Doosan Portable Power - OPERATION and MAINTENANCE … · 2012. 10. 23. · 4 SEBU7772-02 Foreword Foreword Literature Information This manual contains safety, operation instructions,

Manual # 22846539 3/07

UUTi

OPERATION and MAINTENANCE MANUAL

for CATERPILLAR C9 ENGINE

Utility Equipment P.O. Box 868 501 Sanford Ave Mocksville, N.C. 27028

This manual contains important safety information. Do not destroy this manual. This manual must be available to the personnel who operate and maintain this machine. “Copyright @ Caterpillar” - Reproduced by IR with permission.

Doosan

Disclaimer

Doosan

Date

SEBU7772-02February 2006

Operation andMaintenanceManualC9 Industrial EngineJSC1-Up (Engine)MBD1-Up (Engine)JLW1-Up (Engine)

i01658146

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread 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 warningsare 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 pictoriallypresented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis 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 Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications 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 ordeath.

SEBU7772-02 3Table of Contents

Table of Contents

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

Safety Section

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

General Hazard Information ................................... 8

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

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

Crushing Prevention and Cutting Prevention ........ 13

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

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

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

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

Electrical System .................................................. 14

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

Product Information Section

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

Model Views ......................................................... 18

Product Identification Information ........................ 21

Operation Section

Lifting and Storage ................................................ 25

Gauges and Indicators .......................................... 26

Engine Diagnostics ............................................... 36

Engine Starting ..................................................... 41

Engine Operation .................................................. 46

Engine Stopping ................................................... 48

Cold Weather Operation ....................................... 50

Maintenance Section

Refill Capacities .................................................... 52

Maintenance Interval Schedule ............................ 58

Warranty Section

Warranty Information ............................................ 97

Reference Information Section

Engine Ratings ..................................................... 98

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

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

Index Section

Index ................................................................... 106

4 SEBU7772-02Foreword

ForewordLiterature InformationThis manual contains safety, operation instructions,lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.

English is the primary language for all Caterpillarpublications. The English used facilitates translationand consistency in electronic media delivery.

Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Caterpillar dealer for the latestavailable information.

SafetyThis safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance andrepair on this product.

OperationOperating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.

The operation section is a reference for operators.Photographs and illustrations guide the operatorthrough procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic information.

MaintenanceThe maintenance section is a guide to engine care.The illustrated, step-by-step instructions are groupedby fuel consumption, service hours and/or calendartime maintenance intervals. Items in the maintenanceschedule are referenced to detailed instructions thatfollow.

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

Recommended service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more frequent lubrication and maintenance than isspecified in the Maintenance Interval Schedule maybe necessary.

The maintenance schedule items are organized fora preventive maintenance management program. Ifthe preventive maintenance program is followed, aperiodic tune-up is not required. The implementationof a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.

Maintenance IntervalsPerform maintenance on items at multiples of theoriginal requirement. Each level and/or individualitems in each level should be shifted ahead or backdepending upon your specific maintenance practices,operation and application. We recommend thatthe maintenance schedules be reproduced anddisplayed near the engine as a convenient reminder.We also recommend that a maintenance record bemaintained as part of the engine’s permanent record.

See the section in the Operation and MaintenanceManual, “Maintenance Records” for informationregarding documents that are generally acceptedas proof of maintenance or repair. Your authorizedCaterpillar dealer can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.

OverhaulMajor engine overhaul details are not covered in theOperation and Maintenance Manual except for theinterval and the maintenance items in that interval.Major repairs are best left to trained personnel oran authorized Caterpillar dealer. Your Caterpillardealer offers a variety of options regarding overhaulprograms. If you experience a major engine failure,there are also numerous after failure overhaul optionsavailable from your Caterpillar dealer. Consult withyour dealer for information regarding these options.

SEBU7772-02 5Foreword

California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

6 SEBU7772-02Safety SectionSafety Messages

Safety Sectioni02246834

Safety MessagesSMCS Code: 1000; 7405

There may be several specific safety messageson an engine. The exact location of the hazardsand the description of the hazards are reviewed inthis section. Please become familiar with all safetymessages.

Ensure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if the words cannot be read or if thepictures are not visible. When the safety messagesare cleaned, use a cloth, water, and soap. Do not usesolvent, gasoline, or other harsh chemicals to cleanthe safety messages. Solvents, gasoline, or harshchemicals could loosen the adhesive that securesthe safety messages. The safety messages that areloosened could drop off of the engine.

Replace any damaged safety messages or missingsafety messages. If a safety message is attachedto a part of the engine that is replaced, install anew safety message on the replacement part. AnyCaterpillar dealer can provide new safety messages.

Do not work on the engine and do not operate theengine unless the instructions and the warnings in theOperation and Maintenance Manual are understood.Proper care is your responsibility. Failure to followthe instructions or failure to heed the warnings couldresult in injury or in death.

SEBU7772-02 7Safety Section

Safety Messages

g01104158Illustration 1


The following section describes the safety messagesthat are found on the engine.

8 SEBU7772-02Safety SectionGeneral Hazard Information

(1) Universal Warning


The universal safety messages are located on eachside of the valve covers.

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions orheed the warnings could result in serious injuryor death.

i02327617

General Hazard InformationSMCS Code: 1000; 7405


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

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

Engine exhaust contains products of combustionwhich may be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is in an enclosed area, vent theengine exhaust to the outside.

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

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

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


General Hazard Information


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

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

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

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

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

• Use all cleaning solutions with care.

• Report all necessary repairs.

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

• The engine is stopped. Ensure that the enginecannot be started.

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

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

Pressurized Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must be below275 kPa (40 psi).

Fluid Penetration


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

Containing Fluid SpillageCare must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theengine. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component that contains fluids.

Refer to Special Publication, NENG2500, “DealerService Tool Catalog” for the following items:

• Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

• Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

10 SEBU7772-02Safety SectionBurn Prevention

Asbestos Information


Caterpillar equipment and replacement parts that areshipped from Caterpillar are asbestos free. Caterpillarrecommends the use of only genuine Caterpillarreplacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.

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

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestosmaterials.

• A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.

• Use exhaust ventilation on permanent machiningjobs.

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

• Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposalof asbestos.

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

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

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

i01480768

Burn PreventionSMCS Code: 1000; 7405

Do not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.


Fire Prevention and Explosion Prevention

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level after the engine has stoppedand the engine has been allowed to cool.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

i01372254

Fire Prevention and ExplosionPreventionSMCS Code: 1000; 7405


All fuels, most lubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency shutdown.

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

If the application involves the presence of combustiblegases, consult your Caterpillar dealer for additionalinformation about suitable protection devices.

Remove all flammable materials such as fuel, oil, anddebris from the engine. Do not allow any flammablematerials to accumulate on the engine.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in case of a line,a tube, or a seal failure. Exhaust shields must beinstalled correctly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding or flame cutting.

Wiring must be kept in good condition. All electricalwires must be properly routed and securely attached.Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate theengine. Clean all electrical connections and tightenall electrical connections.

Eliminate all wiring that is unattached or unnecessary.Do not use any wires or cables that are smaller thanthe recommended gauge. Do not bypass any fusesand/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and properlymaintained battery cables will help to prevent arcingor sparking.

12 SEBU7772-02Safety SectionFire Prevention and Explosion Prevention

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.

Oil filters and fuel filters must be properly installed.The filter housings must be tightened to the propertorque.


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may cause anexplosion.

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

Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

EtherEther is flammable and poisonous.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

Do not store ether cylinders in living areas or in theengine compartment. Do not store ether cylindersin direct sunlight or in temperatures above 49 °C(120 °F). Keep ether cylinders away from openflames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Do not spray ether into an engine if the engine isequipped with a thermal starting aid for cold weatherstarting.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Caterpillar dealer forrepair or for replacement parts.


Crushing Prevention and Cutting Prevention

Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

i01359666

Crushing Prevention andCutting PreventionSMCS Code: 1000; 7405

Support the component properly when work beneaththe component is performed.

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

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

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

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

Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.

i01372247

Mounting and DismountingSMCS Code: 1000; 7405

Inspect the steps, the handholds, and the work areabefore mounting the engine. Keep these items cleanand keep these items in good repair.

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

Face the engine in order to mount the engine ordismount the engine. Maintain a three-point contactwith the steps and handholds. Use two feet and onehand or use one foot and two hands. Do not use anycontrols as handholds.

Do not stand on components which cannot supportyour weight. Use an adequate ladder or use a workplatform. Secure the climbing equipment so that theequipment will not move.

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

i00911989

Before Starting EngineSMCS Code: 1000

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on,underneath, or close to the engine. All protectiveguards and all protective covers must be installedif the engine must be started in order to performservice procedures. To help prevent an accident thatis caused by parts in rotation, work around the partscarefully.

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuits areprovided in order to help prevent personal injury. Thecircuits are also provided in order to help preventengine damage.

On the initial start-up of a new engine or an enginethat has been serviced, prepare to stop the engineif an overspeed condition occurs. This may beaccomplished by shutting off the fuel supply to theengine and/or shutting off the air supply to the engine.

See the Service Manual for repairs and foradjustments.

14 SEBU7772-02Safety SectionEngine Starting

i00910470

Engine StartingSMCS Code: 1000

If a warning tag is attached to the engine start switchor to the controls, do not start the engine or move thecontrols. Also, do not disengage the parking brakes.Consult with the person that attached the warning tagbefore the engine is started.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine from the operator’s station (cab).Never short across the starting motor terminals orthe batteries. This could bypass the engine neutralstart system and/or the electrical system could bedamaged.

Always start the engine according to the procedurethat is described in the Operation and MaintenanceManual, “Engine Starting” topic (Operation Section).Knowing the correct procedure will help to preventmajor damage to the engine components. Knowingthe procedure will also help to prevent personal injury.

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

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

EtherEther is poisonous and flammable. Do not inhaleether, and do not allow ether to contact the skin.Personal injury could result. Do not smoke whileether cylinders are changed. Use ether in wellventilated areas.

Keep ether cylinders out of the reach of unauthorizedpersons. Store ether cylinders in authorized storageareas only. Do not store ether cylinders in directsunlight or at temperatures above 39 °C (102 °F).Discard the ether cylinders in a safe place. Do notpuncture the ether cylinders. Do not burn the ethercylinders.

i01462046

Engine StoppingSMCS Code: 1000

Stop the engine according to the procedure inthe Operation and Maintenance Manual, “EngineStopping (Operation Section)” in order to avoidoverheating of the engine and accelerated wear ofthe engine components.

Use the Emergency Stop Button (if equipped) ONLYin an emergency situation. Do not use the EmergencyStop Button for normal engine stopping. After anemergency stop, DO NOT start the engine until theproblem that caused the emergency stop has beencorrected.

Stop the engine if an overspeed condition occursduring the initial start-up of a new engine or an enginethat has been overhauled. This may be accomplishedby shutting off the fuel supply to the engine and/orshutting off the air supply to the engine.

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

i02469632

Electrical SystemSMCS Code: 1000; 1400

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

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative “−” jump start cable should be connectedlast from the external power source to the negative“−” terminal of the starting motor. If the starting motoris not equipped with a negative “−” terminal, connectthe jump start cable to the engine block.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is started. Repair all frayedelectrical wires before the engine is started. Refer tothe “Engine Starting” section of this Operation andMaintenance Manual for specific starting instructions.


Electrical System

Grounding Practices


Typical exampleGrounding Stud To Battery Ground


Typical example

Alternate Grounding Stud To Battery Ground

Proper grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Improper grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearingjournal surfaces, and to aluminum components.

Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.

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

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

16 SEBU7772-02Safety SectionEngine Electronics

i01563743

Engine ElectronicsSMCS Code: 1000; 1400; 1900

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

This engine has a comprehensive, programmableEngine Monitoring System. The Engine ControlModule (ECM) has the ability to monitor the engineoperating conditions. If any of the engine parametersextend outside an allowable range, the ECM willinitiate an immediate action.

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

Many of the parameters that are monitored by theECM can be programmed for the engine monitoringfunctions. The following parameters can be monitoredas a part of the Engine Monitoring System:

• Operating Altitude

• Engine Coolant Level

• Engine Coolant Temperature

• Engine Oil Pressure

• Engine Speed

• Fuel Temperature

• Intake Manifold Air Temperature

• System Voltage

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

Note:Many of the engine control systems and displaymodules that are available for Caterpillar Engines willwork in unison with the Engine Monitoring System.Together, the two controls will provide the enginemonitoring function for the specific engine application.Refer to the Electronic Troubleshooting Manual formore information on the Engine Monitoring System.

SEBU7772-02 17Product Information Section

General Information

Product InformationSection

General Informationi02276735

Welding on Engines withElectronic ControlsSMCS Code: 1000

NOTICEBecause the strength of the frame may decrease,some manufacturers do not recommend welding ontoa chassis frame or rail. Consult the OEM of the equip-ment or your Caterpillar dealer regarding welding ona chassis frame or rail.

Proper welding procedures are necessary in orderto avoid damage to the engine’s ECM, sensors,and associated components. When possible,remove the component from the unit and thenweld the component. If removal of the componentis not possible, the following procedure must befollowed when you weld on a unit that is equippedwith a Caterpillar Electronic Engine. The followingprocedure is considered to be the safest procedure toweld on a component. This procedure should providea minimum risk of damage to electronic components.

NOTICEDo not ground the welder to electrical componentssuch as the ECM or sensors. Improper grounding cancause damage to the drive train bearings, hydrauliccomponents, 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 closeas possible to the weld. This will help reduce the pos-sibility of damage.

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

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

3. Disconnect the J1/P1 and J2/P2 connectors fromthe ECM. Move the harness to a position that willnot allow the harness to accidentally move backand make contact with any of the ECM pins.


Use the example above. The current flow from the welder tothe ground clamp of the welder will not cause damage to anyassociated components.

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

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

4. Connect the welding ground cable directly to thepart that will be welded. Place the ground cable asclose as possible to the weld in order to reduce thepossibility of welding current damage to bearings,hydraulic components, electrical components, andground straps.

Note: If electrical/electronic components are usedas a ground for the welder, or electrical/electroniccomponents are located between the welder groundand the weld, current flow from the welder couldseverely damage the component.

5. Protect the wiring harness from welding debrisand spatter.

6. Use standard welding practices to weld thematerials.

18 SEBU7772-02Product Information SectionModel Views

Model Viewsi02497392

Model View IllustrationsSMCS Code: 1000

g00770182Illustration 15Right Side View

(1) Valve mechanism cover(2) Turbocharger(3) Engine oil filler cap(4) Water temperature regulator housing(5) Exhaust manifold(6) Water pump(7) Flywheel housing(8) Engine oil pan(9) Engine oil filter(10) Vibration damper and crankshaft pulley


Left Side View

(11) Engine oil filler(12) Electronic Control Module (ECM)(13) Air compressor(14) Oil drain plug

i01477858

Engine DescriptionSMCS Code: 1000

The Caterpillar C-9 Industrial Engine has thefollowing characteristics:

• In-Line 6 cylinder

• Four stroke cycle

• Hydraulically Actuated Electronic Unit Injection(HEUI)

• Turbocharged

• Air-to-air aftercooled

Engine SpecificationsNote: The front end of the engine is opposite theflywheel end of the engine. The left and the rightsides of the engine are determined from the flywheelend. The number 1 cylinder is the front cylinder.


Model Views

g00609479Illustration 17Cylinder and valve location(A) Exhaust valve(B) Inlet valve

Table 1

C-9 Engine Specifications

Arrangement andCylinders In-Line 6 cylinder

Bore 112.0 mm (4.41 inch)

Stroke 149.0 mm (5.87 inch)

Aspiration ATAAC(1)

Displacement 8.8 L (537 in3)

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

Rotation (flywheel end) Counterclockwise

Valve Lash (inlet) 0.38 mm (0.015 inch)

Valve Lash (exhaust) 0.64 mm (0.025 inch)(1) Air-to-air aftercooled

Electronic Engine FeaturesThe Caterpillar C-9 Engine is designed for electroniccontrols. The integral on board computer controlsthe operation of the engine. Current operatingconditions are monitored. The Electronic ControlModule (ECM) controls the response of the engine tothese conditions and to the demands of the operator.These conditions and operator demands determinethe precise control of fuel injection by the ECM.The electronic engine control system provides thefollowing features:

• Engine speed governor

• Automatic air/fuel ratio control

• Torque rise shaping

• Injection timing control

• System diagnostics

For more information on electronic engine features,refer to the Operation and Maintenance Manual,“Engine Features and Controls” topic (OperationSection).

Additional Features

The following additional features provide increasedengine fuel economy and serviceability:

• Cold starting capability

• Tampering detection

• Diagnostics

Hydraulic Electronic Unit Injectors

Hydraulically Actuated Electronic Unit Injectors(HEUI) perform the following functions:

• Pump the fuel.

• Meter the fuel.

• Time the fuel injection.

The unit injectors are controlled by the ECM whichuses the camshaft position and the engine speedsignals from the engine speed/timing sensors andthe inlet air pressure sensors. The engine’s rated rpmis identified on the Information Plate.

Engine Diagnostics

The engine has built-in diagnostics in order to ensurethat all of the components are functioning properly.In the event of a deviation from the programmedlimits, the operator will be alerted to the conditionby a “DIAGNOSTIC” lamp that is mounted on thedashboard. Under certain conditions, the enginehorsepower and the vehicle speed may be limited.A Caterpillar electronic service tool may be used todisplay the diagnostic code.

There are three types of diagnostic codes: active,logged, and event.

Most of the diagnostic codes are logged and storedin the ECM. For additional information, refer tothe Operation and Maintenance Manual, “EngineDiagnostics” topic (Operation Section).

The ECM provides an electronic governor thatcontrols the injector output in order to maintain thedesired engine rpm. The functionality of electronicgovernor is similar to the Caterpillar mechanicalgovernor, but the electronic governor includesadditional features.

20 SEBU7772-02Product Information SectionModel Views

Engine Cooling and LubricationThe cooling system consists of the followingcomponents:

• Centrifugal pump that is driven by belts

• Water temperature regulator which regulates theengine coolant temperature

• Oil cooler and radiator which incorporates a shuntsystem

The engine lubricating oil that is supplied is cooled.The engine lubricating oil is also filtered. Bypassvalves provide unrestricted flow of lubrication oilto the engine components during the followingconditions:

• High oil viscosity

• Plugged oil cooler or plugged oil filter elements(paper cartridge)

Engine Service LifeEngine efficiency and maximum utilization of engineperformance depend on the adherence to properoperation and maintenance recommendations. Inaddition, use recommended fuels, coolants andlubricants. Use the Operation and MaintenanceManual as a guide for required engine maintenance.

Expected engine life is generally predicted by theaverage power that is demanded. The average powerthat is demanded is based on fuel consumption ofthe engine over a period of time. Reduced hours ofoperation at full throttle and/or operating at reducedthrottle settings result in a lower average powerdemand. Reduced hours of operation will increasethe length of operating time before an engineoverhaul is required. For more information, refer tothe Operation and Maintenance Manual, “OverhaulConsiderations” topic (Maintenance Section).

Aftermarket Products andCaterpillar Engines

NOTICEIn order to maximize fuel system life and preventpremature wear out from abrasive particles in thefuel, a two micron absolute high efficiency fuel filteris required for all Caterpillar Electronic Unit Injectors.Caterpillar High Efficiency Fuel Filters meet theserequirements. Consult your Caterpillar dealer for theproper part numbers.

When auxiliary devices, accessories, or consumables(filters, additives, catalysts, etc) which are madeby other manufacturers are used on Caterpillarproducts, the Caterpillar warranty is not affectedsimply because of such use.

However, failures that result from the installationor use of other manufacturers’ devices,accessories, or consumables are NOT Caterpillardefects. Therefore, the defects are NOT coveredunder the Caterpillar warranty.

Welding and Caterpillar ElectronicEngines

NOTICEBecause the strength of the frame may decrease,some manufacturers do not recommend welding ontoa chassis frame or rail. Consult the OEM of the equip-ment or your Caterpillar dealer regarding welding ona chassis frame or rail.

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

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

2. If the machine has a battery disconnect switch,open the switch. Otherwise, disconnect thenegative “-” battery cable from the battery of thevehicle.

NOTICEDo not ground the welder to electrical componentssuch as the ECM or sensors. Improper grounding cancause damage to the drive train bearings, hydrauliccomponents, 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 closeas possible to the weld. This will help reduce the pos-sibility of damage.

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

4. Protect wiring harnesses from welding debris andspatter. Use proper welding procedures.


Product Identification Information

Product IdentificationInformation

i02240570

Plate Locations and FilmLocationsSMCS Code: 1000

g01129459Illustration 18(1) Serial Number Plate


(2) Information Plate

22 SEBU7772-02Product Information SectionProduct Identification Information

Caterpillar engines are identified by serial numbersand by arrangement numbers. These numbers areshown on the engine serial number plate and on theengine information plate. Caterpillar dealers needthese numbers in order to determine the componentsthat were included with the engine. This permitsaccurate identification of replacement part numbers.

Serial Number Plate (1)The engine serial number plate is located on theupper right side of the engine block.

Engine serial number _____________________________________

Engine model _______________________________________________

Arrangement number _____________________________________

Information Plate (2)The engine information plate is located on the valvecover base near the front of the left side of the engine.

Engine Serial Number ____________________________________

Engine Arrangement Number ___________________________

Engine Modification Number ____________________________

The engine identification plate also contains otherimportant information about the engine.

i00610276

Reference NumbersSMCS Code: 1000

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

Record for ReferenceEngine Model _______________________________________________

Engine Serial No. __________________________________________

Engine Arrangement No. _________________________________

Modification No. ____________________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

Performance Specification No. _________________________

Primary Fuel Filter No. ____________________________________

Water Separator Element No. ___________________________

Secondary Fuel Filter Element No. ____________________

Lubrication Oil Filter Element No. ______________________

Auxiliary Oil Filter Element No. _________________________

Supplemental Coolant Additive Maintenance ElementNo. (Optional) _______________________________________________

Total Lubrication System Capacity _____________________

Total Cooling System Capacity _________________________

Air Cleaner Element No. _________________________________

Fan Drive Belt No. _________________________________________

Alternator Belt No. _________________________________________

i01830750

Emissions Certification FilmSMCS Code: 1000; 7405

Note: This information is pertinent in the UnitedStates, in Canada and in Europe.

A typical example is shown.


Product Identification Information


i02238153

Customer SpecifiedParametersSMCS Code: 1000

To record programmed specifications, use thefollowing blanks.

Customer Passwords

• First Password ___________________________________________

• Second Password ______________________________________

Power Rating (hp at rpm) ______________________________

Rating Selection (A-E) __________________________________

PTO Governor Parameters

• PTO Engine Speed Ramp Rate __________ rpm/sec

Engine Parameters

• Top Engine Limit (TEL) at 100 percent load (IfApplicable) _______________________________________________

• Torque Limit ______________________________________________

• High Idle (If Applicable) ________________________________

• Low Idle ___________________________________________________

• Intermediate Speed ____________________________________

24 SEBU7772-02Product Information SectionProduct Identification Information

Engine Monitoring Mode

• “OFF” ______________________________________________________

• “Warning” _________________________________________________

• “Warning/Derate” ________________________________________

• “Warning/Derate/Shutdown” __________________________

• “Coolant Level Sensor Enable/Disable” ____________

• “Fuel Pressure Sensor Enable/Disable” ___________

• “Inlet Manifold Air Temperature SensorEnable/Disable” _________________________________________

Equipment ID

Maintenance Indicator

• Manual-Hours

• Auto-Hours

• Manual-Fuel

• Auto-Fuel

Auxiliary Pressure

• High Warning Set Point ________________________________

Auxiliary Temperature

• High Warning Set Point ________________________________

SEBU7772-02 25Operation SectionLifting and Storage

Operation Section

Lifting and Storagei01988813

Product LiftingSMCS Code: 1000; 1404; 7002


NOTICENever bend the eyebolts and the brackets. Only loadthe eyebolts and the brackets under tension. Remem-ber that the capacity of an eyebolt is less as the anglebetween the supporting members and the object be-comes less than 90 degrees.

When it is necessary to remove a component at anangle, only use a link bracket that is properly rated forthe weight.

Use a hoist to remove heavy components. Usean adjustable lifting beam to lift the engine. Allsupporting members (chains and cables) should beparallel to each other. The chains and cables shouldbe perpendicular to the top of the object that is beinglifted.

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

To remove the engine ONLY, use the lifting eyes thatare on the engine.

