CAT C15 Instruction SEBU7902-02-01-ALL English

SEBU7902-02
June 2007
Operation and
Maintenance
Manual
C15 Industrial Engine
JRE1-Up (Engine)
i01658146
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. 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 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.
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. 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
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
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. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SEBU7902-02 3
Table of Contents
Table of Contents Warranty Section

Warranty Information ............................................ 82
Foreword ................................................................. 4
Reference Information Section
Safety Section
Engine Ratings ..................................................... 84
Safety Messages .................................................... 6
Customer Service ................................................. 85
General Hazard Information ................................... 7
Reference Materials .............................................. 87
Burn Prevention ...................................................... 9
Index Section
Fire Prevention and Explosion Prevention .............. 9
Index ..................................................................... 91
Crushing Prevention and Cutting Prevention ......... 11
Mounting and Dismounting ................................... 12
Before Starting Engine .......................................... 12
Engine Starting ..................................................... 12
Engine Stopping ................................................... 12
Electrical System .................................................. 13
Engine Electronics ................................................ 14
Product Information Section

General Information .............................................. 15
Model Views ......................................................... 16
Product Identification Information ........................ 19
Operation Section
Lifting and Storage ................................................ 22
Features and Controls .......................................... 23
Engine Diagnostics ............................................... 28
Engine Starting ..................................................... 33
Engine Operation .................................................. 36
Engine Stopping ................................................... 38
Cold Weather Operation ....................................... 39
Maintenance Section
Refill Capacities .................................................... 41
Maintenance Interval Schedule ............................ 44

4 SEBU7902-02
Foreword
Foreword Use fuel consumption or service hours to determine

intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals
Literature Information if they provide more convenient schedules and
approximate the indicated service meter reading.
This manual contains safety, operation instructions,
lubrication and maintenance information. This Recommended service should be performed at the
manual should be stored in or near the engine area appropriate intervals as indicated in the Maintenance
in a literature holder or literature storage area. Read, Interval Schedule. The actual operating environment
study and keep it with the literature and engine of the engine also governs the Maintenance Interval
information. Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
English is the primary language for all Caterpillar more frequent lubrication and maintenance than is
publications. The English used facilitates translation specified in the Maintenance Interval Schedule may
and consistency in electronic media delivery. be necessary.
Some photographs or illustrations in this manual The maintenance schedule items are organized for
show details or attachments that may be different a preventive maintenance management program. If
from your engine. Guards and covers may have the preventive maintenance program is followed, a
been removed for illustrative purposes. Continuing periodic tune-up is not required. The implementation
improvement and advancement of product design of a preventive maintenance management program
may have caused changes to your engine which are should minimize operating costs through cost
not included in this manual. Whenever a question avoidances resulting from reductions in unscheduled
arises regarding your engine, or this manual, please downtime and failures.
consult with your Caterpillar dealer for the latest
available information.
Maintenance Intervals
Safety Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
This safety section lists basic safety precautions. items in each level should be shifted ahead or back
In addition, this section identifies hazardous, depending upon your specific maintenance practices,
warning situations. Read and understand the basic operation and application. We recommend that
precautions listed in the safety section before the maintenance schedules be reproduced and
operating or performing lubrication, maintenance and displayed near the engine as a convenient reminder.
repair on this product. We also recommend that a maintenance record be
maintained as part of the engine’s permanent record.
Operation
See the section in the Operation and Maintenance
Operating techniques outlined in this manual are Manual, “Maintenance Records” for information
basic. They assist with developing the skills and regarding documents that are generally accepted
techniques required to operate the engine more as proof of maintenance or repair. Your authorized
efficiently and economically. Skill and techniques Caterpillar dealer can assist you in adjusting your
develop as the operator gains knowledge of the maintenance schedule to meet the needs of your
engine and its capabilities. operating environment.
The operation section is a reference for operators. Overhaul

Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating Major engine overhaul details are not covered in the
and stopping the engine. This section also includes a Operation and Maintenance Manual except for the
discussion of electronic diagnostic information. interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
Maintenance an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
The maintenance section is a guide to engine care. programs. If you experience a major engine failure,
The illustrated, step-by-step instructions are grouped there are also numerous after failure overhaul options
by fuel consumption, service hours and/or calendar available from your Caterpillar dealer. Consult with
time maintenance intervals. Items in the maintenance your dealer for information regarding these options.
schedule are referenced to detailed instructions that
follow.
SEBU7902-02 5
Foreword
California Proposition 65 Warning

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

contain lead and lead compounds. Wash hands
after handling.
6 SEBU7902-02
Safety Section
Safety Messages
Safety Section
i02093796
Safety Messages
SMCS Code: 1000; 7405
g01068912
Illustration 1
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
Do not operate or work on this engine unless you
message on the replacement part. Your Caterpillar
have read and understand the instructions and
dealer can provide new safety messages.
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact Universal Warning (1)
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility. The safety messages for the universal warning are
located toward the front of the engine on both sides
of the valve cover base.
There may be several specific safety messages on
your engine. The exact location and a description of
the safety messages are reviewed in this section.
Please become familiar with all safety messages.
Ensure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water,
and soap to clean the safety messages. Do not
use solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off
of the engine.
g00934493
Illustration 2
SEBU7902-02 7
Safety Section
General Hazard Information
• Breathers
Do not operate or work on this engine unless you • Drain plugs

have read and understand the instructions and
Use caution when cover plates are removed.
warnings in the Operation and Maintenance Man-
Gradually loosen, but do not remove the last two
ual. Failure to follow the instructions or heed the
bolts or nuts that are located at opposite ends of
warnings could result in injury or death. Contact
the cover plate or the device. Before removing the
any Caterpillar dealer for replacement manuals.
last two bolts or nuts, pry the cover loose in order to
Proper care is your responsibility.
relieve any spring pressure or other pressure.
i02566298

SMCS Code: 1000; 7405
g00702020
Illustration 4
• Wear a hard hat, protective glasses, and other

protective equipment, as required.
• When work is performed around an engine that is

Illustration 3
g00104545 operating, wear protective devices for ears in order
to help prevent damage to hearing.
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls • Do not wear loose clothing or jewelry that can snag
before the engine is serviced or before the engine is on controls or on other parts of the engine.
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar • Ensure that all protective guards and all covers are
dealer. Attach the warning tags to the engine and to secured in place on the engine.
each operator control station. When it is appropriate,
disconnect the starting controls. • Never put maintenance fluids into glass containers.
Glass containers can break.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being • Use all cleaning solutions with care.
serviced.
• Report all necessary repairs.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the Unless other instructions are provided, perform
engine and operate the engine in a well ventilated the maintenance under the following conditions:
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside. • The engine is stopped. Ensure that the engine
cannot be started.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids, • Disconnect the batteries when maintenance
hold a rag over the part that is being removed. is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
• Filler caps Tape the leads in order to help prevent sparks.
• Grease fittings • Do not attempt any repairs that are not understood.
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
• Pressure taps
8 SEBU7902-02
Safety Section
Pressurized Air and Water Asbestos Information

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

used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi) when the air nozzle
is deadheaded. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
g00702022
Illustration 6
Fluid Penetration
Caterpillar equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
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 usually
Illustration 5
g00687600 bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
Always use a board or cardboard when you check contains asbestos is generated.
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause If dust that may contain asbestos is present, there
serious injury and possible death. A pin hole leak can are several guidelines that should be followed:
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment • Never use compressed air for cleaning.
from a doctor that is familiar with this type of injury.
• Avoid brushing materials that contain asbestos.
Containing Fluid Spillage • Avoid grinding materials that contain asbestos.
Care must be taken in order to ensure that fluids • Use a wet method in order to clean up asbestos
are contained during performance of inspection, materials.
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable • A vacuum cleaner that is equipped with a high
containers before opening any compartment or efficiency particulate air filter (HEPA) can also be
disassembling any component that contains fluids. used.
Refer to Special Publication, NENG2500, “Caterpillar • Use exhaust ventilation on permanent machining
Dealer Service Tools Catalog” for the following items: jobs.
• Tools that are suitable for collecting fluids and • Wear an approved respirator if there is no other
equipment that is suitable for collecting fluids way to control the dust.
• Tools that are suitable for containing fluids and

equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.

SEBU7902-02 9
Safety Section
Burn Prevention
• Comply with applicable rules and regulations Check the coolant level after the engine has stopped
for the work place. In the United States, use and the engine has been allowed to cool. Ensure
Occupational Safety and Health Administration that the filler cap is cool before removing the filler
(OSHA) requirements. These OSHA requirements cap. The filler cap must be cool enough to touch with
can be found in “29 CFR 1910.1001”. a bare hand. Remove the filler cap slowly in order
to relieve pressure.
• Obey environmental regulations for the disposal
of asbestos. Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
• Stay away from areas that might have asbestos the skin, the eyes, or the mouth.
particles in the air.
Oils
Dispose of Waste Properly
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot components
to contact the skin.
If the application has a makeup tank, remove the cap

for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
g00706404 Do not smoke while checking the battery electrolyte

Illustration 7
levels. Batteries give off flammable fumes which can
explode.
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
Always wear protective glasses when you work with
disposed of according to local regulations.
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water. i01372254
Fire Prevention and Explosion

Prevention
i02088921
Burn Prevention
SMCS Code: 1000; 7405
SMCS Code: 1000; 7405
Do not touch any part of an operating engine.

Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure in
the appropriate system before any lines, fittings or
related items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns. Illustration 8
g00704000
Allow cooling system components to cool before the
cooling system is drained. All fuels, most lubricants, and some coolant mixtures
are flammable.
10 SEBU7902-02
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 deterioration. The hoses must be properly routed.
a fire. Fire may cause personal injury and property The lines and hoses must have adequate support
damage. and secure 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 fifteen minutes after Oil filters and fuel filters must be properly installed.
an emergency shutdown. The filter 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 Caterpillar 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.
Store fuels and lubricants in properly marked

containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.

g00704059
Illustration 9
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
Use caution when you are refueling an engine. Do
a tube, or a seal failure. Exhaust shields must be
not smoke while you are refueling an engine. Do not
installed correctly.
refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. All electrical

wires must be properly routed and securely attached.
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.
g00704135
Illustration 10
SEBU7902-02 11
Safety Section
Crushing Prevention and Cutting Prevention
Gases from a battery can explode. Keep any open Check lines, tubes and hoses carefully. Do not use
flames or sparks away from the top of a battery. Do your bare hand to check for leaks. Use a board or
not smoke in battery charging areas. cardboard to check for leaks. Tighten all connections
to the recommended torque.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or Replace the parts if any of the following conditions
a hydrometer. are present:
Improper jumper cable connections can cause • End fittings are damaged or leaking.
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific • Outer coverings are chafed or cut.
instructions.
• Wires are exposed.
Do not charge a frozen battery. This may cause an
explosion. • Outer coverings are ballooning.
The batteries must be kept clean. The covers • Flexible part of the hoses are kinked.
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box • Outer covers have embedded armoring.
covers when the engine is operated.
• End fittings are displaced.
Fire Extinguisher Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher. will help to prevent vibration, rubbing against other
parts, and excessive heat.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate. i01359666
Ether Crushing Prevention and

Cutting Prevention
Ether is flammable and poisonous.
SMCS Code: 1000; 7405
Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while you Support the component properly when work beneath
are using an ether spray. the component is performed.
Do not store ether cylinders in living areas or in the Unless other maintenance instructions are provided,
engine compartment. Do not store ether cylinders never attempt adjustments while the engine is
in direct sunlight or in temperatures above 49 °C running.
(120 °F). Keep ether cylinders away from open
flames or sparks. Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
Dispose of used ether cylinders properly. Do not is performed. After the maintenance is performed,
puncture an ether cylinder. Keep ether cylinders reinstall the guards.
away from unauthorized personnel.
Keep objects away from moving fan blades. The fan
Do not spray ether into an engine if the engine is blades will throw objects or cut objects.
equipped with a thermal starting aid for cold weather
starting. When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Lines, Tubes and Hoses Chips or other debris may fly off objects when objects
Do not bend high pressure lines. Do not strike high are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
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 Caterpillar dealer for
repair or for replacement parts.
12 SEBU7902-02
Safety Section
Mounting and Dismounting
i01372247 i02136012
Mounting and Dismounting Engine Starting

SMCS Code: 1000; 7405 SMCS Code: 1000
Inspect the steps, the handholds, and the work area If a warning tag is attached to the engine start switch
before mounting the engine. Keep these items clean or to the controls, DO NOT start the engine or move
and keep these items in good repair. the controls. Consult with the person that attached
the warning tag before the engine is started.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not All protective guards and all protective covers must
climb on the engine, and do not jump off the engine. be installed if the engine must be started in order
to perform service procedures. To help prevent an
Face the engine in order to mount the engine or accident that is caused by parts in rotation, work
dismount the engine. Maintain a three-point contact around the parts carefully.
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any If there is a possibility that unburned gas remains in
controls as handholds. the exhaust system, refer to the purge procedure in
this Operation and Maintenance Manual, “Engine
Do not stand on components which cannot support Starting” topic in the Operation Section.
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the Start the engine from the operator’s compartment or
equipment will not move. from the engine start switch.
Do not carry tools or supplies when you mount the Always start the engine according to the procedure
engine or when you dismount the engine. Use a hand that is described in the Operation and Maintenance
line to raise and lower tools or supplies. Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
i00911989
Knowing the procedure will also help to prevent
Before Starting Engine personal injury.
SMCS Code: 1000 To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Inspect the engine for potential hazards. properly, check the water temperature and the oil
temperature during heater operation.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. All protective Engine exhaust contains products of combustion
guards and all protective covers must be installed which can be harmful to your health. Always start the
if the engine must be started in order to perform engine and operate the engine in a well ventilated
service procedures. To help prevent an accident that area. If the engine is started in an enclosed area,
is caused by parts in rotation, work around the parts vent the engine exhaust to the outside.
carefully.
i01462046
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are Engine Stopping
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent SMCS Code: 1000
engine damage.
Stop the engine according to the procedure in
On the initial start-up of a new engine or an engine the Operation and Maintenance Manual, “Engine
that has been serviced, prepare to stop the engine Stopping (Operation Section)” in order to avoid
if an overspeed condition occurs. This may be overheating of the engine and accelerated wear of
accomplished by shutting off the fuel supply to the the engine components.
engine and/or shutting off the air supply to the engine.
See the Service Manual for repairs and for

adjustments.
SEBU7902-02 13
Safety Section
Electrical System
Use the Emergency Stop Button (if equipped) ONLY Grounding Practices
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corrected.
Stop the engine if an overspeed condition occurs

during the initial start-up of a new engine or an engine
that has been overhauled. This may be accomplished
by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.
To stop an electronically controlled engine, cut the

power to the engine.
i02469632
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible

gases that are produced by some batteries, the g00771448
negative “−” jump start cable should be connected Illustration 11
last from the external power source to the negative Typical example
“−” terminal of the starting motor. If the starting motor Grounding Stud To Battery Ground
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. Refer to
the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.
14 SEBU7902-02
Safety Section
Engine Electronics
i02784356
Engine Electronics
SMCS Code: 1000; 1400; 1900
Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine damage.
This engine has a comprehensive, programmable

Engine Monitoring System. The Engine Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine

monitoring control: WARNING, DERATE, and
SHUTDOWN. These engine monitoring modes have
the ability to limit engine speed and/or the engine
power.
Many of the parameters that are monitored by the

g00771487
Illustration 12 ECM can be programmed for the engine monitoring
Typical example functions. The following parameters can be monitored
Alternate Grounding Stud To Battery Ground
as a part of the Engine Monitoring System:
Proper grounding for the engine electrical system • Operating Altitude

is necessary for optimum engine performance
and reliability. Improper grounding will result in • Engine Coolant Level
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths. • Engine Coolant Temperature
Uncontrolled electrical circuit paths can result in • Engine Oil Pressure

damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components. • Engine Speed
Engines that are installed without engine-to-frame • Fuel Temperature

ground straps can be damaged by electrical
discharge. • Intake Manifold Air Temperature
To ensure that the engine and the engine electrical • System Voltage
systems function properly, an engine-to-frame ground
strap with a direct path to the battery must be used. The Engine Monitoring package can vary for different
This path may be provided by way of a starting motor engine models and different engine applications.
ground, a starting motor ground to the frame, or a However, the monitoring system and the engine
direct engine ground to the frame. monitoring control will be similar for all engines.
All grounds should be tight and free of corrosion. The Note: Many of the engine control systems and display
engine alternator must be grounded to the negative modules that are available for Caterpillar Engines
“-” battery terminal with a wire that is adequate to will work in unison with the Engine Monitoring
handle the full charging current of the alternator. System. Together, the two controls will provide the
engine monitoring function for the specific engine
application. Refer to the Troubleshooting Manual for
more information.
SEBU7902-02 15
General Information
Product Information
Section
General Information
i01472899
Welding on Engines with

Electronic Controls
SMCS Code: 1000
NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
To help avoid damage to the electronic controls,

proper welding procedures are necessary. Before
you weld on equipment with electronic controls,
observe the following precautions:
1. Turn off the engine. Place the engine control

switch in the OFF position.
2. If the engine has a battery disconnect switch, open

the switch. Otherwise, disconnect the negative “-”
battery cable from the battery of the equipment.
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other com-
ponents.
Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.
3. Clamp the ground cable from the welder to the

component that will be welded. Place the clamp
as close as possible to the weld.
4. Protect wiring harnesses from welding debris and

from spatter. Use proper welding procedures.
16 SEBU7902-02
Model Views
Model Views
i02093819
Model View Illustrations

SMCS Code: 1000
g00947237
Illustration 13
(1) Inlet air manifold (5) Low pressure turbocharger (9) Water pump
(2) Lifting eyes (6) High pressure turbocharger (10) Vibration damper
(3) Engine crankcase breather (7) Cooler
(4) Water temperature regulator housing (8) Engine oil filter
SEBU7902-02 17
Model Views
g00947236
Illustration 14
(11) Air compressor (12) Fuel transfer pump (13) Fuel filter
i02093821 Very high injection pressures are produced by

electronically controlled, mechanically actuated unit
Engine Description injectors. The injectors combine the pumping and the
electronic fuel metering (duration and timing) during
SMCS Code: 1000 injection. The unit injectors accurately control smoke
limiting, white smoke, and engine acceleration rates.
Table 1
C15 Engine Specifications There is one unit injector per cylinder. Individual unit
Cylinders and Arrangement In-line six cylinder
injectors meter the fuel. The individual unit injectors
also pump the fuel. The metering and the pumping is
Bore 137.2 mm (5.4 inch) done under high pressure. High injection pressures
help to reduce fuel consumption and emissions.
Stroke 171.5 mm (6.8 inch)
The use of this type of unit injector provides total
Displacement 15.2 L (928 in3) electronic control of injection timing. The injection
timing varies with engine operating conditions. The
Firing Order 1-5-3-6-2-4
engine performance is optimized in the following
Rotation (flywheel end) Counterclockwise areas:
The electronic engines that are covered by this • Starting

manual have the following characteristics: direct fuel
injection, electronic unit injection that is mechanically • Emissions
actuated, turbocharged, and air-to-air aftercooled
(ATAAC). • Noise
The electronic engine control system provides the • Fuel consumption

following functions: electronic governing, automatic
air to fuel ratio control, torque rise shaping, injection The timing advance is achieved through precise
timing control, and system diagnostics. control of the injector firing. Engine speed is
controlled by adjusting the firing duration. The
An electronic governor controls the output of the unit information is provided to the Electronic Control
injectors in order to maintain the engine rpm that Module (ECM) by a engine speed/timing sensor. The
is desired. The functions of the governor include a information is for detection of cylinder position and
programmable low idle and a 20 rpm to 200 rpm engine speed.
governor overrun.
18 SEBU7902-02
Model Views
The engines have built-in diagnostics in order to Welding and Caterpillar Electronic
ensure that all of the components are functioning
and operating properly. In the event of a system
Engines
component deviation from the programmed limits,
the operator will be alerted to the condition by a NOTICE
DIAGNOSTIC lamp that is mounted on the control Because the strength of the frame may decrease,
panel. An electronic service tool that is provided by some manufacturers do not recommend welding onto
Caterpillar may be used to read the numerical code a chassis frame or rail. Consult the OEM of the equip-
of the diagnostic flash code. There are three types of ment or your Caterpillar dealer regarding welding on
diagnostic codes: ACTIVE, LOGGED, and EVENT. a chassis frame or rail.
These codes are logged and stored in the ECM.
Refer to the Operation and Maintenance Manual, To help avoid damage to the electronic controls,
“Engine Diagnostics” for additional information. proper welding procedures are necessary. Before
welding on a vehicle that is equipped with an
The cooling system consists of the following items: electronic engine, observe the following precautions:
a centrifugal pump that is driven by a gear, water
temperature regulator, an oil cooler, and a radiator 1. Turn off the engine. Place the key start switch in
that incorporates a shunt system. the OFF position.
The engine lubricating oil is supplied by a gear 2. If the application has a battery disconnect switch,
type pump. The engine lubricating oil is cooled and open the switch. Otherwise, disconnect the
filtered. Bypass valves provide unrestricted flow negative “-” battery cable from the battery of the
of lubrication oil to the engine parts when the oil vehicle.
viscosity is high or if either the oil cooler or the oil
filter elements (paper cartridge) become plugged.
NOTICE
Engine efficiency, efficiency of emission controls, and Do not ground the welder to electrical components
engine performance depend on adherence to proper such as the ECM or sensors. Improper grounding can
operation and maintenance recommendations. This cause damage to the drive train bearings, hydraulic
includes the use of recommended fuels, coolants components, electrical components, and other com-
and lubrication oils. ponents.
Clamp the ground cable from the welder to the com-

Aftermarket Products and ponent that will be welded. Place the clamp as close
Caterpillar Engines as possible to the weld. This will help reduce the pos-
sibility of damage.
NOTICE
In order to maximize fuel system life and prevent 3. Clamp the ground cable from the welder to the
premature wear out from abrasive particles in the component that will be welded. Place the clamp
fuel, a two micron absolute high efficiency fuel filter as close as possible to the weld.
is required for all Caterpillar Electronic Unit Injectors.
Caterpillar High Efficiency Fuel Filters meet these 4. Protect wiring harnesses from welding debris and
requirements. Consult your Caterpillar dealer for the from spatter. Use proper welding procedures.
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 other manufacturers’ devices,
accessories, or consumables are NOT Caterpillar
defects. Therefore, the defects are NOT covered
under the Caterpillar warranty.
SEBU7902-02 19
Product Identification Information
Product Identification Engine serial number _____________________________________
Information Engine model _______________________________________________
Arrangement number _____________________________________

i02093824
Plate Locations and Film Information Plate (2)

