil cooler core, turn the oil
cooler core onto one end.
• Rod bearings
3. Flush the oil cooler core internally with cleaner in
• Crankshaft seals order to loosen foreign substances. Flushing the
Caterpillar recommends the installation of new parts oil cooler will also help to remove oil from the oil
at each overhaul period. cooler core.
Inspect these parts while the engine is disassembled Note: Caterpillar recommends the use of Hydrosolv
for an overhaul. Liquid Cleaners. Table 13 lists the Hydrosolv Liquid
Cleaners that are available from your Cat dealer.
104 SEBU9107-03
Maintenance Section
Power Take-Off Clutch - Check
Table 13
HydrosolvLiquid Cleaners Caterpillar recommends an S·O·S Coolant Analysis
Part Number Description Size
(Level 2).
1U-5490 Hydrosolv4165 19 L (5 US gallon) S·O·S Coolant Analysis (Level 2)

174-6854 Hydrosolv100 19 L (5 US gallon) An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
4. Use steam to clean the oil cooler core. Steam- system. An S·O·S Coolant Analysis (Level 2)
cleaning the oil cooler core removes any provides the following information:
remaining residue from the cleaner. Flush the fins
of the oil cooler core. Remove any other trapped • Complete S·O·S Coolant Analysis (Level 1)
debris.
• Visual inspection of properties
5. Wash the oil cooler core with hot, soapy water.
Rinse the oil cooler core thoroughly with clean • Identification of metal corrosion
water. • Identification of contaminants
• Identification of built up impurities (corrosion and
scale)
Personal injury can result from air pressure.
S·O·S Coolant Analysis (Level 2) provides a report of
Personal injury can result without following prop- the results of both the analysis and the maintenance
er procedure. When using pressure air, wear a recommendations.
protective face shield and protective clothing.
For more information about coolant analysis, see
Maximum air pressure at the nozzle must be less your Cat dealer.
than 205 kPa (30 psi) for cleaning purposes.
i03901481
6. Dry the oil cooler core with compressed air. Direct
the air in the reverse direction of the normal flow. Power Take-Off Clutch - Check
7. Inspect the components in order to ensure SMCS Code: 3055-535
cleanliness. The oil cooler core should be
pressure tested. Repair the oil cooler core, if NOTICE
necessary. Install the oil cooler core. New power take-offs should have the clutch adjust-
ment checked before being placed into service. The
For more information about cleaning the cores, clutch adjustment should be checked again after the
consult your Cat dealer. first ten hours of operation. New clutch plates have a
“wear in” period, and the clutch may require several
Obtain Coolant Analysis adjustments until the new plates are “worn in”.
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.
For example, considerable deposits are found in the
water jacket areas on the external cooling system,
but the concentrations of coolant additives were
carefully maintained. The coolant water probably
contained minerals that were deposited on the
engine over time.
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 Illustration 92 g00781502
available for water analysis. (1) Instruction plate
(2) Serial number plate
SEBU9107-03 105
Maintenance Section
Radiator - Clean
Check the clutch adjustment regularly after “wear in”. Use a degreaser and steam for removal of oil and
Heavy-duty applications which have engagements grease. Clean both sides of the core. Wash the core
that are frequent and relatively long periods of clutch with detergent and hot water. Thoroughly rinse the
slippage require more frequent adjustment than light- core with clean water.
duty applications. The operating torque should be
measured in order to determine if a clutch adjustment After cleaning, start the engine. This will help in the
is required. removal of debris and drying of the core. Stop the
engine. Use a light bulb behind the core in order to
Refer to the OEM information and instruction plate inspect the core for cleanliness. Repeat the cleaning,
(1) for instructions on lubrication, adjustment, and if necessary.
other recommendations for service. Perform the
maintenance that is specified on the instruction plate. 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.
Do not operate the engine with the Instruction For more detailed information on cleaning and
Plate cover removed from the clutch. Personal in- inspection, refer to Special Publication, SEBD0518,
jury may result. “Know Your Cooling System”.
If the clutch is damaged to the point of burst fail-
ure, expelled pieces can cause personal injury to i02740889
anyone in the immediate area. Proper safeguards
must be followed to help prevent accidents. Starting Motor - Inspect
(If Equipped)
i02372787 SMCS Code: 1451-040; 1453-040
Radiator - Clean Note: The OEM may be responsible for the starting
motor for this engine application. Air starting motors
SMCS Code: 1353-070 are recommended if an explosive atmosphere may
be present. If the starting motor is supplied by an
Note: Adjust the frequency of cleaning according to OEM, refer to the Service Manual for the starter in
the effects of the operating environment. order to locate additional information on the checking
Inspect the radiator for these items: damaged fins, procedure and for specifications.
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary.
The connection of battery cables to a battery and

