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Manual: Safety

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156 views94 pages

Manual: Safety

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Richard Chua

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You are on page 1/ 94

6/10/2016 Page 1 of 94

Manual

DIESEL ENGINES

Caterpillar - 3176B (9CK1), C-10 (2PN1), C-12 (1YN1), 3406E (5EK1) - Operation &
Maintenance

SAFETY
IMPORTANT SAFETY INFORMATION

Most accidents involving product operation, maintenance and repair are

caused by failure to observe basic safety rules or precautions. An
accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential
hazards. This person should also have the necessary training, skills and
tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this

product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on

this product, until you have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided here and on the product. If
these hazard warnings are not heeded, bodily injury or death could occur
to you or other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by
a "Signal Word" such as "WARNING" as 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, explaining the hazard, can
be either written or pictorially presented.

Operations that may cause product damage are identified by NOTICE

labels on the product.
Caterpillar cannot anticipate every possible circumstance that might

involve a potential hazard. The warnings in this information and on the

product are therefore not all inclusive. If a tool, procedure, work method
or operating technique not specifically recommended by Caterpillar is
used, you must satisfy yourself that it is safe for you and others. You
should also ensure that the product will not be damaged or made unsafe
by the operation, lubrication, maintenance or repair procedures you
choose.

The information, specifications, and illustrations are on the basis of

information available at the time it was written. The specifications,
torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given
to the product. Obtain the complete and most current information before
starting any job.
SAFETY

Warning Signs and Labels

There may be several specific safety signs on your engine. Please take
the time to familiarize yourself with the safety signs.

Make sure that you can read all safety signs. Clean or replace these if you
cannot read the words or see the pictures. When cleaning the labels use a
cloth, water and soap. Do not use solvents, gasoline, etc., to clean safety
signs. The use of solvents, gasoline, etc., could loosen the sign's adhesive
and cause the sign to fall off.

You must replace a label if it is damaged, missing or cannot be read. If a

label is attached to a part, and that part is replaced, make sure a new label
is installed on the replaced part.

WARNING: This engine uses high voltage to the unit

injectors. Disconnect the unit injector
enable circuit connector to prevent
personal injury. Do not come in contact
with the injector terminals while the engine
is running.

Fig. 1: Locating Unit Injector Enable Circuit Connectors

General Hazard Information

Attach a DO NOT OPERATE or similar warning tag to start switch or

controls before performing maintenance or repairing the truck engine.

Do not allow unauthorized personnel on, around or in the truck

when maintenance or repair is being performed.
When operating the engine in an enclosed area, vent the exhaust to
the outside.
If the engine is not running, do NOT release the secondary or
parking brake systems unless the truck is blocked or restrained.
Wear a hard hat, protective glasses, hearing protection and other
protective equipment as required by job conditions.
Do not wear loose clothing or jewelry that can catch on controls or
other parts of the engine.
Make certain all protective guards and covers are secured in place.
Never put maintenance fluids into glass containers since glass
containers can break.
Report all needed repairs.

UNLESS INSTRUCTED DIFFERENTLY, PERFORM ALL

MAINTENANCE AS FOLLOWS:
Stop the engine.
Ensure the protective locks or controls are in the applied position.
Apply the secondary (emergency) or parking brakes.
Block or restrain the vehicle before performing maintenance or
repair.
Disconnect the batteries whenever performing any maintenance or
before servicing the electrical system.
Do NOT attempt repairs you do not understand.
When starting an engine after repairs have been made to the fuel
system or governor, make provisions for shutting off the engine's
intake air and/or fuel supply (to stop the engine), in case there is an
overspeed on start-up.
Start the engine only from the operator's station (cab). Never short
across the starter terminals or the batteries as this could bypass the
engine neutral-start system as well as damage the electrical system.
Pressure Air and Water

Pressure air can cause personal injury. When using pressure air for
cleaning, wear a protective face shield, protective clothing and protective
shoes. Pressurized water could cause debris and/or hot water to be blown
and result in personal injury. The maximum air pressure must be below
205 kPa (30 psi) for cleaning purposes.
Fluid Penetration

Always use a board or cardboard protector when checking for a leak.

Escaping fluid under pressure, even a pin-hole size leak, can penetrate
body tissue, causing serious injury or possible death. If fluid is injected
into your skin, it must be treated by a doctor familiar with this type of
injury immediately.
Asbestos Information

This Caterpillar product and replacement parts shipped from the factory
are asbestos free.
Burn Prevention

Do not touch any part of an operating engine. Allow the engine to cool
before any repair or maintenance is performed on the engine. Relieve all
pressure in air, oil, fuel or cooling systems before any lines, fittings or
related items are disconnected or removed.
Coolant

To prevent personal injury, do not step up on engine to remove the filler

cap, if applicable. Use an adequate ladder. At operating temperature, the
engine coolant is hot and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant. Check the coolant level only
after the engine has been stopped and the filler cap is cool enough to
remove with your bare hand.

Remove the cooling system filler cap slowly to relieve pressure. Allow
cooling system components to cool before draining. When pressure is
relieved rapidly, this hot coolant water can turn into steam. Any contact
with hot water or steam can cause severe burns.

Cooling system supplemental additive (conditioner) contains alkali. To

prevent personal injury, avoid contact with the skin and eyes and do not
drink.

Oils

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

Battery electrolyte contains acid and can cause injury. Avoid contact
with the skin and eyes. Wash hands after touching batteries and
connectors. Use of gloves is recommended. Always wear protective
glasses when working with batteries.

Batteries give off flammable fumes which can explode. Always thaw a
frozen battery before jump starting. Frozen batteries can explode. Do not
smoke when observing the battery electrolyte levels.
Fire or Explosion Prevention

Determine whether the engine will be operated in an environment in

which combustible gases could be drawn through the air inlet system.
These gases could cause the engine to overspeed, which in turn could
seriously damage the engine and result in bodily injury or property
damage. If your application involves the presence of combustible gases,
consult your Caterpillar dealer to obtain additional information
concerning protection devices suitable for the application involved.

If equipped with an air conditioner, do not smoke when servicing,

charging or working around air conditioner leaks. Inhaling freon gas
through a lit cigarette or other smoking method, or inhaling fumes
released from a flame contacting freon could cause bodily harm or death.
DO NOT allow these situations to occur when servicing air conditioners
or where freon gas may be present.

All fuels, most lubricants and some coolant mixtures are flammable.
Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel
and gasoline fumes are extremely explosive. Do not smoke while
refueling or in a refueling area.

Keep all fuels and lubricants stored in properly marked containers and
away from all unauthorized persons.

Store all oily rags or other flammable material in a protective container,

in a safe place. Remove all flammable materials such as fuel, oil and

other debris before they accumulate on the truck engine. Do not expose
the engine to flames, burning brush, etc., if at all possible.

Do not weld or flame cut on pipes or tubes that contain flammable fluids.
Clean them thoroughly with nonflammable solvent before welding or
flame cutting on them.

Exhaust shields (if equipped), which protect hot exhaust components

from oil or fuel spray in the event of a line, tube or seal failure, must be
installed correctly.

Provide adequate and proper waste oil disposal. Oil and fuel filters must
be properly installed and housing covers tightened to proper torque when
being changed.
Fire Extinguisher

Have a fire extinguisher available and know how to use it. Inspect and
have it serviced as recommended on its instruction plate.
Crushing or Cutting Prevention

Support equipment and attachments properly when working beneath

them. Never work under a partially tilted cab unless it is properly
secured.

Never attempt adjustments while the engine is running unless otherwise

specified. Stay clear of all rotating and moving parts. Guards should be
in place whenever maintenance is not being performed. Keep objects
away from moving fan blades. They will throw or cut any object or tool
that falls or is pushed into them.

Wear protective glasses when striking objects to avoid injury to your

eyes. Chips or other debris can fly off objects when struck. Make sure no
one can be injured by flying debris before striking any object.
Mounting and Dismounting

Do not climb on, or jump off the engine or stand on components which
cannot support your weight. Use an adequate ladder. Clean steps,
handholds and areas of the truck you will be working on or around.
Before Starting the Engine

Inspect engine for potential hazards. Be sure all protective guards and
covers are installed if an engine must be started to make adjustments or
checks. To help prevent an accident caused by parts in rotation, work
carefully around them.

Do not disable or bypass automatic alarm/shutoff circuits. They are

provided to prevent personal injury and engine damage.
Make provisions for shutting off the air or fuel supply to stop the engine
if there is an overspeed on start-up after performing repair or
maintenance to the engine.
See the appropriate procedures for adjustment and repairs.
Engine Starting

Do not start the engine or move any of the controls or disengage the
parking brakes if there is a warning tag attached to the controls. Check
with the person who attached the tag before starting.

Make sure no one is working on, or close to the engine or engine driven
components before starting it. Always make an inspection of the engine
before and after starting.

Diesel engine exhaust contains products of combustion which may be

harmful to your health. Always start and operate the engine in a well-
ventilated area and, if in an enclosed area, vent the exhaust to the outside.

Start the engine only from the operator's station (cab). Never short across
the electric starting motor terminals or the batteries to start the engine as
this could bypass the engine neutral-start system as well as damage the
electrical system. Always start the engine according to the required
Engine Starting procedure (see Starting the Engine ) to prevent major
engine component damage and personal injury.
Starting Aids (if Used)

Ether and other starting aids are poisonous and flammable. Do not smoke
while using ether or changing ether cylinders. Use ether only in well
ventilated areas.
Do not store replacement ether cylinders in direct sunlight or at
temperatures above 39°C (102°F), in living or sleeping areas, or in the

engine compartment or cab. Keep ether cylinders out of the reach of

unauthorized persons. Discard cylinders or canisters in a safe place. Do
not puncture or burn cylinders or canisters.
Electrical System

Never disconnect any charging unit circuit or battery circuit cable from
the battery when the charging unit is operating. A spark can cause the
flammable vapor mixture of hydrogen and oxygen to explode.

To prevent potential sparks from igniting combustible gases produced by

some batteries, attach the negative (-) boost ground cable last, to the
starter NEGATIVE (-) terminal (if equipped) or to the engine block.
Check regularly for loose or frayed electrical wires. Have all loose or
frayed electrical wires tightened, repaired or replaced before operating
the truck. See Engine Starting for specific starting instructions.
Grounding Practices

Proper grounding for vehicle and engine electrical systems is necessary

for proper vehicle performance and reliability. Improper grounding will
result in uncontrolled and unreliable electrical circuit paths.

Uncontrolled engine electrical circuit paths can result in damage to main

bearings, crankshaft journal surfaces and aluminum components.
Uncontrolled electrical circuit paths can also cause electrical noise which
may degrade vehicle and radio performance.

Engines installed without engine-to-frame ground straps can be damaged

by electrical discharge. To prevent electrical discharge damage, check to
make sure the engine's electrical system has an engine-to-frame ground
strap. For engines which have the alternator connected to an engine
component, the ground strap must connect that component to the frame.
Some engines have starter-to-frame ground straps. But many of these
starters are not electrically grounded to the engine. They have electrical
insulation systems. For this reason, the starter-to-frame ground strap may
not be an acceptable engine ground.

To insure proper functioning of the vehicle and engine electrical systems,

an engine-to-frame ground strap with a direct path to the battery must be
used. This may be provided by way of a starting motor ground, a frame
to starting motor ground, or a direct frame to engine ground.

All grounds should be tight and free of corrosion. The engine alternator
must be battery (-) grounded with a wire size adequate to handle full
alternator charging current. The engine comes equipped with an
alternator ground wire.
Electronic Engine Features

Tampering with the electronic system installation or the truck OEM

wiring installation can be dangerous and could result in personal
injury or death and/or engine damage.

This engine uses high voltage to the electronic unit injectors. Do not
come in contact with the unit injector terminals while the engine is
running.
This engine is equipped with customer selected monitoring features that
may cause reduced power or shutdown under certain conditions. The
monitoring and idle features can only be programmed and/or changed
with electronic service tools and passwords. Read and understand the
information here concerning programmable engine monitoring options
and idle shutdown timer.
Certain features, when selected or programmed, such as low oil pressure,
high coolant temperature or low coolant level could cause the engine
power and/or vehicle speed to be limited and the engine may also shut
down. The shutdown may take as little as 20 seconds from the time the
warning indicator is activated.
Illustrations

The sample model view drawings show various typical features which
may be found on Caterpillar Electronic Diesel Truck Engines. The
drawings are generic and do not reflect all available options.
GENERAL
ENGINE INFORMATION AND IDENTIFICATION

3176B Truck Engine

Fig. 2: 3176B Truck Engine Components

C-10 & C-12 Truck Engine

Fig. 3: C-10 & C-12 Truck Engine Components

3406E Truck Engine

Fig. 4: 3406E Truck Engine Components

Specifications

Fig. 5: Engine Specifications

These Caterpillar Electronic Diesel Truck engines are:

direct injected
mechanically actuated electronic unit injected
turbocharged
air-to-air aftercooled (ATAAC).

The electronic engine control system provides:

electronic governing
automatic air/fuel ratio control
torque rise shaping
injection timing control
system diagnostics.
Functions included in the electronic control are programmable features
of:
cruise control
PTO governing
vehicle speed limiting
high gears rpm limiting
low gears rpm limiting
top engine limiting
idle shutdown timer
retarder control.

Additional benefits which provide engine fuel economy, serviceability,

and driver comfort include:

improved cold starting capability

tamper resistance
diagnostics
progressive shift engine speed control
American Trucking Association (ATA) data link (SAE J1587)
an optional Engine Monitoring Package.

An electronic governor controls the unit injection pump output to

maintain desired engine rpm. The governor functions include
programmable low idle and 20 to 200 rpm governor overrun.

Electronically controlled, mechanically actuated unit injectors, combined

with the pumping, electronic fuel metering (duration and timing) and
injecting elements, produce very high injection pressures. These unit
injectors have full authority over engine fuel delivery to accurately
control smoke limiting, white smoke and engine acceleration rates.

Individual unit injection pumps, one for each cylinder, meter and pump
fuel under high pressure. High injection pressures help to reduce fuel
consumption and emissions. The use of this type of unit fuel injector
provides total electronic control of injection timing. The injection timing
varies with engine operating conditions. This optimizes the engine's
performance for starting, emissions, noise, fuel consumption and
driveability.

Timing advance is achieved by precise control of injector firing. Engine

speed is controlled by adjusting the firing duration. A speed timing
sensor provides information to the Electronic Control Module (ECM) for
detection of cylinder position and engine speed.

The engines have built-in diagnostics to assure that all components are
functioning and operating properly. In the event of a system component
deviation from programmed limits, the operator will be alerted to the
condition by a dashboard mounted CHECK ENGINE/DIAGNOSTIC
lamp. A Caterpillar service tool or cruise control switches (if equipped)
may be used to read the numerical code of the diagnostic flash code.
There are three types of diagnostic codes:
active (fault)
logged

event.

These codes are logged and stored in the system memory. Refer to
Engine Diagnostics for additional information.
The cooling system consists of:

a gear driven centrifugal pump

a water temperature regulator
an oil cooler
an OEM radiator incorporating a shunt system.

The engine lubricating oil, supplied by a gear-type pump, is both cooled

and filtered. Bypass valves provide unrestricted flow of lubrication oil to
the engine parts:

when oil viscosity is high

if either the oil cooler or the oil filter elements (paper cartridge)
become plugged.

Engine efficiency, efficiency of emission controls, and engine

performance depend on adherence to proper operation and maintenance
recommendations, and the use of recommended fuels, coolants and
lubrication oils.
Multi-Torque Rating (If Equipped)

Multi-torque ratings provide for additional torque as engine load

increases. This feature provides higher torque levels and better
driveability while in the top gears ONLY. The engine electronics are able
to determine when the vehicle is in the top gears by calculating the
engine rpm/vehicle speed ratio.
The benefits of Multi-Torque are:

driver feel
less shifting in rolling terrain
less wear on drive line components
more responsive-better engine performance
Welding and Caterpillar Electronic Engines

CAUTION: Because the strength of the frame may

decrease, some manufacturers do not
recommended welding onto a truck frame or
rail. Refer to your OEM regarding welding
on a truck frame or rail.

Before welding on a vehicle equipped with an electronic engine, the

precautions that follow should be observed:

Disconnect all cables connected to the vehicle batteries.

Disconnect both ECM Connectors (J1/P1 and J2/P2).
Do not use the ECM or Engine Ground Stud for grounding of the
welder.
Locate the ground as close as possible to the welding area.
Engine Identification

Caterpillar engines are identified with Serial Numbers, Performance

Specification Numbers (fuel system settings) and Arrangement Numbers.
In some cases Modification Numbers are also used. These numbers are
shown on the Information Plate mounted on the engine.