Locations The engine information plate is located on the valve
cover base near the front of the left side of the engine.
SMCS Code: 1000
Engine Serial Number ____________________________________
Engine Arrangement Number ___________________________
Engine Modification Number ____________________________
The engine identification plate also contains other

important information about the engine.
i02164876
Reference Numbers
SMCS Code: 1000
Information for the following items may be needed to

order parts. Locate the information for your engine.
Record the information in the appropriate space.
Make a copy of this list for a record. Keep the
information for future reference.
Record for Reference

Engine Model _______________________________________________
Engine Serial number _____________________________________
Engine Low Idle rpm ______________________________________
Engine Full Load rpm _____________________________________
Primary Fuel Filter _________________________________________
Illustration 15
g01068240 Water Separator Element ________________________________
(1) Serial number plate
(2) Information plate Secondary Fuel Filter Element __________________________
Caterpillar engines are identified by serial numbers Lubrication Oil Filter Element ___________________________
and by arrangement numbers. These numbers are
shown on the engine serial number plate and on the Auxiliary Oil Filter Element _______________________________
engine information plate. Caterpillar dealers need
these numbers in order to determine the components Total Lubrication System Capacity _____________________
that were included with the engine. This permits
accurate identification of replacement part numbers. Total Cooling System Capacity _________________________
Air Cleaner Element _______________________________________

Serial Number Plate (1)
Fan Drive Belt ______________________________________________
The engine serial number plate is located on the
upper right side of the engine block.
20 SEBU7902-02
Alternator Belt ______________________________________________ • Level 1: Minimal Smoke _______________________________
i00844066
• Level 2: Optimum Performance ______________________
Emissions Certification Film • Level 3: Maximum Acceleration _____________________
SMCS Code: 1000; 7405 PTO Engine Governor
• PTO Engine Speed Ramp Rate __________ rpm/sec

Engine Parameters( If applicable)
• Top Engine Limit (TEL) at 100 percent

load_________________________________________________________
g00284658 • Torque Limit ______________________________________________

Illustration 16
EPA Emissions Certification Film • High Idle___________________________________________________
• Low Idle ___________________________________________________
• Intermediate Speed ____________________________________
Engine Monitoring Mode
Equipment ID
Maintenance Indicator
• Manual Hours
• Auto Hours
g00415538
Illustration 17
• Manual Fuel
European Emissions Certification Film
• Auto Fuel
The EPA Emissions Certification Film (if equipped)
and/or the European Emissions Certification Film (if Auxiliary Pressure
equipped) is located on the side of the engine.
• High Warning Set Point ________________________________
i01517706
Auxiliary Temperature
Customer Specified
• High Warning Set Point ________________________________
Parameters
SMCS Code: 1000 Programmable Monitoring System
(PMS)
To record programmed specifications, use the
following blanks. The Programmable Monitoring System determines
the level of action that is taken by the ECM in
Customer Passwords (Optional) response to a condition that can damage the engine.
These conditions are identified by the ECM from the
• First Password ___________________________________________ signals that are produced from the following sensors
• Second Password ______________________________________ • Inlet Air Temperature Sensor

Programmable Power Rating (hp at rpm) __________ • Engine Coolant Temperature Sensor
Rating Selection (L-N) __________________________________ • Engine Oil Pressure Sensor
Air/Fuel Ratio • Engine Speed/Timing Sensors
SEBU7902-02 21
• Fuel Pressure Sensor

• Coolant Level Sensor
Table 2
Programmable Monitoring System Parameters
Default Time Delay in Seconds Set Points

Parameter Action “Disable”
Value Min Max Default Min Max Default
“High Engine ON Warning YES
Air Inlet
Temperature” ON Derate YES
ON Warning YES
“High Engine
Coolant ON Derate YES
Temperature”
OFF Shutdown YES
ON Warning (1) (1) (1) YES
“Low Engine Oil
ON Derate (1) (1) (1) YES
Pressure”
OFF Shutdown (1) (1) (1) YES
“Engine ON Warning YES

Overspeed”(2) ON Shutdown YES
“High Fuel
Filter Pressure OFF Derate (1) (1) (1) YES
Restriction” (1) (1) (1)
OFF Shutdown YES
“High Fuel
Pressure”

“Low Coolant (3) (3) (3)
Level” ON Derate YES
OFF Shutdown (3) (3) (3) YES
ON Warning YES
“High Fuel
ON Derate YES
Temperature”
OFF Shutdown YES
(1) Map Dependent Value
(2) The time delay on the ET screen for the programmable monitoring system will be represented as zero “0”. This is necessary because the
ET cannot display decimal numbers such as 0.6. The Warning for the engine overspeed will be activated when the engine speed has
reached the set point for the warning for 0.6 seconds.
(3) “Not Applicable”
For additional information on Programmable

Monitoring System refer to Troubleshooting Manual ,
“System Configuration Parameters”.
22 SEBU7902-02
Operation Section
Lifting and Storage
Operation Section i02068367
Product Storage
Lifting and Storage SMCS Code: 1000; 1404; 7002
If the engine will not be started for several weeks, the

i01988813 lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
Product Lifting liner surface. Rust on the cylinder liner surface will
cause increased engine wear and a reduction in
SMCS Code: 1000; 1404; 7002 engine service life.
To help prevent excessive engine wear, use the

following guidelines:
• Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).
• If freezing temperatures are expected, check the

cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
(Maintenance Section).
g00103219
Illustration 18 If an engine is out of operation and if use of the engine
is not planned, special precautions should be made.
NOTICE If the engine will be stored for more than one month,
Never bend the eyebolts and the brackets. Only load a complete protection procedure is recommended.
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle For more detailed information on engine storage, see
between the supporting members and the object be- Special Instruction, SEHS9031, “Storage Procedure
comes less than 90 degrees. For Caterpillar Products”.
When it is necessary to remove a component at an Your Caterpillar dealer can assist in preparing the
angle, only use a link bracket that is properly rated for engine for extended storage periods.
the weight.
Use a hoist to remove heavy components. Use

an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting the fixtures in order to

obtain proper balance and safety.
To remove the engine ONLY, use the lifting eyes that

are on the engine.
Lifting eyes are designed and installed for the specific

engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.
SEBU7902-02 23
Operation Section
Features and Controls
Features and Controls 2. Reduce engine speed to low idle.
3. Check and maintain the oil level.

i02373916
Tachometer (3) – This gauge indicates
Monitoring System engine speed (rpm). When the throttle
control lever is moved to the full throttle
SMCS Code: 1900; 7400; 7402; 7450; 7451 position without load, the engine is running at high
idle. The engine is running at the full load rpm when
The Monitoring System is designed to alert the the throttle control lever is at the full throttle position
operator to an immediate problem with any of the with maximum rated load.
engine systems that are monitored. The Monitoring
System is also designed to alert the operator to an
impending problem with any of the engine systems NOTICE
that are monitored. To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
damage to the engine. The engine can be operated
Indicators and Gauges at high idle without damage, but should never be
allowed to exceed high idle rpm.
Note: The high idle rpm and the full load rpm are
stamped on the Information Plate.
Coolant Temperature (4) – When the

coolant temperature is above the normal
operating value, the coolant temperature
gauge will be in the red zone. Refer to the Messenger
display for any additional information that may be
available.
Warning Lamp (5) – There is a general

fault in the engine. Refer to the Messenger
display for any additional information that
may be available.
Fuel Pressure (6) – This gauge indicates

fuel pressure to the fuel injection pump from
g01063079
the fuel filter. A decrease in fuel pressure
Illustration 19 usually indicates a dirty fuel filter or a plugged fuel
Gauge cluster and indicators filter. As the fuel filter becomes plugged, there will be
a noticeable reduction in the engine’s performance.
Diagnostic Lamp (1) – The diagnostic
lamp is used to indicate the existence System Voltage (7) – This gauge indicates
of a fault by flashing a fault code. For a the voltage of the electrical system.
more detailed discussion of the diagnostic lamp,
please see this Operation and Maintenance Manual,
“Diagnostic Lamp” topic.
Circuit Breaker (8) – Reset the circuit breaker if
a circuit breaker trips. Press the button in order to
Engine Oil Pressure (2) – The oil pressure reset the circuit breaker. If the electrical system is
should be greatest after a cold engine is working properly, the button will remain pressed. If
started. The pressure will decrease as the button does not remain pressed or if the circuit
the engine warms up. The pressure will increase breaker trips soon after being reset, check the
when the engine rpm is increased. The pressure will appropriate electrical circuit. Repair the electrical
stabilize when the engine rpm is stable. circuit, if necessary.
A lower oil pressure is normal at low idle. If the load

is stable and the gauge reading changes, perform
the following procedure:
1. Remove the load.

24 SEBU7902-02
Operation Section
Start Switch (9) – The start switch has three Caterpillar Messenger Display
positions: OFF, RUN, and START. When the start
switch is turned clockwise to the RUN position, the
lamps will flash for five seconds during the system
test. The lamps will then shut off. In the RUN position,
the ECM and electronic systems are powered up.
Idle Speed Switch (10) – When the switch

is in the up position, the engine speed
increases to HIGH IDLE. When the switch
is in the down position, the engine speed decreases
to LOW IDLE.
Maintenance Lamp (11) – The ECM

records data that is related to equipment
maintenance. The ECM will activate g01063102
the maintenance indicator lamp when scheduled Illustration 20
maintenance is due. The maintenance indicator
lamp can be reset by actuating the maintenance Digital display area (15) – The Messenger system
clear switch. The maintenance interval may be shows information on the digital display area.
based on operating hours or fuel consumption.
The ECM provides information that pertains to Previous button (16) – Use the previous button to
maintenance intervals and the last maintenance that return to information that was previously shown on
was performed. the digital display area.
Scroll up/left button (17) – This button is used to

Maintenance Clear Switch (12) – The scroll up through information that is shown on the
maintenance clear switch is required display area. The button can also be used to scroll
to reset the maintenance lamp after to the left through information that is shown on the
maintenance on the engine is performed. display area.
Shutdown Switch (13) – Use the engine Scroll down/right button (18) – This button is used
shutdown switch in order to stop the to scroll down through information that is shown on
engine. Push the shutdown switch in order the display area. The button can also be used to
to put the switch in the OFF position. This will stop scroll to the right through information that is shown
the engine. After the engine stops, turn the knob on the display area.
clockwise. This will reset the engine shutdown switch
to the ON position. OK button (19) – Use this button to confirm
selections that you have made with the scroll up/left
Service Tool Connector (14) – For more information button and the scroll down/right button.
regarding the use of Caterpillar Electronic Technician
(ET) and the PC requirements for Cat ET, refer to Performance Display
the documentation that accompanies your Cat ET
software.
g01054560
Illustration 21
Typical performance display
SEBU7902-02 25
Operation Section
The following options are available through the Settings Display

performance display:
Engine Speed – When you scroll to this option, the

display will show the engine RPM.
Engine Coolant Temperature – When you scroll to

this option, the display will show the engine coolant
temperature in degrees fahrenheit or in degrees
celcius.
Fuel Level – When you scroll to this option, the

display will show the amount of fuel remaining as a
percentage of a full tank.
Totals Display g01054565

Illustration 23
Typical settings display
The following options are available through the

payload display:
MONITORING SYSTEM
Language – Select this option to change the

language shown on the display.
Units – Select this option to choose the desired

measurement system. The choices are metric or
english.
g01054562 Adjust Contrast – Select this option to adjust the
Illustration 22
Typical totals display contrast of the display in order to improve the visibility
of the information.
The following information is available through the
display: Adjust Backlight – Select this option to adjust the
backlighting of the display in order to improve the
CUMULATIVE TOTALS visibility of the information.
Service Hours – When you scroll to this option, the ENGINE

display shows the total amount of service hours that
the engine has accumulated. Equipment ID – Select this option to view the
equipment identification number.
Total Time – When you scroll to this option, the
display shows the total hours for the engine ECM. Product ID – Select this option to view the product
identification number.
Total Fuel – When you scroll to this option, the
display shows the total amount of fuel that has been
consumed.
26 SEBU7902-02
Operation Section
Service Display • Coolant Flow: When you scroll to this option, the
amount of coolant flow is displayed.
• Boost Pressure: When you scroll to this option,

the boost pressure is displayed.
• Atmospheric Pressure: When you scroll to this

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

option, the turbo inlet pressure is displayed.
• Oil Pressure (Abs): When you scroll to this option,

the absolute engine oil pressure is displayed.
g01054566
• Oil Pressure: When you scroll to this option, the
Illustration 24 gauge engine oil pressure is displayed.
Typical service display
• Fuel Temperature: When you scroll to this option,
DIANOSTICS/EVENTS the fuel temperature is displayed.
The following options are password protected. You SYSTEMS TESTS

must enter a password to change the settings.
SYSTEM SELF TEST
View – Select this option to view events logged
by the monitoring system. If you use an authorized If you select this option, the monitoring system will
password, you can clear individual events. initiaite the self-test feature. The self test feature is
similar to the functional test that occurs when you
Clear All Diagnositcs – If you use an authorized turn the start switch from the OFF position to the ON
password, you can select this option to clear all position.
logged events.
SYSTEM INFORMATION
SYSTEM PARAMETERS
MONITORING SYSTEM
MONITORING SYSTEM
• Software Part Number: When you scroll to this
• Battery Voltage: When you scroll to this option, option, the software part number is displayed.
the battery voltage is diplayed.
• ECM Part Number: When you scroll to this option,
• Fuel Level: When you scroll to this option, the fuel the ECM part number is displayed.
level is diplayed.
• Software Release Date: When you scroll to this
• Alternator Status: When you scroll to this option, option, the software release date is displayed.
the alternator status is diplayed.
• Software Description: When you scroll to this
• Engine Speed: When you scroll to this option, the option, the software description is displayed.
engine RPM is displayed.
ENGINE
• Desired Engine Speed: When you scroll to this
option, the desired engine speed is displayed. • ECM Serial Number: When you scroll to this
This parameter is used by the Automatic Retarder option, the ECM serial number is displayed.
Control to prevent the engine from overspeeding. If
you have an approved password, you can change • Software Part Number: When you scroll to this
this parameter. option, the software part number is displayed.
• Throttle Position: When you scroll to this option, • Software Release Date: When you scroll to this
the throttle position is diplayed. option, the software release date is displayed.
• Coolant Temperature: When you scroll to this • Software Description: When you scroll to this
option, the coolant temperature is displayed. option, the software description is displayed.
SEBU7902-02 27
Operation Section
• Engine Serial Number: When you scroll to this

option, the engine serial number is displayed.
TATTLETALE
• Full Tattletale Readout: When you select this

option, all indicators and gauges will display the
maximum values reached during operation.
• Engine Coolant Temperature: When you select

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

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

indicators will display the maximum values reached
during operation. The fuel level gauge will also
show the minimum value reached during operation.
• Clear: If you have an approved password, you can

clear the maximum values stored by the monitoring
system.
28 SEBU7902-02
Operation Section
Engine Diagnostics
Engine Diagnostics i01463253
Diagnostic Lamp
i00863835
SMCS Code: 1000; 1900; 1901; 1902; 7451
Self-Diagnostics
The “DIAGNOSTIC” lamp is used to indicate the
SMCS Code: 1000; 1900; 1901; 1902 existence of an active fault by flashing codes.
The electronic control module has some When the ignition switch is first turned on, the
self-diagnostic ability. When an electronic problem “DIAGNOSTIC” lamp will go through the following
with an input or an output is detected, a diagnostic procedure:
code is generated. This indicates the specific problem
with the circuitry. • The “DIAGNOSTIC” lamp will come on and
the “DIAGNOSTIC” lamp will remain on for five
Diagnostic codes are also generated when an seconds. This checks the operation of the lamp.
abnormal engine operating condition is detected. For
example, a diagnostic code will be generated if the • The “DIAGNOSTIC” lamp will turn off.
low oil pressure alarm is activated. In this case, the
diagnostic code indicates the symptom of a problem. • The “DIAGNOSTIC” lamp will come on again and
This type of diagnostic code is called an event. An the “DIAGNOSTIC” lamp will flash codes for any
event is triggered by the detection of an abnormal active diagnostic codes. Not all diagnostic codes
engine operating condition. have a unique flash code.
A diagnostic code which represents a problem that • The “DIAGNOSTIC” lamp will turn off for five
currently exists is called an active code. seconds.
A diagnostic code that is stored in memory is called • The “DIAGNOSTIC” lamp repeats all active
a logged code. Always service active codes prior to diagnostic codes.
servicing logged codes. Logged codes may include
the following categories: A fault diagnostic code will remain active until the
problem is repaired. The electronic control module
• Intermittent problems will continue flashing the flash code at five second
intervals until the problem is repaired.
• Recorded events
i02496338
• Performance history
Logged codes may not indicate that a repair is
Diagnostic Flash Code
needed. The problems may have been repaired since Retrieval
the logging of the code. Logged codes may be helpful
to troubleshoot intermittent problems. SMCS Code: 1000; 1900; 1901; 1902
Problems with the electronic control system are

reported via these types of codes: flash codes,
SPN/FMI codes, diagnostic codes, and event codes.
SEBU7902-02 29
Operation Section
Engine Diagnostics
Table 3
Cross Reference for Diagnostic Codes
Diagnostic Code
Flash Code SPN(1)/FMI Code or Description of Code
Event Code
1387-15 High Auxiliary Pressure Warning
1387-16 E443(2) High Auxiliary Pressure Derate
1387-00 High Auxiliary Pressure Shutdown
0441-15 High Auxiliary Temperature Warning
0441-16 E445(2) High Auxiliary Temperature Derate
0441-00 High Auxiliary Temperature Shutdown
545-05 Ether Start Relay open/short to +batt
626-05
N/A 2417-05 Ether Injection Control Solenoid open/short to +batt
545-06 Ether Start Relay short to ground
626-06
2417-06 Ether Injection Control Solenoid short to ground
1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt
1835-04 1835-04 Auxiliary Pressure Sensor short to ground
1836-03 1836-03 Auxiliary Temperature Sensor open/short to +batt
1836-04 1836-04 Auxiliary Temperature Sensor short to ground
111-02 111-02 Engine Coolant Level Sensor Loss of Signal
174-03 174-03 Fuel Temperature open/short to +batt
13
174-04 174-04 Fuel Temperature short to ground
678-03 41-03 8 Volt DC Supply short to +batt
678-04 41-04 8 Volt DC Supply short to ground
620-03
21 262-03 5 Volt Sensor DC Power Supply short to +batt
1079-03
620-04
262-04 5 Volt Sensor DC Power Supply short to ground
1079-04
100-03 100-03 Engine Oil Pressure open/short to +batt
24 100-04 100-04 Engine Oil Pressure short to ground
100-10 100-10 Engine Oil Pressure abnormal rate of change
102-03 102-03 Boost Pressure Sensor short to +batt
25 102-04 102-04 Boost Pressure Sensor short to ground
102-10 102-10 Boost Pressure Sensor abnormal rate of change
108-03 274-03 Atmospheric Pressure open/short to +batt
26
108-04 274-04 Atmospheric Pressure short to ground
110-03 110-03 Engine Coolant Temperature open/short to +batt
27
110-04 110-04 Engine Coolant Temperature short to ground
28 91-13 91-13 Throttle Position calibration required
32 91-08 91-08 Throttle Position signal abnormal
(continued)
30 SEBU7902-02
Operation Section
Engine Diagnostics
(Table 3, contd)
Diagnostic Code
Event Code
190-08 190-08 Engine Speed signal abnormal
34
723-08 342-08 Secondary Engine Speed signal abnormal
190-15 Engine Overspeed Warning
35 E362(2)
190-00 Engine Overspeed Shutdown
94-03 94-03 Fuel Pressure open/short to +batt
37
94-04 94-04 Fuel Pressure short to ground
105-03 172-03 Intake Manifold Air Temp open/short to +batt
38
105-04 172-04 Intake Manifold Air Temp short to ground
42 637-13 261-13 Engine Timing calibration required
100-17 Low Engine Oil Pressure Warning
46 100-18 E360(2) Low Engine Oil Pressure Derate
100-01 Low Engine Oil Pressure Shutdown
168-00 168-00 System Voltage high
51 168-01 168-01 System Voltage low
168-02 168-02 System Voltage intermittent/erratic
56 630-02 268-02 Check Programmable Parameters
58 639-09 247-09 J1939 Data Link communications
110-15 High Engine Coolant Temperature Warning
61 110-16 E361(2) High Engine Coolant Temperature Derate
110-00 High Engine Coolant Temperature Shutdown
111-17 Low Engine Coolant Level Warning
62 111-18 E2143(2) Low Engine Coolant Level Derate
111-01 Low Engine Coolant Level Shutdown
63 94-15 E096 High Fuel Pressure Warning
1636-15 High Inlet Air Temperature Warning
64 E539(2)
1636-00 High Inlet Air Temperature Shutdown
174-15 High Fuel Temperature Warning
65 174-16 E363(2) High Fuel Temperature Derate
174-00 High Fuel Temperature Shutdown
651-05 001-05 Injector Cylinder 1 open circuit
71 651-06 001-06 Injector Cylinder 1 short
651-11 001-11 Injector Cylinder #1 fault
(continued)
SEBU7902-02 31
Operation Section
Engine Diagnostics
(Table 3, contd)
Diagnostic Code
Event Code
75 655-05 005-05 Injector Cylinder 5 open circuit
655-06 005-06 Injector Cylinder 5 short
(1) Suspect Parameter Number
(2) Caterpillar Electronic Technician (ET) will display the number 1, 2, or 3 after the event code in order to designate a warning, a derate,
or a shutdown.
For further information, see the troubleshooting guide i01797045

for your engine.
Engine Operation with Active
i02512380
Diagnostic Codes
Fault Logging SMCS Code: 1000; 1900; 1901; 1902
SMCS Code: 1000; 1900; 1901; 1902 If a diagnostic lamp illuminates during normal engine
operation, the system has identified a situation that is
The system provides the capability of Fault Logging. not within the specification. Use Caterpillar electronic
When the Electronic Control Module (ECM) service tools to check the active diagnostic codes.
generates an active diagnostic code, the code will be
logged in the memory of the ECM. The codes that Note: If the customer has selected “DERATE” and if
have been logged in the memory of the ECM can there is a low oil pressure condition, the Electronic
be retrieved with Caterpillar electronic service tools. Control Module (ECM) will limit the engine power
The codes that have been logged can be cleared until the problem is corrected. If the oil pressure is
with Caterpillar electronic service tools. The codes within the normal range, the engine may be operated
that have been logged in the memory of the ECM at the rated speed and load. However, maintenance
will be automatically cleared from the memory after should be performed as soon as possible.
100 hours. The following faults can not be cleared
from the memory of the ECM without using a factory The active diagnostic code should be investigated.
password: overspeed, low engine oil pressure, and The cause of the problem should be corrected as
high engine coolant temperature. soon as possible. If the cause of the active diagnostic
code is repaired and there is only one active
diagnostic code, the diagnostic lamp will turn off.
Operation of the engine and performance of the

engine can be limited as a result of the active
diagnostic code that is generated. Acceleration
rates may be significantly slower. Refer to the
Troubleshooting Guide for more information on the
relationship between these active diagnostic codes
and engine performance.
32 SEBU7902-02
Operation Section
Engine Diagnostics
i01456915 i01801152
Engine Operation with Customer Specified