the disconnection of battery cables from a battery
Personal injury can result from air pressure. may cause an explosion which may result in in-
jury or death. The connection and the disconnec-
Personal injury can result without following prop- tion of other electrical equipment may also cause
er procedure. When using pressure air, wear a an explosion which may result in injury or death.
protective face shield and protective clothing. The procedures for the connection and the dis-
connection of battery cables and other electrical
Maximum air pressure at the nozzle must be less equipment should only be performed in a nonex-
than 205 kPa (30 psi) for cleaning purposes. plosive atmosphere.
If the starting motor fails, the engine may not start in
Pressurized air is the preferred method for removing an emergency situation. A scheduled inspection of
loose debris. Direct the air in the opposite direction of the starting motor is recommended.
the fan's air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move The starting motor pinion and the flywheel ring gear
the air nozzle in a direction that is parallel with the must be in good condition in order for the engine to
tubes. This will remove debris that is between the start properly. The engine will not start if the starting
tubes. motor pinion does not engage the flywheel ring gear.
The teeth of the starting motor pinion and the
Pressurized water may also be used for cleaning. flywheel ring gear can be damaged because of
The maximum water pressure for cleaning purposes irregular engagement.
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
106 SEBU9107-03
Maintenance Section
Walk-Around Inspection
Inspect the starting motor for proper operation. Listen

for grinding when the engine is started. Inspect the NOTICE
For any type of leak (coolant, lube, or fuel) clean up
teeth of the starting motor pinion and the flywheel the fluid. If leaking is observed, find the source and
ring gear. Look for patterns of wear on the teeth. correct the leak. If leaking is suspected, check the flu-
Look for teeth that are broken or chipped. If damaged id levels more often than recommended until the leak
teeth are found, the starting motor pinion and the is found or fixed, or until the suspicion of a leak is
flywheel ring gear must be replaced. proved to be unwarranted.
Electric Starting Motor