Lifting eyes are designed and installed for the specificengine arrangement. Alterations to the lifting eyesand/or the engine make the lifting eyes and the liftingfixtures obsolete. If alterations are made, ensurethat proper lifting devices are provided. Consult yourCaterpillar dealer for information regarding fixturesfor proper engine lifting.

i02068367

Product StorageSMCS Code: 1000; 1404; 7002

If the engine will not be started for several weeks, thelubricating oil will drain from the cylinder walls andfrom the piston rings. Rust can form on the cylinderliner surface. Rust on the cylinder liner surface willcause increased engine wear and a reduction inengine service life.

To help prevent excessive engine wear, use thefollowing guidelines:

• Complete all of the lubrication recommendationsthat are listed in this Operation and MaintenanceManual, “Maintenance Interval Schedule”(Maintenance Section).

• If freezing temperatures are expected, check thecooling system for adequate protection againstfreezing. See this Operation and MaintenanceManual, “Refill Capacities and Recommendations”(Maintenance Section).

If an engine is out of operation and if use of the engineis not planned, special precautions should be made.If the engine will be stored for more than one month,a complete protection procedure is recommended.

For more detailed information on engine storage, seeSpecial Instruction, SEHS9031, “Storage ProcedureFor Caterpillar Products”.

Your Caterpillar dealer can assist in preparing theengine for extended storage periods.

26 SEBU7772-02Operation SectionGauges and Indicators

Gauges and Indicatorsi01465281

Gauges and IndicatorsSMCS Code: 1900; 7450

Your engine may not have the same gauges or all ofthe gauges that are described. For more informationabout the gauge package, see the literature that isprovided by the OEM.

Gauges provide indications of engine performance.Ensure that the gauges are in good working order.Determine the normal operating range by observingthe gauges over a period of time.

Noticeable changes in gauge readings indicatepotential gauge or engine problems. Problems mayalso be indicated by gauge readings that changeeven if the readings are within specifications.Determine the cause of any significant change in thereadings. Then, correct any cause of any significantchange in the readings. Consult your Caterpillardealer for assistance.

Caterpillar requires one lamp in addition to the gaugepackage that is normally provided. The “Diagnostic”lamp is yellow or amber. The “Diagnostic” lamp willcommunicate the status of the engine’s electronicsystem. The optional red “Warning” lamp is alsoavailable. This red “Warning” lamp warns the operatorof engine problems.

The following conditions are some examples of theengine problems:

• Low oil pressure

• High coolant temperature

• Low coolant level

• High inlet air temperature

Engine Oil Pressure – Typical oilpressure for an engine at rated speedwith SAE 10W30 or with SAE 15W40 is

240 to 480 kPa (35 to 70 psi).

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

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check the oil level. Maintain the oil level at theproper amount.

If the gauge continues to fluctuate, consult yourCaterpillar dealer.

The diagnostic lamp will turn on if the oil pressuredrops below 35 kPa (5 psi) at low idle rpm. Thediagnostic code will be logged in the Engine ControlModule (ECM).

Engine Oil Temperature – This gaugeindicates the engine oil temperature. Anoil temperature that is higher than normal

indicates a heat problem in the lubrication systemand/or the cooling system. This problem can damagethe cylinder heads, the cylinder liners, the pistons,and the crankshaft bearings.

Jacket Water Coolant Temperature –Typical temperature range is 88 to 102 °C(190 to 215 °F). The maximum allowable

temperature with the pressurized cooling system is105 °C (220 °F). Higher temperatures may occurunder certain conditions. The water temperaturereading may vary according to load. The readingshould never exceed the boiling point for thepressurized system that is being used.

If the engine is operating above the normal rangeor steam becomes apparent, perform the followingprocedure:

1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut downimmediately or if the engine can be cooled byreducing the load.

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

4. Check the coolant level.

Tachometer – This gauge indicates enginespeed. When the throttle control lever ismoved to the full throttle position without

load, the engine is running at high idle. The engine isrunning at the full load rpm when the throttle controllever is at the full throttle position with maximumrated load.

SEBU7772-02 27Operation Section

Gauges and Indicators

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

Ammeter – This gauge indicates theamount of charge or of discharge in thebattery charging circuit. Operation of the

indicator should be to the right side of “0”(zero).

Service Hour Meter – This gaugeindicates the total number of clock hoursof engine operation. Hours of operation

are logged in the ECM. A service tool is needed toretrieve the hours from the ECM. A Service HourMeter may be installed on the engine.

Fuel Pressure – This gauge indicates fuelpressure to the electronic unit injectors fromthe fuel filter. The indicator should indicate

the “NORMAL” range. A decrease in fuel pressureusually indicates a plugged fuel filter.

Fuel Level – This gauge indicates thelevel of fuel in the fuel tank. The fuel levelgauge registers the fuel level only when the

ignition switch is in the ON position.

i02473318

Monitoring System(If Equipped)SMCS Code: 1900; 7400; 7402; 7450; 7451

S/N: JSC1-Up

S/N: MBD1-Up

The Monitoring System is designed to alert theoperator to an immediate problem with any of theengine systems that are monitored. The MonitoringSystem is also designed to alert the operator to animpending problem with any of the engine systemsthat are monitored.

Indicators and GaugesThe instrument panel may look like illustration 22.The instrument panel may not include all of theinstruments that are shown in the illustration.


Warning Lamp (1) – There is a generalfault in the engine. Refer to the Messengerdisplay for any additional information that

may be available.

Circuit Breaker (2) – Reset the circuitbreaker if a circuit breaker trips. Press thebutton in order to reset the circuit breaker. If

the electrical system is working properly, the buttonwill remain pressed. If the button does not remainpressed or if the circuit breaker trips soon after beingreset, check the appropriate electrical circuit. Repairthe electrical circuit, if necessary.

Diagnostic Lamp (3) – The diagnosticlamp is used to indicate the existenceof a fault by flashing a fault code. For a

more detailed discussion of the diagnostic lamp,please see this Operation and Maintenance Manual,“Diagnostic Lamp” topic.

Start Switch(4) – The start switch hasthree positions: OFF, RUN, and START.When the start switch is turned clockwise

to the RUN position, the lamps will flash for fiveseconds during the system test. The lamps will thenshut off. In the RUN position, the ECM and electronicsystems are powered up.


Idle Speed Switch (5) – When the switchis in the up position, the engine speedincreases to HIGH IDLE. When the switch

is in the down position, the engine speed decreasesto LOW IDLE.

Service Meter (6) – This display indicatesthe total operating hours of the engine. Usethe display in order to determine the service

hour maintenance intervals. Hours of operation arelogged in the ECM. A service tool is needed toretrieve the hours from the ECM.

Shutdown Switch (7) – Use the engineshutdown switch in order to stop theengine. Push the shutdown switch in order

to put the switch in the OFF position. This will stopthe engine. After the engine stops, turn the knobclockwise. This will reset the engine shutdown switchto the ON position.

Tachometer (8) – This gauge indicatesengine speed (rpm). When the throttlecontrol lever is moved to the full throttle

position without load, the engine is running at highidle. The engine is running at the full load rpm whenthe throttle control lever is at the full throttle positionwith maximum rated load.

Voltmeter (9) – This gauge indicates thevoltage of the electrical system. The needlein the red range indicates low voltage or

high voltage.

Fuel Pressure (10) – This gauge indicatesfuel pressure to the fuel injection pump fromthe fuel filter. A decrease in fuel pressure

usually indicates a dirty fuel filter or a plugged fuelfilter. As the fuel filter becomes plugged, there will bea noticeable reduction in the engine’s performance.

Ammeter (11) – This gauge indicates theamount of electrical charge or of dischargein the battery charging circuit. Operation of

the indicator should be to the right side of “0”(zero).

Engine Oil Pressure (12) – The oilpressure should be greatest after acold engine is started. The pressure will

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


1. Remove the load.


3. Check and maintain the oil level.

NOTICETo help prevent engine damage, never exceed thehigh idle rpm. An overspeed can result in serious dam-age to the engine. The engine can be operated at highidle without damage, but the engine should never beallowed to exceed the high idle rpm.

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

Jacket Water Coolant Temperature (13) –Typical temperature range is 87 to 98°C(189 to 208°F). Higher temperatures

may occur under certain conditions. The watertemperature reading may vary according to load. Thereading should never exceed the boiling point for thepressurized system that is being used.

Engine Oil Temperature – This gaugeindicates the engine oil temperature.Maximum oil temperature at rated speed

with a full load is 115 °C (239 °F).

Caterpillar Messenger Display


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

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

“Scroll up/left button” (17) – This button is used toscroll up through information that is shown on thedisplay area. The button can also be used to scrollto the left through information that is shown on thedisplay area.



“Scroll down/right button” (18) – This button isused to scroll down through information that is shownon the display area. The button can also be used toscroll to the right through information that is shownon the display area.

“OK” button (19) – The “OK”button may be used toconfirm the selections that were made with the “scrollup/left” and the “scroll down/right”buttons.

Performance Monitor Panel


Typical performance monitor panel

The following options are available through theperformance monitor panel:

Engine Speed – When you scroll to this option, thepanel will show the engine RPM.

Engine Coolant Temperature – When you scroll tothis option, the panel will show the engine coolanttemperature in degrees fahrenheit or in degreescelsius.

Fuel Level – When you scroll to this option, thepanel will show the amount of fuel in the tank as apercentage of a full tank.

Totals Display


Typical performance monitor panel for totals

The following information is available through thepanel:

CUMULATIVE TOTALS

Service Hours – When you scroll to this option, thepanel shows the total amount of service hours thatthe engine has accumulated.

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

Total Fuel – When you scroll to this option, thepanel shows the total amount of fuel that has beenconsumed.

Performance Monitor Panel for Settings

g01054565Illustration 26Typical performance monitor panel for settings

The following options are available through theperformance monitor panel for payloads:

MONITORING SYSTEM

Language – Select this option in order to changethe language that is shown on the panel.


Units – Select this option in order to choose thedesired system of measurement. The choices aremetric or English.

Adjust Contrast – Select this option in order toadjust the contrast of the panel for improved visibility.

“Adjust Backlight” – Select this option in order toadjust the backlighting of the panel for improvedvisibility.

ENGINE

“Equipment Identification” – Select this optionin order to view the identification number of theequipment.

Product identification – Select this option in orderto view the product identification number.

Performance Monitor Panel for Service

g01054566Illustration 27Typical performance monitor panel for service

DIAGNOSTICS and EVENTS

The following options are password protected.You must enter a password in order to change thesettings.

View – Select this option in order to view events thathave been logged by the monitoring system. If youuse an authorized password, you can clear individualevents.

Clear All Diagnostics – If you use an authorizedpassword, you can select this option in order to clearall logged events.

SYSTEM PARAMETERS

MONITORING SYSTEM

• Battery VoltageWhen you scroll to this option, thebattery voltage is displayed.

• Fuel Level When you scroll to this option, the fuellevel is displayed.

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

• Engine Speed When you scroll to this option, theengine RPM is displayed.

• Desired Engine Speed When you scroll to thisoption, the desired engine speed is displayed.This parameter is used by the Automatic RetarderControl to prevent the engine from overspeeding. Ifyou have an approved password, you can changethis parameter.

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

• Coolant Temperature When you scroll to thisoption, the coolant temperature is displayed.

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

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

• Atmospheric Pressure When you scroll to thisoption, the atmospheric pressure is displayed.

• Turbocharger Inlet Pressure When you scrollto this option, the turbocharger inlet pressure isdisplayed.

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

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

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

SYSTEMS TESTS

• “System Self Test” When you select this option,the monitoring system will initiate the self test.The self test is similar to the functional test thatoccurs when you turn the start switch from the OFFposition to the ON position.

INFORMATION ABOUT SYSTEMS

MONITORING SYSTEM

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

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



• “Software Release Date” When you scroll tothis option, the release date of the software isdisplayed.

• “Software Description” When you scroll to thisoption, the description of the software is displayed.

ENGINE

• “ECM Serial Number” When you scroll to thisoption, the ECM serial number is displayed.

• “Software Part Number” When you scroll to thisoption, the software part number is displayed.



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

TATTLETALE

• “Full Tattletale Readout” When you select thisoption, the indicators and the gauges displaythe maximum values that were reached duringoperation.

• Engine Coolant Temperature When you selectthis option, the indicators will display the maximumvalues that were reached during operation. Theengine coolant temperature gauge will also showthe maximum value that was reached duringoperation.

• Tachometer When you select this option, theindicators will display the maximum values thatwere reached during operation. The tachometerwill also show the maximum value that wasreached during operation.

• Fuel Level When you select this option, theindicators will display the maximum values thatwere reached during operation. The fuel levelgauge will also show the minimum value that wasreached during operation.

• Clear If you have an approved password, you canclear the maximum values that are stored by themonitoring system.

i02472408

Monitoring System(If Equipped)SMCS Code: 1900; 7400; 7402; 7450; 7451

S/N: JSC1-Up

S/N: MBD1-Up

The Monitoring System is designed to alert theoperator to an immediate problem with any of theengine systems that are monitored. The MonitoringSystem is also designed to alert the operator to animpending problem with any of the engine systemsthat are monitored.

Indicators and Gauges

g01063079Illustration 28Gauge cluster and indicators

Diagnostic Lamp (1) – The diagnosticlamp is used to indicate the existenceof a fault by flashing a fault code. For a

more detailed discussion of the diagnostic lamp,please see this Operation and Maintenance Manual,“Diagnostic Lamp” topic.

Engine Oil Pressure (2) – The oil pressureshould be greatest after a cold engine isstarted. The pressure will decrease as

the engine warms up. The pressure will increasewhen the engine rpm is increased. The pressure willstabilize when the engine rpm is stable.



1. Remove the load.


3. Check and maintain the oil level.

Tachometer (3) – This gauge indicatesengine speed (rpm). When the throttlecontrol lever is moved to the full throttle

position without load, the engine is running at highidle. The engine is running at the full load rpm whenthe throttle control lever is at the full throttle positionwith maximum rated load.

NOTICETo help prevent engine damage, never exceed thehigh idle rpm. An overspeed can result in serious dam-age to the engine. The engine can be operated at highidle without damage, but the engine should never beallowed to exceed the high idle rpm.

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

Coolant Temperature (4) – When thecoolant temperature is above the normaloperating value, the coolant temperature

gauge will be in the red zone. Refer to the Messengerpanel for any additional information that may beavailable.

Warning Lamp (5) – There is a generalfault in the engine. Refer to the Messengerpanel for any additional information that

may be available.

Fuel Pressure (6) – This gauge indicatesfuel pressure to the fuel injection pump fromthe fuel filter. A decrease in fuel pressure

usually indicates a dirty fuel filter or a plugged fuelfilter. As the fuel filter becomes plugged, there will bea noticeable reduction in the engine’s performance.

System Voltage (7) – This gauge indicatesthe voltage of the electrical system.

Circuit Breaker (8) – Reset the circuit breaker ifa circuit breaker trips. Press the button in order toreset the circuit breaker. If the electrical system isworking properly, the button will remain pressed. Ifthe button does not remain pressed or if the circuitbreaker trips soon after being reset, check theappropriate electrical circuit. Repair the electricalcircuit, if necessary.

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

Idle Speed Switch (10) –When the switchis in the up position, the engine speedincreases to HIGH IDLE. When the switch

is in the down position, the engine speed decreasesto LOW IDLE.

Maintenance Lamp (11) – The ECMrecords data that is related to equipmentmaintenance. The ECM will activate

the maintenance indicator lamp when scheduledmaintenance is due. The maintenance indicatorlamp can be reset by actuating the maintenanceclear switch. The maintenance interval may bebased on operating hours or fuel consumption.The ECM provides information that pertains tomaintenance intervals and the last maintenance thatwas performed.

Maintenance Clear Switch (12) – Themaintenance clear switch is requiredto reset the maintenance lamp after

maintenance on the engine is performed.

Shutdown Switch (13) – Use the engineshutdown switch in order to stop theengine. Push the shutdown switch in order

to put the switch in the OFF position. This will stopthe engine. After the engine stops, turn the knobclockwise. This will reset the engine shutdown switchto the ON position.

Service Tool Connector (14) – For more informationregarding the use of Caterpillar Electronic Technician(ET) and the PC requirements for Cat ET, refer tothe documentation that accompanies your Cat ETsoftware.



Caterpillar Messenger Display


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

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

“Scroll up/left button” (17) – This button is used toscroll up through information that is shown on thedisplay area. The button can also be used to scrollto the left through information that is shown on thedisplay area.

“Scroll down/right button” (18) – This button isused to scroll down through information that is shownon the display area. The button can also be used toscroll to the right through information that is shownon the display area.

OK button (19) – The “OK”button may be used toconfirm the selections that were made with the “scrollup/left” and the “scroll down/right”buttons.

Performance Monitor Panel


Typical performance monitor panel

The following options are available through theperformance monitor panel:

Engine Speed – When you scroll to this option, thedisplay will show the engine RPM.

Engine Coolant Temperature – When you scroll tothis option, the display will show the engine coolanttemperature in degrees fahrenheit or in degreescelsius.

Fuel Level – When you scroll to this option, thedisplay will show the amount of fuel in the tank as apercentage of a full tank.

Totals Display


Typical totals display

The following information is available through thedisplay:

CUMULATIVE TOTALS

Service Hours – When you scroll to this option, thedisplay shows the total amount of service hours thatthe engine has accumulated.

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

Total Fuel – When you scroll to this option, thedisplay shows the total amount of fuel that has beenconsumed.


Performance Monitor Panel for Settings


Typical performance monitor panel for settings

The following options are available through thepayload display:

MONITORING SYSTEM

Language – Select this option in order to changethe language that is shown on the display.

Units – Select this option in order to choose thedesired system of measurement. The choices aremetric or English.

Adjust Contrast – Select this option in order toadjust the contrast of the display.

“Adjust Backlight” – Select this option in order toadjust the backlighting of the display.

ENGINE

“Equipment Identification” – Select this optionin order to view the identification number of theequipment.

Product Identification – Select this option in orderto view the identification number of the product.

Performance Monitor Panel for Service


Typical service display

DIAGNOSTICS and EVENTS

The following options are password protection.You must enter a password in order to change thesettings.

View – Select this option in order to view events thathave been logged by the monitoring system. If youuse an authorized password, you can clear individualevents.

Clear All Diagnostics – If you use an authorizedpassword, you can select this option in order to clearall logged events.

SYSTEM PARAMETERS

MONITORING SYSTEM

• Battery VoltageWhen you scroll to this option, thebattery voltage is displayed.

• Fuel Level When you scroll to this option, the fuellevel is displayed.

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

• Engine Speed When you scroll to this option, theengine RPM is displayed.

• Desired Engine Speed When you scroll to thisoption, the desired engine speed is displayed.This parameter is used by the Automatic RetarderControl to prevent the engine from overspeeding. Ifyou have an approved password, you can changethis parameter.

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

• Coolant Temperature When you scroll to thisoption, the coolant temperature is displayed.



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

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

• Atmospheric Pressure When you scroll to thisoption, the atmospheric pressure is displayed.

• Turbocharger Inlet Pressure When you scrollto this option, the turbocharger inlet pressure isdisplayed.

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

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

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

SYSTEMS TESTS

• “System Self Test” When you select this option,the monitoring system will initiate the self test.The self test is similar to the functional test thatoccurs when you turn the start switch from the OFFposition to the ON position.

INFORMATION ABOUT SYSTEMS

MONITORING SYSTEM

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

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

• “Software Release Date” When you scroll tothis option, the date of the software release isdisplayed.


ENGINE

• “ECM Serial Number” When you scroll to thisoption, the ECM serial number is displayed.

• “Software Part Number” When you scroll to thisoption, the software part number is displayed.



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

TATTLETALE

• “Full Tattletale Readout” When you select thisoption, the indicators and the gauges displaythe maximum values that were reached duringoperation.

• Engine Coolant Temperature When you selectthis option, the indicators display the maximumvalues that were reached during operation. Theengine coolant temperature gauge will also showthe maximum value that was reached duringoperation.

• Tachometer When you select this option, theindicators will display the maximum values thatwere reached during operation. The tachometerwill also show the maximum value that wasreached during operation.

• Fuel Level When you select this option, theindicators display the maximum values that werereached during operation. The fuel level gauge willalso show the minimum value that was reachedduring operation.

• Clear If you have an approved password, you canclear the maximum values that have been storedby the monitoring system.

36 SEBU7772-02Operation SectionEngine Diagnostics

Engine Diagnosticsi01563934

Self-DiagnosticsSMCS Code: 1000; 1900; 1901; 1902

Caterpillar Electronic Engines have the capability toperform a self-diagnostics test. When the systemdetects an active problem, the “DIAGNOSTIC”lamp is activated. Diagnostic codes will be stored inpermanent memory in the Electronic Control Module(ECM). The diagnostic codes can be retrieved byusing the following components:

• Caterpillar electronic service tools

• “DIAGNOSTIC” lamp

Note: The “DIAGNOSTIC” lamp must be installed bythe OEM or by the customer.

Some installations have electronic displays thatprovide direct readouts of the engine diagnosticcodes. Refer to the manual that is provided by theOEM for more information on retrieving enginediagnostic codes.

Active codes represent problems that currently exist.These problems should be investigated first. If a codeis active, the “DIAGNOSTIC” lamp will flash the flashcode at five second intervals.

Logged codes represent the following items:

• Intermittent problems

• Recorded events

• Performance history

The problems may have been repaired since thelogging of the code. These codes do not indicate thata repair is needed. The codes are guides or signalswhen a situation exists. Codes may be helpful totroubleshoot problems.

When the problems have been corrected, thecorresponding logged fault codes should be cleared.

i01463253

Diagnostic LampSMCS Code: 1000; 1900; 1901; 1902; 7451

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

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

• The “DIAGNOSTIC” lamp will come on andthe “DIAGNOSTIC” lamp will remain on for fiveseconds. This checks the operation of the lamp.

• The “DIAGNOSTIC” lamp will turn off.

• The “DIAGNOSTIC” lamp will come on again andthe “DIAGNOSTIC” lamp will flash codes for anyactive diagnostic codes. Not all diagnostic codeshave a unique flash code.

• The “DIAGNOSTIC” lamp will turn off for fiveseconds.

• The “DIAGNOSTIC” lamp repeats all activediagnostic codes.

A fault diagnostic code will remain active until theproblem is repaired. The electronic control modulewill continue flashing the flash code at five secondintervals until the problem is repaired.

i02238548

Diagnostic Flash CodeRetrievalSMCS Code: 1000; 1900; 1901; 1902

“Diagnostic” LampUse the “DIAGNOSTIC” Lamp or CaterpillarElectronic Technician (ET) in order to determine thediagnostic flash code.

Use the following procedure to retrieve the diagnosticcodes if the engine is equipped with a “DIAGNOSTIC”lamp:

1. Turn the ignition key to the ON position. Theengine does not need to be started in order to viewcodes. The engine does not need to be runningwhile the ignition switch is in the ON position.

The “DIAGNOSTIC” lamp blinks on and off at fivesecond intervals.

SEBU7772-02 37Operation SectionEngine Diagnostics

• When the ignition key is in the ON position, thelamp is checked for proper operation. If thereare any active codes except for Code 34, thecodes are displayed at this time.

Note: The “DIAGNOSTIC” lamp will illuminate for fiveseconds. The lamp will stay on if there is an activediagnostic code.

2. The Active Diagnostic codes will always beflashed. There is no toggle switch that will shutoff the lamp.

3. The “DIAGNOSTIC” lamp will flash in order toindicate a two-digit code. The sequence of flashesrepresents the system diagnostic message.Each digit of the two-digit code is determined bycounting the number of flashes. The lamp flashesat a rate of two times per second. The lamp willpause for one second between digits. The lampwill pause for two seconds between codes.

Table 2 indicates the potential effect on the engineperformance with active flash codes. Table 2 alsoforms a list of Electronic diagnostic codes anddescriptions.