Intermittent Diagnostic Codes Parameters
SMCS Code: 1000; 1900; 1901; 1902 SMCS Code: 1000; 1900; 1901; 1902
If the diagnostic lamp starts to flash codes during Customer specified parameters that will enhance
normal engine operation and the diagnostic lamp the fuel efficiency and the operator’s convenience
shuts off, an intermittent fault may have occurred. If can be programmed into the Electronic Control
a fault has occurred, the fault will be logged into the Module (ECM). Some parameters may affect
memory of the Electronic Control Module (ECM). engine operation. This may lead to complaints from
the operator about power or about performance.
In most cases, it is not necessary to stop the engine The following engine related parameters may be
because of an intermittent code. However, the programmed by the customer by using Caterpillar
operator should retrieve the logged fault codes electronic service tools in order to influence the
and the operator should reference the appropriate operation of the engine:
information in order to identify the nature of the event.
The operator should log any observation that could • Customer Passwords
have caused the lamp to light.
• Power Rating (hp at rpm)
• Low power
• Rating Selection
• Limits of the engine speed
• Air/Fuel Ratio
• Excessive smoke, etc
• PTO Ramp Rate
This information can be useful to help troubleshoot
the situation. The information can also be used for • Low Idle
future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this • High Idle
engine.
• Top Engine Limit
• Torque Limit
• Intermediate Speed
• Engine Monitoring Mode
• Equipment ID
• Maintenance Indicator
• Parameter Lockout
The customer specified parameters can be changed
as often as needed. Password protection is provided
so that the customer can change the parameters. The
customer can authorize someone else to change the
parameters. Ensure that a record of the parameters
is kept in the Operation and Maintenance Manual.
For detailed instructions on programming the engine
for optimum performance and for optimum fuel
economy, consult your Caterpillar dealer.
SEBU7902-02 33
Operation Section
Engine Starting
Engine Starting • 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
i02109067 to the controls.
Before Starting Engine • Ensure that the areas around the rotating parts are
clear.
SMCS Code: 1000; 1400; 1450
• All of the guards must be put in place. Check for
Perform the required daily maintenance and other damaged guards or for missing guards. Repair
periodic maintenance before the engine is started. any damaged guards. Replace damaged guards
Inspect the engine compartment. This inspection can and/or missing guards.
help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, “Maintenance • Disconnect any battery chargers that are not
Interval Schedule” for more information. protected against the high current drain that
is created when the electric starting motor (if
• For the maximum service life of the engine, make equipped) is engaged. Check electrical cables
a thorough inspection before the engine is started. and check the battery for poor connections and
Look for the following items: oil leaks, coolant for corrosion.
leaks, loose bolts, and trash buildup. Remove trash
buildup and arrange for repairs, as needed. • Reset all of the shutoffs or alarm components.
• Inspect the aftercooler for loose connections and • Check the engine lubrication oil level. Maintain the
for debris buildup. oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• Inspect the cooling system hoses for cracks and
for loose clamps. • Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
• Inspect the alternator and accessory drive belts for the coolant level to the “FULL” mark on the coolant
cracks, breaks, and other damage. recovery tank.
• Inspect the wiring for loose connections and for • If the engine is not equipped with a coolant
worn wires or frayed wires. recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If
• Check the fuel supply. Drain water from the water the engine is equipped with a sight glass, maintain
separator (if equipped). Open the fuel supply valve. the coolant level in the sight glass.
NOTICE • Observe the air cleaner service indicator (if

All valves in the fuel return line must be open before equipped). Service the air cleaner when the yellow
and during engine operation to help prevent high fuel diaphragm enters the red zone, or when the red
pressure. High fuel pressure may cause filter housing piston locks in the visible position.
failure or other damage.
• Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove
If the engine has not been started for several weeks, any electrical loads.
fuel may have drained from the fuel system. Air
may have entered the filter housing. Also, when fuel
filters have been changed, some air pockets will be i01903151
trapped in the engine. In these instances, prime the
fuel system. Refer to the Operation and Maintenance
Starting the Engine
Manual, “Fuel System - Prime” for more information
SMCS Code: 1000; 1450
on priming the fuel system.
Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will
control the engine speed during start-up.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start Starting a Cold Engine
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the 1. Disengage any equipment that is driven by the
outside. engine.
34 SEBU7902-02
Operation Section
Engine Starting
2. Turn the keyswitch to the RUN position. Leave the Startability will be improved at temperatures below
keyswitch in the RUN position for 15 seconds. −18 °C (0 °F) from the use of a jacket water heater
or extra battery capacity.
3. Turn the keyswitch to the START position in order
to engage the electric starting motor and crank When No. 2 diesel fuel is used, the following items
the engine. provide a means of minimizing starting problems
and fuel problems in cold weather: engine oil pan
NOTICE heaters, jacket water heaters, fuel heaters, and fuel
Do not engage the starting motor when flywheel is line insulation.
turning. Do not start the engine under load.
Use the procedure that follows for cold weather
If the engine fails to start within 30 seconds, release starting.
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to Note: Do not adjust the engine speed control during
start the engine again. start-up. The electronic control module (ECM) will
control the engine speed during start-up.
4. Allow the keyswitch to return to the RUN position 1. Disengage any driven equipment.
after the engine starts.
2. Turn the keyswitch to the RUN position. Leave the
5. Repeat step 2 through step 4 if the engine fails keyswitch in the RUN position for 20 seconds.
to start.
NOTICE
Starting a Warm Engine Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
1. Disengage any equipment that is driven by the
engine. If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
2. Turn the keyswitch to the START position in order allow the starting motor to cool before attempting to
to engage the electric starting motor and crank start the engine again.
the engine.
3. Turn the keyswitch to the START position in order
NOTICE to engage the starting motor and crank the engine.
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load. 4. Allow the keyswitch to return to the RUN position
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to 5. Repeat step 2 through step 4 if the engine fails
allow the starting motor to cool before attempting to to start.
start the engine again.
6. Allow the engine to idle for three to five minutes, or
allow the engine to idle until the water temperature
3. Allow the keyswitch to return to the RUN position
indicator begins to rise. The engine should run
at low idle smoothly until speed is gradually
increased to high idle. Allow the white smoke to
4. Repeat step 2 and step 3 if the engine fails to start.
disperse before proceeding with normal operation.
i01797227 7. Operate the engine at low load until all systems

reach operating temperature. Check the gauges
Cold Weather Starting during the warm-up period.
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.
SEBU7902-02 35
Operation Section
Engine Starting
i01934760 5. Immediately after the stalled engine is started,

disconnect the jump start cables in reverse order.
Starting with Jump Start
Cables Note: If there is a problem with the alternator or the
battery charger, the engine will not continue to run
SMCS Code: 1000; 1401; 1402; 1900 after starting, unless the power to the engine control
module is supplied by a separate source.
i01646248
Improper jump start cable connections can cause
an explosion resulting in personal injury. After Starting Engine
Prevent sparks near the batteries. Sparks could SMCS Code: 1000
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine. Note: In temperatures from 0 to 60°C (32 to 140°F),
the warm-up time is approximately three minutes. In
temperatures below 0°C (32°F), additional warm-up
If the installation is not equipped with a backup time may be required.
battery system, it may be necessary to start the
engine from an external electrical source. Note: Ensure that the self test for the monitoring
system (if equipped) is completed before operating
NOTICE the engine under load.
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for When the engine idles during warm-up, observe the
jump starting. The use of higher voltage will damage following conditions:
the electrical system.
• Check for any fluid or for any air leaks at idle rpm
Do not reverse the battery cables. The alternator can and at one-half full rpm (no load on the engine)
be damaged. Attach ground cable last and remove before operating the engine under load. This is not
first. possible in some applications.
When using an external electrical source to start the • Operate the engine at low idle until all systems
engine, turn the generator set control switch to the achieve operating temperatures. Check all gauges
“OFF” position. Turn all electrical accessories OFF be- during the warm-up period.
fore attaching the jump start cables.
Note: Gauge readings should be observed and
Ensure that the main power switch is in the OFF posi- the data should be recorded frequently while the
tion before attaching the jump start cables to the en- engine is operating. Comparing the data over time
gine being started. will help to determine normal readings for each
gauge. Comparing data over time will also help
detect abnormal operating developments. Significant
1. Turn the start switch to the OFF position. Turn off changes in the readings should be investigated.
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.
3. Connect one negative end of the jump start cable

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

36 SEBU7902-02
Operation Section
Engine Operation
Engine Operation i01196062
Engaging the Driven

i02176671 Equipment
Engine Operation SMCS Code: 1000
SMCS Code: 1000
If the load varies, or if the load is cyclic, the governor
will adjust the engine rpm, as needed.
Correct operation and maintenance are key factors
in obtaining the maximum life and economy of
Extended operation at low idle or extended
the engine. If the directions in the Operation and
operation at a reduced load may cause increased
Maintenance Manual are followed, costs can be
oil consumption and carbon buildup in the cylinders.
minimized and engine service life can be maximized.
This carbon buildup results in a loss of power and/or
poor performance. When the engine is operated at
The engine can be operated at the rated rpm after the
a reduced load, the engine should be fully loaded
engine reaches operating temperature. The engine
at every four hours in order to burn excess carbon
will reach normal operating temperature sooner
from the cylinders.
during a low engine speed (rpm) and during a low
power demand. This procedure is more effective than
idling the engine at no load. The engine should reach Industrial Engines
operating temperature in a few minutes.
1. When the engine is operating, check the engine
Gauge readings should be observed and the data gauges. The engine gauges should be in the
should be recorded frequently while the engine normal range before you engage the driven
is operating. Comparing the data over time will equipment.
help to determine normal readings for each gauge.
Comparing data over time will also help detect 2. Engage the driven equipment. Begin operating the
abnormal operating developments. Significant engine at low load. Check the gauges and check
changes in the readings should be investigated. the equipment for proper operation. Check the
gauges and check the equipment frequently while
the engine is operating under load.
i00808595
Engine Warm-up i01878039
SMCS Code: 1000 Fuel Conservation Practices

1. Run the engine at low idle for three to five minutes, SMCS Code: 1000; 1250
or run the engine at low idle until the jacket water
temperature starts to rise. The efficiency of the engine can affect the fuel
economy. Caterpillar’s design and technology in
More time may be necessary when the manufacturing provides maximum fuel efficiency in
temperature is below −18° C (0° F). all applications. Follow the recommended procedures
in order to attain optimum performance for the life
2. Check all of the gauges during the warm-up of the engine.
period.
• Avoid spilling fuel.
3. Perform another walk-around inspection. Check
the engine for fluid leaks and air leaks. Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
4. Increase the rpm to the rated rpm. Check for fluid leaks. Repair the fuel lines, as needed.
leaks and air leaks. The engine may be operated
at full rated rpm and at full load when the engine • Be aware of the properties of the different fuels.
oil temperature reaches 60° C (140° F). Use only the recommended fuels.
• Avoid unnecessary operation at no load.

Shut off the engine instead of operating the engine
at no load for long periods of time.
SEBU7902-02 37
Operation Section
Engine Operation
• Observe the service indicator for the air cleaner

frequently, if equipped. Keep the air cleaner
elements clean.
• Maintain a good electrical system.

One bad battery cell will overwork the alternator. This
will consume excess power and excess fuel.
• Ensure that the belts are properly adjusted. The

belts should be in good condition.
• Ensure that all of the connections of the hoses are

tight. The connections should not leak.
• Ensure that the driven equipment is in good

working order.
• Cold engines consume excess fuel. Keep cooling

system components clean and keep cooling
system components in good repair. Never operate
the engine without water temperature regulators.
All of these items will help maintain operating
temperatures.
• Settings for the fuel system and the limits for the
operating altitude are stamped on the Engine
Information Plate. If an engine is moved to a
higher altitude, the settings must be changed by a
Caterpillar dealer. Changing the settings will help
to provide the maximum efficiency for the engine.
Engines can be operated safely at higher altitudes,
but the engines will deliver less horsepower. The
fuel settings should be changed by a Caterpillar
dealer in order to obtain the rated horsepower.
38 SEBU7902-02
Operation Section
Engine Stopping
Engine Stopping i02069570
After Stopping Engine

i01646416
SMCS Code: 1000
Manual Stop Procedure
Note: Before you check the engine oil, do not operate
SMCS Code: 1000 the engine for at least 10 minutes in order to allow
the engine oil to return to the oil pan.
Note: Individual applications will have different
control systems. Ensure that the shutoff procedures • Check the crankcase oil level. Maintain the oil level
are understood. Use the following general guidelines between the “ADD” mark and the “FULL” mark on
in order to stop the engine. the oil level gauge.
1. Remove the load, when possible. Reduce the Note: Only use oil that is recommended in
engine speed (rpm) to low idle. this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” article. Failure to
2. Increase the engine speed (rpm) to no more than do so may result in engine damage.
one-half of the rated rpm. Perform this procedure
for three to five minutes in order to cool the engine. • If necessary, perform minor adjustments. Repair
Reduce the engine speed (rpm) to low idle. any leaks and tighten any loose bolts.
3. After the cool down period, turn the key switch to • Note the service hour meter reading. Perform
the OFF position. the maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
• Fill the fuel tank in order to help prevent

accumulation of moisture in the fuel. Do not overfill
the fuel tank.
• Allow the engine to cool. Check the coolant level.

Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling.
Note: Only use coolant that is recommended in

this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” article. Failure to
do so may result in engine damage.
• If freezing temperatures are expected, check

the coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in
the instructions from the OEM.
SEBU7902-02 39
Operation Section
Cold Weather Operation
Cold Weather Operation i01872912
Fuel and the Effect from Cold

i01646447 Weather
Radiator Restrictions SMCS Code: 1000; 1250
SMCS Code: 1353; 1396
The following fuels are the grades that are available
for Caterpillar engines:
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow
restriction can cause the following conditions: • No. 1
• High exhaust temperatures • No. 2
• Power loss • Blend of No. 1 and No. 2

No. 2 diesel fuel is the most commonly used fuel.
• Excessive fan usage Either No. 1 diesel fuel or a blend of No. 1 and No. 2
is best suited for cold weather operation.
• Reduction in fuel economy
Quantities of No. 1 diesel fuel are limited. No. 1 diesel
If an airflow restriction device must be used, the
fuels are usually available during the months of the
device should have a permanent opening directly
winter in the colder climates. During cold weather
in line with the fan hub. A centered opening that is
operation, if No. 1 diesel fuel is not available, use No.
directly in line with the fan hub is specified in order
2 diesel fuel, if necessary.
to prevent an interrupted airflow on the fan blades.
Interrupted airflow on the fan blades could cause a
There are three major differences between No. 1 and
fan failure.
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
Caterpillar recommends a warning device for the
inlet manifold temperature and/or the installation of
an inlet air temperature gauge. The warning device • Lower cloud point
for the inlet manifold temperature should be set at
75 °C (167 °F). The inlet manifold air temperature • Lower pour point
should not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential • Lower rating of kJ (BTU) per unit volume of fuel
engine damage.
When No. 1 diesel fuel is used, a decrease in power
and in fuel efficiency may be noticed. Other operating
effects should not be experienced.
The cloud point is the temperature when a cloud of

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

purchased. Anticipate the average ambient
temperature for the engine area. Engines that are
fueled in one climate may not operate well if the
engines are moved to another climate. Problems can
result due to changes in temperature.
Before troubleshooting for low power or for poor

performance during cold weather, check the type of
fuel that is being used.
40 SEBU7902-02
Operation Section
Cold Weather Operation
i02010887 Disconnect the fuel heater in warm weather.

Fuel Related Components in Note: Fuel heaters that are controlled by the water
Cold Weather temperature regulator or self-regulating fuel heaters
should be used with this engine. Fuel heaters that
SMCS Code: 1000; 1250 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
Fuel Tanks exceeds 37°C (100°F).
Condensation can form in partially filled fuel tanks. Note: Heat exchanger type fuel heaters should have
Top off the fuel tanks after you operate the engine. a bypass provision in order to prevent overheating of
the fuel in warm weather operation.
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,
and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.
Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual in the Maintenance Section for more
information on priming the fuel system.
The micron rating and the location of a primary fuel

filter is important in cold weather operation. The
primary fuel filter and the fuel supply line are the most
common components that are affected by cold fuel.
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in the fuel system before the primary
fuel filter.
The following fuel heaters are recommended for

Caterpillar engines:
• 7C-3557 Fuel Heater Group

• 7C-3558 Heater Kit
For further information on fuel heaters, consult your
Caterpillar dealer.
SEBU7902-02 41
Maintenance Section
Refill Capacities
Maintenance Section
NOTICE
Caterpillar does not warrant the quality or perfor-
mance of non-Caterpillar fluids.
Refill Capacities
Caterpillar developed the Engine Crankcase Fluid
i02766817 (ECF) specifications to ensure the availability of high
performance commercial diesel engine oils in order
Refill Capacities and to provide satisfactory life and performance in Cat
Recommendations diesel engines.
SMCS Code: 1348; 1395; 7560 Note: If Cat DEO multigrade or DEO-ULS multigrade
oils are not used, use only commercial oils that meet
the following categories or specifications:
Engine Oil
• Commercial oils that meet the requirements of
NOTICE the Cat ECF-1-a, Cat ECF-2, and/or the Cat
These recommendations are subject to change with- ECF-3 specification are acceptable for use in Cat
out notice. Contact your local Caterpillar dealer for the diesel engines. API oils that have not met the
most up to date fluids recommendations. requirements of at least one Cat ECF specification
may cause reduced engine life.
Cat DEO (Diesel Engine Oil) • Commercial alternative oils that are preferred meet
the requirements of the Cat ECF-3 specification or
Caterpillar oils have been developed and tested in the API CJ-4 requirements.
order to provide the full performance and service
life that has been designed and built into Caterpillar Oils that meet API CJ-4 requirements are compliant
Engines. Caterpillar oils are currently used to fill with Cat ECF-3 specifications.
diesel engines at the factory. These oils are offered
by Caterpillar dealers for continued use when the For diesel engines that are equipped with a Diesel
engine oil is changed. Consult your Caterpillar dealer Particulate Filter (DPF), the Cat ECF-3 specification
for more information on these oils. and the API CJ-4 oil category limit sulfated ash to
1.0% or less, which helps maintain the expected DPF
Due to significant variations in the quality and in performance. Use of oil that does not meet the Cat
the performance of commercially available oils, ECF-3 specification or the API CJ-4 oil category may
Caterpillar makes the following recommendations: require more frequent DPF cleaning cycles and may
contribute to DPF plugging.
• Cat DEO (Diesel Engine Oil) (SAE 10W-30)
API CG-4 category oils are fourth choice commercial
• Cat DEO (Diesel Engine Oil) (SAE 15W-40) alternative oils. Oils that meet any of the Cat ECF
specifications will perform better than API CG-4 oil.
• Cat DEO-ULS (Diesel Engine Oil - Ultralow
Sulfur) (15W-40) Note: Do not use API CF or API CF-4 oils in
Caterpillar Direct Injection (DI) diesel engines.
Note: Cat DEO-ULS multigrade is the preferred oil
for use in this engine. NOTICE
In selecting oil for any engine application, both the
Cat DEO multigrade and Cat DEO-ULS multigrade oil viscosity and oil performance category/specifica-
oils are formulated with the correct amounts of tion as specified by the engine manufacturer must be
detergents, dispersants, and alkalinity in order to defined and satisfied. Using only one of these param-
provide superior performance in Cat diesel engines. eters will not sufficiently define oil for an engine appli-
cation.
Commercial Oils
Engine Crankcase Fluid Recommendations for NOTICE
all Caterpillar 3500 Series and smaller direct Failure to follow these oil recommendations can cause
injection (DI) diesel engines shortened engine service life due to deposits and/or
excessive wear.
Note: Non-Caterpillar commercial oils are second
choice oils.
42 SEBU7902-02
Maintenance Section
Refill Capacities
Note: Refer to Special Publication, SEBU6251, Table 5

“Caterpillar Commercial Diesel Engine Fluids Approximate Refill Capacities
Recommendations” for additional information that
relates to lubrication for your engine. Compartment or System Liters Quarts
Engine Crankcase (1) 38 40
Lubricant Viscosity Recommendations
Capacity of the Auxiliary Oil Filter
System(2)
The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during Total Capacity of the Lubrication
cold engine start-up, and the maximum ambient System(3)
temperature during engine operation. (1) Approximate sump capacity of the crankcase includes a
standard oil filter that is factory installed. Engines with auxiliary
Refer to Table 4 (minimum temperature) in order to oil filters will require additional oil. Engines that are equipped
determine the required oil viscosity for starting a cold, with factory installed dual oil filters require an additional 3.7 L
(3.9 qt) of oil. If the engine is equipped with another type
soaked engine. of auxiliary oil filter, refer to the OEM specifications for the
capacity of the auxiliary oil filter.
Refer to Table 4 (maximum temperature) in order to (2) Fill in the capacity of the auxiliary oil filter system (if equipped)
select the oil viscosity for engine operation at the in the space that is provided.
highest ambient temperature that is anticipated. (3) Fill in the total capacity of the lubrication system. Add the
auxiliary oil filter system to the correct capacity of the engine
crankcase that is for your engine. The final number is the total
Note: Generally, use the highest oil viscosity that is capacity of the lubrication system.
available to meet the requirement for the temperature
at start-up.
Fuel
If ambient temperature conditions at engine start-up
require the use of multigrade SAE 0W oil, SAE Fuel Recommendations
0W-40 viscosity grade is preferred over SAE 0W-30.
In North America, diesel fuel that is identified as
Table 4 No. 1-D or No. 2-D in “ASTM D975” generally meet
Engine Oil Viscosities for Ambient Temperatures the specifications. These fuels are distilled from
crude oil. Diesel fuels from other sources could
Ambient Temperature exhibit detrimental properties that are not defined or
Viscosity Grade Minimum Maximum controlled by this specification.
SAE 0W-30 −40 °C (−40 °F) 30 °C (86 °F) Refer to Special Publication, SEBU6251, “Caterpillar
SAE 0W-40 −40 °C (−40 °F) 40 °C (104 °F) Commercial Diesel Engine Fluids Recommendations”
for additional information that relates to diesel fuel.
SAE 5W-30 −30 °C (−22 °F) 30 °C (86 °F)
SAE 5W-40 −30 °C (−22 °F) 50 °C (122 °F) Cooling System
SAE 10W-30 −18 °C (0 °F) 40 °C (104 °F)
SAE 10W-40 −18 °C (0 °F) 50 °C (122 °F)
Coolant Recommendations
SAE 15W-40 −9.5 °C (15 °F) 50 °C (122 °F) NOTICE
Do not use a commercial coolant/antifreeze that only
Note: Supplemental heat is recommended below the meets the ASTM “D3306” specification. This type of
minimum recommended ambient temperature. coolant/antifreeze is made for light duty automotive
applications.
Lubricant Capacities Use only the coolant/antifreeze that is recommended.
The capacity of the engine lubrication system
includes the capacity of the oil filters that are installed The following coolants are the primary types of
at the factory. Auxiliary oil filter systems (if equipped) coolants that are used in Caterpillar Engines:
will require additional oil. Refer to the specifications
that are provided by the OEM of the auxiliary oil filter Preferred – Caterpillar Extended Life Coolant (ELC)
system. or a commercial extended life coolant that meets the
Caterpillar EC-1 specification
SEBU7902-02 43
Maintenance Section
Refill Capacities
Acceptable – Caterpillar Diesel Engine Table 6