NOTICE
Note: Problems with the electric starting motor can Accumulated grease and/or oil on an engine or deck
be caused by the following conditions: malfunction of is a fire hazard. Remove this debris with steam clean-
the solenoid and malfunction of the electric starting ing or high pressure water.
system.
Inspect the electrical system for the following • Ensure that the cooling lines are properly clamped
conditions: and that the cooling lines are tight. Check for
leaks. Check the condition of all pipes.
• Loose connections
• Inspect the water pumps for coolant leaks.
• Corrosion
Note: The water pump seal is lubricated by coolant in
• Wires that are worn or frayed the cooling system. It is normal for a small amount of
leakage to occur as the engine cools down and the
• Cleanliness parts contract.
Make repairs, if necessary. Excessive coolant leakage may indicate the need to
replace the water pump seal. For the removal of
Removal and Installation of the water pumps and the installation of water pumps and/
or seals, refer to the Service Manual for the engine or
Starting Motor consult your Caterpillar dealer.
Refer to the Service Manual, “Disassembly and • Inspect the lubrication system for leaks at the front
Assembly” module for information on removing the crankshaft seal, the rear crankshaft seal, the oil
starting motor and installing the starting motor. pan, the oil filters and the valve cover.
Consult your Caterpillar dealer for assistance. • Inspect the fuel system for leaks. Look for loose
fuel line clamps or for loose fuel line tie-wraps.
i01185304
• Inspect the piping for the air inlet system and the
Walk-Around Inspection elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
SMCS Code: 1000-040 hoses, tubes, wiring harnesses, etc.
Inspect the Engine for Leaks and • Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
for Loose Connections
Belts for multiple groove pulleys must be replaced as
A walk-around inspection should only take a few matched sets. If only one belt is replaced, the belt will
minutes. When the time is taken to perform these carry more load than the belts that are not replaced.
checks, costly repairs and accidents can be avoided. The older belts are stretched. The additional load on
the new belt could cause the belt to break.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting • Drain the water and the sediment from fuel tanks
the engine. Look for items such as oil leaks or on a daily basis in order to ensure that only clean
coolant leaks, loose bolts, worn belts, loose fuel enters the fuel system.
connections and trash buildup. Make repairs, as
needed: • Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
• The guards must be in the proper place. Repair
wires.
damaged guards or replace missing guards.
• Inspect the ground strap for a good connection
• Wipe all caps and plugs before the engine is
and for good condition.
serviced in order to reduce the chance of system
contamination.
SEBU9107-03 107
Maintenance Section
Walk-Around Inspection
• 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.
108 SEBU9107-03
Warranty Section
Warranty Information
Warranty Section that can cause the engine to fail to conform to

applicable emission standards for the warranty
period.
Warranty Information 2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
i02797420 1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
Warranty Information engines) operated and serviced in the state of
California, including all parts of their emission
SMCS Code: 1000
control systems (“emission related components”),
Engines are covered by a standard one year are:
warranty. The coverage of individual warranties may
be different due to the engine application and the a. Designed, built, and equipped so as to
geographic location. conform, at the time of sale, to all applicable
regulations adopted by the California Air
The warranty is shipped with other loose parts, or Resources Board (ARB).
with the Parts Manual, when the engine is shipped.
b. Free from defects in materials and
Engine Protection Plans workmanship which cause the failure of an
emission-related component to be identical in
Extended Warranties and Service all material respects to the component as
Contracts described in the engine manufacturer's
application for certification for the warranty
A wide variety of protection plans are available for period.
Caterpillar Engines. Consult your Caterpillar dealer
for detailed information on the specific programs and 3. New non-road diesel engines installed in
coverages that are available. construction machines conforming to the South
Korean regulations for construction machines
Consult your Caterpillar dealer for information on a
plan that is tailored in order to fit your requirements. manufactured after January 1, 2015, and operated
and serviced in South Korea, including all parts of
their emission control systems (“emission related
i06044323
components”), are:
Emissions Warranty a. Designed, built, and equipped so as to
Information conform, at the time of sale, with applicable
SMCS Code: 1000 emission standards prescribed in the
Enforcement Rule of the Clean Air
The certifying engine manufacturer warrants to the Conservation Act promulgated by South Korea
ultimate purchaser and each subsequent purchaser MOE.
that:
b. Free from defects in materials and
1. New non-road diesel engines and stationary diesel workmanship in emission-related components
engines less than 10 liters per cylinder (including that can cause the engine to fail to conform to
Tier 1 and Tier 2 marine engines < 37 kW, but applicable emission standards for the warranty
excluding locomotive and other marine engines) period.
operated and serviced in the United States and
Canada, including all parts of their emission The aftertreatment system can be expected to
control systems (“emission related components”), function properly for the lifetime of the engine
are: (emissions durability period) subject to prescribed
maintenance requirements being followed.
a. Designed, built, and equipped so as to
conform, at the time of sale, with applicable A detailed explanation of the Emission Control
Warranty that is applicable to new non-road and
emission standards prescribed by the United stationary diesel engines, including the components
States Environmental Protection Agency covered and the warranty period, is found in a
(EPA) by way of regulation. supplemental Special Publication. Consult your
authorized Cat dealer to determine if your engine is
b. Free from defects in materials and subject to an Emission Control Warranty and to
workmanship in emission-related components obtain a copy of the applicable Special Publication.
SEBU9107-03 109
Engine Ratings
Reference Information Table 14