Fuel setting information, engine arrangement, serial number, and the full
load rpm are printed on the Information Plate.

Fuel setting information numbers are also stored in the ECM module and
can be read by using Caterpillar electronic service tools.

Caterpillar dealers need all of these numbers to determine which

components were included on the engine when it was assembled at the
factory. This permits accurate identification of replacement part
numbers.
Serial Number Plate

Fig. 6: Serial Number Plate

The Serial Number Plate is located on the side of the cylinder block.
Information Plate

Fig. 7: Information Plate

The Information Plate is located on the valve cover or air inlet manifold.
Reference Numbers

Ordering Parts

Quality Caterpillar replacement parts are available throughout North

America and the rest of the world. Part stocks are up to date and include
all parts normally required to protect your investment in Caterpillar
engines.

When ordering parts, your order should specify the part number, part
name, quantity and serial number, arrangement number and
modification number of the engine for which the parts are needed. If
in doubt about the part number, please provide your dealer with a
complete description of the needed item.
When maintenance or repair is needed for your Caterpillar engine,
be prepared to give the dealer all the information that is provided on
the Information Plate (see Fig. 7 ).
Discuss the problem with the dealer, such as; when it occurs, what
happens, etc. This will help the dealer in troubleshooting and
solving the problem faster.

Fill in blanks for future reference.

Chassis Serial No.

Engine Model
Engine Serial No.

Engine Arrangement No.

Modification No.

Engine Low Idle RPM

Engine Full Load RPM

Engine Full Torque

Performance Specification No.

Governor Group No.

Fuel Filter No.

Primary Fuel Filter No.

Lubrication Oil Filter Element No.

Auxiliary Oil Filter Element No.

Liquid Supplemental Coolant Additive (Conditioner) Quantity

Supplemental Coolant Additive Maintenance Element No. (If
Equipped)
Air Cleaner Element No.

Fan Drive Belt Set No.

Alternator Belt No.

Lube System Capacity (Total)

Cooling System Capacity (Total)
ENGINE LIFTING AND STORAGE

Engine Lifting

CAUTION: When it is necessary to remove a

component on an angle, remember that the
capacity of an eyebolt is less as the angle
between the supporting members and the
object becomes less than 90 degrees. Eye
bolts and brackets should never be bent
and should only be loaded in tension.

Use a hoist to remove heavy components. Lift the engine by using an

adjustable lifting beam. All supporting members (chains and cables)
should be parallel to each other, and as near perpendicular as possible to
the top of the object being lifted.

Some removals require the use of lifting fixtures to obtain proper balance

and to provide safe handling. Lifting eyes are designed for the
arrangement as sold. Alterations to lifting eyes and/or arrangement
weight make the lifting devices inadequate and deficient. If you make
alterations, you are responsible for providing adequate lifting devices. To
remove the engine, use the two lifting eyes on the front and rear of the
engine.
Engine Storage

Special precautions should be taken for engines remaining out of service

for prolonged time periods.
The lubricating oil will drain from the cylinder walls and piston rings of
engines not started for several weeks. Rust can form on the cylinder liner
surface, which will increase engine wear and may result in shorter engine
life.

Check the cooling system for adequate protection against freezing (if
applicable). A 50/50 solution of Caterpillar (permanent-type) Antifreeze
and approved water will give protection to -37°C (-34°F).
Consult with the appropriate person(s) your Caterpillar dealer for
instructions to prepare your engine for longer storage periods.
SPECIFICATIONS
TORQUE SPECIFICATIONS

Torque for Standard Hose Clamps - Worm Drive Band Type

NOTE: The chart that follows gives the torque values for
initial installation of hose clamps on new hose and
for reassembly or tightening of hose clamps on
existing hose.

Fig. 8: Torque Values For Installation Or Reassembly Of Hose

Clamps
Torque for Constant Torque Hose Clamps Installation

To allow for maximum expansion, install clamps at 5.7 N.m (50 lb

in).
To allow for equal expansion and/or contraction, install clamps at

10.2 N.m (90 lb in).

To allow for maximum contraction, install clamps at 14.1 N.m (125
lb in).
COOLING SYSTEM SPECIFICATIONS

General Coolant Information

According to multiple sources in the industry, forty percent of all engine

failures are cooling system related. Many of these failures could be
avoided with proper cooling system maintenance. To maintain optimum
engine performance, it is imperative that engine coolant maintenance be
as important as the quality of fuel and lubricating oil. It is important that
this section be read carefully.

Coolant provides three main functions:

Cooling - to provide adequate heat transfer.
Corrosion protection - for cavitation erosion/corrosion protection.
Anti-boil/freeze protection.
Coolant is normally composed of three elements:

Water
Additives
Glycol
A brief discussion of each of these elements follows.
Water

CAUTION: Never use water alone without

Supplemental Coolant Additives (SCA's) or
inhibited coolant. Water alone is corrosive
at engine operating temperatures and does
not provide adequate boil protection!

Distilled or deionized water is recommended for use in cooling systems.

DO NOT use hard, tap water or salt softened tap water in engine cooling
systems. If distilled or deionized water is NOT available, use water that
meets the minimum acceptable requirements listed in the following chart.

Fig. 9: Minimum Acceptable Water

If you are not sure of your water's contents, contact your local water
department, agricultural agent, or an independent laboratory to analyze
the water.
Additives

Additives must be added to all coolant mixtures. Additives help prevent

rust, scale and mineral deposits from forming. Additives protect metals
from corrosion, prevent liner cavitation, and contain anti-foaming agents.
Additives deplete during engine operation and need to be replaced. This
is done through the addition of Supplemental Coolant Additives (SCAs)
or Extender.

Nitrites or nitrite and molybdate additives protect the cylinder liner from
cavitation corrosion. Nitrites deplete, creating the need for SCAs or
Extender. SCAs and Extender also contain other inhibitors that deplete
from cooling systems.
Under-concentration of additive levels will not provide the protection
required by the cooling system. Over-concentration can cause additives
to drop out of solution, deposit inside the cooling system or form a gel in
the radiator. Deposits can be in the form of sludge and scale. Deposits
accumulate on hot engine surfaces, reducing cooling system
effectiveness or causing the water pump to leak.

To maintain constant cooling system protection, it is necessary to

monitor or test for SCA. If levels are incorrect, action must be taken to
return the cooling system to the proper additive levels.
Glycol

The glycol in engine coolant is normally one of two varieties, ethylene or

propylene. Glycol raises the boiling point of water to help prevent boil-
over, provides freeze protection, helps prevent water pump cavitation and
reduces cylinder liner pitting. Caterpillar recommends a minimum of 30
percent glycol to 70 percent water for corrosion protection. All
Caterpillar engines with air-to-air after cooling (ATAAC) require a
minimum concentration of 30 percent glycol to prevent water pump
cavitation. While 30 percent glycol is the minimum acceptable volume
Caterpillar recommends, Caterpillar prefers a 50/50 glycol/water coolant

mixture for optimum performance.

Use the following charts to determine concentrations of engine coolant

concentrate to mix with acceptable water to provide the proper anti-
boil/freeze protection.

Fig. 10: Propylene Glycol & Water Concentrations

Fig. 11: Ethylene Glycol & Water Concentrations
Check the coolant solution at each oil change to ensure adequate anti-
boil/freeze protection. Use the 5P0957 (°F) or the 5P3514 (°C) Coolant
Tester. These testers give immediate, accurate readings and can be used
with ethylene or propylene glycol coolants.
Coolant Testing Program

Caterpillar's S.O.S Coolant Analysis is the best way to monitor the

condition of your coolant and your cooling system. The two-level
program is based on periodic samples.
Level I: Basic Coolant Maintenance Check

Recommended at every oil change or 250 hours.

Level I checks for correct chemical balance for proper heat and corrosion
control.

Level I analysis tests for:

glycol
SCA concentrations
pH
conductivity

Level I analysis provides a report of results, and makes

recommendations.
Level II: Comprehensive Cooling System Analysis

Completely analyzes coolant and coolant effects on the cooling system.

Recommended semi-annually or Every 1000 hours.

Level II analysis provides:

full Level I analysis

visual properties inspection
metal corrosion and contaminant identification
identification of built-up impurities that point to corrosion and
scaling problems BEFORE they lead to costly repairs.

Level II analysis provides a report of results, and makes

recommendations.
Caterpillar Coolant Recommendations

Most commercial engine coolant/antifreezes are formulated for gasoline

engine applications and have high silicate content. Caterpillar DOES
NOT recommend these antifreezes. Caterpillar recommendations are as
follows:

Preferred - Caterpillar Long Life Coolant/Antifreeze (LLCA).

Recommended - Caterpillar Diesel Engine Antifreeze/Coolant
(DEAC).
Acceptable - Any low silicate coolant that meets ASTM D4985
requirements when used with SCAs.
Unacceptable - ANY high silicate coolant that is classified as
meeting ASTM D3306.

NOTE: Due to individual engine applications,

maintenance practices may need periodic re-
evaluation to properly maintain the engine's
cooling system.

CAUTION: Never operate without thermostats in the

cooling system. Thermostats maintain the
engine coolant at the proper operating
temperature. Cooling system problems can
arise without thermostats.

CAUTION: For ambient temperatures requiring lower

freeze protection (higher than 50 percent
glycol), use ethylene glycol. DO NOT use

propylene glycol.

Caterpillar recommends that the coolant mixture contain a minimum of

30 percent glycol, 70 percent distilled or deionized water and additives.
While 30 percent glycol is the minimum acceptable volume, Caterpillar
prefers a 50/50 glycol/water coolant mixture for optimum performance.

CAUTION: Never add coolant water to an overheated

engine - engine damage can result. Allow
the engine to cool first. Do not add coolant
water too quickly. Filling the cooling system
at over 19 L (5 US gal) per minute can create
air pockets in the cooling system.

When filling or adding to the coolant to the system, premix the coolant
solution prior to pouring it into the cooling system. Pure undiluted glycol
will freeze at -23°C (-10°F). Use a mixture in a range which will provide
protection to the lowest expected outside (ambient) temperature and
provide the required boil-over protection.

When using Caterpillars coolant, no SCA Precharge is necessary. The

additives are in the coolant. When using commercial coolants meeting
ASTM D4985, the coolant must be precharged with SCA at initial fill
and SCA must be added at regular service intervals. Refer to Fig. 12 .

Fig. 12: Liquid Supplemental Coolant Additive Required By

Capacity
Caterpillar Long Life Coolant/Antifreeze (LLCA)

NOTE: The following information and recommendations

are for Caterpillar Long Life Coolant/Antifreeze
only.

Caterpillar provides Long Life Coolant/Antifreeze (LLCA) for use in

Caterpillar heavy duty diesel engines and automotive applications.
Caterpillar's LLCA has been specifically designed for cooling systems in
diesel and natural gas engines. LLCA's anti-corrosion package is totally
different from the standard antifreezes that have been in use. Caterpillar
LLCA is an ethylene glycol based antifreeze containing organic
corrosion inhibitors and anti-foam agents with fewer nitrites than other

coolants. LLCA has been formulated with the correct levels of these
additives to protect the aluminum parts in diesel engines.

LLCA extends coolant life to 6,000 service hours, 300,000 miles or four
years. LLCA does not require frequent SCA addition. A "one time only"
coolant "Extender" is the only maintenance addition required. The
Extender should be added to the cooling system at 3,000 service hours,
150,000 miles or two years.

Major advantages of Caterpillar LLCA:

improved corrosion protection

better aluminum protection
better liner protection
twice the coolant life
fewer additives mean less chemicals and no chemical fall out
longer radiator life
improves pump seal life
LLCA can be recycled. The drained coolant mixture can be "distilled" to
remove the ethylene glycol and water for reuse.

LLCA is available premixed 50/50 with deionized water, or in

concentrate, in the following quantities.

Fig. 13: Caterpillar LLCA Quantities Available

NOTE: LLCA concentrate is available to lower the freeze

point for arctic conditions. LLCA concentration
can be increased for lower operating temperatures
to 60 percent for -60°C (-76°F). DO NOT use LLCA
at reduced concentrations (less than 50 percent),
since the additives would be reduced along with
the antifreeze.
Long Life Coolant Extender

LLCA Extender is a liquid that is poured into the cooling system halfway
through the LLCA service life.

NOTE: Depletion of additives in LLCA is a function of

operating time. For engine applications with low

operating miles or hours, Extender may not have
to be added at the "Every Two Years" interval. The
Extender may not be required during the "Every
Four Years" interval for applications with very low
operating hours.

The cooling system should be treated with Extender at the 3,000 service
hour interval, 150,000 miles or one-half the LLCA service life. A 15
percent over or under treatment will not create problems within the
cooling system. Use Fig. 14 to determine the recommended amount of
Extender to add to LLCA.

Fig. 14: Recommended Amount Of Extender By Cooling System

Capacity
Cooling System Maintenance When Using LLCA

CAUTION: Mixing LLCA with other products reduces

the effectiveness of the coolant and
shortens coolant life. Mixing LLCA with
other products can result in damage to
cooling system components. Use only
Caterpillar products or commercial products
that have passed the CAT EC-1 specification
for pre-mixed or concentrate coolants. Use
only Caterpillar Extender with LLCA. Failure
to follow these recommendations can result
in shortened cooling system component
life.

Due to the balance of antifreeze and additives, care should be taken to

maintain the proper LLCA concentration. Lowering the proportion of
antifreeze lowers the proportion of additive, thus lowering the coolant's
ability to protect the system from pitting, cavitation, erosion, and
deposits.

NOTE: No cleaning agents are to be used when a system

ALREADY using LLCA is drained, flushed, and
refilled.

CLEAN WATER is the only system cleaning/flushing agent required

when LLCA is drained from the cooling system.

After draining and refilling the cooling system, operate the engine with
the radiator filler cap removed until the coolant reaches normal operating
temperature and coolant level stabilizes. Add coolant mixture as
necessary to fill the system to the proper level.
Make Proper LLCA Additions

NOTE: DO NOT add concentrated LLCA as a makeup

solution for cooling system top-off unless freeze
protection is needed for arctic conditions. Adding
concentrated LLCA increases the concentration of
glycol in the cooling system.

During normal maintenance, use pre-mixed LLCA as a top-off to the

system to bring the coolant up to the proper level. Use LLCA or a
coolant that meets Caterpillar's EC-1 specification. If a coolant that meets
EC-1 is not available, use distilled or de-ionized water as a make-up.
Check the system's glycol level with the 5P0957 (°F) or the 5P3514 (°C)
Coolant Tester. Use LLCA Concentrate to restore the proper glycol
concentration before the engine is exposed to freezing temperatures.

CAUTION: Do not use conventional coolant to top-off a

cooling system using LLCA.

Do not use SCA's in cooling systems using

LLCA.

If the LLCA cooling system has been topped-off with a small amount of
conventional coolant or if SCA was added to the system by mistake, the
system will not be harmed. However, additions of conventional coolant
or repeated additions of SCA's will compromise the system's long life
properties.

Should the system become contaminated with conventional coolant or

SCA exceeding 10 percent of the system's total capacity, either drain the
system and refill with LLCA or maintain the system with conventional
coolant. Continue treating with SCA and change the coolant at the
intervals recommended for conventional coolant.

Changing the Cooling System From Conventional Coolant To Caterpillar LLCA

NOTE: When the coolant is switched from conventional

coolant to LLCA, Caterpillar cleaner should be
used. Refer to Fig. 19 for quantities available. After
the use of Caterpillar cooling system cleaners, the
system MUST be thoroughly flushed with clean
water.

To switch from conventional coolant to LLCA, perform the following

steps:

1. Drain the coolant.

2. Flush the system with clean water to remove any debris.
3. Use Caterpillar cleaner to clean the system. Follow the instructions
on the label.
4. Drain the cleaner, and flush the cooling system with clean water.
5. Fill the cooling system with clean water and operate the engine until
the temperature is 49° to 66°C (120° to 150°F).
6. Drain and flush the cooling system with clean water.
7. Repeat steps five and six.
8. Fill the cooling system with LLCA. Refer to Fig. 38 for the
necessary amounts to refill your system.
9. Attach the PEEP5027 Label to the cooling system to indicate the
system has been switched over to LLCA.
Conventional Diesel Engine Antifreeze/Coolant (DEAC) Information

NOTE: The following information and recommendations

are for Caterpillar DEAC only.

Caterpillar DEAC has been specifically designed for cooling systems in

diesel and natural gas engines. Caterpillar DEAC is an alkaline type,
ethylene glycol based antifreeze containing inorganic corrosion inhibitors
and anti-foam agents. Caterpillar DEAC has been formulated with the
correct levels of these additives to protect metal parts in diesel engines. It
has minimal silicate content and helps reduce the buildup of solid
residues in the cooling system that cause inhibitor dropout and water
pump seal damage. It will furnish adequate corrosion, anti-foam and
cylinder liner/block pitting protection at 30 percent volume solution in

water.

Major advantages of Caterpillar DEAC:

Significantly reduces water pump seal leakage problems caused by

excessive concentration of chemical additives.
There is no need to add SCA on initial fill, which must be done with
other commercially available antifreezes.
Caterpillar DEAC is formulated with a low silicate content. High
silicate antifreezes, used with a supplemental coolant additive, can
cause a build-up of solids over a period of time. Build-up of solids
can cause plugging, loss of heat transfer, and water pump seal
damage.

Caterpillar DEAC is available in the following quantities:

Fig. 15: Caterpillar Antifreeze/Coolant Concentrate

Proper Antifreeze Concentrations

Use the following chart to determine concentrations of Caterpillar

Antifreeze to mix with acceptable water.

Fig. 16: Antifreeze Concentrations (Glycol)

Supplemental Coolant Additive (SCA)

WARNING: Supplemental cooling system additive

contains alkali. To prevent personal injury,
do not drink, avoid contact with the skin
and eyes.

CAUTION: The cooling system MUST contain

supplemental coolant additive (SCA) for
proper engine protection, regardless of
antifreeze concentration.

CAUTION: DO NOT mix Caterpillar SCA or coolant

additive elements with another
manufacturer's products: select a cooling
system treatment and use it exclusively.

SCA is necessary for proper engine maintenance. Most coolant solutions

DO NOT contain sufficient SCA for diesel application.

CAUTION: Do not exceed the recommended six

percent SCA concentration. Excessive SCA
concentration can form deposits on the
higher temperature surfaces of the cooling
system, reducing the engine's heat transfer
characteristics. Reduced heat transfer could
cause cracking of the cylinder head and
other high temperature components.
Excessive SCA concentration could also
result in radiator tube blockage,
overheating, and/or accelerated water pump
seal wear. Never use both liquid SCA and
the spin-on element (if equipped) at the
same time. The use of those additives
together could result in SCA concentration
exceeding the recommended six percent
maximum.

Use liquid SCA or a supplemental coolant additive element (if equipped)

to maintain a three to six percent SCA concentration in the coolant.

NOTE: Caterpillar Test Kits check for concentration of

nitrites in the coolant solution. Some
manufacturers' SCA are phosphate based.
Caterpillar Test Kits provide inaccurate results
with phosphate based SCA. Commercial SCA
products must contain silicates and a minimum of
1200 mg/L or 1200 ppm (70 grains/1 US gal)
nitrites. If another manufacturer's SCA is used, use
that manufacturer's test kit. Follow the
manufacturer's recommendation for cooling
system treatment and test evaluation.

Test the coolant at each oil change to monitor SCA levels. Use the
4C9301 Test Kit to check for and maintain the concentration level of
Caterpillar SCA. The kit determines SCA level and gives maintenance
recommendations for cooling systems. This kit is specifically for use

with Caterpillar SCA's. OR use the 8T5296 Test Kit to check for and
maintain the concentration level of Caterpillar SCA.

The following charts lists the part numbers and quantities of SCA's
(liquid and solid) available. Follow the instructions on the label.

Fig. 17: Liquid Supplemental Coolant Additive Required By

Capacity

Fig. 18: Supplemental Coolant Additive Elements Required By

Capacity
Water Only Cooling Systems

CAUTION: Never use water alone without SCAs or

inhibited coolant.

NOTE: A coolant mixture of water and SCA will cool and

provide some protection to engine components,
but it will NOT provide normal engine service life.

NOTE: Caterpillar recommends a minimum concentration

of 30 percent antifreeze, deionized or distilled
water and SCA for cooling systems to maintain
corrosion protection.

In applications where freeze protection is not required, or where

antifreeze is not available, a coolant mixture of acceptable water and
SCA can be used. When maintaining a water/SCA system, SCA
concentration should be maintained at six to eight percent maximum. DO
NOT exceed eight percent maximum concentration. SCA concentration
levels must be monitored.

The 8T5296 Test Kit can be used to evaluate the SCA concentration of
water-only coolant with the following modifications to label instruction
Step 3 and Step 5.

STEP 3. - Add tap water to the vial up to the 20 ml mark.

STEP 5. - With the defined procedure, the six to eight percent

concentration will yield a 20 to 27 drop range. Fewer drops indicate
under-concentration of SCA and more drops indicate over-concentration.

Adjust the concentration appropriately.

If the SCA concentration is greater than the maximum of eight percent:

drain some of the coolant, refill the system with acceptable water, and re-
test the concentration level.
Initial Fill

SCA is pre-mixed in Caterpillar DEAC. Caterpillar DEAC DOES NOT

require that SCA's be added at initial fill. SCA's are required on a
maintenance basis. For engines equipped with supplemental coolant
additive elements, the last MAINTENANCE element should NOT be
replaced at FLUSH & FILL or Overhaul until the next oil change
interval. This procedure prevents over-concentration of SCA.

SCA's are required when using products other than Caterpillar's

Antifreeze on initial fill, and for subsequent maintenance. If Caterpillar
Antifreeze is NOT used on initial fill of a new or reconditioned engine,
add .95 L (1 qt) of SCA or equivalent for each 19 L (5 US gal) of
antifreeze solution. The coolant should have a three to six percent
concentration of SCA.
Maintenance

Maintaining the cooling system is important because the cooling system

has a direct effect on the operation and service life of the engine.
Improper maintenance can cause a variety of problems which could
reduce engine performance and service life.

Check the antifreeze solution frequently in cold weather to ensure

adequate freeze protection. Test the concentration to monitor the SCA
concentration in your engine's coolant mixture at every oil change. SCA
or a maintenance additive element (if equipped) may be needed at Every
250 Service Hours.

CAUTION: To prevent over-inhibiting the engine's

cooling system, NEVER use both the
supplemental coolant additive AND the
supplemental coolant additive element (if
equipped) at the same time. Use one
method or the other exclusively.

When using Caterpillar DEAC and SCA, the cooling system should be
drained, cleaned and flushed, and new coolant added Every Two Years.
Refer to Every Two Years .
When NOT using Caterpillar DEAC and SCA, the drain/flush period
must be performed at least Every Year.

After draining and refilling the cooling system, operate the engine with
the radiator filler cap removed until the coolant reaches normal operating
temperature and the coolant level stabilizes. Add coolant mixture as
necessary to fill the system to the proper level.
If the engine is NOT equipped with a spin-on element, add 0.25 L (0.5
pt) of SCA for each 19 L (5 US gal) of coolant capacity to maintain the
three to six percent SCA concentration.
Cooling System Cleaning

Draining, cleaning and flushing the cooling system removes small

particles, undesirable chemicals, scale, and other deposit formations. Not
performing maintenance on the cooling system can eventually cause
engine overheating problems that could result in severe damage to the
engine and its components.

NOTE: Clean the cooling system if it becomes

contaminated, the engine overheats, or foaming is
observed in the radiator.

Caterpillar Cooling System Cleaners are designed to clean the system of

harmful scale and corrosion. Cleaners dissolve mineral scale, corrosion
products, light oil contamination, and sludge.
Cooling system cleaners are available in the quantities listed below.
Refer to Drain/Clean/Replace Coolant , and follow the product label
directions for proper usage.

Fig. 19: Caterpillar Cooling System Fast Acting Cleaner

FUEL SPECIFICATIONS

Fuel Recommendations

CAUTION: Fill the fuel tank at the end of each day of

operation to drive out moist air and prevent

condensation. Maintain a fairly constant
level in the day tank (near the top) to avoid
drawing moisture into the tank as the level
decreases.
Do not fill the tank to the top. Fuel expands
as it warms, and may overflow.
Do not fill fuel filters with fuel before
installing them. Contaminated fuel causes
accelerated wear to fuel system parts.

Use fuel only as recommended in this section. The fuel recommended for
use in Caterpillar electronic diesel engines is: No. 2-D diesel fuel with
low sulfur (0.05 percent maximum). No. 1 grades are acceptable.
The following chart lists worldwide fuel standards which meet
Caterpillar requirements.

Fig. 20: Worldwide Fuel Specifications - Diesel Engines

Caterpillar Diesel Engines are capable of burning a wide range of
distillate fuels. Burning clean, stable blends of distillate fuel meeting the
following requirements will provide quality engine service life.

Fig. 21: Distillate Fuel Recommendations - Diesel Engines

NOTE: When economics or fuel availability dictate, other

fuel types may be burned in the engine. Consult
the appropriate person(s) for more information and
advice on any specific fuel.
Cetane Number

Under average starting conditions, direct injection engines require a

minimum cetane number of 40. A higher cetane value may be required
for high altitude or cold weather operation.
Filterability

Clean fuels should have no more than 0.1 percent of sediment and water.
Fuel stored for extended periods of time may oxidize and form solids,
causing filtering problems.

Pour Point

Fuel pour point should be at least 6°C (10°F) below the lowest ambient
temperature at which the engines must start and operate. Lower pour
points of No. 1 or No. 1-D fuel may be necessary in extremely cold
weather.
Cloud Point

The cloud point should be below the lowest ambient temperature at

which the engines must start and operate, to prevent the fuel filter
elements from plugging with wax crystals. Refer to Cold Weather
Operation for additional information.
Viscosity

Fluid viscosity is a measure of resistance to flow. Fuel viscosity is

important because it effects lubrication of fuel system components, and
fuel atomization. The provided viscosity limits address both of those
effects.
Additives

Fuel additives are generally not recommended or needed for the specified
fuels listed. Cetane improvers can be used as necessary for direct
injection engine requirements. Biocides may be needed to eliminate
microorganism growth in storage tanks. In cold conditions, treatment for
entrained water may also be necessary.

Consult your fuel supplier about the use of additives to prevent

incompatibility among additives already in the fuel and the additives to
be used.
Fuel Sulfur

The percentage of sulfur in fuel affects engine oil recommendations. Fuel

sulfur can change chemically during combustion, forming both sulfurous
and sulfuric acids. The acids attack metal surfaces and cause corrosive
wear. Sulfur oxides formed during combustion also produce particulate
exhaust emissions.

Some lubricating oil additives contain alkaline compounds to neutralize

acids in combustion gases and minimize corrosive wear. Reserve
alkalinity in lubricating oil is measured and defined with a Total Base

Number (TBN).

Periodically request fuel sulfur content information from your fuel

supplier. Fuel sulfur content can change with each bulk delivery.

More information concerning fuel sulfur and lubrication can be found in

Lubricant Specifications .
LUBRICANT SPECIFICATIONS

General Information

Caterpillar recognizes and supports the American Petroleum Institute

(API) "Engine Oil Licensing and Certification System" for engine oils.
The API publication No. 1509, 13th edition, contains the detailed
information concerning this system. Engine oils bearing the API symbol
are licensed by the API.

Fig. 22: Examples Of The API Symbol

Diesel engine oil classifications CD, CD-2 and CE will not be API
licensed categories after January 1, 1996. Caterpillar will only reference
those categories that are licensed by the API. The following chart
summarizes the status of the categories.

Fig. 23: Oil Classification Status

Engine Lubricant Specifications

Caterpillar Oil

Caterpillar Oils have been developed, tested, and approved by Caterpillar

to provide the performance and life that has been designed and built into
Caterpillar diesel truck engines. Caterpillar Oils are used for engine
development and factory fill. Due to significant variations in the quality
and performance of commercially available oils, Caterpillar recommends
the following.
Caterpillar Diesel Engine Oil (DEO) (multi-grade)

Caterpillar recommends the use of multi-grade oils in all on-highway

truck engines.

Caterpillar DEO multi-grade oils are formulated with detergents,

dispersants, and sufficient alkalinity to provide superior performance in

Caterpillar diesel truck engines. DEO multi-grade oils are blended in two
viscosity grades: SAE 10W30 and SAE 15W40. Refer to Fig. 25 to
choose the correct viscosity grade based on ambient temperatures. Multi-
grade oils provide the correct viscosity for a broad range of operating
temperatures and for cold engine starts. Multi-grade oils are also
effective in maintaining low oil consumption and low levels of piston
deposits.

Caterpillar DEO multi-grade oils are also qualified for use in other diesel
engines and in gasoline engines. Consult the engine manufacturer's guide
for the recommended specifications, and compare to the specifications of
Caterpillar DEO multi-grade. The current Caterpillar DEO industry
specifications are listed on the label and on the product data sheets.
Commercial Diesel Engine Oils

The performance of commercial diesel engine oils are based on API

categories. These API categories are developed to provide commercial
lubricants for a wide variety of diesel engines that operate at various
conditions.

If Caterpillar DEO (multi-grade) is not used, the following commercial

oils are recommended.
API CF-4 Allowed

API CG-4 oils are preferred for Caterpillar on-highway truck engines
because of the fuel sulfur level. Since October 1, 1993, all USA on-
highway truck diesel fuel has been regulated to a maximum of 0.05
percent sulfur. API CG-4 is the only oil category that evaluates oils with
engine tests utilizing 0.05 percent sulfur fuel.

The following explanations of these API categories can be used to make

the proper choice of a commercial oil.

CG-4: This is the newest oil category. CG-4 oils were primarily
developed for diesel engines that are operating on 0.05 percent sulfur
diesel fuel. All of the laboratory engine tests for this category were run
with 0.05 percent sulfur diesel fuel. This category also defines oils that
have superior soot dispersancy. CG-4 oils will provide improved
viscosity control and improved crankcase cleanliness in applications

where oil soot is a problem. CG-4 oils should also be used in engines that
contain hydraulically actuated fuel injection pumps; these are the first
oils to pass industry tests for foam control and viscosity shear loss. CG-4
oils must also pass recently developed tests for metals corrosion, and
wear. CG-4 oils can be used in all Caterpillar engines where CF-4 oils
are recommended.

CF-4 oils service a wide variety of modern diesel engines. This oil
classification was developed with 0.40 percent sulfur diesel fuel. The
fuel used in the CF-4 tests represents the type of diesel fuels commonly
available world wide. CF-4 oils provide improved piston deposit control
and improved oil control when compared to the CE category oils. CF-4
oils also provide improved soot dispersancy compared to CD or CF
category oils.

Some commercial oils meeting these API specifications may require

shortened oil change intervals as determined by close monitoring of oil
condition and wear metals (Caterpillar S.O.S Oil Analysis Program
preferred).

CAUTION: Failure to follow these oil recommendations

can cause shortened engine life due to
deposits and/or excessive wear.
Total Base Number (TBN) and Fuel Sulfur Levels for Caterpillar Direct Injection (DI) Diesel
Engines

The TBN for a new oil is dependent on the sulfur level of the fuel used.
For direct injection engines running on distillate diesel fuel, the
minimum new oil TBN (by ASTM D 2896) must be 10 times the fuel
sulfur level, and the minimum TBN is 5 regardless of sulfur level, see
Fig. 24 .

Fig. 24: TBN Vs. Fuel Sulfur For Caterpillar DI Diesel Engines
In areas where the fuel sulfur exceeds 1.5 percent, choose an oil with the
highest TBN that is within the API CF-4 or CG-4 categories, and shorten
the oil change period based on oil analysis. The oil analysis should
evaluate oil condition and wear metals. High TBN oils that are not within
the API CF-4 or CG-4 categories can produce excessive piston deposits
leading to a loss of oil control and bore polishing.

CAUTION: Operation at fuel sulfur levels over 1.5

percent may require shortened oil change
periods to maintain adequate wear
protection.
Lubricant Viscosity Recommendations

The proper SAE viscosity grade oil is determined by the minimum

outside temperature at cold engine start up, and the maximum outside
temperature during engine operation. Use the minimum temperature
column on the chart to determine the oil viscosity required for starting a
"cold soaked" engine. Use the maximum temperature column on the
chart to select the viscosity for operation at the highest temperature
anticipated. In general, use the highest viscosity oil available that still
meets the start up temperature requirements.

Fig. 25: Engine Oil Viscosity Protection

Synthetic Base Stock Oils

Synthetic base stock oils are acceptable for use in Caterpillar engines and
machines if these oils meet the performance requirements specified by
Caterpillar for a particular compartment.

Synthetic base stock oils generally outperform non-synthetics in two

areas:

1. Improved low temperature viscosity characteristics, especially in

Arctic conditions.
2. Improved oxidation stability, especially at high operating
temperatures.
Some synthetic base stock oils have performance characteristics that
enhance the useful life of the oil. However, Caterpillar does NOT
recommend the automatic extension of oil drain intervals for any oil,
including synthetic base stock oils. For Caterpillar diesel engines, oil
drain intervals can only be adjusted through an oil analysis program that
contains the following elements: oil condition and wear metals
(Caterpillar S.O.S Oil Analysis preferred), trend analysis, fuel
consumption, and oil consumption.
Re-Refined Base Stock Oils

Re-refined base stock oils are acceptable for use in Caterpillar engines
and machines if these oils meet the performance requirements specified
by Caterpillar for a particular compartment. Re-refined oils can be used
exclusively in a finished oil or in combination with new base stocks. The
US Military and other heavy equipment manufacturers have also
accepted the use of re-refined base stock oils with the same criteria.
The re-refining process should be adequate to remove all wear metals
and oil additives that were present in the used oil. This type of re-refining
is generally accomplished by vacuum distillation and hydrotreating the
used oil. Filtering alone is inadequate for producing a high quality re-
refined base stock from used oil.
After-Market Oil Additives

Caterpillar does NOT recommend the use of after-market oil additives.

After-market oil additives are not necessary to achieve life predictions or
to achieve rated performance. Fully formulated finished oils are made up
of base stocks and commercial additive packages. These additive
packages are blended into the base stocks at precise percentages to
provide finished oils with performance characteristics that meet lubricant
industry standards.

Lubricant industry standard tests do not exist to evaluate the performance

of after-market oil additives. There are also no lubricant industry
standard tests to evaluate the compatibility of these after-market
additives in a finished oil. After-market additives could be incompatible
with the finished oil additive package, and lower the performance of the
finished oil. The after-market additive could fail to mix with the finished
oil, and produce a sludge in the crankcase. Caterpillar discourages the
use of after-market additives in finished oils.

To achieve all the performance that was built into a Caterpillar engine,
follow these guidelines:

Select the proper Caterpillar oil or commercial oil that meets the
compartment specifications.
Select the proper oil viscosity based on Fig. 25 .
Service the engine at the specified interval with new oil and oil
filter.
Perform maintenance at the intervals specified by Maintenance

Schedule .
Caterpillar Lubricating Grease

The National Lubricating Grease Institute (NLGI) classifies grease,

based on ASTM D217-68 Worked Penetration characteristics. Grease
characteristics are given a defined consistency number.

Caterpillar has grease and lubricants for all applications.

Fig. 26: Caterpillar Lubricating Grease

Caterpillar Specialty Lubricants

Fig. 27: Caterpillar Specialty Lubricants

OPERATION
GAUGES

Refer to Truck Owners Manual for information on the layout of your

gauge package. Gauges provide a "look" inside the engine. Be sure they
are in good working order. Determine what is the "normal" operating
range by observing your gauges over a period of time.
Noticeable changes in gauge readings are an indicator of potential gauge
or engine problems. This also applies to gauge readings that have
changed significantly but are still within specifications. The cause of any
sudden or significant change in the readings should be determined and
corrected.
Caterpillar Electronic engines require one lamp in addition to the gauge
package normally provided.

The CHECK ENGINE/DIAGNOSTIC lamp is yellow/amber. The

purpose of the CHECK ENGINE/DIAGNOSTIC (YELLOW) lamp is to
communicate status of the engine's electronic system.

An optional red WARNING lamp is available. The purpose of the

WARNING (RED) lamp is to warn the driver of engine problems such as
low oil pressure, high coolant temperature, low coolant level or high inlet
air temperature.

CAUTION: If no oil pressure is indicated, STOP the

engine. Engine damage can result.

Fig. 28: Instrument Cluster Indicator Lamp Explanations

ENGINE DIAGNOSTICS

Self-Diagnostics

Caterpillar Electronic Truck Engines have self-diagnostic capability.

When the system detects a problem, the CHECK
ENGINE/DIAGNOSTIC (YELLOW) lamp activates. In most cases a
diagnostic code will be stored in permanent memory within the ECM.
The diagnostic code can be retrieved by using either the:

Caterpillar Electronic Tool, or

CHECK ENGINE/DIAGNOSTIC lamp.

Some trucks have electronic dashboards that provide a direct readout of

engine diagnostic codes. Follow the truck manufacturer's instructions to
retrieve engine diagnostic codes if equipped with an electronic dash
display.
Check Engine/Diagnostic Lamp

The CHECK ENGINE/DIAGNOSTIC (YELLOW) lamp on the truck

dashboard is used to communicate the status or operation situations of
the electronic engine and control system.

When the ignition key is turned ON, the YELLOW lamp will illuminate
for five seconds (as a lamp check). The lamp will also illuminate and
blink every five seconds whenever the ECM detects an ACTIVE fault or
condition. If the lamp comes ON and continues to blink every five
seconds after initial start-up, the ECM has detected a system problem.

The YELLOW lamp is also used for the Idle Shutdown Timer. The lamp
will start to flash at a rapid rate 90 seconds before the programmed idle
time expiration is achieved. The engine will shut down after the 90
second interval. To disable the Idle Shutdown Timer, the ALLOW IDLE
SHUTDOWN OVERRIDE must be programmed to YES. The clutch
pedal or service brake pedal must be depressed during this final 90
seconds (YELLOW lamp flashing). A diagnostic event Code, Override
of Idle Shutdown Timer, will be logged on the ECM.

Diagnostic Flash Code Retrieval

CHECK ENGINE/DIAGNOSTIC Lamp in Cab

NOTE: The following procedure can be used to determine

active codes (a constantly flashing lamp indicates
an active code), or any codes which occur after the
engine is started. The procedure cannot be used to
get LOGGED codes which occurred before the
ignition switch was turned on (i.e. from yesterday
or a week ago). A Caterpillar electronic service tool
is necessary to retrieve those logged codes.

All active codes may be viewed using a Caterpillar electronic tool or by

performing the following procedure.

1. Turn the Cruise Control ON/OFF switch OFF.

2. Move the SET/RESUME switch to either position. Hold that
position until lamp begins to flash.

The YELLOW lamp will flash to indicate a 2-digit flash code and the
Cruise Control switch may be released. The sequence of flashes
represents the system diagnostic message. Count the first sequence of
flashes to determine the first digit of the diagnostic code. After a two
second pause, the second sequence of flashes will identify the second
digit of the diagnostic code.

Any additional diagnostic codes will follow (after a pause) and will be
displayed in the same manner. Flash Code 55 signals No Detected Faults
have occurred since the ignition key switch was turned ON.

The following chart lists and describes electronic diagnostic codes.

NOTE: The chart indicates the potential effect on engine

performance with active flash codes.

Fig. 29: Diagnostic Flash Code/Engine Performance Relationship

Some codes record an event rather than a response to a performance
problem. Troubleshooting is not required for codes 35, 41, 47 and 55.
Code 01 will not flash out. Some codes will limit operation or
performance of the engine. Refer to Fig. 29 for these codes.

Operation with Intermittent Diagnostic Codes

If the YELLOW lamp illuminates during engine operation and then shuts
off, an intermittent fault may have occurred. Intermittent faults are
logged into the permanent memory of the ECM.

In most cases it is not necessary to stop the engine and vehicle because of
an intermittent code, however we recommend the operator retrieve the
code(s) and reference the chart to identify the nature of the event. The
operator should note or document the circumstances (low power,
vehicle/engine speed limits, excessive smoke, etc.) involved during the
time the lamp was ON. Documentation may be useful for future
reference, and in helping troubleshoot the situation.
Engine Operation with Active Diagnostic Codes

If the YELLOW lamp stays ON during normal engine operation, first

check to ensure that the engine has proper oil pressure, coolant
temperature and coolant level. If the engine has the proper oil pressure
and the YELLOW lamp is ON, this indicates that the system has
identified a situation that is not within specification.
To retrieve the code(s), refer to Fig. 29 and follow the Suggested Driver
Action (i.e., Shut Down Engine/Vehicle, Service ASAP or Schedule
Service) provided.

NOTE: If low engine oil pressure occurs and the Engine

Monitoring Package mode is programmed to
DERATE, the electronic system will limit the
maximum engine rpm that can be obtained until
the oil pressure problem is corrected. If oil
pressure is registering in the normal range, it is
permissible to operate the engine.

The ACTIVE code should be investigated and corrected as soon as

possible. Repairing the cause of the code will shut the lamp OFF (if there
is only one ACTIVE CODE).
Engine Monitoring Package

This programmable feature monitors:

engine coolant temperature

oil pressure
inlet manifold air temperature
coolant level (if equipped with the sensor supplied by the OEM).

WARNING: If the Shutdown Mode has been selected

and the warning indicator activates, engine
shutdown may take as little as 20 seconds
from the time the warning indicator is
activated. If possible, the vehicle should be
steered carefully off of the roadway and
brought to a stop. The vehicle can be
restarted following shutdown if necessary
for emergency maneuvers.

CAUTION: The Engine Monitoring Package is NOT a

guarantee against catastrophic failures.
Programmed delays and derate schedules
are designed to minimize false alarms and
provide time for the driver to bring the
vehicle to a stop.
Customer Specified Parameters

Customer Specified Parameters can be programmed into the ECM to

enhance fuel efficiency and operator convenience. Some parameters may
affect engine operation and lead to driver complaints about power or
performance, even though the engine is performing to specification.

These parameters allow the owner/customer to influence how the vehicle

is driven. The parameters can be changed as often as needed. Password
protection enables the owner/customer to control the options and who
can change the parameters.
Caterpillar Driver Information Display

The Caterpillar Driver Information Display (Cat ID) can display a variety
of engine and vehicle information. The features of the Cat ID are briefly
described below.
Diagnostic Data

The Cat ID provides diagnostic codes, with both number and a brief text

explanation. These codes, indicating a potentially serious engine

problem, are displayed automatically by Cat ID.
Engine Operating Information

The Cat ID provides information on cruise control set speed, PTO engine
rpm set speed, fuel temperature to the engine, boost and oil pressure, and
coolant temperature.
Vehicle Trip Information

The Cat ID provides information on fuel economy, fuel consumption,

average vehicle speed, idle time, PTO time, idle fuel, and PTO fuel. All
of this information can be tied to the trip segments or the engine history.
Maintenance Information

The last oil and filter change can be entered, allowing the display to
indicate when the next oil and filter change is due.
ENGINE STARTING

Perform required Daily maintenance before starting the engine.

Starting the Engine

WARNING: DO NOT USE ETHER (starting fluids)

unless specifically instructed to do so. The
use could result in engine damage and/or
personal injury. When using starting fluid,
follow the manufacturer's instructions
carefully, use it sparingly and spray it
ONLY WHILE CRANKING THE ENGINE.
Excessive ether can cause piston and ring
damage. Use ether for cold weather starting
purposes only.

Startability will be improved at temperatures below 0°C (32°F) by the

use of a cylinder block coolant heater or other means to heat the
crankcase oil. This will help alleviate white smoke and misfire during
cold weather start-up.

If the vehicle/engine is equipped with a starting fluid (ether) injection

system, begin cranking the engine and depress the ether switch and hold

for three seconds before release. Additional injections may be necessary

to start and/or achieve low idle speed.
Start the engine using the following procedure.

1. Engage the Parking Brake. Place the transmission in NEUTRAL.

Depress the clutch pedal to disengage the flywheel clutch. This
reduces transmission drag and prevents movement of the truck.
Depressing the clutch pedal also reduces battery drain and can mean
the difference between starting and not starting in cold weather.
2. Turn the ignition switch (key) to the ON position.
3. Push the start button or turn the ignition switch (key) to the START
position to crank the engine.

Depressing the throttle while cranking provides no benefit. The

system will automatically provide the correct amount of fuel to
start the engine.
The YELLOW Lamp will flash as a system check. If the lamp fails
to flash while the engine is cranking, notify the appropriate person
(s). If the lamp continues to flash after starting, the ECM has
detected an engine system problem.

4. If the engine fails to start within 30 seconds, release the start

button/ignition switch and wait two minutes to allow the starting
motor to cool before attempting to start the engine again.

CAUTION: Oil pressure should rise within 15

seconds after the engine starts. Do not
increase engine speed until the oil
pressure gauge indicates normal. If oil
pressure is not indicated on gauge
within 15 seconds, DO NOT drive the
truck. STOP the engine, investigate and
correct the cause.

5. Allow the engine to idle about three minutes, or until the water
temperature gauge begins to rise. Check all gauges during the warm-
up period.
Starting Problems

Occasional starting difficulty may be caused by a low battery charge,

lack of fuel, or a wiring harness problem. If those problems are
suspected, perform the appropriate following procedure to start the
engine.
Jumper Cables

WARNING: Improper jumper cable connections can

cause an explosion resulting in personal
injury.
Prevent sparks near the batteries. Sparks
could cause vapors to explode. Do not
allow jumper cable ends to contact each
other or the engine.

CAUTION: When boost starting an engine, follow the

instructions below to properly start the
engine. This engine may be equipped with a
12 or 24 volt starting system. Use only equal
voltage for boost starting. The use of higher
voltage will damage the electrical system.
When using jumper cables always connect
POSITIVE (+) cable to POSITIVE (+) terminal
of battery which is connected to starter
solenoid and NEGATIVE (-) cable from
external source to starter NEGATIVE (-)
terminal. If NOT equipped with a starter
NEGATIVE (-) terminal, connect to the
engine block.
Do not reverse the battery cables. The
alternator can be damaged. Attach ground
cable last and remove first.

1. Turn the START switch OFF. Remove the key and turn all electrical
accessories OFF before attaching cables.
2. Connect one end of the POSITIVE (+) cable to the POSITIVE (+)
terminal of the battery being started. Connect the other end to the
POSITIVE (+) terminal of the power source.
3. Connect one end of the NEGATIVE (-) cable to the NEGATIVE (-)
terminal of the power source. Connect the other end to the starter

NEGATIVE (-) terminal or to the engine block. This prevents

potential sparks from igniting combustible gases produced by some
batteries.
4. Allow sufficient time to partially charge the truck batteries. The
engine will not continue to run after starting if the truck batteries do
not have a partial charge.
5. Start the engine. After the engine starts, disconnect the cable from
the starter NEGATIVE (-) terminal or engine block. Disconnect the
other end from the NEGATIVE (-) terminal of the power source.
6. Disconnect the cable from the POSITIVE (+) terminal of the battery
on the engine being started. Disconnect the cable from the
POSITIVE (+) terminal of the power source.
After the Engine Runs Dry of Fuel

If the engine fuel system is run dry, fill the fuel tank and perform the
following special priming procedure.

CAUTION: Do NOT loosen fuel lines at the fuel

manifold or ECM. The engine components
may be damaged.

NOTE: DO NOT remove the fitting in the fuel filter base to

release air from the fuel system while priming.
Periodic removal of the fitting will result in
increased wear of the threads in the fuel filter base
and lead to fuel leakage.

Fig. 30: Locating Fuel Block (1) & Air Bleed Plug (2) (3176B, C-10,
and C-12 Engines)

Fig. 31: Locating Fuel Block (1) & Air Bleed Plug (2) (3406E Engine)
1. Locate the fuel block (1). Loosen the air bleed plug (2) two full
turns. Unlock and operate the priming pump plunger until fuel
appears at the plug fitting. A considerable number of pump strokes
may be required to fill the fuel lines and the fuel filter. Clean up
excess fuel immediately.

NOTE: The priming pump may be remote mounted in

some applications.

NOTE: The fuel block is located either on top of the

fuel filter mounting base or on the engine
block.

2. Tighten the air bleed plug. Continue to operate priming pump until a
strong resistance is felt, and listen for an audible "click" from the
fuel block. The "click" indicates the valve has opened and the
system is pressurized. Lock the handle on the fuel priming pump.
3. Crank the engine. If the engine starts, but runs rough, continue to
run the engine at low idle until the engine runs smoothly.

CAUTION: Do not crank the engine for more than 30

seconds. If the engine does not start, allow
the starting motor to cool for two minutes
before cranking again.

If the engine will not start, or once started, continues to misfire or

smoke, further priming is necessary.
Harness/Wiring Problem

Fig. 32: Locating ECM

Locate the ECM. Two harness connectors are attached to the ECM. The
upper connector is the engine harness and the lower connector is the
chassis harness. Check the connectors to be sure they are secure. Perform
a "tug test" on EACH wire in the lower connector.

1. Pull (tug) on each wire with approximately 4.5 kg (10 pounds) force.
The wire should remain in the connector.
2. If a wire feels loose, push the wire back into the connector. Then tug
the wire again to ensure it is locked into place.
3. Start the engine. If the engine does not start, contact the appropriate
person(s) for assistance.
OPERATING THE ENGINE

Proper operation, driving techniques and maintenance are key factors in

obtaining the maximum life and economy of Caterpillar truck engines.
Following these recommendations will lower operation costs.
Idling

Electronic engines are shipped from Caterpillar with the idle speed preset
to 600 rpm. Idle speed is adjustable on Caterpillar truck engines.

Avoid excess idling. If the truck is parked for more than five minutes,
STOP the engine. An engine can burn from 2.8 to 5.7 L [0.75 to 1.5
US gal] of fuel per hour while idling. Excessive idling can cause
excessive carbon build-up and/or slobber, which is harmful to the engine.
If extended idle time is required, control the engine speed to 1000 rpm or
greater and take steps to ensure that the coolant temperature exceeds 82°
C (180°F).
Idle Shutdown Timer

The idle shutdown timer can be programmed to shut the engine down
after a specific engine idling time.
To override the idle timer:

1. Program the ALLOW IDLE SHUTDOWN OVERRIDE to YES.

2. The CHECK ENGINE/DIAGNOSTIC (YELLOW) lamp will flash
rapidly 90 seconds prior to shutdown. Depress the service brake or
clutch pedal during the 90 seconds, after the yellow lamp begins to
flash.
The idle shutdown timer will automatically reset to the programmed
value if the truck is moved a short distance.
Cold Mode Operation

Caterpillar truck engines do not require long warm-up times that waste
fuel. It takes just a few minutes in the summer and a bit longer in the
winter to warm up the engine.

A load can be applied to the engine after normal oil pressure is achieved
and the coolant water temperature gauge begins to rise. These engines
use a cold start strategy that limits power until the coolant temperature
reaches 18°C (64°F), or until the engine has been running for 12
minutes. The electronic system automatically idles the engine at 600 rpm
during cold mode operation.
Getting Started

Use progressive shifting techniques. Progressive shifting improves fuel

economy.
Keep engine rpm to a minimum (low to mid rpm range [1200 to
1600 rpm]).
Use only enough rpm to pick up the next gear.

Progressive shifting also reduces acceleration time. Top gear is reached

sooner because it takes less time to synchronize gears during shifting
and the engine is operating at its highest torque range. Experience with
your truck will show you how much rpm is required to make upshifts
under various conditions.

NOTE: These engines may be programmed to encourage

progressive shifting. If acceleration rates slow
dramatically when certain speeds (rpm) are
reached while driving in the lower gears, shift
parameters have been programmed into the ECM.
Shift parameters will limit rpm while driving in
higher gears. These parameters are protected by
customer passwords.
Cruising

The faster a truck is driven, the more fuel it will consume. Increasing
cruising speed from 88 to 104 km/h (55 to 65 mph) will increase fuel
consumption of a typical class 8 truck approximately 0.4 km/L (1 mpg).
Driving faster to increase stop time makes those stops very expensive.
Cruising time provides the greatest opportunity to benefit from operation
in the most efficient rpm range of the engine (1200 to 1600 rpm).
These engines can be equipped with:

Cruise Control
Auto Retarder in Cruise
Auto Retarder in Cruise Med/Hi Increment
Cruise Control

Depending on truck manufacturer, the cruise control switch may be

programmed to operate in one of two modes:

1. The SET position may operate as SET/ACCEL or SET/DECEL.

2. The RESUME position may operate as RESUME/ACCEL or
RESUME/DECEL.

Refer to the markings on the switch or your Truck Owners Manual.

To set the Cruise Control:

1. After you accelerate to the desired speed, turn the ON/OFF switch
ON.
2. Press the SET/RESUME switch to the SET position.

The ECM will control truck speed until the clutch or service brake pedal
is depressed or the ON/OFF switch is turned OFF.

NOTE: You can also accelerate to desired speed and set

the cruise control by pressing the SET/RESUME
switch to the ACCEL position.

To resume speed after an interruption:

Press RESUME and the truck will return to the "set" speed.

Momentarily pressing or "bumping" the SET/RESUME switch to the

ACCEL position will increase vehicle speed by one mph. Press the
switch to the DECEL position to decrease speed by one mph. The
operating range of the cruise control has been programmed into the
ECM.
SoftCruise Control

SoftCruise provides a 8 km/h (5 mph) operating range around the cruise

control setting. Engines are shipped from Caterpillar programmed to
operate in the SoftCruise mode. SoftCruise allows the truck to accelerate
slightly, under power, going down hills and get a "run" at the next hill.
Improved fuel economy can be gained in this mode.

When the SoftCruise control is deactivated, the SET speed is maintained.

Engine Retarder

The Engine Retarder may be programmed to one of three modes:

COAST,
LATCH, or
MANUAL.
COAST Mode

If the Engine retarder is programmed to COAST and the CRUISE switch

is ON, the retarder will activate when you press the service brake.
The Retarder will deactivate when the service brake is released.

If the CRUISE switch is OFF, the retarder will activate regardless of the
service brake.
LATCH Mode

If the Engine retarder is programmed to LATCH and the Cruise switch is

ON, the retarder will activate when you press the service brake.

The Retarder remains active (latched) when the service brake is released.
If the CRUISE switch is OFF, the retarder will activate regardless of the
service brake.
MANUAL Mode

If the Engine Retarder is programmed to MANUAL, the Retarder will

activate regardless of the service brake or Cruise switch position.
Engine Retarder Minimum Vehicle Speed

The minimum vehicle speed for engaging the engine retarder is

programmable. The Retarder Minimum Vehicle Speed has a range from
0 to 205 km/h (0 to 127 mph). A value of 0 (default) allows the Retarder
to activate regardless of vehicle speed.
Auto Retarder In Cruise

The engine retarder can provide less or more braking power as needed by
lower or higher speeds. The braking power can be Low, Medium, or
High.

The Auto Retarder in Cruise feature determines the speed above the
Cruise set speed that the LOW level engine retarder will activate. The

Auto Retarder in Cruise can be programmed to different limits.

For example, if the Auto Retarder is programmed to 3 km/h (2 mph),

LOW level braking power will be applied when your speed goes 3 km/h
(2 mph) over the set Cruise speed.

Programming a value of 0 disables this feature.

To activate the Auto Retarder in Cruise feature:

Turn the engine retarder and the Cruise control ON.

Auto Retarder in Cruise Med/Hi Increment

The Med/Hi increment determines speed above the Auto Retarder in

Cruise speed that the Engine Retarder will activate at the MEDIUM and
HIGH levels. This parameter depends on and operates with Auto
Retarder in Cruise.

The default is 3 km/h (2 mph), with a range of 0 to 8 km/h (0 to 5 mph).

With the Engine Retarder dash switch(s) set to MEDIUM: programming

the Med/Hi increment to 0 activates MEDIUM level retarding at the
programmed Auto Retarder In Cruise speed.
With the Engine Retarder dash switch(s) set to HIGH: programming the
Med/Hi increment to 0 activates HIGH level retarding at the
programmed Auto Retarder In Cruise speed.
AUXILIARY ENGINE BRAKES

WARNING: If your vehicle is equipped with an auxiliary

brake, follow the instructions provided in
the auxiliary brake owner's manual. Failure
to follow the instructions during wet or
slippery conditions could reduce vehicle
control and result in personal injury or
death.

CAUTION: These devices should not be used as a

primary or service brake.

Certain auxiliary engine braking devices are approved for use on these

engines.
BrakeSaver Operation (3406E Only)

The BrakeSaver should NOT be used as a primary or service brake. The

BrakeSaver is not an emergency or quick stop brake. Use the service
brakes for quick stops.

CAUTION: Do not exceed 116°C (240°F) maximum

engine oil temperature at any time.
Do not exceed 2300 rpm in any situation.
Operation of the engine over 2300 rpm will
cause the Electronic system to activate the
CHECK ENGINE lamp, indicating engine
overspeed. Overspeeding can result in
serious damage to your engine.

The BrakeSaver provides auxiliary braking to slow the truck and to

control speed on long downhill grades. Controlling the slowing or
downhill speed of a vehicle by using the BrakeSaver results in reduced
wear on brake linings and brake drums. It helps save the service brakes
for emergency stopping requirements.

No special skills are required to operate or maintain a vehicle equipped

with a BrakeSaver. However, it requires the operator to observe the
engine speed and BrakeSaver oil temperature.

For maximum BrakeSaver effectiveness, select the proper gearing to

keep the engine rpm as close to 2300 rpm as possible without exceeding
2300 rpm. BrakeSaver effort declines as rpm goes down.

Manual operation allows the operator to match driving conditions to any

load or hill. Do not control the vehicle speed with the accelerator while
the manual control is ON. Allow a two second delay for full engagement
and full disengagement.
Manual Control

Fig. 33: Manual Control Lever

The hand-operated control lever is usually mounted on the steering
column. Increasing or decreasing the BrakeSaver action is accomplished

by moving the control lever. Allow a two second delay for full
engagement and full disengagement. Actuating the manual Brakesaver
control will deactivate the Electronic engines' Cruise Control or PTO
control.
Automatic Control

Fig. 34: BrakeSaver Control Selector

The mode selector switch must be in the AUTOMATIC MANUAL
position and the Electronic system Cruise Control ON/OFF switch must
be in the OFF position for automatic control. In this mode, the
BrakeSaver will automatically be engaged when the clutch pedal is
applied and the accelerator pedal is released.

The BrakeSaver will automatically shut off when the clutch pedal is
released or when the accelerator pedal is pressed. It will engage when the
clutch pedal is applied again and the accelerator pedal is released.
Gauges

Fig. 35: BrakeSaver Control Air Pressure & Oil Temp Gauges
CONTROL AIR PRESSURE should not exceed 390 kPa (55 psi). If the
indicator shows little or no pressure, the BrakeSaver may not provide any
braking effort. Control the vehicle stopping with proper downshifting
and service brakes until repairs are made. Stop the vehicle or operate at a
reduced speed.
The BrakeSaver oil temperature gauge indicator should register in the
NORMAL (GREEN) range, less than 116°C (240°F). If the indicator
moves to the RED range, place the BrakeSaver manual control lever to
the OFF position. Operate the vehicle with the service brakes only, or
stop the vehicle and let the engine idle until the oil temperature registers
in the NORMAL range.
To prevent unnecessary fuel consumption and possible heat build-up, do
not leave the BrakeSaver activated when the engine is idling while
parked. Place the control selector switch in MANUAL position, and the
manual control lever in the OFF position.
Compression Brake

Fig. 36: Compression Brake Switches

The compression brake controls may include a dash mounted module or
an ON/OFF switch and a three position "LO," "MED" and "HI" switch.
The compression brake control setting depends on how many cylinders
of braking are desired.

Some applications are equipped with a multi-position switch to provide

variable retarding capability. Operators should become familiar with the
controls on their vehicles. Refer to the Truck or OEM Owners Manual
for the type of operating controls that your truck is equipped with.
Uphill Operation

For best performance, allow the engine to lug down to 1100 to 1200 rpm
before downshifting. Continue to downshift in this manner until you
reach a gear that maintains the desired speed. Continue to operate at low
(1100 to 1200) rpm if the truck will make it to the top without a
downshift. Begin upshifting as the grade of the hill decreases and the
engine begins to accelerate above 1600 rpm. Driving this way will give
you the best fuel economy and performance.

NOTE: Allowing the engine to lug below peak torque is

permissible if the truck is cresting the top of a hill.
However, extended operation at engine speeds
below peak torque (usually 1200 rpm) will raise
exhaust temperature and cylinder pressure. This
can lead to reduced engine life.
Downhill Operation

CAUTION: Do NOT allow the engine rpm to exceed

2300 rpm, engine damage can result.
If equipped with an exhaust or compression
brake, do not exceed 2100 rpm.

On a downgrade, do not coast with the clutch pedal depressed or put the
transmission in NEUTRAL. If you do not want to use power, disengage
the Cruise Control.

Select the correct gear that does not allow the engine speed (rpm) to
exceed 2300 rpm and use the retarder and/or service brakes to control the

speed of the truck. A simple rule is to select the same gear that would be
required to go up the grade.
Saving Fuel

Rolling hills provide great opportunity to reduce fuel consumption.

Avoid downshifting on small hills. Even if the engine must be lugged to
speeds below peak torque the truck should not be downshifted. When
going down hill, use gravity instead of engine power to regain truck
speed.

On grades that require more than one downshift, let the engine lug to
peak torque rpm. If road speed stabilizes with the engine running at or
above peak torque rpm, remain in that gear.

Long steep down grades should be anticipated. Truck speed should be

reduced before cresting the top of a hill and proceeding down a long
steep grade. The way to achieve maximum fuel efficiency is to minimize
the amount of braking that is used to maintain a safe speed.

The engine's ability to hold the truck back increases with engine speed. A
gear should be selected that runs the engine near the high engine rpm
limit for long steep hills when braking is required.

Speed reductions and future stops should be anticipated ahead of

time to save fuel. Downshifts should be avoided and the amount of
braking minimized to improve fuel consumption. By coasting to a stop, a
considerable distance can be traveled without consuming any fuel.
Vehicle Efficiency

An efficient vehicle performs the desired amount of work while

minimizing the power demand on the engine. The major contributors to
power demand are aerodynamic drag (wind resistance), rolling resistance
of the tires, gross weight of the vehicle, losses in the drive train, and the
load from the engine driven accessories.
COLD WEATHER OPERATION

Caterpillar Diesel Truck Engines are designed to operate effectively in

cold weather. However, engine operation in cold weather is dependent on
the type of fuel used and how well the fuel flows through the fuel system.
The purpose of this section is to explain some of the steps that can be

taken to minimize fuel problems when the ambient (outside) temperature

is below freezing.
Fuel and the Effect from Cold Weather

The three types of diesel fuel available for your truck engine are typically
grades No. 1, No. 2 or a blend of No. 1 and No. 2.
There are three major differences between No. 1 and No. 2 diesel fuel.
No. 1 diesel fuel has a lower cloud point, a lower pour point and has a
lower BTU (kJ) (heat content) rating than No. 2 diesel fuel. The BTU
(kJ) rating is where you get power, therefore No. 1 grade fuel will
provide less power and fuel economy, but is less likely to plug filters and
flows better through the fuel system. Keep in mind that No. 1 grade fuel
or fuel blends will not provide as much power as No. 2 grade fuel. You
may notice the difference.

Be aware of these fuel grades when purchasing your diesel fuel. Plan fuel
purchases for cases when you will be driving from warm climates into
cold climates. Trucks that are fueled in one climate may not operate
properly when driven to another climate.
Fuel Filters

Use of an auxiliary primary fuel filter and/or water separator is

required between the fuel tank and the engine mounted fuel filter. Refer
to the Parts Manual for this engine to determine the part numbers
required for a cold weather primary fuel filter.
Winter Fronts/Shutters

Under normal conditions, Caterpillar discourages the use of, and does
NOT recommend, winter fronts or other air flow restriction devices
(shutters) mounted in front of radiators. These devices, if not used
properly, can cause higher exhaust temperatures, power loss, excessive
fan usage and a reduction in fuel economy.

Winter fronts are properly used for overnight parking and very cold
temperatures, along with high winds. In these cases, coolant and inlet
manifold temperatures must be carefully monitored and controlled.

CAUTION: Failure to open the winter fronts in the

morning could cause engine damage and/or

loss of fuel economy.

STOPPING THE ENGINE

CAUTION: Stopping the engine immediately after it has

been working under load can result in
overheating and accelerated wear of the
engine components.
If the engine has been operating at highway
speeds and/or high loads, run at low idle for
at least three minutes to reduce and
stabilize internal engine temperature before
stopping the engine.
Avoiding hot engine shutdowns will
maximize turbocharger shaft and bearing
life.

Make sure the Engine Stopping (shutoff) procedure is understood.

To stop the engine, use the method listed that applies to the shutoff
system on your truck or refer to the OEM truck manufacturer's
instructions for your type of engine shutoff system.

Turn the ignition key switch to the OFF position, or...

Push IN and HOLD the stop button until the engine stops, then
release the button.
After Stopping the Engine

If freezing temperatures are expected, allow the engine jacket water

system to cool; then check the coolant for proper antifreeze protection.
The engine must be protected against freezing to the lowest expected
outside temperature. Add the proper antifreeze/water mixture when
required.

Fill the fuel tank at the end of each day of operation to drive out moist air
and to prevent condensation. Do not fill the tank to the top. Fuel expands
as it gets warm and may overflow.
MAINTENANCE
SCHEDULED OIL SAMPLING (S.O.S)

Caterpillar's Scheduled Oil Sampling (S.O.S) analysis is the best

indicator for determining what is happening inside your engine. S.O.S
analysis is a diagnostic tool used to determine oil performance and
component wear rates with a series of tests designed to identify and
measure contamination such as soot, sulfur, etc., and the presence of fuel,
water and antifreeze in a sample of oil. The tests also determine the
amount of wear metals present in the oil sample, which is compared to
established Caterpillar norms to determine acceptability.

To be effective as an indicator, S.O.S analysis MUST be performed

on a continuing basis. Intermittent sampling will NOT allow wear
rate trend lines to be established.
Obtain S.O.S analysis samples at regularly scheduled intervals to
monitor the condition and maintenance requirements of your engine.

NOTE: S.O.S analysis must include Infrared (IR) in the

analysis. Infrared analysis should always be
accompanied by wear element analysis and
chemical and physical tests to assure accurate
diagnosis. Infrared analysis must be used to
determine oil change intervals.
Obtain Sample

Each oil sample should be taken when the oil is warm and well mixed to
ensure that the sample is representative of the oil in the crankcase. There
are two methods recommended to obtain S.O.S samples from the engine
crankcase.

Use a sampling valve (if equipped).

Use a sampling gun inserted into the sump.
Caterpillar recommends using one of the above methods. If these
methods are not possible, then use a drain stream method when changing
oil. When using the drain stream to obtain the oil sample, DO NOT
sample from the first or final draining. The oil at the beginning or end of
the drain stream is not mixed well enough to be representative of the oil
in the crankcase.

Fig. 37: S.O.S. Analysis Interval Chart

The test results of the oil samples will then be used as a basis for
determining the oil change interval for your engine, giving you the
ultimate time between oil changes without the risk of engine damage.
REFILL CAPACITIES

The REFILL CAPACITIES reflect the crankcase capacity plus filter.

Some engines may use a different sump capacity. Auxiliary oil filter
systems will require additional oil. Refer to the OEM specifications
regarding all other filter capacity.

The Total Cooling System capacity will vary, depending on the radiator
size (capacity) provided by the truck manufacturer. The chart (see Fig.
38 ) is left blank and should be filled in by the customer for maintenance
of Total Cooling System Capacity.

Fig. 38: Lubrication Oil & Cooling System Refill Capacities

MAINTENANCE SCHEDULE

Use fuel consumption, distance (odometer) interval or service

hours/calendar time, whichever occurs first.
Caterpillar recognizes that the distance (odometer) interval is most
commonly used to schedule maintenance for on-highway vehicles.
However, Caterpillar suggests that fuel consumption be used as the
preferred method of determining intervals rather than distance
(odometer) intervals.

NOTE: For maintenance schedule NOTE explanations, see

Fig. 47 .

Fig. 39: Maintenance Schedule - Daily

Fig. 40: Maintenance Schedule - PM Level 1

Fig. 41: Maintenance Schedule - 15,000-60,000 Miles

Fig. 42: Maintenance Schedule - Every 150,000 Miles

Fig. 43: Maintenance Schedule - Every Two Years

Fig. 44: Maintenance Schedule - PM Level 2

Fig. 45: Maintenance Schedule - Every 300,000 Miles

Fig. 46: Maintenance Schedule - Severe Service

Fig. 47: Maintenance Schedule - Notes

CODES

R - REPLACE
C - CHECK
A - ADJUST
CL - CLEAN
D - DRAIN
L - LUBRICATE
E - EVALUATE
I - INSPECT
SERVICE
CORRECT
REPLACE AS NECESSARY
T - TEST/REPLENISH AS NECESSARY
DAILY

You must read and understand the warnings and instructions

contained in Safety , before performing any operation or
maintenance procedures.
Walk-Around Inspection

Inspect Engine for Leaks and Loose Connections

For maximum service life of your truck engine, make a thorough under
the hood inspection before starting the engine. Look for such items as oil
or coolant leaks, worn fan belts, loose connections and trash build-up.
Remove trash build-up and perform corrective maintenance as needed.

Check the fluid levels more frequently than the recommended

maintenance intervals and continue to monitor fluid levels until any leak
is found and fixed.
Wipe all fittings, caps and plugs before performing maintenance to

reduce the chance of system contamination.

Inspect:
Radiator and ATAAC cores for leaks and trash build-up.
Radiator and ATAAC air intake system hoses and elbows for cracks
and loose clamps.
Fan and accessory drive belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced as matched sets. If
only one belt of a two or three belt set is replaced, it will carry more of a
load than the belts not replaced since the older belts are stretched. The
additional load on the new belt could cause it to break.

Inspect:
Water pump for coolant leaks at weep hole. Check the weep hole for
water pump breather filter blockage. Replace the filter if necessary.

NOTE: The water pump seal is lubricated by coolant. It is

normal for a small amount of leakage to occur as
the engine cools down and parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. If excessive
leakage occurs, check the coolant level frequently
and continue to monitor the level until the water
pump is repaired.

Inspect:
Lube system components (such as front and rear crankshaft seals, oil
pan, oil filters and valve covers) for leaks.
Fuel system for leaks, loose fuel line clamps and fittings and loose
or worn hoses.
Air intake system hoses and elbows for cracks and loose clamps.
Engine wiring and electronic wiring harnesses for loose connections
and worn or frayed wires.
Engine electrical grounding system for good connections and
condition.
All guards must be in place. Repair or replace missing or damaged

guards.
Check condition of batteries and the level of electrolyte, unless
equipped with a maintenance free battery. Refer to Truck Owners
Manual or manufacturers' recommendations for battery
maintenance.
Engine Crankcase

CAUTION: Make sure you read and understand the

information in Safety and Lubricant
Specifications before you proceed with
maintenance of the crankcase lube oil
system.
Check Oil Level

The vehicle must be parked on a level surface to perform this

maintenance procedure.

Check the oil level with the engine stopped. DO NOT check the oil
level with the engine running.

Fig. 48: Traditional (1) & Full Range (2) Dipsticks

Maintain the oil level between the ADD and FULL marks on the
ENGINE STOPPED side of the dipstick. Do not fill the crankcase
above the FULL mark.

CAUTION: Operating your engine when the oil level is

above the FULL RANGE zone may reduce
the lubricating characteristics of your oil
and cause engine damage.
Cooling System

CAUTION: Make sure you read and understand the

information in Safety and Cooling System
Specifications before you proceed with
maintenance of the cooling system.
Check Coolant Level

1. Check the coolant level with the engine stopped and cool.

2. Remove the radiator filler cap slowly to relieve any pressure.

3. Maintain the coolant level within 13 mm (1/2 inch) below the
bottom of the fill pipe or to the proper level on the sight glass, if
equipped.
4. Inspect the radiator filler cap. Replace the cap if gaskets are
damaged. Install the filler cap.
5. Inspect the radiator fins. Clean the radiator fins if necessary.
Air Cleaner Indicator (If Equipped)

Check Air Cleaner Service Indicator

Fig. 49: Typical Air Cleaner Indicator

Your engine may be equipped with a different indicator, or a gauge
supplied by the vehicle manufacturer. If the vehicle is equipped with an
inlet air restriction gauge or some other system, follow the OEM or
manufacturer's recommendations.

CAUTION: Never service the air cleaner with the engine

running since this will allow dirt to enter the
engine.

Replace air cleaner elements at intervals recommended by the air

cleaner or truck OEM.
Operating conditions (dust, dirt and debris) may require more
frequent air cleaner element maintenance.
Service the air cleaner when required by the air cleaner indicator.
Check the precleaner (if equipped) daily for accumulation of dirt and
debris. Remove any dirt and debris as needed.
Water Separator (If Equipped)

Drain Water & Sediment

Drain water from the water separator (if equipped). A water

separator is recommended and should be installed between the fuel
tank and the engine fuel inlet.

For location and maintenance of remote mounted water separators, refer

to your OEM location and maintenance instructions.

PM LEVEL 1

You must read and understand the warnings and instructions

contained in Safety , before performing any operation or
maintenance procedures.
Perform the Dipstick Calibration at the first oil change. Refer to Oil
Level Gauge (Dipstick) Calibration . Before proceeding with PM Level
1 maintenance, perform all Daily maintenance requirements.

The ECM is capable of calculating maintenance intervals for PM 1, PM 2

and the Coolant Flush/Fill. PM 1 is programmable based on oil sump size
and fuel consumption, however PM 2 and Coolant Flush/Fill is based on
the Maintenance Schedule interval.

Engine lubricating oil sump capacity can be a factor in adjusting oil

change intervals. Refer to Fig. 54 .
Oil Level Gauge (Dipstick) Calibration

Check Calibration At First Oil Change

Engine oil level will vary depending on angle and slant of OEM engine
installation (angle = front to back tilt, slant = sideways tilt).

Your engine will be equipped with either the Traditional or the Full
Range dipstick. It is a good idea to verify that your dipstick markings are
correct. The most convenient time to verify the markings is when the oil
is changed, preferably at the first oil change.

To verify the ADD and establish the actual FULL mark on the dipstick,
use the following procedure.
3176B, C-10, and C-12 Engines

CAUTION: The vehicle must be parked on a level

surface to perform this maintenance
procedure.

1. Operate the engine until normal operating temperature is achieved.

Stop the engine. Remove the crankcase drain plugs. Plugs from both
the deep and shallow portions of the oil pan should be removed to
allow the oil to drain. Drain the oil from the crankcase for 20

minutes.
2. Remove the used oil filter(s). Install the new oil filter(s). Install the
crankcase drain plug and tighten to 70 +/- 14 N.m (50 +/- 10 lb ft).

Fig. 50: 3176B, C-10 & C-12 Dipstick Calibration Oil Volumes

NOTE: Your engine may be equipped with auxiliary oil

filters and require a different volume than the
standard amounts listed in the chart. Refer to
your OEM specifications.

3. Refer to Fig. 50 . Locate your engine's row. Pour the ADD Mark
volume of oil into the crankcase. Allow enough time for the oil to
drain into the crankcase. Approximately 20 minutes should be
allowed. Check the oil level, wait a few minutes, and check again.
Proceed after the oil level stops changing.
4. Check the oil level on the dipstick. The oil level should be at the
ADD mark. If the oil level is not at the existing ADD mark, grind
off the mark and engrave the new ADD level, using an engraving
pen.
5. Refer to Fig. 50 . Locate your engine's row. Pour the FULL Mark
volume of oil into the crankcase. Allow enough time for the oil to
drain into the crankcase.
6. Check the oil level on the dipstick. The oil level should be at the
FULL mark. If the oil level is not at the existing FULL mark, grind
off the mark and engrave the new FULL level, using an engraving
pen.
7. Refer to Fig. 50 . Locate your engine's row. Pour the ADDITIONAL
volume of oil into the crankcase. Start and run the engine long
enough to ensure the lube system (oil filter[s], etc.) is filled. Inspect
for oil leaks.
8. Stop the engine and allow enough time for the oil to drain into the
crankcase.
9. Check the oil level on the dipstick. If the oil level is not at the
calibrated FULL mark, fill the sump to the calibrated FULL mark.
Record the amount of oil added. This additional oil, plus the oil in
the sump, is the system oil capacity, and the amount of oil needed
for each subsequent oil change. Record the system oil capacity for
future oil changes.

3406E Engines

CAUTION: The vehicle must be parked on a level

surface to perform this maintenance
procedure.

1. Operate the engine until normal operating temperature is achieved.

Stop the engine. Remove the crankcase drain plugs. Plugs from both
the deep and shallow portions of the oil pan should be removed to
allow the oil to drain. The control valve must also be drained on
engines equipped with BrakeSaver. Drain the oil from the crankcase
for 20 minutes.
2. Remove the used oil filter(s). Install the new oil filter(s). Install the
crankcase drain plug and tighten to 70 +/- 14 N.m (50 +/- 10 lb ft).

Fig. 51: 3406E Dipstick Calibration Oil Volumes

NOTE: Your engine may be equipped with auxiliary oil

filters and require a different volume than the
standard amounts listed in the chart. Refer to
your OEM specifications.

Fig. 52: Oil Fill Location For 3406E Dipstick Calibration

3. Refer to Fig. 51 . Locate your engine's row. Pour the ADD Mark
volume of oil into the crankcase. Allow enough time for the oil to
drain into the crankcase. Approximately 20 minutes should be
allowed. Check the oil level, wait a few minutes, and check again.
Proceed after the oil level stops changing.
4. Check the oil level on the dipstick. The oil level should be at the
ADD mark. If the oil level is not at the existing ADD mark, grind
off the mark and engrave the new ADD level, using an engraving
pen.
5. Refer to Fig. 51 . Locate your engine's row. Pour the FULL Mark
volume of oil into the crankcase. Allow enough time for the oil to
drain into the crankcase.
6. Check the oil level on the dipstick. The oil level should be at the
FULL mark. If the oil level is not at the existing FULL mark, grind
off the mark and engrave the new FULL level, using an engraving
pen.

7. Refer to Fig. 51 . Locate your engine's row. Pour the ADDITIONAL

volume of oil into the crankcase. Start and run the engine long
enough to ensure the lube system (oil filter[s], etc.) is filled. Inspect
for oil leaks.
8. Stop the engine and allow enough time for the oil to drain into the
crankcase.
9. Check the oil level on the dipstick. If the oil level is not at the
calibrated FULL mark, fill the sump to the calibrated FULL mark.
Record the amount of oil added. This additional oil, plus the oil in
the sump, is the system oil capacity, and the amount of oil needed
for each subsequent oil change. Record the system oil capacity for
future oil changes.
Engine Oil and Filter(s)

Drain Oil

CAUTION: The vehicle must be parked on a level

surface to perform this maintenance
procedure. Drain the crankcase with the oil
at normal operating temperature and the
engine stopped to allow for the draining of
waste particles that are suspended in the
oil.

1. Remove the crankcase drain plugs. Plugs from both the deep and
shallow portions of the oil pan should be removed to allow the oil to
drain. An oil sample can be obtained for S.O.S (Scheduled Oil
Sampling) analysis at this time.
2. Install both crankcase drain plugs and tighten them to 70 +/- 14 N.m
(50 +/- 10 lb ft).
BrakeSaver (If Equipped) Lube Oil Change

Scheduled maintenance on the BrakeSaver is not required except for the

recommendation that follows. When changing the engine crankcase
lubricating oil, it is also recommended to drain the oil from the oil cooler,
the BrakeSaver control valve, and shallow sump portion of the oil pan.

Remove the drain plug and gasket located on the bottom of the
BrakeSaver control valve. Dirty oil NOT drained from the
BrakeSaver will contaminate fresh oil added to the system.

Replace Filter(s)

NOTE: Change oil filter(s) at every oil change. Make sure

to use the correct Caterpillar oil filter(s) for your
engine arrangement.

CAUTION: Caterpillar oil filters are built to Caterpillar

specifications. Use of an oil filter not
recommended by Caterpillar could result in
severe damage to your engine bearings,
crankshaft, etc., as a result of the larger
debris particles from unfiltered oil entering
your engine lubricating system.

Fig. 53: Locating Dipstick (1), Oil Filler (2), Oil Drain Plugs (3) &
Oil Filter (4)
1. Remove the oil filter(s) with a 2P8250 Filter Wrench.
2. Cut the oil filter case open with a 4C5084 Oil Filter Cutter. Inspect
the exposed oil filter element. Spread the element pleats apart and
inspect the element for metal debris. Due to normal wear, friction,
etc., it is not uncommon to find small amounts of debris in your oil
filter element. If an excessive amount of debris is present, consult
the appropriate person(s) to arrange for further analysis.
3. Wipe the sealing surface of the filter mounting base. Make sure all
of the old gasket is removed.
4. Apply a small amount of clean engine oil to the new filter gasket.

CAUTION: Do NOT fill the oil filters with oil before

installing them. This oil would not be
filtered and could be contaminated.
Contaminated oil will cause accelerated
wear to engine components.

5. Install the new filter(s) until the gasket contacts the base. Use the
rotation index marks, on the filters, as a guide for proper tightening.
Tighten the filter 3/4 of a turn more by hand. Do not over tighten.
Fill Crankcase

NOTE: Refer to Lubricant Specifications and Refill

Capacities for the proper oil and quantity to use.

CAUTION: If equipped with an auxiliary (or remote

mounted oil filter) system, follow the OEM
or filter manufacturer's recommendations.
Either under filling or overfilling of engine
crankcase oil can cause engine damage.

1. Remove the oil filler cap to fill the crankcase with new oil.
2. Refill the crankcase with the amount of oil determined and recorded
during the dipstick calibration. Allow enough time for the oil to
drain into the sump.

CAUTION: DO NOT load or accelerate the engine

before achieving oil pressure on the
gauge.

3. Start the engine and run long enough to ensure the lube system
(including auxiliary filters, etc.) has oil and the oil filter(s) are filled.
Inspect for oil leaks.
4. Stop the engine and allow the oil to drain back to the sump for a
minimum of five minutes. Check the oil level. The oil level reading
should indicate FULL on the ENGINE STOPPED side of the
dipstick. If the oil level is low, add oil to the calibrated FULL level
on the dipstick.
Optimized Oil Change Intervals

Many conditions effect the selection of an optimum oil change interval.

The goal is to maintain engine life and engine performance while fully
utilizing the lubricant. The engine oil must be able to control corrosion,
oxidation, soot, and wear metals during the time between oil changes. In
some severe duty engine applications, reducing the oil change interval
may be necessary in order to maintain engine lubricant integrity.

Fuel consumption, oil consumption, and oil volume are the most
important factors used to calculate an oil change interval.

The rate of fuel consumption is a direct result of the engine load factor.
An engine with a high fuel consumption rate is working harder than an
identical engine with a lower fuel consumption rate.

Oil consumption rates differ between engines of different design and age.
An engine that consumes relatively high amounts of oil will have more
fresh oil in the crankcase than an engine that consumes less oil (assuming
that the oil levels for both engines are properly maintained). Similarly, an
engine with a large oil sump can run longer between oil changes than an
identical engine with a smaller sump.
Caterpillar recommends using Fig. 54 to determine optimum oil change
intervals.

NOTE: The following requirements must be met in order

to use Fig. 54 for determining oil change intervals:

Premium API CG-4 multi-grade oil only (Caterpillar DEO multi-

grade preferred). Contact your oil supplier for your supplier's
premium oil recommendation.
Oil analysis at 16,100 km (10,000 mi) intervals and at all oil drain
intervals. The oil analysis must evaluate oil condition and wear
metals. Caterpillar's S.O.S oil analysis program preferred.
Caterpillar's S.O.S oil analysis program is the only oil analysis
program with Caterpillar approved wear tables and limits for soot
and oxidation.
Use premium oil filter(s): Caterpillar 1R0716 Oil Filter or a filter
with equivalent performance and durability.

Chart Instructions:

1. Determine your average fuel consumption (kilometers per liter or

miles per gallon). Locate the chart column which lists your average
fuel consumption.
2. Determine your available oil in liters or quarts. Oil = sump oil + oil
filter(s) capacity + oil added between oil changes. Locate the row
which lists your available oil.
3. The cell where the column and row intersect lists the maximum
permissible number of kilometers or miles between oil change
intervals.

Example: An average fuel consumption of 2.8 km/L (6.5 mpg) was

determined, along with 45 L (48 qt) of oil. The maximum permissible oil
change interval is 35,420 km (22,000 miles).

CAUTION: Metric units are listed before English units

in this information.

Fig. 54: Caterpillar Maximum Permissible Oil Change Intervals

Fuel System

Fuel Tank Maintenance

Drain water and sediment from the bottom of the engine fuel tanks at
each oil change. Drain the water and sediment from any fuel storage
tanks at the oil change period and/or before tanks are refilled. This will
help prevent water and/or sediment from being pumped from the fuel
storage tank into the engine fuel tank.
Replace/Clean Primary Filter (If Equipped)

Stop the engine.

Turn the ignition/start switch OFF or disconnect the battery and shut
off fuel tank supply valve (if equipped) when performing
maintenance on fuel filters.
Replace

If your engine is equipped with a disposable primary filter element,

follow the OEM recommendation for removing and replacing the
element.
Clean

Perform the following general procedure for engines equipped with a re-
usable primary fuel filter element.

Fig. 55: Identifying Bolt (1), Element (2) & Filter Case (3)
1. Loosen bolt (1) on the filter housing and remove filter case (3).
2. Remove element (2) and wash it in clean, nonflammable solvent.
3. Install element (2) and case (3). Tighten bolt (1) to a torque of 24 +/-
4 N.m (18 +/- 3 lb ft).
Replace Final Fuel Filter

1. It may be necessary to relieve residual fuel pressure from the fuel

system before removing the fuel filter. Use a cloth or container to

catch excess fuel.

CAUTION: Do NOT loosen fuel lines or fittings at

the fuel manifold or ECM. The engine
components may be damaged.

Fig. 56: Locating Fuel Line On Output Side Of Fuel Filter

Loosen any fuel line on the output side of the fuel filter (except at
the ECM) to bleed off any residual pressure.

2. Remove and discard the used fuel filter.

3. Clean the gasket sealing surface of the fuel filter base. Make sure all
of the old gasket is removed.
4. Apply clean diesel fuel to the new fuel filter gasket.

CAUTION: Do NOT fill the fuel filters with fuel

before installing them. The fuel would
not be filtered and could be
contaminated. Contaminated fuel will
cause accelerated wear to fuel system
parts.

5. Install the new fuel filter. Spin the fuel filter onto the fuel filter base
until the gasket contacts the base. Use the rotation index marks on
the filters as a guide for proper tightening. Tighten the filter 3/4 turn
more by hand. Do not over tighten.
6. Open the fuel tank supply valve and prime the fuel system.
Priming the Fuel System After A Fuel Filter Change

Priming the fuel system fills the fuel filter(s) and removes air bubbles
from the fuel system.

NOTE: DO NOT remove the fitting in the fuel filter base to

release air from the fuel system while priming.
Periodic removal of the fitting will result in
increased wear of the threads in the fuel filter base
and lead to fuel leakage.

1a. Crank the engine for 15 seconds. If the engine does not start, go to

step 1b.

Fig. 57: Locating Priming Pump Plunger

1b. Perform this procedure only if the engine will not start. Unlock and
operate the priming pump plunger until a resistance is felt to fill final
filter with fuel. Seventy-five or more pump strokes may be required to
fill the fuel filter. Push the plunger in and tighten by hand. Promptly
continue with the next step.

CAUTION: Do not crank the engine continuously for

more than 30 seconds. Allow the starter
motor to cool for two minutes before
cranking again.

2. Crank the engine promptly after pressurizing fuel system. The

engine should start within 15 seconds.
3. If the engine will not start, allow the starting motor two minutes
to cool and repeat steps 1 and 2.
Priming the System If the Engine Runs Dry

If the engine fuel system is run dry, refer to After the Engine Runs Dry
of Fuel .
Cooling System

CAUTION: Make sure you read and understand the

information in Safety and Cooling System
Specifications before you proceed with
cooling system maintenance.
Test for Supplemental Coolant Additive (SCA) Concentration

Use the 8T5296 Test Kit to check for a three to six percent supplemental
coolant additive (SCA) concentration. If the concentration is less than
three percent, add SCA.
Refer to Cooling System Specifications for the necessary amount
of liquid SCA to add.
If equipped with a SCA spin-on maintenance element, replace the
element.

Add Liquid Supplemental Coolant Additive (SCA)

1. Loosen the radiator filler cap slowly to relieve pressure and remove
the cap.
2. It may be necessary to drain enough coolant from the radiator to
allow for the addition of the liquid SCA.
3. Add liquid SCA according to the requirements for your cooling
system capacity.
4. Inspect the radiator filler cap gaskets. Replace the cap if the gaskets
are damaged. Install the filler cap.
Replace Coolant Additive Element (If Equipped)

1. Close coolant additive element inlet valve (1) and outlet valve (2).
Remove and discard coolant additive element (3).

Fig. 58: Installed SCA Spin-On Element

2. Clean the element mounting base. Make sure all of the old gasket is
removed.
3. Refer to Cooling System Specifications for the proper SCA
element for your system. Coat the gasket of the new SCA element
with a thin film of engine oil. Install the SCA element. Spin the
element until the gasket contacts the base, then tighten 3/4 turn more
by hand. DO NOT over tighten.
4. Open inlet valve (1) and outlet valve (2).
5. Remove the radiator filler cap. Start the engine and check for leaks.
Allow the coolant level to stabilize.
6. Add the proper premixed coolant/water, if necessary, to bring the
coolant to within 13 mm (1/2 inch) below the bottom of the fill pipe
or to the proper level on the sight glass, if equipped.
7. Inspect the filler cap. Replace the cap if the gasket is damaged.
Install the filler cap.
Crankcase Breather

Clean

CAUTION: If the crankcase breather is not maintained

on a regular basis, it will become plugged. A
plugged crankcase breather would result in

excessive crankcase pressure that may

cause crankshaft seal leakage.

Fig. 59: Crankcase Breather For 3176B Engine

Fig. 60: Crankcase Breather For C-10 & C-12 Engines

NOTE: The 3406E Engine may be equipped with a

Standard or Low Profile crankcase breather. No
maintenance is required for the Low Profile
breather.

Fig. 61: 3406E Low Profile Crankcase Breather

Fig. 62: Standard Crankcase Breather For 3406E Engine

1. Loosen hose clamp (1). Remove the hose from assembly (2).
2. Remove the assembly.
3. Wash the breather element in clean, nonflammable solvent. Allow
the breather element to dry.
4. Install the clean, dry assembly.
5. Install hose and clamp (1). Tighten the clamp.
Alternator, Fan and Accessory Drive Belts

Inspect/Replace

Inspect the condition and adjustment of alternator belts and fan drive
belts. Examine all drive belts for wear and replace if they show any signs
of wear.
If one belt in a set requires replacement, always install a new matched set
of belts. Never replace just the worn belt. If only the worn belt is
replaced, the new belt will carry all the load, as it will not be stretched as
much as the older belts. All the belts will fail in rapid succession.
Check Belt Tensioner Position, 3176B, C-10 and C-12

It is essential to check the position of the belt tensioner pulley in order to

maintain proper belt tension.
Hoses and Clamps

Inspect

Inspect all hoses for leaks due to cracking, softness and loose
clamps. Replace hoses that are cracked or soft and tighten loose
clamps.

CAUTION: Do not bend or strike high pressure lines.

Do not install bent or damaged lines, tubes
or hoses. Repair any loose or damaged fuel
and oil lines, tubes and hoses. Leaks can
cause fires. Inspect all lines, tubes and
hoses carefully. Tighten all connections to
the recommended torque.

Check for the following:

End fittings damaged, leaking or displaced.
Outer covering chafed or cut and wire reinforcing exposed.
Outer covering ballooning locally.
Evidence of kinking or crushing of the flexible part of the hose.
Armoring embedded in the outer cover.

A constant torque hose clamp can be used in place of any standard hose
clamp. Make sure the constant torque hose clamp is the same size as the
standard clamp. Due to extreme temperature changes, hose will heat set.
Heat setting causes hose clamps to loosen. Loose hose clamps can result
in leaks. There have been reports of component failures caused by hose
clamps loosening. The constant torque hose clamp will help prevent
these failures.

Each installation application can be different depending on the type of

hose, fitting material and anticipated expansion or contraction of the hose
and fittings. A torque wrench should be used for proper installation of the
constant torque hose clamps.
Cylinder Head Ground Stud

Inspect/Clean/Tighten

Fig. 63: Locating Cylinder Head Ground Stud For 3176B Engines
Fig. 64: Locating C-10 & C-12 Primary (1) & Alternative (2)

Cylinder Head Ground Studs

Fig. 65: Locating Cylinder Head Ground Stud For 3406E Engines
Inspect the OEM/Vehicle wiring harness for good connections and
condition.

The cylinder head (ground stud) must have a wire ground to the battery.
Tighten the ground stud every oil change. Ground wires/straps should be
combined at ground studs dedicated for ground use only. Inspect/Check
all engine grounds. All grounds should be tight and free of corrosion.
Perform the following procedures at least every other oil change, and
more often as conditions require:

Clean the grounding stud and strap terminals with a clean cloth.
If connections are corroded, clean with a solution of baking soda and
water.
Keep the ground stud and strap clean and coated with MPGM grease
or petroleum jelly.
Engine Valve Lash/Unit Injector Preload

This maintenance is to be performed between 24,000 and 96,000 km

(15,000 and 60,000 miles) or between the first and fourth oil changes.
Check/Adjust

WARNING: Be sure the engine cannot be started while

this maintenance is being performed. To
prevent possible injury, do not use the
starting motor to turn the flywheel. Hot
engine components can cause burns. Allow
additional time for the engine to cool before
measuring/adjusting valve lash. The
electronic unit injectors use high voltage.
Disconnect the unit injector enable circuit
connector to prevent personal injury. Do
not come in contact with the injector
terminals while the engine is running.

CAUTION:

Initial valve lash adjustment may be required due to initial wear and
seating of valve train components. On new, rebuilt, or remanufactured
engines, the adjustment is recommended between 24,000 and 96,000 km
(15,000 and 60,000 miles) or between first and fourth oil change
intervals. Subsequent adjustment should be made at the PM 2 interval.

This maintenance is recommended by Caterpillar as part of a preventive

maintenance schedule to provide maximum engine life.

CAUTION: Operation of Caterpillar engines with

improper valve and injector preload
adjustments will reduce engine efficiency.
This reduced efficiency could result in
excessive fuel usage and/or shortened
engine component life.

Adjust the injector preload at the same interval as the valve lash
adjustment. Refer to the appropriate procedure for complete valve
adjustment.
Engine Compression Brake Slave Piston Lash (If Equipped)

This maintenance is to be performed between 24,000 and 96,000 km

(15,000 and 60,000 miles) or between first the and fourth oil changes.
Check/Adjust

The compression brake slave piston lash can be adjusted following the
valve lash is adjustment. Make the slave piston adjustments with the
engine stopped. Refer to the OEM service publications for adjustment
information for this auxiliary braking system.
EVERY 240,000 KM (150,000 MILES) OR TWO YEARS

You must read and understand the warnings and instructions

contained in Safety , before performing any operation or
maintenance procedures.

CAUTION: Make sure you read and understand the

information in Safety and Cooling System
Specifications before you proceed with

cooling system maintenance.

Cooling System-Add Extender (For Engines Using LLCA Only)

For engines using Caterpillar Long Life Coolant/Antifreeze (LLCA),

Extender must be added at every 240,000 km (150,000 miles) or two
years, whichever comes first. Refer to Caterpillar Long Life
Coolant/Antifreeze (LLCA) for the recommended amount of Extender
to add to your cooling system.
EVERY TWO YEARS

You must read and understand the warnings and instructions

contained in Safety , before performing any operation or
maintenance procedures.
The Every Two Years interval is based on fuel consumption or 320,000
km (200,000 miles), whichever comes first.
Cooling System

CAUTION: Do not perform this maintenance until you

read and understand the material in Safety
and Cooling System Specifications .
Drain/Clean/Replace Coolant

Clean/Flush the cooling system before the recommended maintenance

interval if:

Coolant is heavily contaminated.

The engine overheats frequently.
Foaming is observed in the radiator.
The oil cooler has failed, allowing oil to contaminate the coolant.
Fuel has entered the cooling system and contaminated the coolant.

CAUTION: If you do not follow the cooling system

recommendations outlined in Cooling
System Specifications : drain, clean, and
refill the cooling system every year or
161,000 km (100,000 miles), whichever
comes first. Use of commercially available

cooling system cleaners may cause damage

to cooling system components. Use only
cooling system cleaners that are approved
for Caterpillar engines that have aluminum
cooling system and engine components. DO
NOT use a cooling system cleaner that
contains tri-sodium phosphate. Tri-sodium
phosphate will damage the aluminum
components in the engine.

NOTE: A good time to inspect the water pump, replace the

thermostat, and replace hoses is when your
engine's cooling system has been drained.

Drain
1. Stop the engine and allow the engine to cool. Loosen the coolant
filler cap slowly to relieve any pressure, and remove the cap.
2. Remove the cooling system drain plug(s) or open the drain valve.
Open the cab heater valve to drain coolant from the cab heater.
Remove the drain plug from the bottom of the water pump housing
and/or radiator. Allow the coolant to drain.

CAUTION: Dispose of used engine coolant properly

or recycle. Various methods have been
proposed to reclaim used coolant for
reuse in engine cooling systems. The
full distillation procedure is the only
method acceptable by Caterpillar to
reclaim the used coolant. Contact your
Caterpillar dealer for information
regarding disposal and recycling of
used coolant.

Clean
3. Flush the cooling system with clean water to remove any debris.
4. Clean and install all drain plugs and/or close the drain valve(s).

CAUTION: Fill the cooling system no faster than 19

L (5 US gal) per minute to avoid air

locks.

5. Fill the cooling system with a mixture of clean water and Caterpillar
Fast Acting Cooling System Cleaner. Add .5 L (1 pt) of Cleaner per
15 L (4 US gal) of cooling system capacity. Install the radiator filler
cap.
6. Start and run the engine for a minimum of 30 minutes with the
coolant temperature at 82°C (180°F). Stop the engine and allow the
engine to cool.
7. Loosen the filler cap slowly to relieve any pressure, and remove the
cap. Remove the cooling system drain plug(s) or open the drain
valve(s). Allow the cleaning solution to drain. Flush the cooling
system with clean water until the draining water is clear. Clean and
install all drain plugs and/or close the drain valve(s).

Fill
Refer to Cooling System Specifications for all information
regarding acceptable water, coolant/antifreeze, and supplemental
coolant additive requirements. Refer to Fig. 38 for the capacity of
your engine's system.

8. Fill the system with the recommended coolant/antifreeze mixture.

9. Start and run the engine with the filler cap removed. Allow the
coolant to warm, the thermostat to open and the coolant level to
stabilize. Check the coolant level. Add coolant mixture if necessary
to bring the coolant to within 13 mm (1/2 inch) below the bottom of
the fill tube or the correct level on the sight glass (if equipped).
10. Check the condition of the filler cap gasket. If the gasket is
damaged, discard the old filler cap and install a new filler cap. If the
gasket is not damaged, pressure test the filler cap with a 9S8140
Cooling System Pressurizing Pump Group. The correct filler cap
pressure is stamped on the face of the filler cap. If the filler cap does
not hold the correct pressure, install a new filler cap.
11. Start the engine and inspect for coolant leaks and proper operating
temperature. Check for coolant leaks at the oil cooler connections.
Stop the engine.
Cooling Systems with Heavy Deposits or Plugging

NOTE: For the following procedure to be effective, there

must be some active flow through the radiator and
the other cooling system components.

Follow the same steps as outlined above, with the following

modifications to steps 5 and 6:

5. Fill the cooling system with a mixture of clean water and

Caterpillar Fast Acting Cooling System Cleaner. Add .5 L (1 pt) of
Cleaner per 3.8 to 7.6 L (1 to 2 US gal) of cooling system capacity.
Install the radiator filler cap.
6. Start and run the engine for a minimum of 90 minutes with the
coolant temperature at 82°C (180°F). Stop the engine and allow the
engine to cool.
Water Pump

The cooling system clean/flush/replace coolant maintenance provides an

opportunity to inspect the water pump. Check the water pump breather
filter (if equipped) or standpipe for blockage.
Replace Thermostat, Gasket and Seal

NOTE: If replacing the thermostat ONLY, drain the coolant

from the cooling system to a level below the
thermostat housing.

Refer to WATER TEMPERATURE REGULATOR to perform the

maintenance that follows.

1. Stop the engine. Allow the engine to cool. Loosen the radiator filler
cap slowly to relieve any pressure, then remove the cap. Loosen the
hose clamps to disconnect hose assembly from the radiator to
thermostat housing assembly. Remove the thermostat housing
assembly and gaskets from the cylinder head.
2. Remove thermostat and gasket from the housing. Remove the lip-
type seal from the housing.

Install Thermostat

CAUTION: If the thermostat is installed wrong, it

will cause the engine to overheat.

Caterpillar engines incorporate a shunt

design cooling system and require
operating the engine with a thermostat
installed. Depending on load, failure to
operate with a thermostat could result in
either an overheating or excessive
cooling condition.

3. Replace the thermostat, gasket and seal. Install the seal with the lip
of the seal away from the thermostat until the seal is in the housing
counter bore seat. Install thermostat housing, connect the hose
assembly and tighten the hose clamps.
Inspect Air-to-Air Aftercooler

Check the front of the air-to-air aftercooler on a daily basis for

insects, dirt and other debris.
Clean the front of the aftercooler with a stainless steel brush and
soapy water.

NOTE: Depending on your findings and operating

environment, the maintenance interval for
cleaning the air-to-air aftercooler may be an as
needed basis.

Inspect all air ducts and gasket connections at every oil change.
Constant torque hose clamps should be used to secure the ducts.
Refer to Torque Specifications .
Check all welds for cracks. Check the mounting brackets to ensure
they are secure and in good condition.
Examine the aftercooler core fins for external damage, dirt, debris,
salt corrosion, etc. Use a firm stainless steel brush to remove dirt,
debris, salt, etc.
Use compressed air to clean core blockage due to dirt and debris.

NOTE: Whenever air-to-air aftercooler parts are repaired

and/or replaced, a leak test is highly
recommended.

CAUTION: A hose failure or significant system leak will

cause a large drop in boost pressure and

power. The engine can be operated at this
power level long enough to reach a safe
stop or repair area. Sustained operation
under this condition should be avoided.

A slight reduction in power or response, or a small increase in exhaust

temperature, may indicate a small air leak in the charge air cooler core or
piping.
Cleaning Procedure for Air-to-Air Aftercooler System

Caterpillar recommends that the air-to-air aftercooler core be removed,

cleaned, and tested if a turbocharger failure has occurred or if at any time
the turbocharger develops an oil leak.
1. Remove the air-to-air aftercooler core. Remove debris from the inlet
tank.

CAUTION: Do not use caustic cleaners to clean the

air-to-air aftercooler core. Caustic
cleaners will attack the internal metals
of the core and cause leakage.

2. Back flush internally with a solvent to loosen foreign substances and

to remove oil. Caterpillar recommends the use of 8T7570 Hydrosolv
4165 or 8T7571 Hydrosolv 100 Liquid Cleaners.
3. Shake the core vigorously to eliminate any trapped debris.
4. Wash the core with hot, soapy water. Rinse thoroughly with clean
water.
5. Dry the core with compressed air. Blow air in reverse direction of
normal flow. Use all necessary safety equipment while using
compressed air.
6. Inspect the system to ensure cleanliness and install the air-to-air
aftercooler core.
Radiator Fins

Check the radiator fins for debris. High pressure water is recommended
to clean debris from the radiator fins. If necessary, use a light bulb
behind the radiator fins to see if they are completely clean.

Fan Drive Bearing (If Equipped)

Lubricate

Lubricate one fitting with Caterpillar MPGM grease. Refer to Engine

Lubricant Specifications for the proper lubricating grease to use.
Inspect the fan drive pulley assembly. It should be difficult to detect
movement of the shaft in the bearing. If the shaft is loose, an inspection
of the internal components should be made.

If the assembly should require disassembly, refer to the appropriate

procedure.
PM LEVEL 2

You must read and understand the warnings and instructions

contained in Safety , before performing any operation or
maintenance procedures.

All PM Level 2 maintenance is to be performed at the interval

specified in Maintenance Schedule .
Before proceeding with PM Level 2 maintenance, perform all Two Year,
PM Level 1 and Daily maintenance requirements.
Engine

Steam Clean

CAUTION: Accumulated grease and oil on an engine is

a fire hazard. Keep your engine clean.
Remove debris and fluid spills each time a
significant quantity accumulates on the
engine.

Steam cleaning the engine provides for easy detection of fluid leaks.
Repairing an oil or coolant leak upon detection may save money by
avoiding major repairs that could result from low oil or coolant levels.
Steam cleaning the engine as recommended will also improve the
engine's heat transfer characteristics.
Turbocharger

CAUTION: Turbocharger bearing failures can cause

large quantities of oil to enter the air intake
and exhaust systems. Loss of engine
lubricant can result in serious engine
damage.
Minor leakage of a turbocharger housing
under extended low idle operation will not
cause problems as long as a turbocharger
bearing failure has NOT occurred.
When a turbocharger bearing failure is
accompanied by a significant engine
performance loss (exhaust smoke or engine
speed up at no load), DO NOT continue
engine operation until the turbocharger is
repaired or replaced.

An inspection/check of your turbocharger will minimize unscheduled

downtime and reduce the chance for potential damage to other engine
parts.
Inspect/Check

Fig. 66: Turbocharger

1. Remove the exhaust outlet and air inlet piping from the
turbocharger. Visually check for oil leaks.
2. Turn the turbine and compressor wheel by hand. The assembly
should turn freely.
3. Inspect the turbine wheel and compressor wheel for contact with the
turbocharger housing. There should NOT be any visible signs of
contact between the turbine or compressor wheels and the
turbocharger housing.
4. Check the compressor wheel for cleanliness. If only the blade side of
the wheel is dirty, dirt and/or moisture is passing through the air
filtering system. If oil is found only on the back side of the wheel, it
indicates a possible turbocharger oil seal leak.

The leak may be the result of extended engine operation at low idle
or an intake air line restriction (plugged air filters), which causes the
engine to "slobber".

Maintain the compressor wheel/turbine housing by cleaning

with standard shop solvents and a soft bristle brush.
5. Check the end play and bearing clearance on the turbine wheel and
shaft. If the measurements are not within specifications (see the
appropriate procedure ), the turbocharger must be repaired or
replaced.

CAUTION: Ensure the wastegate boost line (if

equipped) is connected properly. Do
NOT tamper with wastegate boost line.
A loose boost line will raise heat
rejection, increase turbocharger speed
and peak cylinder pressure, which will
negatively affect engine performance.

6. When installing or replacing V-band clamps, position the gap

(tightening screw) down if possible so any accumulation of moisture
will drain away.
Removal and Installation

For removal and installation, or repair/replacement options of

turbochargers, see the appropriate person(s) for the procedure and
specifications.
Crankshaft Vibration Damper

Inspect/Check

Damage to, or failure of, the damper will increase torsional vibrations
and result in damage to the crankshaft and other engine components. A
deteriorating vibration damper will cause excessive gear train noise at
variable points in the engine speed range.

Your engine may be equipped with a Rubber Crankshaft Torsional

Vibration Damper. This damper uses a rubber mounted ring to reduce
crankshaft vibration. Some engines are equipped with a Visconic
Torsional Vibration Damper. A visconic damper uses a weight
suspended in oil to reduce crankshaft vibration. Mounted to the
crankshaft, the vibration damper is located behind the belt guard on the
front of the engine.
Rubber Damper (If Equipped)

Inspect rubber dampers for:

deterioration and cracking.

movement of the rubber from its original location.

If any of the above conditions exist, replace the damper. Refer to the
appropriate replacement procedure.
Visconic Damper (If Equipped)

If your engine is equipped with a Visconic damper, the vibration damper

weight is located inside a fluid filled case. The weight moves in the case
to limit torsional vibration. A failing visconic damper has the same
detrimental effects as a failing rubber cushioned damper.

Inspect visconic dampers for evidence of dents, cracks, and fluid leaks.
Replace the damper if it is dented, cracked, or leaking. Refer to the
appropriate replacement procedure.

NOTE: Refer to the appropriate replacement procedure for

the necessary specifications.
Air Compressor

Inspect/Check

WARNING: Do not disconnect the air line from the air

compressor governor without purging the
air brake and auxiliary air systems. Failure
to purge the air brake and auxiliary air
systems before removing the air
compressor and/or air lines could cause
personal injury.

Inspect the air compressor as instructed by the OEM or truck

manufacturers' instructions. For more information on how to check your
air compressor, refer to the appropriate procedure for this engine.
Engine Valve Lash/Unit Injector Preload

Check/Adjust

Refer to Engine Valve Lash/Unit Injector Preload for information

regarding check/adjust procedure.

CAUTION: Refer to the appropriate procedures for

engine valve lash and complete valve
adjustment.
Engine Valve Rotators

WARNING: When inspecting the valve rotators,

protective glasses or face shield and
protective clothing must be worn, to
prevent being burned by hot oil or spray.
The electronic engine uses high voltage to
the unit injectors. Disconnect the unit
injector enable circuit connector to prevent
personal injury. Do not come in contact
with the unit injector terminals while the
engine is running.

Observe rotation of valves with engine idling after setting the valve lash.
Caterpillar recommends replacement of improperly operating valve
rotators. An improperly operating valve rotator will shorten valve life
through accelerated valve face and valve seat wear. If a damaged rotator
is not replaced, valve face guttering could result in pieces of the valve to
fall into the cylinder and cause piston and cylinder head damage.
Unit Injector Preload Adjustment

Adjust injector preload at the same interval as the valve lash adjustment.
Refer to the appropriate procedure for the complete valve adjustment.
Engine Compression Brake Slave Lash (If Equipped)

Check/Adjust

Adjust compression brake slave lash at the same time the valve lash is
adjusted. Make the slave piston adjustments with the engine stopped.
Refer to the appropriate procedure or the OEM service publications for
adjustment information regarding the auxiliary engine brake system.
EVERY FOUR YEARS

You must read and understand the warnings and instructions

contained in Safety , before performing any operation or
maintenance procedures.

Cooling System

CAUTION: Do not perform this maintenance until you

read and understand the material in Safety
and Cooling System Specifications .
Drain/Flush/Replace Coolant (Long Life Coolant/Antifreeze Only)

Caterpillar Long Life Coolant/Antifreeze should be replaced every 6,000

Service Hours or Four Years, whichever comes first. Only clean water is
needed to clean and flush the cooling system when LLCA is drained and
replaced.

Drain
1. Stop the engine and allow the engine to cool. Loosen the coolant
filler cap slowly to relieve any pressure, and remove the cap.
2. Remove the cooling system drain plug(s) or open the drain valve.
Remove the drain plug from the bottom of the water pump housing
(if equipped) and/or radiator. Allow the coolant to drain.

CAUTION: Dispose of used engine coolant properly

Flush
3. Flush the cooling system with clean water to remove any debris.
4. Clean and install all drain plugs and/or close the drain valve(s).

CAUTION: To prevent air locks, fill the cooling

system no faster than 19 L (5 US gal) per
minute.

5. Fill the cooling system with clean water. Install the filler cap.
Operate the engine until warm 49 to 66°C (150 to 120°F).
6. Stop the engine and allow the engine to cool. Loosen the coolant
filler cap slowly to relieve any pressure, and remove the cap.
Remove the cooling system drain plug(s) or open the drain valve.
Allow the water to drain. Flush the cooling system with clean water.
7. Repeat steps 6 and 7.

Fill
8. Fill the cooling system with LLCA. Refer to Fig. 12 for the amount
of LLCA needed to refill your system.
9. Start and run the engine with the filler cap removed. Allow the
LLCA to warm, the thermostat to open, and the coolant level to
stabilize. Add LLCA if necessary to bring the coolant to the proper
level.
10. Check the condition of the filler cap gasket. If the gasket is
damaged, discard the old filler cap and install a new filler cap. If the
gasket is not damaged, use a 9S8140 Cooling System Pressurized
Pump Group to pressure test the filler cap. The correct filler cap
pressure is stamped on the face of the filler cap. If the filler cap does
not hold the correct pressure, install a new filler cap.
11. Start the engine and inspect for coolant leaks and proper operating
temperature. Stop the engine.
SEVERE SERVICE APPLICATION

Maintenance and operation practices affect component life when

operating the engine in severe service applications.
The level of maintenance an engine receives is crucial to its service life.
Other major factors affecting service life are operating speed and loads.

The conditions that follow can indicate severe service operation.

Operation above 36,320 kg (80,000 lb) gross vehicle weight (GVW)

and other high load factor operation such as off-highway.
Frequent high altitude operation above 1,525 meters (5,000 ft).
Extended operation at low idle.
Arctic operation (regular cold starts at temperatures below - 18°C

[0°F]).
Extending lube and air system maintenance beyond recommended
intervals.
Frequent hot shutdowns (minimum five minute cool down periods
after high load factor operation).
Unit Injectors

Fuel quality (amount of water, solid contaminants, etc.) and the quality
of filtration will affect unit injector wear. Normal unit injector wear may
accelerate when the engine operates in a severe application.

This wear can result in elevated exhaust emission levels (black smoke,
etc.) and/or poor engine performance. Single cylinder misfire is not
typically attributed to normal wear and can be repaired by replacing the
faulty unit injector.

CAUTION: The engine will be damaged if a defective

unit injector is used because of the shape of
fuel (spray pattern) that is injected into the
cylinder will be incorrect.

Severe service operation may create the need for evaluation of all unit
injectors prior to overhaul. The conditions that follow can indicate severe
service operation.
Use of fuels NOT recommended by Caterpillar in Fig. 20 and Fig.
21 .
Extreme (high or low) ambient temperature conditions (when fuel
lubricating properties can diminish).
Frequent fuel filter plugging.
Extended fuel system maintenance intervals.
Inadequate fuel tank/storage tank maintenance (excessive water,
sediment or microorganism growth, etc.)
MAINTENANCE RECORDS

Caterpillar recommends that accurate maintenance records be

maintained. Accurate maintenance records can be used for determining
operating costs, establishing maintenance schedules for other engines
being operated in the same environment, and for a variety of other related

business decisions.

Accurate maintenance records can also be used to show compliance with

the required maintenance practices and intervals. Documents such as
dealer work orders, itemized bills, owner's repair orders, receipts and
owner's vehicle log are generally accepted as proof of maintenance or
repair for warranty. Documents must show date of maintenance
performed, kilometers (mileage), unit number, vehicle and/or engine
serial number.

If the vehicle is sold within the warranty period, transfer the records with
the vehicle.
MAINTENANCE LOG

Fig. 67: Maintenance Log

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