Antifreeze/Coolant (DEAC) or a commercial Coolant Service Life
heavy-duty coolant/antifreeze that meets “ASTM
D4985” or “ASTM D5345” specifications Coolant Type Service Life (1)
Caterpillar ELC Six Years

Caterpillar recommends a 1:1 mixture of water and
glycol. This mixture will provide optimum heavy-duty Caterpillar DEAC Three Years
performance as a coolant/antifreeze. Commercial Heavy-Duty
Coolant/Antifreeze that Two Years
Note: Caterpillar DEAC DOES NOT require a meets “ASTM D5345”
treatment with an SCA at the initial fill. Commercial
heavy-duty coolant or antifreeze that meets “ASTM Commercial Heavy-Duty
D4985” or “ASTM D5345” specifications MAY require Coolant/Antifreeze that One Year
meets “ASTM D4985”
a treatment with an SCA at the initial fill. Read the
label or the instructions that are provided by the OEM Caterpillar SCA and
Two Years
of the product. Water
Commercial SCA and
In stationary engine applications and marine engine Water
One Year
applications that do not require protection from
(1) The service life of coolant is also limited by use (service hours).
boiling or freezing, a mixture of SCA and water is
Refer to the specific engine’s Operation and Maintenance
acceptable. Caterpillar recommends a minimum Manual, “Maintenance Interval Schedule” (Maintenance
of six percent to a maximum of eight percent Section).
SCA concentration in those cooling systems.
Distilled water or deionized water is preferred. Water
which has the required properties may be used. For
Coolant Capacities
the water properties, refer to Special Publication,
To properly maintain the cooling system, the total
SEBU6251, “Caterpillar Commercial Diesel Engine
cooling system capacity must be determined. The
Fluids Recommendations” for additional information
total cooling system capacity will vary between
that relates coolant.
individual installations. The total cooling system
capacity can include the following components:
Note: Table 6 is a list of the coolants that are
engine, expansion tank, heat exchanger, radiator,
recommended and the service life (calendar) of the
keel cooler, and piping.
coolants. The service life of coolant is also limited by
use (service hours). Refer to the specific engine’s
Refer to the specifications that are provided by
Operation and Maintenance Manual, “Maintenance
Caterpillar or the OEM of the installation. Record the
Interval Schedule” (Maintenance Section). To
total cooling system capacity in the appropriate Table.
achieve this service life, the coolants must be
properly maintained. The maintenance program Table 7
includes S·O·S coolant analysis.
Approximate Refill Capacities
Compartment or System Liters Quarts
Total Cooling System(1)
(1) The total cooling system capacity includes the following
components: Engine block, Radiator, and Coolant hoses and
lines
44 SEBU7902-02
Maintenance Section
Maintenance Interval Schedule
i02767747 Initial 500 Hours (for New Systems, Refilled

Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) -
SMCS Code: 1000; 7500 Obtain ................................................................. 55
Ensure that all safety information, warnings, and Every 500 Service Hours
instructions are read and understood before any
operation or any maintenance procedures are Belts - Inspect/Adjust/Replace .............................. 48
performed. Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 54
The user is responsible for the performance of Turbocharger - Inspect .......................................... 79
maintenance, including all adjustments, the use of Water Pump - Inspect ........................................... 81
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure Every 500 Service Hours (Deep Sump)
to adhere to proper maintenance intervals and
procedures may result in diminished performance of Engine Oil and Filter - Change ............................. 66
the product and/or accelerated wear of components.
Every 3000 Service Hours or 3 Years
Use mileage, fuel consumption, service hours, or
Cooling System Coolant (DEAC) - Change .......... 48
calendar time, WHICH EVER OCCURS FIRST,
Cooling System Coolant Extender (ELC) - Add .... 53
in order to determine the maintenance intervals.
Products that operate in severe operating conditions Cooling System Water Temperature Regulator -
Replace ............................................................... 56
may require more frequent maintenance.
Engine Protective Devices - Check ...................... 67
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Every 8000 Service Hours or 3 Years
performed. Driven Equipment - Check .................................... 57
When Required Every 12 000 Service Hours or 6 Years
Battery - Replace .................................................. 46 Cooling System Coolant (ELC) - Change ............. 51
Battery or Battery Cable - Disconnect .................. 47
Engine Air Cleaner Element (Dual Element) -
Every 14 400 L (3750 US gal) of Fuel or 250
Clean/Replace .................................................... 59
Engine Storage Procedure - Check ...................... 68 Service Hours or 1 Year
Fuel System - Prime ............................................. 70 Battery Electrolyte Level - Check .......................... 47
Severe Service Application - Check ..................... 78 Electronics Grounding Stud - Inspect/Clean/
Tighten ................................................................ 58
Daily Engine Crankcase Breather - Clean ..................... 63
Engine Oil Sample - Obtain .................................. 65
Cooling System Coolant Level - Check ................ 53
Fuel System Primary Filter (Water Separator)
Engine Air Cleaner Service Indicator - Inspect ..... 62
Element - Replace .............................................. 72
Engine Air Precleaner - Check/Clean ................... 63
Fuel System Secondary Filter - Replace .............. 73
Engine Oil Level - Check ...................................... 64
Hoses and Clamps - Inspect/Replace .................. 75
Fuel System Primary Filter/Water Separator -
Radiator - Clean .................................................... 78
Drain ................................................................... 72
Fuel Tank Water and Sediment - Drain ................. 74
Walk-Around Inspection ........................................ 80 Every 114 000 L (30 000 US gal) of Fuel or
3000 Service Hours
Initial 250 Service Hours (or at first oil Aftercooler Core - Clean/Test ............................... 46
change)
Engine Valve Lash - Inspect/Adjust ...................... 69 Every 170 400 L (45 000 US gal) of Fuel or
3000 Service Hours
Every 250 Service Hours Crankshaft Vibration Damper - Inspect ................. 57
Cooling System Supplemental Coolant Additive Electronic Unit Injector - Inspect/Adjust ................ 58
Engine - Clean ...................................................... 59
(SCA) - Test/Add ................................................. 55
Engine Mounts - Inspect ....................................... 64
Engine Oil and Filter - Change ............................. 66
Starting Motor - Inspect ........................................ 79 Engine Speed/Timing Sensors - Check/Clean/
Calibrate .............................................................. 68
Engine Valve Lash - Inspect/Adjust ...................... 69
SEBU7902-02 45
Maintenance Section
Engine Valve Rotators - Inspect ........................... 69

Fan Drive Bearing - Lubricate ............................... 69
Every 380 000 L (100 000 US gal) of Fuel or

10 000 Service Hours
Overhaul Considerations ...................................... 75
Overhaul
Fan Drive Bearing - Replace ................................ 70
46 SEBU7902-02
Maintenance Section
Aftercooler Core - Clean/Test
i01188617 Note: If parts of the aftercooler system are repaired

or replaced, a leak test is highly recommended. The
Aftercooler Core - Clean/Test FT1984 Aftercooler Testing Group is used to perform
(Air-To-Air Aftercooler) leak tests on the aftercooler. Refer to the Systems
Operation/Testing and Adjusting, “Aftercooler - Test”
SMCS Code: 1064-070; 1064-081 and the Special Instruction, SEHS8622 for the proper
testing procedure.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. Inspect these items for good condition: welds,
mounting brackets, air lines, connections, clamps,
Inspect the cooling air side of the aftercooler for these and seals. Make repairs, if necessary.
items: damaged fins, corrosion, dirt, grease, insects,
leaves, oil, and other debris. Clean the cooling air For more detailed information on cleaning and
side of the aftercooler, if necessary. inspection, see Special Publication, SEBD0518,
“Know Your Cooling System”.
For air-to-air aftercoolers, use the same methods that
are used for cleaning the outside of radiators. i01878164
Battery - Replace
SMCS Code: 1401-510
Personal injury can result from air pressure.
Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing. Batteries give off combustible gases which can
explode. A spark can cause the combustible gas-
Maximum air pressure at the nozzle must be less es to ignite. This can result in severe personal in-
than 205 kPa (30 psi) for cleaning purposes. jury or death.
Ensure proper ventilation for batteries that are in

Pressurized air is the preferred method for removing an enclosure. Follow the proper procedures in or-
loose debris. Direct the air in the opposite direction der to help prevent electrical arcs and/or sparks
of the fan’s air flow. Hold the nozzle approximately near batteries. Do not smoke when batteries are
6 mm (0.25 inch) away from the fins. Slowly move the serviced.
air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.
Pressurized water may also be used for cleaning.

The maximum water pressure for cleaning purposes The battery cables or the batteries should not be
must be less than 275 kPa (40 psi). Use pressurized removed with the battery cover in place. The bat-
water in order to soften mud. Clean the core from tery cover should be removed before any servic-
both sides. ing is attempted.
Use a degreaser and steam for removal of oil and Removing the battery cables or the batteries with
grease. Clean both sides of the core. Wash the core the cover in place may cause a battery explosion
with detergent and hot water. Thoroughly rinse the resulting in personal injury.
core with clean water.
After cleaning, start the engine and accelerate the 1. Switch the engine to the OFF position. Remove
engine to high idle rpm. This will help in the removal all electrical loads.
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect 2. Turn off any battery chargers. Disconnect any
the core for cleanliness. Repeat the cleaning, if battery chargers.
necessary.
3. The NEGATIVE “-” cable connects the NEGATIVE
Inspect the fins for damage. Bent fins may be opened “-” battery terminal to the NEGATIVE “-” terminal
with a “comb”. on the starter motor. Disconnect the cable from
the NEGATIVE “-” battery terminal.
SEBU7902-02 47
Maintenance Section
Battery Electrolyte Level - Check
4. The POSITIVE “+” cable connects the POSITIVE • A mixture of 0.1 kg (0.2 lb) of baking soda and
“+” battery terminal to the POSITIVE “+” terminal 1 L (1 qt) of clean water
on the starting motor. Disconnect the cable from
the POSITIVE “+” battery terminal. • A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate Thoroughly rinse the battery case with clean water.
recycling facility.
Use a fine grade of sandpaper to clean the
5. Remove the used battery. terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
6. Install the new battery. remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Note: Before the cables are connected, ensure that Coat the clamps and the terminals with 5N-5561
the engine start switch is OFF. Silicone Lubricant, petroleum jelly or MPGM.
7. Connect the cable from the starting motor to the

i01492654
POSITIVE “+” battery terminal.
8. Connect the cable from the NEGATIVE “-” terminal

Battery or Battery Cable -
on the starter motor to the NEGATIVE “-” battery Disconnect
terminal.
SMCS Code: 1402-029
i02601752
Battery Electrolyte Level -

The battery cables or the batteries should not be
Check removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
SMCS Code: 1401-535 ing is attempted.
When the engine is not run for long periods of time or Removing the battery cables or the batteries with
when the engine is run for short periods, the batteries the cover in place may cause a battery explosion
may not fully recharge. Ensure a full charge in order resulting in personal injury.
to help prevent the battery from freezing.
1. Turn the start switch to the OFF position. Turn the

ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face 2. Disconnect the negative battery terminal at the
shield and protective clothing when working on or battery that goes to the start switch. Ensure that
near batteries. the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
1. Remove the filler caps. Maintain the electrolyte two batteries must be disconnected.
level to the “FULL” mark on the battery.
3. Tape the leads in order to help prevent accidental
If the addition of water is necessary, use distilled starting.
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially 4. Proceed with necessary system repairs. Reverse
softened water. the steps in order to reconnect all of the cables.
2. Check the condition of the electrolyte with the

245-5829 Coolant Battery Tester Refractometer.
3. Keep the batteries clean.
Clean the battery case with one of the following

cleaning solutions:
48 SEBU7902-02
Maintenance Section
Belts - Inspect/Adjust/Replace
i02042962 3. Move the assembly in order to increase or

decrease the belt tension.
Belts - Inspect/Adjust/Replace
4. Tighten adjusting bolt (2). Tighten mounting bolts
SMCS Code: 1357-025; 1357-040; 1357-510 (1).
Inspection 5. Reinstall the belt guard.
Inspect the alternator belt and the fan drive belts for If new drive belts are installed, check the drive belt
wear and for cracking. Replace the belts if the belts tension again after 30 minutes of engine operation
are not in good condition. at the rated rpm.
Check the belt tension according to the information in Adjustment of the Fan Drive Belt
the Service Manual, “Specifications”.
1. Remove the belt guard.
Slippage of loose belts can reduce the efficiency
of the driven components. Vibration of loose belts 2. Loosen the mounting bolt for the pulley.
can cause unnecessary wear on the following
components: 3. Loosen the adjusting nut for the pulley.
• Belts 4. Move the pulley in order to adjust the belt tension.
• Pulleys 5. Tighten the adjusting nut.
• Bearings 6. Tighten the mounting bolt.

If the belts are too tight, unnecessary stress is placed 7. Reinstall the belt guard.
on the components. This reduces the service life of
the components. If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation
Replacement at the rated rpm.
For applications that require multiple drive belts,

i02070334
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new Cooling System Coolant
drive belt to carry more load because the older drive
belts are stretched. The additional load on the new (DEAC) - Change
drive belt could cause the new drive belt to fail.
SMCS Code: 1350-070; 1395-044
Alternator Belt Adjustment Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.

• Foaming of the coolant
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the

coolant is contaminated.
NOTICE
g00788814 Use of commercially available cooling system clean-
Illustration 25
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
1. Remove the belt guard.
proved for Caterpillar engines.
2. Loosen mounting bolts (1) and adjusting bolt (2).
SEBU7902-02 49
Maintenance Section
Cooling System Coolant (DEAC) - Change
Note: Inspect the water pump and the water

temperature regulator after the cooling system has NOTICE
been drained. This is a good opportunity to replace Fill the cooling system no faster than 19 L (5 US gal)
the water pump, the water temperature regulator and per minute to avoid air locks.
the hoses, if necessary.
3. Fill the cooling system with a mixture of clean
Drain water and Caterpillar Fast Acting Cooling System
Cleaner. Add .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-
ous burns. To open the cooling system filler cap, 4. Start the engine and run the engine at low idle for a
stop the engine and wait until the cooling system minimum of 30 minutes. The coolant temperature
components are cool. Loosen the cooling system should be at least 82 °C (180 °F).
pressure cap slowly in order to relieve the pres-
sure. NOTICE
Improper or incomplete rinsing of the cooling system
1. Stop the engine and allow the engine to cool. can result in damage to copper and other metal com-
Loosen the cooling system filler cap slowly in ponents.
order to relieve any pressure. Remove the cooling
system filler cap. To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
2. Open the cooling system drain valve (if equipped). ter. Continue to flush the system until all signs of the
If the cooling system is not equipped with a drain cleaning agent are gone.
valve, remove one of the drain plugs.
5. Stop the engine and allow the engine to cool.
Allow the coolant to drain. Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
NOTICE cooling system filler cap. Open the drain valve
Dispose of used engine coolant properly or recycle. (if equipped) or remove the cooling system drain
Various methods have been proposed to reclaim used plugs. Allow the water to drain. Flush the cooling
coolant for reuse in engine cooling systems. The full system with clean water. Close the drain valve (if
distillation procedure is the only method acceptable by equipped). Clean the drain plugs. Install the drain
Caterpillar to reclaim the used coolant. plugs. Refer to the Specifications Manual for your
particular engine for more specific information on
the proper torques. Refer to the Specifications,
For information regarding the disposal and the
SENR3130, “Torque Specifications” for more
recycling of used coolant, consult your Caterpillar
general information on the proper torques.
dealer or consult Caterpillar Dealer Service Tools:
Outside Illinois: 1-800-542-TOOL Cooling Systems with Heavy

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Deposits or Plugging
Note: For the following procedure to be effective,
Flush there must be some active flow through the cooling
system components.
1. Flush the cooling system with clean water in order
to remove any debris. 1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the 2. Close the drain valve (if equipped). Clean the
Specifications Manual for your particular engine for drain plugs. Install the drain plugs. Refer to the
more specific information on the proper torques. Specifications Manual for your particular engine for
Refer to the Specifications, SENR3130, “Torque more specific information on the proper torques.
Specifications” for more general information on Refer to the Specifications, SENR3130, “Torque
the proper torques. Specifications” for more general information on
the proper torques.
50 SEBU7902-02
Maintenance Section
Cooling System Coolant (DEAC) - Change
1. Fill the cooling system with coolant/antifreeze.

NOTICE Refer to the Operation and Maintenance Manual,
Fill the cooling system no faster than 19 L (5 US gal) “Refill Capacities and Recommendations” topic
per minute to avoid air locks. (Maintenance Section) for more information on
cooling system specifications. Do not install the
cooling system filler cap.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System 2. Start the engine and run the engine at low idle.
Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L Increase the engine rpm to high idle. Run the
(1 to 2 US gal) of the cooling system capacity. engine at high idle for one minute in order to purge
Install the cooling system filler cap. the air from the cavities of the engine block. Stop
the engine.
4. Start the engine and run the engine at low idle for a
minimum of 90 minutes. The coolant temperature 3. Add coolant to the cooling system until the cooling
should be at least 82 °C (180 °F). system is full.
NOTICE 4. Clean the cooling system filler cap. Inspect the