Engine Rating Information
Section
Perform- Time at Rated Load(1)
Load Examples of
ance
Factor Any One Applications
Engine Ratings Rating Overall
Instance
Pipe line
i01097462 A 100% 100% n/a pumping
Ventilation
Engine Rating Conditions Irrigation pumps

Drilling
SMCS Code: 1000 B 85% 75% n/a applications
Plant air
All engine ratings are based on“SAE J1349”. compressors
Ratings relate to the standard conditions of Fire pumps
“AS1501”, of “ISO3046/1”, of “DIN6271”, and of Chippers
“BS5514”. Less than1
C 70% 50% Rock crushers
hour
Portable air
The engine ratings are gross output ratings. compressors
Gross Output Ratings – The total output capability Snowgroomer
of the engine that is equipped with standard Less than 30 Snowblowers
accessories. D 50% 10%
minutes Cranes
Water well drills
Standard accessories include the following Standby centrifu-
Less than 15
components: E 35% 5% gal pumps
minutes
Oil well servicing
• Oil pumps (1) Both the overall time at rated load and the time the engine is
operated in any one instance must be considered.
• Fuel pumps
• Water pumps NOTICE

Operating engines above the rating definitions can
Subtract the power that is required to drive auxiliary result in shorter service life before overhaul.
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.
“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.
110 SEBU9107-03
Customer Service
Customer Service Europe, Africa, and Middle East

Caterpillar Overseas S.A.
76 Route de Frontenex
i03910306
P.O. Box 6000
CH-1211 Geneva 6
Customer Assistance Switzerland
SMCS Code: 1000; 4450 Phone: 22-849-4444
Fax: 22-849-4544
USA and Canada Far East
Caterpillar Asia Pte. Ltd.
When a problem arises concerning the operation or 7 Tractor Road
the service of an engine, the problem will normally be
managed by the dealer in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level, use the phone number that is listed below to Hong Kong
talk with a Field Service Coordinator: Phone: 852-2848-0333
Fax: 852-2848-0440
1-800-447-4986
The normal hours are from 8:00 to 4:30 Monday Japan
through Friday Central Standard Time. Shin Caterpillar Mitsubishi Ltd.
SBS Tower
3. If your needs have not been met still, submit the 10-1, Yoga 4-Chome
matter in writing to the following address: Setagaya-Ku, Tokyo 158-8530
Japan
Caterpillar Inc. Phone: 81-3-5717-1150
Manager, Customer Service, Engine Division Fax: 81-3-5717-1177
Mossville Bldg AC
P.O. Box 610 Japan
Mossville, Illinois 61552-0610 Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
Please keep in mind: probably, your problem will 4-10-1, Yoga
ultimately be solved at the dealership, using the Setagaya-Ku, Tokyo 158-0097
dealership facilities, equipment, and personnel. Phone: 81-3-5797-4300
Therefore, follow the steps in sequence when a
problem is experienced. Fax: 81-3-5797-4359
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: 305-476-6800
Fax: 305-476-6801
SEBU9107-03 111
Ordering Replacement Parts
Australia and New Zealand

Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
i01028392
Ordering Replacement Parts

