SEBU7902-09 (en-us)

November 2019

Operation and
Maintenance
Manual
C15 Industrial Engines
JRE 1-UP (Engine)
MCW 1-UP (Engine)
P5H 1-UP (Engine)
JAS 1-UP (Engine)
JKG 1-UP (Engine)
PBN 1-UP (Package)
PDM 1-UP (Package)

PUBLICATIONS.CAT.COM
 i06558969

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7902-09 3
Table of Contents

Table of Contents Refill Capacities............................................... 47

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

Foreword ........................................................... 4
Maintenance Interval Schedule (Engines Which
Safety Section
Have Shallow Sumps) ................................... 59
Safety Messages............................................... 6
Maintenance Interval Schedule (Engines Which
Have Deep Sumps) ....................................... 61
General Hazard Information.............................. 7

Burn Prevention............................................... 10 Warranty Section

Fire Prevention and Explosion Prevention.......11 Warranty Information....................................... 98

Crushing Prevention and Cutting Prevention.. 13 Reference Information Section

Mounting and Dismounting ............................. 13 Engine Ratings ................................................ 99

Before Starting Engine .................................... 13 Customer Service.......................................... 100

Engine Starting................................................ 14 Reference Materials ...................................... 102

Engine Stopping .............................................. 14 Index Section

Electrical System............................................. 15 Index.............................................................. 105

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

Product Information Section

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

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

Operation Section

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

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

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

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

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

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

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

Maintenance Section
4 SEBU7902-09
Foreword

Foreword Some photographs or illustrations in this manual

show details or attachments that may be different
from your engine. Guards and covers may have been
California Proposition 65 Warning removed for illustrative purposes. Continuing
improvement and advancement of product design
Diesel engine exhaust and some of its may have caused changes to your engine which are
not included in this manual Whenever a question
constituents are known to the State of arises regarding your engine, or this manual, please
California to cause cancer, birth defects, consult with your Cat dealer for the latest available
and other reproductive harm. information.

WARNING – This product can Safety

expose you to chemicals
including ethylene glycol, which This safety section lists basic safety precautions. In
is known to the State of California to addition, this section identifies hazardous, warning
cause birth defects or other reproductive situations. Read and understand the basic
harm. For more information go to: precautions listed in the safety section before
operating or performing lubrication, maintenance,
and repair on this product.
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands Operation
after handling to avoid incidental Operating techniques outlined in this manual are
ingestion. basic. They assist with developing the skills and
techniques required to operate the engine more
WARNING – This product can efficiently and economically. Skill and techniques
expose you to chemicals develop as the operator gains knowledge of the
including lead and lead engine and its capabilities.
compounds, which are known to the
The operation section is a reference for operators.
State of California to cause cancer, birth Photographs and illustrations guide the operator
defects, or other reproductive harm. For through procedures of inspecting, starting, operating,
more information go to: and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
www.P65Warnings.ca.gov
Maintenance
Wash hands after handling components
that may contain lead. The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
Literature Information by fuel consumption, service hours and/or calendar
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that
This manual contains safety, operation instructions, follow.
lubrication, and maintenance information. This
manual should be stored in or near the engine area in Use fuel consumption or service hours to determine
a literature holder or literature storage area. Read, intervals. Calendar intervals shown (daily, annually,
study, and keep it with the literature and engine etc.) may be used instead of service meter intervals if
information. they provide more convenient schedules and
approximate the indicated service meter reading.
English is the primary language for all Cat
publications. The English used facilitates translation Recommended service should be performed at the
and consistency in electronic media delivery. appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
freezing cold operating conditions, more frequent
lubrication, and maintenance than is specified in the
Maintenance Interval Schedule may be necessary.
SEBU7902-09 5
Foreword

The maintenance schedule items are organized for a

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

Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. We recommend that the
maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engine's permanent record.
See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information
regarding documents that are accepted as proof of
maintenance or repair. Your authorized Cat dealer
can assist you in adjusting your maintenance
schedule to meet the needs of your operating
environment.

Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
authorized Cat dealer. Your Cat dealer offers various
options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available
from your Cat dealer. Consult with your dealer for
information regarding these options.
6 SEBU7902-09
Safety Section
Safety Messages

Safety Section
i02840190

Safety Messages
SMCS Code: 1000; 7405

Illustration 1 g01416710

Universal Warning (1)

Do not operate or work on this engine unless you The safety messages for the universal warning are
have read and understand the instructions and located toward the front of the engine on both sides
warnings in the Operation and Maintenance Man- of the valve cover base.
ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.

There may be several specific safety messages on

your engine. The exact location and a description of
the safety messages are reviewed in this section.
Please become familiar with all safety messages.
Ensure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and
soap to clean the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off of
the engine.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
SEBU7902-09 7
Safety Section
General Hazard Information

Cautiously remove the following parts. To help

prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps

• Grease fittings
• Pressure taps
• Breathers

• Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
Illustration 2 g01105289 bolts or nuts that are located at opposite ends of the
cover plate or the device. Before removing the last
two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.

Do not operate or work on this engine unless you

have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.

i06300340

General Hazard Information

SMCS Code: 1000; 4450; 7405

Illustration 4 g00702020

• Wear a hard hat, protective glasses, and other

protective equipment, as required.

• When work is performed around an engine that is

operating, wear protective devices for ears in
order to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can

snag on controls or on other parts of the engine.
• Ensure that all protective guards and all covers
are secured in place on the engine.
• Never put maintenance fluids into glass
Illustration 3 g03838041 containers. Glass containers can break.
Attach a “Do Not Operate” warning tag to the start • Use all cleaning solutions with care.
switch or controls before the engine is serviced or
repaired. These warning tags (Special Instruction, • Report all necessary repairs.
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each Unless other instructions are provided, perform
operator control station. When appropriate, the maintenance under the following conditions:
disconnect the starting controls.
• The engine is stopped. Ensure that the engine
Do not allow unauthorized personnel on the engine, cannot be started.
or around the engine when the engine is being
serviced.
8 SEBU7902-09
Safety Section
General Hazard Information

• The protective locks or the controls are in the Avoid direct spraying of water on electrical
applied position. connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
• Disconnect the batteries when maintenance is reduce the possibility of fine debris igniting when
performed or when the electrical system is redeposited on hot surfaces.
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks. Fluid Penetration
• When starting a new engine, make provisions to
stop the engine if an overspeed occurs. If an
engine has not been started since service has
been performed, make provisions to stop the
engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine.
• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.

• Start the engine with the operator controls. Never

short across the starting motor terminals or the
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the Illustration 5 g00687600

electrical system could be damaged.

Always use a board or cardboard when you check for
a leak. Leaking fluid that is under pressure can
Pressurized Air and Water penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
Pressurized air and/or water can cause debris and/or cause severe injury. If fluid is injected into your skin,
hot water to be blown out which could result in you must get treatment immediately. Seek treatment
personal injury. from a doctor that is familiar with this type of injury.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air Containing Fluid Spillage
nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective
equipment. The maximum water pressure for NOTICE
cleaning purposes must be below 275 kPa (40 psi). Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
When pressurized air and/or pressurized water is nance, testing, adjusting, and repair of the product.
used for cleaning, wear protective clothing, protective Be prepared to collect the fluid with suitable contain-
shoes, and eye protection. Eye protection includes ers before opening any compartment or disassem-
goggles or a protective face shield. Always wear eye bling any component containing fluids.
protection for cleaning the cooling system. Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
SEBU7902-09 9
Safety Section
General Hazard Information

Static Electricity Hazard when Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. Correct
Fueling with Ultra-low Sulfur Diesel installation of these components will help to prevent
Fuel these effects: vibration, rubbing against other parts
and excessive heat during operation.
The removal of sulfur and other compounds in ultra-
low sulfur diesel fuel (ULSD fuel) decreases the Inhalation
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.

Illustration 6 g02159053
Avoid static electricity risk when fueling. Ultra-
low sulfur diesel fuel (ULSD fuel) poses a greater Exhaust
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death Use caution. Exhaust fumes can be hazardous to
or serious injury from fire or explosion. Consult your health. If you operate the equipment in an
with your fuel or fuel system supplier to ensure enclosed area, adequate ventilation is necessary.
the delivery system is in compliance with fueling
standards for proper grounding and bonding Asbestos Information
practices.
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free.
Lines, Tubes, and Hoses Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
Do not bend or strike high-pressure lines. Do not you handle any replacement parts that contain
install lines, tubes, or hoses that are damaged. asbestos or when you handle asbestos debris.

Repair any fuel lines, oil lines, tubes, or hoses that Use caution. Avoid inhaling dust that might be
are loose or damaged. Leaks can cause fires. generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
Inspect all lines, tubes, and hoses carefully. Do not to your health. The components that may contain
use bare hands to check for leaks. Always use a asbestos fibers are brake pads, brake bands, lining
board or cardboard for checking engine components material, clutch plates, and some gaskets. The
for leaks. Tighten all connections to the asbestos that is used in these components is bound
recommended torque. in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
Check for the following conditions: asbestos is generated.

• End fittings that are damaged or leaking If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Outer covering that is chafed or cut
• Never use compressed air for cleaning.
• Wire that is exposed in reinforced hose
• Avoid brushing materials that contain asbestos.
• Outer covering that is ballooning locally
• Avoid grinding materials that contain asbestos.
• Flexible part of the hose that is kinked or crushed
• Use a wet method in order to clean up asbestos
• Armoring that is embedded in the outer covering materials.
10 SEBU7902-09
Safety Section
Burn Prevention

• A vacuum cleaner that is equipped with a high Reference: The applicable material safety data
efficiency particulate air filter (HEPA) can also be sheets can be found at the following web site by
used. searching using part number or the name:

• Use exhaust ventilation on permanent machining https://catmsds.cat.com/MSDSSearch/servlet/

jobs. cat.cis.ecs.
msdsSearch.controller.
• Wear an approved respirator if there is no other UserIdentificationDisplayServlet
way to control the dust.
• Comply with applicable rules and regulations for Dispose of Waste Properly
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of
asbestos.

• Stay away from areas that might have asbestos

particles in the air.

Softwrap
Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate Illustration 7 g00706404
protective clothing in order to minimize direct contact.
Use good hygiene practices and wash hands Improperly disposing of waste can threaten the
thoroughly after handling Softwrap material. Do not environment. Potentially harmful fluids should be
smoke until washing hands thoroughly after handling disposed of according to local regulations.
Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean Always use leakproof containers when you drain
up debris. fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.

i02088921

Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
appropriate system before any lines, fittings or
related items are disconnected.

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the
cooling system is drained.
SEBU7902-09 11
Safety Section
Fire Prevention and Explosion Prevention

Check the coolant level after the engine has stopped All fuels, most lubricants, and some coolant mixtures
and the engine has been allowed to cool. Ensure that are flammable.
the filler cap is cool before removing the filler cap.
The filler cap must be cool enough to touch with a Always perform a Walk-Around Inspection, which
bare hand. Remove the filler cap slowly in order to may help you identify a fire hazard. Do not operate a
relieve pressure. product when a fire hazard exists. Contact your Cat
dealer for service.
Cooling system conditioner contains alkali. Alkali can
Flammable fluids that are leaking or spilled onto hot
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth. surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property
damage.
Oils
A flash fire may result if the covers for the engine
Hot oil and hot lubricating components can cause crankcase are removed within 15 minutes after an
personal injury. Do not allow hot oil or hot emergency shutdown.
components to contact the skin.
Determine whether the engine will be operated in an
If the application has a makeup tank, remove the cap environment that allows combustible gases to be
for the makeup tank after the engine has stopped. drawn into the air inlet system. These gases could
The filler cap must be cool to the touch. cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Batteries If the application involves the presence of
combustible gases, consult your Cat dealer for
The liquid in a battery is an electrolyte. Electrolyte is additional information about suitable protection
an acid that can cause personal injury. Do not allow devices.
electrolyte to contact the skin or the eyes.
Remove all flammable materials such as fuel, oil, and
Do not smoke while checking the battery electrolyte debris from the engine. Do not allow any flammable
levels. Batteries give off flammable fumes which can materials to accumulate on the engine.
explode.
All fluids that are captured in the fluid spill
Always wear protective glasses when you work with containment basin should be cleaned up
batteries. Wash hands after touching batteries. The immediately. Failure to clean up spilled fluids can
use of gloves is recommended. cause a fire. Fire may cause personal injury and
property damage.
i07254650
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
Fire Prevention and Explosion oily rags and any flammable materials in protective
Prevention containers. Do not smoke in areas that are used for
storing flammable materials.
SMCS Code: 1000; 4450; 7405
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in a line, a tube, or
a seal failure. Exhaust shields must be installed
correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not use flame to cut lines or tanks that
contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Properly route
and attach all electrical wires. Check all electrical
wires daily. Repair any wires that are loose or frayed
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.
Illustration 8 g00704000
Eliminate all wiring that is unattached or
Use of personal protection equipment (PPE) may be unnecessary. Do not use any wires or cables that are
needed. smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
12 SEBU7902-09
Safety Section
Fire Prevention and Explosion Prevention

Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
deterioration. Properly route all hoses. The lines and
hoses must have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
Properly install all oil filters and fuel filters. The filter
housings must be tightened to the proper torque.

Illustration 10 g02298225

Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a
hydrometer.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
Illustration 9 g00704059 instructions.

Use caution when you are refueling an engine. Do Do not charge a frozen battery. Charging a frozen
not smoke while you are refueling an engine. Do not battery may result in an explosion.
refuel an engine near open flames or sparks. Always The batteries must be kept clean. The covers (if
stop the engine before refueling. equipped) must be kept on the cells. Use the
Avoid static electricity risk when fueling. Ultra Low recommended cables, connections, and battery box
Sulfur Diesel (ULSD) poses a greater static ignition covers when the engine is operated.
hazard than earlier diesel formulations with a higher
Sulfur content. Avoid death or serious injury from fire Fire Extinguisher
or explosion. Consult with your fuel or fuel system
supplier to ensure that the delivery system is in Make sure that a fire extinguisher is available. Be
compliance with fueling standards for proper familiar with the operation of the fire extinguisher.
grounding and bonding practices. Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

Ether
Ether is flammable and poisonous.
Use ether in ventilated areas. Do not smoke while
you are replacing an ether cylinder or while you are
using an ether spray.
SEBU7902-09 13
Safety Section
Crushing Prevention and Cutting Prevention

Do not store ether cylinders in living areas or in the Stay clear of all rotating parts and of all moving parts.
engine compartment. Do not store ether cylinders in Leave the guards in place until maintenance is
direct sunlight or in temperatures above 49 °C performed. After the maintenance is performed,
(120 °F). Keep ether cylinders away from open reinstall the guards.
flames or sparks.
Keep objects away from moving fan blades. The fan
Dispose of used ether cylinders properly. Do not blades will throw objects or cut objects.
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel. When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Do not spray ether into an engine if the engine is
equipped with a thermal starting aid for cold weather Chips or other debris may fly off objects when objects
starting. are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
Lines, Tubes, and Hoses
i01372247
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent Mounting and Dismounting
or damaged.
SMCS Code: 1000; 4450; 7405
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Cat dealer for repair or Inspect the steps, the handholds, and the work area
for replacement parts. before mounting the engine. Keep these items clean
and keep these items in good repair.
Check lines, tubes, and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or Mount the engine and dismount the engine only at
cardboard to check for leaks. Tighten all connections locations that have steps and/or handholds. Do not
to the recommended torque. climb on the engine, and do not jump off the engine.

Replace the parts if any of the following conditions Face the engine in order to mount the engine or
are present: dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
• End fittings are damaged or leaking. hand or use one foot and two hands. Do not use any
controls as handholds.
• Outer coverings are chafed or cut. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
• Wires are exposed. platform. Secure the climbing equipment so that the
equipment will not move.
• Outer coverings are ballooning.
Do not carry tools or supplies when you mount the
• Flexible parts of the hoses are kinked. engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
• Outer covers have embedded armoring.
• End fittings are displaced. i03560601

Make sure that all clamps, guards, and heat shields

are installed correctly to prevent vibration, rubbing
Before Starting Engine
against other parts, and excessive heat. SMCS Code: 1000

i01359666 NOTICE
For initial start-up of a new or rebuilt engine, and for
Crushing Prevention and start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
Cutting Prevention occur. This may be accomplished by shutting off the
SMCS Code: 1000; 4450; 7405 air and/or fuel supply to the engine.

Support the component properly when work beneath

the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
14 SEBU7902-09
Safety Section
Engine Starting

To ensure that the jacket water heater (if equipped)

and/or the lube oil heater (if equipped) is working
Engine exhaust contains products of combustion properly, check the water temperature gauge and the
which may be harmful to your health. Always oil temperature gauge during the heater operation.
start and operate the engine in a well ventilated Engine exhaust contains products of combustion that
area and, if in an enclosed area, vent the exhaust can be harmful to your health. Always start the
to the outside.
engine and operate the engine in a well ventilated
Inspect the engine for potential hazards. area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Do not start the engine or move any of the controls if
there is a “DO NOT OPERATE” warning tag or similar Ether
warning tag attached to the start switch or to the
controls. Ether is poisonous and flammable.
Before starting the engine, ensure that no one is on, Do not inhale ether, and do not allow ether to contact
underneath, or close to the engine. Ensure that the the skin. Personal injury could result.
area is free of personnel.
Do not smoke while ether cylinders are changed.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all Use ether in well ventilated areas.
lights work properly, if equipped.
Use ether with care in order to avoid fires.
All protective guards and all protective covers must
be installed if the engine must be started in order to Keep ether cylinders out of the reach of unauthorized
persons.
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work Store ether cylinders in authorized storage areas
around the parts carefully. only.
Do not bypass the automatic shutoff circuits. Do not Do not store ether cylinders in direct sunlight or at
disable the automatic shutoff circuits. The circuits are temperatures above 49 °C (120 °F).
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent Discard the ether cylinders in a safe place. Do not
engine damage. puncture the ether cylinders. Do not burn the ether
cylinders.
See the Service Manual for repairs and for
adjustments.
i07668288

i01103904
Engine Stopping
Engine Starting SMCS Code: 1000
SMCS Code: 1000 • Remove the load in increments.
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move • Open the circuit breaker.
the controls. Consult with the person that attached • Allow the engine to run for five minutes to cool.
the warning tag before the engine is started.
All protective guards and all protective covers must • Stop the engine.
be installed if the engine must be started in order to Use the Emergency Stop Button (if equipped) ONLY
perform service procedures. To help prevent an in an emergency situation. Do not use the
accident that is caused by parts in rotation, work Emergency Stop Button for normal engine stopping.
around the parts carefully. After an emergency stop, DO NOT start the engine
Start the engine from the operator's compartment or until the problem that caused the emergency stop
from the engine start switch. has been corrected.
Stop the engine if an overspeed condition occurs
Always start the engine according to the procedure during the initial start-up of a new engine or an
that is described in this Operation and Maintenance engine that has been overhauled. This may be
Manual, “Engine Starting” topic (Operation Section). accomplished by shutting off the fuel supply to the
Knowing the correct procedure will help to prevent engine and/or shutting off the air supply to the
major damage to the engine components. Knowing engine.
the procedure will also help to prevent personal
injury.
SEBU7902-09 15
Safety Section
Electrical System

To stop an electronically controlled engine, cut the

power to the engine.

i02469632

Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” jump start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. Refer to
the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.

Grounding Practices Illustration 12 g00771487

Typical example
Alternate Grounding Stud To Battery Ground

Proper grounding for the engine electrical system is

necessary for optimum engine performance and
reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
To ensure that the engine and the engine electrical
systems function properly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a starting
motor ground, a starting motor ground to the frame,
or a direct engine ground to the frame.

Illustration 11 g00771448
Typical example
Grounding Stud To Battery Ground
16 SEBU7902-09
Safety Section
Engine Electronics

All grounds should be tight and free of corrosion. The

engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.

i02784356

Engine Electronics
SMCS Code: 1000; 1900

Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.
This engine has a comprehensive, programmable
Engine Monitoring System. The Engine Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine
monitoring control: WARNING, DERATE and
SHUTDOWN. These engine monitoring modes have
the ability to limit engine speed and/or the engine
power.
Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring
functions. The following parameters can be
monitored as a part of the Engine Monitoring System:

• Operating Altitude
• Engine Coolant Level

• Engine Coolant Temperature

• Engine Oil Pressure

• Engine Speed
• Fuel Temperature

• Intake Manifold Air Temperature

• System Voltage
The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: Many of the engine control systems and
display modules that are available for Caterpillar
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting
Manual for more information.
SEBU7902-09 17
Product Information Section
General Information

Product Information
Section

General Information
i02093819

Model View Illustrations

SMCS Code: 1000

Illustration 13 g00947237

(1) Inlet air manifold (5) Low pressure turbocharger (9) Water pump
(2) Lifting eyes (6) High pressure turbocharger (10) Vibration damper
(3) Engine crankcase breather (7) Cooler
(4) Water temperature regulator housing (8) Engine oil filter
18 SEBU7902-09
Product Information Section
Product Description

Illustration 14 g00947236

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

i04250469 Very high injection pressures are produced by

electronically controlled, mechanically actuated unit
Product Description injectors. The injectors combine the pumping and the
electronic fuel metering (duration and timing) during
SMCS Code: 1000; 4450; 4491 injection. The unit injectors accurately control smoke
limiting, white smoke, and engine acceleration rates.
Table 1
C15 Engine Specifications There is one unit injector per cylinder. Individual unit
injectors meter the fuel. The individual unit injectors
Cylinders and Arrangement In-line six cylinder also pump the fuel. The metering and the pumping is
done under high pressure. High injection pressures
Bore 137.2 mm (5.4 inch) help to reduce fuel consumption and emissions. The
Stroke 171.5 mm (6.8 inch) use of this type of unit injector provides total
electronic control of injection timing. The injection
Displacement 15.2 L (928 in3) timing varies with engine operating conditions. The
engine performance is optimized in the following
Firing Order 1-5-3-6-2-4 areas:
Rotation (flywheel end) Counterclockwise • Starting

The electronic engines that are covered by this • Emissions

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

The electronic engine control system provides the The timing advance is achieved through precise
following functions: electronic governing, automatic control of the injector firing. Engine speed is
air to fuel ratio control, torque rise shaping, injection controlled by adjusting the firing duration. The
timing control and system diagnostics. information is provided to the Electronic Control
Module (ECM) by an engine speed/timing sensor.
An electronic governor controls the output of the unit The information is for detection of cylinder position
injectors in order to maintain the engine rpm that is and engine speed.
desired. The functions of the governor include a
programmable low idle and a 20 rpm to 200 rpm
governor overrun.
SEBU7902-09 19
Product Information Section
Product Description

The engines have built-in diagnostics in order to However, failures that result from the installation
ensure that all of the components are functioning and or use of devices, accessories, or consumables
operating properly. In the event of a system from other manufacturers are NOT Caterpillar
component deviation from the programmed limits, the defects. Therefore, the defects are NOT covered
operator is alerted to the condition by a under the Caterpillar warranty.
DIAGNOSTIC lamp that is mounted on the control
panel. An electronic service tool that is provided by Welding and Cat Electronic
Cat may be used to read the numerical code of the
diagnostic flash code. There are three types of Engines
diagnostic codes: ACTIVE, LOGGED and EVENT.
These codes are logged and stored in the ECM. NOTICE
Refer to the Operation and Maintenance Manual, Because the strength of the frame may decrease,
“Engine Diagnostics” for additional information. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
The cooling system consists of the following items: a ment or your Cat dealer regarding welding on a chas-
centrifugal pump that is driven by a gear, water sis frame or rail.
temperature regulator, an oil cooler and a radiator
that incorporates a shunt system. To help avoid damage to the electronic controls,
proper welding procedures are necessary. Before
The engine lubricating oil is supplied by a gear type welding on a vehicle that is equipped with an
pump. The engine lubricating oil is cooled and electronic engine, observe the following precautions:
filtered. Bypass valves provide unrestricted flow of
lubrication oil when the oil viscosity is high or if the oil 1. Turn off the engine. Place the key start switch in
cooler or oil filter elements become plugged. the OFF position.
Engine efficiency, efficiency of emission controls, and 2. If the application has a battery disconnect switch,
engine performance depend on adherence to proper open the switch. Otherwise, disconnect the
operation and maintenance recommendations negative “-” battery cable from the battery of the
including the use of recommended fuels, coolants,
and lubrication oils. vehicle.

NOTICE
Aftermarket Products and Cat Do not ground the welder to electrical components
Engines such as the ECM or sensors. Improper grounding
can cause damage to the drive train bearings, hy-
draulic components, electrical components, and oth-
NOTICE er components.
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a Clamp the ground cable from the welder to the com-
two micron absolute high efficiency fuel filter is re- ponent that will be welded. Place the clamp as close
quired for all Caterpillar Electronic Unit Injectors. Cat- as possible to the weld. This will help reduce the pos-
erpillar High Efficiency Fuel Filters meet these sibility of damage.
requirements. Consult your Caterpillar dealer for the
proper part numbers.
3. Clamp the ground cable from the welder to the
When auxiliary devices, accessories, or component that will be welded. Place the clamp as
consumables which are made by other close as possible to the weld.
manufacturers are used on Cat products, the
Caterpillar warranty is not affected simply because of 4. Protect wiring harnesses from welding debris and
such use. from spatter. Use proper welding procedures.
20 SEBU7902-09
Product Information Section
Product Identification Information

Product Identification Serial Number Plate (1)

Information The engine serial number plate is located on the
upper right side of the engine block.
i02093824
Engine serial number
Plate Locations and Film Engine model
Locations Arrangement number
SMCS Code: 1000; 4450
Information Plate (2)
The engine information plate is located on the valve
cover base near the front of the left side of the
engine.
Engine Serial Number
Engine Arrangement Number
Engine Modification Number
The engine identification plate also contains other
important information about the engine.

i00844066

Emissions Certification Film

SMCS Code: 1000; 7405

Illustration 16 g00284658
EPA Emissions Certification Film

Illustration 15 g01068240
(1) Serial number plate
(2) Information plate

Caterpillar engines are identified by serial numbers

and by arrangement numbers. These numbers are
shown on the engine serial number plate and on the
engine information plate. Caterpillar dealers need
these numbers in order to determine the components
that were included with the engine. This permits
accurate identification of replacement part numbers.
Illustration 17 g00415538
European Emissions Certification Film
SEBU7902-09 21
Product Information Section
Reference Information

The EPA Emissions Certification Film (if equipped) (Table 2, contd)

and/or the European Emissions Certification Film (if Engine air cleaner ele-
equipped) is located on the side of the engine. ment part number

i04128675 Fan drive belt part

number

Reference Information Alternator belt part

number
SMCS Code: 1000; 4450
Information for the following items may be needed to
order parts. Locate the information for your engine.
Record the information on the appropriate space.
Make a copy of this list for a record. Retain the
information for future reference.

Record for Reference

Table 2
System or Component Information

Chassis serial number

Engine model

Engine serial number

Engine arrangement
number
Modification number
Engine low idle rpm

Engine full load rpm

Performance specification
number
Engine horsepower

Primary fuel filter part

number
Water separator element
part number

Secondary fuel filter ele-

ment part number

Lubrication oil filter ele-

ment part number

Auxiliary oil filter element

part number

Supplemental coolant ad-

ditive maintenance ele-
ment part number (if
equipped)

Total lubrication system

capacity

Total cooling system

capacity

(continued)
22 SEBU7902-09
Operation Section
Lifting and Storage

Operation Section i05260537

Product Storage
Lifting and Storage SMCS Code: 7002

i01988813 Storage (Less Than One Year)

Product Lifting If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls,
SMCS Code: 7000; 7002 piston rings, main bearings, connecting rod bearings,
crankshaft and gears.
This lack of lubricant allows corrosion to begin to
appear on the metal. This condition is worse in areas
of high humidity.
When the engine is started again, metal to metal
contact will cause wear before the surfaces receive
oil. To minimize this wear, use the starter to turn the
engine with the throttle in the FUEL OFF position.
When oil pressure is shown on the pressure gauge,
start the engine.
1. Clean the engine of any dirt, rust, grease, and oil.
Inspect the exterior. Paint areas that contain paint
damage with a good quality paint.
2. Remove dirt from the air cleaners. Check all seals,
Illustration 18 g00103219
gaskets, and the filter element for damage.
3. Apply lubricant to all points in this Operation and
NOTICE
Never bend the eyebolts and the brackets. Only load Maintenance Manual, “Maintenance Interval
the eyebolts and the brackets under tension. Re- Schedule”.
member that the capacity of an eyebolt is less as the
angle between the supporting members and the ob- 4. Drain the crankcase oil. Replace the crankcase oil
ject becomes less than 90 degrees. and change the oil filters. For the proper
procedure, refer to this Operation and
When it is necessary to remove a component at an Maintenance Manual.
angle, only use a link bracket that is properly rated for
the weight. 5. If the engine is equipped with an air starting motor,
fill the reservoir with the following mixture: 50
Use a hoist to remove heavy components. Use an percent volatile corrosion inhibitor oil
adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be (<nomen>VCI oil</nomen>) and 50 percent
parallel to each other. The chains and cables should engine oil.
be perpendicular to the top of the object that is being
lifted. 6. Add VCI oil to the crankcase oil. The volume of
VCI oil in the crankcase oil should be 3 to 4
Some removals require lifting the fixtures in order to percent.
obtain proper balance and safety.
Note: If the engine crankcase is full, drain enough
To remove the engine ONLY, use the lifting eyes that engine oil so the mixture can be added.
are on the engine.
7. Remove the air filter elements. Turn the engine at
Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting cranking speed with the throttle control in FUEL
eyes and/or the engine make the lifting eyes and the OFF position. Use a sprayer to add a mixture of 50
lifting fixtures obsolete. If alterations are made, percent VCI oil and 50 percent engine oil into the
ensure that proper lifting devices are provided. air inlet or turbocharger inlet.
Consult your Caterpillar dealer for information
regarding fixtures for proper engine lifting.
SEBU7902-09 23
Operation Section
Product Storage

Note: The mixture of VCI oil can be added to the inlet Ensure that all covers are airtight and
by removing the plug for checking turbocharger boost weatherproof. Use a waterproof weather resistant
pressure. The minimum application rate for the VCI tape such as Kendall No. 231 or an equivalent. Do
oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of not use duct tape. Duct tape will only seal for a
engine displacement. short time.
8. Use a sprayer to apply a mixture of 50 percent VCI 13. Under most conditions, removing the batteries is
oil and 50 percent crankcase oil into the exhaust the best procedure. As an alternative, place the
openings. The minimum application rate for the oil batteries in storage. As needed, periodically
mixture is 5.5 mL per L (3 oz per 1000 cu in) of charge the batteries while the batteries are in
engine displacement. Seal the exhaust pipe and storage.
seal any drain holes in the muffler.
If the batteries are not removed, wash the tops of
9. Remove the fuel from the secondary fuel filter the batteries until the tops are clean. Apply an
housing. Alternately, empty and reinstall the spin- electrical charge to the batteries in order to obtain
on fuel filter element in order to remove any dirt a specific gravity of 1.225.
and water. Drain any sleeve metering fuel pump.
Disconnect the battery terminals. Place a plastic
Clean the primary fuel filter. Fill with calibration cover over the batteries.
fluid or kerosene. Install the primary fuel filter and
operate the priming pump. This procedure will Note: For additional information, refer to Special
send clean oil to the secondary filter and the Instruction, SEHS7633, “Battery Test Procedure”.
engine.
14. Loosen all belts.
Open the fuel tank drain valve in order to drain any
15. Place a waterproof cover over the engine. Ensure
water and dirt from the fuel tank. Apply a spray of
that the engine cover is secure. The cover should
calibration fluid or kerosene at the rate of
be loose enough to allow air to circulate around
30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank
the engine in order to prevent damage from
capacity in order to prevent rust in the fuel tank.
condensation.
Add 0.15 mL per L (.02 oz per 1 gal US) of
commercial biocide such as Biobor JF to the fuel. 16. Attach a tag with the storage date to the engine.
Apply a small amount of oil to the threads on the 17. Remove the waterproof cover at 2 month or 3
fuel tank filler neck and install the cap. Seal all month intervals in order to check the engine for
openings to the tank in order to prevent corrosion. If the engine has signs of corrosion,
evaporation of the fuel and as a preservative. repeat the protection procedure.
10. Remove the fuel nozzles or spark plugs. Apply Coolant System
30 mL (1 oz) of the mixture of oils (50 percent VCI
oil and 50 percent engine oil) into each cylinder. Completely fill the cooling system before storage.
Use a bar or a turning tool in order to turn over the Refer to this Operation and Maintenance Manual,
engine slowly. This procedure puts the oil on the “Fluid Recommendations” for more information about
cylinder walls. Install all fuel nozzles or spark plugs coolants.
and tighten to the correct torque.
11. Spray a thin amount of a mixture of 50 percent
Removal from Storage
VCI oil and 50 percent engine oil onto the following 1. Remove all outside protective covers.
components: flywheel, ring gear teeth and starter
pinion. Install the covers in order to prevent 2. Change the oil and filters.
evaporation of the vapors from the VCI oil. 3. Check the condition of the fan and alternator belts.
12. Apply a heavy amount of Cat Multipurpose Replace the belts, if necessary. Refer to this
Grease (MPGM) to all outside parts that move, Operation and Maintenance Manual, “Belts -
such as rod threads, ball joints, linkage. Inspect/Adjust/Replace” for the correct procedure.

Note: Install all covers. Ensure that tape has been 4. Replace the fuel filter elements.
installed over all openings, air inlets, exhaust 5. Remove the plastic covers from the air cleaner
openings, the flywheel housing, the crankcase elements.
breathers, the dipstick tubes.
24 SEBU7902-09
Operation Section
Product Storage

6. Use a bar or a turning tool in order to turn the

engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
resistance exist.
7. Before starting the engine, remove the valve cover
or covers. Put a large amount of engine oil on the
camshaft, cam followers, and valve mechanism in
order to prevent damage to the mechanism.
8. Pressure-lubricate the engine before starting the
engine. Pressure lubricating the engine ensures
immediate lubrication and prevents damage to the
engine during the first few minutes of engine
operation. If the engine is not equipped with a
prelube pump, contact your Cat dealer for
information about lubrication of the engine before
starting the engine.
9. Check the condition of all rubber hoses. Replace
any worn hoses. Replace any damaged hoses.
10. Before start-up, test the cooling system for a 3
percent to a 6 percent concentration of coolant
conditioner. Add liquid coolant conditioner or a
coolant conditioner element, if equipped.
Test the coolant mixture for proper nitrite level. If
necessary, adjust the coolant mixture.
Prime the engine with clean diesel fuel before
starting.
11. Ensure that the cooling system is clean. Ensure
that the system is full. Ensure that the system has
the correct amount of supplemental cooling
system conditioner.
12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.
13. If the engine was removed from storage in which
temperatures of less than -12°C (10°F) were
encountered, refer to Service Manual, SEBU5898,
“Cold Weather Recommendations Operation and
Maintenance”.
SEBU7902-09 25
Operation Section
Features and Controls

Features and Controls 1. Remove the load.

2. Reduce engine speed to low idle.
i03953970
3. Check and maintain the oil level.
Monitoring System Tachometer (3) – This gauge indicates
(If Equipped) engine speed (rpm). When the throttle
control lever is moved to the full throttle
SMCS Code: 1900; 7400; 7450; 7451 position without load, the engine is running at
high idle. The engine is running at the full load
The Monitoring System is designed to alert the
operator to an immediate problem with any of the rpm when the throttle control lever is at the full
engine systems that are monitored. The Monitoring throttle position with maximum rated load.
System is also designed to alert the operator to an
impending problem with any of the engine systems NOTICE
that are monitored. To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
Indicators and Gauges damage to the engine. The engine can be operated
at high idle without damage, but should never be al-
lowed to exceed high idle rpm.

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

Coolant Temperature (4) – When the

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

Warning Lamp (5) – There is a general

fault in the engine. Refer to the
Messenger display for any additional
information that may be available.
Fuel Pressure (6) – This gauge indicates
fuel pressure to the fuel injection pump
from the fuel filter. A decrease in fuel
pressure usually indicates a dirty fuel filter or a
plugged fuel filter. As the fuel filter becomes
Illustration 19 g01063079 plugged, there will be a noticeable reduction in
Gauge cluster and indicators engine performance.

Diagnostic Lamp (1) – The diagnostic System Voltage (7) – This gauge
lamp is used to indicate the existence of indicates the voltage of the electrical
a fault by flashing a fault code. For a system.
more detailed discussion of the diagnostic lamp,
please see this Operation and Maintenance Circuit Breaker (8) – Reset the circuit breaker if a
Manual, “Diagnostic Lamp” topic. circuit breaker trips. Press the button in order to reset
the circuit breaker. If the electrical system is working
Engine Oil Pressure (2) – The oil properly, the button will remain pressed. If the button
pressure should be greatest after a cold does not remain pressed or if the circuit breaker trips
soon after being reset, check the appropriate
engine is started. The pressure will electrical circuit. Repair the electrical circuit, if
decrease as the engine warms up. The pressure necessary.
will increase when the engine rpm is increased.
The pressure will stabilize when the engine rpm Start Switch (9) – The start switch has three
is stable. positions: OFF, RUN and START. When the start
switch is turned clockwise to the RUN position, the
A lower oil pressure is normal at low idle. If the load is lamps will flash for 5 seconds during the system test.
stable and the gauge reading changes, perform the The lamps will then shut off. In the RUN position, the
following procedure: ECM and electronic systems are powered up.
26 SEBU7902-09
Operation Section
If Equipped

Previous button (16) – Use the previous button to

return to information that was previously shown on
Idle Speed Switch (10) – When the the digital display area.
switch is in the up position, the engine
speed increases to HIGH IDLE. When
Scroll up/left button (17) – This button is used to
the switch is in the down position, the engine
scroll up through information that is shown on the
speed decreases to LOW IDLE. display area. The button can also be used to scroll to
the left through information that is shown on the
Maintenance Lamp (11) – The ECM display area.
records data that is related to equipment
maintenance. The ECM will activate the
maintenance indicator lamp when scheduled Scroll down/right button (18) – This button is used
maintenance is due. The maintenance indicator to scroll down through information that is shown on
lamp can be reset by actuating the maintenance the display area. The button can also be used to
clear switch. The maintenance interval may be scroll to the right through information that is shown on
based on operating hours or fuel consumption. the display area.
The ECM provides information that pertains to
maintenance intervals and the last maintenance OK button (19) – Use this button to confirm
that was performed. selections that you have made with the scroll up/left
button and the scroll down/right button.
Maintenance Clear Switch (12) – The
maintenance clear switch is required to
reset the maintenance lamp after Totals Display
maintenance on the engine is performed.

Shutdown Switch (13) – Use the engine

shutdown switch in order to stop the
engine. Push the shutdown switch in
order to put the switch in the OFF position. After
the engine stops, turn the knob clockwise.
Turning the knob clockwise will reset the engine
shutdown switch to the ON position.
Service Tool Connector (14) – For more information
regarding the use of Cat Electronic Technician (ET)
and the PC requirements for Cat ET, refer to the
documentation.

Caterpillar Messenger Display Illustration 21 g01054562

Typical totals display

The following information is available through the

display:

CUMULATIVE TOTALS
Service Hours – When you scroll to this option, the
display shows the total amount of service hours that
the engine has accumulated.

Total Time – When you scroll to this option, the

display shows the total hours for the engine ECM.

Total Fuel – When you scroll to this option, the

Illustration 20 g01063102 display shows the total amount of fuel that has been
consumed.
Digital display area (15) – The Messenger system
shows information on the digital display area.
SEBU7902-09 27
Operation Section
If Equipped

Settings Display Service Display

Illustration 22 g01054565 Illustration 23 g01054566

Typical settings display Typical service display

The following options are available through the DIANOSTICS/EVENTS

payload display:
The following options are password protected. Enter
MONITORING SYSTEM a password to change the settings.
Language – Select this option to change the View – Select this option to view events logged by
language shown on the display. the monitoring system. If you use an authorized
password, you can clear individual events.
Units – Select this option to choose the desired
measurement system. The choices are metric or Clear All Diagnostics – If you use an authorized
English. password, you can select this option to clear all
logged events.
Adjust Contrast – Select this option to adjust the
contrast of the display in order to improve the visibility SYSTEM PARAMETERS
of the information.
MONITORING SYSTEM
Adjust Backlight – Select this option to adjust the • Battery Voltage: When you scroll to this option,
backlighting of the display in order to improve the
the battery voltage is displayed.
visibility of the information.
• Fuel Level: When you scroll to this option, the
ENGINE fuel level is displayed.

Equipment ID – Select this option to view the • Alternator Status: When you scroll to this
equipment identification number. option, the alternator status is displayed.
• Engine Speed: When you scroll to this option,
Product ID – Select this option to view the product the engine RPM is displayed.
identification number.
• Desired Engine Speed: When you scroll to this
option, the desired engine speed is displayed.
This parameter is used by the Automatic Retarder
Control to prevent the engine from overspeeding.
If you have an approved password, you can
change this parameter.

• Throttle Position: When you scroll to this

option, the throttle position is displayed.

• Coolant Temperature: When you scroll to this

option, the coolant temperature is displayed.
28 SEBU7902-09
Operation Section
If Equipped

• Coolant Flow: When you scroll to this option, TATTLETALE

the amount of coolant flow is displayed.
• Full Tattletale Readout: When you select this
• Boost Pressure: When you scroll to this option, option, all indicators and gauges will display the
the boost pressure is displayed. maximum values reached during operation.
• Atmospheric Pressure: When you scroll to this • Engine Coolant Temperature: When you select
option, the atmospheric pressure is displayed. this option, all indicators and will display the
maximum values reached during operation. The
• Turbo Inlet Pressure: When you scroll to this engine coolant temperature gauge will also show
option, the turbo inlet pressure is displayed. the maximum value reached during operation.
• Oil Pressure (Antilock brake system): When • Tachometer: When you select this option, all
you scroll to this option, the absolute engine oil indicators will display the maximum values
pressure is displayed. reached during operation. The tachometer will
also show the maximum value reached during
• Oil Pressure: When you scroll to this option, the
operation.
gauge engine oil pressure is displayed.
• Fuel Level: When you select this option, all
• Fuel Temperature: When you scroll to this
indicators will display the maximum values
option, the fuel temperature is displayed.
reached during operation. The fuel level gauge will
SYSTEMS TESTS also show the minimum value reached during
operation.
SYSTEM SELF TEST
• Clear: If you have an approved password, you
If you select this option, the monitoring system will can clear the maximum values stored by the
initiate the self-test feature. The self test feature is monitoring system.
like the functional test that occurs when you turn the
start switch from the OFF position to the ON position.

SYSTEM INFORMATION
MONITORING SYSTEM

• Software Part Number: When you scroll to this

option, the software part number is displayed.

• ECM Part Number: When you scroll to this

option, the ECM part number is displayed.
• Software Release Date: When you scroll to this
option, the software release date is displayed.
• Software Description: When you scroll to this
option, the software description is displayed.
ENGINE
• ECM Serial Number: When you scroll to this
option, the ECM serial number is displayed.
• Software Part Number: When you scroll to this
option, the software part number is displayed.
• Software Release Date: When you scroll to this
option, the software release date is displayed.

• Software Description: When you scroll to this

option, the software description is displayed.

• Engine Serial Number: When you scroll to this

option, the engine serial number is displayed.
SEBU7902-09 29
Operation Section
Engine Diagnostics

Engine Diagnostics • The “DIAGNOSTIC” lamp will turn off for five
seconds.
i00863835 • The “DIAGNOSTIC” lamp repeats all active
diagnostic codes.
Self-Diagnostics A fault diagnostic code will remain active until the
SMCS Code: 1000; 1900; 1901; 1902 problem is repaired. The electronic control module
will continue flashing the flash code at five second
The electronic control module has some self- intervals until the problem is repaired.
diagnostic ability. When an electronic problem with
an input or an output is detected, a diagnostic code is
generated. This indicates the specific problem with i02496338
the circuitry.
Diagnostic Flash Code
Diagnostic codes are also generated when an
abnormal engine operating condition is detected. For Retrieval
example, a diagnostic code will be generated if the SMCS Code: 1000; 1900; 1901; 1902
low oil pressure alarm is activated. In this case, the
diagnostic code indicates the symptom of a problem. Problems with the electronic control system are
This type of diagnostic code is called an event. An reported via these types of codes: flash codes, SPN/
event is triggered by the detection of an abnormal FMI codes, diagnostic codes and event codes.
engine operating condition.
A diagnostic code which represents a problem that
currently exists is called an active code.
A diagnostic code that is stored in memory is called a
logged code. Always service active codes prior to
servicing logged codes. Logged codes may include
the following categories:

• Intermittent problems
• Recorded events

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

i01463253

Diagnostic Lamp
SMCS Code: 1000; 1900; 1901; 1902; 7451
The “DIAGNOSTIC” lamp is used to indicate the
existence of an active fault by flashing codes.
When the ignition switch is first turned on, the
“DIAGNOSTIC” lamp will go through the following
procedure:

• The “DIAGNOSTIC” lamp will come on and the

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

• The “DIAGNOSTIC” lamp will turn off.

• The “DIAGNOSTIC” lamp will come on again and
the “DIAGNOSTIC” lamp will flash codes for any
active diagnostic codes. Not all diagnostic codes
have a unique flash code.
30 SEBU7902-09
Operation Section
Diagnostic Flash Code Retrieval

Table 3
Cross Reference for Diagnostic Codes

Diagnostic Code
Flash Code SPN(1)/FMI Code or Description of Code
Event Code
1387-15 High Auxiliary Pressure Warning

1387-16 E443(2) High Auxiliary Pressure Derate

1387-00 High Auxiliary Pressure Shutdown

0441-15 High Auxiliary Temperature Warning

0441-16 E445(2) High Auxiliary Temperature Derate

0441-00 High Auxiliary Temperature Shutdown

545-05 Ether Start Relay open/short to +batt

626-05
N/A 2417-05 Ether Injection Control Solenoid open/short to +batt

545-06 Ether Start Relay short to ground

626-06
2417-06 Ether Injection Control Solenoid short to ground

1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt

1835-04 1835-04 Auxiliary Pressure Sensor short to ground

1836-03 1836-03 Auxiliary Temperature Sensor open/short to +batt

1836-04 1836-04 Auxiliary Temperature Sensor short to ground

111-02 111-02 Engine Coolant Level Sensor Loss of Signal

174-03 174-03 Fuel Temperature open/short to +batt

13
174-04 174-04 Fuel Temperature short to ground

678-03 41-03 8 Volt DC Supply short to +batt

678-04 41-04 8 Volt DC Supply short to ground

620-03
21 262-03 5 Volt Sensor DC Power Supply short to +batt
1079-03
620-04
262-04 5 Volt Sensor DC Power Supply short to ground
1079-04

100-03 100-03 Engine Oil Pressure open/short to +batt

24 100-04 100-04 Engine Oil Pressure short to ground

100-10 100-10 Engine Oil Pressure abnormal rate of change

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

25 102-04 102-04 Boost Pressure Sensor short to ground

102-10 102-10 Boost Pressure Sensor abnormal rate of change

108-03 274-03 Atmospheric Pressure open/short to +batt

26
108-04 274-04 Atmospheric Pressure short to ground

110-03 110-03 Engine Coolant Temperature open/short to +batt

27
110-04 110-04 Engine Coolant Temperature short to ground

(continued)
SEBU7902-09 31
Operation Section
Diagnostic Flash Code Retrieval

(Table 3, contd)
Cross Reference for Diagnostic Codes

Diagnostic Code
Flash Code SPN(1)/FMI Code or Description of Code
Event Code
28 91-13 91-13 Throttle Position calibration required

32 91-08 91-08 Throttle Position signal abnormal

190-08 190-08 Engine Speed signal abnormal

34
723-08 342-08 Secondary Engine Speed signal abnormal

190-15 Engine Overspeed Warning

35 E362(2)
190-00 Engine Overspeed Shutdown

94-03 94-03 Fuel Pressure open/short to +batt

37
94-04 94-04 Fuel Pressure short to ground

105-03 172-03 Intake Manifold Air Temp open/short to +batt

38
105-04 172-04 Intake Manifold Air Temp short to ground

42 637-13 261-13 Engine Timing calibration required

100-17 Low Engine Oil Pressure Warning

46 100-18 E360(2) Low Engine Oil Pressure Derate

100-01 Low Engine Oil Pressure Shutdown

168-00 168-00 System Voltage high

51 168-01 168-01 System Voltage low

168-02 168-02 System Voltage intermittent/erratic

56 630-02 268-02 Check Programmable Parameters

58 639-09 247-09 J1939 Data Link communications

110-15 High Engine Coolant Temperature Warning

61 110-16 E361(2) High Engine Coolant Temperature Derate

110-00 High Engine Coolant Temperature Shutdown

111-17 Low Engine Coolant Level Warning

62 111-18 E2143(2) Low Engine Coolant Level Derate

111-01 Low Engine Coolant Level Shutdown

63 94-15 E096 High Fuel Pressure Warning

1636-15 High Inlet Air Temperature Warning

64 E539(2)
1636-00 High Inlet Air Temperature Shutdown

174-15 High Fuel Temperature Warning

65 174-16 E363(2) High Fuel Temperature Derate

174-00 High Fuel Temperature Shutdown

651-05 001-05 Injector Cylinder 1 open circuit

71
651-06 001-06 Injector Cylinder 1 short

(continued)
32 SEBU7902-09
Operation Section
Fault Logging

(Table 3, contd)
Cross Reference for Diagnostic Codes

Diagnostic Code
Flash Code SPN(1)/FMI Code or Description of Code
Event Code
651-11 001-11 Injector Cylinder #1 fault

652-05 002-05 Injector Cylinder 2 open circuit

72 652-06 002-06 Injector Cylinder 2 short

652-11 002-11 Injector Cylinder #2 fault

653-05 003-05 Injector Cylinder 3 open circuit

73 653-06 003-06 Injector Cylinder 3 short

653-11 003-11 Injector Cylinder #3 fault

654-05 004-05 Injector Cylinder 4 open circuit

74 654-06 004-06 Injector Cylinder 4 short

654-11 004-11 Injector Cylinder #4 fault

75 655-05 005-05 Injector Cylinder 5 open circuit

655-06 005-06 Injector Cylinder 5 short

655-11 005-11 Injector Cylinder #5 fault

656-05 006-05 Injector Cylinder 6 open circuit

76 656-06 006-06 Injector Cylinder 6 short

656-11 006-11 Injector Cylinder #6 fault

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

For further information, see the troubleshooting guide i01797045

for your engine.
Engine Operation with Active
i03840813
Diagnostic Codes
Fault Logging SMCS Code: 1000; 1900; 1901; 1902
SMCS Code: 1000; 1900; 1901; 1902 If a diagnostic lamp illuminates during normal engine
operation, the system has identified a situation that is
The system provides the capability of Fault Logging. not within the specification. Use Caterpillar electronic
When the Electronic Control Module (ECM) service tools to check the active diagnostic codes.
generates an active diagnostic code, the code will be
logged in the memory of the ECM. The codes that Note: If the customer has selected “DERATE” and if
have been logged in the memory of the ECM can be there is a low oil pressure condition, the Electronic
retrieved with Caterpillar electronic service tools. The Control Module (ECM) will limit the engine power
codes that have been logged can be cleared with until the problem is corrected. If the oil pressure is
Caterpillar electronic service tools. The codes that
within the normal range, the engine may be operated
have been logged in the memory of the ECM will be
automatically cleared from the memory after 100 at the rated speed and load. However, maintenance
hours. The following faults cannot be cleared from should be performed as soon as possible.
the memory of the ECM without using a factory The active diagnostic code should be investigated.
password: overspeed, low engine oil pressure and The cause of the problem should be corrected as
high engine coolant temperature. soon as possible. If the cause of the active diagnostic
code is repaired and there is only one active
diagnostic code, the diagnostic lamp will turn off.
SEBU7902-09 33
Operation Section
Engine Operation with Intermittent Diagnostic Codes

Operation of the engine and performance of the Parameter Descriptions

engine can be limited as a result of the active
diagnostic code that is generated. Acceleration rates “ Equipment ID””
may be significantly slower. Refer to the
Troubleshooting Guide for more information on the
“EQUIPMENT ID” allows the customer to enter a
relationship between these active diagnostic codes description into the Electronic Control Module (ECM)
and engine performance. in order to identify the machine. A maximum of 17
characters may be entered in the field. This
i01456915 parameter is only for reference by the customer. This
parameter is not required.
Engine Operation with
“ Engine Serial Number””
Intermittent Diagnostic Codes
SMCS Code: 1000; 1900; 1901; 1902 Program the “ENGINE SERIAL NUMBER” to match
the engine serial number that is stamped on the
If the diagnostic lamp starts to flash codes during engine information plate. If the ECM is replaced, the
normal engine operation and the diagnostic lamp engine serial number from the engine information
shuts off, an intermittent fault may have occurred. If a plate must be programmed into the new ECM.
fault has occurred, the fault will be logged into the
memory of the Electronic Control Module (ECM). Note: When you are requesting factory passwords,
always use the engine serial number that is
In most cases, it is not necessary to stop the engine programmed in the ECM.
because of an intermittent code. However, the
operator should retrieve the logged fault codes and
the operator should reference the appropriate “ Rating Number””
information in order to identify the nature of the event.
The operator should log any observation that could The “RATING NUMBER” corresponds to the selected
have caused the lamp to light. set of performance maps for the application. This
selected set of performance maps comes out of
• Low power several unique sets of maps that are resident in the
flash file. The dealer and/or the OEM will need to
• Limits of the engine speed select the appropriate rating tier, if more than one
rating tier is present. The rating tiers are “A” through
• Excessive smoke, etc “E” .

This information can be useful to help troubleshoot Note: Refer to this Operation and Maintenance
the situation. The information can also be used for Manual, “Engine Rating Definitions” for information.
future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this Factory passwords are required in order to change
engine. the rating number.

i04250489

Configuration Parameters
SMCS Code: 1000; 1900; 1901; 1902

S/N: JRE1–Up
S/N: P5H1–Up
S/N: PDM1–Up
S/N: PBN1–Up
S/N: JAS1–Up
S/N: MCW1–Up
System configuration parameters are parameters
that affect the emissions and the power of the engine.
Default values for the parameters are programmed at
the factory. Some parameters may be changed by
the customer in order to suit the needs of the specific
application.
34 SEBU7902-09
Operation Section
Configuration Parameters

“ Top Engine Limit”” (TEL) “ High Idle Speed””

Illustration 24 g00763900 Illustration 25 g00763900

“TEL” is a customer programmable parameter that The high idle speed is the maximum no-load engine
defines the maximum allowable engine speed for speed when the throttle or the PTO switch is in the
maximum power. “TEL” can be programmed up to maximum position.
the maximum rated engine speed. “TEL” is defined
along the lug curve. Note: “HIGH IDLE SPEED” cannot be programmed
lower than “TEL” .
“ Engine Accel. Rate””
“ Intermediate Engine Speed””
The engine acceleration rate determines the rate of
change of the engine speed (acceleration or The intermediate engine speed defines the speed for
deceleration) during PTO operation. This rate of the engine when the intermediate engine speed
change is also used to achieve intermediate engine switch is activated. This parameter can be
speed. programmed to any engine speed between “Low Idle
Speed” and “TEL” . Engine speed will increase or
“ Low Idle Speed”” engine speed will decrease at the rate that is defined
by the programmed value for “ENGINE ACCEL.
Low speed idle is the minimum allowable operating RATE” .
speed for the engine. This parameter can be
programmed between 600 and 1400 rpm.

“ PTO Mode””
“PTO Mode” allows the ECM to be programmed to
either one of the two PTO configurations that are
available.
“ Ramp Up/Ramp Down”” – When “PTO Mode” is
programmed to “RAMP UP/RAMP DOWN” , the ECM
allows PTO operation with traditional features.
“ Set/Resume”” – When “PTO Mode” is programmed
to “SET/RESUME” , the ECM allows PTO operation
with enhanced features.
SEBU7902-09 35
Operation Section
Configuration Parameters

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

“ Maintenance Indicator Mode””

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

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

“ Throttle Position Sensor””

Illustration 26 g00817759
Program the throttle position sensor to “INSTALLED”
“ENGINE TORQUE LIMIT” can be used to limit if a throttle position sensor is used for desired speed
torque output to the programmed value when the control. Otherwise program this parameter to “NOT
torque limit switch is activated. INSTALLED” .
“ FLS”” (Full Load Setting) “ Coolant Level Sensor””
“FLS” is a number representing the adjustment to the Program the coolant level sensor to “INSTALLED” if a
fuel system made at the factory to fine-tune the fuel coolant level sensor is installed on the engine.
system. The correct value for this parameter is Otherwise program this parameter to “NOT
stamped on the engine information plate. Factory INSTALLED” .
passwords are required in order to change this
parameter.
“ Aux Press Sensor Installation Status””
“ FTS”” (Full Torque Setting) Program “AUX PRESS ENABLE” to “INSTALLED” if
an auxiliary pressure sensor is installed. This will
“FTS” is similar to “FLS” . Factory passwords are allow the Cat Messenger Driver Information Display
required in order to change this parameter. to monitor the pressure of another system. Program
this parameter to “NOT INSTALLED” if an auxiliary
“ Ether Control”” pressure sensor is not installed.

Program the “ETHER CONTROL” to “ENABLED” if

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

“ Air Shutoff””
“AIR SHUTOFF” allows the ECM to be programmed
for operation of an air shutoff system. If this
parameter is programmed to “INSTALLED” , the ECM
will activate the air shutoff solenoid in the event of an
engine overspeed condition.
36 SEBU7902-09
Operation Section
Configuration Parameters

“ Aux Temp Sensor Installation Status””

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

System Configuration Parameters

Table 4
System Configuration Parameters

Available Range or Options Required

Parameter Default
Password
ECM Identification Parameters
“Equipment ID” 17 alphanumeric characters “NOT PROGRAMMED” None

“Engine Serial Number” 0XX00000 or XXX00000 0XX00000 None

“ECM Serial Number” “Read Only” (1)

“Software Gp Part Number” Software Dependent Read Only (1)

“Software Gp Release Date” Software Dependent Read Only (1)

Selected Engine Rating

“Rating Number” Software Dependent Customer

“Rated Power” Software Dependent Read Only (1)

“Rated Peak Torque” Software Dependent Read Only (1)

“Top Engine Speed Range” Software Dependent Read Only (1)

“Test Spec” Software Dependent Read Only (1)

“Top Engine Limit” Software Dependent Customer

“Speed Control”
“Engine Governor Primary Mode” “Speed Control” None
“Min/Max”
“Engine Accel. Rate” 50 to 1000 50 None

“Low Idle Speed” 600 to 1400 700 None

“Ramp Up/Ramp Down”

“PTO Mode” “Ramp Up/Ramp Down” None
“Set/Resume”
“High Idle Speed” 1800 to 2310 2310 Customer

“Intermediate Engine Speed” Programmed “Low Idle” to “TEL” 1100 None

“Maximum Engine Torque Limit” Software Dependent None

“Customer Password #1” 8 alphanumeric characters Blank Customer

“Customer Password #2” 8 alphanumeric characters Blank Customer

“FLS” (Full Load Setting) - 128 to 127 0 Factory

“FTS” (Full Torque Setting) -128 to 127 0 Factory

“No Ether”
“Ether Control” “No Ether” None
“Continuous Flow”

(continued)
SEBU7902-09 37
Operation Section
Configuration Parameters

(Table 4, contd)
System Configuration Parameters

Available Range or Options Required

Parameter Default
Password
“Enabled”
“Air Shutoff” “Disabled” None
“Disabled”
“OFF”
“Auto Fuel”
“Maintenance Indicator Mode” “Auto Hour” “OFF” None
“Man Fuel”
“Man Hour”
100 to 750 Hours 250 Hours
“PM1 Interval” or or None
3785 to 28390 L (1000 to 7500 US gal) 9463 L (2500 US gal)

“Installed”
“Throttle Position Sensor” “Not Installed” None
“Not Installed”
“Installed”
“Coolant Level On” “Not Installed” None
“Not Installed”
“Last Tool to change Customer
Read Only (1)
Parameters”
“Last Tool to change System
Read Only (1)
Parameters”
“On”
“Aux Temp Sensor Installation Status” “Off” None
“Off”
“Aux Press Sensor Installation “On”
“Off” None
Status” “Off”

“Total Tattletale” Read Only (1)

(1) The parameter can only be viewed. No changes are allowed.

Parameters Worksheet (Table 5, contd)

Engine Parameters
Note: A mistake in recording this information will
result in incorrect passwords. “Rated Power”

Table 5
“Rated Peak Torque”
Engine Parameters
ECM Identification Parameters “Top Engine Speed Range”

“Equipment ID”
“Test Spec”

“Engine Serial Number”

“Top Engine Limit”

“ECM Serial Number”

“Engine Accel Rate”

“Software Gp Part Number”

“Low Idle Speed”

“Software Gp Release Date”

“PTO Mode”

Selected Engine Rating

“High Idle Speed”
“Rating Number”

(continued)
(continued)
38 SEBU7902-09
Operation Section
Configuration Parameters

(Table 5, contd)
Engine Parameters (Table 5, contd)
“Intermediate Engine Speed” Injector Code (3)

“Maximum Engine Torque Limit” Injector Code (4)

“Customer Password #1” Injector Code (5)

“Customer Password #2” Injector Code (6)

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

“Maintenance Indicator Mode”

“PM1 Interval”

“Throttle Position Sensor”

“Coolant Level Sensor”

“Last Tool to change Customer

Parameters”
“Last Tool to change System
Parameters”
“Aux Press Temp Installation
Status”
“Aux Press Sensor Installation
Status”
“Total Tattletale”

Information from Engine Information Plate

“Engine Serial Number”

“FLS”

“FTS”

Injector Codes

Injector Code (1)

Injector Code (2)

(continued)
SEBU7902-09 39
Operation Section
Engine Starting

Engine Starting • Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
i02109067 to the controls.

Before Starting Engine • Ensure that the areas around the rotating parts are
clear.
SMCS Code: 1000; 1400; 1450
• All of the guards must be put in place. Check for
Perform the required daily maintenance and other
damaged guards or for missing guards. Repair
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can any damaged guards. Replace damaged guards
help prevent major repairs at a later date. Refer to and/or missing guards.
the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for more • Disconnect any battery chargers that are not
information. protected against the high current drain that is
created when the electric starting motor (if
• For the maximum service life of the engine, make equipped) is engaged. Check electrical cables and
a thorough inspection before the engine is started. check the battery for poor connections and for
Look for the following items: oil leaks, coolant corrosion.
leaks, loose bolts and trash buildup. Remove trash
buildup and arrange for repairs, as needed. • Reset all of the shutoffs or alarm components.

• Inspect the aftercooler for loose connections and • Check the engine lubrication oil level. Maintain the
for debris buildup. oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• Inspect the cooling system hoses for cracks and
for loose clamps. • Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
• Inspect the alternator and accessory drive belts for the coolant level to the “FULL” mark on the coolant
cracks, breaks, and other damage. recovery tank.

• Inspect the wiring for loose connections and for • If the engine is not equipped with a coolant
worn wires or frayed wires. recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If
• Check the fuel supply. Drain water from the water the engine is equipped with a sight glass, maintain
separator (if equipped). Open the fuel supply the coolant level in the sight glass.
valve.
• Observe the air cleaner service indicator (if
NOTICE equipped). Service the air cleaner when the yellow
All valves in the fuel return line must be open before diaphragm enters the red zone, or when the red
and during engine operation to help prevent high fuel piston locks in the visible position.
pressure. High fuel pressure may cause filter housing
failure or other damage. • Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove
any electrical loads.
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air may i01797227
have entered the filter housing. Also, when fuel filters
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel Cold Weather Starting
system. Refer to the Operation and Maintenance SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Manual, “Fuel System - Prime” for more information
on priming the fuel system.

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
Engine exhaust contains products of combustion personal injury.
which may be harmful to your health. Always
start and operate the engine in a well ventilated Startability will be improved at temperatures below
area and, if in an enclosed area, vent the exhaust −18 °C (0 °F) from the use of a jacket water heater or
to the outside. extra battery capacity.
40 SEBU7902-09
Operation Section
Starting the Engine

When No. 2 diesel fuel is used, the following items 2. Turn the keyswitch to the RUN position. Leave the
provide a means of minimizing starting problems and keyswitch in the RUN position for 15 seconds.
fuel problems in cold weather: engine oil pan heaters,
jacket water heaters, fuel heaters and fuel line 3. Turn the keyswitch to the START position in order
insulation. to engage the electric starting motor and crank the
engine.
Use the procedure that follows for cold weather
starting.
NOTICE
Note: Do not adjust the engine speed control during Do not engage the starting motor when flywheel is
start-up. The electronic control module (ECM) will turning. Do not start the engine under load.
control the engine speed during start-up. If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
1. Disengage any driven equipment. allow the starting motor to cool before attempting to
start the engine again.
2. Turn the keyswitch to the RUN position. Leave the
keyswitch in the RUN position for 20 seconds.
4. Allow the keyswitch to return to the RUN position
NOTICE after the engine starts.
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load. 5. Repeat step 2 through step 4 if the engine fails to
start.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to Starting a Warm Engine
start the engine again.
1. Disengage any equipment that is driven by the
engine.
3. Turn the keyswitch to the START position in order
to engage the starting motor and crank the engine. 2. Turn the keyswitch to the START position in order
to engage the electric starting motor and crank the
4. Allow the keyswitch to return to the RUN position
engine.
after the engine starts.
5. Repeat step 2 through step 4 if the engine fails to NOTICE
start. Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
6. Allow the engine to idle for three to five minutes, or
allow the engine to idle until the water temperature If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
indicator begins to rise. The engine should run at allow the starting motor to cool before attempting to
low idle smoothly until speed is gradually start the engine again.
increased to high idle. Allow the white smoke to
disperse before proceeding with normal operation.
3. Allow the keyswitch to return to the RUN position
7. Operate the engine at low load until all systems after the engine starts.
reach operating temperature. Check the gauges
4. Repeat step 2 and step 3 if the engine fails to start.
during the warm-up period.
i04471308
i01903151

Starting the Engine Starting with Jump Start

SMCS Code: 1000; 1450
Cables
SMCS Code: 1000; 1401; 1402; 1900
Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will
control the engine speed during start-up.
Improper jump start cable connections can cause
Starting a Cold Engine an explosion resulting in personal injury.

1. Disengage any equipment that is driven by the Prevent sparks near the batteries. Sparks could
engine. cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
SEBU7902-09 41
Operation Section
After Starting Engine

If the installation is not equipped with a backup Note: Ensure that the self test for the monitoring
battery system, an external electrical source may be system (if equipped) is completed before operating
necessary to start the engine. the engine under load.

NOTICE When the engine idles during warm-up, observe the

Using a battery source with the same voltage as the following conditions:
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage • Check for any fluid or for any air leaks at idle rpm
the electrical system. and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
Do not reverse the battery cables. The alternator can possible in some applications.
be damaged. Attach the negative cable last and re-
move first. • Operate the engine at low idle until all systems
achieve operating temperatures. Check all gauges
When using an external electrical source to start the
engine, turn the generator set control switch to the during the warm-up period.
“OFF” position. Turn all electrical accessories OFF Note: Gauge readings should be observed and the
before attaching the jump-start cables.
data should be recorded frequently while the engine
Ensure that the main power switch is in the OFF posi- is operating. Comparing the data over time will help
tion before attaching the jump-start cables to the en- to determine normal readings for each gauge.
gine being started. Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
1. Turn the start switch to the OFF position. Turn off
all accessories.
2. Connect one positive end of the jump-start cable to
the positive cable terminal of the discharged
battery. Connect the other positive end of the
jump-start cable to the positive cable terminal of
the electrical source.
3. Connect one negative end of the jump-start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump-start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.
4. Start the engine.
5. Immediately after the stalled engine is started,
disconnect the jump-start cables in reverse order.
Note: If there is a problem with the alternator or the
battery charger, the engine will not continue to run
after starting, unless the power to the engine control
module is supplied by a separate source.

i01646248

After Starting Engine

SMCS Code: 1000

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

the warm-up time is approximately three minutes. In
temperatures below 0°C (32°F), additional warm-up
time may be required.
42 SEBU7902-09
Operation Section
Engine Operation

Engine Operation Engines rated for constant speed use are allowed to
complete a starting sequence, an operation at a
single constant speed, and a shutdown sequence.
i06545691 Every time the engine is run, each of these
operations should occur only once. The starting
Engine Operation sequence and shutdown sequence can include a
short period of operation at the low idle speed for
SMCS Code: 1000 purposes of warming up and cooling down the engine
or driven equipment. The emissions type approval is
Correct operation and maintenance are key factors in not valid for operation of a constant speed engine in
obtaining the maximum life and economy of the a manner different from that described above.
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be i01196062
minimized and engine service life can be maximized.
The engine can be operated at the rated rpm after Engaging the Driven
the engine reaches operating temperature. The
engine will reach normal operating temperature Equipment
sooner during a low engine speed (rpm) and during a SMCS Code: 1000
low-power demand. This procedure is more effective
than idling the engine at no load. The engine should If the load varies, or if the load is cyclic, the governor
reach operating temperature in a few minutes. will adjust the engine rpm, as needed.
Gauge readings should be observed and the data Extended operation at low idle or extended operation
should be recorded frequently while the engine is at a reduced load may cause increased oil
operating. Comparing the data over time will help to consumption and carbon buildup in the cylinders.
determine normal readings for each gauge. This carbon buildup results in a loss of power and/or
Comparing data over time will also help detect poor performance. When the engine is operated at a
abnormal operating developments. Significant reduced load, the engine should be fully loaded at
changes in the readings should be investigated. every four hours in order to burn excess carbon from
the cylinders.
Minimum Engine Run Time
Industrial Engines
Changes to the operating cycle may be required
when the engines are applied in a manner that will 1. When the engine is operating, check the engine
result in repeated occurrences of less than one hour gauges. The engine gauges should be in the
of continuous run time. normal range before you engage the driven
In order for the exhaust aftertreatment to function equipment.
properly, the engine must complete a DPF
regeneration to 0 percent soot load once in every 24 2. Engage the driven equipment. Begin operating the
hours of engine run time. engine at low load. Check the gauges and check
the equipment for proper operation. Check the
After this regeneration to 0 percent soot has finished, gauges and check the equipment frequently while
an additional 70 minutes of run time is needed for Cat
Regeneration System fuel nozzle maintenance. Both the engine is operating under load.
of these requirements can be run with or without load
on the engine. i05893104

Fuel Conservation Practices

SMCS Code: 1000; 1250
The efficiency of the engine can affect the fuel
economy. The design and technology used
byCaterpillar in manufacturing provides maximum
fuel efficiency in all applications. Follow the
recommended procedures in order to attain optimum
performance for the life of the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
SEBU7902-09 43
Operation Section
Fuel Conservation Practices

• Be aware of the properties of the different fuels.

Use only the recommended fuels.

• Avoid unnecessary operation at no load.

Shut off the engine instead of operating the engine at
no load for long periods of time.
• Observe the service indicator for the air cleaner
frequently, if equipped. Keep the air cleaner
elements clean.
• Do not remove the cover for the air cleaner unless
the air filter service indicator indicates the need for
cleaning of the filter.
• Maintain a good electrical system.
One bad battery cell will overwork the alternator. This
will consume excess power and excess fuel.

• Ensure that the belts are properly adjusted. The

belts should be in good condition.

• Ensure that all of the connections of the hoses are

tight. The connections should not leak.
• Ensure that the driven equipment is in good
working order.
• Cold engines consume excess fuel. Keep cooling
system components clean and keep cooling
system components in good repair. Never operate
the engine without water temperature regulators.
All of these items will help maintain operating
temperatures.
44 SEBU7902-09
Operation Section
Cold Weather Operation

Cold Weather Operation There are three major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
i01646447
• Lower cloud point
Radiator Restrictions • Lower pour point
SMCS Code: 1353; 1396
• Lower rating of kJ (BTU) per unit volume of fuel
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow When No. 1 diesel fuel is used, a decrease in power
restriction can cause the following conditions: and in fuel efficiency may be noticed. Other operating
effects should not be experienced.
• High exhaust temperatures
The cloud point is the temperature when a cloud of
• Power loss wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is the
• Excessive fan usage temperature when diesel fuel will thicken. The diesel
fuel becomes more resistant to flow through fuel
• Reduction in fuel economy pumps and through fuel lines.
If an airflow restriction device must be used, the Be aware of these values when diesel fuel is
device should have a permanent opening directly in purchased. Anticipate the average ambient
line with the fan hub. A centered opening that is temperature for the engine area. Engines that are
directly in line with the fan hub is specified in order to fueled in one climate may not operate well if the
prevent an interrupted airflow on the fan blades. engines are moved to another climate. Problems can
Interrupted airflow on the fan blades could cause a result due to changes in temperature.
fan failure.
Before troubleshooting for low power or for poor
Caterpillar recommends a warning device for the inlet performance during cold weather, check the type of
manifold temperature and/or the installation of an fuel that is being used.
inlet air temperature gauge. The warning device for
the inlet manifold temperature should be set at 75 °C
(167 °F). The inlet manifold air temperature should i02010887
not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential Fuel Related Components in
engine damage.
Cold Weather
i01872912 SMCS Code: 1000; 1250; 1280

Fuel and the Effect from Cold Fuel Tanks

Weather Condensation can form in partially filled fuel tanks.
SMCS Code: 1000; 1250; 1280 Top off the fuel tanks after you operate the engine.

The following fuels are the grades that are available Fuel tanks should contain some provision for draining
for Caterpillar engines: water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
• No. 1 and sediment to settle below the end of the fuel
supply pipe.
• No. 2
Some fuel tanks use supply lines that take fuel
• Blend of No. 1 and No. 2 directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
No. 2 diesel fuel is the most commonly used fuel. the fuel system filter is important.
Either No. 1 diesel fuel or a blend of No. 1 and No. 2
is best suited for cold weather operation.
Quantities of No. 1 diesel fuel are limited. No. 1
diesel fuels are usually available during the months
of the winter in the colder climates. During cold
weather operation, if No. 1 diesel fuel is not available,
use No. 2 diesel fuel, if necessary.
SEBU7902-09 45
Operation Section
Fuel Related Components in Cold Weather

Drain the water and sediment from any fuel storage

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

Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual in the Maintenance Section for more
information on priming the fuel system.
The micron rating and the location of a primary fuel
filter is important in cold weather operation. The
primary fuel filter and the fuel supply line are the most
common components that are affected by cold fuel.

Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in the fuel system before the primary fuel
filter.
The following fuel heaters are recommended for
Caterpillar engines:

• 7C-3557 Fuel Heater Group

• 7C-3558 Heater Kit
For further information on fuel heaters, consult your
Caterpillar dealer.
Disconnect the fuel heater in warm weather.
Note: Fuel heaters that are controlled by the water
temperature regulator or self-regulating fuel heaters
should be used with this engine. Fuel heaters that are
not controlled by the water temperature regulator can
heat the fuel in excess of 65°C (149°F). A loss of
engine power can occur if the fuel supply
temperature exceeds 37°C (100°F).
Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
the fuel in warm weather operation.
46 SEBU7902-09
Operation Section
Engine Stopping

Engine Stopping • Fill the fuel tank to prevent accumulation of

moisture in the fuel. Do not overfill the fuel tank.
i04315380 • Allow the engine to cool. Check the coolant level.
Maintain the cooling system at 13 mm (0.5 inch)
Manual Stop Procedure from the bottom of the pipe for filling.
SMCS Code: 1000; 7418 Note: Only use coolant that is recommended in this
Operation and Maintenance Manual, “Fluid
NOTICE Recommendations” article. Failure to do so may
Stopping the engine immediately after it has been result in engine damage.
working under load can result in overheating and ac-
celerated wear of the engine components. • If freezing temperatures are expected, check the
coolant for proper antifreeze protection. The
If the engine has been operating at high rpm and/or cooling system must be protected against freezing
high loads, run at low idle for at least three minutes to to the lowest expected outside temperature. Add
reduce and stabilize internal engine temperature be- the proper coolant/water mixture, if necessary.
fore stopping the engine.
• Perform all required periodic maintenance on all
Avoiding hot engine shutdowns will maximize turbo- driven equipment. This maintenance is outlined in
charger shaft and bearing life. the instructions from the OEM.

Note: Individual applications have different control

systems. Ensure that the shutoff procedures are
understood. Use the following general guidelines in
order to stop the engine.

1. Remove the load from the engine so that the

engine has no more than 30% power.
2. Run the engine at the programmed low idle speed
for at least 3 minutes.
3. After the cool down period, turn the start switch to
the OFF position.

i04137729

After Stopping Engine

SMCS Code: 1000

Note: After operation, allow 10 minutes for the

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

• Check the crankcase oil level. Maintain the oil

level between the “ADD” mark and the “FULL”
mark on the oil level gauge.

Note: Only use oil that is recommended in this

Operation and Maintenance Manual, “Fluid
Recommendations” article. Failure to do so may
result in engine damage.
• If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.

• Note the service hour meter reading. Perform the

maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
SEBU7902-09 47
Maintenance Section
Refill Capacities

Maintenance Section The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will
require additional oil. Refer to the OEM specifications
Refill Capacities for the capacity of the auxiliary oil filter.
Table 6
i06014408 Refill Capacities for a C15 Industrial Engine

Refill Capacities Engine crankcase with a shallow sump oil

pan
34 L (36 qt)

SMCS Code: 1000; 1348; 1395; 7560

Engine crankcase with a middle sump oil 60 L (63 qt)
Refer to this Operation and Maintenance Manual, pan (deep sump)
“Fluid Recommendations” for information about the Engine crankcase with a flat bottom oil pan 68 L (72 qt)
correct fluids for use in your Cat Diesel Engine.
(deep sump)

Engine Oil
Coolant
TO properly maintain the cooling system, the total
cooling system capacity must be determined. The
total cooling system capacity varies between
individual installations. The total cooling system
capacity can include the following components:
engine, radiator, piping and heat exchanger.
Refer to the specifications that are provided by
Illustration 27 g02109595 Caterpillar or by the OEM of the installation. Record
Shallow sump oil pan the total cooling system capacity in 7 .
The shallow sump oil pan may be a front sump oil Table 7
pan or a rear sump oil pan. Approximate Refill Capacities

Compartment or System Liters Quarts

Cooling System

i04327214

Fluid Recommendations
SMCS Code: 1280; 1348; 1395; 7560
Illustration 28 g02109596
Deep sump oil pan Refer to this Operation and Maintenance Manual,
The center sump oil pan is a deep sump oil pan. “Severe Service Application” for information about
operating an engine in a severe service application.
Note: The interval for changing the coolant varies
depending on the type of coolant being replaced.
Refer to this article, “Coolant Recommendations”, for
the intervals for changing the coolant.

Diesel Engine Oil

For more information, refer to Special Publication,
Illustration 29 g02109598 SEBU6251, “Cat Commercial Diesel Engine Fluids
Deep sump oil pan Recommendations”.
The flat bottom oil pan is a deep sump oil pan.
48 SEBU7902-09
Maintenance Section
Fluid Recommendations

Cat Diesel Engine Oil (Cat DEO) (Table 9, contd)

API CI-4 / CI-4 PLUS Oil Category per-
Cat oils have been developed and tested in order to formance requirements
provide the full performance and service life that has
been designed and built into Cat engines. Cat oils Cat ECF-2
Passing standard Cat C13 engine test
are currently used to fill Cat Diesel Engines at the per API requirements
factory. These oils are offered by Cat dealers for
Oils of sulfated ash > 1.50 percent are
continued use when the engine oil is changed.
not allowed
Consult your Cat dealer for more information on
these oils. API CH-4 Oil Category performance
requirements
Due to significant variations in the quality and in the
performance of commercially available oils, For oils that are between 1.30 percent
Caterpillar makes the following recommendations: Cat ECF-1-a
and 1.50 percent sulfated ash, passing
Table 8 one additional Cat 1P SCOTE test
(“ASTM D6681”) is required
Cat Lubricants Viscosity Grade
Oils of sulfated ash > 1.50 percent are
SAE 15W-40 not allowed
Cat DEO-ULS
Diesel Engine SAE 10W-30
Oil-Ultra Low In selecting oil for any engine application, both of the
Cat DEO-ULS SYN SAE 5W-40
Sulfur following must be satisfied: the oil viscosity and the
Cat Cold Weather category of oil performance or the specification for oil
SAE 0W-40 performance . Using only one of these parameters
DEO-ULS
will not sufficiently define oil for an engine
SAE 15W-40 application.
Diesel Engine Cat DEO
SAE 10W-30
Oil The proper SAE viscosity grade of oil is determined
Cat DEO SYN SAE 5W-40 by the following temperatures: minimum ambient
temperature during cold engine start-up and
maximum ambient temperature during engine
Note: Cat DEO and Cat DEO-ULS multigrade oils
operation.
are the preferred oils for use in this Cat Diesel
Engine. Refer to Table 10 (minimum temperature) in order to
determine the required oil viscosity for starting a cold
Commercial Oil engine.

Note: Non-Cat commercial oils are second choice Refer to Table 10 (maximum temperature) in order to
oils for your engine. select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
NOTICE Note: Generally, use the highest oil viscosity that is
Caterpillar does not warrant the quality or perform- available to meet the requirement for the temperature
ance of non-Cat fluids. at start-up.
The three current Caterpillar ECF specifications are: Table 10
Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each
higher Cat ECF specification provides increased Lubricant Viscosities for Ambient Temperatures
performance over lower Cat ECF specifications. for Cat Diesel Engines

A commercial oil must meet the following standards Oil Type and Per- °C °F
Viscosity
to be considered an equivalent of a Cat Diesel formance
Grade Min Max Min Max
Requirements
Engine Oil:
Table 9 Cat ECF-1-a
Cat ECF-2 SAE 0W-30 −40 30 −40 86
Cat Engine Crankcase Fluids (ECF) Definitions
Cat ECF-3
Cat Performance Cat Cold Weather
Cat ECF Specifications Requirements
Requirement DEO-ULS
Cat ECF-1-a SAE 0W-40 −40 40 −40 104
API CJ-4 Oil Category performance
Cat ECF-3 Cat ECF-2
requirements
Cat ECF-3

(continued)
(continued)
SEBU7902-09 49
Maintenance Section
Fluid Recommendations

(Table 10, contd) (Table 11, contd)

(1) When using fuel with 0.10% sulfur (1000 ppm) or higher, refer
Lubricant Viscosities for Ambient Temperatures
to this Operation and Maintenance Manual, “Severe Service
for Cat Diesel Engines Application” for more information.
(2) For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
Cat DEO-ULS
refer to TBN and engine oil guidelines given in this section.
Cat ECF-1-a (3) Cat DEO-ULS may be used if an oil analysis program is fol-
SAE 5W-30 −30 30 −22 86
Cat ECF-2 lowed. Base the oil change interval on the analysis.
Cat ECF-3
Cat DEO-ULS SYN S·O·S Services Oil Analysis
Cat DEO
Cat ECF-1-a SAE 5W-40 −30 50 −22 122 Caterpillar has developed a maintenance tool that
Cat ECF-2 evaluates oil degradation. the maintenance
Cat ECF-3 management also detects the early signs of wear on
Cat ECF-1-a internal components. The Caterpillar tool for oil
SAE 10W- analysis is called S·O·S oil analysis and the tool is
Cat ECF-2 −18 40 0 104
30 part of the S·O·S Services program. S·O·S oil
Cat ECF-3
analysis divides oil analysis into four categories:
SAE 10W-
−18 50 0 122
Cat DEO-ULS 40 • Component wear rate
Cat DEO SAE 15W-
−9.5 50 15 122 • Oil condition
40

• Oil contamination
Note: A cold soaked start occurs when the engine
has not been operated recently, allowing the oil to • Identification of oil
become more viscous due to cooler ambient
These four types of analysis are used to monitor the
temperatures. Supplemental heat is recommended
condition of your equipment. The four types of
for cold soaked starts below the minimum ambient analysis will also help you identify potential problems.
temperature. Supplemental heat may be necessary A properly administered S·O·S oil analysis program
for cold soaked starts that are above the minimum will reduce repair costs and the program will lessen
temperature depending on factors such as parasitic the impact of downtime.
load.
The S·O·S Oil Analysis program uses a wide range
Total Base Number (TBN) and Fuel Sulfur of tests to determine the condition of the oil and the
crankcase. Guidelines that are based on experience
Levels and a correlation to failures have been established
for these tests. Exceeding one or more of these
The use of Cat S·O·S Services oil analysis is guidelines could indicate serious fluid degradation or
recommended strongly for determining oil life. a pending component failure. A trained person at
your Cat dealership should make the final analysis.
The minimum required Total Base Number (TBN) for
oil depends on the fuel sulfur level. The TBN for new
oil is typically determined by the “ASTM D2896” NOTICE
procedure. For direct injection engines that use Always use a designated pump for oil sampling, and
distillate fuel, the following guidelines apply: use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
Table 11 ples may contaminate the samples that are being
TBN recommendations for applications in Cat engines drawn. This contaminate may cause a false analysis
(1) and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
TBN of Com-
Fuel Sulfur Level per-
Cat Engine Oils mercial Engine
cent (ppm)
Oils
≤0.05 percent (≤500 Cat DEO-ULS
Min 7
ppm) Cat DEO

0. 1- 0.05 percent Cat DEO-ULS

Min 7
(1000-500 ppm) Cat DEO

Above 0.1 percent

Cat DEO(3) Min 10
(above 1000 ppm)(2)

(continued)
50 SEBU7902-09
Maintenance Section
Fluid Recommendations

Refer to Special Publication, SEBU6251, “Cat Note: The permissible fuels are some crude oils,
Commercial Diesel Engine Fluids some blends of crude oil with distillate fuel, some
Recommendations” in order to obtain additional biodiesel, and some marine diesel fuel. These fuels
information about S·O·S Services oil analysis. You are not suitable for use in all engine applications.
can also contact your local Cat dealer. The acceptability of these fuels for use is determined
on a case by case basis. A complete fuel analysis is
Fuel required. Consult your Cat dealer for further
information.
Note: Caterpillar strongly recommends the filtration
of fuel through a fuel filter with a rating of four
NOTICE
microns(c) absolute or less. This filtration should be The footnotes are a key part of the “Caterpillar Speci-
located on the device that dispenses the fuel to the fication for Distillate Diesel Fuel for Off-Highway Die-
fuel tank for the engine. This filtration should also be sel Engines” Table. Read ALL of the footnotes.
located on the device that dispenses fuel from the
bulk storage tank. Series filtration is recommended. Table 12
Caterpillar Specification for Distillate Fuel for Nonroad
NOTICE Diesel Engines
In order to meet expected fuel system component life,
4 micron (c) absolute or less secondary fuel filtration ASTM
is required for all Cat Diesel Engines that are Specifications Requirements Test ISO Test
equipped with unit injected fuel systems. All current
Aromatics 35% maximum “D1319” “ISO 3837”
Cat Diesel Engines are factory equipped with Cat Ad-
vanced Efficiency 4 micron(c) absolute fuel filters. 0.01% maximum
Ash “D482” “ISO 6245”
(weight)
Caterpillar does not warrant the quality or perform-
ance of non-Cat fluids and filters. Carbon Residue 0.35% maximum
“D524” “ISO 4262”
on 10% Bottoms (weight)
Diesel engines can burn a wide variety of fuels.
These fuels are divided into two general groups. The 40 minimum (DI
engines) “D613”
two groups are called the preferred fuels and the Cetane Number (1) or “ISO 5165”
permissible fuels. 35 minimum (PC “D6890”
engines)
Note: The permissible fuels are some crude oils,
some blends of crude oil with distillate fuel, some The cloud point
biodiesel, and some marine diesel fuel. These fuels must not exceed
are not suitable for use in all engine applications. The Cloud Point the lowest ex- “D2500” “ISO 3015”
acceptability of these fuels for use is determined on pected ambient
temperature.
an individual basis. A complete fuel analysis is
required. Copper Strip
No. 3 maximum “D130” “ISO 2160”
Corrosion
For more information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids 10% at 282 °C
Recommendations” or consult your Cat dealer for (540 °F)
further information. maximum
Distillation “D86” “ISO 3405”
90% at 360 °C
Diesel Distillate Fuel (680 °F)
maximum
Diesel engines may burn a wide variety of fuels. legal limit
Flash Point “D93” “ISO 2719”
These fuels are divided into two general groups. The
two groups are called the preferred fuels and the Minimum of 80%
permissible fuels. reflectance after
No equiva-
Thermal Stability aging for 180 mi- “D6468”
The preferred fuels provide maximum engine lent test
nutes at 150 °C
service life and performance. The preferred fuels (302 °F)
are distillate fuels. These fuels are commonly called
diesel fuel, furnace oil, gas oil, or kerosene. These 30 minimum No equiva-
API Gravity (2) “D287”
fuels must meet the “Cat Specification for Distillate 45 maximum lent test
Diesel Fuel for Off-Highway Diesel Engines” found in
this Special Publication, “Distillate Diesel Fuel”
article.
(continued)
SEBU7902-09 51
Maintenance Section
Fluid Recommendations

(Table 12, contd) Biodiesel

Caterpillar Specification for Distillate Fuel for Nonroad
A biodiesel blend of up to 20 percent may be used in
Diesel Engines
the engine when the fuel blend meets the
ASTM recommendations in table 13 and meets the
Specifications Requirements Test ISO Test recommendations in Special Publication, SEBU6251,
“Biodiesel”.
6 °C (10 °F) mini-
Pour Point mum below ambi- “D97” “ISO 3016” Note: A complete Cat S·O·S Services oil analysis
ent temperature program is recommended strongly when using
biodiesel blends above 5 percent.
“D5453” ISO 20846
Sulfur (3)(4)(5) or or Table 13
“D2622” ISO 20884
Biodiesel Blends for Cat Commercial Diesel Engines
1.4 cSt minimum
and 20.0 cSt max- Distillate diesel fuel
Biodiesel blend stock Final blend
imum as delivered used for blend
to the fuel injec-
Caterpillar distillate
Kinematic tion pumps Caterpillar biodiesel B20: “ASTM
- - diesel fuel specifica-
Viscosity specification, “ASTM D7467” and “API”
1.4 cSt minimum tion, “ASTM D975” or
D6751” or “EN14214” gravity 30-45
and 4.5 cSt maxi- “EN590”
mum as delivered
to the rotary fuel
injection pumps Fuel Additives
“D1796” Cat Diesel Fuel Conditioner
Water and
0.05% maximum or “ISO 3734”
Sediment
“D2709” Cat Diesel Fuel Conditioner is a proprietary
No equiva- formulation that has been extensively tested for use
Water 0.05% maximum “D6304” with distillate diesel fuels for use in Cat Diesel
lent test
Engines. Cat Diesel Fuel Conditioner is a high
Sediment
0.05% maximum
“D473” “ISO 3735”
performance diesel fuel conditioner for use with lower
(weight) quality fuels that do not meet the minimum
requirements of any of the following:
Gums and Resins 10 mg per 100 mL
(6) “D381” “ISO 6246”
maximum • “Caterpillar Specification for Distillate Diesel Fuel”
0.52 mm
(0.0205 inch) No equiva- • National Conference on Weights and Measures
Lubricity “D6079” (NCWM) Premium Diesel definition (refer to the
maximum at 60 °C lent test
(140 °F) 2004 or newer National Institute of Standards &
(1) Alternatively, to ensure a minimum cetane number of 35 (PC
Technology (NIST) Handbook).
engines), and 40 (DI engines), distillate diesel fuel should have
a minimum cetane index of 37.5 (PC engines), and 44.2 (DI en- • EN590 (non-arctic)
gines) when the “ASTM D4737-96a” test method is used. A fuel
with a higher cetane number may be required for operation at a • ASTM D975
higher altitude or in cold weather.
(2) Via standards tables, the equivalent kg/m3 (kilograms per cubic Cat Diesel Fuel Conditioner is the only fuel
meter) using the “ASTM D287” test method temperature of conditioner/additive available to the end user that is
15.56° C (60° F) for the minimum API gravity of 30 is 875.7 kg/ tested and approved by Caterpillar for use in Cat
m3, and for the maximum API gravity of 45 is 801.3 kg/m3. Diesel Engines.
(3) ULSD 0.0015% (<15 ppm S) is required by law for Tier 4 en-
gines and engines with aftertreatment devices. Refer to Special Publication, SEBU6251, “Cat
(4) Certain Cat fuel systems and engine components can operate
on fuel with a maximum sulfur content of 3%. Contact your Cat
Commercial Diesel Engine Fluids
dealer for guidance about appropriate maintenance intervals Recommendations” for information about the use of
and fluids for engines operating on fuel with sulfur levels be- Cat Diesel Fuel Conditioner.
tween 0.1% and 3%.
(5) An engine which operates on fuel with 0.1% (1000 ppm) of sul- Cat Diesel Fuel System Cleaner
fur or more is operating in a severe service application. Refer to
this Operation and Maintenance Manual, “Severe Service Ap- Note: Cat Diesel Fuel System Cleaner is the only fuel
plication” for information about operating an engine in a severe
service application. system cleaner available to the end user that is
(6) Follow the test conditions and procedures for gasoline (motor). tested and approved by Caterpillar for use in Cat
Diesel Engines.
52 SEBU7902-09
Maintenance Section
Fluid Recommendations

Cat Diesel Fuel System Cleaner is a proven high

performance detergent product designed specifically
for cleaning deposits that form in the fuel system. The cooling system operates under pressure
Deposits in the fuel system reduce system which is controlled by the radiator pressure cap.
performance and can increase fuel consumption. Cat Removing the cap while the system is hot may al-
Diesel Fuel System Cleaner addresses the deposits low the escape of hot coolant and steam, causing
formed due to the use of degraded diesel fuel, poor serious burns.
quality diesel fuel, and diesel fuel containing high
quantities of high molecular weight compounds. Cat Before you remove the radiator cap, allow the
Diesel Fuel System Cleaner addresses deposits system to cool. Use a thick cloth and turn the ra-
formed due to the use of biodiesel, biodiesel blends, diator cap slowly to the first stop to allow pres-
and biodiesel that does not meet the appropriate sure to escape before fully removing the cap.
quality specifications. Continued use of Cat Diesel
Fuel System Cleaner is proven to inhibit the growth of Avoid contact with coolant.
new deposits.
Caterpillar strongly recommends that Cat Diesel
Fuel System Cleaner be used with biodiesel and NOTICE
Never add coolant to an overheated engine. Engine
biodiesel blends. Cat Diesel Fuel System Cleaner is damage could result. Allow the engine to cool first.
suitable for use with biodiesel/biodiesel blends that
meet Caterpillar biodiesel recommendations and
requirements. Not all fuel cleaners are suitable for
use with biodiesel/biodiesel blends. Read and follow NOTICE
all applicable label usage instructions. Also, refer to If the engine is to be stored in, or shipped to an area
Special Publication, SEBU6251, “Cat Commercial with below freezing temperatures, the cooling system
Diesel Engine Fluids Recommendations” “Distillate must be either protected to the lowest outside tem-
Diesel Fuel”, article and also refer to the “Biodiesel” perature or drained completely in order to prevent
article, which includes Caterpillar biodiesel damage caused by freezing coolant.
recommendations and requirements.
Never operate an engine without water temperature
Aftermarket Fuel Additives regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
There are many different types of fuel additives that proper operating temperature. Cooling system
are available to use. Caterpillar does not generally problems can develop without water temperature
recommend the use of fuel additives. regulators. Removing the regulators allows some
coolant to bypass the radiator, potentially causing
In special circumstances, Caterpillar recognizes the overheating.
need for fuel additives. Use fuel additives with
caution. The additive may not be compatible with the
fuel. Some additives may precipitate. This action Coolant Recommendations
causes deposits in the fuel system. The deposits may
cause seizure. Some additives may plug fuel filters. Note: A Cat Diesel Engine equipped with air-to-air
Some additives may be corrosive, and some aftercooling (ATAAC) requires a minimum of 30
additives may be harmful to the elastomers in the fuel percent glycol to help prevent water pump cavitation.
system. Some additives may damage emission
control systems. Some additives may raise fuel sulfur
levels above the maximum levels that are allowed by
the following agencies: EPA and other regulatory
agencies. Contact your fuel supplier for those
circumstances when fuel additives are required. Your
fuel supplier can make recommendations for
additives to use and for the proper level of treatment.
Note: For best results, your fuel supplier should treat
the fuel when additives are needed.

Cooling System
Note: Refer to Special Publication , SEBU6251, “Cat
Commercial Diesel Engine Fluids
Recommendations” for complete information about
the proper fluids for use in the cooling system.
SEBU7902-09 53
Maintenance Section
Fluid Recommendations

Table 14
Coolant Recommendations for use in Cat Diesel Engines
Service Hours
Recommendations Product (1)(2)(3)
Required Maintenance

Add Cat ELC Extender at

12000 hours or
Cat ELC (Cat Extended Life Coolant) 6000 service hours or
6 years
one half of service life
Preferred
Add Cat ELC Extender at
12000 hours or
Cat ELI (Cat Extended Life Inhibitor) 6000 service hours or
6 years
one half of service life
Cat EC-1 specification and “ASTM D6210” and
Organic Additive Technology (OAT) based on a combination of a
Add Extender at 3000
monocarboxylic acid and a dicarboxylic acid 6000 hours or 6
Min requirements service hours or one half
Phosphate, borate, and silicate free years
of service life
Tolyltriazole: minimum typical concnetration of 900 ppm
Nitrite: minimum typical concentration of 500 ppm in new coolants

SCA (Supplemental cool-

3000 hours or 3
Acceptable Cat DEAC (Cat Diesel Engine Antifreeze/Coolant) ant additive) at mainte-
years
nance intervals
“ASTM D6210” and
Min requirements for fully Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US
3000 hours or 2 SCA at maintenance
formulated Heavy Duty gal) and maximum of 2400 ppm (140 grains/US gal)
years intervals
Commercial coolants Silicon concentration: minimum of 100 ppm and maximum of 275
ppm

“ASTM D4985” and(1)

Min requirements for Com- Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US
3000 hours or 1 SCA at initial fill and SCA
mercial coolants requiring gal) and maximum of 2400 ppm (140 grains/US gal)
year at maintenance intervals
SCA precharge Silicon concentration: minimum of 100 ppm and maximum of 275
ppm
(1) New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets
Reagent 4 “ASTM D1193” requirements.
(2) Maintain the in-service coolant at the given limits.
(3) When referring to the service hours, use the interval that occurs first. These coolant change intervals are only achievable with annual S·O·S
Services Level 2 coolant sampling analysis.

Table 15
Special Requirements
Cat C7-C32 Marine Engines with heat exchangers
Minimum of 30% glycol is required. 50% Glycol is recommended.
Cat diesel engines equipped with air-to-air aftercooling (ATAAC) Water alone or water with SCA or with ELI is NOT allowed.
54 SEBU7902-09
Maintenance Section
Fluid Recommendations

The following properties of the coolant are tested:

NOTICE
Use Only Approved SCAs and Extenders
• Glycol concentration for freeze protection and boil
Conventional coolants require the maintenance addi- protection
tion of SCA throughout the expected life of the cool-
ants. Do NOT use an SCA with a coolant unless • Ability to protect from erosion and corrosion
approved specifically by the coolant supplier. The
coolant manufacturer is responsible for ensuring • pH
compatibility and acceptable performance.
• Conductivity
To help ensure expected performance, EC-1 coolants
require the one time maintenance addition of an ex- • Visual analysis
tender at coolant service mid-life. Do not use an ex-
tender with a coolant unless the extender has been • Odor analysis
approved specifically for use by the coolant manufac-
turer. The coolant manufacturer is responsible for en- The results are reported, and appropriate
suring compatibility and acceptable performance. recommendations are made.

Failure to follow these recommendations can result in S·O·S Services Coolant Analysis (Level 2)
shortened cooling system component life.
A coolant analysis (Level 2) is a comprehensive
Cat ELC can be recycled into conventional coolants. chemical evaluation of the coolant. This analysis is
also a check of the overall condition of the cooling
For more information, refer to Special Publication, system.
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”. The S·O·S coolant analysis (Level 2) has the
following features:
S·O·S Services Coolant Analysis
• Full coolant analysis (Level 1)
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and • Identification of metal corrosion and of
corrosion. The analysis also tests the ability of the contaminants
coolant to protect the engine from boiling and
freezing. S·O·S coolant analysis can be done at your • Identification of buildup of the impurities that
Cat dealer. Cat S·O·S coolant analysis is the best cause corrosion
way to monitor the condition of your coolant and your
cooling system. S·O·S coolant analysis is a program • Identification of buildup of the impurities that
that is based on periodic samples. cause scaling
Table 16 • Determination of the possibility of electrolysis
within the cooling system of the engine
Recommended Interval
The results are reported, and appropriate
Type of Level 1 Level 2 recommendations are made.
Coolant
For more information on S·O·S coolant analysis,
Cat DEAC consult your Cat dealer.
Conventional Heavy- Every 250 hours Yearly(1)
Duty Coolants
Greases
Cat ELC
Cat ELI
Optional Yearly(1)
If it is necessary to choose a single grease, always
Commercial EC-1 choose a grease that meets or exceeds the
Coolants requirements of the most demanding application.
(1) The Level 2 Coolant Analysis should be performed sooner if a Remember that the products which barely meet the
problem is suspected or identified. minimum performance requirements can be
expected to barely produce the minimum lives of your
Note: Check the SCA (Supplemental Coolant parts. False economy is being used if a grease is
Additive) of the conventional coolant at every oil purchased with the lowest cost as the only
consideration. Instead, use the grease that yields the
change or at every 250 hours. Perform this check at
lowest total operating cost. The cost should be based
the interval that occurs first. on an analysis that includes the costs of parts, labor,
downtime, and the cost of the amount of grease that
S·O·S Services Coolant Analysis (Level 1)
is required.
A coolant analysis (Level 1) is a test of the properties
of the coolant.
SEBU7902-09 55
Maintenance Section
Fluid Recommendations

For more information, refer to Special Publication,

SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.
56 SEBU7902-09
Maintenance Section
Maintenance Recommendations

Maintenance Do not loosen the high pressure fuel lines in order to

remove air pressure from the fuel system.
Recommendations
Engine Oil
i02909163
To relieve pressure from the lubricating system, turn
System Pressure Release off the engine.
SMCS Code: 1250; 1300; 1350; 5050 i05909227

Coolant System Welding on Engines with

Electronic Controls
SMCS Code: 1000
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra- NOTICE
diator is cool. Then loosen cap slowly to relieve Because the strength of the frame may decrease,
the pressure. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Cat dealer regarding welding on a chas-
off the engine. Allow the cooling system pressure cap sis frame or rail.
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure. Proper welding procedures are necessary in order to
avoid damage to the engine ECM, sensors, and
Fuel System associated components. When possible, remove the
component from the unit and then weld the
component. If removal of the component is not
To relieve the pressure from the fuel system, turn off
possible, the correct procedure must be followed.
the engine.
When welding on a unit that is equipped with a Cat
Electronic Engine, the following is considered to be
High Pressure Fuel Lines (If Equipped) the safest procedure:

NOTICE
Do not ground the welder to electrical components
Contact with high pressure fuel may cause fluid such as the ECM or sensors. Improper grounding
penetration and burn hazards. High pressure fuel can cause damage to the drive train, the bearings,
hydraulic components, electrical components, and
spray may cause a fire hazard. Failure to follow
other components.
these inspection, maintenance and service in-
structions may cause personal injury or death. Do not ground the welder across the centerline of the
package. Improper grounding could cause damage
The high pressure fuel lines are the fuel lines that are to the bearings, the crankshaft, the rotor shaft, and
between the high pressure fuel pump and the high other components.
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These Clamp the ground cable from the welder to the com-
fuel lines are different from fuel lines on other fuel ponent that will be welded. Place the clamp as close
systems. as possible to the weld. This will help reduce the pos-
This is because of the following differences: sibility of damage.

• The high pressure fuel lines are constantly

charged with high pressure. Note: Perform the welding in areas that are free from
explosive hazards.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system. 1. Stop the engine. Turn the switched power to the
OFF position.
Before any service or repair is performed on the
engine fuel lines, perform the following tasks: 2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
1. Stop the engine. open the switch.
2. Wait for ten minutes.
SEBU7902-09 57
Maintenance Section
Severe Service Application

3. Disconnect the J1/P1 and J2/P2 connectors from 5. Connect the welding ground cable directly to the
the ECM. Move the harness to a position that will part that will be welded. Place the ground cable as
not allow the harness to move back accidentally, close as possible to the weld. This location will
and contact any of the ECM pins. reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
4. Disconnect any component with a microprocessor
components, and ground straps.
from the engine harness, such as:
Note: If electrical/electronic components are used as
• Engine ECM a ground for the welder, current flow from the welder
could severely damage the component. Current flow
• Product Link
from the welder could also severely damage
electrical/electronic components that are located
• Cell/Sat Radio
between the welder ground and the weld.
• DOC Identity Modules
6. Protect the wiring harness from welding debris and
spatter.
7. Use standard welding practices to weld the
materials.

i05083249

Severe Service Application

SMCS Code: 1000
An engine which operates outside of normal
conditions is operating in a severe service
application.
An engine that operates in a severe service
application may need more frequent maintenance
intervals in order to maximize the following
conditions:
• Reliability

• Service life
The number of individual applications cause the
impossibility of identifying all of the factors which may
contribute to severe service operation. Consult your
Caterpillar dealer for the unique maintenance that
may be necessary for your engine.
An application is a severe service application if any of
Illustration 30 g01075639 the following conditions apply:
Use the example above. The current flow from the
welder to the ground clamp of the welder will not Severe Environmental Factors
damage any associated components.
(1) Engine • Frequent operation in dirty air
(2) Welding electrode
(3) Keyswitch in the OFF position • Frequent operation at an altitude which is above
(4) Battery disconnect switch in the open position 1525 m (5000 ft)
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
• Frequent operation in ambient temperatures which
(8) Minimum distance between the component that is being are above 32° C (90° F)
welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
58 SEBU7902-09
Maintenance Section
Severe Service Application

• Frequent operation in ambient temperatures which • Extending maintenance intervals for changing the
are below 0° C (32° F) engine oil and engine coolant without S·O·S
validation
Severe Operating Conditions • Extending maintenance intervals for changing air
filters, oil filters, and fuel filters
• Frequent operation with inlet air which has a
corrosive content • Failure to use a water separator
• Operation with inlet air which has a combustible • Using filters which are not recommended by
content Special Publication, PEWJ0074, “2008 Cat Filter
and Fluid Application Guide”
• Operation which is outside of the intended
application • Storing the engine for more than 3 months but less
than 1 yr (For information about engine storage,
• Operation with a plugged fuel filter
refer to Special Publication, SEHS9031, “Storage
• Extended operation at low idle (more than 20% of Procedure for Caterpillar Products”)
hours)
• Storing the engine for 1 yr to 2 years (For
• Frequent cold starts at temperatures below 0° C information about engine storage, refer to Special
(32° F) Instruction, REHS5001, “The Long Term Storage
and Recovery of Certain Commercial Engines”)
• Frequent dry starts (starting after more than 72
hours of shutdown)
• Frequent hot shutdowns (shutting down the
engine without the minimum of 2 minutes to 5
minutes of cool down time)
• Operation above the engine rated speed

• Operation below the peak torque speed

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

• Operating with fuel which contains greater than

1000 ppm (0.1%) sulfur

• Operating with a blend of distillate fuel which

contains more than 5 percent biodiesel

Improper Maintenance Procedures

(Maintenance Procedures Which
May Contribute to a Severe Service
Application)
• Inadequate maintenance of fuel storage tanks
from causes such as excessive water, sediment,
and microorganism growth.
• Extending maintenance intervals beyond the
recommended intervals
• Using fluids which are not recommended in
Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids
Recommendations”
SEBU7902-09 59
Maintenance Section
Maintenance Interval Schedule

i05757049 “ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 78

Maintenance Interval Schedule “ Fuel System Primary Filter/Water Separator - Drain”

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
(Engines Which Have Shallow “ Fuel Tank Water and Sediment - Drain” . . . . . . . . .
Sumps) “Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 96
SMCS Code: 1000; 4450; 7500
Ensure that all safety information, warnings, and Initial 250 Service Hours (or at first
instructions are read and understood before any oil change)
operation or any maintenance procedures are
performed. The user is responsible for the “ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . . .
performance of all maintenance including the
following procedures: all adjustments , the use of “ Engine Valve Rotators - Inspect” . . . . . . . . . . . . . 83
proper lubricants, fluids, filters and the installation of
new components due to normal wear and aging . The
performance of this product may be diminished if Every 250 Service Hours
proper maintenance intervals and procedures are not
followed. Components may experience accelerated “ Battery Electrolyte Level - Check” . . . . . . . . . . . . . .
wear if proper maintenance intervals and procedures
are not followed. “ Coolant Sample (Level 1) - Obtain” . . . . . . . . . . . 69

Note: Use whichever of the following that occurs first “ Cooling System Supplemental Coolant Additive
(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . 71
in order to determine the maintenance intervals:
service hours and calendar time . Before each “ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 79
consecutive interval is performed, all maintenance
from the previous intervals must be performed. “ Engine Oil and Filter - Change” . . . . . . . . . . . . . . 80
Refer to this Operation and Maintenance Manual, “ Fuel System Primary Filter (Water Separator)
“Refill Capacities” to determine the type of oil pan Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 86
with which your engine is equipped.
“ Fuel System Secondary Filter - Replace” . . . . . . 87
Products that operate in severe operating conditions
may require more frequent maintenance. Refer to “Grounding Stud - Inspect/Clean/Tighten” . . . . . . . 89
this Operation and Maintenance Manual, “Severe
Service Applications” to determine if the engine is “ Hoses and Clamps - Inspect/Replace” . . . . . . . . . .
operating in a severe service application.
“ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 94
When Required “ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 95

“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 63 Initial 500 Hours (for New Systems,

“ Battery or Battery Cable - Disconnect” . . . . . . . . . . Refilled Systems, and Converted
“ Coolant - Change” . . . . . . . . . . . . . . . . . . . . . . . . . 65 Systems)
“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . 67 “ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 70

“ Engine Air Cleaner Element (Dual Element) -

Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . 73
Every 500 Service Hours
“ Engine Oil and Filter - Change” . . . . . . . . . . . . . . 80 “ Belts - Inspect/Adjust/Replace” . . . . . . . . . . . . . . 65

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

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

Daily
“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . . 68
“ Engine Air Cleaner Service Indicator - Inspect” . . .
“ Engine Air Precleaner - Check/Clean” . . . . . . . . . . .
60 SEBU7902-09
Maintenance Section
Engines Which Have Shallow Sumps

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

Every 1000 Service Hours

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

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

Every 3000 Service Hours or 3

Years
“ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . . 63
“ Coolant Temperature Regulator - Replace” . . . . 70
“ Crankshaft Vibration Damper - Inspect” . . . . . . . 72
“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . 72
“ Electronic Unit Injector - Check/Replace” . . . . . . . .
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 78
“ Engine Protective Devices - Check” . . . . . . . . . . 82
“ Engine Speed/Timing Sensor - Clean/Inspect” . . 82
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . . .
“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . . 83
“ Fan Drive Bearing - Lubricate” . . . . . . . . . . . . . . . 84

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

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

Overhaul
“ Fan Drive Bearing - Replace” . . . . . . . . . . . . . . . . 84
SEBU7902-09 61
Maintenance Section
Maintenance Interval Schedule

i05757058 “ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 78

Maintenance Interval Schedule “ Fuel System Primary Filter/Water Separator - Drain”

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
(Engines Which Have Deep “ Fuel Tank Water and Sediment - Drain” . . . . . . . . .
Sumps) “Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 96
SMCS Code: 1000; 4450; 7500
Ensure that all safety information, warnings, and Every 250 Service Hours
instructions are read and understood before any
operation or any maintenance procedures are “ Battery Electrolyte Level - Check” . . . . . . . . . . . . . .
performed. The user is responsible for the
performance of all maintenance including the “ Coolant Sample (Level 1) - Obtain” . . . . . . . . . . . 69
following procedures: all adjustments , the use of
“ Cooling System Supplemental Coolant Additive
proper lubricants, fluids, filters and the installation of
(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . 71
new components due to normal wear and aging . The
performance of this product may be diminished if “ Fuel System Primary Filter (Water Separator)
proper maintenance intervals and procedures are not Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 86
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures “ Fuel System Secondary Filter - Replace” . . . . . . 87
are not followed.
“Grounding Stud - Inspect/Clean/Tighten” . . . . . . . 89
Note: Use whichever of the following that occurs first
in order to determine the maintenance intervals: “ Hoses and Clamps - Inspect/Replace” . . . . . . . . . .
service hours and calendar time . Before each
consecutive interval is performed, all maintenance “ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 94
from the previous intervals must be performed. “ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 95
Refer to this Operation and Maintenance Manual,
“Refill Capacities” to determine the type of oil pan Initial 500 Service Hours (or at first
with which your engine is equipped.
oil change)
Products that operate in severe operating conditions
may require more frequent maintenance. Refer to “ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . . .
this Operation and Maintenance Manual, “Severe
Service Applications” to determine if the engine is “ Engine Valve Rotators - Inspect” . . . . . . . . . . . . . 83
operating in a severe service application.
Initial 500 Hours (for New Systems,
When Required Refilled Systems, and Converted
“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 63 Systems)
“ Battery or Battery Cable - Disconnect” . . . . . . . . . . “ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 70

“ Coolant - Change” . . . . . . . . . . . . . . . . . . . . . . . . . 65 Every 500 Service Hours

“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . 67
“ Belts - Inspect/Adjust/Replace” . . . . . . . . . . . . . . 65
“ Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . 73 “ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 79

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

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

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

Daily
“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . . 68
“ Engine Air Cleaner Service Indicator - Inspect” . . .
“ Engine Air Precleaner - Check/Clean” . . . . . . . . . . .
62 SEBU7902-09
Maintenance Section
Engines Which Have Deep Sumps

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

Every 1000 Service Hours

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

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

Every 3000 Service Hours or 3

Years
“ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . . 63
“ Coolant Temperature Regulator - Replace” . . . . 70
“ Crankshaft Vibration Damper - Inspect” . . . . . . . 72
“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . 72
“ Electronic Unit Injector - Check/Replace” . . . . . . . .
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 78
“ Engine Protective Devices - Check” . . . . . . . . . . 82
“ Engine Speed/Timing Sensor - Clean/Inspect” . . 82
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . . .
“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . . 83
“ Fan Drive Bearing - Lubricate” . . . . . . . . . . . . . . . 84

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

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

Overhaul
“ Fan Drive Bearing - Replace” . . . . . . . . . . . . . . . . 84
SEBU7902-09 63
Maintenance Section
Aftercooler Core - Clean/Test

i02783957 Inspect these items for good condition: welds,

mounting brackets, air lines, connections, clamps
Aftercooler Core - Clean/Test and seals. Make repairs, if necessary.

(Air-To-Air Aftercooler (If For more detailed information on cleaning and

inspection, see Special Publication, SEBD0518,
Equipped)) “Know Your Cooling System”.
SMCS Code: 1064-070; 1064-081
i01878164
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. Battery - Replace
Inspect the aftercooler for these items: damaged fins, SMCS Code: 1401-510
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the aftercooler, if necessary.
For air-to-air aftercoolers, use the same methods that Batteries give off combustible gases which can
are used for cleaning radiators.
explode. A spark can cause the combustible
gases to ignite. This can result in severe personal
injury or death.

Personal injury can result from air pressure. Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
Personal injury can result without following prop- der to help prevent electrical arcs and/or sparks
er procedure. When using pressure air, wear a near batteries. Do not smoke when batteries are
protective face shield and protective clothing. serviced.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

The battery cables or the batteries should not be

Pressurized air is the preferred method for removing
removed with the battery cover in place. The bat-
loose debris. Direct the air in the opposite direction of
tery cover should be removed before any servic-
the fan's air flow. Hold the nozzle approximately
ing is attempted.
6 mm (0.25 inch) away from the fins. The maximum
air pressure for cleaning purposes must be below Removing the battery cables or the batteries with
205 kPa (30 psi) when the air nozzle is deadheaded. the cover in place may cause a battery explosion
Slowly move the air nozzle in a direction that is resulting in personal injury.
parallel with the tubes. This will remove debris that is
between the tubes.
1. Switch the engine to the OFF position. Remove all
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes electrical loads.
must be less than 275 kPa (40 psi). Use pressurized 2. Turn off any battery chargers. Disconnect any
water in order to soften mud. Clean the core from battery chargers.
both sides.
Use a degreaser and steam for removal of oil and 3. The NEGATIVE “-” cable connects the NEGATIVE
grease. Clean both sides of the core. Wash the core “-” battery terminal to the NEGATIVE “-” terminal
with detergent and hot water. Thoroughly rinse the on the starter motor. Disconnect the cable from the
core with clean water. NEGATIVE “-” battery terminal.
After cleaning, start the engine and accelerate the 4. The POSITIVE “+” cable connects the POSITIVE
engine to high idle rpm. This will help in the removal “+” battery terminal to the POSITIVE “+” terminal
of debris and drying of the core. Stop the engine. Use on the starting motor. Disconnect the cable from
a light bulb behind the core in order to inspect the
core for cleanliness. Repeat the cleaning, if the POSITIVE “+” battery terminal.
necessary.
Note: Always recycle a battery. Never discard a
Inspect the fins for damage. Bent fins may be opened battery. Return used batteries to an appropriate
with a “comb”. recycling facility.

Note: If parts of the aftercooler system are repaired 5. Remove the used battery.
or replaced, a leak test is highly recommended.
6. Install the new battery.
64 SEBU7902-09
Maintenance Section
Battery Electrolyte Level - Check

Note: Before the cables are connected, ensure that Use the 1U-9921 Battery Service Tool to clean
the engine start switch is OFF. the battery terminals. Use a wire brush to clean
the cable clamps. Clean the items until the
7. Connect the cable from the starting motor to the surfaces are bright or shiny. DO NOT remove
POSITIVE “+” battery terminal. material excessively. Excessive removal of
8. Connect the cable from the NEGATIVE “-” terminal material can cause the clamps to fit improperly.
on the starter motor to the NEGATIVE “-” battery Coat the clamps and the terminals with the Loctite
®
terminal. product listed below, petroleum jelly or MPGM.

• For Americas North - Loctite LB8632

i07419560

• For Europe and Africa, Middle East, CIS

Battery Electrolyte Level - (AMEC) - Loctite LB8104
Check
• For Asia Pacific - Loctite LB8801
SMCS Code: 1401-535-FLV
• For Americas South - Loctite LB Superlube
When the engine has not run for long or short periods
of time, the batteries may not fully recharge. Ensure a For ordering the products listed above, go to the
full charge to help prevent the battery from freezing.
following address.
In warmer climates, check the electrolyte level more
frequently. http://www.loctite.com/en/meta/meta-nav/
location-selector.html
Ensure that the electrolyte level is 13 mm (0.5 inch)
above the top of the separators. i06738663

Battery or Battery Cable -

All lead-acid batteries contain sulfuric acid which
Disconnect
can burn the skin and clothing. Always wear a SMCS Code: 1401; 1402-029
face shield and protective clothing when working
on or near batteries.

1. Remove the filler caps. Maintain the electrolyte The battery cables or the batteries should not be
level to the “FULL” mark on the battery. removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
If the addition of water is necessary, use distilled ing is attempted.
water. If distilled water is not available, use clean
water that is low in minerals. Do not use artificially Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
softened water. resulting in personal injury.
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer. 1. Turn the start switch to the OFF position. Turn the
3. Keep the batteries clean. ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
Clean the battery case with one of the following
cleaning solutions: 2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
• A mixture of 0.1 kg (0.2 lb) of baking soda and the cable cannot contact the terminal. When four
1 L (1 qt) of clean water 12 volt batteries are involved, the negative side of
two batteries must be disconnected.
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water 3. Tape the leads in order to help prevent accidental
starting.
Thoroughly rinse the battery case with clean
4. Proceed with necessary system repairs. Reverse
water.
the steps in order to reconnect all of the cables.
SEBU7902-09 65
Maintenance Section
Belts - Inspect/Adjust/Replace

i02042962 3. Move the assembly in order to increase or

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

• Belts 4. Move the pulley in order to adjust the belt tension.

5. Tighten the adjusting nut.
• Pulleys
6. Tighten the mounting bolt.
• Bearings
7. Reinstall the belt guard.
If the belts are too tight, unnecessary stress is placed
on the components. This reduces the service life of If new drive belts are installed, check the drive belt
the components. tension again after 30 minutes of engine operation
at the rated rpm.
Replacement
i04538352
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing Coolant - Change
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive SMCS Code: 1350-044; 1352; 1395; 1395-044
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail. Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for the correct intervals for
changing the coolant.
Alternator Belt Adjustment
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.

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

• The fuel has entered the cooling system and the

coolant is contaminated.

Illustration 31 g00788814

1. Remove the belt guard.

2. Loosen mounting bolts (1) and adjusting bolt (2).
66 SEBU7902-09
Maintenance Section
Coolant - Change

Drain the Cooling System Inside USA 1-800-542-TOOL

Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL
International 1-309-578-7372
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, Flush
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system Systems Filled with Cat ELC, Cat ELI, or
pressure cap slowly in order to relieve the
pressure. a Conventional Coolant that Meets the
Cat EC-1 Requirements and the
Standards of ASTM D6210
NOTICE
Care must be taken to ensure that fluids are con- 1. Flush the cooling system with clean water in order
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. to remove any debris.
Be prepared to collect the fluid with suitable contain- 2. Close the drain valve (if equipped). Clean the drain
ers before opening any compartment or disassem-
bling any component containing fluids. plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, “Torque
Refer to Special Publication, NENG2500, “Cat Dealer Specifications” for more information on the proper
Service Tool Catalog” or refer to Special Publication, torques.
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain NOTICE
fluids on Cat products. Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Dispose of all fluids according to local regulations
and mandates.
3. Fill the cooling system with clean water. Install the
1. Stop the engine and allow the engine to cool. cooling system filler cap.
Ensure that the engine will not start when the 4. Start and run the engine at low idle until the
cooling system is drained. temperature reaches 49 to 66 °C (120 to 150 °F).
2. Loosen the cooling system filler cap slowly in order 5. Stop the engine and allow the engine to cool.
to relieve any pressure. Remove the cooling Loosen the cooling system filler cap slowly in
system filler cap. order to relieve any pressure. Remove the cooling
3. Open the cooling system drain valve (if equipped). system filler cap. Open the drain valve (if
If the cooling system is not equipped with a drain equipped) or remove the cooling system drain
valve, remove one of the drain plugs. plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if
Note: If equipped, be sure to drain the heater and equipped). Clean the drain plugs. Install the drain
any related supply and return lines. plugs. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more
Allow the coolant to drain. information on the proper torques.
NOTICE Systems Filled with Cat DEAC,
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim Conventional Coolant which does not
used coolant for reuse in engine cooling systems. Meet the Cat EC-1 Requirements, or
The full distillation procedure is the only method ac-
ceptable by Caterpillar to reclaim the used coolant. Supplemental Coolant Additive (SCA)
and Water
For information regarding the disposal and the 3. Flush the cooling system with clean water in order
recycling of used coolant, consult your Cat dealer or
to remove any debris.
consult Cat Dealer Service Tool Group:
4. Close the drain valve (if equipped). Clean the drain
plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques.
SEBU7902-09 67
Maintenance Section
Coolant Extender (ELC) - Add

1. Fill the cooling system. Refer to this Operation and

NOTICE
Fill the cooling system no faster than 19 L (5 US gal) Maintenance Manual, “Fluid Recommendations”
per minute to avoid air locks. for more information on cooling system
specifications Refer to this Operation and
Maintenance Manual, “Refill Capacities” for
5. Fill the cooling system with a mixture of clean
information about the capacity of the cooling
water and Cat Fast Acting Cooling System
system. Do not install the cooling system filler cap.
Cleaner.
2. Start and run the engine at low idle. Increase the
6. Choose 1 of the following options.
engine rpm to high idle. Run the engine at high
• Add 0.5 L (1 pint) of cleaner per 15 L idle for 1 minute in order to purge the air from the
(4 US gal) of the cooling system capacity. cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level
• For cooling systems with heavy deposits or
within 13 mm (0.5 inch) below the bottom of the
plugging, add 0.5 L (1 pint) of cleaner per
pipe for filling. Maintain the coolant level within
3.8 to 7.6 L (1 to 2 US gal) of the cooling
13 mm (0.5 inch) to the proper level on the sight
system capacity.
glass (if equipped).
7. Install the cooling system filler cap. 4. Clean the cooling system filler cap. Inspect the
8. Start and run the engine at low idle for a minimum gasket that is on the cooling system filler cap. Only
of 30 minutes. For cooling systems with heavy install the used filler cap if the gasket is not
deposits or plugging, run the engine for 90 damaged. Use a 9S-8140 Pressurizing Pump to
minutes. The coolant temperature should be at pressure test a reinstalled cooling system filler
least 82 °C (180 °F). cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
NOTICE system filler cap. If the cooling system filler cap
Improper or incomplete rinsing of the cooling system does not retain the correct pressure, install a new
can result in damage to copper and other metal cooling system filler cap.
components.
5. Start the engine. Inspect the cooling system for
To avoid damage to the cooling system, make sure to leaks and for proper operating temperature.
completely flush the cooling system with clear water.
Continue to flush the system until all signs of the
i04862631
cleaning agent are gone.
Coolant Extender (ELC) - Add
9. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in SMCS Code: 1352-544-NL
order to relieve any pressure. Remove the cooling Note: Refer to this Operation and Maintenance
system filler cap. Open the drain valve (if Manual, “Fluid Recommendations” (Cooling System)
equipped) or remove the cooling system drain for the maintenance interval for the addition of the
plugs. Allow the water to drain. Flush the cooling coolant extender.
system with clean water. If equipped, be sure to
flush the heater and any related supply and return Cat ELC (Extended Life Coolant) and Cat ELI
(Extended Life Inhibitor) do not require the frequent
lines. Close the drain valve (if equipped). Clean additions of any supplemental cooling additives. The
the drain plugs. Install the drain plugs. Refer to the Cat ELC Extender will only be added one time.
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper Note: Do not use conventional supplemental coolant
torques. additive (SCA) with Cat ELC or with Cat ELI.
Check the cooling system only when the engine is
Fill the Cooling System stopped and cool.

NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
68 SEBU7902-09
Maintenance Section
Coolant Level - Check

i04156593

Personal injury can result from hot coolant, Coolant Level - Check
steam and alkali. SMCS Code: 1395-082
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to Check the coolant level when the engine is stopped
heaters or the engine contain hot coolant or and cool.
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.

NOTICE
Care must be taken to ensure that fluids are con- Illustration 32 g00285520
tained during performance of inspection, mainte- Cooling system filler cap
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Pressurized System: Hot coolant can cause seri-
Refer to Special Publication, NENG2500, “Cat Dealer ous burns. To open the cooling system filler cap,
Service Tool Catalog” or refer to Special Publication, stop the engine and wait until the cooling system
PECJ0003, “Cat Shop Supplies and Tools Catalog” components are cool. Loosen the cooling system
for tools and supplies suitable to collect and contain pressure cap slowly in order to relieve the
fluids on Cat products. pressure.
Dispose of all fluids according to local regulations
and mandates. 1. Remove the cooling system filler cap slowly in
order to relieve pressure.
1. Loosen the cooling system filler cap slowly in order 2. Maintain the coolant level within 13 mm (0.5 inch)
to relieve pressure. Remove the cooling system of the bottom of the filler pipe. If the engine is
filler cap. equipped with a sight glass, maintain the coolant
2. If necessary, drain enough coolant from the level to the proper level in the sight glass.
cooling system in order to add the Cat ELC
Extender.
3. Add Cat ELC Extender according to the
requirements for the cooling system capacity.
Refer to this Operation and Maintenance Manual,
“Refill Capacities” for the coolant capacity.
4. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
For further information, refer to this Operation and
Maintenance Manual, , “Fluid Recommendations”.
Illustration 33 g00103639
Typical filler cap gaskets
SEBU7902-09 69
Maintenance Section
Coolant Sample (Level 1) - Obtain

3. Clean the cooling system filler cap and check the • Keep the lids on empty sampling bottles until you
condition of the filler cap gaskets. Replace the are ready to collect the sample.
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap. • Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
4. Inspect the cooling system for leaks. contamination.

• Never collect samples from expansion bottles.

i04333559

• Never collect samples from the drain for a system.

Coolant Sample (Level 1) -
Obtain Timing of the Sampling
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 Table 17
Testing the engine coolant is important to ensure that Recommended Interval
the engine is protected from internal cavitation and
corrosion. The analysis also tests the ability of the Type of
coolant to protect the engine from boiling and Level 1 Level 2
freezing. S·O·S Systems Coolant Analysis can be Coolant
done at your Cat dealer. Cat S·O·S coolant analysis Cat DEAC
is the best way to monitor the condition of your Cat SCA
coolant and your cooling system. S·O·S coolant Every 250 hours Yearly(1)
Conventional Heavy-
analysis is a program that is based on periodic Duty Coolants
samples.
Cat ELC
Note: Obtaining a Coolant Sample (Level 1) is Cat ELI
Optional(1) Yearly(1)
optional if the cooling system is filled with one of Commercial EC-1
the following coolants: Cat ELC (Extended Life Coolants
Coolant)., Cat ELI (Extended Life Inhibitor) and (1) The Level 2 Coolant Analysis should be performed sooner if a
Conventional Heavy-Duty Coolant. problem is suspected or identified.

Note: Obtain a Coolant Sample (Level 1) if the Note: Check the SCA (Supplemental Coolant
cooling system is filled with any of the following Additive) of the conventional coolant at every oil
coolants: Cat DEAC, Cat SCA and Conventional change or at every 250 hours. Perform this check at
Heavy-Duty Coolants. the interval that occurs first.
For additional information about coolant analysis and Obtain the sample of the coolant as close as possible
about other coolants, see this Operation and to the recommended sampling interval. In order to
Maintenance Manual, “Fluid Recommendations” or receive the full effect of S·O·S analysis, establish a
consult your Cat dealer. consistent trend of data. In order to establish a
pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for
Sampling Conditions collecting samples can be obtained from your Cat
dealer.
If the engine is equipped with a sampling port, the
engine should be running at operating temperature
when the sample is obtained. NOTICE
Always use a designated pump for oil sampling, and
If the engine is not equipped with a sampling port, the use a separate designated pump for coolant sam-
coolant should be warm. pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
Use the following guidelines for proper sampling of drawn. This contaminate may cause a false analysis
the coolant: and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
• Complete the information on the label for the
sampling bottle before you begin to take the
samples. Submit the sample for Level 1 analysis.

• Keep the unused sampling bottles stored in plastic

bags.
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
70 SEBU7902-09
Maintenance Section
Coolant Sample (Level 2) - Obtain

Note: Level 1 results may indicate a need for Level 2 A water temperature regulator that fails in the closed
Analysis. position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
i04638756
head or piston seizure problems.

Coolant Sample (Level 2) - NOTICE

Failure to replace your water temperature regulator
Obtain on a regularly scheduled basis could cause severe
engine damage.
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Caterpillar engines incorporate a shunt design cool-
An S·O·S Coolant Analysis (Level 2) is a ing system and require operating the engine with a
comprehensive chemical evaluation of the coolant. water temperature regulator installed.
This analysis is also a check of the overall condition
of the cooling system. The S·O·S Coolant Analysis If the water temperature regulator is installed incor-
(Level 2) has the following features: rectly, the engine may overheat, causing cylinder
head damage. Ensure that the new water tempera-
• Full coolant analysis (Level 1) ture regulator is installed in the original position. En-
sure that the water temperature regulator vent hole is
• Identification of metal corrosion and contaminants open.
• Identification of buildup of the impurities that Do not use liquid gasket material on the gasket or cyl-
cause corrosion and scaling inder head surface.

• Determination of the possibility of electrolysis

within the cooling system of the engine NOTICE
Care must be taken to ensure that fluids are con-
The results are reported and appropriate tained during performance of inspection, mainte-
recommendations are made. nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Obtaining the Sample ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Operation and Maintenance Manual, Refer to Special Publication, NENG2500, “Cat Dealer
“Coolant Sample (Level 1) - Obtain” for the guidelines Service Tool Catalog” or refer to Special Publication,
for proper sampling of the coolant. PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
Submit the sample for Level 2 analysis.
fluids on Cat products.
For further information, refer to this Operation and
Dispose of all fluids according to local regulations
Maintenance Manual, “Fluid Recommendations”.
and mandates.
i04240223
Note: If replacing only the water temperature
Coolant Temperature regulator, only drain the coolant to a level that is
Regulator - Replace below the water temperature regulator housing.

SMCS Code: 1355-510 Refer to two articles in the Disassembly and

Assembly Manual, “Water Temperature Regulator -
Replace the water temperature regulator before the Remove and Water Temperature Regulator - Install”
water temperature regulator fails. Replacing the for the replacement procedure or consult your Cat
water temperature regulator reduces the chances for dealer.
unscheduled downtime.
A water temperature regulator that fails in a partially
opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear of
the cylinder liner.
SEBU7902-09 71
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i04269112
NOTICE
Care must be taken to ensure that fluids are con-
Cooling System Supplemental tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Coolant Additive (SCA) - Test/ Be prepared to collect the fluid with suitable contain-
Add ers before opening any compartment or disassem-
bling any component containing fluids.
(Systems Which are Filled with
Refer to Special Publication, NENG2500, “Cat Dealer
Conventional Coolant) Service Tool Catalog” and to Special Publication,
SMCS Code: 1352-045; 1395-081 GECJ0003, “Cat Shop Supplies and Tools” for tools
and supplies suitable to collect and contain fluids on
This maintenance procedure is required for Cat products.
conventional coolants such as DEAC.Do not
perform this maintenance for cooling systems Dispose of all fluids according to applicable regula-
that are filled with Cat Extended Life Coolant (Cat tions and mandates.
ELC) or Cat Extended Life Inhibitor (Cat ELI).
Note: Caterpillar recommends that an S·O·S Coolant
Analysis (Level 1) be performed to check the
concentration of SCA.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact
with the skin and eyes. Do not drink cooling sys- Maintain the Proper Concentration
tem coolant additive. of SCA in the Coolant

NOTICE
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur- Pressurized System: Hot coolant can cause seri-
faces of the cooling system, reducing the engine's ous burns. To open the cooling system filler cap,
heat transfer characteristics. Reduced heat transfer stop the engine and wait until the cooling system
could cause cracking of the cylinder head and other components are cool. Loosen the cooling system
high temperature components. pressure cap slowly in order to relieve the
pressure.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat ex- 1. Remove the cooling system filler cap slowly.
changer, overheating, and/or accelerated wear of the
water pump seal. 2. Test the concentration of the SCA with a
286-2578 Nitrite Test Strip or review the results
Do not exceed the recommended amount of supple- of the S·O·S Coolant Analysis (Level 1).
mental coolant additive concentration.
3. If necessary, drain some coolant in order to allow
space for the addition of the SCA.
NOTICE
Do NOT mix brands or types of SCA. Do NOT mix 4. Add the amount of SCA required to maintain a
SCAs and extenders. concentration of 3 percent to 6 percent SCA in the
coolant.
Failure to follow the recommendations can result in
shortened cooling system component life. 5. Clean the cooling system filler cap. Install the
cooling system filler cap.

NOTICE
Use Only Approved SCAs. Conventional coolants
require the maintenance addition of SCA throughout
their expected life. Do NOT use an SCA with a cool-
ant unless specifically approved by the coolant sup-
plier for use with their coolant. It is the responsibility
of the coolant manufacturer to ensure compatibility
and acceptable performance.
Failure to follow the recommendations can result in
shortened cooling system component life.
72 SEBU7902-09
Maintenance Section
Crankshaft Vibration Damper - Inspect

For further information, refer to Special Publication, Refer to the Disassembly and Assembly Manual,
SEBU6251, “Cat Commercial Diesel Engine Fluids “Vibration Damper and Pulley - Remove and Install”
Recommendations”. or consult your Cat dealer for information about
damper replacement.
i05264144
i00934883
Crankshaft Vibration Damper -
Inspect Driven Equipment - Check
SMCS Code: 3279-535
SMCS Code: 1205-040
Damage to the crankshaft vibration damper or failure Check the Alignment
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to the To minimize bearing problems and vibration of the
crankshaft and to other engine components. A engine crankshaft and the driven equipment, the
damper that is damaged can cause excessive gear alignment between the engine and driven equipment
train noise at variable points in the speed range. must be properly maintained.
The damper is mounted to the crankshaft which is Check the alignment according to the instructions
located behind the belt guard on the front of the that are provided by the following manufacturers:
engine.
• Caterpillar
Visconic Damper
• OEM of the drive coupling
The visconic damper has a weight that is located
inside a fluid filled case. The weight moves in the • OEM of the driven equipment
case in order to limit torsional vibration. Torque all of the fasteners to the proper
Inspect the damper for evidence of fluid leaks. If a specifications.
fluid leak is found, determine the type of fluid. The
fluid in the damper is silicone. Silicone has the Inspect the Drive Coupling
following characteristics: transparent, viscous,
smooth and adhering. Inspect the drive coupling according to the
instructions that are provided by the OEM of the
If the fluid leak is oil, inspect the crankshaft seals for coupling. For the following service information, see
leaks. If a leak is observed, replace the crankshaft the literature that is provided by the OEM of the
seals. coupling:
Inspect the damper and repair or replace the damper
for any of the following reasons: • Lubrication requirements

• The damper is dented, cracked, or leaking. • Specifications for the end play

• The paint on the damper is discolored from heat. • “Reusability Guidelines”

• The engine has had a failure because of a broken • Replacement instructions

crankshaft.
Inspect the Rear Gear Train
• Analysis of the oil has revealed that the front main
bearing is badly worn. Inspect the crankshaft gear. If excessive wear is
found, replace the crankshaft gear and the large
• There is a large amount of gear train wear that is cluster idler.
not caused by a lack of oil.
If any gear causes damage to other gears through
failure, replace the entire rear gear train.
SEBU7902-09 73
Maintenance Section
Electronic Unit Injector - Check/Replace

For the correct parts, see the Parts Manual for the i06103535
engine. For removal and replacement instructions,
see the Service Manual, “Disassembly and
Assembly” module. Consult your Caterpillar dealer
Engine - Clean
for assistance. SMCS Code: 1000-070

i06826449

Electronic Unit Injector - Personal injury or death can result from high
voltage.
Check/Replace
Moisture can create paths of electrical
SMCS Code: 1251-510; 1251-535; 1290-535; 1290-
conductivity.
510
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “ DO
NOT OPERATE”” .
Be sure the engine cannot be started while this
maintenance is being performed. To prevent pos-
sible injury, do not use the starting motor to turn NOTICE
the flywheel. Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and
Hot engine components can cause burns. Allow fluid spills whenever a significant quantity accumu-
additional time for the engine to cool before lates on the engine.
measuring/adjusting the unit injectors.
Periodic cleaning of the engine is recommended.
The electronic unit injectors use high voltage. Steam cleaning the engine will remove accumulated
Disconnect the unit injector enable circuit con- oil and grease. A clean engine provides the following
nector in order to prevent personal injury. Do not benefits:
come in contact with the injector terminals while
the engine is running. • Easy detection of fluid leaks
The operation of a Cat Engine with an electronic unit • Maximum heat transfer characteristics
injector which is improperly adjusted may reduce
engine efficiency. This reduced efficiency may result • Ease of maintenance
in excessive fuel usage and/or shortened engine
component life. Note: Caution must be used in order to prevent
electrical components from being damaged by
Note: Only qualified service personnel should excessive water when you clean the engine. Avoid
perform this maintenance. electrical components such as the alternator, the
starter, and the ECM.
Refer to the Systems Operation, Testing and
Adjusting, “Electronic Unit Injector - Test” for the test
i04322011
procedure. Refer to Systems Operation, Testing and
Adjusting, “Engine Valve Lash — Inspect/Adjust” for
the adjustment procedure. Engine Air Cleaner Element
Refer to the Disassembly and Assembly Manual for (Dual Element) - Inspect/Clean/
the procedure applicable for the removal and
replacement of the injector.
Replace
SMCS Code: 1051; 1054-510; 1054-040; 1054-070
NOTICE
The camshafts must be correctly timed with the NOTICE
crankshaft before an adjustment of the lash for the Never run the engine without an air cleaner element
fuel injector is made. The timing pins must be re- installed. Never run the engine with a damaged air
moved from the camshafts before the crankshaft is cleaner element. Do not use air cleaner elements
turned or damage to the cylinder block will be the with damaged pleats, gaskets or seals. Dirt entering
result. the engine causes premature wear and damage to
engine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.
74 SEBU7902-09
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
engine wear. Your Cat dealer has the proper air
cleaner elements for your application. Consult your
Cat dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily for

accumulation of dirt and debris. Remove any dirt Illustration 34 g00736431
and debris, as needed. (1) Cover
(2) Primary air cleaner element
• Operating conditions (dust, dirt, and debris) may (3) Secondary air cleaner element
(4) Turbocharger air inlet
require more frequent service of the air cleaner
element.
1. Remove the cover. Remove the primary air cleaner
• The air cleaner element may be cleaned up to six element.
times if the element is properly cleaned and
inspected. 2. The secondary air cleaner element should be
removed and discarded for every three cleanings
• The air cleaner element should be replaced at of the primary air cleaner element.
least one time per year. This replacement should
be performed regardless of the number of Note: Refer to “Cleaning the Primary Air Cleaner
cleanings. Elements”.

Replace the dirty paper air cleaner elements with 3. Cover the turbocharger air inlet with tape in order
clean air cleaner elements. Before installation, to keep out dirt.
thoroughly check the air cleaner elements for tears
and/or holes in the filter material. Inspect the gasket 4. Clean the inside of the air cleaner cover and body
or the seal of the air cleaner element for damage. with a clean, dry cloth.
Maintain a supply of suitable air cleaner elements for
replacement purposes. 5. Remove the tape for the turbocharger air inlet.
Install the secondary air cleaner element. Install a
Dual Element Air Cleaners primary air cleaner element that is new or cleaned.

The dual element air cleaner contains a primary air 6. Install the air cleaner cover.
cleaner element and a secondary air cleaner
element. The primary air cleaner element can be
used up to six times if the element is properly
cleaned and inspected. The primary air cleaner
element should be replaced at least one time per
year. This replacement should be performed
regardless of the number of cleanings.
The secondary air cleaner element is not serviceable
or washable. The secondary air cleaner element
should be removed and discarded for every three
cleanings of the primary air cleaner element. When
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more
frequent replacement.
SEBU7902-09 75
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

7. Reset the air cleaner service indicator. Pressurized Air

Cleaning the Primary Air Cleaner

Elements Personal injury can result from air pressure.

NOTICE Personal injury can result without following prop-

Caterpillar recommends certified air filter cleaning er procedure. When using pressure air, wear a
services that are available at Cat dealers. The Cat protective face shield and protective clothing.
cleaning process uses proven procedures to assure
consistent quality and sufficient filter life. Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Observe the following guidelines if you attempt to
clean the filter element: Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
Do not tap or strike the filter element in order to re- than two times. Pressurized air will not remove
move dust. deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets,
or seals. Dirt entering the engine will cause damage
to engine components.

The primary air cleaner element can be used up to

six times if the element is properly cleaned and
inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
The primary air cleaner element should be replaced Illustration 35 g00281692
at least one time per year. This replacement should
be performed regardless of the number of cleanings. Note: When the primary air cleaner elements are
cleaned, always begin with the clean side (inside) in
Use clean primary air cleaner elements while dirty order to force dirt particles toward the dirty side
elements are being cleaned. (outside).

NOTICE To help prevent damage to the paper pleats, aim the

Do not clean the air cleaner elements by bumping or hose so that the air flows inside the element along
tapping. This could damage the seals. Do not use el- the length of the filter. Do not aim the stream of air
ements with damaged pleats, gaskets or seals. Dam- directly at the primary air cleaner element. Dirt could
aged elements will allow dirt to pass through. Engine be forced further into the pleats.
damage could result.
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
Visually inspect the primary air cleaner elements
before cleaning. Inspect the air cleaner elements for Vacuum Cleaning
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
Vacuum cleaning is a good method for cleaning
There are two common methods that are used to primary air cleaner elements which require daily
clean primary air cleaner elements: cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
• Pressurized air to vacuum cleaning. Vacuum cleaning will not
remove deposits of carbon and oil.
• Vacuum cleaning
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
76 SEBU7902-09
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Inspecting the Primary Air Cleaner

Elements

Illustration 37 g00281694

Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An airflow restriction
Illustration 36 g00281693
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inspect the clean, dry primary air cleaner element. Inhibited (VCI) paper.
Use a 60W blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner Place the primary air cleaner element into a box for
element. Rotate the primary air cleaner element. storage. For identification, mark the outside of the
Inspect the primary air cleaner element for tears and/ box and mark the primary air cleaner element.
or holes. Inspect the primary air cleaner element for Include the following information:
light that may show through the filter material. If
necessary, compare the primary air cleaner element • Date of cleaning
to a new primary air cleaner element that has the
same part number. • Number of cleanings
Do not use a primary air cleaner element that has Store the box in a dry location.
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
i06103548
pleats, gaskets, or seals. Discard damaged primary
air cleaner elements.
Engine Air Cleaner Service
Storing Primary Air Cleaner Elements Indicator - Inspect
If a primary air cleaner element that passes (If Equipped)
inspection will not be used, the primary air cleaner SMCS Code: 7452-040
element can be stored for future use.
Some engines may be equipped with a different
service indicator.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before and after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the clean
side of the air cleaner housing or in a remote
location.
SEBU7902-09 77
Maintenance Section
Engine Air Precleaner - Check/Clean

Note: When a new service indicator is installed,

excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque of
2 N·m (18 lb in).

i07819526

Engine Air Precleaner - Check/

Clean
SMCS Code: 1055-535; 1055-070

Illustration 38 g00103777
Typical service indicator

Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner element
should be replaced when one of the following
conditions occur:
• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service Indicator

Illustration 39 g01453058
Service indicators are important instruments. Typical engine air precleaner
(1) Wing nut
• Check for ease of resetting. The service indicator (2) Cover
should reset in less than three pushes. (3) Body

• Check the movement of the service indicator core Remove wing nut (1) and cover (2). Check for an
when the engine is run at full load speed. The core accumulation of dirt and debris in body (3). Clean the
should latch approximately at the greatest vacuum body, if necessary.
that is attained.
After cleaning the precleaner, install cover (2) and
If the service indicator does not reset easily, or if the wing nut (1).
core does not latch at the greatest vacuum, the
service indicator should be replaced. If the new Note: When the engine is operated in dusty
service indicator will not reset, the hole for the service conditions, more frequent cleaning is required.
indicator may be plugged.
Do not tap or strike the air cleaner element.
If necessary, replace the service indicator more
frequently in environments that are severely dusty.
i02489863
Replace the service indicator annually regardless of
the operating conditions. Replace the service
indicator when the engine is overhauled, and Engine Crankcase Breather -
whenever major engine components are replaced. Clean
SMCS Code: 1317-070

NOTICE
Perform this maintenance with the engine stopped.
If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.
78 SEBU7902-09
Maintenance Section
Engine Mounts - Inspect

5. Install hose (2) on valve cover (3). Install hose

clamp (1).

i02139969

Engine Mounts - Inspect

SMCS Code: 1152-040; 1152
Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused
by the following conditions:

• Improper mounting of the engine

• Deterioration of the engine mounts
Any engine mount that shows deterioration should be
replaced. Refer to the Specifications Manual,
SENR3130, “Torque Specifications”. Refer to your
Caterpillar dealer for more information.

i04285621
Illustration 40 g00908595

Engine Oil Level - Check

1. Loosen hose clamp (1) and remove hose (2) from
valve cover (3). SMCS Code: 1348-535-FLV

2. Remove the valve cover (3). Refer to the

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

Illustration 42 g01456636
(1) Oil level gauge
(2) Oil filler cap
Illustration 41 g00908611

3. Wash breather (4) in solvent that is clean and

nonflammable. Allow the breather to dry before
installation.
4. Install the valve cover (3). Refer to the
Disassembly and Assembly Manual.
SEBU7902-09 79
Maintenance Section
Engine Oil Sample - Obtain

i04237495

Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil
Illustration 43 g00110310 analysis provides infrared analysis, which is required
(Y) “ADD” mark for determining nitration and oxidation levels.
(X) “FULL” mark
Obtain the Sample and the
NOTICE Analysis
Perform this maintenance with the engine stopped.

1. Maintain the oil level between the “ADD” mark (Y)

and the “FULL” mark (X) on the oil level gauge . Hot oil and hot components can cause personal
Do not fill the crankcase above the “FULL” mark injury. Do not allow hot oil or hot components to
(X). contact the skin.

Before you take the oil sample, complete the Label,

NOTICE PEEP5031 for identification of the sample. In order to
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge help obtain the most accurate analysis, provide the
(dipstick). following information:

An overfull crankcase can cause the crankshaft to dip • Engine model

into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These • Service hours on the engine
bubbles (foam) can cause the following problems: re-
• The number of hours that have accumulated since
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the the last oil change
crankcase breathers and excessive oil consumption.
• The amount of oil that has been added since the
Excessive oil consumption will cause deposits to form last oil change
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the follow- To ensure that the sample is representative of the oil
ing problems: guttering of the valves, packing of in the crankcase, obtain a warm, mixed oil sample.
carbon under the piston rings and wear of the cylin- To avoid contamination of the oil samples, the tools
der liner. and the supplies that are used for obtaining oil
If the oil level is above the “FULL” mark on the oil lev- samples must be clean.
el gauge, drain some of the oil immediately.
Caterpillar recommends using the sampling valve in
order to obtain oil samples. The quality and the
2. Remove the oil filler cap and add oil, if necessary. consistency of the samples are better when the
For the correct oil to use, see this Operation and sampling valve is used. The location of the sampling
Maintenance Manual, “Fluid Recommendations” valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
topic. Do not fill the crankcase above the “FULL”
mark (X) on the oil level gauge. Clean the oil filler The 169-8373 Fluid Sampling Bottle is
cap. Install the oil filler cap. recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
3. Record the amount of oil that is added. For the needed for obtaining oil samples. Instructions are
next oil sample and analysis, include the total also provided.
amount of oil that has been added since the
previous sample. This will help to provide the most
accurate oil analysis.
80 SEBU7902-09
Maintenance Section
Engine Oil and Filter - Change

• The type of oil pan

NOTICE
Always use a designated pump for oil sampling, and
• The refill capacity for engine oil
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam- Table 18
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis Intervals for Changing the Engine Oil and Engine Oil Filter(1)
and an incorrect interpretation that could lead to con- Every 14200 L (3750 US gal) or
cerns by both dealers and customers. Shallow sump
250 service hours or 1 yr

Every 28400 L (7500 US gal) or

If the engine is not equipped with a sampling valve, Deep sump
500 service hours or 1 yr
use the 1U-5718 Vacuum Pump. The pump is
(1) Choose the interval that occurs first.
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion into
the sump. Drain the Engine Oil
For instructions, see Special Publication, PEGJ0047,
“How To Take A Good S·O·S Oil Sample”. Consult NOTICE
your Cat dealer for complete information and Care must be taken to ensure that fluids are con-
assistance in establishing an S·O·S program for your tained during performance of inspection, mainte-
engine. nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
i04268709 ers before opening any compartment or disassem-
bling any component containing fluids.
Engine Oil and Filter - Change Refer to Special Publication, NENG2500, “Cat Dealer
SMCS Code: 1318-510 Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Hot oil and hot components can cause personal Dispose of all fluids according to local regulations
injury. Do not allow hot oil or hot components to and mandates.
contact the skin.
After the engine has been run at the normal
Do not drain the oil when the engine is cold. As the oil operating temperature, stop the engine. Use one of
cools, suspended waste particles settle on the the following methods to drain the engine crankcase
bottom of the oil pan. The waste particles are not oil:
removed with the draining cold oil. Drain the
crankcase with the engine stopped. Drain the • If the engine is equipped with a drain valve, turn
crankcase with the oil warm. This draining method the drain valve knob counterclockwise in order to
allows the waste particles that are suspended in the drain the oil. After the oil has drained, turn the
oil to be drained properly. drain valve knob clockwise in order to close the
drain valve.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through • If the engine is not equipped with a drain valve,
the engine lubrication system with the new oil. remove the oil drain plug in order to allow the oil to
drain. If the engine is equipped with a shallow
Interval for Engine Oil and Engine sump, remove the bottom oil drain plugs from both
Oil Filter Change ends of the oil pan.

Note: The intervals stated in table 18 are only valid

when preferred lubricants are used. Using fluids
other than the preferred fluids causes the engine to
operate in a severe service application. Refer to this
Operation and Maintenance Manual, “Severe Service
Application” for information about the effect of using
fluids which are not preferred on the maintenance
intervals.
Refer to this Operation and Maintenance Manual,
“Refill Capacities” before this procedure is started in
order to determine the following:
SEBU7902-09 81
Maintenance Section
Engine Oil and Filter - Change

After the oil has drained, the oil drain plugs should be 3. Clean the sealing surface of the filter mounting
cleaned and installed. base. Ensure that all of the old oil filter gasket is
removed.
Replace the Oil Filter 4. Apply clean engine oil to the new oil filter gasket.

NOTICE NOTICE
Caterpillar oil filters are built to Caterpillar specifica- Do not fill the oil filters with oil before installing them.
tions. Use of an oil filter not recommended by Cater- This oil would not be filtered and could be contami-
pillar could result in severe engine damage to the nated. Contaminated oil can cause accelerated wear
engine bearings, crankshaft, etc., as a result of the to engine components.
larger waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recom-
mended by Caterpillar. 5. Install the oil filter. Tighten the oil filter until the oil
filter gasket contacts the base. Tighten the oil filter
by hand according to the instructions that are
1. Remove the oil filter with a 1U-8760 Chain shown on the oil filter. Do not overtighten the oil
Wrench. filter.
2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the Fill the Engine Crankcase
oil filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early wear 1. Remove the oil filler cap.
or a pending failure. 2. Refer to the Operation and Maintenance Manual,
Use a magnet to differentiate between the ferrous “Refill Capacities” for the amount of oil required to
metals and the nonferrous metals that are found in fill the crankcase. Fill the crankcase and replace
the oil filter element. Ferrous metals may indicate the oil filler cap.
wear on the steel and cast iron parts of the engine.
NOTICE
Nonferrous metals may indicate wear on the If equipped with an auxiliary oil filter system or a re-
aluminum parts, brass parts, or bronze parts of the mote oil filter system, follow the OEM or filter manu-
engine. Parts that may be affected include the facturer's recommendations. Under filling or
following items: main bearings, rod bearings, overfilling the crankcase with oil can cause engine
damage.
turbocharger bearings and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the NOTICE
To prevent crankshaft bearing damage, crank the en-
oil filter. Consult your Cat dealer in order to gine with the fuel OFF. This will fill the oil filters before
arrange for a further analysis if an excessive starting the engine. Do not crank the engine for more
amount of debris is found in the oil filter. than 30 seconds.

3. Start the engine and run the engine at “LOW IDLE”

for 2 minutes. Perform this procedure in order to
ensure that the lubrication system has oil and that
the oil filters are filled. Inspect the oil filter for oil
leaks.
4. Stop the engine and allow the oil to drain back to
the sump for a minimum of 10 minutes.

Illustration 44 g00103713
Typical filter mounting base and filter gasket
82 SEBU7902-09
Maintenance Section
Engine Protective Devices - Check

5. Remove the oil level gauge in order to check the oil Consult your Caterpillar dealer or refer to the Service
level. Maintain the oil level between the “ADD” and Manual for more information.
“FULL” marks on the oil level gauge.
i04230693

i02861779
Engine Speed/Timing Sensor -
Engine Protective Devices - Clean/Inspect
Check SMCS Code: 1905-070; 1905-040; 1907-070; 1907-
SMCS Code: 7400-535 040

Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that are
loose, broken, or damaged. Damaged wiring or
components should be repaired or replaced
immediately.

Calibration Check
NOTICE
During testing, abnormal operating conditions must
be simulated.
The tests must be performed correctly in order to pre- Illustration 45 g02407038
vent possible damage to the engine.
Left side view
Alarms and shutoffs must function properly. Alarms (1) Secondary speed/timing sensor
provide timely warning to the operator. Shutoffs help (2) Primary speed/timing sensor
to prevent damage to the engine. It is impossible to
determine if the engine protective devices are in 1. Remove the speed/timing sensors from the front
good working order during normal operation. housing. Check the condition of the plastic end of
Malfunctions must be simulated in order to test the the speed/timing sensors for wear and/or
engine protective devices. To prevent damage to the
engine, only authorized service personnel or your contaminants.
Caterpillar dealer should perform the tests. 2. Clean the metal shavings and other debris from
the face of the speed/timing sensors. Install the
sensors into the front housing.

i01458399

Engine Storage Procedure -

Check
SMCS Code: 1000-535
The oil change interval may be extended to 12
months for a vehicle that is operated seasonally and
placed in storage for the remainder of the year by
using the required storage procedures and the
required start-up procedures. This extension is
permitted if the following categories for oil change
intervals in the Operation and Maintenance Manual,
“Maintenance Interval Schedule” have not been
reached:

• Mileage
• Operating hours
SEBU7902-09 83
Maintenance Section
Engine Valve Lash - Check

• Fuel consumption
If an engine is out of operation and if use of the
engine is not planned, special precautions should be Ensure that the engine cannot be started while
made. If the engine will be stored for more than three this maintenance is being performed. To help pre-
months, a complete protection procedure is vent possible injury, do not use the starting motor
recommended. For more detailed information on to turn the flywheel.
engine storage, see Special Instruction, SEHS9031,
“Storage Procedure For Caterpillar Products”. Hot engine components can cause burns. Allow
additional time for the engine to cool before
If the engine will not be started for several weeks, the measuring/adjusting valve lash clearance.
lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface. Rust on the cylinder liner surface will i01597115
cause increased engine wear and a reduction in
engine service life. Caterpillar recommends the use
of volatile corrosion inhibitor (VCI) oil in order to
Engine Valve Rotators -
prevent internal engine damage due to moisture Inspect
during storage. These inhibitors in the VCI oil act by
evaporating inside the engine. The inhibitors then SMCS Code: 1109-040
condense over the inside surfaces of the engine. The
evaporation process and the condensing process
offers full protection to surfaces that cannot be
reached with preservatives. 0.9 L (1.0 qt) of When inspecting the valve rotators, protective
4C-6792 VCI oil will treat 28.4 L (30.0 qt) of engine glasses or face shield and protective clothing
oil. This will give a 3 percent concentration of VCI oil. must be worn, to help prevent being burned by
The engine must be completely sealed when the hot oil or spray.
engine is stored in order for the VCI oil to function
properly. The VCI oil is easily cleaned from the Engine valve rotators rotate the valves when the
engine when you remove the engine from storage. engine runs. This helps to prevent deposits from
The volatile vapors are removed by simply running building up on the valves and the valve seats.
the engine to operating temperature. A mineral oil
base is left behind after the volatile vapors are Perform the following steps after the engine valve
removed. lash is set, but before the valve covers are installed:
1. Start the engine according to Operation and
i07139300
Maintenance Manual, “Engine Starting” (Operation
Section) for the procedure.
Engine Valve Lash - Check
SMCS Code: 1105-535 2. Operate the engine at low idle.
3. Observe the top surface of each valve rotator. The
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is valve rotators should turn slightly when the valves
recommended at the first scheduled oil change. The close.
adjustment is necessary due to the initial wear of the
valve train components and to the seating of the NOTICE
valve train components. A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
The maintenance is recommended by Caterpillar as shorten valve life. If a damaged rotator is not re-
part of a lubrication and preventive maintenance placed, valve face guttering could result and cause
schedule to help provide maximum engine life. pieces of the valve to fall into the cylinder. This can
cause piston and cylinder head damage.
Note: Only qualified service personnel should
perform this maintenance. For procedures on
adjusting the valve lash and adjusting the valve If a valve fails to rotate, consult your Caterpillar
bridge, see Systems Operation/Testing and dealer.
Adjusting, “Engine Valve Lash - Inspect/Adjust”.
Consult your Cat dealer for assistance.
Note: For information on adjusting the unit injector
refer to Testing and Adjusting, RENR1232, Unit
Injector Adjustment.
84 SEBU7902-09
Maintenance Section
Fan Drive Bearing - Lubricate

i02784507 i02075183

Fan Drive Bearing - Lubricate Fuel System - Prime

SMCS Code: 1359-086-BD SMCS Code: 1250-548; 1258-548
Some of the fan drives have grease fittings and some
of the fan drives do not have grease fittings. If there is The Secondary Fuel Filter Has
no grease fitting, periodic lubrication is not required. Been Replaced
The fan drive requires grease only if the fan drive is
equipped with a zerk.

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
Illustration 46 g00746166
clean the area around a fuel system component that
Typical location of the grease fitting (if equipped) that will be disconnected. Fit a suitable cover over discon-
is for the fan drive bearing nected fuel system component.
The pulley is shown with the belt guards that have
been removed.
Note: Refer to Operation and Maintenance Manual,
Lubricate the grease fitting that is on the fan drive “Fuel System Secondary Filter - Replace” for
bearing with High Speed Ball Bearing Grease or the information on replacing the filter.
equivalent.
1. Turn the ignition switch to the “OFF” position.
Inspect the fan drive pulley assembly for wear or for
damage. If the shaft is loose, an inspection of the
internal components should be performed. Refer to
the Systems Operation Testing and Adjusting Manual
for additional information.

i02053753

Fan Drive Bearing - Replace

SMCS Code: 1359-510-BD

1. Remove Bearings. Refer to Disassembly and

Assembly, “Bearing Removal”.
2. Measure the bearing housings for roundness and
for proper size.
Illustration 47 g00975199
3. Replace the bearings. (1) Fuel priming pump
(2) Air purge screw
(3) Priming valve (If Equipped)

2. Turn the priming valve (3) (If Equipped) to the

“Closed (Prime)” position in order to prime the fuel
system.
SEBU7902-09 85
Maintenance Section
Fuel System - Prime

3. Open air purge screw (2) for the fuel filter by three
full turns. Do not remove the air purge screw.

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

4. Start the engine. The engine should start and the

engine should run smoothly.

Note: You may use the fuel priming pump for the fuel
filter (IF EQUIPPED) instead of starting the engine
and running the engine.

5. While the engine is running, observe air purge Illustration 48 g00975199

screw (2). When a small drop of fuel appears at (1) Fuel priming pump
(2) Air purge screw
the threads of the air purge screw, close and (3) Priming valve (If Equipped)
tighten air purge screw (2).

Note: There may be a noticeable change in the 3. Turn the priming valve (3) (If Equipped) to the
sound of the running engine when the air purge “Closed (Prime)” position in order to prime the fuel
screw is tightened. The change in the sound of the system.
engine is normal. 4. Open air purge screw (2) for the fuel filter by three
Note: Failure to tighten all fittings could result in full turns. Do not remove the air purge screw.
serious fuel leaks.
NOTICE
6. Clean any residual fuel from the engine Do not crank the engine continuously for more than
components. 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
7. After the engine has operated smoothly for 30
seconds, turn the priming valve (3) to the “Open 5. Crank the engine for 30 seconds. Use a suitable
(Run)” position. container to catch the fuel while you crank the
Note: Shortened injector life may occur if the priming engine. Allow the starter motor to cool for 2
valve (3) is left in the “Closed (Prime)” position. minutes.
Note: You may use the fuel priming pump (1) (IF
The Engine Has Been Run Out of EQUIPPED) for the fuel filter instead of cranking the
Fuel engine.

6. Crank the engine for 30 seconds. Allow the starter

NOTICE motor to cool for 2 minutes.
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately. 7. Repeat Step 6 until the engine starts and the
engine runs.
NOTICE Note: Failure to tighten all fittings could result in
Do not allow dirt to enter the fuel system. Thoroughly serious fuel leaks.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon- 8. After the engine has operated smoothly for 30
nected fuel system component.
seconds, turn the priming valve (3) to the “Open
(Run)” position.
1. Turn the ignition switch to the “OFF” position.
Note: Shortened injector life may occur if the priming
2. Fill the fuel tank(s) with clean diesel fuel. valve (3) is left in the “Closed (Prime)” position.
86 SEBU7902-09
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

9. Clean any residual fuel from the engine

NOTICE
components. Do not fill fuel filters with fuel before installing
them. The fuel will not be filtered and could be
i05354209 contaminated. Contaminated fuel will cause ac-
celerated wear to fuel system parts. The fuel sys-
tem should be primed prior to starting the engine.
Fuel System Primary Filter
(Water Separator) Element - 1. Close the main fuel supply valve.
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.
The primary filter/water separator also provides
filtration in order to help extend the life of the
secondary fuel filter. The element should be changed
regularly. If a vacuum gauge is installed, the primary
filter/water separator should be changed at
50 to 70 kPa (15 to 20 inches Hg).

Replace the Element Illustration 49 g01453091

(1) Element
(2) Bowl
(3) Drain
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent 2. Remove element (1) from the element mounting
possible injury, turn the start switch off when base while bowl (2) is attached.
changing fuel filters or water separator elements.
Clean up fuel spills immediately. 3. Dispose of the contents of the filter. Remove bowl
(2) from element (1). The bowl is reusable. Do not
discard the bowl. Dispose of the used element.
NOTICE 4. Remove the O-ring from the gland of the bowl.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Clean the following components:
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain- • Bowl
ers before opening any compartment or disassem-
bling any component containing fluids. • O-ring

Refer to Special Publication, NENG2500, “Dealer • Mounting base

Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. Inspect the O-ring for damage and for
deterioration. Replace the O-ring, if necessary.
Dispose of all fluids according to local regulations
and mandates. 5. Lubricate the O-ring with clean diesel fuel.
6. Install bowl (2) on a new element. Tighten the bowl
NOTICE by hand. Do not use tools in order to tighten the
Do not allow dirt to enter the fuel system. Thoroughly bowl.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon- 7. Lubricate the top seal of element (1) with clean
nected fuel system component. diesel fuel. Install the new element on the
mounting base. Tighten the element by hand.
SEBU7902-09 87
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the
fuel system.

8. Open the main fuel supply valve.

9. Start the engine and check for leaks. Run the
engine for 1 minute. Stop the engine and check for
leaks again.
Detecting leaks is difficult while the engine is
running. The primary filter/water separator is under
suction. A leak will allow air to enter the fuel. The Illustration 50 g01453091
air in the fuel can cause low power due to aeration
(1) Element
of the fuel. Ensure that the components are (2) Bowl
correctly installed to prevent air from entering the (3) Drain
fuel system.
Bowl (2) should be monitored daily for signs of water.
If water is present, drain the water from the bowl.
i02927285
1. Open drain (3). The drain is a self-ventilated drain.
Fuel System Primary Filter/ Catch the draining water in a suitable container.
Water Separator - Drain Dispose of the water properly.

SMCS Code: 1260-543; 1263-543 2. Close drain (3).

NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
Fuel leaked or spilled onto hot surfaces or electri- ened securely to help prevent air from entering the
cal components can cause a fire. To help prevent fuel system.
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately. i03478081

NOTICE
Fuel System Secondary Filter -
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
Replace
nance, testing, adjusting, and repair of the product. SMCS Code: 1261-510-SE
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer Fuel leaked or spilled onto hot surfaces or electri-
Service Tool Catalog” for tools and supplies suitable cal components can cause a fire. To help prevent
to collect and contain fluids on Cat products. possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Dispose of all fluids according to local regulations Clean up fuel spills immediately.
and mandates.

NOTICE
NOTICE Do not allow dirt to enter the fuel system. Thoroughly
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that
clean the area around a fuel system component that will be disconnected. Fit a suitable cover over any
will be disconnected. Fit a suitable cover over discon- disconnected fuel system components.
nected fuel system component.
88 SEBU7902-09
Maintenance Section
Fuel Tank Water and Sediment - Drain

6. Install the new fuel filter. Spin the fuel filter onto the
NOTICE
Care must be taken to ensure that fluids are con- fuel filter base until the gasket contacts the base.
tained during performance of inspection, mainte- Use the rotation index marks on the filters as a
nance, testing, adjusting, and repair of the product. guide for proper tightening. Tighten the filter
Be prepared to collect the fluid with suitable contain- according to the instructions that are on the fuel
ers before opening any compartment or disassem- filter. Do not overtighten the filter.
bling any component containing fluids.
7. Open the fuel supply valve. The engine will need to
Refer to Special Publication, NENG2500, “Cat Dealer
be purged of air. Refer to the Operation and
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” Maintenance Manual, “Fuel System - Prime” topic
for tools and supplies suitable to collect and contain (Maintenance Section) for more information.
fluids on Cat products.
i06104305
Dispose of all fluids according to local regulations
and mandates.
Fuel Tank Water and Sediment
1. Stop the engine. Turn the ignition switch to the
- Drain
OFF position or disconnect the battery. Refer to SMCS Code: 1273-543-M&S
the Operation and Maintenance Manual, “Battery
or Battery Cable - Disconnect” topic (Maintenance NOTICE
Section) for more information. Shut off the fuel Care must be taken to ensure that fluids are con-
supply valve (if equipped). tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
2. It may be necessary to relieve residual fuel Be prepared to collect the fluid with suitable contain-
pressure from the fuel system before the fuel filter ers before opening any compartment or disassem-
bling any component containing fluids.
is removed. Wait for one to five minutes until the
fuel pressure has lowered. Use a suitable Refer to Special Publication, NENG2500, “Cat Dealer
container in order to catch any fuel that may spill. Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
3. Remove the used fuel filter and discard the used for tools and supplies suitable to collect and contain
fuel filter. fluids on Cat products.
4. Clean the gasket sealing surface of the fuel filter Dispose of all fluids according to local regulations
base. Ensure that all of the old gasket is removed. and mandates.
5. Apply clean diesel fuel to the new fuel filter gasket.

NOTICE Fuel Tank

Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be Fuel quality is critical to the performance and to the
contaminated. Contaminated fuel will cause acceler- service life of the engine. Water in the fuel can cause
ated wear to fuel system parts. excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
NOTICE fuel system and the fuel returns to the fuel tank. This
In order to meet expected fuel system component life, causes water to accumulate in fuel tanks. Draining
4 micron (c) absolute or less secondary fuel filtration the fuel tank regularly and obtaining fuel from reliable
is required for all Cat Diesel Engines that are sources can help to eliminate water in the fuel. The
equipped with unit injected fuel systems. All current fuel tank utilizes a fuel tank vent to prevent an air lock
Cat Diesel Engines are factory equipped with Cat Ad- or vacuum. Ensure that the vent is free of debris and
vanced Efficiency 4 micron(c) absolute fuel filters. not damaged.

Caterpillar does not warrant the quality or perform- Drain the Water and the Sediment
ance of non-Cat fluids and filters.
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Prepare to catch water and sediment in an
appropriate container. Connect a hose (if necessary)
to the valve prior to opening the valve.
SEBU7902-09 89
Maintenance Section
Grounding Stud - Inspect/Clean/Tighten

Open the drain valve on the bottom of the fuel tank in If a bulk storage tank has been refilled or moved
order to drain the water and the sediment. Close the recently, allow adequate time for the sediment to
drain valve. settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
Note: Failure to close the drain properly could result sediment. Filtering fuel that is pumped from the
in fuel leakage, which could have detrimental results storage tank helps to ensure the quality of the fuel.
to performance. When possible, water separators should be used.
Check the fuel daily. Drain the water and sediment
i04176149
from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow 5 to 10 minutes before Grounding Stud - Inspect/
performing this procedure.
Clean/Tighten
Fill the fuel tank after operating the engine in order to SMCS Code: 7423-040; 7423-070; 7423-079
drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
overflow.
The connection of battery cables to a battery and
Some fuel tanks use stand pipes that allow water and the disconnection of battery cables from a battery
sediment to settle below the end of the fuel stand may cause an explosion which may result in in-
pipe. Some fuel tanks use supply lines that take fuel jury or death. The connection and the disconnec-
directly from the bottom of the tank. If the engine is tion of other electrical equipment may also cause
equipped with this system, regular maintenance of an explosion which may result in injury or death.
the fuel system filter is important. The procedures for the connection and the dis-
connection of battery cables and other electrical
Fuel Storage Tanks equipment should only be performed in a nonex-
plosive atmosphere.
Drain the water and the sediment from the fuel
storage tank during the following conditions:
• Weekly

• Refill of the tank

This procedure will help prevent water or sediment
from being pumped from the storage tank into the
engine fuel tank. A four micron(c) absolute filter for
the breather vent on the fuel tank is also
recommended.

Illustration 51 g00765094
Typical example
Electronics grounding stud (side view)

Inspect the OEM harness for good connections.

Inspect the condition of the OEM harness.
90 SEBU7902-09
Maintenance Section
Hoses and Clamps - Inspect/Replace

The electronics grounding stud must have a wire • Flexible part of the hose that is kinked or crushed
ground to the battery. Tighten the electronics
grounding stud at every oil change. Ground wires • Armoring that is embedded in the outer covering
and straps should be combined at engine grounds.
All grounds should be tight and free of corrosion. • Exhaust bellows for leaks or damage

• Clean the electronics grounding stud and the • Hoses which exhibit signs of leakage which are
terminals for the electronics ground strap with a not the result of loose couplings or clamps
clean cloth.
Inspect all clamps for the following conditions.
• If the connections are corroded, clean the Replace any clamp which exhibits signs of any of the
connections with a solution of baking soda and following conditions.
water.
• Cracking
• Keep the electronics grounding stud and the strap
• Looseness
clean and coated with MPGM grease or petroleum
jelly. • Damage

i06825542 Inspect all couplings for leaks. Replace any coupling

which exhibits signs of leaks.
Hoses and Clamps - Inspect/ Each installation application can be different. The
Replace differences depend on the following factors:
SMCS Code: 7554-510; 7554-040 • Type of hose
Hoses and clamps must be inspected periodically • Type of fitting material
and replaced at the recommended interval to ensure
safe and continuous operation of the engine. Failure • Anticipated expansion and contraction of the hose
to replace a fuel hose at the recommended change
interval may result in a hazardous situation. Take • Anticipated expansion and contraction of the
proper safety precautions before inspecting or fittings
replacing hoses and clamps.
Due to extreme temperature changes, the hose will
Note: Always use a board or cardboard when the heat set. Heat setting causes hose clamps to loosen
engine components are checked for leaks. Leaking which can result in leaks. A constant torque hose
fluid that is under pressure can cause serious injury clamp will help to prevent loose hose clamps.
or possible death. Leaks that are the size of a pin
hole are included. Refer to Operation and Replace hoses that are cracked or soft. Replace
Maintenance Manual, “General Hazard Information” hoses that show signs of leakage. Replace hoses
for more information. that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace
Note: Ensure that the hose is compatible with the hose clamps which are loose.
application.
Replace the Hoses and the Clamps
Inspect Tubes, Hoses, Bellows, and
Clamps NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
Inspect all tubes and hoses for leaks that are caused nance, testing, adjusting, and repair of the product.
by the following conditions. Replace any tube or hose Be prepared to collect the fluid with suitable contain-
which exhibits any of the following conditions. Failure ers before opening any compartment or disassem-
to replace a tube or hose which exhibits any of the bling any component containing fluids.
following conditions may result in a hazardous
situation. Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
• Hoses which are cracked PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
• Hoses which are soft fluids on Cat products.
• Outer covering that is chafed or cut Dispose of all fluids according to local regulations
and mandates.
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
SEBU7902-09 91
Maintenance Section
Hoses and Clamps - Inspect/Replace

Cooling System Fuel System

Pressurized System: Hot coolant can cause seri- Personal injury can result from removing hoses
ous burns. To open the cooling system filler cap, or fittings in a pressure system.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system Failure to relieve pressure can cause personal
pressure cap slowly in order to relieve the injury.
pressure.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.

Personal injury can result from removing hoses

or fittings in a pressure system.
Contact with high pressure fuel may cause fluid
Failure to relieve pressure can cause personal penetration and burn hazards. High pressure fuel
injury. spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
Do not disconnect or remove hoses or fittings un- structions may cause personal injury or death.
til all pressure in the system has been relieved.

1. Stop the engine. NOTICE

Do not bend or strike high pressure lines. Do not in-
2. Allow the engine to cool. stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
3. Before servicing a coolant hose, slowly loosen the hoses. Leaks can cause fires. Inspect all lines, tubes
filler cap for the cooling system to relieve any and hoses carefully. Tighten all connections to the
pressure. recommended torque.

4. Remove the filler cap for the cooling system.

NOTICE
5. Drain the coolant from the cooling system to a Do not allow dirt to enter the fuel system. Thoroughly
level that is below the hose that is being replaced. clean the area around a fuel system component that
Drain the coolant into a suitable clean container. will be disconnected. Fit a suitable cover over any
The coolant can be reused. disconnected fuel system components.
6. Remove the hose clamps.
Note: High-pressure fuel lines may be installed
7. Disconnect the old hose. between the high-pressure fuel pump and the fuel
8. Replace the old hose with a new hose. injectors. High-pressure fuel lines are constantly
charged with high pressure. Do not check the high-
9. Install hose clamps which have been inspected or pressure fuel lines with the engine or the starting
install new hose clamps. Refer to Specifications, motor in operation. Wait for 10 minutes after the
SENR3130, “Torque Specifications” “Hose engine stops before you perform any service or
Clamps” for information about selecting and repair on high-pressure fuel lines. Waiting for 10
installing the proper hose clamps. minutes will allow the pressure to be purged.

10. Refill the cooling system. 1. Drain the fuel from the fuel system to a level that is
below the hose that is being replaced.
11. Clean the coolant filler cap. Inspect the gaskets
on the filler cap. Inspect the gasket seat. Inspect 2. Remove the hose clamps.
the vacuum valve and seat for debris or damage.
3. Disconnect the old hose.
Replace the filler cap if the gaskets are damaged.
Install the filler cap. Note: When servicing fuel system, use cap/s or
12. Start the engine. Inspect the cooling system for cover/s as required to protect the system and
maintain fuel system cleanliness.
leaks.
4. Replace the old hose with a new hose.
92 SEBU7902-09
Maintenance Section
Overhaul Considerations

5. Install hose clamps which have been inspected or 4. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications, install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications” “Hose SENR3130, “Torque Specifications” “Hose
Clamps” for information about selecting and Clamps” for information about selecting and
installing the proper hose clamps. installing the proper hose clamps.
6. Carefully inspect the engine for any spilled fuel. Note: The bellows and the V-clamps that are used on
Make sure that no fuel remains on or close to the the exhaust bellows should never be reused.
engine.
5. Start the engine. Inspect the air lines for leaks.
Note: Fuel must be added to the fuel system ahead
of the fuel filter. i01848653

7. Refill the fuel system. Refer to this Operation and

Maintenance Manual, “Fuel System - Prime” for
Overhaul Considerations
information about priming the engine with fuel. SMCS Code: 7595-043
8. Start the engine. Inspect the fuel system for leaks. Reduced hours of operation at full load will result in a
lower average power demand. A decreased average
Lubrication System power demand should increase both the engine
service life and the overhaul interval.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
Hot oil and hot components can cause personal The following factors are important when a decision
injury. Do not allow hot oil or hot components to is being made on the proper time for an engine
contact the skin. overhaul:

1. Drain the oil from the lubrication system to a level • The need for preventive maintenance
that is below the hose that is being replaced. • The quality of the fuel that is being used
2. Remove the hose clamps.
• The operating conditions
3. Disconnect the old hose.
• The results of the S·O·S analysis
4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or Oil Consumption as an Overhaul
install new hose clamps. Refer to Specifications, Indicator
SENR3130, “Torque Specifications” “Hose
Clamps” for information about selecting and Oil consumption, fuel consumption, and maintenance
installing the proper hose clamps. information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
6. Refill the lubrication system. Refer to this consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
Operation and Maintenance Manual, “Engine Oil
for the maintenance intervals.
Level - Check” to ensure that the lubrication
system is filled with the proper amount of engine Oil consumption is in proportion to the percentage of
oil. the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
7. Start the engine. Inspect the lubrication system for consumed per hour also increases.
leaks.
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
Air System bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
1. Remove the hose clamps. dealer for assistance in determining the typical oil
2. Disconnect the old hose. consumption rate for your engine.

3. Replace the old hose with a new hose. When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
SEBU7902-09 93
Maintenance Section
Overhaul Considerations

Overhaul Options Unit Fuel Injector

Before Failure Overhaul Clean the fuel injector body and replace the O-rings.
Replace the O-rings and the gasket on the injector
A planned overhaul before failure may be the best sleeve. Clean the area around the injector seating in
value for the following reasons: the injector sleeve. Refer to the Service Manual for
the complete procedure, or consult with your
• Costly unplanned downtime can be avoided. Caterpillar dealer for assistance.
• Many original parts can be reused according to the Rebuild or Exchange
standards for reusable parts.
• The engine service life can be extended without Cylinder Head Assembly, Connecting Rods,
the risk of a major catastrophe due to engine Pistons, Cylinder Liners, Turbocharger, Cylinder
failure. Packs, Oil Pump, and Fuel Transfer Pump

• The best cost/value relationship per hour of These components should be inspected according to
extended life can be attained. the instructions that are found in various Caterpillar
reusability publications. The Special Publication,
After Failure Overhaul SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
If a major engine failure occurs and the engine must
be removed, many options are available. An overhaul If the parts comply with the established inspection
should be performed if the engine block or the specifications that are expressed in the reusable
crankshaft needs to be repaired. parts guideline, the parts should be reused.

If the engine block is repairable and/or the crankshaft Parts that are not within the established inspection
is repairable, the overhaul cost should be between 40 specifications should be dealt with in one of the
percent and 50 percent of the cost of a new engine following manners:
with a similar exchange core.
• Salvaging
This lower cost can be attributed to three aspects:
• Repairing
• Specially designed Caterpillar engine features
• Replacing
• Caterpillar dealer exchange components
Parts that do not comply with the established
• Caterpillar Inc. remanufactured exchange inspection specifications can result in the following
problems:
components
• Unscheduled downtime
Overhaul Recommendation
• Costly repairs
To minimize downtime, a scheduled engine overhaul
by your Caterpillar dealer is recommended. This will • Damage to other engine parts
provide you with the best cost/value relationship.
• Reduced engine efficiency
Note: Overhaul programs vary according to the
engine application and according to the dealer that • Increased fuel consumption
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available Reduced engine efficiency and increased fuel
consumption translates into higher operating costs.
overhaul programs and about overhaul services for
Therefore, Caterpillar Inc. recommends repairing out-
extending the engine life. of-spec parts or replacing out-of-spec parts.
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the following Inspection and/or Replacement
maintenance recommendations.
Piston Rings, Crankshaft Bearings, Valve
Rotators, and Crankshaft Seals
The following components may not last until the
second overhaul.
• Thrust bearings
• Main bearings
94 SEBU7902-09
Maintenance Section
Radiator - Clean

• Rod bearings Obtain Coolant Analysis

• Valve rotators The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits or
• Crankshaft seals with S·O·S Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine is
Caterpillar Inc. recommends the installation of new
overhauled.
parts at each overhaul period.
A coolant analysis can be conducted in order to verify
Inspect these parts while the engine is disassembled the condition of the water that is being used in the
for an overhaul. cooling system. A full water analysis can be obtained
Inspect the crankshaft for any of the following by consulting your local water utility company or an
conditions: agricultural agent. Private laboratories are also
available for water analysis.
• Deflection
Caterpillar Inc. recommends an S·O·S Coolant
• Damage to the journals Analysis (Level 2).

• Bearing material that has seized to the journals S·O·S Coolant Analysis (Level 2)

Check the journal taper and the profile of the An S·O·S Coolant Analysis (Level 2) is a
crankshaft journals. Check these components by comprehensive coolant analysis which completely
interpreting the wear patterns on the following analyzes the coolant and the effects on the cooling
components: system. An S·O·S Coolant Analysis (Level 2)
provides the following information:
• Rod bearing
• Complete S·O·S Coolant Analysis (Level 2)
• Main bearings
• Visual inspection of properties
Note: If the crankshaft is removed for any reason,
use the magnetic particle inspection process to check • Identification of metal corrosion
for cracks in the crankshaft.
• Identification of contaminants
Inspect the camshaft for damage to the journals and
to the lobes. • Identification of built up impurities (corrosion and
scale)
Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check for S·O·S Coolant Analysis (Level 2) provides a report of
cracks in the camshaft. the results of both the analysis and the maintenance
recommendations.
Inspect the following components for signs of wear or
for signs of scuffing: For more information about coolant analysis, consult
your Caterpillar dealer.
• Camshaft bearings
i04020194
• Camshaft followers
Caterpillar Inc. recommends replacing the crankshaft Radiator - Clean
vibration damper. SMCS Code: 1353-070
Oil Cooler Core and Aftercooler Core Note: Adjust the frequency of cleaning according to
During an overhaul, the removal of the oil cooler core the effects of the operating environment.
and the aftercooler core is recommended. The oil Inspect the radiator for these items: damaged fins,
cooler core and the aftercooler core should be
cleaned and pressure tested. corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary.
NOTICE
Do not use caustic cleaners to clean the core.
Caustic cleaners can attack the internal metals of the
core and cause leakage.
SEBU7902-09 95
Maintenance Section
Starting Motor - Inspect

i05965726

Personal injury can result from air pressure. Turbocharger - Inspect

Personal injury can result without following prop- SMCS Code: 1052-040
er procedure. When using pressure air, wear a Periodic inspection and cleaning are recommended
protective face shield and protective clothing. for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through
The maximum air pressure for cleaning purposes
the air inlet system. Therefore, by-products from oil
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded. and from combustion can collect in the turbocharger
compressor housing. Over time, this buildup can
contribute to loss of engine power, increased black
Pressurized air is the preferred method for removing smoke and overall loss of engine efficiency.
loose debris. Direct the air in the opposite direction of
the air flow. Hold the nozzle approximately 6 mm If the turbocharger fails during engine operation,
(0.25 inch) away from the fins. Slowly move the air damage to the turbocharger compressor wheel and/
nozzle in a direction that is parallel with the tubes. or to the engine may occur. Damage to the
This movement will remove debris that is between turbocharger compressor wheel can cause additional
the tubes. damage to the pistons, the valves, and the cylinder
head.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes NOTICE
must be less than 275 kPa (40 psi). Use pressurized Turbocharger bearing failures can cause large quan-
water in order to soften mud. Clean the core from tities of oil to enter the air inlet and exhaust systems.
both sides. Loss of engine lubricant can result in serious engine
damage.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core Minor leakage of a turbocharger housing under ex-
with detergent and hot water. Thoroughly rinse the tended low idle operation should not cause problems
core with clean water. as long as a turbocharger bearing failure has not
After cleaning, start the engine and accelerate the occurred.
engine to high idle rpm. This procedure will help in When a turbocharger bearing failure is accompanied
the removal of debris and drying of the core. Stop the by a significant engine performance loss (exhaust
engine. Use a light bulb behind the core in order to smoke or engine rpm up at no load), do not continue
inspect the core for cleanliness. Repeat the cleaning, engine operation until the turbocharger is repaired or
if necessary. replaced.
Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition: An inspection of the turbocharger can minimize
welds, mounting brackets, air lines, connections, unscheduled downtime. An inspection of the
clamps and seals. Make repairs, if necessary. turbocharger can also reduce the chance for potential
damage to other engine parts.
i00651416
Note: Turbocharger components require precision
Starting Motor - Inspect clearances. The turbocharger cartridge must be
balanced due to high rpm. Severe Service
SMCS Code: 1451-040; 1453-040 Applications can accelerate component wear. Severe
Service Applications require more frequent
Caterpillar Inc. recommends a scheduled inspection inspections of the cartridge.
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
Check the starting motor for proper operation. Check
the electrical connections and clean the electrical
connections. Refer to the Service Manual for more
information on the checking procedure and for
specifications or consult your Caterpillar dealer for
assistance.
96 SEBU7902-09
Maintenance Section
Walk-Around Inspection

Removal and Installation For maximum engine service life, make a thorough
inspection of the engine compartment before starting
For options regarding the removal, installation, repair, the engine. Look for items such as oil leaks or
and replacement, consult your Cat dealer. Refer to coolant leaks, loose bolts, worn belts, loose
the Service Manual for this engine for the procedure connections and trash buildup. Make repairs, as
and specifications. needed:
• The guards must be in the proper place. Repair
Cleaning and Inspecting damaged guards or replace missing guards.
1. Remove the exhaust outlet piping and remove the • Wipe all caps and plugs before the engine is
air inlet piping from the turbocharger. Visually serviced in order to reduce the chance of system
inspect the piping for the presence of oil. Clean the contamination.
interior of the pipes in order to prevent dirt from
entering during reassembly. NOTICE
For any type of leak (coolant, lube, or fuel) clean up
2. Turn the compressor wheel and the turbine wheel the fluid. If leaking is observed, find the source and
by hand. The assembly should turn freely. Inspect correct the leak. If leaking is suspected, check the flu-
the compressor wheel and the turbine wheel for id levels more often than recommended until the leak
contact with the turbocharger housing. There is found or fixed, or until the suspicion of a leak is
should not be any visible signs of contact between proved to be unwarranted.
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
NOTICE
contact between the rotating turbine wheel or the Accumulated grease and/or oil on an engine or deck
compressor wheel and the turbocharger housing, is a fire hazard. Remove this debris with steam clean-
the turbocharger must be reconditioned. ing or high pressure water.

3. Check the compressor wheel for cleanliness. If

only the blade side of the wheel is dirty, dirt and/or • Ensure that the cooling lines are properly clamped
moisture is passing through the air filtering and that the cooling lines are tight. Check for
system. If oil is found only on the back side of the leaks. Check the condition of all pipes.
wheel, there is a possibility of a failed turbocharger • Inspect the water pumps for coolant leaks.
oil seal.
Note: The water pump seal is lubricated by coolant in
The presence of oil may be the result of extended
the cooling system. It is normal for a small amount of
engine operation at low idle. The presence of oil leakage to occur as the engine cools down and the
may also be the result of a restriction of the line for parts contract.
the inlet air (plugged air filters), which causes the
turbocharger to slobber. Excessive coolant leakage may indicate the need to
replace the water pump seal. For the removal of
4. Inspect the bore of the turbine housing for water pumps and the installation of water pumps and/
corrosion. or seals, refer to the Service Manual for the engine or
consult your Caterpillar dealer.
5. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush. • Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
6. Fasten the air inlet piping and the exhaust outlet pan, the oil filters and the valve cover.
piping to the turbocharger housing.
• Inspect the fuel system for leaks. Look for loose
i01185304 fuel line clamps or for loose fuel line tie-wraps.

Walk-Around Inspection • Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure
SMCS Code: 1000-040 that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
Inspect the Engine for Leaks and • Inspect the alternator belt and the accessory drive
for Loose Connections belts for cracks, breaks or other damage.
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
SEBU7902-09 97
Maintenance Section
Water Pump - Inspect

Belts for multiple groove pulleys must be replaced as Inspect the water pump for wear, cracks, pin holes,
matched sets. If only one belt is replaced, the belt will and proper operation. Refer to the Parts Manual for
carry more load than the belts that are not replaced. the correct part numbers for your engine or consult
The older belts are stretched. The additional load on your Cat dealer if repair is needed or replacement is
the new belt could cause the belt to break. needed.
• Drain the water and the sediment from fuel tanks
on a daily basis in order to ensure that only clean
fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.

• Inspect the ground strap for a good connection

and for good condition.
• Inspect the ECM to the cylinder head ground strap
for a good connection and for good condition.
• Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.

• Check the condition of the gauges. Replace any

gauges that are cracked. Replace any gauge that
can not be calibrated.

i05264233

Water Pump - Inspect

SMCS Code: 1361-040
A failed water pump might cause severe engine
overheating problems that could result in the
following conditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

A failed water pump might cause severe engine
overheating problems. Overheating could result in
cracks in the cylinder head, a piston seizure, or other
potential damage to the engine.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of
the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
Disassemble and Water Pump - Assemble” for the
disassembly and assembly procedure. If necessary
to remove the water pump, refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
Remove and Water Pump - Install”.
98 SEBU7902-09
Warranty Section
Warranty Information

Warranty Section 3. New non-road diesel engines installed in

construction machines conforming to the South
Korean regulations for construction machines
Warranty Information manufactured after January 1, 2015, and operated
and serviced in South Korea, including all parts of
their emission control systems (“emission related
i06112217 components”), are:
Emissions Warranty a. Designed, built, and equipped so as to conform,
at the time of sale, with applicable emission
Information standards prescribed in the Enforcement Rule
SMCS Code: 1000 of the Clean Air Conservation Act promulgated
by South Korea MOE.
The certifying engine manufacturer warrants to the
ultimate purchaser and each subsequent purchaser b. Free from defects in materials and
that: workmanship in emission-related components
1. New non-road diesel engines and stationary diesel that can cause the engine to fail to conform to
engines less than 10 liters per cylinder (including applicable emission standards for the warranty
Tier 1 and Tier 2 marine engines < 37 kW, but period.
excluding locomotive and other marine engines) A detailed explanation of the Emission Control
operated and serviced in the United States and Warranty that is applicable to new non-road and
Canada, including all parts of their emission stationary diesel engines, including the components
control systems (“emission related components”), covered and the warranty period, is found in a
are: supplemental Special Publication. Consult your
authorized Cat dealer to determine if your engine is
a. Designed, built, and equipped so as to conform, subject to an Emission Control Warranty and to
at the time of sale, with applicable emission obtain a copy of the applicable Special Publication.
standards prescribed by the United States
Environmental Protection Agency (EPA) by way
of regulation.
b. Free from defects in materials and
workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.
2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to conform,
at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
(ARB).
b. Free from defects in materials and
workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the engine manufacturer's
application for certification for the warranty
period.
SEBU7902-09 99
Reference Information Section
Engine Ratings

Reference Information Table 19

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

Engine Rating Conditions Irrigation pumps

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

• Water pumps NOTICE

Operating engines above the rating definitions can
Subtract the power that is required to drive auxiliary result in shorter service life before overhaul.
components from the gross output. This will produce
the net power that is available for the external load
(flywheel).

i03880100

Engine Rating Definitions

SMCS Code: 1000
In selecting a rating for a specific application, the
most important consideration is the time that is spent
at full throttle. These rating definitions identify the
percent of time at full throttle. The definitions also
identify the corresponding times below rated rpm.
Refer to this Operation and Maintenance Manual,
“Configuration Parameters” for information about the
rating for this engine.
Note: The examples of the applications are only for
reference. For an exact determination of the
appropriate rating, follow the OEM specifications or
consult your Caterpillar dealer.
100 SEBU7902-09
Reference Information Section
Customer Service

Customer Service Europe, Africa, and Middle East

Caterpillar Overseas S.A.
76 Route de Frontenex
i07240427
P.O. Box 6000
CH-1211 Geneva 6
Customer Assistance Switzerland
SMCS Code: 1000; 4450 Phone: 22-849-4444
Fax: 22-849-4544
USA and Canada Far East
Caterpillar Asia Pte. Ltd.
When a problem arises concerning the operation or 7 Tractor Road
the service of an engine, the problem will normally be
managed by the dealer in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level, use the phone number that is listed below to Hong Kong
talk with a Field Service Coordinator: Phone: 852-2848-0333
Fax: 852-2848-0440
1-800-447-4986
The normal hours are from 8:00 to 4:30 Monday Japan
Shin Caterpillar Mitsubishi Ltd.
through Friday Central Standard Time.
SBS Tower
3. If your needs have not been met still, submit the 10-1, Yoga 4-Chome
matter in writing to the following address: Setagaya-Ku, Tokyo 158-8530
Japan
Designated Compliance Officer Heavy-Duty and Phone: 81-3-5717-1150
Nonroad Engine Group 6403-J, Fax: 81-3-5717-1177
US Ave, NW, Washington,
DC 20460 Japan
Email address: complianceinfo@epa.gov. Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
Please keep in mind: probably, your problem will 4-10-1, Yoga
ultimately be solved at the dealership, using the Setagaya-Ku, Tokyo 158-0097
dealership facilities, equipment, and personnel. Phone: 81-3-5797-4300
Therefore, follow the steps in sequence when a Fax: 81-3-5797-4359
problem is experienced.

Outside of the USA and of Canada

If a problem arises outside the USA and outside
Canada, and if the problem cannot be resolved at the
dealer level, consult the appropriate Caterpillar office.

Latin America, Mexico, Carribean

Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801
SEBU7902-09 101
Reference Information Section
Ordering Replacement Parts

Australia and New Zealand

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

i07500661

Ordering Replacement Parts

SMCS Code: 4450; 7567

When replacement parts are required for this

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

Quality Cat replacement parts are available from Cat

dealers throughout the world. Cat dealer parts
inventories are up-to-date. The parts stocks include
all the parts that are normally needed to protect your
Cat engine investment.
When you order parts, specify the following
information:
• Part number

• Part name
• Quantity
If there is a question concerning the part number,
provide your dealer with a complete description of the
needed item.
When a Cat engine requires maintenance and/or
repair, provide the dealer with all the information that
is stamped on the Information Plate. This information
is described in this Operation and Maintenance
Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This information will help the
dealer in troubleshooting the problem and solving the
problem faster.
102 SEBU7902-09
Reference Information Section
Reference Materials

Reference Materials
i05264255

Maintenance Records
SMCS Code: 1000; 4450
Caterpillar Inc. recommends the retention of accurate
maintenance records. Accurate maintenance records
can be used for the following purposes:
• Determine operating costs.

• Establish maintenance schedules for other

engines that are operated in the same
environment.

• Show compliance with the required maintenance

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

Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
• Dealer work orders and itemized bills
• Owner repair costs

• Owner receipts
• Maintenance log
SEBU7902-09 103
Reference Information Section
Maintenance Log

i01176304

Maintenance Log
SMCS Code: 1000; 4450

Table 20
Engine Model Customer Identifier

Serial Number Arrangement Number

Service Quantity Of
Service Item Date Authorization
Hours Fuel
104 SEBU7902-09
Reference Information Section
Reference Material

i04365942 • Special Publications, PEDP7036, “S·O·S Fluids

Analysis Cornerstone”
Reference Material
• Special Publications, PEHP7076, “Understanding
SMCS Code: 1000; 4450 S·O·S Services Tests”
The following literature can be obtained through any • Special Publication, PEHP7052, “Making the Most
Cat dealer. of S·O·S Services”

Coolants • Special Publication, PEGJ0045, “Reporting

Particle Count by ISO Code”
• Special Publication, PMEP5027, “Label - Cat ELC
Radiator Label” • Special Publication, PEGJ0046, “Understanding
Your S·O·S Services Results”
• Datasheet, PEHJ0067, “Cat ELC (Extended Life
Coolant)” (Worldwide) Miscellaneous
• Datasheet, PEHP9554, “Cat DEAC (Diesel • Special Publication, SEBU6251, “Cat Commercial
Engine Antifreeze/Coolant) (Concentrate)” Diesel Engine Fluids Recommendations”

Fuels • Service Manual, SENR9840, “C15 and C18

Industrial Engine Service Manual”
• Special Publication, SEBD0717, “Diesel Fuels and
Your Engine” • Special Publication, PECP9067, “One Safe
Source”
• Special Publication, SENR9620, “Improving Fuel
System Durability” • Special Instruction, REHS0354, “Charging System
Troubleshooting”
Lubricants • Special Publication, SEBF8029, “Index to
Guidelines for Reusable Parts and Salvage
• Datasheet, PEHJ0159, “Cat DEO-ULS (SAE Operations”
15W-40)” (North America - Canada, Mexico, and
United States) • Special Publication, SEBF8062, “Guideline for
Reusable Parts - Cleaning and Inspection of Air
• Datasheet, PEHJ0059, “Cat DEO (SAE 10W-30 Filters”
and SAE 15W-40)” (North America - Canada,
Mexico, and United States) • Special Publication, SEBU5898, “Cold Weather
Recommendations for all Cat Machines”
• Datasheet, PEHJ0021, “Cat DEO (SAE 10W-30
and SAE 15W-40)” (Worldwide - except North • Special Instruction, SEHS9031, “Storage
America, Egypt, Saudi Arabia, and Brazil) Procedure for Cat Products”
• Datasheet, PEHJ0072, “Cat DEO (SAE 10W-30 • Special Instruction, SEHS8622, “Using the FT-
and SAE 15W-40)” (Brazil) 1984 Air-To-Air Aftercooler Leak Test Group”
• Datasheet, PEHJ0091, “Cat DEO (SAE 10W-30 • Special Instruction, SEHS7633, “Battery Test
and SAE 15W-40)” (Egypt and Saudi Arabia) Procedure”
• Datasheet, PEHP7062, “Cat DEO SYN (SAE 5W- • Special Instruction, SEHS7332, “Do Not Operate
40)” Tag”
• Datasheet, PEHJ0008, “Cat Arctic DEO (SAE 0W-
30)” (Canada and United States)

S·O·S Services
• Special Publication, PEHJ0191, “S·O·S Coolant
Analysis”
• Special Publication, PEGJ0047, “How To Take A
Good Oil Sample”
SEBU7902-09 105
Index Section

Index
A Crushing Prevention and Cutting Prevention.. 13
Customer Assistance .................................... 100
After Starting Engine ....................................... 41
Outside of the USA and of Canada ........... 100
After Stopping Engine ..................................... 46
USA and Canada....................................... 100
Aftercooler Core - Clean/Test (Air-To-Air
Customer Service.......................................... 100
Aftercooler (If Equipped)) .............................. 63

D
B
Diagnostic Flash Code Retrieval..................... 29
Battery - Replace............................................. 63
Diagnostic Lamp.............................................. 29
Battery Electrolyte Level - Check .................... 64
Driven Equipment - Check .............................. 72
Battery or Battery Cable - Disconnect............. 64
Check the Alignment ................................... 72
Before Starting Engine .............................. 13, 39
Inspect the Drive Coupling .......................... 72
Belts - Inspect/Adjust/Replace ........................ 65
Inspect the Rear Gear Train ........................ 72
Adjustment of the Fan Drive Belt................. 65
Alternator Belt Adjustment........................... 65
Inspection .................................................... 65 E
Replacement................................................ 65 Electrical System............................................. 15
Burn Prevention............................................... 10 Grounding Practices .................................... 15
Batteries........................................................11 Electronic Unit Injector - Check/Replace ........ 73
Coolant ........................................................ 10 Emissions Certification Film ............................ 20
Oils................................................................11 Emissions Warranty Information ..................... 98
Engaging the Driven Equipment ..................... 42
C Industrial Engines ........................................ 42
Engine - Clean................................................. 73
Cold Weather Operation ................................. 44
Engine Air Cleaner Element (Dual Element)
Cold Weather Starting ..................................... 39
- Inspect/Clean/Replace ................................ 73
Configuration Parameters ............................... 33
Cleaning the Primary Air Cleaner
Parameter Descriptions ............................... 33
Elements .................................................... 75
System Configuration Parameters .............. 36
Servicing the Air Cleaner Elements............. 74
Coolant - Change ............................................ 65
Engine Air Cleaner Service Indicator -
Drain the Cooling System............................ 66
Inspect (If Equipped) ..................................... 76
Fill the Cooling System ................................ 67
Test the Service Indicator ............................ 77
Flush ............................................................ 66
Engine Air Precleaner - Check/Clean ............. 77
Coolant Extender (ELC) - Add ........................ 67
Engine Crankcase Breather - Clean ............... 77
Coolant Level - Check ..................................... 68
Engine Diagnostics ......................................... 29
Coolant Sample (Level 1) - Obtain.................. 69
Engine Electronics........................................... 16
Sampling Conditions.................................... 69
Engine Mounts - Inspect.................................. 78
Timing of the Sampling ................................ 69
Engine Oil and Filter - Change ........................ 80
Coolant Sample (Level 2) - Obtain.................. 70
Drain the Engine Oil..................................... 80
Obtaining the Sample .................................. 70
Fill the Engine Crankcase............................ 81
Coolant Temperature Regulator - Replace ..... 70
Interval for Engine Oil and Engine Oil Filter
Cooling System Supplemental Coolant
Change ...................................................... 80
Additive (SCA) - Test/Add (Systems
Replace the Oil Filter ................................... 81
Which are Filled with Conventional
Engine Oil Level - Check................................. 78
Coolant) ......................................................... 71
Engine Oil Sample - Obtain............................. 79
Maintain the Proper Concentration of SCA in
Obtain the Sample and the Analysis ........... 79
the Coolant................................................. 71
Engine Operation ............................................ 42
Crankshaft Vibration Damper - Inspect........... 72
Minimum Engine Run Time ......................... 42
Visconic Damper.......................................... 72
106 SEBU7902-09
Index Section

Engine Operation with Active Diagnostic Fuel System Primary Filter (Water Separator)
Codes ............................................................ 32 Element - Replace ......................................... 86
Engine Operation with Intermittent Replace the Element ................................... 86
Diagnostic Codes .......................................... 33 Fuel System Primary Filter/Water
Engine Protective Devices - Check................. 82 Separator - Drain ........................................... 87
Calibration Check ........................................ 82 Fuel System Secondary Filter - Replace ........ 87
Visual Inspection.......................................... 82 Fuel Tank Water and Sediment - Drain ........... 88
Engine Rating Conditions................................ 99 Drain the Water and the Sediment .............. 88
Engine Rating Definitions................................ 99 Fuel Storage Tanks...................................... 89
Engine Ratings ................................................ 99 Fuel Tank ..................................................... 88
Engine Speed/Timing Sensor - Clean/
Inspect ........................................................... 82 G
Engine Starting.......................................... 14, 39
Ether ............................................................ 14 General Hazard Information.............................. 7
Engine Stopping ........................................ 14, 46 Containing Fluid Spillage............................... 8
Engine Storage Procedure - Check ................ 82 Dispose of Waste Properly .......................... 10
Engine Valve Lash - Check ............................. 83 Fluid Penetration ........................................... 8
Engine Valve Rotators - Inspect ...................... 83 Inhalation ....................................................... 9
Lines, Tubes, and Hoses ............................... 9
Pressurized Air and Water............................. 8
F
Softwrap....................................................... 10
Fan Drive Bearing - Lubricate ......................... 84 Static Electricity Hazard when Fueling with
Fan Drive Bearing - Replace ........................... 84 Ultra-low Sulfur Diesel Fuel ......................... 9
Fault Logging................................................... 32 General Information ........................................ 17
Features and Controls..................................... 25 Grounding Stud - Inspect/Clean/Tighten......... 89
Fire Prevention and Explosion Prevention.......11
Ether ............................................................ 12 H
Fire Extinguisher.......................................... 12
Lines, Tubes, and Hoses ............................. 13 Hoses and Clamps - Inspect/Replace............. 90
Fluid Recommendations ................................. 47 Inspect Tubes, Hoses, Bellows, and
Cooling System............................................ 52 Clamps....................................................... 90
Diesel Engine Oil ......................................... 47 Replace the Hoses and the Clamps ............ 90
Fuel .............................................................. 50
Greases ....................................................... 54 I
Foreword ........................................................... 4
Important Safety Information............................. 2
California Proposition 65 Warning ................. 4
Literature Information .................................... 4
Maintenance .................................................. 4 L
Maintenance Intervals ................................... 5 Lifting and Storage .......................................... 22
Operation ....................................................... 4
Overhaul ........................................................ 5
M
Safety............................................................. 4
Fuel and the Effect from Cold Weather ........... 44 Maintenance Interval Schedule................. 59, 61
Fuel Conservation Practices ........................... 42 Maintenance Interval Schedule (Engines Which
Fuel Related Components in Cold Weather ... 44 Have Deep Sumps)
Fuel Filters ................................................... 45 Daily ............................................................. 61
Fuel Heaters ................................................ 45 Every 1000 Service Hours........................... 62
Fuel Tanks ................................................... 44 Every 250 Service Hours ............................. 61
Fuel System - Prime ........................................ 84 Every 3000 Service Hours or 3 Years ......... 62
The Engine Has Been Run Out of Fuel ....... 85 Every 500 Service Hours ............................. 61
The Secondary Fuel Filter Has Been Every 585,000 L (154,540 US gal) of Fuel .. 62
Replaced.................................................... 84 Every Year ................................................... 62
SEBU7902-09 107
Index Section

Initial 500 Hours (for New Systems, Refilled Removal from Storage................................. 23
Systems, and Converted Systems) ........... 61 Storage (Less Than One Year).................... 22
Initial 500 Service Hours (or at first oil
change) ...................................................... 61 R
Overhaul ...................................................... 62
When Required............................................ 61 Radiator - Clean .............................................. 94
Maintenance Interval Schedule (Engines Which Radiator Restrictions....................................... 44
Have Shallow Sumps) Reference Information..................................... 21
Daily ............................................................. 59 Record for Reference .................................. 21
Every 1000 Service Hours........................... 60 Reference Information Section ....................... 99
Every 250 Service Hours ............................. 59 Reference Material ........................................ 104
Every 3000 Service Hours or 3 Years ......... 60 Coolants..................................................... 104
Every 500 Service Hours ............................. 59 Fuels .......................................................... 104
Every 585,000 L (154,540 US gal) of Fuel .. 60 Lubricants .................................................. 104
Every Year ................................................... 60 Miscellaneous ............................................ 104
Initial 250 Service Hours (or at first oil S·O·S Services .......................................... 104
change) ...................................................... 59 Reference Materials ...................................... 102
Initial 500 Hours (for New Systems, Refilled Refill Capacities............................................... 47
Systems, and Converted Systems) ........... 59 Coolant ........................................................ 47
Overhaul ...................................................... 60 Engine Oil .................................................... 47
When Required............................................ 59
Maintenance Log........................................... 103 S
Maintenance Recommendations .................... 56
Safety Messages............................................... 6
Maintenance Records ................................... 102
Universal Warning (1) .................................... 6
Maintenance Section....................................... 47
Safety Section ................................................... 6
Manual Stop Procedure .................................. 46
Self-Diagnostics .............................................. 29
Model View Illustrations .................................. 17
Severe Service Application ............................. 57
Monitoring System (If Equipped)..................... 25
Improper Maintenance Procedures
Caterpillar Messenger Display ................... 26
(Maintenance Procedures Which May
Indicators and Gauges ................................ 25
Contribute to a Severe Service
Mounting and Dismounting ............................. 13
Application) ................................................ 58
Severe Environmental Factors .................... 57
O Severe Operating Conditions ...................... 58
Operation Section............................................ 22 Starting Motor - Inspect ................................... 95
Ordering Replacement Parts......................... 101 Starting the Engine.......................................... 40
Overhaul Considerations................................. 92 Starting a Cold Engine................................. 40
Oil Consumption as an Overhaul Indicator.. 92 Starting a Warm Engine............................... 40
Overhaul Recommendation......................... 93 Starting with Jump Start Cables...................... 40
System Pressure Release............................... 56
Coolant System ........................................... 56
P
Engine Oil .................................................... 56
Plate Locations and Film Locations ................ 20 Fuel System................................................. 56
Information Plate (2) .................................... 20
Serial Number Plate (1) ............................... 20 T
Product Description ......................................... 18
Aftermarket Products and Cat Engines ...... 19 Table of Contents .............................................. 3
Welding and Cat Electronic Engines .......... 19 Turbocharger - Inspect .................................... 95
Product Identification Information ................... 20 Cleaning and Inspecting .............................. 96
Product Information Section............................ 17 Removal and Installation ............................. 96
Product Lifting ................................................. 22
Product Storage .............................................. 22
108 SEBU7902-09
Index Section

W
Walk-Around Inspection .................................. 96
Inspect the Engine for Leaks and for Loose
Connections ............................................... 96
Warranty Information....................................... 98
Warranty Section............................................. 98
Water Pump - Inspect...................................... 97
Welding on Engines with Electronic
Controls ......................................................... 56
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
SEBU7902 CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Yellow”, the
©2019 Caterpillar “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used
All Rights Reserved herein, are trademarks of Caterpillar and may not be used without permission.

110 November 2019