Improper or incomplete rinsing of the cooling system gasket that is on the cooling system filler cap. If
can result in damage to copper and other metal com- the gasket that is on the cooling system filler cap
ponents. is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap.
To avoid damage to the cooling system, make sure If the gasket that is on the cooling system filler
to completely flush the cooling system with clear wa- cap is not damaged, perform a pressure test. A
ter. Continue to flush the system until all signs of the 9S-8140 Pressurizing Pump is used to perform
cleaning agent are gone. the pressure test. The correct pressure for the
cooling system filler cap is stamped on the face of
the cooling system filler cap. If the cooling system
5. Stop the engine and allow the engine to cool. filler cap does not retain the correct pressure,
Loosen the cooling system filler cap slowly install a new cooling system filler cap.
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve 5. Loosen the cap for the coolant recovery tank
(if equipped) or remove the cooling system drain slowly in order to relieve any pressure. Remove
plugs. Allow the water to drain. Flush the cooling the cap for the coolant recovery tank.
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain 6. Pour coolant into the coolant recovery tank until
plugs. Refer to the Specifications Manual for your the coolant reaches the “COLD FULL” mark.
particular engine for more specific information on DO NOT fill the coolant recovery tank above the
the proper torques. Refer to the Specifications, “COLD FULL” mark.
SENR3130, “Torque Specifications” for more
general information on the proper torques. 7. Clean the cap for the coolant recovery tank. Install
the cap for the coolant recovery tank.
Fill
8. Start the engine. Inspect the cooling system for
Refer to the Operation and Maintenance Manual, leaks and for proper operating temperature.
“Refill Capacities and Recommendations” topic for
the capacity of the engine’s system and for coolant Engines that are Not Equipped with a
recommendations. Coolant Recovery Tank
Engines that are Equipped with a Coolant NOTICE
Recovery Tank Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) 1. Fill the cooling system with coolant/antifreeze.
per minute to avoid air locks. Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
SEBU7902-02 51
Maintenance Section
Cooling System Coolant (ELC) - Change
2. Start the engine and run the engine at low idle. Drain
Increase the engine rpm to high idle. Run the
engine at high idle for one minute in order to purge
the air from the cavities of the engine block. Stop
the engine. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
3. Check the coolant level. Maintain the coolant level stop the engine and wait until the cooling system
within 13 mm (.5 inch) below the bottom of the components are cool. Loosen the cooling system
pipe for filling. Maintain the coolant level within pressure cap slowly in order to relieve the pres-
13 mm (.5 inch) to the proper level on the sight sure.
glass (if equipped).
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 order to relieve any pressure. Remove the cooling
is damaged, discard the old cooling system filler system filler cap.
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler 2. Open the cooling system drain valve (if equipped).
cap is not damaged, perform a pressure test. A If the cooling system is not equipped with a drain
9S-8140 Pressurizing Pump is used to perform valve, remove the cooling system drain plugs.
the pressure test. The correct pressure for the
cooling system filler cap is stamped on the face of Allow the coolant to drain.
the cooling system filler cap. If the cooling system
filler cap does not retain the correct pressure, NOTICE
install a new cooling system filler cap. Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
5. Start the engine. Inspect the cooling system for coolant for reuse in engine cooling systems. The full
leaks and for proper operating temperature. distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
i02070355
For information regarding the disposal and the
Cooling System Coolant (ELC) recycling of used coolant, consult your Caterpillar
- Change dealer or consult Caterpillar Dealer Service Tools:
SMCS Code: 1350-070; 1395-044 Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Clean the cooling system and flush the cooling Canada: 1-800-523-TOOL
system before the recommended maintenance
interval if the following conditions exist: Flush
• The engine overheats frequently. 1. Flush the cooling system with clean water in order
to remove any debris.
• Foaming of the coolant
2. Close the drain valve (if equipped). Clean the
• The oil has entered the cooling system and the drain plugs. Install the drain plugs. Refer to the
coolant is contaminated. Specifications Manual for your particular engine for
more specific information on the proper torques.
• The fuel has entered the cooling system and the Refer to the Specifications, SENR3130, “Torque
coolant is contaminated. Specifications” for more general information on
the proper torques.
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and
replaced. NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
Note: Inspect the water pump and the water per minute to avoid air locks.
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.
52 SEBU7902-02
Maintenance Section
Cooling System Coolant (ELC) - Change
4. Start the engine and run the engine at low 5. Loosen the cap for the coolant recovery tank
idle until the temperature reaches 49 to 66 °C slowly in order to relieve any pressure. Remove
(120 to 150 °F). the cap for the coolant recovery tank.
5. Stop the engine and allow the engine to cool. 6. Pour Extended Life Coolant (ELC) into the coolant
Loosen the cooling system filler cap slowly recovery tank until the coolant reaches the “COLD
in order to relieve any pressure. Remove the FULL” mark. DO NOT fill the coolant recovery tank
cooling system filler cap. Open the drain valve above the “COLD FULL” mark.
(if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling 7. Clean the cap for the coolant recovery tank. Install
system with clean water. Close the drain valve (if the cap for the coolant recovery tank.
equipped). Clean the drain plugs. Install the drain
plugs. Refer to the Specifications Manual for your 8. Start the engine. Inspect the cooling system for
particular engine for more specific information on leaks and for proper operating temperature.
the proper torques. Refer to the Specifications,
SENR3130, “Torque Specifications” for more Engines that are NOT Equipped with a
general information on the proper torques.
Coolant Recovery Tank
Fill NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
Engines that are Equipped with a Coolant per minute to avoid air locks.
Recovery Tank
1. Fill the cooling system with Extended Life Coolant
NOTICE (ELC). Refer to the Operation and Maintenance
Fill the cooling system no faster than 19 L (5 US gal) Manual, “Refill Capacities and Recommendations”
per minute to avoid air locks. topic (Maintenance Section) for more information
on cooling system specifications. Do not install the
1. Fill the cooling system with Extended Life Coolant cooling system filler cap.
(ELC). Refer to the Operation and Maintenance
2. Start the engine and operate the engine at low
Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information idle. Increase the engine rpm to high idle. Operate
the engine at high idle for one minute in order to
on cooling system specifications. Do not install the
purge air from the cavities of the engine block.
Stop the engine.
2. Start the engine and operate the engine at low
3. Check the coolant level. Maintain the coolant level
idle. Increase the engine rpm to high idle. Operate
the engine at high idle for one minute in order to within 13 mm (.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
purge air from the cavities of the engine block.
13 mm (.5 inch) to the proper level on the sight
Stop the engine.
glass (if equipped).
3. Pour more ELC into the cooling system until the
4. Clean the cooling system filler cap. Inspect the
cooling system is full.
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap is
is damaged, discard the old cooling system filler
not damaged, use a 9S-8140 Pressurizing Pump
cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap is in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
not damaged, use a 9S-8140 Pressurizing Pump
filler cap is stamped on the face of the cooling
in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
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
leaks and for proper operating temperature.
SEBU7902-02 53
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i02482066
NOTICE
Cooling System Coolant Care must be taken to ensure that fluids are contained
Extender (ELC) - Add during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
SMCS Code: 1352-045; 1395-081 collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Cat ELC (Extended Life Coolant) does not require nent containing fluids.
the frequent additions of any supplemental cooling
additives which are associated with the present Refer to Special Publication, NENG2500, “Caterpillar
conventional coolants. The Cat ELC Extender only Dealer Service Tool Catalog” for tools and supplies
needs to be added once. suitable to collect and contain fluids on Caterpillar
products.
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender Dispose of all fluids according to local regulations and
with Cat ELC. mandates.
Do NOT use conventional supplemental coolant addi- 1. Loosen the cooling system filler cap slowly in
tive (SCA) with Cat ELC. Mixing Cat ELC with conven- order to relieve pressure. Remove the cooling
tional coolants and/or conventional SCA reduces the system filler cap.
Cat ELC service life.
2. It may be necessary to drain enough coolant from
Check the cooling system only when the engine is the cooling system in order to add the Cat ELC
stopped and cool. Extender.
3. Add Cat ELC Extender according to the

requirements for your engine’s cooling system
capacity. Refer to the Operation and Maintenance
Personal injury can result from hot coolant, steam Manual, “Refill Capacities and Recommendations”
and alkali. article for more information.
At operating temperature, engine coolant is hot 4. Clean the cooling system filler cap. Inspect the
and under pressure. The radiator and all lines gaskets on the cooling system filler cap. Replace
to heaters or the engine contain hot coolant or the cooling system filler cap if the gaskets are
steam. Any contact can cause severe burns. damaged. Install the cooling system filler cap.
Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and i01197583
cooling system pressure cap is cool enough to

touch with your bare hand.
Cooling System Coolant Level
- Check
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing SMCS Code: 1395-082
burns.
Check the coolant level when the engine is stopped
Cooling System Coolant Additive contains alkali. and cool.
Avoid contact with skin and eyes.
54 SEBU7902-02
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
i02785196
Cooling System Coolant

Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Note: Obtaining a Coolant Sample (Level 1) is

optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems that
are filled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended interval
that is stated in the Maintenance Interval Schedule.
Illustration 26
g00285520 Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant
Cooling system filler cap
instead of Cat ELC. This includes the following
types of coolants:
• Commercial long life coolants that meet the

Pressurized System: Hot coolant can cause seri- Caterpillar Engine Coolant Specification -1
ous burns. To open the cooling system filler cap, (Caterpillar EC-1)
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system • Cat DEAC (Diesel Engine Antifreeze/Coolant)
pressure cap slowly in order to relieve the pres-
sure. • Commercial heavy-duty coolant/antifreeze
Table 8
1. Remove the cooling system filler cap slowly in
Recommended Interval
order to relieve pressure.
Type of Coolant Level 1 Level 2
2. Maintain the coolant level within 13 mm (0.5 inch)
Every 250
of the bottom of the filler pipe. If the engine is Cat DEAC
Hours(1)
Yearly(1)(2)
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass. Cat ELC Optional(2) Yearly(2)
(1) This is the recommended interval for coolant samples for all
conventional heavy-duty coolant/antifreeze. This is also the
recommended interval for coolant samples of commercial
coolants that meet the Cat EC-1 specification for engine
coolant.
(2) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
Illustration 27
g00103639 dealers and customers.
Typical filler cap gaskets
Note: Level 1 results may indicate a need for
3. Clean the cooling system filler cap and check the Level 2 Analysis.
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.

SEBU7902-02 55
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Obtain the sample of the coolant as close as possible Submit the sample for Level 2 analysis.
to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you For additional information about coolant analysis,
must establish a consistent trend of data. In order refer to the Operation and Maintenance Manual,
to establish a pertinent history of data, perform “Refill Capacities and Recommendations” topic or
consistent samplings that are evenly spaced. consult your Caterpillar dealer.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
i02785244
Use the following guidelines for proper sampling of

the coolant:
Cooling System Supplemental
Coolant Additive (SCA) -
• Complete the information on the label for the Test/Add
sampling bottle before you begin to take the
samples.
SMCS Code: 1352-045; 1395-081
• Keep the unused sampling bottles stored in plastic This maintenance procedure is required for
bags.
conventional coolants such as DEAC and for
mixtures of water and SCA. This maintenance is
• Obtain coolant samples directly from the coolant NOT required for cooling systems that are filled
sample port. You should not obtain the samples
with Extended Life Coolant.
from any other location.
• Keep the lids on empty sampling bottles until you

are ready to collect the sample.
Cooling system coolant additive contains alkali.
• Place the sample in the mailing tube immediately To help prevent personal injury, avoid contact with
after obtaining the sample in order to avoid the skin and eyes. Do not drink cooling system
contamination. coolant additive.
• Never collect samples from expansion bottles. Note: Caterpillar recommends an S·O·S coolant
analysis (Level 1).
• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis. Test the Concentration of the SCA
For additional information about coolant analysis, Coolant/Antifreeze and SCA
refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic or NOTICE
consult your Caterpillar dealer. Do not exceed the recommended six percent supple-
mental coolant additive concentration.
i02785234
Test the concentration of the SCA with the 8T-5296
Cooling System Coolant Coolant Conditioner Test Kit.
Sample (Level 2) - Obtain
Water and SCA
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
NOTICE Do not exceed the recommended eight percent sup-
Always use a designated pump for oil sampling, and plemental coolant additive concentration.
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This Test the concentration of the SCA with the 8T-5296
contaminate may cause a false analysis and an incor- Coolant Conditioner Test Kit. Use the instructions
rect interpretation that could lead to concerns by both that follow:
dealers and customers.
1. Fill the syringe to the “1.0 ml” mark with the
coolant.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain” 2. Dispense the 1.0 mL coolant sample from the
for the guidelines for proper sampling of the coolant. syringe into the empty mixing bottle.
56 SEBU7902-02
Maintenance Section
Cooling System Water Temperature Regulator - Replace
3. Add tap water to the mixing bottle in order to bring

the level up to the “10 ml” mark. Place the cap on NOTICE
the bottle and shake the bottle. Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
4. Add 2 to 3 drops of the “NITRITE INDICATOR faces of the cooling system, reducing the engine’s
SOLUTION B” to the mixing bottle. Move the bottle heat transfer characteristics. Reduced heat transfer
in a circular motion in order to mix the solution. could cause cracking of the cylinder head and other
high temperature components.
5. Add 1 drop of “NITRITE TEST SOLUTION A” to
the mixing bottle. Move the bottle in a circular Excessive supplemental coolant additive concentra-
motion in order to mix the solution. tion could also result in blockage of the heat exchang-
er, overheating, and/or accelerated wear of the water
6. Repeat 5 until the solution changes color from red pump seal.
to light gray, green, or blue. Record the number of
drops of “NITRITE TEST SOLUTION A” that were Do not exceed the recommended amount of supple-
required to cause the color change. mental coolant additive concentration.
7. Use Table 9 to interpret the results.

3. Add the proper amount of SCA. For the
Table 9 proper amount of SCA, refer to this Operation
and Maintenance Manual, “Refill Capacities
Number of Concentration Maintenance and Recommendations” topic. The proper
Drops of SCA Required
concentration of SCA depends on the type of
Less than 25 Less than the Add SCA. coolant that is used. For the proper concentration
recommended Retest the of SCA, refer to the Operation and Maintenance
concentration of coolant. Manual, “Refill Capacities and Recommendations”
SCA topic or consult your Caterpillar dealer..
25 to 30 The None
recommended 4. Clean the cooling system filler cap. Install the
concentration of cooling system filler cap.
SCA
More than 30 More than the Remove the i02623972
recommended coolant.
concentration of Replace with Cooling System Water
SCA water only
Retest the Temperature Regulator -
coolant.
Replace
SMCS Code: 1355-510
Add the SCA, If Necessary
Replace the water temperature regulator before
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Pressurized System: Hot coolant can cause seri- Replacing the water temperature regulator reduces
ous burns. To open the cooling system filler cap, the chances for unscheduled downtime.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system A water temperature regulator that fails in a
pressure cap slowly in order to relieve the pres- partially opened position can cause overheating or
sure. overcooling of the engine.
A water temperature regulator that fails in the closed

1. Remove the cooling system filler cap slowly. position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
Note: Always dispose of fluids according to local head or piston seizure problems.
regulations.
2. If necessary, drain some coolant in order to allow

space for the addition of the SCA.
SEBU7902-02 57
Maintenance Section
Crankshaft Vibration Damper - Inspect
A water temperature regulator that fails in the open Visconic Damper

position will cause the engine operating temperature
to be too low during partial load operation. Low The visconic damper has a weight that is located
engine operating temperatures during partial loads inside a fluid filled case. The weight moves in the
could cause an excessive carbon buildup inside the case in order to limit torsional vibration.
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear Inspect the damper for evidence of fluid leaks. If
of the cylinder liner. a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has
NOTICE the following characteristics: transparent, viscous,
Failure to replace your water temperature regulator smooth, and difficult to remove from surfaces.
on a regularly scheduled basis could cause severe
engine damage. If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace the crankshaft
Caterpillar engines incorporate a shunt design cooling seals.
system and require operating the engine with a water
temperature regulator installed. Inspect the damper and repair or replace the damper
for any of the following reasons:
If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder head • The damper is dented, cracked, or leaking.
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that • The paint on the damper is discolored from heat.
the water temperature regulator vent hole is open.
• The engine has had a failure because of a broken
Do not use liquid gasket material on the gasket or crankshaft.
cylinder head surface.
• Analysis of the oil has revealed that the front main
bearing is badly worn.
Refer to two articles in the Disassembly and
Assembly Manual, “Water Temperature Regulators • There is a large amount of gear train wear that is
- Remove and Water Temperature Regulators - not caused by a lack of oil.
Install” for the replacement procedure of the water
temperature regulator, or consult your Caterpillar Refer to the Service Manual or consult your
dealer. Caterpillar dealer for information about damper
replacement.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to
i00934883
a level that is below the water temperature regulator
housing. Driven Equipment - Check
i00934535 SMCS Code: 3279-535
Crankshaft Vibration Damper Check the Alignment

- Inspect
To minimize bearing problems and vibration of the
SMCS Code: 1205-040 engine crankshaft and the driven equipment, the
alignment between the engine and driven equipment
Damage to the crankshaft vibration damper or failure must be properly maintained.
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to Check the alignment according to the instructions
the crankshaft and to other engine components. A that are provided by the following manufacturers:
damper that is damaged can cause excessive gear
train noise at variable points in the speed range. • Caterpillar
The damper is mounted to the crankshaft which is • OEM of the drive coupling
located behind the belt guard on the front of the
engine. • OEM of the driven equipment
Torque all of the fasteners to the proper specifications.
58 SEBU7902-02
Maintenance Section
Electronic Unit Injector - Inspect/Adjust
Inspect the Drive Coupling The operation of Caterpillar engines with improper
adjustments of the electronic unit injector can reduce
Inspect the drive coupling according to the engine efficiency. This reduced efficiency could result
instructions that are provided by the OEM of the in excessive fuel usage and/or shortened engine
coupling. For the following service information, see component life.
the literature that is provided by the OEM of the
coupling: Only qualified service personnel should perform
this maintenance. Refer to the following topics
• Lubrication requirements for your engine for the correct procedure: Refer
to the Systems Operation, Testing and Adjusting,
• Specifications for the end play “Electronic Unit Injector - Test” for the test procedure,
and Systems Operation, Testing and Adjusting,
• “Reusability Guidelines” “Electronic Unit Injector - Adjust” for the correct
procedure for adjusting the injectors.
• Replacement instructions
NOTICE
Inspect the Rear Gear Train The camshafts must be correctly timed with the crank-
shaft before an adjustment of the lash for the fuel in-
Inspect the crankshaft gear. If excessive wear is jector is made. The timing pins must be removed from
found, replace the crankshaft gear and the large the camshafts before the crankshaft is turned or dam-
cluster idler. age to the cylinder block will be the result.
If any gear causes damage to other gears through

failure, replace the entire rear gear train. i02052170
For the correct parts, see the Parts Manual for the Electronics Grounding Stud -
engine. For removal and replacement instructions,
see the Service Manual, “Disassembly and
Inspect/Clean/Tighten
Assembly” module. Consult your Caterpillar dealer SMCS Code: 7423-040; 7423-070; 7423-079
for assistance.
i02070777
Electronic Unit Injector - The connection of battery cables to a battery and

the disconnection of battery cables from a battery
Inspect/Adjust may cause an explosion which may result in injury
or death. The connection and the disconnection
SMCS Code: 1251-025; 1251-040; 1290-025; of other electrical equipment may also cause an
1290-040 explosion which may result in injury or death. The
procedures for the connection and the disconnec-
tion of battery cables and other electrical equip-
ment should only be performed in a nonexplosive
Be sure the engine cannot be started while this atmosphere.
maintenance is being performed. To prevent pos-
sible 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 mea-
suring/adjusting the unit injectors.
The electronic unit injectors use high voltage. Dis-

connect the unit injector enable circuit connector
in order to prevent personal injury. Do not come
in contact with the injector terminals while the en-
gine is running.
SEBU7902-02 59
Maintenance Section
Engine - Clean
i01646701
Engine - Clean
SMCS Code: 1000-070
Personal injury or death can result from high volt-

age.
Moisture can create paths of electrical conductiv-

ity.
Make sure that the electrical system is OFF. Lock

out the starting controls and tag the controls “DO
NOT OPERATE”.
NOTICE
Accumulated grease and oil on an engine is a fire haz-
Illustration 28
g00765094 ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
Electronics grounding stud (side view)
the engine.
Inspect the OEM harness for good connections.
Inspect the condition of the OEM harness. Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
The electronics grounding stud must have a wire oil and grease. A clean engine provides the following
ground to the battery. Tighten the electronics benefits:
grounding stud at every oil change. Ground wires
and straps should be combined at engine grounds. • Easy detection of fluid leaks
All grounds should be tight and free of corrosion.
• Maximum heat transfer characteristics
• Clean the electronics grounding stud and the
terminals for the electronics ground strap with a • Ease of maintenance
clean cloth.
Note: Caution must be used in order to prevent
• If the connections are corroded, clean the electrical components from being damaged by
connections with a solution of baking soda and excessive water when you clean the engine. Avoid
water. electrical components such as the alternator, the
starter, and the ECM.
• Keep the electronics grounding stud and the strap
clean and coated with MPGM grease or petroleum
jelly. i01553486
Engine Air Cleaner Element

(Dual Element) - Clean/Replace
SMCS Code: 1054-037; 1054-510
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
60 SEBU7902-02
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
wear. Your Caterpillar dealer has the proper air
cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.
g00736431
Illustration 29
• Check the precleaner (if equipped) daily for (1) Cover
accumulation of dirt and debris. Remove any dirt (2) Primary air cleaner element
and debris, as needed. (3) Secondary air cleaner element
(4) Turbocharger air inlet
• Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner 1. Remove the cover. Remove the primary air
element. cleaner element.
• The air cleaner element may be cleaned up to 2. The secondary air cleaner element should be
six times if the element is properly cleaned and removed and discarded for every three cleanings
inspected. of the primary air cleaner element.
• The air cleaner element should be replaced at least Note: Refer to “Cleaning the Primary Air Cleaner
one time per year. This replacement should be Elements”.
performed regardless of the number of cleanings.
3. Cover the turbocharger air inlet with tape in order
Replace the dirty paper air cleaner elements with to keep dirt out.
clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked 4. Clean the inside of the air cleaner cover and body
for tears and/or holes in the filter material. Inspect with a clean, dry cloth.
the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner 5. Remove the tape for the turbocharger air inlet.
elements for replacement purposes. Install the secondary air cleaner element. Install a
primary air cleaner element that is new or cleaned.
Dual Element Air Cleaners
6. Install the air cleaner cover.
The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner 7. Reset the air cleaner service indicator.
element. The primary air cleaner element can be
used up to six times if the element is properly cleaned
and inspected. The primary air cleaner element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.
The secondary air cleaner element is not serviceable

or washable. The secondary air cleaner element
should be removed and discarded for every three
cleanings of the primary air cleaner element. When
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more
frequent replacement.
SEBU7902-02 61
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Cleaning the Primary Air Cleaner Pressurized Air

Elements Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
NOTICE than two times. Pressurized air will not remove
Caterpillar recommends certified air filter cleaning ser- deposits of carbon and oil. Use filtered, dry air with a
vices that are available at Caterpillar dealers. The maximum pressure of 207 kPa (30 psi).
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to

clean the filter element:
Do not tap or strike the filter element in order to re-

move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage Illustration 30
g00281692
to the pleats.
Note: When the primary air cleaner elements are
Do not use air filters with damaged pleats, gaskets, or cleaned, always begin with the clean side (inside)
seals. Dirt entering the engine will cause damage to in order to force dirt particles toward the dirty side
engine components. (outside).
The primary air cleaner element can be used up Aim the hose so that the air flows inside the element
to six times if the element is properly cleaned and along the length of the filter in order to help prevent
inspected. When the primary air cleaner element is damage to the paper pleats. Do not aim the stream
cleaned, check for rips or tears in the filter material. of air directly at the primary air cleaner element. Dirt
The primary air cleaner element should be replaced could be forced further into the pleats.
at least one time per year. This replacement should
be performed regardless of the number of cleanings. Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
Use clean primary air cleaner elements while dirty
elements are being cleaned. Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
NOTICE
primary air cleaner elements which require daily
Do not clean the air cleaner elements by bumping or
cleaning because of a dry, dusty environment.
tapping. This could damage the seals. Do not use el-
Cleaning with pressurized air is recommended prior
ements with damaged pleats, gaskets or seals. Dam-
to vacuum cleaning. Vacuum cleaning will not remove
aged elements will allow dirt to pass through. Engine
deposits of carbon and oil.
damage could result.
Note: Refer to “Inspecting the Primary Air Cleaner
Visually inspect the primary air cleaner elements Elements”.
before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
There are two common methods that are used to

clean primary air cleaner elements:
• Pressurized air
• Vacuum cleaning
62 SEBU7902-02
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Inspecting the Primary Air Cleaner Do not use paint, a waterproof cover, or plastic as a
Elements protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air cleaner element into a box

for storage. For identification, mark the outside of
the box and mark the primary air cleaner element.
Include the following information:
• Date of cleaning
• Number of cleanings
Store the box in a dry location.
g00281693
Illustration 31
i01900118
Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a similar
Engine Air Cleaner Service
facility. Place the blue light in the primary air cleaner Indicator - Inspect
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears
(If Equipped)
and/or holes. Inspect the primary air cleaner element SMCS Code: 7452-040
for light that may show through the filter material. If it
is necessary in order to confirm the result, compare
Some engines may be equipped with a different
the primary air cleaner element to a new primary air service indicator.
cleaner element that has the same part number.
Some engines are equipped with a differential gauge
Do not use a primary air cleaner element that has for inlet air pressure. The differential gauge for inlet
any tears and/or holes in the filter material. Do not air pressure displays the difference in the pressure
use a primary air cleaner element with damaged
that is measured before the air cleaner element and
pleats, gaskets or seals. Discard damaged primary the pressure that is measured after the air cleaner
air cleaner elements. element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
Storing Primary Air Cleaner Elements equipped with a different type of service indicator,
follow the OEM recommendations in order to service
If a primary air cleaner element that passes inspection the air cleaner service indicator.
will not be used, the primary air cleaner element can
be stored for future use. The service indicator may be mounted on the air
cleaner housing or in a remote location.
g00281694
Illustration 32
g00103777
Illustration 33
Typical service indicator
SEBU7902-02 63
Maintenance Section
Engine Air Precleaner - Check/Clean
Observe the service indicator. The air cleaner i00720883

element should be cleaned or the air cleaner element
should be replaced when one of the following Engine Air Precleaner -
conditions occur: Check/Clean
• The yellow diaphragm enters the red zone. SMCS Code: 1055-070; 1055-535
• The red piston locks in the visible position.
Test the Service Indicator