SMCS Code: 4450; 7567
When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent speci-
fications including, but not limited to, physical di-
mensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following
information:
• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
112 SEBU9107-03
Reference Materials
Reference Materials i05975063
i05264255
Reference Material
SMCS Code: 1000; 4450
Maintenance Records Additional literature regarding your product may be
SMCS Code: 1000; 4450 purchased from your local Cat dealer or by visiting
www.cat.com. Use the product name, sales model,
Caterpillar Inc. recommends the retention of accurate and serial number in order to obtain the correct
maintenance records. Accurate maintenance records information for your product.
can be used for the following purposes:
• Determine operating costs.
• Establish maintenance schedules for other

engines that are operated in the same
environment.
• Show compliance with the required maintenance

practices and maintenance intervals.
Maintenance records can be used for various other
business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is managed. Accurate
maintenance records can help your Cat dealer to
fine-tune the recommended maintenance intervals in
order to meet the specific operating situation. This
should result in a lower engine operating cost.
Records should be kept for the following items:
Fuel Consumption – A record of fuel consumption is
essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul
intervals.
Service Hours – A record of service hours is
essential to determine when the speed sensitive
components should be inspected or repaired.
Documents – These items should be easy to obtain,
and these items should be kept in the engine history
file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number and engine serial number. The following
types of documents should be kept as proof of
maintenance or repair for warranty:
Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
• Dealer work orders and itemized bills
• Owner repair costs
• Owner receipts
• Maintenance log
SEBU9107-03 113
Index Section
Index
A Coolant Extender (ELC) - Add ........................ 79
Coolant Level - Check ..................................... 80
Additional Messages ......................................... 8
Coolant Sample (Level 1) - Obtain.................. 81
After Starting Engine ....................................... 49
Coolant Sample (Level 2) - Obtain.................. 81
Extended Idle at Cold Ambient
Coolant Temperature Regulator - Replace ..... 82
Temperature............................................... 49
Cooling System Supplemental Coolant
After Stopping Engine ..................................... 56
Additive (SCA) - Test/Add.............................. 82
Air Compressor - Check (If equipped)............. 72
Cooling Systems that Use Conventional
Air Shutoff - Test (If Equipped) ........................ 72
Coolant....................................................... 83
Air Tank Moisture and Sediment - Drain (If
Cooling Systems that Use Water and
Equipped) ...................................................... 73
SCA............................................................ 83
ARD Spark Plug - Clean.................................. 71
Crushing Prevention and Cutting Prevention.. 14
Installing the Spark Plug .............................. 71
Customer Assistance .....................................110
Removing the Spark Plug............................ 71
Outside of the USA and of Canada ............110
USA and Canada........................................110
B Customer Service...........................................110
Battery - Recycle ............................................. 73
Battery - Replace............................................. 73 D
Battery Disconnect Switch (If Equipped)......... 39
DEF Filler Screen - Clean ............................... 84
Battery Electrolyte Level - Check .................... 74
DEF Manifold Filters - Replace ....................... 84
Battery or Battery Cable - Disconnect............. 74
Diesel Exhaust Fluid - Fill................................ 86
Before Starting Engine .................................... 46
Diesel Exhaust Fluid Filter - Replace .............. 87
Belts - Inspect/Adjust/Replace ........................ 74
Diesel Particulate Filter - Clean....................... 88
Alternator Belt .............................................. 75
Diesel Particulate Filter Regeneration ............ 50
Drive Belt for the Air Compressor (If
Modes of Regeneration ............................... 51
Equipped)................................................... 75
Regeneration ............................................... 50
Inspection .................................................... 74
Regeneration Indicators .............................. 50
Burn Prevention............................................... 12
Regeneration Switch ................................... 50
Batteries....................................................... 12
Regeneration System Warning Indicators... 51
Coolant ........................................................ 12
Regeneration Triggers................................. 51
Oils............................................................... 12
Driven Equipment - Check .............................. 88
C
E
Cold Weather Operation ................................. 53
Electrical System............................................. 15
Cold Weather Starting ..................................... 46
Grounding Practices .................................... 16
Ether Injection System (If Equipped)........... 47
Emissions Warranty Information ................... 108
Compression Brake - Inspect/Adjust/
Engaging the Driven Equipment ..................... 52
Replace ......................................................... 76
Engine - Clean................................................. 88
Coolant (DEAC) - Change............................... 76
Engine Air Cleaner Service Indicator -
Cooling Systems with Heavy Deposits or
Inspect (If Equipped) ..................................... 89