Table 2

Diagnostic Flash Codes for C-9 Industrial Engine

Effect On Engine Performance Suggested Action by theOperator

Diagnostic Flash CodeEngineMisfire

LowPower

ReducedEngineSpeed

EngineShutDown

Shutdown theEngine(1)

Service(2)ScheduleServicefor theEngine.(3)

15 Open or Short Circuit of InjectionActuation Pressure Sensor X X

17 High Injection ActuationPressure X X

18Open or Short for the InjectionActuation Pressure ControlValve

X X

21 Sensor Supply Voltage AboveNormal or Below Normal (4) X X

24 Oil Pressure Sensor Fault (4) X

25 Inlet Manifold Air PressureSensor Fault(5) X

26 Atmospheric Pressure SensorFault(4) X X

27 Coolant Temperature SensorFault(4) X X X

28 Check the Adjustments for theThrottle Position Sensor. X X X

34 Loss Of Engine RPM Signal X X X(continued)


(Table 2, contd)

Diagnostic Flash Codes for C-9 Industrial Engine

Effect On Engine Performance Suggested Action by theOperator

Diagnostic Flash CodeEngineMisfire

LowPower

ReducedEngineSpeed

EngineShutDown

Shutdown theEngine(1)

Service(2)ScheduleServicefor theEngine.(3)

35 Event for Engine Overspeed X X

37 Fuel Pressure Sensor Fault(4) X

38 Inlet Manifold Air TemperatureSensor Fault(4) X X X

39Mechanical Failure of theInjection Actuation PressureSensor

X X

42 Check the Calibration of theTiming Sensor. X X X X X

46 Low Oil Pressure Event X X X

51 Intermittent Battery Power to theECM X X X X X

52 Personality Module Fault X X X X X

56The following parameters mustbe checked: Customer andSystem

X X X

59 Incorrect Engine Software X X X X

61 Event for High CoolantTemperature X X X X

62 Event for Low Coolant Level X X X X

63 Low Fuel Pressure Event X X X X

64 Even for High Inlet Manifold AirTemperature X X X

72 Fault of Cylinder 1 or Cylinder 2 X X X

73 Fault of Cylinder 3 or Cylinder 4 X X X

74 Fault of Cylinder 5 or Cylinder 6 X X X(1) Shut down the Engine: Operate the engine cautiously. Get immediate service. Severe engine damage may result.(2) The operator should go to the nearest location for service.(3) The operator should investigate the problem at a convenient time.(4) The Diagnostic Flash Codes reduce the effectiveness of the Engine Monitoring feature.(5) These Diagnostic Flash Codes may affect the system only under specific environmental conditions such as engine start-up at coldtemperatures, etc.

SEBU7772-02 39Operation SectionEngine Diagnostics

i01463504

Fault LoggingSMCS Code: 1000; 1900; 1901; 1902

The system provides the capability of Fault Logging.When the Electronic Control Module (ECM)generates an active diagnostic code, the code will belogged in the memory of the ECM. The codes thathave been logged in the memory of the ECM canbe retrieved with Caterpillar electronic service tools.The codes that have been logged can be clearedwith Caterpillar electronic service tools. The codesthat have been logged in the memory of the ECMwill be automatically cleared from the memory after100 hours. The following faults can not be clearedfrom the memory of the ECM without using a factorypassword: overspeed, low engine oil pressure, andhigh engine coolant temperature.

i01563981

Engine Operation with ActiveDiagnostic CodesSMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp starts to flash codes duringnormal engine operation, the system has identifieda situation that is not within the specification. UseCaterpillar electronic service tools to check the activediagnostic codes.

Note: If the customer has selected “DERATE” and ifthere is a low oil pressure condition, the ElectronicControl Module (ECM) will limit the engine power untilthe problem is corrected. If the oil pressure is withinthe normal range, the engine may be operated at therated speed and load. However, maintenance shouldbe performed as soon as possible. Refer to Operationand Maintenance Manual, “Diagnostic Flash CodeRetrieval” for more information on flash codes.

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

Operation of the engine and performance of theengine can be limited as a result of the activediagnostic code that is generated. Acceleration ratesmay be significantly slower. Refer to the Operationand Maintenance Manual for more information on therelationship between these active diagnostic codesand engine performance.

i01456915

Engine Operation withIntermittent Diagnostic CodesSMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp starts to flash codes duringnormal engine operation and the diagnostic lampshuts off, an intermittent fault may have occurred. Ifa fault has occurred, the fault will be logged into thememory of the Electronic Control Module (ECM).

In most cases, it is not necessary to stop the enginebecause of an intermittent code. However, theoperator should retrieve the logged fault codesand the operator should reference the appropriateinformation in order to identify the nature of the event.The operator should log any observation that couldhave caused the lamp to light.

• Low power

• Limits of the engine speed

• Excessive smoke, etc

This information can be useful to help troubleshootthe situation. The information can also be used forfuture reference. For more information on diagnosticcodes, refer to the Troubleshooting Guide for thisengine.


i02239577

Customer SpecifiedParametersSMCS Code: 1000; 1900; 1901; 1902

Customer specified parameters that will enhancethe fuel efficiency and the operator’s conveniencecan be programmed into the Electronic ControlModule (ECM). Some parameters may affectengine operation. This may lead to complaints fromthe operator about power or about performance.The following engine related parameters may beprogrammed by the customer by using Caterpillarelectronic service tools in order to influence theoperation of the engine:

• Customer Passwords

• Power Rating (hp at rpm)

• Rating Selection (A-E)

• PTO Ramp Rate

• Engine Parameters: Low Idle, High Idle, TopEngine Limit, Torque Limit, and Intermediate Speed

• Engine Monitoring Mode

• Equipment ID

• Maintenance Indicator

• Auxiliary Pressure

• Auxiliary Temperature

• Parameter Lock Out

The customer specified parameters can be changedas often as needed. Password protection is providedso that the customer can change the parameters. Thecustomer can authorize someone else to change theparameters. Ensure that a record of the parametersis kept in the Operation and Maintenance Manual.For detailed instructions on programming the enginefor optimum performance and for optimum fueleconomy, consult your Caterpillar dealer.

SEBU7772-02 41Operation SectionEngine Starting

Engine Startingi01486758

Before Starting EngineSMCS Code: 1000; 1400; 1450

Perform the required daily maintenance and otherperiodic maintenance before the engine is started.Inspect the engine compartment. This inspection canhelp prevent major repairs at a later date. Refer to theOperation and Maintenance Manual, “MaintenanceInterval Schedule” for more information.

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

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

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

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

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

NOTICEAll valves in the fuel return line must be open beforeand during engine operation to help prevent high fuelpressure. High fuel pressure may cause filter housingfailure or other damage.

If the engine has not been started for several weeks,fuel may have drained from the fuel system. Airmay have entered the filter housing. Also, when fuelfilters have been changed, some air pockets will betrapped in the engine. In these instances, prime thefuel system. Refer to the Operation and MaintenanceManual, “Fuel System - Prime” for more informationon priming the fuel system.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

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

• Ensure that the areas around the rotating parts areclear.

• All of the guards must be put in place. Check fordamaged guards or for missing guards. Repairany damaged guards. Replace damaged guardsand/or missing guards.

• Disconnect any battery chargers that are notprotected against the high current drain thatis created when the electric starting motor (ifequipped) is engaged. Check electrical cablesand check the battery for poor connections andfor corrosion.

• Reset all of the shutoffs or alarm components.

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

• Check the coolant level. Observe the coolant levelin the coolant recovery tank (if equipped). Maintainthe coolant level to the “FULL” mark on the coolantrecovery tank.

• If the engine is not equipped with a coolantrecovery tank maintain the coolant level within13 mm (0.5 inch) of the bottom of the filler pipe. Ifthe engine is equipped with a sight glass, maintainthe coolant level in the sight glass.

• Observe the air cleaner service indicator (ifequipped). Service the air cleaner when the yellowdiaphragm enters the red zone, or when the redpiston locks in the visible position.

• Ensure that any driven equipment has beendisengaged. Minimize electrical loads or removeany electrical loads.

i02497100

Starting the EngineSMCS Code: 1000; 1450

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

42 SEBU7772-02Operation SectionEngine Starting

Initial InspectionPerform the required daily maintenance and otherperiodic maintenance before you start the engine.Inspect the engine compartment. This inspection canhelp prevent major repairs at a later date. Refer to theOperation and Maintenance Manual, “Walk-AroundInspection” topic (Maintenance Section) for moreinformation.

• For the maximum service life of the engine, makea thorough inspection before you start the engine.Look for the following items: oil leaks, coolantleaks, loose bolts, and trash buildup. Remove trashbuildup and arrange for repairs, as needed.

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

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

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

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

NOTICEAll valves in the fuel return line must be open beforeand during engine operation to help prevent high fuelpressure. High fuel pressure may cause filter housingfailure or other damage.

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

• Ensure that the areas around the rotating parts areclear.

• All of the guards must be put in place. Check fordamaged guards or for missing guards. Repairany damaged guards. Replace damaged guardsand/or missing guards.

• Disconnect any battery chargers that are notprotected against the high current drain thatis created when the electric starting motor (ifequipped) is engaged. Check electrical cablesand check the battery for poor connections andfor corrosion.

• Reset all of the shutoffs or alarm components.

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

• Check the coolant level. Observe the coolant levelin the coolant recovery tank (if equipped). Maintainthe coolant level to the “FULL” mark on the coolantrecovery tank.

• If the engine is not equipped with a coolantrecovery tank maintain the coolant level within13 mm (.5 inch) of the bottom of the filler pipe. Ifthe engine is equipped with a sight glass, maintainthe coolant level in the sight glass.

• Observe the air cleaner service indicator (ifequipped). Service the air cleaner when the yellowdiaphragm enters the red zone, or when the redpiston locks in the visible position.

• Ensure that any driven equipment has beendisengaged. Remove any electrical loads.

Cold Weather StartingStarting the engine and operation in cold weatheris dependent on the type of fuel that is used, the oilviscosity, and other optional starting aids. For moreinformation, refer to the Operation and MaintenanceManual, “Cold Weather Operation” topic (OperationSection).

Air Inlet Heater

DO NOT USE ETHER (starting fluids) unlessspecifically instructed to do so. If the engine isequipped with an Air Inlet Heater (electrically orfuel ignited manifold heater), DO NOT use ether(starting fluids) at any time. The use could resultin engine damage and/or personal injury.

Note: There will be an indicator lamp on the controlpanel that is marked “AIR INLET HEATER”.

For detailed information on the operation of the AirInlet Heater, refer to Troubleshooting Manual, “AirInlet Heater Circuit - Test”.

Refer to the Owner’s Manual of the OEM for yourtype of controls. Use the following procedure to startthe engine.

1. Place the transmission in NEUTRAL. Disengagethe flywheel clutch in order to allow the engine tostart faster. This also reduces the draining of thebattery.

2. Turn the ignition switch to the ON position.


The “WARNING and DIAGNOSTIC” lamp (ifequipped) will flash while the engine is cranking.The lamp should turn off after proper engineoil pressure is achieved. If the lamp fails toflash, notify your authorized Caterpillar dealer.If the lamp continues to flash, the ElectronicControl Module (ECM) has detected a problemin the system. For more information, refer to theOperation and Maintenance Manual, “DiagnosticFlash Code Retrival” (Operation Section).

NOTICEDo not engage the starting motor when flywheel isturning. Do not start the engine under load.

If the engine fails to start within 30 seconds, releasethe starter switch or button and wait two minutes toallow the starting motor to cool before attempting tostart the engine again.

3. Push the start button or turn the ignition switch tothe START position in order to crank the engine.

Do not push down or hold the throttle downwhile the engine is cranked. The system willautomatically provide the correct amount of fuelthat is needed to start the engine.

4. If the engine fails to start within 30 seconds,release the start button, or the ignition switch. Waitfor two minutes in order to allow the starting motorto cool before attempting to start the engine again.

Note: The “WARNING and DIAGNOSTIC” lamps (ifequipped) may come on after the engine is started. Ifthis occurs, the ECM has detected a problem with thesystem. For more information, refer to the Operationand Maintenance Manual, “Diagnostic Flash CodeRetrival” (Operation Section) .

NOTICEOil pressure should rise within 15 seconds after theengine starts. Do not increase engine rpm until the oilpressure gauge indicates normal. If oil pressure is notindicated on the gauge within 15 seconds, DO NOToperate the engine. STOP the engine, investigate andcorrect the cause.

5. Allow the engine to idle for approximatelythree minutes. Idle the engine until the watertemperature gauge has begun to rise. Check allgauges during the warm-up period.

Note: Oil pressures and fuel pressures should be inthe normal range on the instrument panel. Enginesthat are equipped with “WARNING” lamps do nothave an operating range. The “WARNING andDIAGNOSTIC” lamp (if equipped) will flash whilethe engine is cranking. The lamp should turn offafter proper engine oil pressure or fuel pressureis achieved. Do not apply a load to the engine orincrease engine rpm until the oil pressure gaugeindicates at least normal pressure. Inspect the enginefor leaks and/or unusual noises.

After the engine has started, the air inlet heater maycontinue to operate in a “Continuous” mode and/or inan “Intermittent” mode. The air inlet heater will turnOFF when the sum of the coolant temperature andthe air inlet temperature exceeds 35 °C or 127 °F.

If the engine is operated with a low load, the enginewill reach normal operating temperature sooner thanidling the engine with no load. When the engine isidled in cold weather, increase the engine rpm toapproximately 1000 to 1200 rpm. This will warmup the engine more quickly. Do not exceed therecommended rpm in order to increase the speedof the warm-up. Limit unnecessary idle time to tenminutes.

Ether Injection System

Personal injury or property damage can resultfrom alcohol or starting fluids.

Alcohol or starting fluids are highly flammable andtoxic and if improperly stored could result in injuryor property damage.

DO NOT USE ETHER (starting fluids) unlessspecifically instructed to do so. If the engine isequipped with an Air Inlet Heater (electrically orfuel ignited manifold heater), DO NOT use ether(starting fluids) at any time. The use could resultin engine damage and/or personal injury.

Starting ProblemsAn occasional starting problem may be caused byone of the following items:

• Low battery charge

• Lack of fuel

• Problem with the wiring harness

44 SEBU7772-02Operation SectionEngine Starting

If the engine fuel system has been run dry, fill thefuel tank and prime the fuel system. Refer to theOperation and Maintenance Manual, “Fuel System -Prime” topic (Maintenance Section).

If the other problems are suspected, perform theappropriate procedure in order to start the engine.

Problems with the Wiring Harness


ECM Connector J2/P2

Locate the ECM. Check the connector in order toensure that the connector is secure. Lightly pull eachof the wires in the chassis harness.

1. Pull each wire with approximately 4.5 kg (10 lb) offorce. The wire should remain in the connector.

2. If a wire is loose, push the wire back into theconnector. Pull the wire again in order to ensurethat the wire is secure.

3. Start the engine. If the engine does not start,consult the nearest Caterpillar dealer forassistance.

i01797227

Cold Weather StartingSMCS Code: 1000; 1250; 1450; 1453; 1456; 1900

Do not use aerosol types of starting aids such asether. Such use could result in an explosion andpersonal injury.

Startability will be improved at temperatures below−18 °C (0 °F) from the use of a jacket water heateror extra battery capacity.

When No. 2 diesel fuel is used, the following itemsprovide a means of minimizing starting problemsand fuel problems in cold weather: engine oil panheaters, jacket water heaters, fuel heaters, and fuelline insulation.

Use the procedure that follows for cold weatherstarting.

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

1. Disengage any driven equipment.

2. Turn the keyswitch to the RUN position. Leave thekeyswitch in the RUN position for 20 seconds.

NOTICEDo not engage the starting motor when flywheel isturning. Do not start the engine under load.

If the engine fails to start within 30 seconds, releasethe starter switch or button and wait two minutes toallow the starting motor to cool before attempting tostart the engine again.

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

4. Allow the keyswitch to return to the RUN positionafter the engine starts.

5. Repeat step 2 through step 4 if the engine failsto start.

6. Allow the engine to idle for three to five minutes, orallow the engine to idle until the water temperatureindicator begins to rise. The engine should runat low idle smoothly until speed is graduallyincreased to high idle. Allow the white smoke todisperse before proceeding with normal operation.

7. Operate the engine at low load until all systemsreach operating temperature. Check the gaugesduring the warm-up period.


i02308903

Starting with Jump StartCablesSMCS Code: 1000; 1401; 1402; 1900

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

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jump startcable ends to contact each other or the engine.

If the installation is not equipped with a backupbattery system, it may be necessary to start theengine from an external electrical source.

For information on troubleshooting the chargingsystem, refer to Special Instruction, REHS0354,“Charging System Troubleshooting”.

Many batteries which are considered unusable arestill rechargeable. After jump starting, the alternatormay not be able to fully recharge batteries thatare severely discharged. The batteries must becharged to the proper voltage with a battery charger.For information on testing and charging, refer tothe Special Instruction, SEHS7633, “Battery TestProcedure”.

NOTICEUsing a battery source with the same voltage as theelectric starting motor. Use ONLY equal voltage forjump starting. The use of higher voltage will damagethe electrical system.

Do not reverse the battery cables. The alternator canbe damaged. Attach ground cable last and removefirst.

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

Ensure that the main power switch is in the OFF posi-tion before attaching the jump start cables to the en-gine being started.

1. Turn the start switch on the stalled engine to theOFF position. Turn off all accessories.

2. Connect one positive end of the jump start cableto the positive cable terminal of the dischargedbattery. Connect the other positive end of the jumpstart cable to the positive cable terminal of theelectrical source.

3. Connect one negative end of the jump start cableto the negative cable terminal of the electricalsource. Connect the other negative end of thejump start cable to the engine block or to thechassis ground. This procedure helps to preventpotential sparks from igniting combustible gasesthat are produced by some batteries.

4. Charge the batteries. The engine will not continueto run after starting if the batteries have not beencharged.

5. Start the engine.

6. Immediately after the stalled engine is started,disconnect the jump start cables in reverse order.

Refer to the Electrical Schematic for your engine.Consult your Caterpillar dealer for more information.

i01646248

After Starting EngineSMCS Code: 1000

Note: In temperatures from 0 to 60°C (32 to 140°F),the warm-up time is approximately three minutes. Intemperatures below 0°C (32°F), additional warm-uptime may be required.

Note: Ensure that the self test for the monitoringsystem (if equipped) is completed before operatingthe engine under load.

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

• Check for any fluid or for any air leaks at idle rpmand at one-half full rpm (no load on the engine)before operating the engine under load. This is notpossible in some applications.

• Operate the engine at low idle until all systemsachieve operating temperatures. Check all gaugesduring the warm-up period.

Note: Gauge readings should be observed andthe data should be recorded frequently while theengine is operating. Comparing the data over timewill help to determine normal readings for eachgauge. Comparing data over time will also helpdetect abnormal operating developments. Significantchanges in the readings should be investigated.

46 SEBU7772-02Operation SectionEngine Operation

Engine Operationi00718869

Engine OperationSMCS Code: 1000

Proper operation and maintenance are key factorsin obtaining the maximum life and economy ofthe engine. If the directions in the Operation andMaintenance Manual are followed, costs can beminimized and engine service life can be maximized.

The time that is needed for the engine to reachnormal operating temperature can be less than thetime needed for a walk-around inspection of theengine.

After the engine is started and after the enginereaches normal operating temperature, the enginecan be operated at the rated rpm. The engine willreach normal operating temperature faster whenthe engine is at rated speed. The engine will reachnormal operating temperature faster when the engineis at low power demand. This procedure is moreeffective than idling the engine at no load. The engineshould reach operating temperature in a few minutes.

Gauge readings should be observed and the datashould be recorded frequently while the engineis operating. Comparing the data over time willhelp to determine normal readings for each gauge.Comparing data over time will also help detectabnormal operating developments. Significantchanges in the readings should be investigated.

i01646335

Engaging the DrivenEquipmentSMCS Code: 1000

1. Operate the engine at one-half of the rated rpm,when possible.

2. Engage the driven equipment without a load onthe equipment, when possible.

Interrupted starts put excessive stress on the drivetrain. Interrupted starts also waste fuel. To get thedriven equipment in motion, engage the clutchsmoothly with no load on the equipment. Thismethod should produce a start that is smooth andeasy. The engine rpm should not increase and theclutch should not slip.

3. Ensure that the ranges of the gauges are normalwhen the engine is operating at one-half ofthe rated rpm. Ensure that all gauges operateproperly.

4. Increase the engine rpm to the rated rpm. Alwaysincrease the engine rpm to the rated rpm beforethe load is applied.

5. Apply the load. Begin operating the engine at lowload. Check the gauges and equipment for properoperation. After normal oil pressure is reachedand the temperature gauge begins to move,the engine may be operated at full load. Checkthe gauges and equipment frequently when theengine is operated under load.

Extended operation at low idle or at reduced loadmay cause increased oil consumption and carbonbuildup in the cylinders. This carbon buildupresults in a loss of power and/or poor performance.

i01878039

Fuel Conservation PracticesSMCS Code: 1000; 1250

The efficiency of the engine can affect the fueleconomy. Caterpillar’s design and technology inmanufacturing provides maximum fuel efficiency inall applications. Follow the recommended proceduresin order to attain optimum performance for the lifeof the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuelmay overflow from the fuel tank. Inspect fuel lines forleaks. Repair the fuel lines, as needed.

SEBU7772-02 47Operation SectionEngine Operation

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

• Avoid unnecessary operation at no load.

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

• Observe the service indicator for the air cleanerfrequently, if equipped. Keep the air cleanerelements clean.

• Maintain a good electrical system.

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

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

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

• Ensure that the driven equipment is in goodworking order.

• Cold engines consume excess fuel. Keep coolingsystem components clean and keep coolingsystem components in good repair. Never operatethe engine without water temperature regulators.All of these items will help maintain operatingtemperatures.

• Settings for the fuel system and the limits for theoperating altitude are stamped on the EngineInformation Plate. If an engine is moved to ahigher altitude, the settings must be changed by aCaterpillar dealer. Changing the settings will helpto provide the maximum efficiency for the engine.Engines can be operated safely at higher altitudes,but the engines will deliver less horsepower. Thefuel settings should be changed by a Caterpillardealer in order to obtain the rated horsepower.

48 SEBU7772-02Operation SectionEngine Stopping

Engine Stoppingi02255774

Emergency StoppingSMCS Code: 1000; 7418

NOTICEEmergency shutoff controls are for EMERGENCY useONLY. DO NOT use emergency shutoff devices orcontrols for normal stopping procedure.

Ensure that any components for the external systemthat support the engine operation are secured afterthe engine is stopped.

Emergency Stop Button


Typical emergency stop button

The emergency stop button is in the OUT position fornormal engine operation. Push the emergency stopbutton. The engine will not start when the button islocked. Turn the button clockwise in order to reset.

Refer to Operation and Maintenance Manual,“Features and Controls” for the location and theoperation of the emergency stop button.

i01646416

Manual Stop ProcedureSMCS Code: 1000

Note: Individual applications will have differentcontrol systems. Ensure that the shutoff proceduresare understood. Use the following general guidelinesin order to stop the engine.

1. Remove the load, when possible. Reduce theengine speed (rpm) to low idle.

2. Increase the engine speed (rpm) to no more thanone-half of the rated rpm. Perform this procedurefor three to five minutes in order to cool the engine.Reduce the engine speed (rpm) to low idle.

3. After the cool down period, turn the key switch tothe OFF position.

SEBU7772-02 49Operation SectionEngine Stopping

i01465494

After Stopping EngineSMCS Code: 1000

Note: Before you check the engine oil, do not operatethe engine for at least 10 minutes in order to allowthe engine oil to return to the oil pan.

• Check the crankcase oil level. Maintain the oil levelbetween the “ADD” mark and the “FULL” mark onthe oil level gauge.

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

• Note the service hour meter reading. Performthe maintenance that is in the Operation andMaintenance Manual, “Maintenance IntervalSchedule”.

• Fill the fuel tank in order to help preventaccumulation of moisture in the fuel. Do not overfillthe fuel tank.

NOTICEOnly use antifreeze/coolant mixtures recommended inthe Coolant Specifications that are in the Operationand Maintenance Manual. Failure to do so can causeengine damage.

• Allow the engine to cool. Check the coolant level.

• If freezing temperatures are expected, checkthe coolant for proper antifreeze protection. Thecooling system must be protected against freezingto the lowest expected outside temperature. Addthe proper coolant/water mixture, if necessary.

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

50 SEBU7772-02Operation SectionCold Weather Operation

Cold Weather Operationi01457051

Radiator RestrictionsSMCS Code: 1353; 1396

Caterpillar discourages the use of airflow restrictiondevices that are mounted in front of radiators. Airflowrestriction can cause the following conditions:

• High exhaust temperatures

• Power loss

• Excessive fan usage

• Reduction in fuel economy

If an airflow restriction device must be used, thedevice should have a permanent opening directlyin line with the fan hub. The device must have aminimum opening dimension of at least 770 cm2

(120 in2).

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

Caterpillar recommends a warning device for theinlet manifold temperature and/or the installation ofan inlet air temperature gauge. The warning devicefor the inlet manifold temperature should be set at75 °C (167 °F). The inlet manifold air temperatureshould not exceed 75 °C (167 °F). Temperatures thatexceed this limit can cause power loss and potentialengine damage.

i02237624

Fuel and the Effect from ColdWeatherSMCS Code: 1000; 1250

The following fuels are the grades that are availablefor Caterpillar engines:

• No. 1

• No. 2

• Blend of No. 1 and No. 2

No. 2 diesel fuel is the most commonly used fuel.Either No. 1 diesel fuel or a blend of No. 1 and No. 2is best suited for cold weather operation.

Quantities of No. 1 diesel fuel are limited. No. 1 dieselfuels are usually available during the months of thewinter in the colder climates. During cold weatheroperation, if No. 1 diesel fuel is not available, use No.2 diesel fuel, if necessary.

There are three major differences between No. 1 andNo. 2 diesel fuel. No. 1 diesel fuel has the followingproperties:

• Lower cloud point

• Lower pour point

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

When No. 1 diesel fuel is used, a decrease in powerand in fuel efficiency may be noticed. Other operatingeffects should not be experienced.

The cloud point is the temperature when a cloud ofwax crystals begins to form in the fuel. These crystalscan cause the fuel filters to plug. The pour point isthe temperature when diesel fuel will thicken. Thediesel fuel becomes more resistant to flow throughfuel pumps and through fuel lines.

Be aware of these values when diesel fuel ispurchased. Anticipate the average ambienttemperature of the area. Engines that are fueled inone climate may not operate well if the engines aremoved to another climate. Problems can result dueto changes in temperature.

Before troubleshooting for low power or for poorperformance in the winter, check the type of fuel thatis being used.

When No. 2 diesel fuel is used the followingcomponents provide a means of minimizing problemsin cold weather:

• Starting aids

• Engine oil pan heaters

• Engine coolant heaters

• Fuel heaters

• Fuel line insulation

For more information on cold weather operation,see Special Publication, SEBU5898, “Cold WeatherRecommendations”.


Cold Weather Operation

i01505157

Fuel Related Components inCold WeatherSMCS Code: 1000; 1250

Fuel TanksCondensation can form in partially filled fuel tanks.Top off the fuel tanks after operating the engine.

Fuel tanks should contain some provision for drainingwater and sediment from the bottom of the tanks.Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe.

Some fuel tanks use supply lines that take fueldirectly from the bottom of the tank. If the engine isequipped with this system, regular maintenance ofthe fuel system filter is important.

Drain the water and sediment from any fuel storagetank at the following intervals:

• Weekly

• Oil changes

• Refueling of the fuel tank

This will help prevent water and/or sediment frombeing pumped from the fuel storage tank and intothe engine fuel tank.

Fuel Filters

NOTICEDo not fill the fuel filters with fuel before installing them.The fuel would not be filtered and could be contami-nated. Contaminated fuel will cause accelerated wearto fuel system parts.

NOTICEIn order to maximize fuel system life and prevent pre-mature wear out from abrasive particles in the fuel,a two micron absolute high efficiency fuel filter is re-quired for all Caterpillar Hydraulic Electronic Unit In-jectors. Caterpillar High Efficiency Fuel Filters meetthese requirements. Consult your Caterpillar dealerfor the proper part numbers.

These engines are equipped with a primaryfilter/water separator. The primary filter/waterseparator must use a 10 micron filter to a 15 micronfilter. The filters are becoming more critical as fuelinjection pressures increase to 209 MPa (30000 psi)and higher psi. For more information on priming thefuel system, see the Operation and MaintenanceManual, “Fuel System - Prime” topic (MaintenanceSection).

Fuel HeatersFuel heaters help to prevent fuel filters from pluggingin cold weather due to waxing. A fuel heater shouldbe installed in order for the fuel to be heated beforethe fuel enters the primary fuel filter.

Select a fuel heater that is mechanically simple, yetadequate for the application. The fuel heater shouldalso help to prevent overheating of the fuel. High fueltemperatures reduce engine performance and theavailability of engine power. Choose a fuel heaterwith a large heating surface. The fuel heater shouldbe practical in size. Small heaters can be too hot dueto the limited surface area.

Disconnect the fuel heater in warm weather.

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

Note: Heat exchanger type fuel heaters should havea bypass provision in order to prevent overheating ofthe fuel in warm weather operation.

For further information on fuel heaters, consult yourCaterpillar dealer.

52 SEBU7772-02Maintenance SectionRefill Capacities

Maintenance Section

Refill Capacitiesi02485485

Refill Capacities andRecommendationsSMCS Code: 1348; 1395; 7560

NOTICEEvery attempt is made to provide accurate, up-to-dateinformation. By the use of this document, you agreethat Caterpillar Inc. is not responsible for errors oromissions.

NOTICEThese recommendations are subject to change with-out prior notice. Contact your Caterpillar dealer for themost up to date recommendations.

Lubrication System

NOTICEThe Engine Crankcase Fluid - 1 (ECF-1) specifica-tion has been introducedby Caterpillar in order to pro-vide additional performance to the oils that are mar-keted under the American Petroleum Institute (API)categories of oil. The API Engine Oil Licensing andCertification System is recognized by Caterpillar. Fordetailed information about this system, see the lat-estedition of the “API publication No. 1509”. Engineoils that bear the API symbol are authorized by API.The ECF-1 specification is applicable to those oil man-ufacturers whose products meet the specification re-quirements.

Caterpillar Diesel Engine Oil (DEO)

Caterpillar oils have been developed and tested inorder to provide the full performance and servicelife that has been designed and built into CaterpillarEngines. Cat DEO exceeds the requirements ofthe ECF-1 specification by passing four additionalproprietary tests of diesel engine oil. Caterpillaroils are currently used to fill diesel engines at thefactory. These oils are offered by Caterpillar dealersfor continued use when the engine oil is changed.Consult your Caterpillar dealer for more informationon these oils.

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

• Cat DEO (Diesel Engine Oil) (SAE 10W-30)

• Cat DEO (Diesel Engine Oil) (SAE 15W-40)

Cat DEO multigrade oil is formulated with the correctamounts of detergents, dispersants, and alkalinity inorder to provide superior performance in Caterpillardiesel engines.

Cat DEO multigrade oil is available in variousviscosity grades that include SAE 10W-30 andSAE 15W-40. Choose the correct oil viscosity forthe ambient temperature by referring to table 3.Multigrade oils provide the correct viscosity for abroad range of operating temperatures.

Multigrade oils are effective in maintaining low oilconsumption and low levels of piston deposits.

Consult your Caterpillar dealer for part numbers andfor available sizes of containers.

Note: Cat DEO multigrade exceeds the requirementsof the ECF-1 specification. Cat DEO SAE 15W-40exceeds the performance requirements for thefollowing API classifications: API CI-4, API CI-4PLUS, API CH-4, API CG-4, and API CF. Cat DEOSAE 15W-40 oil also passes additional proprietarytests that include the following tests: sticking of thepiston ring, stable oil control, tests for wear, and testsfor soot. Proprietary tests help ensure that Caterpillarmultigrade oil provides superior performance inCaterpillar diesel engines. In addition, Caterpillarmultigrade oil exceeds many of the performancerequirements of other manufacturers of dieselengines. Therefore, this oil is an excellent choice formany mixed fleets. True high performance oil isproduced by using a combination of the followingfactors: industry standard tests, proprietarytests, field tests, and prior experience with similarformulations. The design and the developmentof Caterpillar lubricants that are both highperformance and high quality are based on thesefactors.

Commercial Oils

Engine Crankcase Fluid Recommendations for allCaterpillar Diesel Engines

Note: Commercial oils that conform to therequirements of the Caterpillar ECF-1 specificationare acceptable but these oils are not preferred.

• Only commercial oils that meet the requirementsof Caterpillar’s ECF-1 (Engine Crankcase Fluidspecification - 1) are acceptable for use inCaterpillar commercial diesel engines. API CH-4,API CI-4, and API CI-4 PLUS oils that have notmet the requirements of Caterpillar’s ECF-1specification may cause reduced engine life.

SEBU7772-02 53Maintenance Section

Refill Capacities

• API CG-4 multigrade oils are acceptable for allCaterpillar commercial diesel engines. When APICG-4 oils are used, do not exceed the standardoil drain interval. Refer to this Operation andMaintenance Manual, “Maintenance IntervalSchedule” for the oil drain interval.

Refer to Special Publication, SEBU6251, “CaterpillarCommercial Diesel Engine Fluids Recommendations”for more complete information about choosing oils foryour Caterpillar diesel engine.

NOTICEFailure to follow these oil recommendations can causeshortened engine service life due to deposits and/orexcessive wear.

Lubricant Viscosity Recommendations

The proper SAE viscosity grade of oil is determinedby the minimum ambient temperature duringcold engine start-up, and the maximum ambienttemperature during engine operation.

Refer to Table 3 (minimum temperature) in order todetermine the required oil viscosity for starting a coldengine.

Refer to Table 3(maximum temperature) in order toselect the oil viscosity for engine operation at thehighest ambient temperature that is anticipated.

Note: Generally, use the highest oil viscosity that isavailable to meet the requirement for the temperatureat start-up.

If ambient temperature conditions at engine start-uprequire the use of multigrade SAE 0W oil, SAE0W-40 viscosity grade is generally preferred overSAE 0W-20 or SAE 0W-30.

Note: SAE 10W-30 is the preferred viscosity gradefor this engine when the ambient temperature isabove −18 °C (0 °F) and below 40 °C (104 °F).

Table 3

Lubricant Viscosities for Ambient Temperatures

Ambient Temperature

Viscosity Grade Minimum Maximum

SAE 0W-20 −40 °C (−40 °F) 10 °C (50 °F)

SAE 0W-30 −40 °C (−40 °F) 30 °C (86 °F)

SAE 0W-40 −40 °C (−40 °F) 40 °C (104 °F)

SAE 5W-30 −30 °C (−22 °F) 30 °C (86 °F)

SAE 5W-40 −30 °C (−22 °F) 50 °C (122 °F)

SAE 10W-30(2) −18 °C (0 °F) 40 °C (104 °F)

SAE 10W-40 −18 °C (0 °F) 50 °C (122 °F)

SAE 15W-40 −9.5 °C (15 °F) 50 °C (122 °F)(2) SAE 10W-30 is the preferred viscosity grade for the 3116, 3126,C7, and C9 diesel engines when the ambient temperature isabove −18 °C (0 °F) and below 40 °C (104 °F).

Note: Supplemental heat is recommended forcold-soaked starts below the minimum ambienttemperature. Supplemental heat may be requiredfor cold-soaked starts that are above the minimumtemperature that is stated, depending on the parasiticload and other factors. Cold-soaked starts occurwhen the engine has not been operated for a periodof time and when the cooler ambient temperaturesallow the oil to become more viscous.

S·O·S Services Oil Analysis

Caterpillar has developed a tool for maintenancemanagement that evaluates oil degradation and thetool also detects the early signs of wear on internalcomponents. The Caterpillar tool for oil analysis iscalled S·O·S oil analysis and the tool is part of theS·O·S Services program. S·O·S oil analysis dividesoil analysis into three categories:

• Component wear rate

• Contamination of oil

• Condition of oil

• Identification of oil

Note: Refer to Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engine FluidRecommendations” or contact your local Caterpillardealer for additional information concerning theS·O·S oil analysis program.


Refill Capacities (Engine Oil)

The refill capacities for the engine crankcase reflectthe approximate capacity of the crankcase or sumpplus standard oil filters. Auxiliary oil filter systems willrequire additional oil. Refer to the OEM specificationsfor the capacity of the auxiliary oil filter.

Table 4

C-9 Industrial EngineApproximate Refill Capacities

Refill Capacity forChanging the Oiland the FilterSystem

Liters Quarts

Oil Sump(1) 30 32(1) These values are approximate capacities for the crankcase oilsump which include the standard oil filters that are installedat the factory. Engines with auxiliary oil filters will requireadditional oil. Refer to the OEM specifications for the capacityof the auxiliary oil filter.

Lubricating GreaseCaterpillar provides various greases that vary inperformance from a moderate performance toan extremely high performance. These greasesservice the entire line of Caterpillar products in thewide variety of climates throughout the world. Youcan find a Caterpillar grease that will exceed anyoriginal equipment manufacturer’s performancerequirements. (OEM).

Before selecting a specific grease, the performancerequirements must be determined. Consult therecommendations for grease that are given by theOEM for the equipment. Consult with your Caterpillardealer for a list of greases that meet or exceed theperformance requirements.

Note: Always choose a grease that meets or exceedsthe recommendations of an equipment manufacturer.

If it is necessary to choose a single grease,always choose a grease that meets or exceeds therequirements of the most demanding application.Remember that lubricants that barely meet theminimum performance requirements can be expectedto barely meet the minimum life of the part. Falseeconomy is being used if a grease is purchased withthe lowest cost as the only consideration. Instead,use the grease that yields the lowest total operatingcost. This cost should be based on an analysis thatincludes the costs of parts, labor, downtime, and thecost of the amount of grease that is required.

Because some greases are not chemicallycompatible, purge all of the old grease from a jointwhen the following conditions exist.

• The grease in a joint is changed from one type ofgrease to another type of grease.

• The grease that will be used in the joint will besupplied by a supplier that did not supply thegrease that is currently in the joint.

Consult your supplier in order to determine if thegreases are compatible.

If in doubt, Purge!

Note: All Caterpillar greases are compatible witheach other.

FuelIn North America, diesel fuel that is identified asNo. 1-D or No. 2-D in “ASTM D975” with the S15designation generally meet the specifications.Caterpillar recommends diesel fuels that are distilledfrom crude oil. Diesel fuels from other sources couldexhibit detrimental properties that are not defined orcontrolled by this specification.

In the USA, 0.05 percent diesel fuels have beenused in all on-highway truck engines since 1 January1994. This low sulfur diesel fuel was mandated as ameans of directly reducing particulate emissions fromdiesel truck engines. This low sulfur fuel will also beused in Caterpillar commercial diesel engines whenlow emissions are required. This fuel will be usedwhen the fuel supplier can provide this type of fuel.Caterpillar has not seen any detrimental effects with0.05 percent sulfur fuel in Caterpillar diesel engines.

NOTICEOperating with fuels that do not meet Caterpillar’s rec-ommendations can cause the following effects: start-ing difficulty, poor combustion, deposits in the fuel in-jectors, reduced service life of the fuel system, de-posits in the combustion chamber, and reduced ser-vice life of the engine.

NOTICEHeavy Fuel Oil (HFO), Residual fuel, or Blended fuelmust NOT be used in Caterpillar diesel engines (ex-cept in 3600 Series HFO engines). Blended fuel isresidual fuel that has been diluted with a lighter fuel(cutter stock) so that they will flow. Blended fuels arealso referred to as heavy fuel oils. Severe componentwear and component failures will result if HFO typefuels are used in engines that are configured to usedistillate fuel.


Refill Capacities

In extreme cold ambient conditions, you may use thedistillate fuels that are specified in Table 5. However,the fuel that is selected must meet the requirementsthat are specified in Table 5. These fuels are intendedto be used in operating temperatures that are downto −54 °C (−65 °F).

Table 5

Distillate Fuels (1)

Specification Grade

“MIL-DUL-5624T” JP-5

“ASTM D1655-05” Jet-A-1

“MIL-DTL-83133E” JP-8(1) The fuels that are listed in this table may not meet all of therequirements that are specified in this table . Consult thesupplier for the recommended additives in order to maintainthe proper fuel lubricity.

These fuels are lighter than the No. 2 grades of fuel.The cetane number of the fuels in Table 5 must beat least 40. If the viscosity is below 1.4 cSt at 40 °C(104 °F), use the fuel only in temperatures below0 °C (32 °F). Do not use any fuels with a viscosity ofless than 1.2 cSt at 40 °C (104 °F).

Note: Fuel cooling may be required in order tomaintain the minimum viscosity of 1.4 cSt at the fuelinjection pump.

There are many other diesel fuel specifications thatare published by governments and by technologicalsocieties. Usually, those specifications do notreview all the requirements that are addressedin this specification. To ensure optimum engineperformance, a complete fuel analysis should beobtained before engine operation.

Note: Refer to Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engine FluidsRecommendations” for the Caterpillar Specificationfor distillate fuel and for additional information thatrelates to fuel for your engine.

Refill Capacities (Fuel System)

Refer to the “Operation and Maintenance Manual”that is provided by the OEM for capacities of the fuelsystem.

Cooling SystemThe following types of coolants may be used inCaterpillar diesel engines:

Preferred – Cat ELC (Extended Life Coolant) ora commercial extended life coolant that meets theCaterpillar EC-1 specification

Acceptable – A Cat DEAC (Diesel EngineAntifreeze/Coolant) or a commercial heavy-dutycoolant that meets “ASTM D4985”, or “ASTM D6210”specifications

Note: Cat DEAC does not require a treatment withan SCA (Supplemental Coolant Additive) at theinitial fill. However, a commercial heavy-duty coolantthat only meets the “ASTM D4985” specificationWILL require a treatment with an SCA at the initialfill. A commercial heavy-duty coolant that meetsthe “ASTM D6210” specification will NOT requirea treatment with an SCA at the initial fill. Read thelabel or the instructions that are provided by themanufacturer of the commercial heavy-duty coolant.

Note: These coolants WILL require a treatment witha supplemental coolant additive on a maintenancebasis.

NOTICEDo not use a commercial coolant/antifreeze that on-ly meets the ASTM D3306 specification. This type ofcoolant/antifreeze is made for light duty automotiveapplications.

Caterpillar recommends a 1:1 mixture of water andglycol. This mixture of water and glycol will provideoptimum heavy-duty performance as a coolant.

NOTICEAll Caterpillar diesel engines equipped with air-to-airaftercooling (ATAAC) require a minimum of 30 percentglycol to prevent water pump cavitation.


Table 6

Coolant Service Life

Coolant Service Life(1)(2)

Cat® ELC 965,606 kilometers(600,000 miles), 12000hours, or 6 years(3)

Commercial coolant thatmeets the Caterpillar EC-1

specification

482,803 kilometers(300,000 miles), 6000hours, or 6 years(4)

CAT® DEAC 321,869 kilometers(200,000 miles), 3000hours, or 3 years

Commercial Heavy-Dutycoolant that meets “ASTM

D6210”

241,402 kilometers(150,000 miles), 3000hours, or 2 years

Commercial Heavy-Dutycoolant that meets “ASTM

D4985”

241,402 kilometers(150,000 miles), 3000hours, or 1 year

(1) Use the interval that occurs first.(2) Refer to this Operation and Maintenance Manual, “MaintenanceInterval Schedule” in order to find the correct interval forreplacing the water temperature regulator.

(3) Cat ELC Extender must be added at 6000 service hours or onehalf of the service life of the ELC.

(4) An extender must be added at 3000 service hours or one halfof the service life of the coolant.

Note: These coolant change intervals are onlyachievable with annual S·O·S Services Level 2coolant sampling and analysis.

Distilled water or deionized water isrecommended for use in engine cooling systems.

If distilled water or deionized water is not available,use water that meets or exceeds the properties thatare listed in 7.

Table 7

Caterpillar MinimumAcceptable Water Requirements

Property Maximum Limit ASTM Test

Chloride (Cl) 40 mg/L(2.4 grains/US gal)

“D512”,“D4327”

Sulfate (SO4) 100 mg/L(5.9 grains/US gal) “D516”

Total Hardness 170 mg/L(10 grains/US gal) “D1126”

Total Solids 340 mg/L(20 grain/US gal)

“FederalMethod2540B”(1)

Acidity pH of 5.5 to 9.0 “D1293”(1) Total dissolved solids dried at 103 - 105ºC, “Standard Methodfor the Examination of Water and Wastewater”, AmericanPublic Health Association, et al, 1015 15th Street, N.W.Washington, DC 20005

DO NOT use the following types of water in coolingsystems: hard water, softened water that has beenconditioned with salt, and sea water.

Glycol

Glycol in the coolant helps to provide protectionagainst the following conditions:

• Boiling

• Freezing

• Cavitation of the water pump and cylinder liners

For optimum performance, Caterpillar recommends a1:1 mixture of a water/glycol solution.

Note: Use a mixture that will provide protectionagainst the lowest ambient temperature.

Note: 100 percent pure glycol will freeze at atemperature of −23 °C (−9 °F).

Most conventional heavy-duty coolants use ethyleneglycol. Propylene glycol may also be used. In a 1:1mixture with water, ethylene and propylene glycolprovide similar protection against freezing andboiling.

Refer to Tables 8 and 9 for additional information.

Table 8

Ethylene Glycol

Concentration FreezeProtection

BoilProtection(1)

50 Percent −37 °C (−34 °F) 106 °C (223 °F)

60 Percent −52 °C (−62 °F) 111 °C (232 °F)(1) Protection from boiling is increased with the use of apressurized radiator.

NOTICEDo not use propylene glycol in concentrations that ex-ceed 50 percent glycol because of propylene glycol’sreduced heat transfer capability. Use ethylene glycolin conditions that require additional protection againstboiling or freezing.


Refill Capacities

Table 9

Propylene Glycol

Concentration FreezeProtection

BoilProtection

50 Percent −32 °C (−26 °F) 106 °C (223 °F)

To check the concentration of glycol, use 245-5829Coolant Test Kit . The testers give readings that areimmediate and accurate. The testers can be usedwith ethylene or propylene glycol.

Note: Propylene glycol coolant that is used inCaterpillar Diesel Engine cooling systems mustmeet ASTM D6210-04, “Fully-Formulated PropyleneGlycol-Based Engine Coolant for Heavy-DutyEngines” standards. When propylene glycol is usedin heavy-duty diesel engines, Supplemental CoolantAdditive (SCA) must be added regularly for protectionfor the liner cavitation. Consult your Caterpillar dealerfor more information.

S·O·S Services Coolant Analysis

Testing the engine coolant is important to ensure thatthe engine is protected from internal cavitation andfrom corrosion. The analysis also tests the ability ofthe coolant to protect the engine from boiling andfrom freezing. The S·O·S coolant analysis can bedone at your Caterpillar dealer. Caterpillar S·O·Scoolant analysis is the best way to monitor thecondition of your coolant and your cooling system.S·O·S coolant analysis is a program that is basedon periodic samples.

Refill Capacity (Coolant System)

To maintain the cooling system, the total coolingsystem capacity must be known. The capacity ofthe total cooling system will vary. The capacity willdepend on the size of the radiator (capacity) that isprovided by the vehicle manufacturer. Table 10shouldbe completed by the customer for the maintenanceof the cooling system.

Table 10

Approximate Capacity of the Cooling System

Compartmentor System Liters Quarts

Total CoolingSystem(1)

(1) The total cooling system capacity includes the followingcomponents:the engine block, the radiator, and all coolanthoses and lines.

Note: Refer to Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engine FluidsRecommendations” for additional information thatrelates to coolant for your engine.

58 SEBU7772-02Maintenance SectionMaintenance Interval Schedule

i02471504

Maintenance Interval ScheduleSMCS Code: 1000; 7500

Ensure that all safety information, warnings, andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance ofmaintenance, including all adjustments, the use ofproper lubricants, fluids, filters, and the replacementof components due to normal wear and aging. Theperformance of this product may be diminished ifproper maintenance intervals and procedures are notfollowed. Components may experience acceleratedwear if proper maintenance intervals and proceduresare not followed.

Use fuel consumption, service hours, or calendartime, WHICH EVER OCCURS FIRST, in order todetermine the maintenance intervals. Products thatoperate in severe operating conditions may requiremore frequent maintenance.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

When Required

Battery - Replace .................................................. 62Battery or Battery Cable - Disconnect .................. 64Engine Air Cleaner Element (Dual Element) -Clean/Replace .................................................... 75Engine Storage Procedure - Check ...................... 83Fuel System - Prime ............................................. 84Severe Service Application - Check ..................... 93

Daily

Air Tank Moisture and Sediment - Drain ............... 62Cooling System Coolant Level - Check ................ 70Driven Equipment - Check .................................... 74Engine Air Cleaner Service Indicator - Inspect ..... 77Engine Oil Level - Check ...................................... 79Fuel System Primary Filter/Water Separator -Drain ................................................................... 85Power Take-Off Clutch - Check/Adjust/Lubricate .. 92Walk-Around Inspection ........................................ 95

Initial 20 to 40 Service Hours

Belts - Inspect/Adjust ............................................ 65

Every Week

Battery Charger - Check ....................................... 63Engine Air Precleaner - Check/Clean ................... 78Jacket Water Heater - Check ................................ 89

Every 250 Service Hours

Belts - Inspect/Adjust ............................................ 65

Initial 500 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ................................................................. 71Engine Valve Lash - Inspect/Adjust ...................... 83

Every 500 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ................................................................. 71

Every Year

Cooling System Coolant Sample (Level 1) -Obtain ................................................................. 71Cooling System Coolant Sample (Level 2) -Obtain ................................................................. 71

Every 6000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 68

Every 10 000 Service Hours

Cylinder Head Grounding Stud - Inspect/Clean/Tighten ................................................................ 74Fuel System Primary Filter (Water Separator)Element - Replace .............................................. 85

PM Level 1 - Every 10 400 L (2750 US gal) ofFuel or 250 Service Hours or 6 Months

Air Compressor Filter - Clean/Replace ................. 61Battery Electrolyte Level - Check .......................... 64Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 72Engine Oil Sample - Obtain .................................. 80Engine Oil and Filter - Change ............................. 80Fan Drive Bearing - Lubricate ............................... 83Fuel System Primary Filter (Water Separator)Element - Replace .............................................. 85Fuel System Secondary Filter - Replace .............. 86Fuel Tank Water and Sediment - Drain ................. 87Hoses and Clamps - Inspect/Replace .................. 88Radiator - Clean .................................................... 92

PM Level 2 - Every 83 250 L (22 000 US gal)of Fuel or 2000 Service Hours or 1 Year

Aftercooler Core - Inspect ..................................... 60Alternator - Inspect ............................................... 62Engine Crankcase Breather - Clean ..................... 78Engine Valve Lash - Inspect/Adjust ...................... 83

PM Level 3 - Every 166 500 L (44 000 US gal)of Fuel or 4000 Service Hours or 2 Years

Aftercooler Core - Clean/Test ............................... 60Air Compressor - Inspect ...................................... 61


Maintenance Interval Schedule

Belt Tensioner - Inspect ........................................ 64Cooling System Coolant (DEAC) - Change .......... 66Cooling System Coolant Extender (ELC) - Add .... 69Cooling System Water Temperature Regulator -Replace ............................................................... 73Crankshaft Vibration Damper - Inspect ................. 73Engine - Clean ...................................................... 74Engine Mounts - Inspect ....................................... 79

Every 208 000 L (55 000 US gal) of Fuel or5000 Service Hours

Starting Motor - Inspect ........................................ 93Turbocharger - Inspect .......................................... 94Water Pump - Inspect ........................................... 95

Every 340 000 L (90 000 US gal) of Fuel or10 000 Service Hours

Cylinder Head Grounding Stud - Inspect/Clean/Tighten ................................................................ 74Overhaul Considerations ...................................... 89

60 SEBU7772-02Maintenance SectionAftercooler Core - Clean/Test

i01546702

Aftercooler Core - Clean/TestSMCS Code: 1064-070; 1064-081

1. Remove the core. Refer to the Service Manualfor the procedure.

2. Turn the aftercooler core upside-down in orderto remove debris.

NOTICEDo not use a high concentration of caustic cleaner toclean the core. A high concentration of caustic cleanercan attack the internal metals of the core and causeleakage. Only use the recommended concentration ofcleaner.

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolvliquid cleaner. Table 11 lists Hydrosolv liquidcleaners that are available from your Caterpillardealer.

Table 11

Hydrosolv Liquid Cleaners(1)

PartNumber Description Size

1U-5490 Hydrosolv 4165 19 L (5 US gallon)

174-6854 Hydrosolv 100 19 L (5 US gallon)(1) Use a two to five percent concentration of the cleaner attemperatures up to 93°C (200°F). Refer to ApplicationGuide, NEHS0526 or consult your Caterpillar dealer for moreinformation.

4. Steam clean the core in order to remove anyresidue. Flush the fins of the aftercooler core.Remove any other trapped debris.

5. Wash the core with hot, soapy water. Rinse thecore thoroughly with clean water.

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.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

6. Dry the core with compressed air. Direct the air inthe reverse direction of the normal flow.

7. Inspect the core in order to ensure cleanliness.Pressure test the core. Many shops that serviceradiators are equipped to perform pressure tests.If necessary, repair the core.

8. Install the core. Refer to the Service Manual forthe procedure.

For more information on cleaning the core, consultyour Caterpillar dealer.

i01468985

Aftercooler Core - InspectSMCS Code: 1064-040

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

Inspect the aftercooler for these items: damaged fins,corrosion, dirt, grease, insects, leaves, oil, and otherdebris. Clean the aftercooler, if necessary.

For air-to-air aftercoolers, use the same methods thatare used for cleaning radiators.




Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the fan’s air flow. Hold the nozzle approximately6 mm (.25 inch) away from the fins. Slowly move theair 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 purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

Use a degreaser and steam for removal of oil andgrease. Clean both sides of the core. Wash the corewith detergent and hot water. Thoroughly rinse thecore with clean water.


Air Compressor - Inspect

After cleaning, start the engine and accelerate theengine to high idle rpm. This will help in the removalof debris and drying of the core. Stop the engine.Use a light bulb behind the core in order to inspectthe core for cleanliness. Repeat the cleaning, ifnecessary.

Inspect the fins for damage. Bent fins may be openedwith a “comb”.

Note: If parts of the aftercooler system are repairedor replaced, a leak test is highly recommended. TheFT1984 Aftercooler Testing Group is used to performleak tests on the aftercooler. Refer to the SystemsOperation/Testing and Adjusting, “Aftercooler - Test”and the Special Instruction, SEHS8622 for the propertesting procedure.

Inspect these items for good condition: welds,mounting brackets, air lines, connections, clamps,and seals. Make repairs, if necessary.

For more detailed information on cleaning andinspection, see Special Publication, SEBD0518,“Know Your Cooling System”.

i02113479

Air Compressor - InspectSMCS Code: 1803-040

Do not disconnect the air line from the air com-pressor governor without purging the air brakeand the auxiliary air systems. Failure to purge theair brake and the auxiliary air systems before re-moving the air compressor and/or the air linescould cause personal injury.


(1) Pressure relief valve

If the air compressor pressure relief valve that ismounted in the air compressor cylinder head isbypassing compressed air, there is a malfunctionin the air system, possibly ice blockage. Underthese conditions, your engine may have insuffi-cient air for normal brake operation.

Do not operate the engine until the reason for theair bypass is identified and corrected. Failure toheed this warning could lead to property damage,personal injury, or death to the operator or by-standers.

The function of the pressure relief valve is to bypassair when there is a malfunction in the air compressorsystem.

The pressure relief valve releases air at 1723 kPa(250 psi). Do not stand near the pressure reliefvalve. Compressed air may be released withoutwarning. All personnel should also stay clear of theair compressor when the engine is operating and theair compressor is exposed.

Refer to the Service Manual or refer to the OEMspecifications in order to find information concerningthe air compressor. Consult your Caterpillar dealerfor assistance.

i01544231

Air Compressor Filter -Clean/Replace(If Equipped)SMCS Code: 1803-070-FQ; 1803-510-FQ

One of the single most important aspects ofpreventive maintenance for the air compressor is theinduction of clean air. The type of maintenance that isrequired for the air compressor and the maintenanceinterval depends on the type of air induction systemthat is used. Operating conditions (dust, dirt anddebris) may require more frequent service.

Refer to the Service Manual for the type of aircompressor that is installed on the engine. Followthe maintenance recommendations that are providedby the OEM of the air compressor. Some enginesuse boost air pressure so the engine air cleaner willrequire servicing.

62 SEBU7772-02Maintenance SectionAir Tank Moisture and Sediment - Drain

i00847451

Air Tank Moisture andSediment - Drain(If Equipped)SMCS Code: 1466-543-M&S

Moisture and sediment in the air starting system cancause the following conditions:

• Freezing

• Corrosion of internal parts

• Malfunction of the air starting system

When opening the drain valve, wear protectivegloves, a protective face shield, protective cloth-ing, and protective shoes. Pressurized air couldcause debris to be blown and result in personalinjury.

1. Open the drain valve that is on the bottom of theair tank. Allow the moisture and sediment to drain.

2. Close the drain valve.

3. Check the air supply pressure. The air startingmotor requires a minimum of 620 kPa (90 psi) ofair pressure to operate properly. The maximum airpressure must not exceed 1550 kPa (225 psi).The normal air pressure will be 758 to 965 kPa(110 to 140 psi).

i00072207

Alternator - InspectSMCS Code: 1405-040

Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and proper battery charging. Inspect theammeter (if equipped) during engine operation inorder to ensure proper battery performance and/orproper performance of the electrical system. Makerepairs, as required. Refer to the Service Manual.

Check the alternator and the battery charger forproper operation. If the batteries are properlycharged, the ammeter reading should be very nearzero. All batteries should be kept charged. Thebatteries should be kept warm because temperatureaffects the cranking power. If the battery is too cold,the battery will not crank the engine. The battery willnot crank the engine, even if the engine is warm.When the engine is not run for long periods of timeor if the engine is run for short periods, the batteriesmay not fully charge. A battery with a low charge willfreeze more easily than a battery with a full charge.

i02153996

Battery - ReplaceSMCS Code: 1401-510

Batteries give off combustible gases which canexplode. A spark can cause the combustible gas-es to ignite. This can result in severe personal in-jury or death.

Ensure proper ventilation for batteries that are inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the key start switch to the OFF position.Remove the key and all electrical loads.

2. Turn OFF the battery charger. Disconnect thecharger.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the ground plane. Disconnectthe cable from the NEGATIVE “-” battery terminal.

4. The POSITIVE “+” cable connects the POSITIVE“+” battery terminal to the starting motor.Disconnect the cable from the POSITIVE “+”battery terminal.


Battery Charger - Check

Note: Always recycle a battery. Never discard abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure thatthe key start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE “+” battery terminal.

8. Connect the cable from the ground plane to theNEGATIVE “-” battery terminal.

i01039758

Battery Charger - CheckSMCS Code: 1401-535

Checking Before Start-UpCheck the battery charger for proper operation. Ifthe batteries are properly charged, the needle of theammeter will register near “0” (zero).

The battery charger must not produce excessivecurrent during start-up. Alternatively, the chargermust be automatically disconnected for start-up.If the engine has an alternator, the charger mustbe automatically disconnected during start-up andduring engine operation.

Charging the Battery

Never disconnect any charging unit circuit or bat-tery circuit cable from the battery when the charg-ing unit is operated. A spark can cause an explo-sion from the flammable vapor mixture of hydro-gen and oxygen that is released from the elec-trolyte through the battery outlets. Injury to per-sonnel can be the result.

Perform the following procedure to charge thebattery:

1. Ensure that the charger is turned OFF.

2. Adjust the voltage of the charger in order to matchthe voltage of the battery.

3. Connect the POSITIVE “+” lead of the chargerto the POSITIVE “+” battery terminal. Connectthe NEGATIVE “-” lead of the charger to theNEGATIVE “-” battery terminal.

4. Turn ON the battery charger.

Overcharging of Batteries

Overcharging reduces the service life of batteries.Use a battery charger that will not overcharge thebattery. DO NOT charge the battery if the meter ofthe battery charger is in the RED zone.

Overcharging is indicated by the following symptoms:

• The battery is very warm to the touch.

• A strong odor of acid is present.

• The battery emits smoke or a dense vapor (gas).

Perform one of the following procedures if the batteryshows symptoms of overcharging:

• Reduce the rate of charging by a significantamount. Complete the charging at the reducedrate.

• Turn OFF the charger.

Table 12 describes the effects of overcharging ondifferent types of batteries.

Table 12

Effects of Overcharging Batteries

Type of Battery Effect

All of the battery cells havea low level of electrolyte.

When the plates of thebattery are inspectedthrough the filler holes, theplates may appear to bewarped. This is caused byan excessive temperature.

Caterpillar General ServiceBatteriesCaterpillar Premium HighOutput Batteries

The battery may not passa load test.

The battery may not accepta charging current.

Caterpillar MaintenanceFree Batteries

The battery may not passa load test.

64 SEBU7772-02Maintenance SectionBattery Electrolyte Level - Check

Checking After StoppingEnsure that the battery charger is connectedproperly. Observe the meter of the charger. Recordthe amperage.

i02340858

Battery Electrolyte Level -CheckSMCS Code: 1401-535

When the engine is not run for long periods of time orwhen the engine is run for short periods, the batteriesmay not fully recharge. Ensure a full charge in orderto help prevent the battery from freezing. If batteriesare properly charged, ammeter reading should bevery near zero, when the engine is in operation.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

1. Remove the filler caps. Maintain the electrolytelevel to the “FULL” mark on the battery.

If the addition of water is necessary, use distilledwater. If distilled water is not available use cleanwater that is low in minerals. Do not use artificiallysoftened water.

2. Check the condition of the electrolyte with the245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and1 L (1 qt) of clean water

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L(1 qt) of clean water

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fit properly.Coat the clamps and the terminals with 5N-5561Silicone Lubricant, petroleum jelly or MPGM.

i01492654

Battery or Battery Cable -DisconnectSMCS Code: 1402-029

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the start switch to the OFF position. Turn theignition switch (if equipped) to the OFF positionand remove the key and all electrical loads.

2. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal. When four12 volt batteries are involved, the negative side oftwo batteries must be disconnected.

3. Tape the leads in order to help prevent accidentalstarting.

4. Proceed with necessary system repairs. Reversethe steps in order to reconnect all of the cables.

i01555583

Belt Tensioner - Inspect(If Equipped)SMCS Code: 1358-040


Belt tensioner

SEBU7772-02 65Maintenance SectionBelts - Inspect/Adjust

Inspect the belt tensioner for unusual noise,excessive looseness and/or shaking of the bearings.

If the belt tensioner should require disassembly, referto the Service Manual for the procedure.

i02486694

Belts - Inspect/AdjustSMCS Code: 1357-025; 1357-040

InspectionBelt tension should be checked initially betweenthe first 20 to 40 hours of engine operation.

After the initial check, the belt tension should bechecked at every oil change.

To maximize the engine performance, inspect thebelts for wear and for cracking. Replace belts that areworn or damaged.

For applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new belt tocarry more load because the older belt is stretched.The additional load on the new belt could cause thenew belt to break.

If the belts are too loose, vibration causesunnecessary wear on the belts and pulleys. Loosebelts may slip enough to cause overheating.

If the belts are too tight, unnecessary stresses areplaced on the pulley bearings and on the belts. Thismay shorten the service life of the components.

Remove the belt guard, if equipped. Inspect thecondition and adjustment of the alternator belts andaccessory drive belts (if equipped).

To check the belt tension, apply 110 N (25 lb ft)of force midway between the pulleys. A correctlyadjusted belt will deflect 9 mm (0.35 inch) to 15 mm(0.59 inch).

If the belt does not require replacement or adjustment,install the belt guard. If the belt requires adjustmentor replacement, perform the following procedure toadjust the belt tension.

Adjustment

Alternator Belt

g00768640Illustration 38(1) Nut(2) Adjusting Nut(3) Bolt(4) Nut

1. Slightly loosen mounting bolt (3) and nut (4).

2. Loosen nut (1).

3. Tighten adjusting bolt (2) and mounting bolts (3)and (4). Tighten bolt (1). Refer to the SpecificationsManual, SENR3130, “Torque Specifications”.

If new belts are installed, check the belt tension againafter 30 minutes of engine operation at the rated rpm.

66 SEBU7772-02Maintenance SectionCooling System Coolant (DEAC) - Change

Water Pump Belt


Typical exampleExploded view of the drive assembly for a water pump belt

(1) Mounting bolt(2) Square hole(3) Adjusting bolt

1. Slightly loosen mounting bolt (1) and adjustingbolt (3).

2. Adjust the belt tension with a square drive insquare hole (2).

3. Tighten adjusting bolt (3) and mounting bolt (1).Refer to the Specifications Manual, SENR3130,“Torque Specifications”.

4. Install the belt guard, if equipped.

If new belts are installed, check the belt tension after30 minutes of engine operation at the rated rpm.

i02139869

Cooling System Coolant(DEAC) - ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

NOTICEUse of commercially available cooling system clean-ers may cause damage to cooling system compo-nents. Use only cooling system cleaners that are ap-proved for Caterpillar engines.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulator andthe hoses, if necessary.

Drain


1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

2. Open the cooling system drain valve (if equipped).If the cooling system is not equipped with a drainvalve, remove one of the drain plugs.

Note: If equipped, be sure to drain the heater andany related supply and return lines.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Dealer Service ToolGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush1. Flush the cooling system with clean water in orderto remove any debris.


Cooling System Coolant (DEAC) - Change

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theSpecifications Manual, SENR3130, “TorqueSpecifications” for more information on the propertorques.

NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

4. Start and run the engine at low idle for a minimumof 30 minutes. The coolant temperature should beat least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve (ifequipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. If equipped, be sure toflush the heater and any related supply and returnlines. Close the drain valve (if equipped). Cleanthe drain plugs. Install the drain plugs. Refer tothe Specifications Manual, SENR3130, “TorqueSpecifications” for more information on the propertorques.

Cooling Systems with HeavyDeposits or PluggingNote: For the following procedure to be effective,there must be some active flow through the coolingsystem components.

1. Flush the cooling system with clean water in orderto remove any debris.

Note: If equipped, be sure to flush the heater andany related supply and return lines.

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to theSpecifications Manual, SENR3130, “TorqueSpecifications” for more information on the propertorques.


3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity. Install the cooling system filler cap.

4. Start and run the engine at low idle for a minimumof 90 minutes. The coolant temperature should beat least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve (ifequipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve(if equipped). Clean the drain plugs. Install thedrain plugs. Refer to the Specifications Manual,SENR3130, “Torque Specifications” for moreinformation on the proper torques.

Fill


1. Fill the cooling system with coolant/antifreeze.Refer to the Operation and Maintenance Manual,“Refill Capacitites and Recommendations” topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

68 SEBU7772-02Maintenance SectionCooling System Coolant (ELC) - Change

2. Start and run the engine at low idle. Increase theengine rpm to 1500 rpm. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap.If the gasket that is on the cooling system fillercap is not damaged, perform a pressure test. A9S-8140 Pressurizing Pump is used to performthe pressure test. The correct pressure for thecooling system filler cap is stamped on the face ofthe cooling system filler cap. If the cooling systemfiller cap does not retain the correct pressure,install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i02173402

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

Note: When the cooling system is cleaned, onlyclean water is needed when the ELC is drained andreplaced.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained. This is a good opportunity to replacethe water pump, the water temperature regulator andthe hoses, if necessary.

Drain


1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

2. Open the cooling system drain valve (if equipped).If the cooling system is not equipped with a drainvalve, remove the cooling system drain plugs.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Caterpillardealer or consult Caterpillar Dealer Service ToolGroup:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOL

Flush1. Flush the cooling system with clean water in orderto remove any debris.

Note: If equipped, be sure to flush the heater andany related supply and return lines.

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. For theproper torque, refer to the Specifications Manual,SENR3130, “Torque Specifications”.


3. Fill the cooling system with clean water. Install thecooling system filler cap.


Cooling System Coolant Extender (ELC) - Add

4. Start and run the engine at low idle until thetemperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve (ifequipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve(if equipped). Clean the drain plugs. Install thedrain plugs. For the proper torque, refer to theSpecifications Manual, SENR3130, “TorqueSpecifications”.

Fill


1. Fill the cooling system with Extended Life Coolant(ELC). See Special Publication, SEBU6385,“Caterpillar On-highway Diesel Truck EngineFluids Recommendations” for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to high idle. Run the engine at highidle for one minute in order to purge the air fromthe cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass (if equipped).

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. Ifthe gasket that is on the cooling system filler capis damaged, discard the old cooling system fillercap and install a new cooling system filler cap. Ifthe gasket that is on the cooling system filler cap isnot damaged, use a 9S-8140 Pressurizing Pumpin order to pressure test the cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install a newcooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i02482066

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-045; 1395-081

Cat ELC (Extended Life Coolant) does not requirethe frequent additions of any supplemental coolingadditives which are associated with the presentconventional coolants. The Cat ELC Extender onlyneeds to be added once.

NOTICEUse only Cat Extended Life Coolant (ELC) Extenderwith Cat ELC.

Do NOT use conventional supplemental coolant addi-tive (SCA) with Cat ELC. Mixing Cat ELC with conven-tional coolants and/or conventional SCA reduces theCat ELC service life.

Check the cooling system only when the engine isstopped and cool.

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

70 SEBU7772-02Maintenance SectionCooling System Coolant Level - Check

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. It may be necessary to drain enough coolant fromthe cooling system in order to add the Cat ELCExtender.

3. Add Cat ELC Extender according to therequirements for your engine’s cooling systemcapacity. Refer to the Operation and MaintenanceManual, “Refill Capacities and Recommendations”article for more information.

4. Clean the cooling system filler cap. Inspect thegaskets on the cooling system filler cap. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

i01197583

Cooling System Coolant Level- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

g00285520Illustration 40Cooling system filler cap


1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel to the proper level in the sight glass.


Typical filler cap gaskets

3. Clean the cooling system filler cap and check thecondition of the filler cap gaskets. Replace thecooling system filler cap if the filler cap gaskets aredamaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.


Cooling System Coolant Sample (Level 1) - Obtain

i02326688

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Obtaining a Coolant Sample (Level 1) isoptional if the cooling system is filled with CatELC (Extended Life Coolant). Cooling systems thatare filled with Cat ELC should have a Coolant Sample(Level 2) that is obtained at the recommended intervalthat is stated in the Maintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC. This includes the followingtypes of coolants.

Table 13

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEAC Every 250Hours(1) Yearly(1)(2)

Cat ELC Optional(2) Yearly(2)

(1) This is the recommended interval for coolant samples for allconventional heavy-duty coolant/antifreeze. This is also therecommended interval for coolant samples of commercialcoolants that meet the Cat EC-1 specification for enginecoolant.

(2) The Level 2 Coolant Analysis should be performed sooner if aproblem is suspected or identified.

• Commercial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Level 1 results may indicate a need forLevel 2 Analysis.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis,see Special Publication, SEBU6251, “CaterpillarCommercial Diesel Engine Fluids Recommendations”or consult your Caterpillar dealer.

i01987714

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542


Refer to Operation and Maintenance Manual,“Cooling System Coolant Sample (Level 1) - Obtain”for the guidelines for proper sampling of the coolant.

72 SEBU7772-02Maintenance SectionCooling System Supplemental Coolant Additive (SCA) - Test/Add

Submit the sample for Level 2 analysis.

For additional information about coolantanalysis, see Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engines FluidsRecommendations” or consult your Caterpillar dealer.

i02017557

Cooling System SupplementalCoolant Additive (SCA) -Test/AddSMCS Code: 1352-045; 1395-081

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and eyes. Do not drink cooling systemcoolant additive.

Note: Caterpillar recommends an S·O·S coolantanalysis (Level 1).

Test the Concentration of the SCA

Coolant/Antifreeze and SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Follow the instructionsthat are provided in the kit.

Water and SCA

NOTICEDo not exceed the recommended eight percent sup-plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Use the instructionsthat follow:

1. Fill the syringe to the “1.0 ml” mark with thecoolant.

2. Dispense the 1.0 mL coolant sample from thesyringe into the empty mixing bottle.

3. Add tap water to the mixing bottle in order to bringthe level up to the “10 ml” mark. Place the cap onthe bottle and shake the bottle.

4. Add 2 to 3 drops of the “NITRITE INDICATORSOLUTION B” to the mixing bottle. Move the bottlein a circular motion in order to mix the solution.

5. Add 1 drop of “NITRITE TEST SOLUTION A” tothe mixing bottle. Move the bottle in a circularmotion in order to mix the solution.

6. Repeat 5 until the solution changes color from redto light gray, green, or blue. Record the number ofdrops of “NITRITE TEST SOLUTION A” that wererequired to cause the color change.

7. Use Table 14 to interpret the results.

Table 14

Number ofDrops

Concentrationof SCA

MaintenanceRequired

Less than 25 Less than therecommendedconcentration ofSCA

Add SCA.Retest thecoolant.

25 to 30 Therecommendedconcentration ofSCA

None

More than 30 More than therecommendedconcentration ofSCA

Remove thecoolant.Replace withwater onlyRetest thecoolant.

Add the SCA, If Necessary


1. Remove the cooling system filler cap slowly.

Note: Always dispose of fluids according to localregulations.

2. If necessary, drain some coolant in order to allowspace for the addition of the SCA.


Cooling System Water Temperature Regulator - Replace

NOTICEExcessive supplemental coolant additive concentra-tion can form deposits on the higher temperature sur-faces of the cooling system, reducing the engine’sheat transfer characteristics. Reduced heat transfercould cause cracking of the cylinder head and otherhigh temperature components.

Excessive supplemental coolant additive concentra-tion could also result in blockage of the heat exchang-er, overheating, and/or accelerated wear of the waterpump seal.

Do not exceed the recommended amount of supple-mental coolant additive concentration.

3. Add the proper amount of SCA. The concentrationof the SCA depends on the type of coolant thatis used. To determine the proper amount, seethis Operation and Maintenance Manual, “RefillCapacities and Recommendations” topic.

4. Clean the cooling system filler cap. Install thecooling system filler cap.

i00912898

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510

Replace the water temperature regulator beforethe water temperature regulator fails. This is arecommended preventive maintenance practice.Replacing the water temperature regulator reducesthe chances for unscheduled downtime.

A water temperature regulator that fails in apartially opened position can cause overheating orovercooling of the engine.

A water temperature regulator that fails in the closedposition can cause excessive overheating. Excessiveoverheating could result in cracking of the cylinderhead or piston seizure problems.

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup inside thecylinders. This excessive carbon buildup could resultin an accelerated wear of the piston rings and wearof the cylinder liner.

NOTICEFailure to replace your water temperature regulatoron a regularly scheduled basis could cause severeengine damage.

Caterpillar engines incorporate a shunt design coolingsystem and require operating the engine with a watertemperature regulator installed.

If the water temperature regulator is installed incor-rectly, the enginemay overheat, causing cylinder headdamage. Ensure that the new water temperature reg-ulator is installed in the original position. Ensure thatthe water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket orcylinder head surface.

Refer to the Service Manual for the replacementprocedure of the water temperature regulator, orconsult your Caterpillar dealer.

Note: If only the water temperature regulators arereplaced, drain the coolant from the cooling system toa level that is below the water temperature regulatorhousing.

i00072369

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040

Damage to the crankshaft vibration damper or failureof the crankshaft vibration damper can increasetorsional vibrations. This can result in damage tothe crankshaft and to other engine components. Adeteriorating damper can cause excessive gear trainnoise at variable points in the speed range.

The damper is mounted to the crankshaft which islocated behind the belt guard on the front of theengine.

Removal and InstallationRefer to the Service Manual for the damper removalprocedure and for the damper installation procedure.

Visconic DamperThe visconic damper has a weight that is locatedinside a fluid filled case. The weight moves in thecase in order to limit torsional vibration. Inspect thedamper for evidence of dents, cracks or leaks of thefluid.

74 SEBU7772-02Maintenance SectionCylinder Head Grounding Stud - Inspect/Clean/Tighten

Replace the damper if the damper is dented, crackedor leaking. Refer to the Service Manual or consultyour Caterpillar dealer for damper replacement.

i01473487

Cylinder Head Grounding Stud- Inspect/Clean/TightenSMCS Code: 7423-040; 7423-070; 7423-079

g00768411Illustration 42Typical example

Inspect the OEM harness for good connections andcondition.

The electrical grounding stud must have a wireground to the battery. Tighten the electrical groundingstud at every oil change. Ground wires and strapsshould be combined at engine grounds. All groundsshould be tight and free of corrosion.

• If the connections are corroded, clean theconnections with a solution of baking soda andwater.

• Keep the electrical grounding stud and the strapclean and coated with MPGM grease or petroleumjelly.

i00174798

Driven Equipment - CheckSMCS Code: 3279-535

Refer to the OEM specifications for more informationon the following maintenance recommendations forthe driven equipment:

• Inspection

• Adjustment

• Lubrication

• Other maintenance recommendations

Perform any maintenance for the driven equipmentwhich is recommended by the OEM.

i01646701

Engine - CleanSMCS 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. Lockout the starting controls and tag the controls “DONOT OPERATE”.

NOTICEAccumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Periodic cleaning of the engine is recommended.Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides the followingbenefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

Note: Caution must be used in order to preventelectrical components from being damaged byexcessive water when you clean the engine. Avoidelectrical components such as the alternator, thestarter, and the ECM.


Engine Air Cleaner Element (Dual Element) - Clean/Replace

i01553486

Engine Air Cleaner Element(Dual Element) - Clean/ReplaceSMCS Code: 1054-037; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

Servicing the Air Cleaner ElementsIf the air cleaner element becomes plugged, the aircan split the material of the air cleaner element.Unfiltered air will drastically accelerate internal enginewear. Your Caterpillar dealer has the proper aircleaner elements for your application. Consult yourCaterpillar dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

• Operating conditions (dust, dirt and debris) mayrequire more frequent service of the air cleanerelement.

• The air cleaner element may be cleaned up tosix times if the element is properly cleaned andinspected.

• The air cleaner element should be replaced at leastone time per year. This replacement should beperformed regardless of the number of cleanings.

Replace the dirty paper air cleaner elements withclean air cleaner elements. Before installation, theair cleaner elements should be thoroughly checkedfor tears and/or holes in the filter material. Inspectthe gasket or the seal of the air cleaner element fordamage. Maintain a supply of suitable air cleanerelements for replacement purposes.

Dual Element Air Cleaners

The dual element air cleaner contains a primaryair cleaner element and a secondary air cleanerelement. The primary air cleaner element can beused up to six times if the element is properly cleanedand inspected. The primary air cleaner elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

The secondary air cleaner element is not serviceableor washable. The secondary air cleaner elementshould be removed and discarded for every threecleanings of the primary air cleaner element. Whenthe engine is operating in environments that aredusty or dirty, air cleaner elements may require morefrequent replacement.


(1) Cover(2) Primary air cleaner element(3) Secondary air cleaner element(4) Turbocharger air inlet

1. Remove the cover. Remove the primary aircleaner element.

2. The secondary air cleaner element should beremoved and discarded for every three cleaningsof the primary air cleaner element.

Note: Refer to “Cleaning the Primary Air CleanerElements”.

3. Cover the turbocharger air inlet with tape in orderto keep dirt out.

4. Clean the inside of the air cleaner cover and bodywith a clean, dry cloth.

5. Remove the tape for the turbocharger air inlet.Install the secondary air cleaner element. Install aprimary air cleaner element that is new or cleaned.

6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.

76 SEBU7772-02Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

Cleaning the Primary Air CleanerElements

NOTICECaterpillar recommends certified air filter cleaning ser-vices that are available at Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean 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 removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary air cleaner element can be used upto six times if the element is properly cleaned andinspected. When the primary air cleaner element iscleaned, check for rips or tears in the filter material.The primary air cleaner element should be replacedat least one time per year. This replacement shouldbe performed regardless of the number of cleanings.

Use clean primary air cleaner elements while dirtyelements are being cleaned.

NOTICEDo not clean the air cleaner elements by bumping ortapping. This could damage the seals. Do not use el-ements with damaged pleats, gaskets or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air cleaner elementsbefore cleaning. Inspect the air cleaner elements fordamage to the seal, the gaskets, and the outer cover.Discard any damaged air cleaner elements.

There are two common methods that are used toclean primary air cleaner elements:

• Pressurized air

• Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean primary aircleaner elements that have not been cleaned morethan two times. Pressurized air will not removedeposits of carbon and oil. Use filtered, dry air with amaximum pressure of 207 kPa (30 psi).


Note: When the primary air cleaner elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the streamof air directly at the primary air cleaner element. Dirtcould be forced further into the pleats.

Note: Refer to “Inspecting the Primary Air CleanerElements”.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningprimary air cleaner elements which require dailycleaning because of a dry, dusty environment.Cleaning with pressurized air is recommended priorto vacuum cleaning. Vacuum cleaning will not removedeposits of carbon and oil.

Note: Refer to “Inspecting the Primary Air CleanerElements”.


Engine Air Cleaner Service Indicator - Inspect

Inspecting the Primary Air CleanerElements


Inspect the clean, dry primary air cleaner element.Use a 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary air cleanerelement. Rotate the primary air cleaner element.Inspect the primary air cleaner element for tearsand/or holes. Inspect the primary air cleaner elementfor light that may show through the filter material. If itis necessary in order to confirm the result, comparethe primary air cleaner element to a new primary aircleaner element that has the same part number.

Do not use a primary air cleaner element that hasany tears and/or holes in the filter material. Do notuse a primary air cleaner element with damagedpleats, gaskets or seals. Discard damaged primaryair cleaner elements.

Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes inspectionwill not be used, the primary air cleaner element canbe stored for future use.


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An airflow restrictionmay result. To protect against dirt and damage, wrapthe primary air cleaner elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary air cleaner element into a boxfor storage. For identification, mark the outside ofthe 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.

i01900118

Engine Air Cleaner ServiceIndicator - Inspect(If Equipped)SMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differential gaugefor inlet air pressure. The differential gauge for inletair pressure displays the difference in the pressurethat is measured before the air cleaner element andthe pressure that is measured after the air cleanerelement. As the air cleaner element becomes dirty,the pressure differential rises. If your engine isequipped with a different type of service indicator,follow the OEM recommendations in order to servicethe air cleaner service indicator.

The service indicator may be mounted on the aircleaner housing or in a remote location.


Typical service indicator

78 SEBU7772-02Maintenance SectionEngine Air Precleaner - Check/Clean

Observe the service indicator. The air cleanerelement should be cleaned or the air cleaner elementshould be replaced when one of the followingconditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service IndicatorService indicators are important instruments.

• Check for ease of resetting. The service indicatorshould reset in less than three pushes.

• Check the movement of the yellow core when theengine is accelerated to the engine rated speed.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If the newservice indicator will not reset, the hole for the serviceindicator may be plugged.

The service indicator may need to be replacedfrequently in environments that are severely dusty, ifnecessary. Replace the service indicator annuallyregardless of the operating conditions. Replace theservice indicator when the engine is overhauled, andwhenever major engine components are replaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 N·m (18 lb in).

i02498263

Engine Air Precleaner -Check/CleanSMCS Code: 1055-070; 1055-535


Typical precleaner(1) Wing nut(2) Cover(3) Body

Check the engine air precleaner weekly for debrisand dirt. Clean the precleaner when any materialwhich would impair the performance of the engine isfound. Check and clean the precleaner by performingthe following steps:

1. Remove wing nut (1) and cover (2).

2. Check for an accumulation of dirt and debris inbody (3).

3. Clean the body, if necessary.

4. After cleaning the precleaner, install cover (2) andwing nut (1).

Your precleaner may vary from the precleaner whichis pictured above. For further information aboutmaintaining your precleaner, see your Caterpillardealer.

Note: When the engine is operated in dustyapplications, more frequent cleaning is required..

i01724662

Engine Crankcase Breather -CleanSMCS Code: 1317-070

NOTICEPerform this maintenance with the engine stopped.


Engine Mounts - Inspect

NOTICEIf the crankcase breather is not maintained on a regu-lar basis, it can become plugged. A plugged breatherwill cause excessive crankcase pressure that maycause crankshaft seal leakage.

g00768439Illustration 49(1) Breather assembly(2) Bolt(3) Hose clamp(4) Hose

1. Loosen hose clamp (3) and remove hose (4) frombreather assembly (1).

2. Remove bolt (2) and the washer. Remove thebreather assembly (1) and the seal.

3. Wash the breather element in solvent that is cleanand nonflammable. Allow the breather element todry before installation.

4. Install a breather element that is clean and dry.Install breather assembly (1) and the seal.

5. Install bolt (2) and the washer. Referto Specifications, SENR3130, “TorqueSpecifications” for the correct torque.

6. Install hose (4) on breather assembly (1).Tighten hose clamp (3). Refer to Specifications,SENR3130, “Torque Specifications” for the correcttorques.

i02139969

Engine Mounts - InspectSMCS Code: 1152-040

Inspect the engine mounts for deterioration and forproper bolt torque. Engine vibration can be causedby the following conditions:

• Improper mounting of the engine

• Deterioration of the engine mounts

Any engine mount that shows deterioration shouldbe replaced. Refer to the Specifications Manual,SENR3130, “Torque Specifications”. Refer to yourCaterpillar dealer for more information.

i00623423

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

g00110310Illustration 50(Y) “ADD” mark. (X) “FULL” mark.

NOTICEPerform this maintenance with the engine stopped.

1. Maintain the oil level between “ADD” mark (Y) and“FULL” mark (X) on oil level gauge (1). Do not fillthe crankcase above “FULL” mark (X).

NOTICEOperating your engine when the oil level is above the“FULL” mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oil’s lubricating char-acteristics and could result in the loss of power.

2. Remove the oil filler cap and add oil, if necessary.Clean the oil filler cap. Install the oil filler cap.

80 SEBU7772-02Maintenance SectionEngine Oil Sample - Obtain

i01935337

Engine Oil Sample - ObtainSMCS Code: 1000-008; 1348-554-SM;7542-554-OC, SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regularly scheduled intervals in orderto monitor the condition of the engine and themaintenance requirements of the engine. S·O·S oilanalysis provides infrared analysis, which is requiredfor determining nitration and oxidation levels.

Obtain the Sample and the Analysis


Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

• Engine model

• Service hours on the engine

• The number of hours that have accumulated sincethe last oil change

• The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of theoil in the crankcase, obtain a warm, well mixed oilsample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.


If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEHP6001,“How To Take A Good Oil Sample”. Consult yourCaterpillar dealer for complete information andassistance in establishing an S·O·S program for yourengine.

i02488152

Engine Oil and Filter - ChangeSMCS Code: 1318-510; 1348-044

Selection of Oil Change Interval


Caterpillar oil filters are recommended for oilchanges. Recommended multigrade oil types arelisted in Table 15. Do not use single grade oils.

Cat DEO Multigrade Oils exceed industry standardECF-1. Any oil that is used in a Caterpillar enginemust meet the ECF-1 standard. Abnormally harshoperating cycles or harsh environments canshorten the service life of the engine oil. Arctictemperatures, corrosive environments, or extremelydusty conditions may require a reduction in engineoil change intervals from the recommendations inTable 15. Poor maintenance of air filters or of fuelfilters requires reduced oil change intervals. See yourCaterpillar dealer for more information if this productwill experience abnormally harsh operating cycles orharsh environments.

Refer to this Operation and Maintenance Manual,“Refill Capacities and Recommendations” for furtherinformation about oils that may be used in Caterpillarengines.


Engine Oil and Filter - Change

Table 15

Oil Change Interval for C-9 Industrial Engine (1)

Operating Conditions

Severe

FuelSulfurfrom0.3% to0.5%

MultigradeOil Type

Normal(2) HighLoadFactorabove43 L(11 USgal perhour offuel)(3)

(4)

Altitudeabove1830 m(6000 ft)

Cat DEOPreferred 250 hr 250 hr 250 hr 250 hr(6)

API CH-411.0

minimumTBN(4)Preferred

250 hr 250 hr 250 hr 250 hr(6)

API CH-4TBN(4)

below 11.0250 hr 250 hr 250 hr(5) 250 hr(6)

API CG-4 250 hr 250 hr(5) 250 hr(5) 250 hr(6)

(1) The standard oil change interval in this engine is 250 hours,if the operating conditions and recommended oil types thatare listed in this table are met. If the type of oil, the quality ofthe oil and the operating conditions meet certain standards,the oil change intervals may be increased to 500 hours. Referto Special Publication, PEDP7035, “Optimizing Oil ChangeIntervals” in order to determine whether the oil change intervalcan be extended beyond 250 hours.

(2) Normal conditions include these factors: Fuel sulfur below0.3%, altitude below 1830 m (6000 ft), and good air filter andfuel filter maintenance. Normal conditions do not include highload factor, harsh operating cycles, or harsh environments.

(3) High load factors can shorten the service life of your engine oil.Continuous heavy load cycles and very little idle time resultin increased fuel consumption and oil contamination. Thesefactors deplete the oil additives more rapidly. If the averagefuel consumption of your engine exceed 43 L (11 US gal) perhour, follow the “High Load Factor” recommendations in Table15. To determine average fuel consumption for your engine,measure average fuel consumption for a period of 50 to 100hours. If the application of the engine is changed, the averagefuel consumption may change.

(4) For sulfur content above 0.5%, refer to, “Total Base Number(TBN) and Fuel Sulfur Levels for Direct Injection (DI) DieselEngines” in Special Publication, SEBU6251, “CaterpillarCommercial Diesel Engine Fluids Recommendations”.

(5) In order to verify an oil change interval of 500 hours, refer to“Program A” below.

(6) Use “Program B” below to determine an appropriate interval.

Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additionalinformation on these programs.

Program A

• Proceed to Program B.

• Change to a preferred oil type in Table 15.

Program B

Optimizing Oil Change Intervals

Begin with a 250 hour oil change interval. The oilchange intervals are adjusted by increments. Eachinterval is adjusted an additional 50 hours. Periodic oilsampling and analysis is done during each interval.The analysis includes oil viscosity and infrared (IR)analysis of the oil. Repeat Program B if you changethe application of the engine.

If an oil sample does not pass the analysis, shortenthe oil change interval, or change to a preferredmultigrade oil type in the listing above.

References

Reference: Form, PEDP7035, “Optimizing OilChange Intervals”

Reference: Form, PEDP7036, “S·O·S Fluid Analysis”

Reference: Form, PEDP7076, “Understanding theS·O·S Oil Analysis Tests”

Drain the Engine OilAfter the engine has been run at the normal operatingtemperature, stop the engine. Attach a “DO NOTOPERATE” or a similar warning tag to the ignitionkeyswitch before the engine is serviced. Catch theoil in a suitable container. Recycle the used oil, ordispose of the used oil properly.

1. Remove the oil drain plug in order to allow the oilto drain.

2. After the oil has drained, the oil drain plug shouldbe cleaned and installed.

Replace the Oil Filter

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

1. Remove the oil filter with a 185-3630 StrapWrench.

82 SEBU7772-02Maintenance SectionEngine Oil and Filter - Change

g00588944Illustration 51Element with debris

2. Cut the oil filter open with a 175-7546 Oil FilterCutter . Break apart the pleats and inspect theoil filter for metal debris. An excessive amountof metal debris in the oil filter may indicate earlywear or a pending failure.

Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are found inthe oil filter element. Ferrous metals may indicatewear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is notuncommon to find small amounts of debris in theoil filter. Consult your Caterpillar dealer in orderto arrange for a further analysis if an excessiveamount of debris is found in the oil filter.


Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mountingbase. Ensure that all of the old oil filter gasket isremoved.

4. Apply clean engine oil to the new oil filter gasket.

NOTICEDo not fill the oil filters with oil before installing them.This oil would not be filtered and could be contaminat-ed. Contaminated oil can cause accelerated wear toengine components.

5. Install the oil filter. Tighten the oil filter until theoil filter gasket contacts the base. Tighten the oilfilter by hand according to the instructions that areshown on the oil filter. Do not overtighten the oilfilter.

Fill the Engine Crankcase1. Remove the oil filler cap. Fill the crankcase withthe proper amount of oil. Refer to the Operationand Maintenance Manual, “Refill Capacities andRecommendations” topic (Maintenance Section)for more information.

NOTICEIf equipped with an auxiliary oil filter or system, extraoil must be added when filling the crankcase. Followthe OEM or filter manufacturer’s recommendations. Ifthe extra oil is not added, the engine may starve foroil.

NOTICETo help prevent crankshaft or bearing damage, crankengine to fill all filters before starting. Do not crankengine for more than 30 seconds.

2. Start the engine and run the engine at “LOWIDLE” for two minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain back tothe sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the “ADD”and “FULL” marks on the “ENGINE STOPPED”side of the oil level gauge.


Engine Storage Procedure - Check

i01430860

Engine Storage Procedure -CheckSMCS Code: 1000-535

Caterpillar requires all engines that are stored formore than 3 months to follow storage proceduresand start-up procedures. These procedures providemaximum protection to internal engine components.Refer to Special Instruction, SEHS9031, “StorageProcedure For Caterpillar Products” for informationon these procedures.

An extension of the oil change interval to 12 monthsis permitted if you follow the required procedures forstorage and start-up. This extension is permitted if thefollowing intervals in the Operation and MaintenanceManual, “Maintenance Interval Schedule” have notbeen reached:

• Operating hours

• Fuel consumption

i00869628

Engine Valve Lash -Inspect/AdjustSMCS Code: 1102-025

The initial valve lash adjustment on new engines,rebuilt engines, or remanufactured engines isrecommended at the first scheduled oil change. Theadjustment is necessary due to the initial wear ofthe valve train components and to the seating of thevalve train components.

This maintenance is recommended by Caterpillaras part of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuringthe valve lash. To obtain an accurate measurement,allow the valves to cool before this maintenance isperformed.

Refer to the Service Manual for more information.

i02239650

Fan Drive Bearing - LubricateSMCS Code: 1359-086-BD

Some of the fan drives have grease fittings and someof the fan drives do not have grease fittings. If there isno grease fitting, periodic lubrication is not required.The fan drive requires grease only if the fan driveis equipped with a zerk.

g00746166Illustration 53Typical location of the grease fitting (if equipped) that is for the fandrive bearing

The pulley is shown with the belt guards that have been removed.

Lubricate the grease fitting that is on the fan drivebearing with Bearing Lubricant or the equivalent.

Inspect the fan drive pulley assembly for wear or fordamage. If the shaft is loose, an inspection of theinternal components should be performed. Refer tothe Service Manual for additional information.

84 SEBU7772-02Maintenance SectionFuel System - Prime

i02113137

Fuel System - PrimeSMCS Code: 1258-548

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over any dis-connected fuel system components.

Prime the fuel system in order to fill the fuel filter.Prime the fuel system in order to purge trapped air.The fuel system should be primed under the followingconditions:

• Running out of fuel

• Storage

• Replacement of the fuel filter

Engines that are Equipped with aFuel Priming Pump

NOTICEDo not loosen the fuel lines at the fuel manifold. Thefittings may be damaged and/or a loss of priming pres-sure may occur when the fuel lines are loosened.

1. Open the fuel priming pump and operate the fuelpriming pump until a strong pressure is felt. Thisprocedure will require considerable strokes. Lockthe fuel priming pump.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

2. Promptly start the engine. If the engine runsrough, continue to operate the engine at low idle.Do not raise the engine rpm above an idle, untilthe engine operates smoothly.

3. If the engine does not start, open the fuel primingpump and repeat Steps 1 and 2 in order to startthe engine.

Engines that are Not Equipped witha Fuel Priming PumpIf the engine is not equipped with a fuel primingpump, you can use the following procedures to primethe fuel system. These procedures will allow onlyfiltered fuel to enter the fuel system.

Fuel Filter Bases that are Equipped witha Plug


g01076450Illustration 54(1) Plug(2) Fuel filter

1. Remove plug (1) in order to fill fuel filter (2).Ensure that air is able to vent from the fitting ofthe plug while the fuel filter is being filled. Cleanup any spilled fuel immediately. Clean plug (1).Install plug (1).


2. Start the engine and operate the engine at lowidle. Do not raise the engine speed above an idle,until the engine operates smoothly.

Fuel Filter Bases that are Not Equippedwith a Plug



Fuel System Primary Filter/Water Separator - Drain

1. Operate the starting motor. This will fill the fuelfilter and the fuel lines with fuel.

2. Once the engine starts, operate the engine at lowidle. Do not raise the engine speed above an idle,until the engine operates smoothly.

i00259781

Fuel System PrimaryFilter/Water Separator - DrainSMCS Code: 1260-543; 1263-543



(1) Element. (2) Bowl. (3) Drain.

Bowl (2) should be monitored daily for signs of water.If water is present, drain the water from the bowl.

1. Open drain (3). The drain is a self-ventilated drain.Catch the draining water in a suitable container.Dispose of the water properly.

2. Close drain (3).

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering the fuelsystem.

i02415789

Fuel System Primary Filter(Water Separator) Element -ReplaceSMCS Code: 1260-510-FQ; 1263-510-FQ

Water in the fuel can cause the engine to run rough.Water in the fuel may cause a electronic unit injectorto fail. If the fuel has been contaminated with water,the element should be changed before the regularlyscheduled interval.

The primary filter/water separator also providesfiltration in order to help extend the life of thesecondary fuel filter. The element should be changedregularly. If a vacuum gauge is installed, the primaryfilter/water separator should be changed at 50 to 70kPa (15 to 20 inches hg).

Replace the Element


Note: A 10 to 15 micron absolute high efficiencyfuel filter is required for Caterpillar Electronic UnitInjectors. Caterpillar High Efficiency Fuel Filters meetthese requirements. Consult your Caterpillar dealerfor the proper part number.

1. Close the main fuel supply valve.


(1) Element. (2) Bowl. (3) Drain.

2. Remove element (1) from the element mountingbase while bowl (2) is attached.

86 SEBU7772-02Maintenance SectionFuel System Secondary Filter - Replace


NOTICEUse a suitable container to catch any fuel that mightspill. Clean up any spilled fuel immediately.

3. Dispose of the fuel in the fuel filter element.Remove bowl (2) from element (1). The bowl isreusable. Do not discard the bowl. Dispose of theused element.

4. Remove the O-ring from the gland of the bowl.Clean the following components:

• Bowl

• O-ring

• Mounting base

Inspect the O-ring for damage and fordeterioration. Replace the O-ring, if necessary.

5. Lubricate the O-ring with clean diesel fuel.

6. Install bowl (2) on a new element. Tighten thebowl by hand. Do not use tools in order to tightenthe bowl.

NOTICEThe primary filter/water separator may be prefilled withfuel to avoid rough running/stalling of the engine dueto air. Do not fill the secondary filter with fuel beforeinstallation. The fuel would not be filtered and couldbe contaminated. Contaminated fuel will cause accel-erated wear to fuel system parts.

7. Lubricate the top seal of element (1) with cleandiesel fuel. The element may be filled with fuel atthis time. Install the new element on the mountingbase. Tighten the element by hand.

NOTICEThe water separator is under suction during normalengine operation. Ensure that the vent plug is tight-ened securely to help prevent air from entering the fu-el system.

8. Open the main fuel supply valve.

9. Start the engine and check for leaks. Run theengine for one minute. Stop the engine and checkfor leaks again.

Detection of leaks is difficult while the engineis running. The primary filter/water separator isunder suction. A leak will allow air to enter the fuel.The air in the fuel can cause low power due toaeration of the fuel. If air enters the fuel, check thecomponents for overtightening or under tightening.

i01503750

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE



NOTICEUse a suitable container to catch any fuel that mightspill. Clean up any spilled fuel immediately.

1. Stop the engine. Turn the ignition switch to theOFF position or disconnect the battery. Refer tothe Operation and Maintenance Manual, “Batteryor Battery Cable - Disconnect” topic (MaintenanceSection) for more information. Shut off the fuelsupply valve (if equipped).

2. Remove the used fuel filter and discard the usedfuel filter.

3. Clean the gasket sealing surface of the fuel filterbase. Ensure that all of the old gasket is removed.

4. Apply clean diesel fuel to the new fuel filter gasket.

NOTICEDo not fill the secondary fuel filter with fuel before in-stalling. The fuel would not be filtered and could becontaminated. Contaminated fuel will cause acceler-ated wear to fuel system parts.


Fuel Tank Water and Sediment - Drain

NOTICEIn order to maximize fuel system life and prevent pre-mature wear out from abrasive particles in the fuel,a two micron absolute high efficiency fuel filter is re-quired for all Caterpillar Hydraulic Electronic Unit In-jectors. Caterpillar High Efficiency Fuel Filters meetthese requirements. Consult your Caterpillar dealerfor the proper part numbers.

5. Install the new fuel filter. Spin the fuel filter ontothe fuel filter base until the gasket contacts thebase. Use the rotation index marks on the filtersas a guide for proper tightening. Tighten the filterfor an additional one turn (360 degrees) by hand.Do not overtighten the filter.

6. Open the fuel supply valve. Prime the fuel system.Refer to the Operation and Maintenance Manual,“Fuel System - Prime” topic (Maintenance Section)for more information. Start the engine and inspectthe fuel system for leaks.


Note: There should be enough residual fuel in thecylinder head in order to start the engine. If theengine stops after starting, do not crank the enginefor more than 30 seconds. Then allow the startingmotor to cool for two minutes. Repeat this procedureuntil the engine starts and the engine operates.

i02436696

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

Fuel TankFuel quality is critical to the performance and to theservice life of the engine. Water in the fuel can causeexcessive wear to the fuel system. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes through thefuel system and the fuel returns to the fuel tank. Thiscauses water to accumulate in fuel tanks. Drainingthe fuel tank regularly and obtaining fuel from reliablesources can help to eliminate water in the fuel.

Drain the Water and the SedimentFuel tanks should contain some provision for drainingwater and draining sediment from the bottom of thefuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

Check the fuel daily. Drain the water and sedimentfrom the fuel tank after operating the engine or drainthe water and sediment from the fuel tank after thefuel tank has been filled. Allow five to ten minutesbefore performing this procedure.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayoverflow.

Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel directly from the bottom of the tank. Ifthe engine is equipped with this system, regularmaintenance of the fuel system filter is important.

Fuel Storage TanksDrain the water and the sediment from the fuelstorage tank during the following conditions:

• Weekly

• Oil change

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank. A 2 micron filter for the breather vent on thefuel tank is also recommended. Refer to SpecialPublication, SENR9620, “Improving Fuel SystemDurablity”.

88 SEBU7772-02Maintenance SectionHoses and Clamps - Inspect/Replace

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaffles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from thestorage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

i02121526

Hoses and Clamps -Inspect/ReplaceSMCS Code: 7554-040; 7554-510

Inspect all hoses for leaks that are caused by thefollowing conditions:

• Cracking

• Softness

• Loose clamps

Replace hoses that are cracked or soft. Tighten anyloose clamps.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubesand hoses carefully. Tighten all connections to the rec-ommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

A constant torque hose clamp can be used in placeof any standard hose clamp. Ensure that the constanttorque hose clamp is the same size as the standardclamp.

Due to extreme temperature changes, the hose willheat set. Heat setting causes hose clamps to loosen.This can result in leaks. A constant torque hoseclamp will help to prevent loose hose clamps.

Each installation application can be different. Thedifferences depend on the following factors:

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps


1. Stop the engine. Allow the engine to cool.

2. Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

Note: Drain the coolant into a suitable, cleancontainer. The coolant can be reused.

3. Drain the coolant from the cooling system to alevel that is below the hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: Refer to the Specifications, SENR3130,“Torque Specifications” in order to locate the propertorques.

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler cap’s gaskets. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

10.Start the engine. Inspect the cooling system forleaks.


Jacket Water Heater - Check

i02486400

Jacket Water Heater - CheckSMCS Code: 1383-535

Jacket water heaters help to improve startability inambient temperatures that are below 21 °C (70 °F).All installations that require automatic starting shouldhave jacket water heaters.

Check the operation of the jacket water heater. Foran ambient temperature of 0 °C (32 °F), the heatershould maintain the jacket water coolant temperatureat approximately 32 °C (90 °F).

i02436705

Overhaul ConsiderationsSMCS Code: 7595-043

Reduced hours of operation at full load will result ina lower average power demand and reduced fuelconsumption. A decreased average power demandshould increase both the engine service life and theoverhaul interval.

The need for an overhaul is generally indicatedby increased fuel consumption, increased oilconsumption, excessive engine blowby, andreduced power. Arctic temperatures, extremely hightemperatures, corrosive environments, or extremelydusty conditions contribute to premature wear andthe need for an overhaul.

The following factors are important when a decisionis being made on the proper time for an engineoverhaul:

• The need for preventive maintenance

• The quality of the fuel that is being used

• The operating conditions

• The results of the S·O·S analysis

Oil Consumption as an OverhaulIndicatorOil consumption, fuel consumption, and maintenanceinformation can be used to estimate the totaloperating cost for your Caterpillar engine. Oilconsumption can also be used to estimate therequired capacity of a makeup oil tank that is suitablefor the maintenance intervals.

Oil consumption is in proportion to the percentageof the rated engine load. As the percentage of theengine load is increased, the amount of oil that isconsumed per hour also increases.

The oil consumption rate (brake specific oilconsumption) is measured in grams per kW/h (lb perbhp). The brake specific oil consumption (BSOC)depends on the engine load. Consult your Caterpillardealer for assistance in determining the typical oilconsumption rate for your engine.

When an engine’s oil consumption has risen to threetimes the original oil consumption rate due to normalwear, an engine overhaul should be scheduled.There may be a corresponding increase in blowbyand a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

A planned overhaul before failure may be the bestvalue for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according to thestandards for reusable parts.

• The engine’s service life can be extended withoutthe risk of a major catastrophe due to enginefailure.

• The best cost/value relationship per hour ofextended life can be attained.

After Failure Overhaul

If a major engine failure occurs and the enginemust be removed, many options are available. Anoverhaul should be performed if the engine block orthe crankshaft needs to be repaired.

If the engine block is repairable and/or the crankshaftis repairable, the overhaul cost should be between 40percent and 50 percent of the cost of a new enginewith a similar exchange core.

This lower cost can be attributed to three aspects:

• Specially designed Caterpillar engine features

• Caterpillar dealer exchange components

• Caterpillar Inc. remanufactured exchangecomponents

90 SEBU7772-02Maintenance SectionOverhaul Considerations

Overhaul RecommendationTo minimize downtime, Caterpillar Inc. recommendsa scheduled engine overhaul by your Caterpillardealer before the engine fails. This will provide youwith the best cost/value relationship.

Note: Overhaul programs vary according to theengine application and according to the dealer thatperforms the overhaul. Consult your Caterpillardealer for specific information about the availableoverhaul programs and about overhaul services forextending the engine life.

If an overhaul is performed without overhaul servicefrom your Caterpillar dealer, be aware of the followingmaintenance recommendations.

Rebuild or Exchange

Cylinder Head Assembly, Cylinder Packs, OilPump, and Fuel Transfer Pump

These components should be inspected according tothe instructions that are found in various Caterpillarreusability publications. The Special Publication,SEBF8029 lists the reusability publications that areneeded for inspecting the engine parts.

If the parts comply with the established inspectionspecifications that are expressed in the reusableparts guideline, the parts should be reused.

Parts that are not within the established inspectionspecifications should be dealt with in one of thefollowing manners:

• Salvaging

• Repairing

• Replacing

Using out-of-spec parts can result in the followingproblems:

• Unscheduled downtime

• Costly repairs

• Damage to other engine parts

• Reduced engine efficiency

• Increased fuel consumption

Reduced engine efficiency and increased fuelconsumption translates into higher operating costs.Therefore, Caterpillar Inc. recommends repairingout-of-spec parts or replacing out-of-spec parts.

Inspection and/or Replacement

Crankshaft Bearings, Valve Rotators, andCrankshaft Seals

The following components may not last until thesecond overhaul.

• Thrust bearings

• Main bearings

• Rod bearings

• Valve rotators

• Crankshaft seals

Caterpillar Inc. recommends the installation of newparts at each overhaul period.

Inspect these parts while the engine is disassembledfor an overhaul.

Inspect the crankshaft for any of the followingconditions:

• Deflection

• Damage to the journals

• Bearing material that has seized to the journals

Check the journal taper and the profile of thecrankshaft journals. Check these components byinterpreting the wear patterns on the followingcomponents:

• Rod bearing

• Main bearings

Inspect the camshaft for damage to the journals andto the lobes.

Note: If the camshaft is removed for any reason, usethe magnetic particle inspection process to check forcracks in the camshaft.

Inspect the following components for signs of wear orfor signs of scuffing:

• Camshaft bearings

• Camshaft followers

Caterpillar Inc. recommends replacing the crankshaftvibration damper.


Overhaul Considerations

Oil Cooler Core

During an overhaul, Caterpillar Inc. recommends theremoval of the oil cooler core. Clean the oil coolercore. Then, pressure test the oil cooler core.

NOTICEDo not use caustic cleaners to clean the core.

Caustic cleaners can attack the internal metals of thecore and cause leakage.

Note: Use this cleaning procedure to clean the oilcooler core.

1. Remove the oil cooler core.

2. Remove any debris from the oil cooler core. Toremove debris from the oil cooler core, turn the oilcooler core onto one end.

3. Flush the oil cooler core internally with cleaner inorder to loosen foreign substances. This will alsohelp to remove oil from the oil cooler core.

Note: Caterpillar Inc. recommends the use ofHydrosolv Liquid Cleaners. Table 16 lists theHydrosolv Liquid Cleaners that are available fromyour Caterpillar dealer.

Table 16

HydrosolvLiquid Cleaners

PartNumber Description Size

1U-8812 4 L (1 US gallon)

1U-5490 19 L (5 US gallon)

8T-7570

Hydrosolv4165

208 L (55 US gallon)

1U-8804 4 L (1 US gallon)

1U-5492 19 L (5 US gallon)

8T-5571

Hydrosolv100

208 L (55 US gallon)

4. Use steam to clean the oil cooler core. Thisremoves any remaining residue from the cleaner.Flush the fins of the oil cooler core. Remove anyother trapped debris.

5. Wash the oil cooler core with hot, soapy water.Rinse the oil cooler core thoroughly with cleanwater.




6. Dry the oil cooler core with compressed air. Directthe air in the reverse direction of the normal flow.

7. Inspect the components in order to ensurecleanliness. The oil cooler core should bepressure tested. Repair the oil cooler core, ifnecessary. Install the oil cooler core.

For more information about cleaning the cores,consult your Caterpillar dealer.

Obtain Coolant Analysis

The concentration of supplemental coolant additive(SCA) should be checked regularly with test kitsor with S·O·S Coolant Analysis (Level 1). Furthercoolant analysis is recommended when the engineis overhauled.

For example, considerable deposits are found in thewater jacket areas on the external cooling system, butthe concentrations of coolant additives were carefullymaintained. The coolant water probably containedminerals that were deposited on the engine over time.

A coolant analysis can be conducted in order to verifythe condition of the water that is being used in thecooling system. A full water analysis can be obtainedby consulting your local water utility company oran agricultural agent. Private laboratories are alsoavailable for water analysis.

Caterpillar Inc. recommends an S·O·S CoolantAnalysis (Level 2).

S·O·S Coolant Analysis (Level 2)

An S·O·S Coolant Analysis (Level 2) is acomprehensive coolant analysis which completelyanalyzes the coolant and the effects on the coolingsystem. An S·O·S Coolant Analysis (Level 2) providesthe following information:

• Complete S·O·S Coolant Analysis (Level 1)

• Visual inspection of properties

• Identification of metal corrosion

92 SEBU7772-02Maintenance SectionPower Take-Off Clutch - Check/Adjust/Lubricate

• Identification of contaminants

• Identification of built up impurities (corrosion andscale)

S·O·S Coolant Analysis (Level 2) provides a report ofthe results of both the analysis and the maintenancerecommendations.

For more information about coolant analysis, seeyour Caterpillar dealer.

i01506009

Power Take-Off Clutch -Check/Adjust/LubricateSMCS Code: 3055-036; 3055-086

NOTICENew power take-offs should have the clutch adjust-ment checked before being placed into service. Theclutch adjustment should be checked again after thefirst ten hours of operation. New clutch plates have a“wear in” period, and the clutch may require severaladjustments until the new plates are “worn in”.


(1) Instruction plate(2) Serial number plate

Check the clutch adjustment regularly after “wear in”.Heavy-duty applications which have engagementsthat are frequent and relatively long periods ofclutch slippage require more frequent adjustmentthan light-duty applications. The operating torqueshould be measured in order to determine if a clutchadjustment is required.

Refer to the OEM information and instruction plate(1) for instructions on lubrication, adjustment, andother recommendations for service. Perform themaintenance that is specified on the instruction plate.

Do not operate the engine with the InstructionPlate cover removed from the clutch. Personalinjury may result.

If the clutch is damaged to the point of burst fail-ure, expelled pieces can cause personal injury toanyone in the immediate area. Proper safeguardsmust be followed to help prevent accidents.

i01604510

Radiator - CleanSMCS Code: 1353-070

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

Inspect the radiator for these items: damaged fins,corrosion, dirt, grease, insects, leaves, oil, and otherdebris. Clean the radiator, if necessary.




Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the fan’s air flow. Hold the nozzle approximately6 mm (0.25 inch) away from the fins. Slowly move theair 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 purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

Use a degreaser and steam for removal of oil andgrease. Clean both sides of the core. Wash the corewith detergent and hot water. Thoroughly rinse thecore with clean water.

After cleaning, start the engine and accelerate theengine to high idle rpm. This will help in the removalof debris and drying of the core. Stop the engine.Use a light bulb behind the core in order to inspectthe core for cleanliness. Repeat the cleaning, ifnecessary.


Severe Service Application - Check

Inspect the fins for damage. Bent fins may be openedwith a “comb”. Inspect these items for good condition:welds, mounting brackets, air lines, connections,clamps, and seals. Make repairs, if necessary.

For more detailed information on cleaning andinspection, refer to Special Publication, SEBD0518,“Know Your Cooling System”.

i00151038

Severe Service Application -CheckSMCS Code: 1000-535

Severe service is an application of an engine thatexceeds current published standards for that engine.Caterpillar maintains standards for the followingengine parameters:

• Performance (power range, speed range, and fuelconsumption)

• Fuel quality

• Altitude range

• Maintenance intervals

• Oil selection and maintenance

• Coolant selection and maintenance

• Environmental qualities

• Installation

Refer to the standards for the engine or consult withyour Caterpillar dealer in order to determine if theengine is operating within the defined parameters.

Severe service operation can accelerate componentwear. Engines that operate under severe conditionsmay need more frequent maintenance intervals inorder to ensure maximum reliability and retention offull service life.

Due to individual applications, it is not possible toidentify all of the factors which can contribute tosevere service operation. Consult your Caterpillardealer for the unique maintenance that is necessaryfor the engine.

The operating environment, improper operatingprocedures and improper maintenance procedurescan be factors which contribute to severe serviceconditions.

Environmental FactorsAmbient temperatures – The engine may beexposed to extended operation in extremelycold environments or hot environments. Valvecomponents can be damaged by carbon buildup ifthe engine is frequently started and stopped in verycold temperatures. Extremely hot inlet air reducesengine performance.

Air Quality – The engine may be exposed toextended operation in an environment that is dirtyor dusty, unless the equipment is cleaned regularly.Mud, dirt and dust can encase components.Maintenance can be very difficult. The buildup cancontain corrosive chemicals.

Buildup – Compounds, elements, corrosivechemicals and salt can damage some components.

Altitude – Problems can arise when the engine isoperated at altitudes that are higher than the intendedsettings for that application. Necessary adjustmentsshould 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

Improper Maintenance Procedures• Extending the maintenance intervals

• Failure to use recommended fuel, lubricants andcoolant/antifreeze

i00651416

Starting Motor - InspectSMCS Code: 1451-040; 1453-040

Caterpillar Inc. recommends a scheduled inspectionof the starting motor. If the starting motor fails, theengine may not start in an emergency situation.

Check the starting motor for proper operation. Checkthe electrical connections and clean the electricalconnections. Refer to the Service Manual for moreinformation on the checking procedure and forspecifications or consult your Caterpillar dealer forassistance.

94 SEBU7772-02Maintenance SectionTurbocharger - Inspect

i01539769

Turbocharger - InspectSMCS Code: 1052-040; 1052

Periodic inspection and cleaning is recommendedfor the turbocharger compressor housing (inlet side).Any fumes from the crankcase are filtered throughthe air inlet system. Therefore, by-products from oiland from combustion can collect in the turbochargercompressor housing. Over time, this buildup cancontribute to loss of engine power, increased blacksmoke and overall loss of engine efficiency.

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage to theturbocharger compressor wheel can cause additionaldamage to the pistons, the valves, and the cylinderhead.

NOTICETurbocharger bearing failures can cause large quan-tities of oil to enter the air inlet and exhaust systems.Loss of engine lubricant can result in serious enginedamage.

Minor leakage of a turbocharger housing under ex-tended low idle operation should not cause problemsas long as a turbocharger bearing failure has not oc-curred.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is repaired orreplaced.

An inspection of the turbocharger can minimizeunscheduled downtime. An inspection of theturbocharger can also reduce the chance for potentialdamage to other engine parts.

Note: Turbocharger components require precisionclearances. The turbocharger cartridge mustbe balanced due to high rpm. Severe ServiceApplications can accelerate component wear.Severe Service Applications require more frequentinspections of the cartridge.

Removal and InstallationFor options regarding the removal, installation, repairand replacement, consult your Caterpillar dealer.Refer to the Service Manual for this engine for theprocedure and specifications.

Cleaning and Inspecting1. Remove the exhaust outlet piping and removethe air inlet piping from the turbocharger. Visuallyinspect the piping for the presence of oil. Cleanthe interior of the pipes in order to prevent dirtfrom entering during reassembly.

2. Turn the compressor wheel and the turbine wheelby hand. The assembly should turn freely. Inspectthe compressor wheel and the turbine wheel forcontact with the turbocharger housing. Thereshould not be any visible signs of contact betweenthe turbine wheel or compressor wheel and theturbocharger housing. If there is any indication ofcontact between the rotating turbine wheel or thecompressor wheel and the turbocharger housing,the turbocharger must be reconditioned.

3. Check the compressor wheel for cleanliness.If only the blade side of the wheel is dirty, dirtand/or moisture is passing through the air filteringsystem. If oil is found only on the back side of thewheel, there is a possibility of a failed turbochargeroil seal.

The presence of oil may be the result of extendedengine operation at low idle. The presence of oilmay also be the result of a restriction of the linefor the inlet air (plugged air filters), which causesthe turbocharger to slobber.

4. Use a dial indicator to check the end clearanceon the shaft. If the measured end play is greaterthan the Service Manual specifications, theturbocharger should be repaired or replaced.An end play measurement that is less than theminimum Service Manual specifications couldindicate carbon buildup on the turbine wheel. Theturbocharger should be disassembled for cleaningand for inspection if the measured end play is lessthan the minimum Service Manual specifications.

5. Inspect the bore of the turbine housing forcorrosion.

6. Clean the turbocharger housing with standardshop solvents and a soft bristle brush.

7. Fasten the air inlet piping and the exhaust outletpiping to the turbocharger housing.


Walk-Around Inspection

i01185304

Walk-Around InspectionSMCS Code: 1000-040

Inspect the Engine for Leaks andfor Loose ConnectionsA walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thoroughinspection of the engine compartment before startingthe engine. Look for items such as oil leaks or coolantleaks, loose bolts, worn belts, loose connections andtrash buildup. Make repairs, as needed:

• The guards must be in the proper place. Repairdamaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICEAccumulated grease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaningor high pressure water.

• Ensure that the cooling lines are properly clampedand that the cooling lines are tight. Check for leaks.Check the condition of all pipes.

• Inspect the water pumps for coolant leaks.

Note: The water pump seal is lubricated by coolantin the cooling system. It is normal for a small amountof leakage to occur as the engine cools down andthe parts contract.

Excessive coolant leakage may indicate the needto replace the water pump seal. For the removal ofwater pumps and the installation of water pumpsand/or seals, refer to the Service Manual for theengine or consult your Caterpillar dealer.

• Inspect the lubrication system for leaks at the frontcrankshaft seal, the rear crankshaft seal, the oilpan, the oil filters and the valve cover.

• Inspect the fuel system for leaks. Look for loosefuel line clamps or for loose fuel line tie-wraps.

• Inspect the piping for the air inlet system and theelbows for cracks and for loose clamps. Ensurethat hoses and tubes are not contacting otherhoses, tubes, wiring harnesses, etc.

• Inspect the alternator belt and the accessory drivebelts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced asmatched sets. If only one belt is replaced, the belt willcarry more load than the belts that are not replaced.The older belts are stretched. The additional load onthe new belt could cause the belt to break.

• Drain the water and the sediment from fuel tankson a daily basis in order to ensure that only cleanfuel enters the fuel system.

• Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

• Inspect the ground strap for a good connection andfor good condition.

• Inspect the ECM to the cylinder head ground strapfor a good connection and for good condition.

• Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolyte levelof the batteries, unless the engine is equipped witha maintenance free battery.

• Check the condition of the gauges. Replace anygauges that are cracked. Replace any gauge thatcan not be calibrated.

i01057943

Water Pump - InspectSMCS Code: 1361-040; 1361

A failed water pump might cause severe engineoverheating problems that could result in the followingconditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

Visually inspect the water pump for leaks. If anyleaking is observed, replace the water pump sealor the water pump assembly. Refer to the ServiceManual for the disassembly and assembly procedure.

96 SEBU7772-02Maintenance SectionWater Pump - Inspect

Note: Refer to the Service Manual or consult yourCaterpillar dealer if any repair is needed or anyreplacement is needed.

SEBU7772-02 97Warranty Section

Warranty Information

Warranty Section

Warranty Informationi01087950

Emissions WarrantyInformationSMCS Code: 1000

This engine may be certified to comply with exhaustemission standards and gaseous emission standardsthat are prescribed by law at the time of manufacture,and this engine may be covered by an EmissionsWarranty. A detailed explanation of the EmissionsWarranty that is applicable to emissions certifiedengines is found in Supplement, SEBU6981, “FederalEmissions Control Warranty Information”. Consultyour authorized Caterpillar dealer to determine if yourengine is emissions certified and if your engine issubject to an Emissions Warranty.

98 SEBU7772-02Reference Information SectionEngine Ratings

Reference InformationSection

Engine Ratingsi00727327

Engine Rating ConditionsSMCS Code: 1000

All engine ratings are in compliance with the followingstandard ambient air conditions of “SAE J1349”:

• 99 kPa (29.3 inches of Hg)

• 30 percent relative humidity

• A temperature of 25 °C (77 °F)

Ratings relate to the standard conditions of“ISO8665”, of “ISO3046/1”, of “DIN6271”, and of“BS5514”.

The engine ratings are based on the following fuelspecifications:

• Low heat value (LHV) of the fuel of 42 780 kJ/kg(18,390 Btu/lb) at 29 °C (84 °F)

• Gravity (API) of 35 degrees at 15 °C (60 °F)

• Specific gravity of .849 at 15 °C (60 °F)

• Density of 850 kg/m3 (7.085 lb/US gal)

The engine ratings are gross output ratings.

Gross Output Ratings – The total output capabilityof the engine that is equipped with standardaccessories.

Standard accessories include the followingcomponents:

• Oil pumps

• Fuel pumps

• Water pumps

Subtract the power that is required to drive auxiliarycomponents from the gross output. This will producethe net power that is available for the external load(flywheel).

i00819749

Engine Rating DefinitionsSMCS Code: 1000

It is important to know the use of the engine sothat the rating will match the operating profile. Theproper rating selection is also important so that thecustomer’s perception of price and value is realized.

In selecting a rating for a specific application, themost important consideration is the time that is spentat full throttle. These rating definitions identify thepercent of time at full throttle. The definitions alsoidentify the corresponding times below rated rpm.

Note: The examples of the applications are onlyfor reference. For an exact determination of theappropriate rating, follow the OEM specifications orconsult your Caterpillar dealer.

A Rating – This rating is used for heavy-dutyapplications that are operated at rated load and atrated rpm up to 100 percent. This rating is used forengines that operate without interruption of loadcycling. Typical applications include the followingexamples: pipeline pumping and ventilation.

B Rating – This rating is used when power and/orrpm are cyclic. The engine should be run at full load.The engine should not exceed 80 percent of theduty cycle. Typical applications include the followingexamples: irrigation, operation where normal pumpdemand is 85 percent of the engine rating, oilpumping/drilling, field mechanical pumping/drilling,and stationary/plant air compressors.

C Rating – This rating is used when power and/orrpm are cyclic. The horsepower and the rpm of theengine can be utilized continuously for one hour. Thisis followed by one hour of operation at the A ratingor below the A rating. The engine should be run atfull load. The engine should not exceed 50 percentof the duty cycle. Typical applications include thefollowing examples: agricultural tractors, harvestersand combines, off-highway trucks, fire pumps, blasthole drills, rock curshers, wood chippers with hightorque rise, and oil field hoisting.

D Rating – This rating is used when rated poweris required for periodic overloads. The maximumhorsepower and the rpm of the engine can be utilizedcontinuously for a maximum of 30 minutes. This isfollowed by one hour of operation at the C rating. Theengine should be run at full load. The engine shouldnot exceed 10 percent of the duty cycle. Typicalapplications include the following examples: offshorecranes, runway snow blowers, water well drills,portable air compressors, and fire pump certificationpower.

SEBU7772-02 99Reference Information Section

Engine Ratings

E Rating – This rating is used when rated poweris required for a short time for initial starting orfor sudden overload. The rating is also used foremergency service when standard power is notavailable. The horsepower and the rpm of the enginecan be utilized continuously for a maximum of 15minutes. This is followed by one hour of operationat the C rating or by the duration of the emergency.The engine should be run at full load. The engineshould not exceed 5 percent of the duty cycle. Typicalapplications include the following examples: standbycentrifugal water pumps, oil field well servicing, crashtrucks, portable air compressors, and gas turbinestarting motors.

NOTICEOperating engines above the rating definitions can re-sult in shorter service life before overhaul.

100 SEBU7772-02Reference Information SectionCustomer Service

Customer Servicei02097871

Customer AssistanceSMCS Code: 1000

USA and CanadaWhen a problem arises concerning the operation ofan engine or concerning the service of an engine,the problem will normally be managed by the dealerin your area.

Your satisfaction is a primary concern to Caterpillarand to Caterpillar dealers. If you have a problem thathas not been handled to your complete satisfaction,follow these steps:

1. Discuss your problem with a manager from thedealership.

2. If your problem cannot be resolved at the dealerlevel without additional assistance, use the phonenumber that is listed below to talk with a FieldService Coordinator:

1-800-447-4986

The normal hours are from 8:00 to 4:30 Mondaythrough Friday Central Standard Time.

3. If your needs have not been met still, submit thematter in writing to the following address:

Caterpillar Inc.Manager, Customer Service, Engine DivisionMossville Bldg ACP.O. Box 610Mossville, Illinois 61552-0610

Please keep in mind: probably, your problem willultimately be solved at the dealership, using thedealership’s facilities, equipment, and personnel.Therefore, follow the steps in sequence when aproblem is experienced.

Outside of the USA and of CanadaIf a problem arises outside the USA and outsideCanada, and if the problem cannot be resolved at thedealer level, consult the appropriate Caterpillar office.

Latin America, Mexico, CarribeanCaterpillar Americas Co.701 Waterford Way, Suite 200Miami, FL 33126-4670USAPhone: 305-476-6800Fax: 305-476-6801

Europe, Africa, and Middle EastCaterpillar Overseas S.A.76 Route de FrontenexP.O. Box 6000CH-1211 Geneva 6SwitzerlandPhone: 22-849-4444Fax: 22-849-4544

Far EastCaterpillar Asia Pte. Ltd.7 Tractor RoadJurong, Singapore 627968Republic of SingaporePhone: 65-662-8333Fax: 65-662-8302

ChinaCaterpillar China Ltd.37/F., The Lee Gardens33 Hysan AvenueCauseway BayG.P.O. Box 3069Hong KongPhone: 852-2848-0333Fax: 852-2848-0440

JapanShin Caterpillar Mitsubishi Ltd.SBS Tower10-1, Yoga 4-ChomeSetagaya-Ku, Tokyo 158-8530JapanPhone: 81-3-5717-1150Fax: 81-3-5717-1177

JapanCaterpillar Power Systems, Inc.SBS Tower (14th floor)4-10-1, YogaSetagaya-Ku, Tokyo 158-0097Phone: 81-3-5797-4300Fax: 81-3-5797-4359

Australia and New ZealandCaterpillar of Australia Ltd.1 Caterpillar DrivePrivate Mail Bag 4Tullamarine, Victoria 3043AustraliaPhone: 03-9953-9333Fax: 03-9335-3366


Customer Service

i01028392

Ordering Replacement PartsSMCS Code: 7567

When replacement parts are required for thisproduct Caterpillar recommends using Caterpillarreplacement parts or parts with equivalent spec-ifications including, but not limited to, physicaldimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

Quality Caterpillar replacement parts are availablefrom Caterpillar dealers throughout the world.Caterpillar dealers’ parts inventories are up-to-date.The parts stocks include all of the parts that arenormally needed to protect your Caterpillar engineinvestment.

When you order parts, please specify the followinginformation:

• Part number

• Part name

• Quantity

If there is a question concerning the part number,please provide your dealer with a completedescription of the needed item.

When a Caterpillar engine requires maintenanceand/or repair, provide the dealer with all theinformation that is stamped on the Information Plate.This information is described in this Operation andMaintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform thedealer about the conditions of the problem and thenature of the problem. Inform the dealer about whenthe problem occurs. This will help the dealer introubleshooting the problem and solving the problemfaster.

102 SEBU7772-02Reference Information SectionReference Materials

Reference Materialsi02486643

Reference MaterialSMCS Code: 1000

The following literature can be obtained through anyCaterpillar dealer.

Coolants• Data Sheet, PEHJ0067, “Cat ELC (Extended LifeCoolant) (Worldwide Formulation)”

• Data Sheet, PEHP9554, “Diesel EngineAntifreeze/Coolant (DEAC)”

• Special Publication, PMEP5027, “Label - ELCRadiator Label”

• Special Publication, SEBD0518, “Know YourCooling System”

• Special Publication, SEBD0970, “Coolant and YourEngine”

Fuels• Special Publication, SEBD0717, “Diesel Fuels andYour Engine”

• Special Publication, SENR9620, “Improving FuelSystem Durability”

Greases• Data Sheet, NEHP6010, “Cat Ultra 5Moly Grease”

• Data Sheet, NEHP6011, “Arctic Platinum GreaseSpec Sheet”

• Data Sheet, NEHP6012, “Cat Desert Gold Grease”

• Data Sheet, NEHP6015, “Cat Special PurposeGrease”

• Special Publication, PEGJ0035, “Grease SelectionGuide”

• Data Sheet, PEHJ0088, “Cat Multipurpose Grease”

• Data Sheet, PEHP0002, “Molybdenum GreaseData Sheet”

• Data Sheet, PEHP6002, “Cat Advanced 3MolyGrease”

Lubricants• Special Publication, PEDP7035, “Optimizing OilChange Intervals”

• Data Sheet, PEHJ0008, “Cat Arctic DEO SYN”

• Data Sheet, PEHJ0021, “Product Data Sheet forCat DEO (Diesel Engine Oil) APD, EAME, LACDOnly”

• Data Sheet, PEHJ0059, “Cat DEO (for NorthAmerica)”

• Data Sheet, PEHJ0072, “Cat DEO (Brazil Only)”

• Data Sheet, PEHJ0091, “Cat DEO (Egypt andSaudi Arabia)”

• Special Publication, PEHP6001, “How To Take AGood Oil Sample”

• Data Sheet, PEHP7062, “Full Synthetic DieselEngine Oil Data Sheet”

• Special Publication, PELJ0179, “FLU03-02Caterpillar Engine Crankcase Fluid-1Specifications (All World Market Areas)”

• Special Publication, SEBD0640, “Oil and YourEngine”

S·O·S Services• Data Sheet, NEHP6013, “S·O·S Fluids AnalysisProducts”

• Special Publication, PEDP7036, “S·O·S FluidsAnalysis Cornerstone”

• Special Publication, PEHP7057, “S·O·S CoolantAnalysis”

• Special Publication, PEHP7076, “UnderstandingS·O·S Services Tests”

Miscellaneous• Special Publication, NEHS0526, “ServiceTechnology Application Guide”

• Special Instruction, NENG2500, “Caterpillar DealerService Tool Catalog”

• Special Publication, PECP9067, “One SafeSource”

• Special Instruction, REHS0354, “Charging SystemTroubleshooting for All Engines”


Reference Materials

• Special Instruction, REHS0871, “ElectronicInstallation Guide”.

• Special Publication, SEBF8029, “Index toGuidelines for Reusable Parts and SalvageOperations”

• Special Publication, SEBF8062, “Guideline forReusable Parts - Procedure to Inspect and CleanAir Filters”

• Special Publication, SEBU6251, “CaterpillarCommercial Diesel Engine FluidsRecommendations”

• Special Instruction, SEHS7332, “Warning Tag -Danger Do Not Operate”

• Special Instruction, SEHS7633, “Battery TestProcedure”

• Special Instruction, SEHS8622, “Using theFT-1984 Aftercooler Testing Group”

• Special Instruction, SEHS9031, “StorageProcedure for Caterpillar Products”

• Specifications, SENR3130, “Torque SpecificationsModule”

• Service Manual, SENR7600, “C9 IndustrialEngines”

• Service Manual, SENR9800, “C9, C15, & C18Acert AGCO Tractor Engines”

• Special Instruction, SMHS7001, “Assembly of FanDrive Pulley Assemblies”

Additional Reference MaterialThe “Engine Fluids Data Book” can be obtained fromthe following locations: local technological society,local library, and local college. If necessary, consultEMA at the following address:

Engine Manufacturers AssociatonTwo North LaSalle Street, Suite 2200Chicago, IL, USA 60602E-mail: [email protected]: (312) 827-8700Facsimile: (312) 827-8737

The “Society of Automotive Engineers (SAE)Specifications” can be found in your SAE handbook.This publication can also be obtained from thefollowing locations: local technological society, locallibrary, and local college. If necessary, consult SAEat the following address:

SAE International400 Commonwealth DriveWarrendale, PA, USA 15096-0001Telephone: (724) 776-4841

The “American Petroleum Institute Publication No.1509” can be obtained from the following locations:local technological society, local library, and localcollege. If necessary, consult API at the followingaddress:

American Petroleum Institute1220 L St. N.W.Washington, DC, USA 20005Telephone: (202) 682-8000

The International Organization for Standardization(ISO) offers information and customer serviceregarding international standards and standardizingactivities. ISO can also supply information on thefollowing subjects that are not controlled by ISO:national standards, local standards, regulations,certification, and related activities. Consult themember of ISO in your country.

International Organization for Standardization(ISO)1, rue de VarembéCase postale 56CH-1211 Genève 20SwitzerlandTelephone: +41 22 749 01 11Facsimile: +41 22 733 34 30E-mail: [email protected] site: http://www.iso.ch

European classifications are established by theCounseil International Des Machines a Combustion(CIMAC) (International Council on CombustionEngines).

CIMAC Central SecretariatLyoner Strasse 1860528 FrankfurtGermanyTelephone: +49 69 6603 1567Facsimile: +49 69 6603 1566

i00912149

Maintenance RecordsSMCS Code: 1000

Caterpillar Inc. recommends the retention of accuratemaintenance records. Accurate maintenance recordscan be used for the following purposes:

• Determine operating costs.

104 SEBU7772-02Reference Information SectionReference Materials

• Establish maintenance schedules for other enginesthat are operated in the same environment.

• Show compliance with the required maintenancepractices and maintenance intervals.

Maintenance records can be used for a variety ofother business decisions that are related to enginemaintenance.

Maintenance records are a key element of amaintenance program that is well managed. Accuratemaintenance records can help your Caterpillar dealerto fine tune the recommended maintenance intervalsin order to meet the specific operating situation. Thisshould result in a lower engine operating cost.

Records should be kept for the following items:

Fuel Consumption – A record of fuel consumptionis essential in order to determine when the loadsensitive components should be inspected orrepaired. Fuel consumption also determines overhaulintervals.

Service Hours – A record of service hours isessential to determine when the speed sensitivecomponents should be inspected or repaired.

Documents – These items should be easy toobtain, and these items should be kept in the enginehistory file. All of the documents should show thisinformation: date, service hours, fuel consumption,unit number, and engine serial number. The followingtypes of documents should be kept as proof ofmaintenance or repair for warranty:

Keep the following types of documents as proof ofmaintenance for warranty. Also, keep these types ofdocuments as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owner’s repair costs

• Owner’s receipts

• Maintenance log


Reference Materials

i01176304

Maintenance LogSMCS Code: 1000

Table 17

Engine Model Customer Identifier

Serial Number Arrangement Number

ServiceHours

QuantityOf Fuel Service Item Date Authorization

106 SEBU7772-02Index Section

Index

A

After Starting Engine ............................................. 45After Stopping Engine............................................ 49Aftercooler Core - Clean/Test ................................ 60Aftercooler Core - Inspect...................................... 60Air Compressor - Inspect....................................... 61Air Compressor Filter - Clean/Replace (IfEquipped) ............................................................ 61Air Tank Moisture and Sediment - Drain (IfEquipped) ............................................................ 62Alternator - Inspect ................................................ 62

B

Battery - Replace................................................... 62Battery Charger - Check........................................ 63Checking After Stopping .................................... 64Checking Before Start-Up.................................. 63

Battery Electrolyte Level - Check .......................... 64Battery or Battery Cable - Disconnect ................... 64Before Starting Engine .................................... 13, 41Belt Tensioner - Inspect (If Equipped) ................... 64Belts - Inspect/Adjust............................................. 65Adjustment ......................................................... 65Inspection........................................................... 65

Burn Prevention..................................................... 10Batteries.............................................................. 11Coolant............................................................... 10Oils...................................................................... 11

C

Cold Weather Operation........................................ 50Cold Weather Starting ........................................... 44Cooling System Coolant (DEAC) - Change........... 66Cooling Systems with Heavy Deposits orPlugging ........................................................... 67Drain .................................................................. 66Fill ...................................................................... 67Flush .................................................................. 66

Cooling System Coolant (ELC) - Change.............. 68Drain .................................................................. 68Fill ...................................................................... 69Flush .................................................................. 68

Cooling System Coolant Extender (ELC) - Add..... 69Cooling System Coolant Level - Check ................. 70Cooling System Coolant Sample (Level 1) -Obtain .................................................................. 71Cooling System Coolant Sample (Level 2) -Obtain .................................................................. 71Cooling System Supplemental Coolant Additive(SCA) - Test/Add.................................................. 72Add the SCA, If Necessary ................................ 72Test the Concentration of the SCA..................... 72

Cooling System Water Temperature Regulator -Replace................................................................ 73Crankshaft Vibration Damper - Inspect ................. 73Removal and Installation.................................... 73Visconic Damper................................................ 73

Crushing Prevention and Cutting Prevention ........ 13Customer Assistance........................................... 100Outside of the USA and of Canada.................. 100USA and Canada............................................. 100

Customer Service ................................................ 100Customer Specified Parameters...................... 23, 40Cylinder Head Grounding Stud - Inspect/Clean/Tighten................................................................. 74

D

Diagnostic Flash Code Retrieval ........................... 36“Diagnostic” Lamp.............................................. 36

Diagnostic Lamp.................................................... 36Driven Equipment - Check..................................... 74

E

Electrical System................................................... 14Grounding Practices .......................................... 15

Emergency Stopping ............................................. 48Emergency Stop Button ..................................... 48

Emissions Certification Film .................................. 22Emissions Warranty Information............................ 97Engaging the Driven Equipment............................ 46Engine - Clean....................................................... 74Engine Air Cleaner Element (Dual Element) -Clean/Replace ..................................................... 75Cleaning the Primary Air Cleaner Elements ...... 76Servicing the Air Cleaner Elements ................... 75

Engine Air Cleaner Service Indicator - Inspect (IfEquipped) ............................................................ 77Test the Service Indicator................................... 78

Engine Air Precleaner - Check/Clean.................... 78Engine Crankcase Breather - Clean...................... 78Engine Description ................................................ 18Aftermarket Products and Caterpillar Engines... 20Electronic Engine Features................................ 19Engine Cooling and Lubrication ......................... 20Engine Service Life ............................................ 20Engine Specifications......................................... 18Welding and Caterpillar Electronic Engines....... 20

Engine Diagnostics................................................ 36Engine Electronics................................................. 16Engine Mounts - Inspect........................................ 79Engine Oil and Filter - Change .............................. 80Drain the Engine Oil........................................... 81Fill the Engine Crankcase.................................. 82Replace the Oil Filter ......................................... 81Selection of Oil Change Interval ........................ 80

Engine Oil Level - Check....................................... 79

SEBU7772-02 107Index Section

Engine Oil Sample - Obtain ................................... 80Obtain the Sample and the Analysis.................. 80

Engine Operation................................................... 46Engine Operation with Active Diagnostic Codes ... 39Engine Operation with Intermittent DiagnosticCodes .................................................................. 39Engine Rating Conditions...................................... 98Engine Rating Definitions ...................................... 98Engine Ratings ...................................................... 98Engine Starting ................................................ 14, 41Ether .................................................................. 14

Engine Stopping .............................................. 14, 48Engine Storage Procedure - Check....................... 83Engine Valve Lash - Inspect/Adjust ....................... 83

F

Fan Drive Bearing - Lubricate................................ 83Fault Logging......................................................... 39Fire Prevention and Explosion Prevention ............. 11Ether .................................................................. 12Fire Extinguisher ................................................ 12Lines, Tubes and Hoses .................................... 12

Foreword ................................................................. 5California Proposition 65 Warning ....................... 5Literature Information........................................... 4Maintenance ........................................................ 4Maintenance Intervals.......................................... 4Operation ............................................................. 4Overhaul .............................................................. 4Safety................................................................... 4

Fuel and the Effect from Cold Weather ................. 50Fuel Conservation Practices.................................. 46Fuel Related Components in Cold Weather .......... 51Fuel Filters ......................................................... 51Fuel Heaters ...................................................... 51Fuel Tanks.......................................................... 51

Fuel System - Prime.............................................. 84Engines that are Equipped with a Fuel PrimingPump................................................................ 84Engines that are Not Equipped with a Fuel PrimingPump................................................................ 84

Fuel System Primary Filter (Water Separator)Element - Replace ............................................... 85Replace the Element.......................................... 85

Fuel System Primary Filter/Water Separator -Drain .................................................................... 85Fuel System Secondary Filter - Replace............... 86Fuel Tank Water and Sediment - Drain ................. 87Drain the Water and the Sediment..................... 87Fuel Storage Tanks............................................ 87Fuel Tank ........................................................... 87

G

Gauges and Indicators .......................................... 26

General Hazard Information .................................... 8Asbestos Information ......................................... 10Containing Fluid Spillage ..................................... 9Dispose of Waste Properly ................................ 10Fluid Penetration.................................................. 9Pressurized Air and Water ................................... 9

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

H

Hoses and Clamps - Inspect/Replace ................... 88Replace the Hoses and the Clamps .................. 88

I

Important Safety Information ................................... 2

J

Jacket Water Heater - Check ................................ 89

L

Lifting and Storage ................................................ 25

M

Maintenance Interval Schedule ............................. 58Maintenance Log................................................. 105Maintenance Records.......................................... 103Maintenance Section............................................. 52Manual Stop Procedure......................................... 48Model View Illustrations......................................... 18Model Views .......................................................... 18Monitoring System (If Equipped) ..................... 27, 31Caterpillar Messenger Display ..................... 28, 33Indicators and Gauges................................. 27, 31

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

O

Operation Section.................................................. 25Ordering Replacement Parts ............................... 101Overhaul Considerations....................................... 89Oil Consumption as an Overhaul Indicator ........ 89Overhaul Recommendation ............................... 90

P

Plate Locations and Film Locations....................... 21Information Plate (2) .......................................... 22Serial Number Plate (1) ..................................... 22

Power Take-Off Clutch - Check/Adjust/Lubricate .. 92Product Identification Information .......................... 21

108 SEBU7772-02Index Section

Product Information Section .................................. 17Product Lifting........................................................ 25Product Storage..................................................... 25

R

Radiator - Clean .................................................... 92Radiator Restrictions ............................................. 50Reference Information Section .............................. 98Reference Material .............................................. 102Additional Reference Material.......................... 103Coolants........................................................... 102Fuels ................................................................ 102Greases ........................................................... 102Lubricants ........................................................ 102Miscellaneous .................................................. 102S·O·S Services................................................. 102

Reference Materials ............................................ 102Reference Numbers .............................................. 22Record for Reference......................................... 22

Refill Capacities..................................................... 52Refill Capacities and Recommendations............... 52Cooling System.................................................. 55Fuel .................................................................... 54Lubricating Grease............................................. 54Lubrication System ............................................ 52

S

Safety Messages..................................................... 6Safety Section ......................................................... 6Self-Diagnostics..................................................... 36Severe Service Application - Check ...................... 93Environmental Factors ....................................... 93Improper Maintenance Procedures.................... 93Improper Operating Procedures ........................ 93

Starting Motor - Inspect ......................................... 93Starting the Engine................................................ 41Air Inlet Heater ................................................... 42Cold Weather Starting........................................ 42Ether Injection System....................................... 43Initial Inspection ................................................. 42Problems with the Wiring Harness..................... 44Starting Problems .............................................. 43

Starting with Jump Start Cables ............................ 45

T

Table of Contents..................................................... 3Turbocharger - Inspect .......................................... 94Cleaning and Inspecting .................................... 94Removal and Installation.................................... 94

W

Walk-Around Inspection ........................................ 95Inspect the Engine for Leaks and for LooseConnections ..................................................... 95

Warranty Information ............................................. 97Warranty Section ................................................... 97Water Pump - Inspect ............................................ 95Welding on Engines with Electronic Controls ........ 17

Product and Dealer InformationNote: For product identification plate locations, see the section “Product Identification Information” in the Operationand Maintenance Manual.

Delivery Date:

Product InformationModel:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer InformationName: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:

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