Service indicators are important instruments.
• Check for ease of resetting. The service indicator

should reset in less than three pushes.
• Check the movement of the yellow core when the

engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.
g00287039
If the service indicator does not reset easily, or if the Illustration 34
yellow core does not latch at the greatest vacuum, Typical engine precleaner
the service indicator should be replaced. If the new (1) Wing nut
service indicator will not reset, the hole for the service (2) Cover
indicator may be plugged. (3) Body
The service indicator may need to be replaced Remove wing nut (1) and cover (2). Check for an
frequently in environments that are severely dusty, if accumulation of dirt and debris in body (3). Clean the
necessary. Replace the service indicator annually body, if necessary.
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and After cleaning the precleaner, install cover (2) and
whenever major engine components are replaced. wing nut (1).
Note: When a new service indicator is installed, Note: When the engine is operated in dusty
excessive force may crack the top of the service applications, more frequent cleaning is required.
indicator. Tighten the service indicator to a torque
of 2 N·m (18 lb in). i02489863
Engine Crankcase Breather -

Clean
SMCS Code: 1317-070
NOTICE
Perform this maintenance with the engine stopped.
If the crankcase breather is not maintained on a

regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.
64 SEBU7902-02
Maintenance Section
Engine Mounts - Inspect
i02139969
Engine Mounts - Inspect

SMCS Code: 1152-040
Inspect the engine mounts for deterioration and for

proper bolt torque. Engine vibration can be caused
by the following conditions:
• Improper mounting of the engine

• Deterioration of the engine mounts
Any engine mount that shows deterioration should
be replaced. Refer to the Specifications Manual,
SENR3130, “Torque Specifications”. Refer to your
Caterpillar dealer for more information.
i02073191
Illustration 35
g00908595 Engine Oil Level - Check
1. Loosen hose clamp (1) and remove hose (2) from SMCS Code: 1348-535-FLV
valve cover (3).
2. Remove the valve cover (3). Refer to the

Disassembly and Assembly Manual. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
g00908611
Illustration 36
3. Wash breather (4) in solvent that is clean and g00622328

Illustration 37
nonflammable. Allow the breather to dry before
installation. (1) Oil level gauge
(2) Oil filler cap
4. Install the valve cover (3). Refer to the
Disassembly and Assembly Manual.
5. Install hose (2) on valve cover (3). Install hose

clamp (1).
SEBU7902-02 65
Maintenance Section
Engine Oil Sample - Obtain
i01935337
Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1348-554-SM;
7542-554-OC, SM
In addition to a good preventive maintenance

Illustration 38
g00110310 program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order
(Y) “ADD” mark
(X) “FULL” mark
to monitor the condition of the engine and the
maintenance requirements of the engine. S·O·S oil
analysis provides infrared analysis, which is required
NOTICE for determining nitration and oxidation levels.
Perform this maintenance with the engine stopped.
Obtain the Sample and the Analysis
1. Maintain the oil level between “ADD” mark (Y) and
“FULL” mark (X) on oil level gauge (1). Do not fill
the crankcase above “FULL” mark (X).
Hot oil and hot components can cause personal
NOTICE injury. Do not allow hot oil or hot components to
Engine damage can occur if the crankcase is filled contact the skin.
above the “FULL” mark on the oil level gauge (dip-
stick).
Before you take the oil sample, complete the Label,
An overfull crankcase can enable the crankshaft to PEEP5031 for identification of the sample. In order
dip into the oil. This will reduce the power that is de- to help obtain the most accurate analysis, provide
veloped and also force air bubbles into the oil. These the following information:
bubbles (foam) can cause the following problems: re-
duction of the oil’s ability to lubricate, reduction of oil • Engine model
pressure, inadequate cooling of the pistons, oil blow-
ing out of the crankcase breathers, and excessive oil • Service hours on the engine
consumption.
• The number of hours that have accumulated since
Excessive oil consumption will enable deposits to form the last oil change
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following • The amount of oil that has been added since the
problems: guttering of the valves, packing of carbon last oil change
under the piston rings, and wear of the cylinder liner.
To ensure that the sample is representative of the
If the oil level is above the “FULL” mark on the oil level oil in the crankcase, obtain a warm, well mixed oil
gauge, drain some of the oil immediately. sample.
To avoid contamination of the oil samples, the tools

2. Remove oil filler cap (2) and add oil, if necessary. and the supplies that are used for obtaining oil
For the correct oil to use, see this Operation samples must be clean.
and Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section). Caterpillar recommends using the sampling valve
Do not fill the crankcase above “FULL” mark (X) in order to obtain oil samples. The quality and the
on the oil level gauge. Clean the oil filler cap. consistency of the samples are better when the
Install the oil filler cap. sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
3. Record the amount of oil that is added. For the obtained during normal engine operation.
next oil sample and analysis, include the total
amount of oil that has been added since the The 169-8373 Fluid Sampling Bottle is
previous sample. This will help to provide the most recommended for use with the sampling valve. The
accurate oil analysis. fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
66 SEBU7902-02
Maintenance Section
Engine Oil and Filter - Change
• If the engine is not equipped with a drain valve,

NOTICE remove the oil drain plug in order to allow the oil
Always use a designated pump for oil sampling, and to drain. If the engine is equipped with a shallow
use a separate designated pump for coolant sampling. sump, remove the bottom oil drain plugs from both
Using the same pump for both types of samples may ends of the oil pan.
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor- After the oil has drained, the oil drain plugs should
rect interpretation that could lead to concerns by both be cleaned and installed.
dealers and customers.
Replace the Oil Filter
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is NOTICE
designed to accept sampling bottles. Disposable Caterpillar oil filters are built to Caterpillar speci-
tubing must be attached to the pump for insertion fications. Use of an oil filter not recommended by
into the sump. Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
For instructions, see Special Publication, PEHP6001, the larger waste particles from unfiltered oil entering
“How To Take A Good Oil Sample”. Consult your the engine lubricating system. Only use oil filters
Caterpillar dealer for complete information and recommended by Caterpillar.
assistance in establishing an S·O·S program for your
engine.
1. Remove the oil filter with a 1U-8760 Chain
Wrench.
i02539745
Engine Oil and Filter - Change 2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the
SMCS Code: 1318-510; 1348-044 oil filter for metal debris. An excessive amount
of metal debris in the oil filter may indicate early
wear or a pending failure.
Use a magnet to differentiate between the ferrous

Hot oil and hot components can cause personal metals and the nonferrous metals that are found in
injury. Do not allow hot oil or hot components to the oil filter element. Ferrous metals may indicate
contact the skin. wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the

Do not drain the oil when the engine is cold. As the oil
aluminum parts, brass parts or bronze parts of
cools, suspended waste particles settle on the bottom
the engine. Parts that may be affected include
of the oil pan. The waste particles are not removed
the following items: main bearings, rod bearings,
with the draining cold oil. Drain the crankcase with
turbocharger bearings, and cylinder heads.
the engine stopped. Drain the crankcase with the
oil warm. This draining method allows the waste
Due to normal wear and friction, it is not
particles that are suspended in the oil to be drained
uncommon to find small amounts of debris in the
properly.
oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive
Failure to follow this recommended procedure will
amount of debris is found in the oil filter.
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
Drain the Engine Oil

After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
• If the engine is equipped with a drain valve, turn the

drain valve knob counterclockwise in order to drain
the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.
SEBU7902-02 67
Maintenance Section
Engine Protective Devices - Check
3. Stop the engine and allow the oil to drain back to

the sump for a minimum of ten minutes.
4. Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the oil level gauge.
i02074911
Engine Protective Devices -

Check
SMCS Code: 7400-535
g00103713
Illustration 39
Typical filter mounting base and filter gasket
Visual Inspection
Visually check the condition of all gauges, sensors
3. Clean the sealing surface of the filter mounting
and wiring. Look for wiring and components that
base. Ensure that all of the old oil filter gasket is
are loose, broken, or damaged. Damaged wiring
removed.
or components should be repaired or replaced
immediately.
4. Apply clean engine oil to the new oil filter gasket.
NOTICE
Calibration Check
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat- NOTICE
ed. Contaminated oil can cause accelerated wear to During testing, abnormal operating conditions must be
engine components. simulated.
The tests must be performed correctly in order to pre-

5. Install the oil filter. Tighten the oil filter until the vent possible damage to the engine.
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that are
shown on the oil filter. Do not overtighten the oil Alarms and shutoffs must function properly. Alarms
filter. provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
Fill the Engine Crankcase in good working order during normal operation.
Malfunctions must be simulated in order to test the
1. Remove the oil filler cap. Refer to the Operation engine protective devices. To prevent damage to the
and Maintenance Manual, “Refill Capacities and engine, only authorized service personnel or your
Recommendations” for more information. Caterpillar dealer should perform the tests.
NOTICE • For the calibration of temperature contactors, see

If equipped with an auxiliary oil filter system or a re- Special Instruction, SEHS9827, “Calibration of
mote oil filter system, follow the OEM or filter manu- Temperature Contactors”.
facturer’s recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage. • For the calibration of pressure contactors, see
Special Instruction, SEHS9828, “Calibration of
Pressure Contactors”.
NOTICE
To prevent crankshaft bearing damage, crank the en- Consult your Caterpillar dealer or refer to the Service
gine with the fuel OFF. This will fill the oil filters before Manual for more information.
starting the engine. Do not crank the engine for more
than 30 seconds.
2. Start the engine and run the engine at “LOW

IDLE” for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
68 SEBU7902-02
Maintenance Section
Engine Speed/Timing Sensors - Check/Clean/Calibrate
i01464654 i01458399
Engine Speed/Timing Sensors Engine Storage Procedure -

- Check/Clean/Calibrate Check
SMCS Code: 1912-040; 1912-070; 1912-524 SMCS Code: 1000-535
The oil change interval may be extended to 12

months for a vehicle that is operated seasonally
and placed in storage for the remainder of the year
by using the required storage procedures and the
required start-up procedures. This extension is
permitted if the following categories for oil change
intervals in the Operation and Maintenance Manual,
“Maintenance Interval Schedule” have not been
reached:
• Mileage
• Operating hours
• Fuel consumption
If an engine is out of operation and if use of the
engine is not planned, special precautions should
be made. If the engine will be stored for more than
three months, a complete protection procedure is
Illustration 40
g00765246 recommended. For more detailed information on
engine storage, see Special Instruction, SEHS9031,
Left side view
“Storage Procedure For Caterpillar Products”.
(1) Secondary speed/timing sensor
(2) Primary speed/timing sensor
If the engine will not be started for several weeks, the
lubricating oil will drain from the cylinder walls and
1. Remove the speed/timing sensors from the front from the piston rings. Rust can form on the cylinder
housing. Check the condition of the plastic end liner surface. Rust on the cylinder liner surface will
of the speed/timing sensors for wear and/or cause increased engine wear and a reduction in
contaminants. engine service life. Caterpillar recommends the
use of volatile corrosion inhibitor (VCI) oil in order
2. Clean the metal shavings and other debris from to prevent internal engine damage due to moisture
the face of the speed/timing sensors. Use the during storage. These inhibitors in the VCI oil act by
procedure in the Service Manual in order to evaporating inside the engine. The inhibitors then
calibrate the speed/timing sensors. condense over the inside surfaces of the engine. The
evaporation process and the condensing process
Refer to the Service Manual for more information on offers full protection to surfaces that cannot be
the speed/timing sensors. reached with preservatives. 0.9 L (1.0 qt) of 4C-6792
VCI oil will treat 28.4 L (30.0 qt) of engine oil. This
will give a 3 percent concentration of VCI oil. The
engine must be completely sealed when the engine
is stored in order for the VCI oil to function properly.
The VCI oil is easily cleaned from the engine when
you remove the engine from storage. The volatile
vapors are removed by simply running the engine
to operating temperature. A mineral oil base is left
behind after the volatile vapors are removed.
SEBU7902-02 69
Maintenance Section
Engine Valve Lash - Inspect/Adjust
i01849001 i01597115
Engine Valve Lash - Engine Valve Rotators - Inspect

Inspect/Adjust SMCS Code: 1109-040
SMCS Code: 1102-025
The initial valve lash adjustment on new engines,

rebuilt engines, or remanufactured engines is When inspecting the valve rotators, protective
recommended at the first scheduled oil change. The glasses or face shield and protective clothing
adjustment is necessary due to the initial wear of must be worn, to help prevent being burned by
the valve train components and to the seating of the hot oil or spray.
valve train components.
Engine valve rotators rotate the valves when the
This maintenance is recommended by Caterpillar engine runs. This helps to prevent deposits from
as part of a lubrication and preventive maintenance building up on the valves and the valve seats.
schedule in order to help provide maximum engine
life. Perform the following steps after the engine valve
lash is set, but before the valve covers are installed:
NOTICE
Only qualified service personnel should perform this 1. Start the engine according to Operation and
maintenance. Refer to the Service Manual or your Maintenance Manual, “Engine Starting” (Operation
Caterpillar dealer for the complete valve lash adjust- Section) for the procedure.
ment procedure.
2. Operate the engine at low idle.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re- 3. Observe the top surface of each valve rotator. The
duced efficiency could result in excessive fuel usage valve rotators should turn slightly when the valves
and/or shortened engine component life. close.
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
Ensure that the engine can not be started while shorten valve life. If a damaged rotator is not replaced,
this maintenance is being performed. To help pre- valve face guttering could result and cause pieces of
vent possible injury, do not use the starting motor the valve to fall into the cylinder. This can cause piston
to turn the flywheel. and cylinder head damage.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea- If a valve fails to rotate, consult your Caterpillar
suring/adjusting valve lash clearance. dealer.
Ensure that the engine is stopped before measuring i02784507

the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance is Fan Drive Bearing - Lubricate
performed.
SMCS Code: 1359-086-BD
The following components should be inspected and
adjusted when the valves are inspected and adjusted. Some of the fan drives have grease fittings and some
of the fan drives do not have grease fittings. If there is
• Valve actuators no grease fitting, periodic lubrication is not required.
The fan drive requires grease only if the fan drive
• Injectors is equipped with a zerk.
• Compression brakes
Refer to the Service Manual for more information.
70 SEBU7902-02
Maintenance Section
Fan Drive Bearing - Replace
i02075183
Fuel System - Prime

SMCS Code: 1258-548
The Secondary Fuel Filter Has

Been Replaced
Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
Illustration 41
g00746166 vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Typical location of the grease fitting (if equipped) that is for the fan
drive bearing
Clean up fuel spills immediately.
The pulley is shown with the belt guards that have been removed.
NOTICE
Lubricate the grease fitting that is on the fan drive Use a suitable container to catch any fuel that might
bearing with High Speed Ball Bearing Grease or the spill. Clean up any spilled fuel immediately.
equivalent.
Inspect the fan drive pulley assembly for wear or for NOTICE
damage. If the shaft is loose, an inspection of the Do not allow dirt to enter the fuel system. Thoroughly
internal components should be performed. Refer to clean the area around a fuel system component that
the Systems Operation Testing and Adjusting Manual will be disconnected. Fit a suitable cover over discon-
for additional information. nected fuel system component.
i02053753 Note: Refer to Operation and Maintenance Manual,

“Fuel System Secondary Filter - Replace” for
Fan Drive Bearing - Replace information on replacing the filter.
SMCS Code: 1359-510-BD 1. Turn the ignition switch to the “OFF” position.
1. Remove Bearings. Refer to Disassembly and
Assembly, “Bearing Removal”.
2. Measure the bearing housings for roundness and

for proper size.
3. Replace the bearings.
g00975199
Illustration 42
(1) Fuel priming pump
(2) Air purge screw
(3) Priming valve (If Equipped)
2. Turn the priming valve (3) (If Equipped) to the

“Closed (Prime)” position in order to prime the fuel
system.
3. Open air purge screw (2) for the fuel filter by three
full turns. Do not remove the air purge screw.
SEBU7902-02 71
Maintenance Section
Fuel System - Prime
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Start the engine. The engine should start and the

engine should run smoothly.
Note: You may use the fuel priming pump for the fuel
filter (IF EQUIPPED) instead of starting the engine
and running the engine.
5. While the engine is running, observe air purge

g00975199
screw (2). When a small drop of fuel appears Illustration 43
at the threads of the air purge screw, close and (1) Fuel priming pump
tighten air purge screw (2). (2) Air purge screw
(3) Priming valve (If Equipped)
Note: There may be a noticeable change in the
sound of the running engine when the air purge 3. Turn the priming valve (3) (If Equipped) to the
screw is tightened. The change in the sound of the “Closed (Prime)” position in order to prime the fuel
engine is normal. system.
Note: Failure to tighten all fittings could result in 4. Open air purge screw (2) for the fuel filter by three
serious fuel leaks. full turns. Do not remove the air purge screw.
6. Clean any residual fuel from the engine NOTICE

components. Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
7. After the engine has operated smoothly for 30 minutes before cranking the engine again.
seconds, turn the priming valve (3) to the “Open
(Run)” position.
5. Crank the engine for 30 seconds. Use a suitable
Note: Shortened injector life may occur if the priming container to catch the fuel while you crank the
valve (3) is left in the “Closed (Prime)” position. engine. Allow the starter motor to cool for 2
minutes.
The Engine Has Been Run Out of Note: You may use the fuel priming pump (1) (IF
Fuel EQUIPPED) for the fuel filter instead of cranking the
engine.
NOTICE
Use a suitable container to catch any fuel that might 6. Crank the engine for 30 seconds. Allow the starter
spill. Clean up any spilled fuel immediately. motor to cool for 2 minutes.
7. Repeat Step 6 until the engine starts and the

NOTICE engine runs.
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that Note: Failure to tighten all fittings could result in
will be disconnected. Fit a suitable cover over discon- serious fuel leaks.
nected fuel system component.
8. After the engine has operated smoothly for 30
seconds, turn the priming valve (3) to the “Open
1. Turn the ignition switch to the “OFF” position. (Run)” position.
2. Fill the fuel tank(s) with clean diesel fuel. Note: Shortened injector life may occur if the priming
valve (3) is left in the “Closed (Prime)” position.
9. Clean any residual fuel from the engine

components.
72 SEBU7902-02
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
i01341997 i02053433
Fuel System Primary Fuel System Primary Filter

Filter/Water Separator - Drain (Water Separator) Element -
SMCS Code: 1260-543; 1263-543
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Water in the fuel can cause the engine to run rough.

Fuel leaked or spilled onto hot surfaces or elec- Water in the fuel may cause a electronic unit injector
trical components can cause a fire. To help pre- to fail. If the fuel has been contaminated with water,
vent possible injury, turn the start switch off when the element should be changed before the regularly
changing fuel filters or water separator elements. scheduled interval.
The primary filter/water separator also provides
filtration in order to help extend the life of the
NOTICE secondary fuel filter. The element should be changed
Use a suitable container to catch any fuel that might regularly. If a vacuum gauge is installed, the
spill. Clean up any spilled fuel immediately. primary filter/water separator should be changed at
50 to 70 kPa (15 to 20 inches Hg).
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly Replace the Element
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
1. Close the main fuel supply valve.
g00709596
Illustration 44
(1) Element
(2) Bowl
(3) Drain
g00104012
Bowl (2) should be monitored daily for signs of water. Illustration 45
If water is present, drain the water from the bowl. Element (1), Bowl (2), and Drain (3)
1. Open drain (3). The drain is a self-ventilated drain. 2. Remove element (1) from the element mounting
Catch the draining water in a suitable container. base while bowl (2) is attached.
Dispose of the water properly.
3. Dispose of the contents of the filter. Remove bowl
2. Close drain (3). (2) from element (1). The bowl is reusable. Do not
discard the bowl. Dispose of the used element.
NOTICE
The water separator is under suction during normal 4. Remove the O-ring from the gland of the bowl.
engine operation. Ensure that the drain valve is tight- Clean the following components:
ened securely to help prevent air from entering the fuel
system. • Bowl
SEBU7902-02 73
Maintenance Section
Fuel System Secondary Filter - Replace
• O-ring i01776046
• Mounting base Fuel System Secondary Filter -

Inspect the O-ring for damage and for
Replace
deterioration. Replace the O-ring, if necessary. SMCS Code: 1261-510-SE
5. Lubricate the O-ring with clean diesel fuel.
6. Install bowl (2) on a new element. Tighten the

bowl by hand. Do not use tools in order to tighten Fuel leaked or spilled onto hot surfaces or elec-
the bowl. trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
NOTICE
The primary filter/water separator may be prefilled with
fuel to avoid rough running/stalling of the engine due
to air. Do not fill the secondary filter with fuel before NOTICE
installation. The fuel would not be filtered and could Do not allow dirt to enter the fuel system. Thoroughly
be contaminated. Contaminated fuel will cause accel- clean the area around a fuel system component that
erated wear to fuel system parts. will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
7. Lubricate the top seal of element (1) with clean
diesel fuel. The element may be filled with fuel at
NOTICE
this time. Install the new element on the mounting Use a suitable container to catch any fuel that might
base. Tighten the element by hand.
spill. Clean up any spilled fuel immediately.
NOTICE
The water separator is under suction during normal 1. Stop the engine. Turn the ignition switch to the
engine operation. Ensure that the vent plug is tight- OFF position or disconnect the battery. Refer to
ened securely to help prevent air from entering the fu- the Operation and Maintenance Manual, “Battery
el system. or Battery Cable - Disconnect” topic (Maintenance
Section) for more information. Shut off the fuel
supply valve (if equipped).
8. Open the main fuel supply valve.
2. It may be necessary to relieve residual fuel
9. Start the engine and check for leaks. Run the pressure from the fuel system before the fuel
engine for one minute. Stop the engine and check filter is removed. Wait for one to five minutes until
for leaks again. the fuel pressure has lowered. Use a suitable
container in order to catch any fuel that may spill.
Detecting leaks is difficult while the engine is
running. The primary filter/water separator is 3. Remove the used fuel filter and discard the used
under suction. A leak will allow air to enter the fuel. fuel filter.
The air in the fuel can cause low power due to
aeration of the fuel. If air enters the fuel, check the 4. Clean the gasket sealing surface of the fuel filter
components for overtightening or undertightening. base. Ensure that all of the old gasket is removed.
5. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
74 SEBU7902-02
Maintenance Section
Fuel Tank Water and Sediment - Drain
Drain the Water and the Sediment

NOTICE
In order to maximize fuel system life and prevent pre- Fuel tanks should contain some provision for draining
mature wear out from abrasive particles in the fuel, a water and draining sediment from the bottom of the
two micron high efficiency fuel filter is required for all fuel tanks.
Caterpillar Electronic Unit Injectors. Caterpillar High
Efficiency Fuel Filters meet these requirements. Con- Open the drain valve on the bottom of the fuel tank
sult your Caterpillar dealer for the proper part num- in order to drain the water and the sediment. Close
bers. the drain valve.
Check the fuel daily. Drain the water and sediment

6. Install the new fuel filter. Spin the fuel filter onto from the fuel tank after operating the engine or drain
the fuel filter base until the gasket contacts the the water and sediment from the fuel tank after the
base. Use the rotation index marks on the filters fuel tank has been filled. Allow five to ten minutes
as a guide for proper tightening. Tighten the filter before performing this procedure.
according to the instructions that are on the fuel
filter. Do not overtighten the filter. Fill the fuel tank after operating the engine in
order to drive out moist air. This will help prevent
7. Open the fuel supply valve. The engine will need condensation. Do not fill the tank to the top. The
to be purged of air. Refer to the Operation and fuel expands as the fuel gets warm. The tank may
Maintenance Manual, “Fuel System - Prime” topic overflow.
(Maintenance Section) for more information.
Some fuel tanks use supply pipes that allow water
i02571779 and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
Fuel Tank Water and Sediment take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
- Drain maintenance of the fuel system filter is important.
SMCS Code: 1273-543-M&S
Fuel Storage Tanks
NOTICE
Care must be taken to ensure that fluids are contained Drain the water and the sediment from the fuel
during performance of inspection, maintenance, test- storage tank during the following conditions:
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- • Weekly
ing any compartment or disassembling any compo-
nent containing fluids. • Oil change
Refer to Special Publication, NENG2500, “Caterpillar • Refill of the tank

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar This will help prevent water or sediment from being
products. pumped from the storage tank into the engine fuel
tank. A 4 micron [c] filter for the breather vent on
Dispose of all fluids according to local regulations and the fuel tank is also recommended. Refer to Special
mandates. Publication, SENR9620, “Improving Fuel System
Durablity”.
Fuel Tank If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to
Fuel quality is critical to the performance and to the settle before filling the engine fuel tank. Internal
service life of the engine. Water in the fuel can cause baffles in the bulk storage tank will also help trap
excessive wear to the fuel system. Condensation sediment. Filtering fuel that is pumped from the
occurs during the heating and cooling of fuel. The storage tank helps to ensure the quality of the fuel.
condensation occurs as the fuel passes through the When possible, water separators should be used.
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
SEBU7902-02 75
Maintenance Section
Hoses and Clamps - Inspect/Replace
i02121526 • Anticipated expansion and contraction of the

fittings
Hoses and Clamps -
Inspect/Replace Replace the Hoses and the Clamps
SMCS Code: 7554-040; 7554-510
Inspect all hoses for leaks that are caused by the

following conditions: Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
• Cracking stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
• Softness pressure cap slowly in order to relieve the pres-
sure.
• Loose clamps
1. Stop the engine. Allow the engine to cool.
Replace hoses that are cracked or soft. Tighten any
loose clamps. 2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
NOTICE system filler cap.
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair Note: Drain the coolant into a suitable, clean
any loose or damaged fuel and oil lines, tubes and container. The coolant can be reused.
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec- 3. Drain the coolant from the cooling system to a
ommended torque. level that is below the hose that is being replaced.
4. Remove the hose clamps.

Check for the following conditions:
5. Disconnect the old hose.
• End fittings that are damaged or leaking
6. Replace the old hose with a new hose.
• Outer covering that is chafed or cut
7. Install the hose clamps with a torque wrench.
• Exposed wire that is used for reinforcement
Note: Refer to the Specifications, SENR3130,
• Outer covering that is ballooning locally “Torque Specifications” in order to locate the proper
torques.
• Flexible part of the hose that is kinked or crushed
8. Refill the cooling system.
• Armoring that is embedded in the outer covering
A constant torque hose clamp can be used in place cooling system filler cap’s gaskets. Replace
of any standard hose clamp. Ensure that the constant the cooling system filler cap if the gaskets are
torque hose clamp is the same size as the standard damaged. Install the cooling system filler cap.
clamp.
Due to extreme temperature changes, the hose will leaks.
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps. i01848653
Each installation application can be different. The Overhaul Considerations

differences depend on the following factors:
SMCS Code: 7595-043
• Type of hose
Reduced hours of operation at full load will result in a
• Type of fitting material lower average power demand. A decreased average
power demand should increase both the engine
• Anticipated expansion and contraction of the hose service life and the overhaul interval.
76 SEBU7902-02
Maintenance Section
Overhaul Considerations
The need for an overhaul is generally indicated by After Failure Overhaul

increased fuel consumption and by reduced power.
If a major engine failure occurs and the engine
The following factors are important when a decision must be removed, many options are available. An
is being made on the proper time for an engine overhaul should be performed if the engine block or
overhaul: the crankshaft needs to be repaired.
• The need for preventive maintenance If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
• The quality of the fuel that is being used percent and 50 percent of the cost of a new engine
with a similar exchange core.
• The operating conditions
This lower cost can be attributed to three aspects:
• The results of the S·O·S analysis
• Specially designed Caterpillar engine features
Oil Consumption as an Overhaul
• Caterpillar dealer exchange components
Indicator
• Caterpillar Inc. remanufactured exchange
Oil consumption, fuel consumption, and maintenance components
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
Overhaul Recommendation
required capacity of a makeup oil tank that is suitable
for the maintenance intervals. To minimize downtime, a scheduled engine overhaul
by your Caterpillar dealer is recommended. This will
provide you with the best cost/value relationship.
Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the
Note: Overhaul programs vary according to the
engine load is increased, the amount of oil that is
engine application and according to the dealer that
consumed per hour also increases.
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available
The oil consumption rate (brake specific oil
overhaul programs and about overhaul services for
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC) extending the engine life.
depends on the engine load. Consult your Caterpillar
If an overhaul is performed without overhaul service
dealer for assistance in determining the typical oil
consumption rate for your engine. from your Caterpillar dealer, be aware of the following
maintenance recommendations.
When an engine’s oil consumption has risen to three
times the original oil consumption rate due to normal Unit Fuel Injector
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby Clean the fuel injector body and replace the O-rings.
and a slight increase in fuel consumption. Replace the O-rings and the gasket on the injector
sleeve. Clean the area around the injector seating
in the injector sleeve. Refer to the Service Manual
Overhaul Options
for the complete procedure, or consult with your
Caterpillar dealer for assistance.
Before Failure Overhaul
A planned overhaul before failure may be the best Rebuild or Exchange

value for the following reasons:
Cylinder Head Assembly, Connecting Rods,
• Costly unplanned downtime can be avoided. Pistons, Cylinder Liners, Turbocharger, Cylinder
Packs, Oil Pump, and Fuel Transfer Pump
• Many original parts can be reused according to the
standards for reusable parts. These components should be inspected according to
the instructions that are found in various Caterpillar
• The engine service life can be extended without the reusability publications. The Special Publication,
risk of a major catastrophe due to engine failure. SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
• The best cost/value relationship per hour of
extended life can be attained.
SEBU7902-02 77
Maintenance Section
Overhaul Considerations
If the parts comply with the established inspection • Damage to the journals
specifications that are expressed in the reusable
parts guideline, the parts should be reused. • Bearing material that has seized to the journals
Parts that are not within the established inspection Check the journal taper and the profile of the
specifications should be dealt with in one of the crankshaft journals. Check these components by
following manners: interpreting the wear patterns on the following
components:
• Salvaging
• Rod bearing
• Repairing
• Main bearings
• Replacing
Note: If the crankshaft is removed for any reason,
Parts that do not comply with the established use the magnetic particle inspection process to check
inspection specifications can result in the following for cracks in the crankshaft.
problems:
Inspect the camshaft for damage to the journals and
• Unscheduled downtime to the lobes.
• Costly repairs Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check for
• Damage to other engine parts cracks in the camshaft.
• Reduced engine efficiency Inspect the following components for signs of wear or
for signs of scuffing:
• Increased fuel consumption
• Camshaft bearings
Reduced engine efficiency and increased fuel
consumption translates into higher operating costs. • Camshaft followers
Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts. Caterpillar Inc. recommends replacing the crankshaft
vibration damper.
Inspection and/or Replacement
Oil Cooler Core and Aftercooler Core
Piston Rings, Crankshaft Bearings, Valve
Rotators, and Crankshaft Seals During an overhaul, the removal of the oil cooler
core and the aftercooler core is recommended. The
The following components may not last until the oil cooler core and the aftercooler core should be
second overhaul. cleaned and pressure tested.
• Thrust bearings NOTICE

Do not use caustic cleaners to clean the core.
• Main bearings
Caustic cleaners can attack the internal metals of the
• Rod bearings core and cause leakage.
• Valve rotators
Obtain Coolant Analysis
• Crankshaft seals
The concentration of supplemental coolant additive
Caterpillar Inc. recommends the installation of new (SCA) should be checked regularly with test kits
parts at each overhaul period. or with S·O·S Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine
Inspect these parts while the engine is disassembled is overhauled.
for an overhaul.
Inspect the crankshaft for any of the following

conditions:
• Deflection
78 SEBU7902-02
Maintenance Section
Radiator - Clean
A coolant analysis can be conducted in order to verify Pressurized air is the preferred method for removing
the condition of the water that is being used in the loose debris. Direct the air in the opposite direction
cooling system. A full water analysis can be obtained of the fan’s air flow. Hold the nozzle approximately
by consulting your local water utility company or 6 mm (0.25 inch) away from the fins. Slowly move the
an agricultural agent. Private laboratories are also air nozzle in a direction that is parallel with the tubes.
available for water analysis. This will remove debris that is between the tubes.
Caterpillar Inc. recommends an S·O·S Coolant Pressurized water may also be used for cleaning.
Analysis (Level 2). The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
S·O·S Coolant Analysis (Level 2) water in order to soften mud. Clean the core from
both sides.
An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely Use a degreaser and steam for removal of oil and
analyzes the coolant and the effects on the cooling grease. Clean both sides of the core. Wash the core
system. An S·O·S Coolant Analysis (Level 2) provides with detergent and hot water. Thoroughly rinse the
the following information: core with clean water.
• Complete S·O·S Coolant Analysis (Level 2) After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
• Visual inspection of properties of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
• Identification of metal corrosion the core for cleanliness. Repeat the cleaning, if
necessary.
• Identification of contaminants
Inspect the fins for damage. Bent fins may be opened
• Identification of built up impurities (corrosion and with a “comb”. Inspect these items for good condition:
scale) welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance For more detailed information on cleaning and
recommendations. inspection, refer to Special Publication, SEBD0518,
“Know Your Cooling System”.
For more information about coolant analysis, consult
your Caterpillar dealer.
i00151038
i02559063 Severe Service Application -

Radiator - Clean Check
SMCS Code: 1000-535
SMCS Code: 1353-070
Severe service is an application of an engine that
Note: Adjust the frequency of cleaning according to
exceeds current published standards for that engine.
the effects of the operating environment.
Caterpillar maintains standards for the following
engine parameters:
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary. • Performance (power range, speed range, and fuel
consumption)
• Fuel quality
Personal injury can result from air pressure. • Altitude range
Personal injury can result without following prop- • Maintenance intervals
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing. • Oil selection and maintenance
The maximum air pressure for cleaning purposes • Coolant selection and maintenance
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded. • Environmental qualities
SEBU7902-02 79
Maintenance Section
Starting Motor - Inspect
• Installation Improper Maintenance Procedures

Refer to the standards for the engine or consult with • Extending the maintenance intervals
your Caterpillar dealer in order to determine if the
engine is operating within the defined parameters. • Failure to use recommended fuel, lubricants and
coolant/antifreeze
Severe service operation can accelerate component
wear. Engines that operate under severe conditions
i00651416
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention of
full service life.
Starting Motor - Inspect
SMCS Code: 1451-040; 1453-040
Due to individual applications, it is not possible to
identify all of the factors which can contribute to Caterpillar Inc. recommends a scheduled inspection
severe service operation. Consult your Caterpillar of the starting motor. If the starting motor fails, the
dealer for the unique maintenance that is necessary engine may not start in an emergency situation.
for the engine.
Check the starting motor for proper operation. Check
The operating environment, improper operating the electrical connections and clean the electrical
procedures and improper maintenance procedures connections. Refer to the Service Manual for more
can be factors which contribute to severe service information on the checking procedure and for
conditions. specifications or consult your Caterpillar dealer for
assistance.
Environmental Factors
i01539769
Ambient temperatures – The engine may be
exposed to extended operation in extremely
cold environments or hot environments. Valve
Turbocharger - Inspect
components can be damaged by carbon buildup if SMCS Code: 1052-040; 1052
the engine is frequently started and stopped in very
cold temperatures. Extremely hot inlet air reduces Periodic inspection and cleaning is recommended
engine performance. for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through
Air Quality – The engine may be exposed to the air inlet system. Therefore, by-products from oil
extended operation in an environment that is dirty and from combustion can collect in the turbocharger
or dusty, unless the equipment is cleaned regularly. compressor housing. Over time, this buildup can
Mud, dirt and dust can encase components. contribute to loss of engine power, increased black
Maintenance can be very difficult. The buildup can smoke and overall loss of engine efficiency.
contain corrosive chemicals.
If the turbocharger fails during engine operation,
Buildup – Compounds, elements, corrosive damage to the turbocharger compressor wheel
chemicals and salt can damage some components. and/or to the engine may occur. Damage to the
turbocharger compressor wheel can cause additional
Altitude – Problems can arise when the engine is damage to the pistons, the valves, and the cylinder
operated at altitudes that are higher than the intended head.
settings for that application. Necessary adjustments
should be made.
Improper Operating Procedures

• Extended operation at low idle
• Frequent hot shutdowns
• Operating at excessive loads
• Operating at excessive speeds
• Operating outside the intended application
80 SEBU7902-02
Maintenance Section
Walk-Around Inspection
3. Check the compressor wheel for cleanliness.

NOTICE If only the blade side of the wheel is dirty, dirt
Turbocharger bearing failures can cause large quan- and/or moisture is passing through the air filtering
tities of oil to enter the air inlet and exhaust systems. system. If oil is found only on the back side of the
Loss of engine lubricant can result in serious engine wheel, there is a possibility of a failed turbocharger
damage. oil seal.
Minor leakage of a turbocharger housing under ex- The presence of oil may be the result of extended
tended low idle operation should not cause problems engine operation at low idle. The presence of oil
as long as a turbocharger bearing failure has not oc- may also be the result of a restriction of the line for
curred. the inlet air (plugged air filters), which causes the
turbocharger to slobber.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust 4. Use a dial indicator to check the end clearance
smoke or engine rpm up at no load), do not continue on the shaft. If the measured end play is greater
engine operation until the turbocharger is repaired or than the Service Manual specifications, the
replaced. turbocharger should be repaired or replaced.
An end play measurement that is less than the
minimum Service Manual specifications could
An inspection of the turbocharger can minimize indicate carbon buildup on the turbine wheel. The
unscheduled downtime. An inspection of the turbocharger should be disassembled for cleaning
turbocharger can also reduce the chance for potential and for inspection if the measured end play is less
damage to other engine parts. than the minimum Service Manual specifications.
Note: Turbocharger components require precision 5. Inspect the bore of the turbine housing for
clearances. The turbocharger cartridge must corrosion.
be balanced due to high rpm. Severe Service
Applications can accelerate component wear. 6. Clean the turbocharger housing with standard
Severe Service Applications require more frequent shop solvents and a soft bristle brush.
inspections of the cartridge.
7. Fasten the air inlet piping and the exhaust outlet
Removal and Installation piping to the turbocharger housing.
For options regarding the removal, installation, repair i01185304

and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine for the Walk-Around Inspection
procedure and specifications.
SMCS Code: 1000-040
Cleaning and Inspecting
Inspect the Engine for Leaks and
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually for Loose Connections
inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt A walk-around inspection should only take a few
from entering during reassembly. minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect For maximum engine service life, make a thorough
the compressor wheel and the turbine wheel for inspection of the engine compartment before starting
contact with the turbocharger housing. There the engine. Look for items such as oil leaks or coolant
should not be any visible signs of contact between leaks, loose bolts, worn belts, loose connections and
the turbine wheel or compressor wheel and the trash buildup. Make repairs, as needed:
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the • The guards must be in the proper place. Repair
compressor wheel and the turbocharger housing, damaged guards or replace missing guards.
the turbocharger must be reconditioned.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
SEBU7902-02 81
Maintenance Section
Water Pump - Inspect
• Inspect the ground strap for a good connection and

NOTICE for good condition.
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct • Inspect the ECM to the cylinder head ground strap
the leak. If leaking is suspected, check the fluid levels for a good connection and for good condition.
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be • Disconnect any battery chargers that are not
unwarranted. 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
NOTICE a maintenance free battery.
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning • Check the condition of the gauges. Replace any
or high pressure water. gauges that are cracked. Replace any gauge that
can not be calibrated.
• Ensure that the cooling lines are properly clamped
and that the cooling lines are tight. Check for leaks. i01057943
Check the condition of all pipes.
Water Pump - Inspect
• Inspect the water pumps for coolant leaks.
SMCS Code: 1361-040; 1361
Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount A failed water pump might cause severe engine
of leakage to occur as the engine cools down and overheating problems that could result in the following
the parts contract. conditions:
Excessive coolant leakage may indicate the need • Cracks in the cylinder head
to replace the water pump seal. For the removal of
water pumps and the installation of water pumps • A piston seizure
and/or seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer. • Other potential damage to the engine
• Inspect the lubrication system for leaks at the front Visually inspect the water pump for leaks. If any
crankshaft seal, the rear crankshaft seal, the oil leaking is observed, replace the water pump seal
pan, the oil filters and the valve cover. or the water pump assembly. Refer to the Service
Manual for the disassembly and assembly procedure.
• Inspect the fuel system for leaks. Look for loose
fuel line clamps or for loose fuel line tie-wraps. Note: Refer to the Service Manual or consult your
Caterpillar dealer if any repair is needed or any
• Inspect the piping for the air inlet system and the replacement is needed.
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
• Inspect the alternator belt and the accessory drive

belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced as

matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
• Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.
82 SEBU7902-02
Warranty Section
Warranty Information
Warranty Section The following information is an explanation of

maintenance items for emission related components.
See the Operation and Maintenance Manual,
“Maintenance Interval Schedule” (Maintenance
Warranty Information Section) for the specific interval for the following
items.
i02212087 EXHAUST AFTERTREATMENT SYSTEM –

Aftertreatment devices are sensitive to the type of
Emissions Warranty fuel that is used and the operating schedule. Low
Information quality fuel may cause increases in exhaust back
pressure or clogging resulting in loss of power. An
SMCS Code: 1000 authorized Caterpillar dealer can determine if the
aftertreatment device needs service.
Maintenance Recommendations UNIT INJECTORS – Unit injectors are subject to tip
wear as a result of fuel contamination. This damage
Caterpillar Inc. engines are certified by the United can cause the following conditions: an increase in
States Environmental Protection Agency (EPA) in fuel consumption, black smoke, misfire, and rough
order to comply with exhaust emission standards and running engine. The unit injector should be inspected,
gaseous emission standards that are prescribed by tested and replaced, if necessary. Unit injectors can
Federal laws at the time of manufacture. be tested by an authorized Caterpillar dealer.
Efficiency of the emission control and the engine TURBOCHARGER – Check for any unusual sound
performance depends on adherence to proper or vibration in the turbocharger. Inspect the inlet
operation and maintenance recommendations and piping and connections and inspect the exhaust
use of recommended fuels and lubricating oils. piping and connections. Check the condition of
According to recommendations, major adjustments the bearing. Perform the maintenance that is
and repairs should be made by your authorized described in the Operation and Maintenance Manual,
Caterpillar dealer. “Maintenance Interval Schedule” (Maintenance
Section).
Various chemical fuel additives which claim to reduce
visible smoke are available commercially. Although ELECTRONIC ENGINE CONTROL – This
additives have been used to solve some isolated component is a device that is designed to control
smoke problems in the field, additives are not engine operation with respect to the amount of fuel
recommended for general use. The engines should injected, the injection timing as well as controlling
be certified without smoke depressants according to the black smoke emission of the engine during the
federal smoke regulations. engine’s operation when low inlet manifold pressure
exists.
Take corrective steps immediately after worn parts
which may affect emission levels are discovered in Any erratic engine behavior may indicate a need
order to ensure the proper operation of the emission for replacement or repair. Your Caterpillar dealer is
control systems. The use of genuine Caterpillar parts equipped with the necessary tools, personnel and
is recommended. Suppliers of non-Caterpillar parts procedures in order to perform this service.
must ensure the owner that the use of such parts will
not adversely affect emission levels. The owner is encouraged to keep adequate
maintenance records. However, the absence of such
Regular maintenance intervals with a special records will not invalidate the warranty. Refer to the
emphasis on the following items are necessary in Operation and Maintenance Manual, “Maintenance
order to keep exhaust emissions within acceptable Log” (Reference Materials Section).
limits for the useful life of the engine. Refer to the
Operation and Maintenance Manual, “Severe Service The owner may perform routine maintenance, repairs
Application - Check” topic (Maintenance Section). and other work that is outside of the warranty. The
If the engine is operating under severe conditions, work may be done at any repair facility. Such work
adjust the maintenance schedule accordingly. does not need to be performed at a designated
See your authorized Caterpillar dealer in order to station that is determined by the warranty in order for
help analyze your specific application, operating the warranty to remain in force.
environment and maintenance schedule adjustments.
SEBU7902-02 83
Warranty Section
Warranty Information
Customer Assistance (Emission

Control Systems Warranty)
Caterpillar Inc. intends to ensure that the Emission
Control Systems warranty is properly administered. If
you do not receive adequate warranty service under
the Emission Control Systems Warranty, call or write
to the following address:
Caterpillar Inc.
Manager, Engine Business
P.O. Box 0600 Mossville, IL 61552
Authorized dealers are recommended for major

maintenance and for repair work. Authorized dealers
are staffed with trained personnel and proper
tools. Authorized dealers are aware of the latest
maintenance methods and procedures. If owners or
other persons desire to perform the work, a Service
Manual should be purchased and current service
information should be obtained from a Caterpillar
dealer.
84 SEBU7902-02
Engine Ratings
Reference Information “IND A (Continuous)” – This rating allows operation

at the engine’s rated load and speed for 100 percent
Section of the time without interruption or load cycling. The
engine may be operated at full load for 100 percent of
the duty cycle. The following applications are typical:
pipeline pumping, ventilation, and applications that
Engine Ratings are specified by the customer.
“IND B” – This rating is for service with power and/or

i01097462 speed that is cyclic. Full load operation must not
Engine Rating Conditions exceed 80 percent of the duty cycle. The following
applications are typical: irrigation with a normal pump
SMCS Code: 1000 demand that is 85 percent of the engine rating,
mechanical pumping and/or drilling in an oil field, and
All engine ratings are based on“SAE J1349”. stationary plant air compressors.
“IND C (Intermittent)” – This rating is for service