Plugging ..................................................... 77
Test the Service Indicator ............................ 89
Drain ............................................................ 76
Engine Diagnostics ......................................... 45
Fill ................................................................ 77
Engine Electronics........................................... 17
Flush ............................................................ 76
Engine Mounts - Inspect.................................. 89
Coolant (ELC) - Change.................................. 78
Engine Oil and Filter - Change ........................ 91
Drain ............................................................ 78
Drain the Engine Oil..................................... 92
Fill ................................................................ 79
Fill the Engine Crankcase............................ 93
Flush ............................................................ 78
114 SEBU9107-03
Index Section
Replace the Oil Filter ................................... 92 Drain the Water and the Sediment .............. 97
Selection of Oil Change Interval .................. 91 Fuel Storage Tanks...................................... 97
Engine Oil Level - Check................................. 89 Fuel Tank ..................................................... 97
Engine Oil Sample - Obtain............................. 90 Fumes Disposal Filter Element - Replace....... 97
Obtain the Sample and the Analysis ........... 90
Engine Operation ............................................ 50 G
Engine Rating Conditions.............................. 109
Engine Rating Definitions.............................. 109 General Hazard Information.............................. 8
Engine Ratings .............................................. 109 Containing Fluid Spillage............................. 10
Engine Starting.......................................... 15, 46 Dispose of Waste Properly .......................... 12
Engine Stopping ........................................ 15, 55 Fluid Penetration ......................................... 10
Engine Storage Procedure - Check ................ 93 Inhalation ......................................................11
Engine Valve Lash - Check ............................. 93 Lines, Tubes, and Hoses ............................. 10
Pressurized Air and Water............................. 9
Softwrap........................................................11
F
Static Electricity Hazard when Fueling with
Fault Logging................................................... 45 Ultra-low Sulfur Diesel Fuel ....................... 10
Features and Controls..................................... 31 General Information ........................................ 18
Fire Prevention and Explosion Prevention...... 12 Grounding Stud - Inspect/Clean/Tighten......... 98
Ether ............................................................ 14
Fire Extinguisher.......................................... 14 H
Lines, Tubes, and Hoses ............................. 14
Fluid Recommendations ................................. 57 Hoses and Clamps - Inspect/Replace............. 98
Biodiesel ...................................................... 63 Inspect the Hoses and the Clamps.............. 99
Coolant ........................................................ 60 Replace the Hoses and the Clamps ............ 99
Diesel Engine Oil ......................................... 57
Diesel Exhaust Fluid .................................... 61 I
Diesel Fuel Recommendations ................... 59
Important Safety Information............................. 2
Fuel Additives .............................................. 63
Injector (Diesel Exhaust Fluid) - Replace...... 101
Lubricating Grease ...................................... 60
Foreword ........................................................... 4
California Proposition 65 Warning ................. 4 L
Literature Information .................................... 4 Lifting and Storage .......................................... 26
Maintenance .................................................. 4
Maintenance Intervals ................................... 4
M
Operation ....................................................... 4
Overhaul ........................................................ 4 Maintenance Interval Schedule................. 67, 69
Safety............................................................. 4 Daily ............................................................. 67
Fuel and the Effect from Cold Weather ........... 53 Every 10 000 Service Hours ........................ 67
Fuel Conservation Practices ........................... 52 Every 12 000 Service Hours or 6 Years....... 67
Fuel Related Components in Cold Weather ... 53 Every 2000 Service Hours or 1 Year ........... 67
Fuel Heaters ................................................ 54 Every 250 Service Hours ............................. 67
Fuel Tanks ................................................... 53 Every 2500 Service Hours........................... 68
Fuel System - Prime ........................................ 94 Every 3000 Service Hours or 3 Years ......... 68
Key-on Priming (if equipped) ....................... 94 Every 340 500 L (90 000 US gal) of Fuel .... 67
Manual Switch Priming (if equipped)........... 94 Every 4000 Service Hours........................... 68
Fuel System Primary Filter (Water Every 4000 Service Hours or 2 Years ......... 68
Separator) Element - Replace....................... 95 Every 500 Service Hours ............................. 67
Fuel System Primary Filter/Water Every 5000 Service Hours........................... 68
Separator - Drain ........................................... 94 Every 6000 Service Hours or 3 Years ......... 67
Fuel System Secondary Filter - Replace ........ 96 When Required............................................ 67
Fuel Tank Water and Sediment - Drain ........... 97
SEBU9107-03 115
Index Section
Maintenance Interval Schedule (Engines With Product Storage .............................................. 27

Ratings Greater Than 359 hp) Extended Storage (Engine with DEF
Daily ............................................................. 69 Tank) .......................................................... 29
Every 10 000 Service Hours ........................ 69 Removal from Extended Storage (Engine with
Every 12 000 Service Hours or 6 Years....... 69 DEF Tank) .................................................. 29
Every 2000 Service Hours or 1 Year ........... 70 Removal from Storage................................. 29
Every 250 Service Hours ............................. 69 Storage (Less Than One Year).................... 27
Every 2500 Service Hours........................... 70
Every 3000 Service Hours or 3 Years ......... 70 R
Every 340 500 L (90 000 US gal) of Fuel .... 69
Every 4000 Service Hours........................... 70 Radiator - Clean ............................................ 105
Every 4000 Service Hours or 2 Years ......... 70 Radiator Restrictions....................................... 53
Every 500 Service Hours ............................. 69 Reference Information..................................... 25
Every 5000 Service Hours........................... 70 Record for Reference .................................. 25
Every 6000 Service Hours or 3 Years ......... 69 Reference Information Section ..................... 109
Initial 500 Service Hours.............................. 69 Reference Material .........................................112
When Required............................................ 69 Reference Materials .......................................112
Maintenance Recommendations .................... 64 Refill Capacities............................................... 57
Maintenance Records ....................................112 Coolant Refill Capacities ............................. 57
Maintenance Section....................................... 57 Lubricant Refill Capacities ........................... 57
Manual Stop Procedure .................................. 56
Model View Illustrations .................................. 18 S
Monitoring System........................................... 39
Safety Messages............................................... 5
Instrument Panel ......................................... 40
High Pressure (2)........................................... 7
Mounting and Dismounting ............................. 15
Sulfuric Acid Burn (3)..................................... 7
Universal Warning (1) .................................... 6
O Safety Section ................................................... 5
Operation Section............................................ 26 Selective Catalytic Reduction Warning
Ordering Replacement Parts.......................... 111 System........................................................... 31
Overhaul Considerations............................... 102 Definitions .................................................... 31
Oil Consumption as an Overhaul Inducement Strategy for DEF Level
Indicator ................................................... 102 (European Union) ...................................... 32
Overhaul Recommendation....................... 102 Inducement Strategy for DEF Level
(Worldwide)................................................ 34
Inducement Strategy for Escalating Time
P
Inducement Faults (European Union) ....... 33
Plate Locations and Film Locations ................ 23 Inducement Strategy for Escalating Time
Power Take-Off Clutch - Check..................... 104 Inducement Faults (Worldwide)................. 35
Product Description ......................................... 21 Operator Inducement Emergency Override for
Aftermarket Products and Caterpillar Cat Engines Equipped with Selective
Engines ...................................................... 22 Catalytic Reduction Systems (If
Electronic Engine Features ......................... 21 Equipped)................................................... 36
Engine Service Life...................................... 22 Override Activation Method ......................... 37
Engine Specifications .................................. 21 Override Usage Report................................ 38
Product Identification Information ................... 23 Resetting the Override................................. 38
Product Information Section............................ 18 Setting the Override through Cat Electronic
Product Lifting ................................................. 26 Technician (ET) .......................................... 37
Clean Emission Module Lifting .................... 27 Setting the Override through Electronic
Engine and Factory Mounted CEM ............. 26 Display Menu ............................................. 38
Engine and Installed Radiator Only............. 27 Setting the Override with Switch.................. 38
Radiator Only............................................... 27 Self-Diagnostics .............................................. 45
116 SEBU9107-03
Index Section
Severe Service Application ............................. 65