Ratings relate to the standard conditions of “AS1501”,
of “ISO3046/1”, of “DIN6271”, and of “BS5514”. with power and/or speed that is cyclic. The engine
can be operated continuously for one hour at
the “C” rating. This is followed by one hour of
The engine ratings are gross output ratings.
operation at the “A” rating or below the “A” rating.
Gross Output Ratings – The total output capability Continuous power may be supplied by engines
with the “C” rating. However, operation at full load
of the engine that is equipped with standard
accessories. must not exceed 50 percent of the duty cycle. The
following applications are typical: agricultural tractors,
harvesters, combines, off-highway trucks, power for
Standard accessories include the following
components: fire pumps, drilling for blast holes, rock crushers with
high torque rise, wood chippers with high torque rise,
and oil field hoisting.
• Oil pumps
• Fuel pumps
• Water pumps
Subtract the power that is required to drive auxiliary
components from the gross output. This will produce
the net power that is available for the external load
(flywheel).
i01257714
Engine Rating Definitions

SMCS Code: 1000
The ratings must be reduced in order to accommodate

changes in the altitude. The ratings must be reduced
according to the data for derating that is obtained
from the test specification for the engine.
All of the ratings that are defined have a

manufacturing tolerance of ± three percent.
Use the following guidelines in order to determine the

applicable engine rating.
NOTICE
Operating an engine at a greater power output than
the engine is rated for will reduce the service life of
the engine before overhaul.
SEBU7902-02 85
Customer Service
Customer Service Latin America, Mexico, Carribean

Caterpillar Americas Co.
701 Waterford Way, Suite 200
i02097871 Miami, FL 33126-4670
USA
Customer Assistance Phone: 305-476-6800
Fax: 305-476-6801
SMCS Code: 1000
Europe, Africa, and Middle East
USA and Canada Caterpillar Overseas S.A.
76 Route de Frontenex
When a problem arises concerning the operation of P.O. Box 6000
an engine or concerning the service of an engine, CH-1211 Geneva 6
the problem will normally be managed by the dealer Switzerland
in your area. Phone: 22-849-4444
Fax: 22-849-4544
Your satisfaction is a primary concern to Caterpillar
and to Caterpillar dealers. If you have a problem that Far East
has not been handled to your complete satisfaction, Caterpillar Asia Pte. Ltd.
follow these steps: 7 Tractor Road
Jurong, Singapore 627968
1. Discuss your problem with a manager from the Republic of Singapore
dealership. Phone: 65-662-8333
Fax: 65-662-8302
2. If your problem cannot be resolved at the dealer
level without additional assistance, use the phone China
number that is listed below to talk with a Field Caterpillar China Ltd.
Service Coordinator: 37/F., The Lee Gardens
33 Hysan Avenue
1-800-447-4986 Causeway Bay
G.P.O. Box 3069
The normal hours are from 8:00 to 4:30 Monday Hong Kong
through Friday Central Standard Time. Phone: 852-2848-0333
Fax: 852-2848-0440
3. If your needs have not been met still, submit the
matter in writing to the following address: Japan
Shin Caterpillar Mitsubishi Ltd.
Caterpillar Inc. SBS Tower
Manager, Customer Service, Engine Division 10-1, Yoga 4-Chome
Mossville Bldg AC Setagaya-Ku, Tokyo 158-8530
P.O. Box 610 Japan
Mossville, Illinois 61552-0610 Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Please keep in mind: probably, your problem will
ultimately be solved at the dealership, using the Japan
dealership’s facilities, equipment, and personnel. Caterpillar Power Systems, Inc.
Therefore, follow the steps in sequence when a SBS Tower (14th floor)
problem is experienced. 4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Phone: 81-3-5797-4300
Outside of the USA and of Canada Fax: 81-3-5797-4359
If a problem arises outside the USA and outside Australia and New Zealand
Canada, and if the problem cannot be resolved at the Caterpillar of Australia Ltd.
dealer level, consult the appropriate Caterpillar office. 1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
86 SEBU7902-02
Customer Service
i01028392
Ordering Replacement Parts

SMCS Code: 7567
When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, 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.
SEBU7902-02 87
Reference Materials
Reference Materials • Data Sheet, PEHJ0091, “Cat DEO (SAE 10W-30

and SAE 15W-40)” Egypt and Saudi Arabia
i02769293 • Special Publication, PEDP7035, “Optimizing Oil

Change Intervals”
Reference Material
• Special Publications, PEDP7036, “S·O·S Fluids
SMCS Code: 1000 Analysis Cornerstone”
The following literature can be obtained through any
• Special Publication, PEGJ0035, “Grease Selection
Caterpillar dealer. Guide”
Coolants • Special Publication, PEHP6001, “How To Take A

Good Oil Sample”
• Data Sheet, PEHJ0067, “Cat ELC (Extended Life
Coolant)” • Special Publication, PEHP9516, “Product Data
Sheet for Special Application Engine Oil For
• Data Sheet, PEHP7057, “S·O·S Coolant Analysis” Caterpillar 3116 and 3126 Marine Diesel Engines
with Mechanical Unit Injectors”
• Special Publication, PEEP5027, “Label - ELC
Radiator Label” • Special Publication, PEWP3014, “Cat Fluids
Selector Dial (International)”
• Special Publication, SEBD0518, “Know Your
Cooling System” • Special Publication, PEWP9733, “Cat Fluids
Selector Dial (North America)”
• Special Publication, SEBD0970, “Coolant and Your
Engine” • Special Publication, SEBD0640, “Oil and Your
Engine”
Fuels
Miscellaneous
• Module, SENR9620, “Improving Fuel System
Durability” Special Publication, PECP6026, “One Safe Source”
English language for use in NACD
• Module, SENR9646, “Improving Fuel System
Durability” Special Publication, PECP6027, “One Safe Source”
English language for use in COSA
• Special Publication, SEBD0717, “Diesel Fuels and
Your Engine” Special Publication, PECP6028, “One Safe Source”
English language for use in non NACD and non
COSA
Lubricants
• Service Manual, SENR9595, “C-9 Industrial Engine
• Data Sheet, NEHP6015, “Cat High Speed Ball Service Manual”
Bearing Grease” NLGI grade 2
• Special Instruction, REHS0871, “Electronic
• Data Sheet, PEHP0002, “Cat Advanced 3Moly Installation Guide”
Grease” NLGI grade 2
• Special Instruction, SEHS7332, “Warning Tag -
• Data Sheet, PEHJ0021, “Cat DEO (SAE 10W-30 Danger Do Not Operate”
and SAE 15W-40)” Worldwide except North
America, Egypt, Saudi Arabia, and Brazil
• Special Instruction, SEHS7633, “Battery Test
Procedure”
• Data Sheet, PEHJ0059, “Cat DEO (SAE 10W-30
and SAE 15W-40)” Canada, Mexico, and the
United States
• Special Instruction, SEHS8622, “Using the FT-
1984 Air-To-Air Aftercooler Leak Test Group”
• Data Sheet, PEHJ0072, “Cat DEO (SAE 10W-30 • Special Instruction, SEHS8742, “Using the 8T-8697
and SAE 15W-40)” Brazil Electronic Control Analyzer Programmer (ECAP)”
• Data Sheet, PEHJ0088, “Cat Multipurpose Grease” • Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”
88 SEBU7902-02
Reference Materials
• Special Instruction, SEHS9827, “Calibration of SAE International

Temperature Contactors” 400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
• Special Instruction, SEHS9828, “Calibration of Telephone: (724) 776-4841
Pressure Contactors”
The “American Petroleum Institute Publication No.
• Special Instruction, SMHS7001, “Assembly of Fan 1509” can be obtained from the following locations:
Drive Pulley Assemblies” local technological society, local library, and local
college. If necessary, consult API at the following
• Special Publication, NEHS0526, “Service address:
Technology Application Guide”
American Petroleum Institute
• Special Publication, NENG2500, “Tools and Shop 1220 L St. N.W.
Products Guide” Washington, DC, USA 20005
Telephone: (202) 682-8000
• Special Publication, PECP9067, “One Safe
Source” The International Organization for Standardization
(ISO) offers information and customer service
• Special Publication, PEDP0026, “Power Analysis regarding international standards and standardizing
Report” activities. ISO can also supply information on the
following subjects that are not controlled by ISO:
• Special Publication, SEBF8029, “Index to national standards, local standards, regulations,
Guidelines for Reusable Parts and Salvage certification, and related activities. Consult the
Operations” member of ISO in your country.
• Special Publication, SEBF8062, “Guideline for International Organization for Standardization

Reusable Parts - Procedure to Inspect and Clean (ISO)
Air Filters” 1, rue de Varembé
Case postale 56
• Special Publication, SEBU6251, “Caterpillar CH-1211 Genève 20
Commercial Diesel Engine Fluids Switzerland
Recommendations For Lubricants, Diesel Telephone: +41 22 749 01 11
Fuel, and Coolants” Facsimile: +41 22 733 34 30
E-mail: central@iso.ch
• Specifications, SENR3130, “Torque Specifications Web site: http://www.iso.ch
Module”
European classifications are established by the
Counseil International Des Machines a Combustion
Additional Reference Material (CIMAC) (International Council on Combustion
The “Engine Fluids Data Book” can be obtained from Engines).
the following locations: local technological society,
CIMAC Central Secretariat
local library, and local college. If necessary, consult
EMA at the following address: Lyoner Strasse 18
60528 Frankfurt
Germany
Engine Manufacturers Associaton
Two North LaSalle Street, Suite 2200 Telephone: +49 69 6603 1567
Facsimile: +49 69 6603 1566
Chicago, IL, USA 60602
E-mail: ema@enginemanufacturers.org
Telephone: (312) 827-8700 i00912149
Facsimile: (312) 827-8737
Maintenance Records
The “Society of Automotive Engineers (SAE)
Specifications” can be found in your SAE handbook. SMCS Code: 1000
This publication can also be obtained from the
following locations: local technological society, local Caterpillar Inc. recommends the retention of accurate
library, and local college. If necessary, consult SAE maintenance records. Accurate maintenance records
at the following address: can be used for the following purposes:
• Determine operating costs.

SEBU7902-02 89
Reference Materials
• 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 a variety of

other business decisions that are related to engine
maintenance.
Maintenance records are a key element of a

maintenance program that is well managed. Accurate
maintenance records can help your Caterpillar 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’s repair costs
• Owner’s receipts
• Maintenance log
90 SEBU7902-02
Reference Materials
i01176304
Maintenance Log
SMCS Code: 1000
Table 10
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity
Service Item Date Authorization
Hours Of Fuel
SEBU7902-02 91
Index Section
Index
A Customer Specified Parameters...................... 20, 32
Programmable Monitoring System (PMS) ......... 20
After Starting Engine ............................................. 35
After Stopping Engine............................................ 38
Aftercooler Core - Clean/Test (Air-To-Air D
Aftercooler) .......................................................... 46
Diagnostic Flash Code Retrieval ........................... 28
Diagnostic Lamp.................................................... 28
B Driven Equipment - Check..................................... 57
Check the Alignment.......................................... 57
Battery - Replace................................................... 46 Inspect the Drive Coupling................................. 58
Battery Electrolyte Level - Check .......................... 47 Inspect the Rear Gear Train .............................. 58
Battery or Battery Cable - Disconnect ................... 47
Before Starting Engine .................................... 12, 33
Belts - Inspect/Adjust/Replace............................... 48 E
Adjustment of the Fan Drive Belt ....................... 48
Alternator Belt Adjustment ................................. 48 Electrical System ................................................... 13
Inspection........................................................... 48 Grounding Practices .......................................... 13
Replacement...................................................... 48 Electronic Unit Injector - Inspect/Adjust................. 58
Burn Prevention....................................................... 9 Electronics Grounding Stud - Inspect/Clean/
Batteries............................................................... 9 Tighten................................................................. 58
Coolant................................................................. 9 Emissions Certification Film .................................. 20
Oils....................................................................... 9 Emissions Warranty Information............................ 82
Customer Assistance (Emission Control Systems
Warranty) ......................................................... 83
C Maintenance Recommendations ....................... 82
Engaging the Driven Equipment............................ 36
Cold Weather Operation........................................ 39 Industrial Engines .............................................. 36
Cold Weather Starting ........................................... 34 Engine - Clean....................................................... 59
Cooling System Coolant (DEAC) - Change........... 48 Engine Air Cleaner Element (Dual Element) -
Cooling Systems with Heavy Deposits or Clean/Replace ..................................................... 59
Plugging ........................................................... 49 Cleaning the Primary Air Cleaner Elements ...... 61
Drain .................................................................. 49 Servicing the Air Cleaner Elements ................... 60
Fill ...................................................................... 50 Engine Air Cleaner Service Indicator - Inspect (If
Flush .................................................................. 49 Equipped) ............................................................ 62
Cooling System Coolant (ELC) - Change.............. 51 Test the Service Indicator................................... 63
Drain .................................................................. 51 Engine Air Precleaner - Check/Clean.................... 63
Fill ...................................................................... 52 Engine Crankcase Breather - Clean...................... 63
Flush .................................................................. 51 Engine Description ................................................ 17
Cooling System Coolant Extender (ELC) - Add..... 53 Aftermarket Products and Caterpillar Engines... 18
Cooling System Coolant Level - Check ................. 53 Welding and Caterpillar Electronic Engines....... 18
Cooling System Coolant Sample (Level 1) - Engine Diagnostics................................................ 28
Obtain .................................................................. 54 Engine Electronics................................................. 14
Cooling System Coolant Sample (Level 2) - Engine Mounts - Inspect........................................ 64
Obtain .................................................................. 55 Engine Oil and Filter - Change .............................. 66
Cooling System Supplemental Coolant Additive Drain the Engine Oil........................................... 66
(SCA) - Test/Add.................................................. 55 Fill the Engine Crankcase .................................. 67
Add the SCA, If Necessary ................................ 56 Replace the Oil Filter ......................................... 66
Test the Concentration of the SCA..................... 55 Engine Oil Level - Check ....................................... 64
Cooling System Water Temperature Regulator - Engine Oil Sample - Obtain ................................... 65
Replace................................................................ 56 Obtain the Sample and the Analysis.................. 65
Crankshaft Vibration Damper - Inspect ................. 57 Engine Operation................................................... 36
Visconic Damper................................................ 57 Engine Operation with Active Diagnostic Codes ... 31
Crushing Prevention and Cutting Prevention ......... 11 Engine Operation with Intermittent Diagnostic
Customer Assistance............................................. 85 Codes .................................................................. 32
Outside of the USA and of Canada.................... 85 Engine Protective Devices - Check ....................... 67
USA and Canada ............................................... 85 Calibration Check............................................... 67
Customer Service .................................................. 85 Visual Inspection................................................ 67
92 SEBU7902-02
Index Section
Engine Rating Conditions ...................................... 84 H

Engine Rating Definitions ...................................... 84
Engine Ratings ...................................................... 84 Hoses and Clamps - Inspect/Replace ................... 75
Engine Speed/Timing Sensors - Check/Clean/ Replace the Hoses and the Clamps .................. 75
Calibrate .............................................................. 68
Engine Starting ................................................ 12, 33
Engine Stopping .............................................. 12, 38 I
Engine Storage Procedure - Check....................... 68
Engine Valve Lash - Inspect/Adjust ....................... 69 Important Safety Information ................................... 2
Engine Valve Rotators - Inspect ............................ 69
Engine Warm-up.................................................... 36
L
F Lifting and Storage ................................................ 22
Fan Drive Bearing - Lubricate................................ 69

Fan Drive Bearing - Replace ................................. 70 M
Fault Logging......................................................... 31
Features and Controls ........................................... 23 Maintenance Interval Schedule ............................. 44
Fire Prevention and Explosion Prevention .............. 9 Maintenance Log ................................................... 90
Ether ................................................................... 11 Maintenance Records............................................ 88
Fire Extinguisher ................................................. 11 Maintenance Section ............................................. 41
Lines, Tubes and Hoses ..................................... 11 Manual Stop Procedure......................................... 38
Foreword ................................................................. 5 Model View Illustrations......................................... 16
California Proposition 65 Warning ....................... 5 Model Views .......................................................... 16
Literature Information........................................... 4 Monitoring System................................................. 23
Maintenance ........................................................ 4 Caterpillar Messenger Display ........................... 24
Maintenance Intervals.......................................... 4 Indicators and Gauges....................................... 23
Operation ............................................................. 4 Mounting and Dismounting.................................... 12
Overhaul .............................................................. 4
Safety................................................................... 4
Fuel and the Effect from Cold Weather ................. 39 O
Fuel Conservation Practices.................................. 36
Fuel Related Components in Cold Weather .......... 40 Operation Section.................................................. 22
Fuel Filters ......................................................... 40 Ordering Replacement Parts ................................. 86
Fuel Heaters ...................................................... 40 Overhaul Considerations ....................................... 75
Fuel Tanks.......................................................... 40 Oil Consumption as an Overhaul Indicator ........ 76
Fuel System - Prime .............................................. 70 Overhaul Recommendation ............................... 76
The Engine Has Been Run Out of Fuel ............. 71
The Secondary Fuel Filter Has Been Replaced.. 70
Fuel System Primary Filter (Water Separator) P
Element - Replace ............................................... 72
Replace the Element.......................................... 72 Plate Locations and Film Locations....................... 19
Fuel System Primary Filter/Water Separator - Information Plate (2) .......................................... 19
Drain .................................................................... 72 Serial Number Plate (1) ..................................... 19
Fuel System Secondary Filter - Replace ............... 73 Product Identification Information .......................... 19
Fuel Tank Water and Sediment - Drain ................. 74 Product Information Section .................................. 15
Drain the Water and the Sediment..................... 74 Product Lifting........................................................ 22
Fuel Storage Tanks ............................................ 74 Product Storage..................................................... 22
Fuel Tank ........................................................... 74
R
G
Radiator - Clean .................................................... 78
General Hazard Information .................................... 7 Radiator Restrictions ............................................. 39
Asbestos Information ........................................... 8 Reference Information Section .............................. 84
Containing Fluid Spillage ..................................... 8
Dispose of Waste Properly .................................. 9
Fluid Penetration.................................................. 8
Pressurized Air and Water ................................... 8
General Information............................................... 15
SEBU7902-02 93
Index Section
Reference Material ................................................ 87

Additional Reference Material............................ 88
Coolants............................................................. 87
Fuels .................................................................. 87
Lubricants .......................................................... 87
Miscellaneous .................................................... 87
Reference Materials .............................................. 87
Reference Numbers .............................................. 19
Record for Reference......................................... 19
Refill Capacities..................................................... 41
Refill Capacities and Recommendations............... 41
Cooling System.................................................. 42
Engine Oil .......................................................... 41
Fuel .................................................................... 42
Safety Messages ..................................................... 6

Universal Warning (1) .......................................... 6
Safety Section ......................................................... 6
Self-Diagnostics..................................................... 28
Severe Service Application - Check ...................... 78
Environmental Factors ....................................... 79
Improper Maintenance Procedures.................... 79
Improper Operating Procedures ........................ 79
Starting Motor - Inspect ......................................... 79
Starting the Engine ................................................ 33
Starting a Cold Engine ....................................... 33
Starting a Warm Engine..................................... 34
Starting with Jump Start Cables ............................ 35
Table of Contents..................................................... 3
Turbocharger - Inspect .......................................... 79
Cleaning and Inspecting .................................... 80
Removal and Installation.................................... 80
Walk-Around Inspection ........................................ 80

Inspect the Engine for Leaks and for Loose
Connections ..................................................... 80
Warranty Information ............................................. 82
Warranty Section ................................................... 82
Water Pump - Inspect............................................ 81
Welding on Engines with Electronic Controls ........ 15
94 SEBU7902-02
Index Section
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:
©2007 Caterpillar
All Rights Reserved Printed in U.S.A.

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SEBU7902-02

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Warranty Section

Mounting and Dismounting ................................... 12

Before Starting Engine .......................................... 12

Engine Starting ..................................................... 12

Engine Stopping ................................................... 12

Electrical System .................................................. 13

Engine Electronics ................................................ 14

Product Information Section

Model Views ......................................................... 16

Product Identification Information ........................ 19

Features and Controls .......................................... 23

Engine Diagnostics ............................................... 28

Engine Starting ..................................................... 33

Engine Operation .................................................. 36

Engine Stopping ................................................... 38

Cold Weather Operation ....................................... 39

Maintenance Interval Schedule ............................ 44

Foreword Use fuel consumption or service hours to determine

The operation section is a reference for operators. Overhaul

California Proposition 65 Warning

Battery posts, terminals and related accessories

Replace any safety message that is damaged or

Ensure that all of the safety messages are legible.

Do not operate or work on this engine unless you • Drain plugs

General Hazard Information

• Wear a hard hat, protective glasses, and other

• When work is performed around an engine that is

Pressurized Air and Water Asbestos Information

When pressurized air and/or pressurized water is

The maximum air pressure for cleaning purposes

Use caution. Avoid inhaling dust that might be

• Tools that are suitable for containing fluids and

Obey all local regulations for the disposal of liquids.

If the application has a makeup tank, remove the cap

g00706404 Do not smoke while checking the battery electrolyte

Fire Prevention and Explosion

Do not touch any part of an operating engine.

If the application involves the presence of combustible

Remove all flammable materials such as fuel, oil, and

Store fuels and lubricants in properly marked

Do not expose the engine to any flame.

Wiring must be kept in good condition. All electrical

Eliminate all wiring that is unattached or unnecessary.

Arcing or sparking could cause a fire. Secure

Ether Crushing Prevention and

Repair any lines that are loose or damaged. Leaks

Mounting and Dismounting Engine Starting

See the Service Manual for repairs and for

Stop the engine if an overspeed condition occurs

To stop an electronically controlled engine, cut the

Never disconnect any charging unit circuit or battery

To help prevent sparks from igniting combustible

Check the electrical wires daily for wires that are

Tampering with the electronic system installation

This engine has a comprehensive, programmable

Alternator Belt ________________ • Level 1: Minimal Smoke _