Improper Maintenance Procedures
(Maintenance Procedures Which May
Contribute to a Severe Service
Application) ................................................ 66
Severe Environmental Factors .................... 65
Severe Operating Conditions ...................... 65
Starting Motor - Inspect (If Equipped) ........... 105
Electric Starting Motor ............................... 106
Removal and Installation of the Starting
Motor ........................................................ 106
Starting the Engine.......................................... 47
Problems with the Wiring Harness .............. 48
Starting Problems ........................................ 47
Starting the Engine ...................................... 47
Starting with Jump Start Cables (Do Not
Use This Procedure in Hazardous
Locations that have Explosive
Atmospheres) ................................................ 48
Stopping the Engine ........................................ 55
Delayed Engine Shutdown (If Enabled) ...... 55
System Pressure Release............................... 64
Coolant System ........................................... 64
Engine Oil .................................................... 64
Fuel System................................................. 64
T
Table of Contents .............................................. 3
W
Walk-Around Inspection ................................ 106
Inspect the Engine for Leaks and for Loose
Connections ............................................. 106
Warranty Information..................................... 108
Engine Protection Plans ............................ 108
Warranty Section........................................... 108
Welding on Engines with Electronic
Controls ......................................................... 64
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
SEBU9107 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2016 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.
118 February 2016

Operation and Maintenance Manual: C9.3 Industrial Engine

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SEBU9107-03 (en-us)

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Refill Capacities............................................... 57

Maintenance Recommendations .................... 64

Product Information Section

General Information ........................................ 18

Product Identification Information ................... 23

Lifting and Storage .......................................... 26

Features and Controls..................................... 31

Engine Diagnostics ......................................... 45

Engine Operation ............................................ 50

Cold Weather Operation ................................. 53

Engine Stopping .............................................. 55

Foreword Recommended service should be performed at the

Maintenance California Proposition 65 Warning

Universal Warning (1)

One safety message is located on the left side of the

One safety message for high pressure (2) is located

The safety message for sulfuric acid burn (3) is

This notice is located next to the battery disconnect

Pressurized Air and Water

• Report all necessary repairs.

• The protective locks or the controls are in the

• Disconnect the batteries when maintenance is

Avoid direct spraying of water on electrical Static Electricity Hazard when

• Wire that is exposed in reinforced hose

• Flexible part of the hose that is kinked or crushed

• Stay away from areas that might have asbestos

• Never use compressed air for cleaning.

• Avoid grinding materials that contain asbestos.

Dispose of Waste Properly Oils

Illustration 10 g00706404 Fire Prevention and Explosion

Always use leakproof containers when you drain

Wiring must be kept in good condition. Properly route

Do not store ether cylinders in living areas or in the

Lines, Tubes, and Hoses

SMCS Code: 1000; 4450; 7405 i06299648

Inspect the steps, the handholds, and the work area

All grounds should be tight and free of corrosion. The

Tampering with the electronic system installation

• Illumination of a warning lamp or warning alarm

Note: Many of the engine control systems and

Model View Illustrations

(16) Secondary fuel filter base (17) Fuel temperature sensor

i04135811 (Table 1, contd)

• Injection timing control

• Aftertreatment regeneration control

• Cold starting capability

Displacement 9.3 L (568 in3)

Firing Order 1-5-3-6-2-4

Rotation (flywheel end) Counterclockwise

The fuel pump pressurizes the fuel. The fuel pump

Engine Service Life

Aftermarket Products and

When auxiliary devices, accessories, or

Plate Locations and Film

The following information is on the information plate: