SEBU7385-04

December 2001

Operation and
Maintenance
Manual
C-10 and C-12 Engines
BCX1-Up (Engine)
BDL1-Up (Engine)
 i01658146

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents Fuel Specifications ................................................ 63

Cooling System Specifications ............................. 65

Foreword ................................................................. 4
Refill Capacities .................................................... 77
Safety Section Maintenance Interval Schedule (C-10 Industrial
Engines) .............................................................. 78
Safety Signs and Labels ......................................... 6
Maintenance Interval Schedule (C-12 Industrial
General Hazard Information ................................... 7
Engines) .............................................................. 80
Burn Prevention .................................................... 10
Warranty Section
Fire Prevention and Explosion Prevention ............ 10
Warranty Information .......................................... 119
Crushing Prevention and Cutting Prevention ........ 12
Reference Information Section
Mounting and Dismounting ................................... 13
Engine Ratings ................................................... 120
Before Starting Engine .......................................... 13
Customer Service ............................................... 122
Engine Starting ..................................................... 13
Reference Materials ............................................ 124
Engine Stopping ................................................... 14
Index Section
Electrical System .................................................. 14
Index ................................................................... 128
Engine Electronics ................................................ 15

Product Information Section

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

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

Product Identification Information ........................ 22

Operation Section
Lifting and Storage ................................................ 27

Gauges and Indicators .......................................... 28

Features and Controls .......................................... 32

Engine Diagnostics ............................................... 37

Engine Starting ..................................................... 42

Engine Operation .................................................. 47

Engine Stopping ................................................... 49

Cold Weather Operation ....................................... 51

Maintenance Section
Torque Specifications ............................................ 53

Lubricant Specifications ........................................ 56

4
Foreword

Foreword Use fuel consumption or service hours to determine

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

Operating techniques outlined in this manual are See the section in the Operation and Maintenance
basic. They assist with developing the skills and Manual, “Maintenance Records” for information
techniques required to operate the engine more regarding documents that are generally accepted
efficiently and economically. Skill and techniques as proof of maintenance or repair. Your authorized
develop as the operator gains knowledge of the Caterpillar dealer can assist you in adjusting your
engine and its capabilities. maintenance schedule to meet the needs of your
operating environment.
The operation section is a reference for operators.
Photographs and illustrations guide the operator Overhaul
through procedures of inspecting, starting,
operating and stopping the engine. This section Major engine overhaul details are not covered in the
also includes a discussion of electronic diagnostic Operation and Maintenance Manual except for the
information. interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
Maintenance an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
The maintenance section is a guide to engine programs. If you experience a major engine failure,
care. The illustrated, step-by-step instructions are there are also numerous after failure overhaul
grouped by fuel consumption, service hours and/or options available from your Caterpillar dealer.
calendar time maintenance intervals. Items in the Consult with your dealer for information regarding
maintenance schedule are referenced to detailed these options.
instructions that follow.
 5
Foreword

California Proposition 65 Warning

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

Battery posts, terminals and related accessories

contain lead and lead compounds. Wash hands
after handling.
6
Safety Section
Safety Signs and Labels

Safety Section Electronic Unit Injectors

i01480345

Safety Signs and Labels

SMCS Code: 1000; 7405

There may be several specific safety signs on an

engine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Please become familiar with all safety signs.

Ensure that all of the safety signs are legible. Clean

the safety signs or replace the safety signs if the
words cannot be read or if the pictures are not Illustration 1 g00547460
visible. When the safety signs are cleaned, use a
cloth, water, and soap. Do not use solvent, gasoline, The warning label for the electronic unit injector is
or other harsh chemicals to clean the safety signs. located on the valve cover base.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety signs. The
safety signs that are loosened could drop off of
the engine.

Replace any damaged safety signs or missing

safety signs. If a safety sign is attached to a part of
the engine that is replaced, install a new safety sign
on the replacement part. Any Caterpillar dealer can
provide new safety signs. Safety signs can also be
ordered from the Parts Manual for this engine.

Do not work on the engine and do not operate the

engine unless the instructions and warnings in the
Operation and Maintenance Manual are understood.
g00103125
Proper care is your responsibility. Failure to follow
the instructions or failure to heed the warnings
could result in injury or in death.

Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.
Do not operate or work on this engine unless you
have read and understand the instructions and The Electronic Control Module (ECM) sends a high
warnings in the Operation and Maintenance Man- voltage signal to the injector solenoid. To help
ual. Failure to follow the instructions or heed the prevent personal injury, disconnect the electronic
warnings could result in injury or death. Contact unit injector enable circuit connector. Do not come
any Caterpillar dealer for replacement manuals. in contact with the electronic unit injector terminals
Proper care is your responsibility. while the engine is running.

The warning labels that may be found on the engine

are illustrated and described.
 7
Safety Section
General Hazard Information

Clutch Engine Lifting

g00367054
Illustration 3

The warning label for lifting the engine with a fuel

tank is located on the fuel tank (if equipped).

g00107406
Illustration 2

The warning label for the clutch is located on the

clutch housing (if equipped).

g00100728

Lift eyes or tank can fail when lifting tank con-

taining fluids resulting in possible personal injury.
g00107407 Drain tank of all fluids before lifting.
Rotating gears can cause entanglement of the
fingers. Rotating gears can cause entanglement of i01377208
the hands. Do not service this component without
first reading the operator manual. General Hazard Information
SMCS Code: 1000; 7405

g00104545
Illustration 4
8
Safety Section
General Hazard Information

Attach a “Do Not Operate” warning tag or a similar • Do not wear loose clothing or jewelry that can
warning tag to the start switch or to the controls snag on controls or on other parts of the engine.
before the engine is serviced or before the engine
is repaired. These warning tags (Special Instruction, • Ensure that all protective guards and all covers
SEHS7332) are available from your Caterpillar are secured in place on the engine.
dealer. Attach the warning tags to the engine
and to each operator control station. When it is • Never put maintenance fluids into glass
appropriate, disconnect the starting controls. containers. Glass containers can break.

Do not allow unauthorized personnel on the engine, • Use all cleaning solutions with care.
or around the engine when the engine is being
serviced. • Report all necessary repairs.
Engine exhaust contains products of combustion Unless other instructions are provided, perform
which may be harmful to your health. Always the maintenance under the following conditions:
start the engine and operate the engine in a well
ventilated area. If the engine is in an enclosed area, • The engine is stopped. Ensure that the engine
vent the engine exhaust to the outside. cannot be started.

Cautiously remove the following parts. To help • Disconnect the batteries when maintenance
prevent spraying or splashing of pressurized fluids, is performed or when the electrical system is
hold a rag over the part that is being removed. serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• Filler caps
• Do not attempt any repairs that are not
• Grease fittings understood. Use the proper tools. Replace
any equipment that is damaged or repair the
• Pressure taps equipment.

• Breathers Pressure Air and Water

• Drain plugs Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result
Use caution when cover plates are removed.
in personal injury.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of When pressure air and/or pressure water is used
the cover plate or the device. Before removing the
for cleaning, wear protective clothing, protective
last two bolts or nuts, pry the cover loose in order
shoes, and eye protection. Eye protection includes
to relieve any spring pressure or other pressure. goggles or a protective face shield.

The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be
below 275 kPa (40 psi).

g00702020
Illustration 5

• 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.
 9
Safety Section
General Hazard Information

Fluid Penetration Asbestos Information

g00687600 g00702022
Illustration 6 Illustration 7

Always use a board or cardboard when you check Caterpillar equipment and replacement parts that
for a leak. Leaking fluid that is under pressure can are shipped from Caterpillar are asbestos free.
penetrate body tissue. Fluid penetration can cause Caterpillar recommends the use of only genuine
serious injury and possible death. A pin hole leak Caterpillar replacement parts. Use the following
can cause severe injury. If fluid is injected into your guidelines when you handle any replacement parts
skin, you must get treatment immediately. Seek that contain asbestos or when you handle asbestos
treatment from a doctor that is familiar with this type debris.
of injury.
Use caution. Avoid inhaling dust that might be
generated when you handle components that
Containing Fluid Spillage contain asbestos fibers. Inhaling this dust can
be hazardous to your health. The components
Care must be taken in order to ensure that fluids
that may contain asbestos fibers are brake pads,
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the brake bands, lining material, clutch plates, and
some gaskets. The asbestos that is used in these
engine. Prepare to collect the fluid with suitable
components is usually bound in a resin or sealed in
containers before opening any compartment or
disassembling any component containing fluids. some way. Normal handling is not hazardous unless
airborne dust that contains asbestos is generated.
Refer to Special Publication, NENG2500, “Tools and
Shop Products Guide” for the following items: If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids • Never use compressed air for cleaning.

• Tools that are suitable for containing fluids and • Avoid brushing materials that contain asbestos.
equipment that is suitable for containing fluids
• Avoid grinding materials that contain asbestos.
Obey all local regulations for the disposal of liquids.
• Use a wet method in order to clean up asbestos
materials.

• A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be
used.

• Use exhaust ventilation on permanent machining

jobs.

• Wear an approved respirator if there is no other

way to control the dust.
10
Safety Section
Burn Prevention

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

Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.

Batteries
Electrolyte is an acid. Electrolyte can cause
g00706404 personal injury. Do not allow electrolyte to contact
Illustration 8
the skin or the eyes. Always wear protective glasses
for servicing batteries. Wash hands after touching
Improperly disposing of waste can threaten the
the batteries and connectors. Use of gloves is
environment. Potentially harmful fluids should be recommended.
disposed of according to local regulations.

Always use leakproof containers when you drain i01372254

fluids. Do not pour waste onto the ground, down a
drain, or into any source of water. Fire Prevention and Explosion
Prevention
i01480768
SMCS Code: 1000; 7405
Burn Prevention
SMCS Code: 1000; 7405

Do not touch any part of an operating engine.

Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.

Coolant
When the engine is at operating temperature, the Illustration 9
g00704000
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or All fuels, most lubricants, and some coolant mixtures
to the engine contain hot coolant. are flammable.
 11
Safety Section
Fire Prevention and Explosion Prevention

Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause deterioration. The hoses must be properly routed.
a fire. Fire may cause personal injury and property The lines and hoses must have adequate support
damage. and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after Oil filters and fuel filters must be properly installed.
an emergency shutdown. The filter housings must be tightened to the proper
torque.
Determine whether the engine will be operated in
an environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.

If the application involves the presence of

combustible gases, consult your Caterpillar dealer
for additional information about suitable protection
devices.

Remove all flammable materials such as fuel, oil,

and debris from the engine. Do not allow any
flammable materials to accumulate on the engine.

Store fuels and lubricants in properly marked

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

Do not expose the engine to any flame. g00704059

Illustration 10

Exhaust shields (if equipped) protect hot exhaust

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

Wiring must be kept in good condition. All electrical

wires must be properly routed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate
the engine. Clean all electrical connections and
tighten all electrical connections.

Eliminate all wiring that is unattached or

unnecessary. Do not use any wires or cables that
are smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
g00704135
or sparking. Illustration 11
12
Safety Section
Crushing Prevention and Cutting Prevention

Gases from a battery can explode. Keep any open Check lines, tubes and hoses carefully. Do not
flames or sparks away from the top of a battery. Do use your bare hand to check for leaks. Use a
not smoke in battery charging areas. board or cardboard to check for leaks. Tighten all
connections to the recommended torque.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or Replace the parts if any of the following conditions
a hydrometer. are present:

Improper jumper cable connections can cause • End fittings are damaged or leaking.
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific • Outer coverings are chafed or cut.
instructions.
• Wires are exposed.
Do not charge a frozen battery. This may cause
an explosion. • Outer coverings are ballooning.
The batteries must be kept clean. The covers (if • Flexible part of the hoses are kinked.
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery • Outer covers have embedded armoring.
box covers when the engine is operated.
• End fittings are displaced.
Fire Extinguisher Make sure that all clamps, guards, and heat shields
Make sure that a fire extinguisher is available. Be are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
familiar with the operation of the fire extinguisher.
parts, and excessive heat.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate. i01359666

Ether Crushing Prevention and

Cutting Prevention
Ether is flammable and poisonous.
SMCS Code: 1000; 7405
Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while Support the component properly when work
you are using an ether spray. beneath the component is performed.

Do not store ether cylinders in living areas or in the Unless other maintenance instructions are provided,
engine compartment. Do not store ether cylinders never attempt adjustments while the engine is
in direct sunlight or in temperatures above 49 C running.
(120 F). Keep ether cylinders away from open
flames or sparks. Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
Dispose of used ether cylinders properly. Do not is performed. After the maintenance is performed,
puncture an ether cylinder. Keep ether cylinders reinstall the guards.
away from unauthorized personnel.
Keep objects away from moving fan blades. The
Do not spray ether into an engine if the engine fan blades will throw objects or cut objects.
is equipped with a thermal starting aid for cold
weather starting. When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Lines, Tubes and Hoses Chips or other debris may fly off objects when
objects are struck. Before objects are struck, ensure
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent that no one will be injured by flying debris.
or damaged.

Repair any lines that are loose or damaged. Leaks

can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
 13
Safety Section
Mounting and Dismounting

i01372247 i00910470

Mounting and Dismounting Engine Starting

SMCS Code: 1000; 7405 SMCS Code: 1000

Inspect the steps, the handholds, and the work If a warning tag is attached to the engine start
area before mounting the engine. Keep these items switch or to the controls, do not start the engine
clean and keep these items in good repair. or move the controls. Also, do not disengage
the parking brakes. Consult with the person that
Mount the engine and dismount the engine only at attached the warning tag before the engine is
locations that have steps and/or handholds. Do not started.
climb on the engine, and do not jump off the engine.
All protective guards and all protective covers must
Face the engine in order to mount the engine or be installed if the engine must be started in order
dismount the engine. Maintain a three-point contact to perform service procedures. To help prevent an
with the steps and handholds. Use two feet and one accident that is caused by parts in rotation, work
hand or use one foot and two hands. Do not use around the parts carefully.
any controls as handholds.
Start the engine from the operator’s station (cab).
Do not stand on components which cannot support Never short across the starting motor terminals or
your weight. Use an adequate ladder or use a work the batteries. This could bypass the engine neutral
platform. Secure the climbing equipment so that the start system and/or the electrical system could be
equipment will not move. damaged.

Do not carry tools or supplies when you mount the Always start the engine according to the procedure
engine or when you dismount the engine. Use a that is described in the Operation and Maintenance
hand line to raise and lower tools or supplies. Manual, “Engine Starting” topic (Operation Section).
Knowing the correct procedure will help to prevent
major damage to the engine components. Knowing
i00911989
the procedure will also help to prevent personal
Before Starting Engine injury.

SMCS Code: 1000 To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Inspect the engine for potential hazards. properly, check the water temperature gauge
and the oil temperature gauge during the heater
Before starting the engine, ensure that no one is on, operation.
underneath, or close to the engine. All protective
guards and all protective covers must be installed Engine exhaust contains products of combustion
if the engine must be started in order to perform that can be harmful to your health. Always start the
service procedures. To help prevent an accident engine and operate the engine in a well ventilated
that is caused by parts in rotation, work around the area. If the engine is started in an enclosed area,
parts carefully. vent the engine exhaust to the outside.

Do not bypass the automatic shutoff circuits. Do not Ether

disable the automatic shutoff circuits. The circuits
are provided in order to help prevent personal Ether is poisonous and flammable. Do not inhale
injury. The circuits are also provided in order to help ether, and do not allow ether to contact the skin.
prevent engine damage. Personal injury could result. Do not smoke while
ether cylinders are changed. Use ether in well
On the initial start-up of a new engine or an engine ventilated areas.
that has been serviced, prepare to stop the engine
if an overspeed condition occurs. This may be Keep ether cylinders out of the reach of
accomplished by shutting off the fuel supply to unauthorized persons. Store ether cylinders in
the engine and/or shutting off the air supply to the authorized storage areas only. Do not store ether
engine. cylinders in direct sunlight or at temperatures above
39 C (102 F). Discard the ether cylinders in a safe
See the Service Manual for repairs and for place. Do not puncture the ether cylinders. Do not
adjustments. burn the ether cylinders.
14
Safety Section
Engine Stopping

i01462046 Grounding Practices

Engine Stopping
SMCS Code: 1000

Stop the engine according to the procedure in

the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
the engine components.

Use the Emergency Stop Button (if equipped)

ONLY in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.

Stop the engine if an overspeed condition occurs

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

To stop an electronically controlled engine, cut the

power to the engine.

g00771448
i01481981 Illustration 12
Typical example
Electrical System Grounding Stud To Battery Ground

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. See
the Operation and Maintenance Manual for specific
starting instructions.
 15
Safety Section
Engine Electronics

i01563743

Engine Electronics
SMCS Code: 1000; 1400; 1900

Tampering with the electronic system installation

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

This engine has a comprehensive, programmable

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

The following actions are available for engine

monitoring control: WARNING, DERATE, and
SHUTDOWN. These engine monitoring modes have
the ability to limit engine speed and/or the engine
power.

Many of the parameters that are monitored by

g00771487
Illustration 13 the ECM can be programmed for the engine
Typical example monitoring functions. The following parameters can
Alternate Grounding Stud To Battery Ground
be monitored as a part of the Engine Monitoring
System:
Proper grounding for the engine electrical system
is necessary for optimum engine performance • Operating Altitude
and reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable • Engine Coolant Level
electrical circuit paths.
• Engine Coolant Temperature
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing • Engine Oil Pressure
journal surfaces, and to aluminum components.
• Engine Speed
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical • Fuel Temperature
discharge.
• Intake Manifold Air Temperature
To ensure that the engine and the engine electrical
systems function properly, an engine-to-frame • System Voltage
ground strap with a direct path to the battery must
be used. This path may be provided by way of a The Engine Monitoring package can vary for
starting motor ground, a starting motor ground to different engine models and different engine
the frame, or a direct engine ground to the frame. applications. However, the monitoring system and
the engine monitoring control will be similar for all
All grounds should be tight and free of corrosion. engines.
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.
16
Safety Section
Engine Electronics

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 Electronic
Troubleshooting Manual for more information on the
Engine Monitoring System.
 17
Product Information Section
General Information

Product Information
Section

General Information
i01456258

Welding on Engines with

Electronic Controls
SMCS Code: 1000

NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding
onto a chassis frame or rail. Consult the OEM of
the equipment or your Caterpillar dealer regarding
welding on a chassis frame or rail. Illustration 14
g00765012

Use the example above. The current flow from the welder to
the ground clamp of the welder will not cause damage to any
Proper welding procedures are necessary in order associated components.
to avoid damage to the engine’s ECM, sensors,
(1) Engine
and associated components. When possible, (2) Welding rod
remove the component from the unit and then (3) Keyswitch in the OFF position
weld the component. If removal of the component (4) Battery disconnect switch in the open position
is not possible, the following procedure must be (5) Disconnected battery cables
followed when you weld on a unit that is equipped (6) Battery
(7) Electrical/Electronic component
with a Caterpillar Electronic Engine. The following (8) Maximum distance between the component that is being
procedure is considered to be the safest procedure welded and any electrical/electronic component
to weld on a component. This procedure should (9) The component that is being welded
provide a minimum risk of damage to electronic (10) Current path of the welder
(11) Ground clamp for the welder
components.
4. Connect the welding ground cable directly to
NOTICE the part that will be welded. Place the ground
Do not ground the welder to electrical components cable as close as possible to the weld in order to
such as the ECM or sensors. Improper grounding can reduce the possibility of welding current damage
cause damage to the drive train bearings, hydraulic to bearings, hydraulic components, electrical
components, electrical components, and other com- components, and ground straps.
ponents.
Note: If electrical/electronic components are used
Clamp the ground cable from the welder to the com- as a ground for the welder, or electrical/electronic
ponent that will be welded. Place the clamp as close components are located between the welder ground
as possible to the weld. This will help reduce the pos- and the weld, current flow from the welder could
sibility of damage. severely damage the component.

1. Stop the engine. Turn the switched power to the 5. Protect the wiring harness from welding debris
OFF position. and spatter.

2. Disconnect the negative battery cable from 6. Use standard welding practices to weld the
the battery. If a battery disconnect switch is materials.
provided, open the switch.

3. Disconnect the J1/P1 and J2/P2 connectors from

the ECM. Move the harness to a position that will
not allow the harness to accidentally move back
and make contact with any of the ECM pins.
18
Product Information Section
Model Views

Model Views
i01483096

Model View Illustrations

SMCS Code: 1000

The following model views show typical C-10 and

C-12 Industrial Engine features. Due to individual
applications, your engine may appear different from
the illustrations.

g00466918
Illustration 15
Right side view
(1) Lifting eye (7) Oil level gauge (13) Mounting for bypass oil filter
(2) Inlet manifold (8) Exhaust manifold (14) Oil drain plug
(3) Connection for ether starting aid (9) Belt tightener (15) Connection for oil pressure and location
(4) Boost connection (10) Flywheel housing for live oil sample
(5) Turbocharger (11) Coolant conditioner (if equipped) (16) Inlet for oil heater
(6) Oil filler tube (12) Oil filter (17) Crankshaft pulley and vibration damper
 19
Product Information Section
Model Views

g00771731
Illustration 16
Left side view
(18) Air compressor (21) Fuel priming pump and fuel filter (24) Oil drain plug
(19) Fumes disposal tube (22) Fuel inlet (25) Oil pan
(20) Bleeder valve (23) Bypass for oil return (26) Electronic Control Module (ECM)

i01517111

Engine Description
SMCS Code: 1000

The Caterpillar C-10 and C-12 Industrial Engines

provide the following features:

• Four cycle
• Direct fuel injection
• Electronic unit injection
• Turbocharged
• Air-to-air aftercooled
The electronic engine control system provides the
following features:
g00771722
Illustration 17
• Engine and auxiliary monitoring
Left side view
(27) Customer Connector • Electronic governing
(28) Electronics Ground Stud
• Cold start conditions
20
Product Information Section
Model Views

• Automatic air/fuel ratio control Engine Service Life

• Integrated ether start Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
• Torque rise shaping operation and maintenance recommendations. Use
the Operation and Maintenance Manual as a guide
• Automatic altitude compensation for required engine maintenance.

• Injection timing control Expected engine life is generally predicted

by the average power that is demanded. The
• Fuel temperature compensation average power that is demanded is based on fuel
consumption of the engine over a period of time.
• System diagnostics Reduced hours of operation at full throttle and/or
operating at reduced throttle settings result in a
Electronic unit injectors combine the metering of lower average power demand. Operating at lower
fuel (duration and timing) and the injection of fuel. average power demand will increase the length
Electronic unit injectors produce very high injection of operating time before an engine overhaul is
pressures. required. Refer to the Operation and Maintenance
Manual for more information.
The Electronic Control Module (ECM) controls
the amount of fuel that is injected by varying the
signals to the electronic unit injectors. High injection
Engine Specifications
pressures help to reduce fuel consumption and
emissions. The use of this type of electronic unit
injector helps to provide precise control of injection
timing. The injection timing varies with engine
operating conditions. This optimizes the engine’s
performance for starting, emissions, noise, and fuel
consumption.

The timing advance is achieved through the

precise control of injector firing. Engine speed
is controlled by adjusting the firing duration. An
engine speed/timing sensor provides information
to the ECM for detection of cylinder position and
engine speed.
g00386924
Illustration 18
The engine has built-in diagnostics that are used in
order to ensure that all of the components function (A) Exhaust valves. (B) Inlet valves.
properly.

The cooling system consists of the following

components:

• Centrifugal pump that is driven by gears

• One water temperature regulator which regulates
the engine coolant temperature

• Oil cooler
The engine lubricating oil, that is supplied by a gear
type pump, is cooled. The engine lubricating oil is
also filtered. Bypass valves provide unrestricted
flow of lubrication oil to the engine components
during the following conditions:

• High oil viscosity

• Plugged oil cooler or plugged oil filter elements
(paper cartridge)
 21
Product Information Section
Model Views

Table 1
C-10 Industrial Engine Specifications
Cylinders and Arrangement 6 In-Line
Bore 125 mm (4.9 inch)
Stroke 140 mm (5.5 inch)
Compression Ratio 16:1
Aspiration TA(1)
Displacement 10.3 L (629 in3)
Firing Order 1-5-3-6-2-4
Rotation that is viewed from the
Counterclockwise
flywheel
Valve Lash Setting (Inlet) 0.38 mm (0.015 inch)
Valve Lash Setting (Exhaust) 0.64 mm (0.025 inch)
(1) Turbocharged aftercooled

Table 2
C-12 Industrial Engine Specifications
Cylinders and Arrangement 6 In-Line
Bore 130 mm (5.1 inch)
Stroke 150 mm (5.9 inch)
Compression Ratio 16:1
Aspiration TA(1)
Displacement 12 L (728 in3)
Firing Order 1-5-3-6-2-4
Rotation that is viewed from the
Counterclockwise
flywheel
Valve Lash Setting (Inlet) 0.38 mm (0.015 inch)
Valve Lash Setting (Exhaust) 0.64 mm (0.025 inch)
(1) Turbocharged aftercooled
22
Product Information Section
Product Identification Information

Product Identification i01484593

Information Information Plate

SMCS Code: 1000
i01517622

Engine Identification
SMCS Code: 1000

Caterpillar engines are identified with serial

numbers, with performance specification numbers,
and with arrangement numbers. These numbers
are shown on the Serial Number Plate and the
Information Plate that are mounted on the engine.

Caterpillar dealers need these numbers in order to

determine the components that were included with
the engine. This permits accurate identification of
g00764335
replacement part numbers. Illustration 20

The Information Plate is on the valve cover. The

i01461841
following information is on the Information Plate:
Serial Number Plate engine serial number, engine model, engine
arrangement number, maximum altitude of the
SMCS Code: 1000 engine that is necessary to achieve the rated power,
horsepower, high idle, full load rpm, fuel settings,
and other information.

i00610276

Reference Numbers
SMCS Code: 1000
g00764267
Illustration 19
Information for the following items may be needed
The Serial Number Plate is located on the right side to order parts. Locate the information for your
of the cylinder block near the rear of the engine. engine. Record the information on the appropriate
space. Make a copy of this list for a record. Retain
The following information is stamped on the Serial the information for future reference.
Number Plate: engine serial number, engine model,
and arrangement number. Record for Reference
Engine Model ______________________________________________

Engine Serial No. __________________________________________

Engine Arrangement No. ________________________________

Modification No. ___________________________________________

Engine Low Idle rpm _____________________________________

Engine Full Load rpm ____________________________________

Performance Specification No. _________________________

Primary Fuel Filter No. ___________________________________

Water Separator Element No. __________________________

 23
Product Information Section
Product Identification Information

Secondary Fuel Filter Element No. ____________________

Lubrication Oil Filter Element No. _____________________

Auxiliary Oil Filter Element No. _________________________

Supplemental Coolant Additive Maintenance

Element No. (Optional) ___________________________________

Total Lubrication System Capacity ____________________

Total Cooling System Capacity ________________________

Air Cleaner Element No. _________________________________

Fan Drive Belt No. ________________________________________

Alternator Belt No. ________________________________________

i01542360

Emissions Certification Film

SMCS Code: 1000; 7405

Note: This information is pertinent in the United

States and in Canada.

A typical example is shown.

24
Product Information Section
Product Identification Information

g00776690
Illustration 21

i01517706 Rating Selection (L-N) __________________________________

Customer Specified Air/Fuel Ratio
Parameters
• Level 1: Minimal Smoke ______________________________
SMCS Code: 1000
• Level 2: Optimum Performance _____________________
To record programmed specifications, use the
following blanks. • Level 3: Maximum Acceleration ____________________
Customer Passwords (Optional) PTO Engine Governor

• First Password __________________________________________ • PTO Engine Speed Ramp Rate __________ rpm/sec

• Second Password ______________________________________ Engine Parameters( If applicable)

Programmable Power Rating (hp at rpm) __________ • Top Engine Limit (TEL) at 100 percent
load_________________________________________________________
 25
Product Information Section
Product Identification Information

• Torque Limit ______________________________________________

• High Idle___________________________________________________
• Low Idle __________________________________________________
• Intermediate Speed ____________________________________
Engine Monitoring Mode

Equipment ID

Maintenance Indicator

• Manual Hours
• Auto Hours
• Manual Fuel
• Auto Fuel
Auxiliary Pressure

• High Warning Set Point _______________________________

Auxiliary Temperature

• High Warning Set Point _______________________________

Programmable Monitoring System

(PMS)
The Programmable Monitoring System determines
the level of action that is taken by the ECM in
response to a condition that can damage the
engine. These conditions are identified by the
ECM from the signals that are produced from the
following sensors

• Inlet Air Temperature Sensor

• Engine Coolant Temperature Sensor
• Engine Oil Pressure Sensor
• Engine Speed/Timing Sensors
• Fuel Pressure Sensor
• Coolant Level Sensor
26
Product Information Section
Product Identification Information

Table 3
Programmable Monitoring System Parameters

Default Time Delay in Seconds Set Points

Parameter Action “Disable”
Value Min Max Default Min Max Default
“High Engine ON Warning YES
Air Inlet
Temperature” ON Derate YES

ON Warning YES
“High Engine
Coolant ON Derate YES
Temperature”
OFF Shutdown YES
ON Warning (1) (1) (1) YES
“Low Engine Oil (1) (1) (1)
ON Derate YES
Pressure”
OFF Shutdown (1) (1) (1) YES

“Engine ON Warning YES

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

ON Warning (3) (3) (3) YES

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

For additional information on Programmable

Monitoring System refer to Troubleshooting Manual ,
“System Configuration Parameters”.
 27
Operation Section
Lifting and Storage

Operation Section i00777190

Engine Storage
Lifting and Storage SMCS Code: 1000

If the engine will not be started for several weeks,

i01028344 the lubricating oil will drain from the cylinder walls
and from the piston rings. Rust can form on the
Engine Lifting cylinder liner surface. Rust on the cylinder liner
surface will cause increased engine wear and a
SMCS Code: 1000; 1122 reduction in engine service life.

To help prevent excessive engine wear, use the

following guidelines:

• Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).

• If freezing temperatures are expected, check the

cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, “General Coolant Information”
(Maintenance Section).
g00103219
Illustration 22 If an engine is out of operation and if use of the
engine is not planned, special precautions should
NOTICE be made. If the engine will be stored for more than
Never bend the eyebolts and the brackets. Only load one month, a complete protection procedure is
the eyebolts and the brackets under tension. Remem- recommended.
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be- For more detailed information on engine storage,
comes less than 90 degrees. see Special Instruction, SEHS9031, “Storage
Procedure For Caterpillar Products”.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for Your Caterpillar dealer can assist in preparing the
the weight. engine for extended storage periods.

Use a hoist to remove heavy components. Use

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

Some removals require lifting the fixtures in order to

obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that

are on the engine.

Lifting eyes are designed and installed for the

specific engine arrangement. Alterations to the lifting
eyes and/or the engine make the lifting eyes and
the lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Caterpillar dealer for information
regarding fixtures for proper engine lifting.
28
Operation Section
Gauges and Indicators

Gauges and Indicators 3. Check the oil level. Maintain the oil level at the
proper amount.

i01465281 If the gauge continues to fluctuate, consult your

Caterpillar dealer.
Gauges and Indicators
The diagnostic lamp will turn on if the oil pressure
SMCS Code: 1900; 7450 drops below 35 kPa (5 psi) at low idle rpm. The
diagnostic code will be logged in the Engine Control
Your engine may not have the same gauges or all of Module (ECM).
the gauges that are described. For more information
about the gauge package, see the literature that Engine Oil Temperature – This gauge
is provided by the OEM. indicates the engine oil temperature. An
oil temperature that is higher than normal
Gauges provide indications of engine performance. indicates a heat problem in the lubrication system
Ensure that the gauges are in good working order. and/or the cooling system. This problem can
Determine the normal operating range by observing damage the cylinder heads, the cylinder liners, the
the gauges over a period of time. pistons, and the crankshaft bearings.

Noticeable changes in gauge readings indicate

Jacket Water Coolant Temperature –
potential gauge or engine problems. Problems may
Typical temperature range is 88 to 102 C
also be indicated by gauge readings that change
(190 to 215 F). The maximum allowable
even if the readings are within specifications.
temperature with the pressurized cooling system is
Determine the cause of any significant change
105 C (220 F). Higher temperatures may occur
in the readings. Then, correct any cause of any
under certain conditions. The water temperature
significant change in the readings. Consult your
reading may vary according to load. The reading
Caterpillar dealer for assistance.
should never exceed the boiling point for the
pressurized system that is being used.
Caterpillar requires one lamp in addition to
the gauge package that is normally provided.
The “Diagnostic” lamp is yellow or amber. The If the engine is operating above the normal range
“Diagnostic” lamp will communicate the status of or steam becomes apparent, perform the following
the engine’s electronic system. The optional red procedure:
“Warning” lamp is also available. This red “Warning”
lamp warns the operator of engine problems. 1. Reduce the load and the engine rpm.

The following conditions are some examples of the 2. Inspect the cooling system for leaks.
engine problems:
3. Determine if the engine must be shut down
• Low oil pressure immediately or if the engine can be cooled by
reducing the load.
• High coolant temperature
• Low coolant level
Pressurized System: Hot coolant can cause seri-
• High inlet air temperature ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
Engine Oil Pressure – Typical oil pressure
components are cool. Loosen the cooling system
for an engine at rated speed with
pressure cap slowly in order to relieve the pres-
SAE 10W30 or with SAE 15W40 is
sure.
240 to 480 kPa (35 to 70 psi).

A lower oil pressure is normal at low idle. If the load 4. Check the coolant level.
is stable and the gauge reading changes, perform
the following procedure: Tachometer – This gauge indicates engine
speed. When the throttle control lever is
1. Remove the load. moved to the full throttle position without
load, the engine is running at high idle. The engine
2. Reduce engine speed to low idle. is running at the full load rpm when the throttle
control lever is at the full throttle position with
maximum rated load.
 29
Operation Section
Gauges and Indicators

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

Ammeter – This gauge indicates the

amount of charge or of discharge in the
battery charging circuit. Operation of the
indicator should be to the right side of “0”(zero).

Service Hour Meter – This gauge indicates

the total number of clock hours of engine
operation. Hours of operation are logged
in the ECM. A service tool is needed to retrieve the
hours from the ECM. A Service Hour Meter may be
installed on the engine.

Fuel Pressure – This gauge indicates fuel

pressure to the electronic unit injectors
from the fuel filter. The indicator should
indicate the “NORMAL” range. A decrease in fuel
pressure usually indicates a plugged fuel filter.

Fuel Level – This gauge indicates the

level of fuel in the fuel tank. The fuel level
gauge registers the fuel level only when
the ignition switch is in the ON position.

i01518477

Engine Monitoring System

(EMS)
SMCS Code: 7490

g00788015
Illustration 23
(1) Main unit (2) Tachometer (unit) (3) Quad gauge
30
Operation Section
Gauges and Indicators

The Caterpillar Engine Monitoring System (EMS) is Table 4

an option. The engine parameters are displayed in Abbreviation Parameter
both digital display and analog. The EMS display is
for electronically controlled engines. Spd Engine Speed
GA-1 Engine Oil Pressure
The EMS includes three individual gauge units. The
units can be installed in various combinations. The GA-2 Coolant Temperature
main unit must be used if any of the units are used.
GA-3 Battery Voltage
Refer to the EMS Operator’s Guide, LEXH7530 for GA-4 Fuel Pressure
additional information. For information on installation
Boost Boost Pressure
and troubleshooting, refer to Installation Guide,
SENR1025. IAirT Inlet Air Temperature
FuelT Fuel Temperature
EMS Main Unit AccrP Auxiliary Pressure
AccrT Auxiliary Temperature
Fuel Fuel Rate
Hrs Engine Hours
Load Percent of Engine Load
(speed and derate)

Note: For detailed information on the exact

parameters for your engine, refer to the Operation
and Maintenance Manual, “Gauges and Indicators”.

Quad Gauge Unit

g00595165
Illustration 24
(4) Engine oil pressure
(5) Engine coolant temperature
(6) Fuel pressure
(7) Inlet manifold temperature
(8) Fuel temperature
(9) Engine coolant level
(10) Battery voltage
(11) Active engine derate
(12) Auxiliary temperature
(13) Auxiliary pressure

The Engine Monitoring System provides warning

lamps. Refer to Illustration 24. The Engine
Monitoring System provides a LCD display for
engine parameters. When the scroll switch is
depressed, the parameters will scroll on the screen. Illustration 25
g00595166
The EMS displays the real time value for the (14) Engine oil pressure
parameter that is selected. The default is engine (15) Engine coolant temperature
speed. (16) Battery voltage
(17) Fuel pressure
The parameters are abbreviated on the LCD
display. Table 4 lists the parameters. The quad gauge unit displays the following
information: engine oil pressure, engine coolant
temperature, battery voltage, and fuel pressure
 31
Operation Section
Gauges and Indicators

Note: The gauge needles may not always return to

zero position when the engine is not running.

Note: For detailed information on the exact

parameters for your engine, refer to the Operation
and Maintenance Manual, “Gauges and Indicators”.

Tachometer Unit

g00788023
Illustration 26
(18) Tachometer

The tachometer displays the engine speed (rpm) on

an analog gauge.

Note: For detailed information on the exact

parameters for your engine, refer to the Operation
and Maintenance Manual, “Gauges and Indicators”.

Communication Data Link

The EMS provides two pins that are connected to
the data link. The data link is available to share data
with other modules. The ECM processes engine
parameters. The parameters will then be transmitted
to the EMS through the data link. The EMS receives
the information. The information is then displayed
on various gauges.

For additional information, refer to the

Troubleshooting Manual, “Cat Data Link
Circuit-Test”.
32
Operation Section
Features and Controls

Features and Controls

i01653542

Sensors and Electrical

Components
SMCS Code: 1900; 7400

Sensor Locations

g00788117
Illustration 27
(1) Coolant Temperature Sensor (5) Fuel Pressure Sensor (8) Engine Oil Pressure Sensor
(2) Customer Connector J61/P61 (6) Atmospheric Pressure Sensor (9) ECM Connector J2/P2
(3) Service Tool Connector J63/P63 (7) Timing Calibration Probe Connector (10) ECM Connector J1/P1
(4) Fuel Temperature Sensor P400 (11) Electronic ground lug
 33
Operation Section
Features and Controls

g00788132
Illustration 28
(12) Primary Engine Speed/Timing Sensor (13) Secondary Engine Speed/Timing (14) Intake Manifold Air Temperature
Sensor (15) Turbocharger Outlet Pressure Sensor

Alarm Lamps (Diagnostic and Diagnostic Lamp Operation

Warning) Installation of a diagnostic lamp is strongly
recommended. The diagnostic lamp is used to
Installation of both a warning lamp and a diagnostic
alert the operator of an electronic control system
lamp is strongly recommended in order to alert the
operator of problems that may be detected by the malfunction (active diagnostic code).
ECM.
Caterpillar’s proprietary two digit flash codes can
be viewed from the diagnostic lamp. A sequence
Lamp Driver Electrical Specifications of flashes represents the system diagnostic
message (flash code). The first sequence of flashes
Electrical specifications for the ECM low side represents the first digit of the flash code. After a
drivers that are used for the diagnostic lamp and two second pause, a second sequence of flashes
the warning lamp allow a maximum current load which represent the second digit of the flash code
of 0.30 Amp (300 mA). The ECM does not provide will occur. Any additional flash codes will follow after
diagnostic codes for either lamp circuit. a pause. These flash codes will be displayed in the
same manner.
Low side ECM drivers provide a path to the negative
battery in order to activate the device (lamp, Note: Flash codes should only be used to indicate
etc) that is connected to the circuit. While circuit the nature of a diagnostic condition. Do not use
protection is recommended for the lamp driver flash codes to perform detailed troubleshooting.
circuits, Caterpillar does not require dedicated
circuit protection. Warning Lamp Operation

Installation of a warning lamp is strongly

recommended. The warning lamp is used to alert
the operator of an engine operating condition which
has the potential to cause engine damage (event
code).
34
Operation Section
Features and Controls

The warning lamp will come ON for five seconds Maintenance Due Lamp and Maintenance
when the ECM is first turned ON in order to indicate Due Reset Switch
that the lamp circuit is functional.
The maintenance due lamp illuminates in order to
Auxiliary Pressure Sensor alert the operator when scheduled maintenance is
due. When the maintenance due reset switch is
An additional pressure sensor input is provided in activated, the maintenance interval values (fuel or
order to allow an auxiliary pressure to be displayed hours) in the ECM are reset to zero.
on the ET EMS display modules, and J1939 (CAN)
display modules. Overspeed Verify Switch

To utilize this feature, the Caterpillar supplied An overspeed shutdown feature is provided in order
pressure sensor must be used and the parameter to help prevent damage to the engine or driven
“Aux Press Enable” must be programmed to equipment in the event of an overspeed condition.
“Enabled”. This pressure sensor is an analog The overspeed verify switch allows the operator
sensor with an operating range of 0 to 2900 kPa or a service technician to quickly verify that the
(0 to 420 psi). overspeed protection system is operating correctly.
When the overspeed verify switch is activated, the
engine will shut down when engine speed reaches
Auxiliary Temperature Sensor 75 percent of the overspeed setpoint. The ECM
shuts down the engine by disabling fuel injection
An additional temperature sensor input is provided and activating the relay for the air shutoff solenoid.
in order to allow an auxiliary temperature to be
displayed on ET EMS display modules, and J1939 Note: The air shutoff solenoid must be manually
(CAN) display modules. reset in order to restart the engine.
To utilize this feature, the Caterpillar supplied PTO Switches
temperature sensor must be used and the
parameter “Aux Temp Enable” must be programmed The ECM can be programmed to operate in either
to “Enabled”. This temperature sensor is a digital one of the two PTO configurations that are available.
PWM sensor with an operating range of 0 to 120 C When “PTO Mode” is programmed to “Ramp
(32 to 216 F). Up/Ramp Down”, the ECM allows PTO operation
with traditional features. When “PTO Mode” is
Engine Speed/Timing Sensor programmed to “Set/Resume”, the ECM allows PTO
operation with enhanced features.
If the ECM does not receive a signal from primary
speed/timing sensor (12), the “DIAGNOSTIC” lamp PTO Enable Switch
will indicate a diagnostic fault code which will be
logged in the ECM memory. The PTO enable switch is used to determine
whether the ECM should acknowledge the PTO
If the ECM does not receive a signal from the ramp up/down switch.
primary speed/timing sensor, the ECM will read the
signal from the secondary speed/timing sensor. The PTO Ramp Up/Down Switch
ECM continually checks in order to determine if
there is a signal from both sensors. If either sensor When the PTO enable switch is in the ON position,
fails, the faulty sensor should be replaced. the throttle position sensor is disabled and the
desired engine speed is controlled by the PTO
Intermittent failure of the sensors will cause erratic ramp up/down switch. The Ramp Up input and
engine control. the Ramp Down input cannot be connected to the
negative battery at the same time. If this occurs, the
ECM will generate a diagnostic code and the ECM
Intermediate Engine Speed Switch will make no adjustments to the desired engine
speed when the unit is in the PTO mode.
The intermediate engine speed switch allows the
operator to change the desired engine speed from
the current engine speed to the programmed value
for “Intermediate Engine Speed”. Engine speed will
ramp at the rate that is defined by the programmed
value for “Engine Accel. Rate”.
 35
Operation Section
Features and Controls

Note: The ECM will use the selected speed that Remote Shutdown Switch
is higher when the ECM chooses between the
throttle input or the PTO input. When the switch is When the remote shutdown switch is activated, the
toggled, the engine will respond according to the ECM disables the fuel injection in order to stop the
programmed value for “Engine Accel. Rate”. When engine. To restart the engine, the remote shutdown
the switch is open, the engine will maintain the switch must be deactivated and switched power to
current engine rpm. “Opened” in this case means the ECM must be cycled.
that the switch is in the center position.
Note: The air shutoff solenoid is not activated and
Set Switch (Ramp Up) the ECM remains energized.

• If the input is momentarily connected to the Throttle Position Sensor

negative battery cable terminal, the desired
engine speed will be set to the current engine The throttle position sensor (TPS) eliminates the
speed. mechanical throttle and governor linkages. The TPS
interprets the position of the throttle lever into an
• If the input is connected to the negative battery electrical signal that is sent to the ECM. The throttle
cable terminal and held in that position, the position signal and the engine speed/timing signal
desired engine speed will increase according to are processed by the ECM in order to precisely
the programmed value for “Engine Accel. Rate”. control engine speed.

• After the desired engine speed is set, momentarily Torque Limit Switch
connecting this input to the negative battery
cable terminal will increase the engine speed in Torque output is limited to the programmed value
increments of 20 rpm. for “Engine Torque Limit” when the torque limit
switch is activated.
Resume Switch (Ramp Down)
SAE J1939 Data Link
• If this input is momentarily connected to the
negative battery, the desired engine speed will The SAE J1939 data link is used to communicate
be set to the last known value that was used engine information to a J1939 receiving device. The
during PTO operation. CAN data link is limited to the broadcast only.

• If this input is connected to the negative Coolant Level Sensor

battery and held in that position, the desired
engine speed will decrease at the rate that is An optional coolant level sensor allows the ECM to
programmed for “Engine Accel. Rate”.
monitor the coolant level in order to have the ability
to warn the operator of a low coolant level.
• After the desired engine speed is set, momentarily
connecting this input to the negative battery will
The sensor output voltage is approximately 0 VDC
decrease the engine speed in increments of 20
(negative battery) when coolant is present. The
rpm. sensor output voltage is approximately 5 VDC when
coolant is not present. The ECM supplies the sensor
PTO Interrupt Switch
with 8 VDC.
When this input is open, the ECM uses the throttle
Note: The sensor must be mounted in a position
position sensor as the source for determining the
which keeps the sensing element immersed under
desired engine speed. When this input is connected all operating conditions. The sensor is normally
to the negative battery, the ECM returns control of
installed in the radiator top tank. The sensor is
the desired engine speed to the PTO.
supplied with thread sealant on the threads, so
it is not necessary to apply thread sealant on
When control of the desired engine speed is
a new sensor. If the sensor has been removed,
transferred from the throttle position sensor to the
apply 5P-3413 Pipe Sealant to the threads before
PTO, engine speed will change at the rate that is reinstalling the sensor.
programmed for “Engine Accel. Rate”. The PTO
set speed will be lost whenever the keyswitch is
turned OFF.
36
Operation Section
Features and Controls

Ether Injection System i00078545

The ECM can drive an ether control relay in order Engine Shutoff Control
to aid in cold weather starting and operation. In
automatic mode, ether injection is controlled by the SMCS Code: 1900; 7418
ECM. A starting aid switch allows the operator to
manually inject additional ether. Secondary shutoff controls are electrically operated.
Know the types and the locations of the shutoff
Note: Do not connect the ether valve directly to the controls, the conditions which cause each control
ECM output. Install a relay between the ether valve to function, and the resetting procedure that is
and the ECM. required to start the engine.

Always determine the cause of the shutdown. Before

i01516479 the engine is restarted, make the necessary repairs.
Alarm Switches
i01491446
SMCS Code: 1900; 7400
Cold Start Strategy
Engines may be equipped with alarms in order
to alert the operator when undesirable operating SMCS Code: 1450; 1456; 1900
conditions occur. When an alarm is activated,
corrective measures must be made before the The ECM will set the cold start strategy when the
situation becomes an emergency. coolant temperature is below 18 C (64 F).

Alarm systems are electrically operated. The When the cold start strategy is activated, low idle
operation of all electric alarms utilize components rpm will be increased to 1000 rpm and the engine’s
that actuate switches in a sensing unit. power will be limited.

Alarms are set at critical operating conditions for Cold mode operation will be deactivated when any
the following items: of the following conditions have been met:

• operating temperatures • Coolant temperature reaches 18 C (64 F).

• operating pressures • The engine has been running for fourteen

minutes.
• operating levels
Cold mode operation varies the fuel injection amount
• operating speeds for white smoke cleanup. Cold mode operation
also varies the timing for white smoke cleanup. The
A history of all of the engine faults and events are engine operating temperature is usually reached
maintained in the Electronic Control Module (ECM). before the walk-around inspection is completed.
These faults can be either Active Codes or Logged The engine will idle at the programmed low idle rpm
Codes. Refer to the Operation and Maintenance in order to be put in gear.
Manual for the definitions of the codes.
NOTICE
System diagnostics can be connected to a visual A machine equipped with this electronically controlled
signal (lamp) and/or an audio signal (bell or engine should not be moved until it is out of Cold Mode
horn). The signal will continue until the condition operation.
is corrected.
If the machine is operated while in Cold Mode opera-
A switch may be installed in the alarm circuit in tion power will be noticeably reduced.
order to disable the alarm signal while the engine is
stopped for repairs. Ensure that the alarm switch is
reset after repairs have been made. After the cold mode is completed, the engine
should be operated at mid-speed to low speed
until normal operating temperature is reached. The
engine will reach normal operating temperature
faster when the engine is operated at low speed
and low power demand.
 37
Operation Section
Engine Diagnostics

Engine Diagnostics i01463253

Diagnostic Lamp
i01563934
SMCS Code: 1000; 1900; 1901; 1902; 7451
Self-Diagnostics
The “DIAGNOSTIC” lamp is used to indicate the
SMCS Code: 1000; 1900; 1901; 1902 existence of an active fault by flashing codes.

Caterpillar Electronic Engines have the capability to When the ignition switch is first turned on, the
perform a self-diagnostics test. When the system “DIAGNOSTIC” lamp will go through the following
detects an active problem, the “DIAGNOSTIC” lamp procedure:
is activated. Diagnostic codes will be stored in
permanent memory in the Electronic Control Module • The “DIAGNOSTIC” lamp will come on and
(ECM). The diagnostic codes can be retrieved by the “DIAGNOSTIC” lamp will remain on for five
using the following components: seconds. This checks the operation of the lamp.

• Caterpillar electronic service tools • The “DIAGNOSTIC” lamp will turn off.
• “DIAGNOSTIC” lamp • The “DIAGNOSTIC” lamp will come on again and
the “DIAGNOSTIC” lamp will flash codes for any
Note: The “DIAGNOSTIC” lamp must be installed by active diagnostic codes. Not all diagnostic codes
the OEM or by the customer. have a unique flash code.

Some installations have electronic displays that • The “DIAGNOSTIC” lamp will turn off for five
provide direct readouts of the engine diagnostic seconds.
codes. Refer to the manual that is provided by
the OEM for more information on retrieving engine • The “DIAGNOSTIC” lamp repeats all active
diagnostic codes. diagnostic codes.

Active codes represent problems that currently A fault diagnostic code will remain active until the
exist. These problems should be investigated first. If problem is repaired. The electronic control module
a code is active, the “DIAGNOSTIC” lamp will flash will continue flashing the flash code at five second
the flash code at five second intervals. intervals until the problem is repaired.

Logged codes represent the following items:

i01453378

• Intermittent problems Diagnostic Flash Code

• Recorded events Retrieval
• Performance history SMCS Code: 1000; 1900; 1901; 1902

The problems may have been repaired since the “Diagnostic” Lamp
logging of the code. These codes do not indicate
that a repair is needed. The codes are guides or Use the “DIAGNOSTIC” Lamp or a Caterpillar
signals when a situation exists. Codes may be electronic service tool to determine the diagnostic
helpful to troubleshoot problems. flash code.
When the problems have been corrected, the Use the following procedure to retrieve the
corresponding logged fault codes should be diagnostic codes if the engine is equipped with a
cleared. “DIAGNOSTIC” lamp:

1. Turn the ignition key to the ON position. The

engine does not need to be started in order to
view codes. The engine does not need to be
running while the ignition switch is in the ON
position.

The “DIAGNOSTIC” lamp blinks on and off at five

second intervals.
38
Operation Section
Engine Diagnostics

• When the ignition key is in the ON position,

the lamp is checked for proper operation. All
active codes will be displayed except for code
34. The engine must be running to get the
speed timing “DIAGNOSTIC” code.

Note: The “DIAGNOSTIC” lamp will illuminate for

five seconds. The lamp will stay on if there is an
active diagnostic code.

2. The diagnostic codes will always be flashed.

There is no toggle switch that will shut off the
lamp.

3. The “DIAGNOSTIC” lamp will flash in order

to indicate a two-digit code. The sequence
of flashes represents the system diagnostic
message. Each digit of the two-digit code is
determined by counting the number of flashes.
The lamp flashes at a rate of two times per
second. The lamp will pause for one second
between digits. The lamp will pause for two
seconds between codes.

Table 5 indicates the potential effect on the engine

performance with active flash codes. Table 5 also
forms a list of Electronic diagnostic codes and
descriptions.
Table 5
Diagnostic Flash Codes for C-10 and C-12 Industrial Engines
Effect On Engine Performance Suggested Action by the Operator
Schedule
Diagnostic Flash Code Reduced Engine Shut
Engine Low Service
Engine Shut down the Service(2)
Misfire Power for the
Speed Down Engine(1)
Engine.(3)
Fault for the Fuel Temperature
13 X
Sensor(4)
Sensor Supply Voltage Above
21 X
Normal or Below Normal(4)
24 Oil Pressure Sensor Fault (4) X
Inlet Manifold Air Pressure
25 X
Sensor Fault(5)
Atmospheric Pressure Sensor
26 X
Fault(4)
Coolant Temperature Sensor
27 X X X X
Fault(4)
Check the Adjustments for the
28 X X X
Throttle Position Sensor.
34 Loss Of Engine RPM Signal X X X X
35 Event for Engine Overspeed X X
37 Fuel Pressure Sensor Fault(4) X
Inlet Manifold Air Temperature
38 X X X X
Sensor Fault(4)
(continued)
 39
Operation Section
Engine Diagnostics

(Table 5, contd)
Diagnostic Flash Codes for C-10 and C-12 Industrial Engines
Effect On Engine Performance Suggested Action by the Operator
Schedule
Diagnostic Flash Code Reduced Engine Shut
Engine Low Service
Engine Shut down the Service(2)
Misfire Power for the
Speed Down Engine(1)
Engine.(3)
Check the Calibration of the
42 X X X X X
Timing Sensor.
46 Low Oil Pressure Event X X X X
Intermittent Battery Power to the
51 X X X X
ECM
52 Personality Module Fault X X X X
The following parameters must
56 be checked: Customer and X X X
System
59 Incorrect Engine Software X X X X
Event for High Coolant
61 X X X
Temperature
62 Event for Low Coolant Level X X X
63 Low Fuel Pressure Event X X X X
High Inlet Manifold Air
64 X X X
Temperature Event
65 Event for High Fuel Temperature X X X
72 Fault of Cylinder 1 or Cylinder 2 X X X
73 Fault of Cylinder 3 or Cylinder 4 X X X
74 Fault of Cylinder 5 or Cylinder 6 X X X
(1) Shut down the Engine: Operate the engine cautiously. Get immediate service. Severe engine damage may result.
(2) The operator should go to the nearest location for service.
(3) The operator should investigate the problem at a convenient time.
(4) The Diagnostic Flash Codes reduce the effectiveness of the Engine Monitoring feature.
(5) These Diagnostic Flash Codes may affect the system only under specific environmental conditions such as engine start-up at cold
temperatures, etc.

For further information or assistance for repairs, i01463504

consult an authorized Caterpillar dealer.
Fault Logging
SMCS Code: 1000; 1900; 1901; 1902

The system provides the capability of Fault

Logging. When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will
be logged in the memory of the ECM. The codes
that have been logged in the memory of the ECM
can be retrieved with Caterpillar electronic service
tools. The codes that have been logged can be
cleared with Caterpillar electronic service tools.
The codes that have been logged in the memory
of the ECM will be automatically cleared from the
memory after 100 hours. The following faults can
not be cleared from the memory of the ECM without
using a factory password: overspeed, low engine
oil pressure, and high engine coolant temperature.
40
Operation Section
Engine Diagnostics

i01563981 i01456915

Engine Operation with Active Engine Operation with

Diagnostic Codes Intermittent Diagnostic Codes
SMCS Code: 1000; 1900; 1901; 1902 SMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp starts to flash codes during If the diagnostic lamp starts to flash codes during
normal engine operation, the system has identified normal engine operation and the diagnostic lamp
a situation that is not within the specification. Use shuts off, an intermittent fault may have occurred. If
Caterpillar electronic service tools to check the a fault has occurred, the fault will be logged into the
active diagnostic codes. memory of the Electronic Control Module (ECM).

Note: If the customer has selected “DERATE” and if In most cases, it is not necessary to stop the
there is a low oil pressure condition, the Electronic engine because of an intermittent code. However,
Control Module (ECM) will limit the engine power the operator should retrieve the logged fault codes
until the problem is corrected. If the oil pressure and the operator should reference the appropriate
is within the normal range, the engine may be information in order to identify the nature of the
operated at the rated speed and load. However, event. The operator should log any observation that
maintenance should be performed as soon as could have caused the lamp to light.
possible. Refer to Operation and Maintenance
Manual, “Diagnostic Flash Code Retrieval” for more • Low power
information on flash codes.
• Limits of the engine speed
The active diagnostic code should be investigated.
The cause of the problem should be corrected • Excessive smoke, etc
as soon as possible. If the cause of the active
diagnostic code is repaired and there is only one This information can be useful to help troubleshoot
active diagnostic code, the diagnostic lamp will the situation. The information can also be used for
turn off. future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this
Operation of the engine and performance of the engine.
engine can be limited as a result of the active
diagnostic code that is generated. Acceleration
rates may be significantly slower. Refer to the
Operation and Maintenance Manual for more
information on the relationship between these active
diagnostic codes and engine performance.
 41
Operation Section
Engine Diagnostics

i00160113

Customer Specified
Parameters
SMCS Code: 1000; 1900; 1901; 1902

Customer specified parameters that will enhance

the fuel efficiency and the operator’s convenience
can be programmed into the Electronic Control
Module (ECM). Some parameters may affect engine
operation. This may lead to complaints from the
operator about power or about performance.
The following engine related parameters may be
programmed by the customer by using Caterpillar
electronic service tools in order to influence the
operation of the engine:

• Customer Passwords
• Power Rating (hp at rpm)
• Rating Selection (A-E)
• Air/Fuel Ratio
• PTO Ramp Rate
• Engine Parameters: Low Idle, High Idle, Top
Engine Limit, Torque Limit, and Intermediate
Speed

• Engine Monitoring Mode

• Equipment ID
• Maintenance Indicator
• Auxiliary Pressure
• Auxiliary Temperature
• Parameter Lock Out
The customer specified parameters can be
changed as often as needed. Password protection
is provided so that the customer can change the
parameters. The customer can authorize someone
else to change the parameters. Ensure that a record
of the parameters is kept in the Operation and
Maintenance Manual. For detailed instructions on
programming the engine for optimum performance
and for optimum fuel economy, consult your
Caterpillar dealer.
42
Operation Section
Engine Starting

Engine Starting
Engine exhaust contains products of combustion
i01486758
which may be harmful to your health. Always start
Before Starting Engine and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
SMCS Code: 1000; 1400; 1450 outside.

Perform the required daily maintenance and • Do not start the engine or move any of the
other periodic maintenance before the engine is controls if there is a “DO NOT OPERATE” warning
started. Inspect the engine compartment. This tag or similar warning tag attached to the start
inspection can help prevent major repairs at a switch or to the controls.
later date. Refer to the Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more • Ensure that the areas around the rotating parts
information. are clear.

• For the maximum service life of the engine, • All of the guards must be put in place. Check for
make a thorough inspection before the engine damaged guards or for missing guards. Repair
is started. Look for the following items: oil leaks, any damaged guards. Replace damaged guards
coolant leaks, loose bolts, and trash buildup. and/or missing guards.
Remove trash buildup and arrange for repairs,
as needed. • Disconnect any battery chargers that are not
protected against the high current drain that
• Inspect the cooling system hoses for cracks and is created when the electric starting motor (if
for loose clamps. equipped) is engaged. Check electrical cables
and check the battery for poor connections and
• Inspect the alternator and accessory drive belts for corrosion.
for cracks, breaks, and other damage.
• Reset all of the shutoffs or alarm components.
• Inspect the wiring for loose connections and for
worn wires or frayed wires. • Check the engine lubrication oil level. Maintain
the oil level between the “ADD” mark and the
• Check the fuel supply. Drain water from the water “FULL” mark on the oil level gauge.
separator (if equipped). Open the fuel supply
valve. • Check the coolant level. Observe the coolant
level in the coolant recovery tank (if equipped).
NOTICE Maintain the coolant level to the “FULL” mark on
All valves in the fuel return line must be open before the coolant recovery tank.
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing • If the engine is not equipped with a coolant
failure or other damage. recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe.
If the engine is equipped with a sight glass,
If the engine has not been started for several maintain the coolant level in the sight glass.
weeks, fuel may have drained from the fuel system.
Air may have entered the filter housing. Also, when
• Observe the air cleaner service indicator (if
fuel filters have been changed, some air pockets equipped). Service the air cleaner when the
will be trapped in the engine. In these instances, yellow diaphragm enters the red zone, or when
prime the fuel system. Refer to the Operation and the red piston locks in the visible position.
Maintenance Manual, “Fuel System - Prime” for
more information on priming the fuel system. • Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove
any electrical loads.
 43
Operation Section
Engine Starting

i01646219 5. Allow the engine to idle for approximately

three minutes. Idle the engine until the water
Starting the Engine temperature gauge has begun to rise. Check all
gauges during the warm-up period.
SMCS Code: 1000; 1450
Note: Oil pressures and fuel pressures should be
This start procedure may be used for all engines in the normal range on the instrument panel. Do
that are not equipped with an Air Inlet Heater not apply a load to the engine or increase engine
regardless of ambient temperature. rpm until the oil pressure gauge indicates at least
normal pressure. Inspect the engine for leaks and/or
Refer to the Owner’s Manual of the OEM for your unusual noises.
type of controls. Use the following procedure to
start the engine.
i01463542
1. Place the transmission in NEUTRAL. Disengage
the flywheel clutch in order to allow the engine Cold Weather Starting
to start faster. This also reduces the draining of
the battery. SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900

2. Turn the keyswitch to the ON position. Refer to the Owner’s Manual of the OEM for your
type of controls. Use the following procedure in
The “CHECK ENGINE/DIAGNOSTIC” lamp will order to start the engine.
flash while the engine is cranking. The lamp
should turn off after proper engine oil pressure
is achieved. If the lamp fails to flash, notify
your authorized Caterpillar dealer. If the lamp DO NOT USE ETHER (starting fluids) unless
continues to flash, the Electronic Control Module specifically instructed to do so. If the engine is
(ECM) has detected a problem in the system. equipped with an Air Inlet Heater (electrically or
Refer to the Operation and Maintenance Manual, fuel ignited manifold heater), DO NOT use ether
“Diagnostic Flash Code Retrival” (Operation (starting fluids) at any time. The use could result
Section) for more information. in engine damage and/or personal injury.
3. Push the start button or turn the keyswitch to the
START position in order to crank the engine. Startability will be improved at temperatures below
10C (50F) from the use of a cylinder block coolant
Do not push down or hold the throttle down heater or from other means that are used to heat
while the engine is cranked. The system will the crankcase oil. Some engine applications use
automatically provide the correct amount of fuel a jacket water heater to improve startability. This
that is needed to start the engine. will help reduce white smoke and misfire during
start-up in cold weather.
4. If the engine fails to start within 30 seconds,
release the start button, or the keyswitch. Wait for NOTICE
two minutes in order to allow the starting motor to When using ether (starting fluid), follow the manufac-
cool before attempting to start the engine again. turer’s instructions carefully, use it sparingly and spray
it only while cranking the engine. Excessive ether can
Note: The “CHECK ENGINE/DIAGNOSTIC” lamp cause piston and ring damage. Use ether (starting flu-
may come on after the engine is started. If this id) for cold weather starting purposes only.
occurs, the ECM has detected a problem with the
system. Refer to the Operation and Maintenance
Manual, “Diagnostic Flash Code Retrival” (Operation For engines that are not equipped with an Air Inlet
Section) for more information. Heater, use ether when temperatures are below 0C
(32F). If the engine is equipped with an injection
system for starting fluid, crank the engine. Depress
NOTICE the ether switch for three seconds. Additional
Oil pressure should rise within 15 seconds after the injections may be necessary in order to start the
engine starts. Do not increase engine rpm until the oil engine.
pressure gauge indicates normal. If oil pressure is not
indicated on the gauge within 15 seconds, DO NOT
operate the engine. STOP the engine, investigate and
correct the cause.
44
Operation Section
Engine Starting

Note: If the engine has not been run for several Note: The “CHECK ENGINE/DIAGNOSTIC” lamp
weeks, fuel may have drained. Air may have moved may come on after the engine is started. If this
into the filter housing. Also, when fuel filters have occurs, the Electronic Control Module (ECM) has
been changed, some air will be left in the filter detected a problem with the system. Refer to the
housing. Refer to the Operation and Maintenance Operation and Maintenance Manual, “Diagnostic
Manual, “Fuel System - Prime” (Maintenance Flash Code Retrival” for more information.
Section) for more information on priming the fuel
system. 5. Allow the engine to idle for approximately
three minutes. Idle the engine until the water
NOTICE temperature gauge has begun to rise. Check all
Do not engage the starting motor when flywheel is gauges during the warm-up period.
turning. Do not start the engine under load.
Note: The oil pressures and fuel pressures should
If the engine fails to start within 30 seconds, release be in the normal range on the instrument panel. Do
the starter switch or button and wait two minutes to not apply a load to the engine or increase engine
allow the starting motor to cool before attempting to rpm until the oil pressure gauge indicates at least
start the engine again. normal pressure. Inspect the engine for leaks and/or
unusual noises.

1. Place the transmission in NEUTRAL. Disengage

i01037941
the flywheel clutch in order to allow the engine
to start faster. This also reduces draining of the
battery.
Starting with Jump Start
Cables
2. Turn the ignition switch to the ON position.
SMCS Code: 1000; 1401; 1402; 1900
The “CHECK ENGINE/DIAGNOSTIC” lamp will
flash while the engine is cranking. The lamp
should turn off after proper engine oil pressure
is achieved. If the lamp fails to flash, notify Improper jump start cable connections can cause
your authorized Caterpillar dealer. If the lamp an explosion resulting in personal injury.
continues to flash, the Electronic Control Module
(ECM) has detected a problem in the system. Prevent sparks near the batteries. Sparks could
Refer to the Operation and Maintenance Manual, cause vapors to explode. Do not allow jump start
“Diagnostic Flash Code Retrival” for more cable ends to contact each other or the engine.
information.

3. Push the start button or turn the ignition switch to If the installation is not equipped with a backup
the START position in order to crank the engine. battery system, it may be necessary to start the
engine from an external electrical source.
Do not push down or hold the throttle down
while the engine is cranked. The system will First, determine the reason that it is necessary to
automatically provide the correct amount of fuel start with power from an external source. Refer to
that is needed to start the engine. Special Instruction, SEHS7768, “Use of the 6V-2150
Starting/Charging Analyzer”.
4. If the engine fails to start within 30 seconds,
release the start button, or the ignition switch. Many batteries which are considered unusable are
Wait for two minutes in order to allow the starting still rechargeable. After jump starting, the alternator
motor to cool before attempting to start the may not be able to fully recharge batteries that
engine again. are severely discharged. The batteries must be
charged to the proper voltage with a battery
NOTICE charger. For information on testing and charging,
refer to the Special Instruction, SEHS7633, “Battery
Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine speed until the Test Procedure”.
oil pressure gauge indicates normal. If oil pressure
is not indicated on the gauge within 15 seconds, DO
NOT operate the engine. STOP the engine, investigate
and correct the cause.
 45
Operation Section
Engine Starting

i01646248
NOTICE
Using a battery source with the same voltage as the
After Starting Engine
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage SMCS Code: 1000
the electrical system.
Note: In temperatures from 0 to 60C (32 to 140F),
Do not reverse the battery cables. The alternator can the warm-up time is approximately three minutes. In
temperatures below 0C (32F), additional warm-up
be damaged. Attach ground cable last and remove
time may be required.
first.
Note: Ensure that the self test for the monitoring
When using an external electrical source to start the
system (if equipped) is completed before operating
engine, turn the engine control switch to the “OFF” po-
sition. Turn all electrical accessories OFF before at- the engine under load.
taching the jump start cables.
When the engine idles during warm-up, observe
Ensure that the main power switch is in the OFF posi- the following conditions:
tion before attaching the jump start cables to the en-
gine being started. • Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is
1. Turn the start switch on the stalled engine to the not possible in some applications.
OFF position. Turn off all accessories.
• Operate the engine at low idle until all systems
2. Connect one positive end of the jump start cable achieve operating temperatures. Check all
to the positive cable terminal of the discharged gauges during the warm-up period.
battery. Connect the other positive end of the
jump start cable to the positive cable terminal Note: Gauge readings should be observed and the
of the electrical source. data should be recorded frequently while the engine
is operating. Comparing the data over time will
3. Connect one negative end of the jump start cable help to determine normal readings for each gauge.
to the negative cable terminal of the electrical Comparing data over time will also help detect
source. Connect the other negative end of the abnormal operating developments. Significant
jump start cable to the engine block or to the changes in the readings should be investigated.
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.

4. Charge the batteries. The engine will not

continue to run after starting if the batteries have
not been charged.

5. Start the engine.

6. Immediately after the stalled engine is started,

disconnect the jump start cables in reverse order.

Refer to the Electrical Schematic for your engine.

Consult your Caterpillar dealer for more information.
46
Operation Section
Engine Starting

i01400713

Air Starting
SMCS Code: 1451

For good life of the air starting motor, the air supply
must be free from dirt and water.

1. Open the drain valve and close the drain valve

in order to drain condensation and oil carryover.
This drain valve is located on the bottom of the
air tank.

2. Check the air supply pressure. The air starting

motor requires a minimum of 690 kPa (100 psi)
air pressure to operate properly. The maximum
air pressure must not exceed 1550 kPa (225 psi).
The normal operating air pressure will be
758 to 965 kPa (110 to 140 psi).

g00738000
Illustration 29
(1) Air valve

3. Press the air valve or press the start button for

the engine in order to crank the engine. After
the engine starts, release the air valve or release
the start button.
 47
Operation Section
Engine Operation

Engine Operation i00160358

Engine Warm-up
i01646252
SMCS Code: 1000
Engine Operation
1. Run the engine at low idle for three to five
SMCS Code: 1000 minutes or run the engine until the jacket water
temperature starts to rise.
Proper operation and maintenance are key factors
in obtaining the maximum life and economy of 2. Check all of the gauges during the warm-up
the engine. If the directions in the Operation and period.
Maintenance Manual are followed, costs can
be minimized and engine service life can be 3. Make another walk-around inspection. Check the
maximized. engine for fluid leaks and air leaks. Measure
the engine oil level. Maintain the engine oil level
The time that is needed for the engine to reach between the “ADD” mark and the “FULL” mark
normal operating temperature can be less than on the engine oil level gauge.
the time taken for a walk-around inspection of the
engine. 4. Increase the rpm to one-half of the rated speed.
Check for fluid leaks and air leaks. The engine
The engine can be operated at the rated rpm after may be operated at full rated speed and full
the engine is started and after the engine reaches load when the jacket water temperature reaches
operating temperature. The engine will reach normal 66C (150F).
operating temperature sooner during a low engine
speed (rpm) and during a low power demand. This
procedure is more effective than idling the engine
at no load. The engine should reach operating
temperature in a few minutes.

Gauge readings should be observed and the data

should be recorded frequently while the engine is
operating. Comparing the data over time will help
to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
48
Operation Section
Engine Operation

i01646335 Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines
Engaging the Driven for leaks. Repair the fuel lines, as needed.
Equipment
• Be aware of the properties of the different fuels.
SMCS Code: 1000 Use only the recommended fuels.

1. Operate the engine at one-half of the rated rpm, • Avoid unnecessary idling.
when possible.
Shut off the engine rather than idle for long periods
2. Engage the driven equipment without a load on of time.
the equipment, when possible.
• Observe the service indicator frequently. Keep
Interrupted starts put excessive stress on the the air cleaner elements clean.
drive train. Interrupted starts also waste fuel. To
get the driven equipment in motion, engage the • Ensure that the turbochargers are operating
clutch smoothly with no load on the equipment. correctly so that the proper air/fuel ratio is
This method should produce a start that is maintained. Clean exhaust indicates proper
smooth and easy. The engine rpm should not functioning.
increase and the clutch should not slip.
• Maintain a good electrical system.
3. Ensure that the ranges of the gauges are normal
when the engine is operating at one-half of One defective battery cell will overwork the
the rated rpm. Ensure that all gauges operate alternator. This will consume excess power and
properly. excess fuel.

4. Increase the engine rpm to the rated rpm. Always • Ensure that the belts are properly adjusted. The
increase the engine rpm to the rated rpm before belts should be in good condition.
the load is applied.
• Ensure that all of the connections of the hoses
5. Apply the load. Begin operating the engine at are tight. The connections should not leak.
low load. Check the gauges and equipment for
proper operation. After normal oil pressure is • Ensure that the driven equipment is in good
reached and the temperature gauge begins to working order.
move, the engine may be operated at full load.
Check the gauges and equipment frequently • Cold engines consume excess fuel. Utilize heat
when the engine is operated under load. from the jacket water system and the exhaust
system, when possible. Keep cooling system
Extended operation at low idle or at reduced components clean and keep cooling system
load may cause increased oil consumption and components in good repair. Never operate the
carbon buildup in the cylinders. This carbon engine without water temperature regulators.
buildup results in a loss of power and/or poor All of these items will help maintain operating
performance. temperatures.

• Settings for the fuel system and the limits for the
i00165110 operating altitude are stamped on the Engine
Information Plate. If an engine is moved to a
Fuel Conservation Practices higher altitude, the settings must be changed
by a Caterpillar dealer. Changing the settings
SMCS Code: 1000; 1250 will help prevent damage to the turbocharger.
Changing the settings will help to provide the
The efficiency of the engine can affect the fuel maximum efficiency for the engine. Engines can
economy. Caterpillar’s design and technology in be operated safely at higher altitudes, but the
manufacturing provides maximum fuel efficiency engines will deliver less horsepower. The fuel
in all applications. Follow the recommended settings should be changed by a Caterpillar
procedures in order to attain optimum performance dealer in order to obtain the rated horsepower.
for the life of the engine.

• Avoid spilling fuel.

 49
Operation Section
Engine Stopping

Engine Stopping i01646416

Manual Stop Procedure

i01057253
SMCS Code: 1000
Emergency Stopping
Note: Individual applications will have different
SMCS Code: 1000; 7418 control systems. Ensure that the shutoff procedures
are understood. Use the following general
guidelines in order to stop the engine.
NOTICE
Emergency shutoff controls are for EMERGENCY use
1. Remove the load, when possible. Reduce the
ONLY. DO NOT use emergency shutoff devices or
engine speed (rpm) to low idle.
controls for normal stopping procedure.
2. Increase the engine speed (rpm) to no more
Ensure that any components for the external system than one-half of the rated rpm. Perform this
that support the engine operation are secured after procedure for three to five minutes in order to
the engine is stopped. cool the engine. Reduce the engine speed (rpm)
to low idle.
Emergency Stop Button 3. After the cool down period, turn the key switch
to the OFF position.

g00104303
Illustration 30
Typical emergency stop button

The emergency stop button is in the OUT position

for normal engine operation. Push the emergency
stop button. The engine will not start when the
button is locked. Turn the button clockwise in order
to reset.
50
Operation Section
Engine Stopping

i01402990

After Stopping Engine

SMCS Code: 1000

Note: Before you check the engine oil, do not

operate the engine for at least 10 minutes in order
to allow the engine oil to return to the oil pan.

• Check the crankcase oil level. Maintain the oil

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

• If necessary, perform minor adjustments. Repair

any leaks and tighten any loose bolts.

• Note the service hour meter reading. Perform

the maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.

• Fill the fuel tank in order to help prevent

accumulation of moisture in the fuel. Do not
overfill the fuel tank.

NOTICE
Only use antifreeze/coolant mixtures recommended in
the Coolant Specifications that are in the Operation
and Maintenance Manual. Failure to do so can cause
engine damage.

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

Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling.

• If freezing temperatures are expected, check

the coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in
the instructions from the OEM.
 51
Operation Section
Cold Weather Operation

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
i01457051 cold weather operation, if No. 1 diesel fuel is not
available, use No. 2 diesel fuel, if necessary.
Radiator Restrictions
There are three major differences between No. 1
SMCS Code: 1353; 1396 and No. 2 diesel fuel. No. 1 diesel fuel has the
following properties:
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow • Lower cloud point
restriction can cause the following conditions:
• Lower pour point
• High exhaust temperatures
• Lower rating of kJ (BTU) per unit volume of fuel
• Power loss
When No. 1 diesel fuel is used, a decrease in
• Excessive fan usage power and in fuel efficiency may be noticed. Other
operating effects should not be experienced.
• Reduction in fuel economy
The cloud point is the temperature when a cloud
If an airflow restriction device must be used, the of wax crystals begins to form in the fuel. These
device should have a permanent opening directly crystals can cause the fuel filters to plug. The
in line with the fan hub. The device must have a pour point is the temperature when diesel fuel will
minimum opening dimension of at least 770 cm2 thicken. The diesel fuel becomes more resistant to
(120 in2). flow through fuel pumps and through fuel lines.

A centered opening that is directly in line with Be aware of these values when diesel fuel is
the fan hub is specified in order to prevent an purchased. Anticipate the average ambient
interrupted airflow on the fan blades. Interrupted temperature within the area that the engine will be
airflow on the fan blades could cause a fan failure. operated. Engines that are fueled in one climate
may not operate well if the engines are moved
Caterpillar recommends a warning device for the to another climate. Problems can result due to
inlet manifold temperature and/or the installation of changes in temperature.
an inlet air temperature gauge. The warning device
for the inlet manifold temperature should be set at Before troubleshooting for low power or for poor
75 C (167 F). The inlet manifold air temperature performance in the winter, check the type of fuel
should not exceed 75 C (167 F). Temperatures that is being used.
that exceed this limit can cause power loss and
potential engine damage. When No. 2 diesel fuel is used the following
components provide a means of minimizing
problems in cold weather:
i01190421

Fuel and the Effect from Cold • Starting aids

Weather • Engine oil pan heaters
SMCS Code: 1000; 1250 • Engine coolant heaters
The following fuels are the grades that are available • Fuel heaters
for Caterpillar engines:
• Fuel line insulation
• No. 1
For more information on cold weather operation, see
• No. 2 Operation and Maintenance Manual, SEBU5898,
“Cold Weather Recommendations”.
• Blend of No. 1 and No. 2
No. 2 diesel fuel is the most commonly used fuel.
Either No. 1 diesel fuel or a blend of No. 1 and No.
2 is best suited for cold weather operation.
52
Operation Section
Cold Weather Operation

i01505157 These engines are equipped with a primary

filter/water separator. The primary filter/water
Fuel Related Components in separator must use a 10 micron filter to a 15 micron
Cold Weather filter. The filters are becoming more critical as fuel
injection pressures increase to 209 MPa (30000 psi)
SMCS Code: 1000; 1250 and higher psi. For more information on priming the
fuel system, see the Operation and Maintenance
Manual, “Fuel System - Prime” topic (Maintenance
Fuel Tanks Section).
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after operating the engine. Fuel Heaters
Fuel tanks should contain some provision for Fuel heaters help to prevent fuel filters from
draining water and sediment from the bottom of the plugging in cold weather due to waxing. A fuel
tanks. Some fuel tanks use supply pipes that allow heater should be installed in order for the fuel to be
water and sediment to settle below the end of the heated before the fuel enters the primary fuel filter.
fuel supply pipe.
Select a fuel heater that is mechanically simple,
Some fuel tanks use supply lines that take fuel yet adequate for the application. The fuel heater
directly from the bottom of the tank. If the engine is should also help to prevent overheating of the fuel.
equipped with this system, regular maintenance of High fuel temperatures reduce engine performance
the fuel system filter is important. and the availability of engine power. Choose a fuel
heater with a large heating surface. The fuel heater
Drain the water and sediment from any fuel storage should be practical in size. Small heaters can be
tank at the following intervals: too hot due to the limited surface area.

• Weekly Disconnect the fuel heater in warm weather.

• Oil changes Note: Fuel heaters that are controlled by the water
temperature regulator or self-regulating fuel heaters
• Refueling of the fuel tank should be used with this engine. Fuel heaters
that are not controlled by the water temperature
This will help prevent water and/or sediment from regulator can heat the fuel in excess of 65 C
being pumped from the fuel storage tank and into (149 F). A loss of engine power can occur if the
the engine fuel tank. fuel supply temperature exceeds 37 C (100 F).

Note: Heat exchanger type fuel heaters should have

Fuel Filters a bypass provision in order to prevent overheating
of the fuel in warm weather operation.
NOTICE
Do not fill the fuel filters with fuel before installing them. For further information on fuel heaters, consult your
The fuel would not be filtered and could be contami- Caterpillar dealer.
nated. Contaminated fuel will cause accelerated wear
to fuel system parts.

NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel,
a two micron absolute high efficiency fuel filter is re-
quired for all Caterpillar Hydraulic Electronic Unit In-
jectors. Caterpillar High Efficiency Fuel Filters meet
these requirements. Consult your Caterpillar dealer for
the proper part numbers.
 53
Maintenance Section
Torque Specifications

Maintenance Section i00621349

Standard Torque for Inch

Fasteners
Torque Specifications
SMCS Code: 7553
i01252954 Table 6

General Torque Information Inch Nuts and Bolts

Thread Size
SMCS Code: 7553 Standard Torque
Inch
1/4 12 ± 3 N·m (9 ± 2 lb ft)
5/16 25 ± 6 N·m (18 ± 4 lb ft)
Mismatched or incorrect fasteners can result in 3/8 47 ± 9 N·m (35 ± 7 lb ft)
damage or malfunction, or personal injury.
7/16 70 ± 15 N·m (50 ± 11 lb ft)
Take care to avoid mixing metric dimensioned fas- 1/2 105 ± 20 N·m (75 ± 15 lb ft)
teners and inch dimensioned fasteners.
9/16 160 ± 30 N·m (120 ± 22 lb ft)
Exceptions to these torques are given in the Service 5/8 215 ± 40 N·m (160 ± 30 lb ft)
Manual, if necessary. 3/4 370 ± 50 N·m (275 ± 37 lb ft)
Prior to installation of any hardware, ensure that 7/8 620 ± 80 N·m (460 ± 60 lb ft)
components are in near new condition. Bolts and 1 900 ± 100 N·m (660 ± 75 lb ft)
threads must not be worn or damaged. Threads
must not have burrs or nicks. Hardware must be 1 1/8 1300 ± 150 N·m (960 ± 110 lb ft)
free of rust and corrosion. Clean the hardware with
1 1/4 1800 ± 200 N·m (1320 ± 150 lb ft)
a noncorrosive cleaner. Do not lubricate the fastener
threads except for the rust preventive. The rust 1 3/8 2400 ± 300 N·m (1780 ± 220 lb ft)
preventive should be applied by the supplier of that
1 1/2 3100 ± 350 N·m (2280 ± 260 lb ft)
component for purposes of shipping and storage.
Other applications for lubricating components may
also be specified in the Service Manual. Table 7
Inch Taperlock Studs
Thread Size
Standard Torque
Inch
1/4 8 ± 3 N·m (6 ± 2 lb ft)
5/16 17 ± 5 N·m (13 ± 4 lb ft)
3/8 35 ± 5 N·m (26 ± 4 lb ft)
7/16 45 ± 10 N·m (33 ± 7 lb ft)
1/2 65 ± 10 N·m (48 ± 7 lb ft)
5/8 110 ± 20 N·m (80 ± 15 lb ft)
3/4 170 ± 30 N·m (125 ± 22 lb ft)
7/8 260 ± 40 N·m (190 ± 30 lb ft)
1 400 ± 60 N·m (300 ± 44 lb ft)
1 1/8 525 ± 60 N·m (390 ± 44 lb ft)
1 1/4 750 ± 80 N·m (550 ± 60 lb ft)
1 3/8 950 ± 125 N·m (700 ± 90 lb ft)
1 1/2 1200 ± 150 N·m (880 ± 110 lb ft)
54
Maintenance Section
Torque Specifications

i00621350 i01206505

Standard Torque for Metric Standard Torque for Worm

Fasteners Drive Band Hose Clamps
SMCS Code: 7553 SMCS Code: 7553; 7554
Table 8
Metric Nuts and Bolts
Thread Size
Standard Torque
Metric
M6 12 ± 3 N·m (9 ± 2 lb ft)
M8 28 ± 7 N·m (21 ± 5 lb ft) g00280501
Illustration 31
M10 55 ± 10 N·m (41 ± 7 lb ft)
Table 10
M12 100 ± 20 N·m (75 ± 15 lb ft)
Initial Installation Torque
M14 160 ± 30 N·m (120 ± 22 lb ft) Width of Clamp
On New Hose
M16 240 ± 40 N·m (175 ± 30 lb ft) 7.9 mm (0.31 inch) 0.9 ± 0.2 N·m (8 ± 2 lb in)
M20 460 ± 60 N·m (340 ± 44 lb ft) 13.5 mm (0.53 inch) 4.5 ± 0.5 N·m (40 ± 4 lb in)
M24 800 ± 100 N·m (590 ± 75 lb ft) 15.9 mm (0.63 inch) 7.5 ± 0.5 N·m (65 ± 4 lb in)
M30 1600 ± 200 N·m (1180 ± 150 lb ft) Reassembly or Retightening
Width of Clamp
Torque
M36 2700 ± 300 N·m (2000 ± 220 lb ft)
7.9 mm (0.31 inch) 0.7 ± 0.2 N·m (6 ± 2 lb in)
Table 9 13.5 mm (0.53 inch) 3.0 ± 0.5 N·m (27 ± 4 lb in)
Metric Taperlock Studs
15.9 mm (0.63 inch) 4.5 ± 0.5 N·m (40 ± 4 lb in)
Thread Size
Standard Torque
Metric
i01394891
M6 8 ± 3 N·m (6 ± 2 lb ft)
M8 17 ± 5 N·m (13 ± 4 lb ft) Standard Torque for Constant
M10 35 ± 5 N·m (26 ± 4 lb ft) Torque Hose Clamps
M12 65 ± 10 N·m (48 ± 7 lb ft) SMCS Code: 7553; 7554
M16 110 ± 20 N·m (80 ± 15 lb ft)
Use a constant torque hose clamp in place of any
M20 170 ± 30 N·m (125 ± 22 lb ft) standard hose clamp. Ensure that the constant
M24 400 ± 60 N·m (300 ± 44 lb ft) torque hose clamp is the same size as the standard
hose clamp. Due to extreme temperature changes,
M30 750 ± 80 N·m (550 ± 60 lb ft) the hose will heat set. Heat setting can cause hose
M36 1200 ± 150 N·m (880 ± 110 lb ft) clamps to loosen. Loose hose clamps can result
in leaks. There have been reports of component
failures that have been caused by hose clamps that
have loosened. The constant torque hose clamp will
help prevent these failures.
 55
Maintenance Section
Torque Specifications

g00735086
Illustration 32

Use a torque wrench for proper installation of the

constant torque hose clamps. The constant torque
hose clamp is installed correctly under the following
conditions:

• Screw tip (1) extends 6.35 mm (0.25 inch) (X)

beyond the housing.

• The belleville washers are collapsed nearly

flat after screw (2) is tightened to a torque of
11 ± 1 N·m (98 ± 9 lb in).
56
Maintenance Section
Lubricant Specifications

Lubricant Specifications Table 11

API Classifications

i01111306 Current Obsolete

Lubricant Information CF-4, CG-4, CH-4 CE

CF CC, CD
SMCS Code: 1000; 1300; 7581
CF-2(1) CD-2(1)
(1) CD-2 and API CF-2 are classifications for two-cycle diesel
General Information engines. Caterpillar does not sell engines that utilize CD-2 and
API CF-2 oils.
Because of government regulations regarding
the certification of engine exhaust emissions, the Note: API CF is not the same classification as
lubricant recommendations must be followed. API CF-4. API CF oils are only recommended
for Caterpillar 3600 Series Diesel Engines and
Engine Manufacturers Association Caterpillar engines with precombustion chamber
(PC) fuel systems.
(EMA) Oils
The “Engine Manufacturers Association Grease
Recommended Guideline on Diesel Engine Oil” is
recognized by Caterpillar. For detailed information The classifications of grease are based on the
about this guideline, see the latest edition of EMA “ASTM D217” worked penetration characteristics.
publication, “EMA LRG-1”. These characteristics for grease are given a defined
consistency number.

API Oils Terminology

The Engine Oil Licensing and Certification System Certain abbreviations follow the nomenclature of
by the American Petroleum Institute (API) is “SAE J754”. Some classifications follow “SAE J183”
recognized by Caterpillar. For detailed information abbreviations, and some classifications follow the
about this system, see the latest edition of the “API “EMA Recommended Guideline on Diesel Engine
publication No. 1509”. Engine oils that bear the API Oil”. In addition to Caterpillar definitions, there
symbol are authorized by API. are other definitions that will be of assistance in
purchasing lubricants. Recommended oil viscosities
can be found in this publication, “Engine Oil” topic
(Maintenance Section).

i01539915

Engine Oil
SMCS Code: 1300; 1348; 7581

Caterpillar Diesel Engine Oil

Caterpillar Oils have been developed and tested in
g00546535
order to provide the full performance and service
Illustration 33 life that has been designed and built into Caterpillar
Typical API symbol Engines. Caterpillar Oils are currently used to fill
diesel engines at the factory. These oils are offered
Diesel engine oils CC, CD, CD-2, and CE have by Caterpillar dealers for continued use when the
not been API authorized classifications since 1 engine oil is changed. Consult your Caterpillar
January 1996. Table 11 summarizes the status of dealer for more information on these oils.
the classifications.
Due to significant variations in the quality and in
the performance of commercially available oils,
Caterpillar makes the following recommendations:

• Caterpillar Diesel Engine Oil (10W30)

 57
Maintenance Section
Lubricant Specifications

• Caterpillar Diesel Engine Oil (15W40) EMA LRG-1 – The Engine Manufacturers
Association (EMA) has developed lubricant
Caterpillar multigrade Diesel Engine Oil is recommendations as an alternative to the API oil
formulated with the correct amounts of detergents, classification system. LRG-1 is a Recommended
dispersants, and alkalinity in order to provide Guideline that defines a level of oil performance
superior performance in Caterpillar Diesel Engines. for these types of diesel engines: high speed, four
stroke cycle, heavy-duty, and light duty. LRG-1
Caterpillar multigrade Diesel Engine Oil is available oils may be used in Caterpillar engines when the
in two viscosity grades (10W30 and 15W40). For following oils are recommended: API CH-4, API
direct injection engines, see Table 12 in order CG-4, and API CF-4. LRG-1 oils are intended to
to choose the correct viscosity grade for the provide superior performance in comparison to API
ambient temperature. Multigrade oils provide the CG-4 and API CF-4.
correct viscosity for a broad range of operating
temperatures. LRG-1 oils will meet the needs of high performance
Caterpillar diesel engines that are operating in
Multigrade oils are effective in maintaining low oil many applications. The tests and the test limits that
consumption and low levels of piston deposits. are used to define LRG-1 are similar to the new
API CH-4 classification. Therefore, these oils will
Caterpillar multigrade Diesel Engine Oil can be also meet the requirements of the low emissions
used in other diesel engines and in gasoline diesel engines. LRG-1 oils are designed to control
engines. See the engine manufacturer’s guide for the harmful effects of soot with improved wear
the recommended specifications. Compare the resistance and improved resistance to plugging of
specifications to the specifications of Caterpillar the oil filter. These oils will also provide superior
multigrade Diesel Engine Oil. The current industry piston deposit control for engines with either
standards for Caterpillar Diesel Engine Oil are listed two-piece steel pistons or aluminum pistons.
on the product label and on the data sheets for the
product. All LRG-1 oils must complete a full test program
with the base stock and with the viscosity grade of
Consult your Caterpillar dealer for part numbers the finished commercial oil. The use of “API Base
and for available sizes of containers. Oil Interchange Guidelines” are not appropriate for
LRG-1 oils. This feature reduces the variation in
performance that can occur when base stocks are
Commercial Oils changed in commercial oil formulations.
The performance of commercial diesel engine
LRG-1 oils are recommended for use in extended
oils is based on American Petroleum Institute
(API) classifications. These API classifications are oil change interval programs that optimize oil life.
These oil change interval programs are based
developed in order to provide commercial lubricants
on oil analysis. LRG-1 oils are recommended
for a broad range of diesel engines that operate at
various conditions. for conditions that demand a premium oil. Your
Caterpillar dealer has the specific guidelines for
optimizing oil change intervals.
If Caterpillar multigrade Diesel Engine Oil is not
used, only use commercial oils that meet the
API CH-4 – API CH-4 oils were developed in
following classifications:
order to meet the requirements of the new high
performance diesel engines. Also, the oil was
• EMA LRG-1 multigrade oil (preferred oil) designed to meet the requirements of the low
emissions diesel engines. API CH-4 oils are also
• API CH-4 multigrade oil (preferred oil) acceptable for use in older diesel engines and in
diesel engines that use high sulfur diesel fuel. API
• API CG-4 multigrade oil (preferred oil) CH-4 oils may be used in Caterpillar engines that
use API CG-4 and API CF-4 oils. API CH-4 oils will
• API CF-4 multigrade oil (acceptable oil) generally exceed the performance of API CG-4 oils
in the following criteria: deposits on pistons, control
In order to make the proper choice of a commercial
oil, refer to the following explanations: of oil consumption, wear of piston rings, valve train
wear, viscosity control, and corrosion.
58
Maintenance Section
Lubricant Specifications

Three new engine tests were developed for the Some commercial oils that meet the API
API CH-4 oil. The first test specifically evaluates classifications may require reduced oil change
deposits on pistons for engines with the two-piece intervals. To determine the oil change interval,
steel piston. This test (piston deposit) also measures closely monitor the condition of the oil and perform a
the control of oil consumption. A second test is wear metal analysis. Caterpillar’s S·O·S oil analysis
conducted with moderate oil soot. The second program is the preferred method.
test measures the following criteria: wear of piston
rings, wear of cylinder liners, and resistance to NOTICE
corrosion. A third new test measures the following Failure to follow these oil recommendations can cause
characteristics with high levels of soot in the oil: shortened engine service life due to deposits and/or
wear of the valve train, resistance of the oil in excessive wear.
plugging the oil filter, and control of sludge.

In addition to the new tests, API CH-4 oils have Total Base Number (TBN) and Fuel
tougher limits for viscosity control in applications
that generate high soot. The oils also have improved Sulfur Levels for Direct Injection
oxidation resistance. API CH-4 oils must pass an (DI) Diesel Engines
additional test (piston deposit) for engines that use
aluminum pistons (single piece). Oil performance is The Total Base Number (TBN) for an oil depends on
also established for engines that operate in areas the fuel sulfur level. For direct injection engines that
with high sulfur diesel fuel. use distillate fuel, the minimum TBN of the new oil
must be 10 times the fuel sulfur level. The TBN is
All of these improvements allow the API CH-4 oil defined by “ASTM D2896”. The minimum TBN of
to achieve optimum oil change intervals. API CH-4 the oil is 5 regardless of fuel sulfur level. Illustration
oils are recommended for use in extended oil 34 demonstrates the TBN.
change intervals. API CH-4 oils are recommended
for conditions that demand a premium oil. Your
Caterpillar dealer has specific guidelines for
optimizing oil change intervals.

API CG-4 – API CG-4 oils were developed primarily

for diesel engines that use a 0.05 percent level of
fuel sulfur. However, API CG-4 oils can be used
with higher sulfur fuels. The TBN of the new oil
determines the maximum fuel sulfur level for API
CG-4 and API CF-4 oils. See Illustration 34.

API CG-4 oils are the first oils that are required to
pass industry standard tests for foam control and
viscosity shear loss. API CG-4 oils must also pass
g00799818
tests that were developed for corrosion, wear and Illustration 34
oxidation. (Y) TBN by “ASTM D2896”
(X) Percentage of fuel sulfur by weight
API CF-4 – These oils service a wide variety of (1) TBN of new oil
(2) Change the oil when the TBN deteriorates to 50 percent of
modern diesel engines. API CF-4 oils provide more the original TBN.
stable oil control and reduced piston deposits in
comparison to API CF and the obsolete CE and CD Use the following guidelines for fuel sulfur levels
classifications of oil. API CF-4 oils provide improved that exceed 1.5 percent:
soot dispersancy in comparison to API CF and
obsolete CD oils. The API CF-4 classification was
developed with a 0.40 percent sulfur diesel fuel.
• Choose an oil with the highest TBN that meets
one of these classifications: EMA LRG-1, API
This represents the type of diesel fuels that are CH-4, API CG-4, and API CF-4.
commonly available worldwide.

Note: Do not use single grade API CF oils or

• Reduce the oil change interval. Base the oil
change interval on the oil analysis. Ensure that
multigrade API CF oils in Caterpillar Direct Injection the oil analysis includes the condition of the oil
(DI) Commercial Diesel Engines. and a wear metal analysis.
 59
Maintenance Section
Lubricant Specifications

Excessive piston deposits can be produced by an i01111406

oil with a high TBN. These deposits can lead to a
loss of control of the oil consumption and to the Synthetic Base Stock Oils
polishing of the cylinder bore.
SMCS Code: 1300; 1348; 7581
NOTICE Synthetic base oils are acceptable for use
Operating Direct Injection (DI) diesel engines with fuel in Caterpillar engines if these oils meet the
sulfur levels over 1.0 percent may require shortened performance requirements that are specified for the
oil change intervals in order to help maintain adequate engine compartment.
wear protection.
Synthetic base oils generally perform better than
conventional oils in the following two areas:
Lubricant Viscosity Recommendations
for Direct Injection (DI) Diesel Engines • Synthetic base oils have improved flow at low
temperatures especially in arctic conditions.
The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during • Synthetic base oils have improved oxidation
cold engine start-up, and the maximum ambient stability especially at high operating temperatures.
temperature during engine operation.
Some synthetic base oils have performance
Refer to Table 12 (minimum temperature) in order characteristics that enhance the service life of the
to determine the required oil viscosity for starting oil. However, Caterpillar does not recommend the
a cold engine. automatic extension of oil change intervals for
any type of oil. Oil change intervals for Caterpillar
Refer to Table 12 (maximum temperature) in order engines can only be adjusted after an oil analysis
to select the oil viscosity for engine operation at the program that contains the following tests: oil
highest ambient temperature that is anticipated. condition and wear metal analysis (Caterpillar’s
S·O·S oil analysis), trend analysis, fuel consumption,
Generally, use the highest oil viscosity that and oil consumption.
is available to meet the requirement for the
temperature at start-up.
i01111412
Table 12
Engine Oil Viscosity
Re-refined Base Stock Oils
Caterpillar DEO Ambient Temperature SMCS Code: 1300; 7581
Multigrade
EMA LRG-1 Re-refined base stock oils are acceptable for
API CH-4 use in Caterpillar engines if these oils meet the
API CG-4 and Minimum Maximum performance requirements that are specified by
API CF-4 Caterpillar. Re-refined base stock oils can be used
Viscosity Grade exclusively in finished oil or in a combination with
SAE 0W20 −40 C (−40 F) 10 C (50 F) new base stock oils. The US military specifications
and the specifications of other heavy equipment
SAE 0W30 −40 C (−40 F) 30 C (86 F) manufacturers also allow the use of re-refined base
SAE 0W40 −40 C (−40 F) 40 C (104 F) stock oils that meet the same criteria.
SAE 5W30 −30 C (−22 F) 30 C (86 F) The process that is used to make re-refined base
SAE 5W40 −30 C (−22 F) 40 C (104 F) stock oil should adequately remove all wear metals
that are in the used oil and all additives that are
SAE 10W30 −20 C (−4 F) 40 C (104 F) in the used oil. The process that is used to make
SAE 15W40 −15 C (5 F) 50 C (122 F)
re-refined base stock oil generally involves the
processes of vacuum distillation and hydrotreating
the used oil. Filtering is inadequate for the
production of high quality re-refined base stock oils
from used oil.
60
Maintenance Section
Lubricant Specifications

i01113213 i01123104

Cold Weather Lubricants Aftermarket Oil Additives

SMCS Code: 1300; 1348; 7581 SMCS Code: 1300; 1348; 7581

When an engine is started and an engine is Caterpillar does not recommend the use of
operated in ambient temperatures below −20 C aftermarket additives in oil. It is not necessary to
(−4 F), use multigrade oils that are capable of use aftermarket additives in order to achieve the
flowing in low temperatures. engine’s maximum service life or rated performance.
Fully formulated, finished oils consist of base oils
These oils have lubricant viscosity grades of SAE and of commercial additive packages. These
0W or SAE 5W. additive packages are blended into the base oils
at precise percentages in order to help provide
When an engine is started and operated in ambient finished oils with performance characteristics that
temperatures below −30 C (−22 F), use a synthetic meet industry standards.
base stock multigrade oil with a 0W viscosity grade
or with a 5W viscosity grade. Use an oil with a pour There are no industry standard tests that evaluate
point that is lower than −50 C (−58 F). the performance or the compatibility of aftermarket
additives in finished oil. Aftermarket additives may
The number of acceptable lubricants is limited in not be compatible with the finished oil’s additive
cold weather conditions. Caterpillar recommends package, which could lower the performance of the
the following lubricants for use in cold weather finished oil. The aftermarket additive could fail to
conditions: mix with the finished oil. This could produce sludge
in the crankcase. Caterpillar discourages the use of
First Choice – use an oil with an EMA LRG-1 aftermarket additives in finished oils.
Recommended Guideline or use a CH-4 oil that is
API licensed with an SAE 0W20, SAE 0W30, SAE To achieve the best performance from a Caterpillar
0W40, SAE 5W30, or SAE 5W40 lubricant viscosity engine, conform to the following guidelines:
grade. A CG-4 oil that is API licensed with an SAE
0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE • Select the proper Caterpillar oil or a commercial
5W40 lubricant viscosity grade may also be used. oil that meets the “EMA Recommended Guideline
A CF-4 oil that is API licensed with an SAE 0W20, on Diesel Engine Oil” or the recommended API
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 classification.
lubricant viscosity grade may also be used.
• See the appropriate “Lubricant Viscosities” table
Second Choice – use an oil that contains the CH-4, in order to find the correct oil viscosity grade for
CG-4, or CF-4 additive package although the oil your engine.
has not been tested for the requirements of the
API license. The oil must have an SAE 0W20, • At the specified interval, service the engine
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 compartment. Use new oil and install a new oil
lubricant viscosity grade. filter.

NOTICE • Perform maintenance at the intervals that are

Shortened engine service life could result if second specified in the Operation and Maintenance
choice oils are used. Manual, “Maintenance Interval Schedule”.

i01585773

Lubricating Grease
SMCS Code: 7581

Caterpillar provides greases in order to cover a

variety of applications and extreme temperature
conditions. Consult your Caterpillar dealer for part
numbers and for available sizes of containers.
 61
Maintenance Section
Lubricant Specifications

Note: Some greases may not be used with other • Increased retention
greases. When a commercial grease is used,
ensure that the grease is compatible with the • Resistance to heavy loads
grease that is currently used in the system. If the
commercial grease is not compatible, the system This product is recommended for heavily loaded pin
must be purged. If any questions arise concerning joints and for journal bearings. This product meets
the compatibility of a grease, consult the supplier. the certification of “GC-LB”. Normal operating
temperatures for this product are −28 to 149 C
(−18 to 300 F) for the NLGI No. 0 grade. Normal
Multipurpose Greases operating temperatures for this product are
−18 to 149 C (0 to 300 F) for the NLGI No. 2 grade.
Multipurpose Lithium Complex Grease
(MPGL) Note: If MPGM is not available, use a multipurpose
type grease which contains three to five percent
Multipurpose Lithium Complex Grease (MPGL) molybdenum.
is a general purpose lithium complex grease for
medium-duty applications. This product has good
characteristics at high temperatures such as a
Special Purpose Grease (SPG)
dropping point of 260 C (500 F). MPGL contains
unleaded extreme pressure additives, antiwear Bearing Lubricant (SPG)
inhibitors, and corrosion inhibitors that provide extra
protection in the following applications: Bearing Lubricant (SPG) is available in a NLGI
No. 2 grade with a polyurea thickener. This
• Construction grease is recommended for high temperature
antifriction bearings in the following applications:
• Agricultural electric starting motors, alternators, fan drives,
and generators. The Bearing Lubricant (SPG) has
• Automotive an effective operating range of −29 to 177 C
(−20 to 350 F).
MPGL meets the requirements for extended service
intervals of automotive chassis points. MPGL also Water and Temperature Resistant Grease
meets the requirements for extended service (WTR)
intervals of wheel bearings with disc brakes in
automobiles, in vans and in light trucks. This The Water and Temperature Resistant Grease is
product meets the NLGI certification of “GC-LB”. designed for use whenever the following conditions
MPGL is also available in a NLGI No. 2 grade. are a concern: water washout, severe corrosion,
Normal operating temperatures for this product are and high operating temperatures. The Water and
−28 to 149 C (−18 to 300 F). This product is also Temperature Resistant Grease provides extreme
available as a white lithium complex grease. pressure protection, antiwear protection, rust
protection and corrosion protection. The Water and
Multipurpose Lithium Complex Grease Temperature Resistant Grease is an environmentally
with Molybdenum (MPGM) friendly grease which does not contain the following
materials: antimony, sulfur, barium, zinc, lead, and
Multipurpose Lithium Complex Grease with phosphorous materials. The Water and Temperature
Molybdenum (MPGM) is a general purpose Resistant Grease has excellent shear stability. Water
lithium complex grease that is used for light-duty and Temperature Resistant Grease can also resist
applications and for medium-duty applications. The breakdown in the presence of water. The Water
MPGM is available in the following grades: NLGI and Temperature Resistant Grease works well in
No. 2 grade and NLGI No. 0 grade. The MPGM is the following applications:
strengthened with a molybdenum disulfide and a
polymer for extra lubrication and protection. MPGM • Construction
contains unleaded additives. MPGM also contains
antiwear inhibitors, rust inhibitors, and corrosion • Agricultural
inhibitors that are for protection and lubrication in
many environments. The MPGM is formulated with a • Automotive
base fluid that has high viscosity.
• Industrial
The MPGM has the following features:
• Marine
• Increased protection against water washout
62
Maintenance Section
Lubricant Specifications

This product meets the NLGI certification of i01065849

“GC-LB”. Normal operating temperatures for this
product are −40 to 204C (−40 to 400F). S·O·S Oil Analysis
SMCS Code: 1348; 7542; 7581
Caterpillar Premium Grease (CPG)
Caterpillar recommends the use of the S·O·S
Desert Gold (CPG) oil analysis program in order to monitor the
condition and the maintenance requirements of
Desert Gold is a heavy-duty, premium synthetic the equipment. The S·O·S oil analysis program will
grease that is developed for the most extreme complement the preventive maintenance program.
operating environments. This grease is formulated
with the following characteristics: high viscosity The S·O·S oil analysis is a diagnostic tool that is
synthetic base fluid, polymers, molybdenum used to determine oil performance and component
disulfide, high viscosity index, and high dropping wear rates. Contamination can be identified and
point. measured through the use of the S·O·S oil analysis.
The S·O·S oil analysis includes the following tests:
Desert Gold will protect equipment against
heavy shock loads. Desert Gold protects against • The Wear Rate Analysis monitors the wear of the
corrosion in extreme heat, in moist conditions, or engine’s metals. The amount of wear metal and
in dusty conditions. This product has excellent type of wear metal that is in the oil is analyzed.
characteristics of adhesion and of stability. The increase in the rate of engine wear metal in
Desert Gold provides longer protection than other the oil is as important as the quantity of engine
greases. Desert Gold is an environmentally friendly wear metal in the oil. For this reason, regular
grease which does not contain the following sampling at specified intervals is necessary
materials: antimony, sulfur, barium, zinc, lead, in order to establish wear rates. Intermittent
and phosphorous materials. Normal operating sampling does not allow wear rate trend lines
temperatures are −6 to 230 C (21 to 450 F). Desert to be established. Engine wear metals in the oil
Gold can operate at higher temperatures for short sample are compared to established Caterpillar
time periods. Desert Gold has additional extreme norms in order to determine acceptability.
pressure protection for highly loaded pin joints.
• Tests are conducted in order to detect
Arctic Platinum (CPG) contamination of the oil by water, glycol or fuel.

Arctic Platinum is a super-premium extreme • The Oil Condition Analysis determines the loss
pressure lubricating grease that is developed for of the oil’s lubricating properties. An infrared
lubrication in temperatures that are below zero to analysis is used to compare the properties of
moderate operating temperatures. Arctic Platinum new oil to the properties of the used oil sample.
is available in grades 000, 00, 0, 1, and 2. These This analysis allows technicians to determine
grades ensure pumpability in central lube systems in the amount of deterioration of the oil during use.
a variety of ambient temperatures from −60 to 18 C This analysis also allows technicians to verify
(−76 to 65 F). Arctic Platinum has a high dropping the performance of the oil according to the
point. Arctic Platinum contains a five percent specification during the entire oil change interval.
concentrate of molybdenum disulfide for protection
against extra heavy loads. Arctic Platinum provides The test results of the oil samples will then be used
excellent corrosion protection and rust protection. as a basis for determining the oil change interval
Arctic Platinum is an environmentally friendly grease for the engine. The results of the S·O·S oil analysis
which does not contain the following materials: may allow the engine to operate longer between oil
antimony, sulfur, barium, zinc, and phosphorous. changes without the risk of engine damage.
Table 13
Arctic Platinum is designed for long life lubrication
of the following components: horizontal pivot S·O·S Oil Analysis Interval
bearings, lower link bearings, steering cylinders,
Compartment Interval
kingbolt bearings, upper hitch link bearings, and
ejector carrier roller bearings. This grease is extra Engine crankcase Every 250 Service Hours
tacky for retention on excavator carbody bearings.
Arctic Platinum has additional extreme pressure
For more information, see Special Publication,
protection for highly loaded pin joints.
PEDP7036, “S·O·S Fluid Analysis”. Consult your
Caterpillar dealer for complete information and
assistance about the program.
 63
Maintenance Section
Fuel Specifications

Fuel Specifications (Table 14, contd)

Caterpillar Specifications for Distillate Diesel Fuel

i01196007 Specifications Requirements ASTM

Test
Fuel Recommendations 10% at 282 C (540 F) “D86”
maximum
SMCS Code: 1250; 1280 Distillation
90% at 360 C (680 F)
Diesel engines have the ability to burn a wide maximum
variety of fuels. These fuels are divided into two Flash Point legal limit “D93”
general groups. The two groups are called the
preferred fuels and the permissible fuels. 30 minimum “D287”
API Gravity
45 maximum
The preferred fuels provide maximum engine
service life and performance. The preferred fuels 6 C (10 F) minimum “D97”
are distillate fuels. These fuels are commonly called Pour Point below ambient
diesel fuel, furnace fuel, gas oil, or kerosene. temperature
3% maximum “D3605”
The permissible fuels are crude oils or blended Sulfur (1) or
fuels. Use of these fuels can result in higher “D1552”
maintenance costs and in reduced engine service
1.4 cSt minimum and 20.0 “D445”
life. Kinematic
cSt maximum at 40 C
Viscosity (2)
(104 F)
Diesel fuels that meet the specifications in Table 14
will help to provide maximum engine service life Water and 0.1% maximum “D1796”
and performance. In North America, diesel fuel that Sediment
is identified as No. 1-D or No. 2-D in “ASTM D975” Water 0.1% maximum “D1744”
generally meet the specifications. Table 14 is for
diesel fuels that are distilled from crude oil. Diesel Sediment 0.05% maximum (weight) “D473”
fuels from other sources could exhibit detrimental Gums and 10 mg per 100 mL “D381”
properties that are not defined or controlled by this Resins (3) maximum
specification.
3100 g minimum “D6078”
Table 14
0.45 mm (0.018 inch)
Caterpillar Specifications for Distillate Diesel Fuel (4) maximum at 60 C
Lubricity
(140 F) “D6079”
Specifications Requirements ASTM
Test 0.38 mm (0.015 inch)
maximum at 25 C (77 F)
Aromatics 35% maximum “D1319”
(1) Caterpillar fuel systems and engine components can
Ash 0.02% maximum (weight) “D482” operate on high sulfur fuels. Fuel sulfur levels affect exhaust
emissions. High sulfur fuels also increase the potential for
Carbon 0.35% maximum (weight) “D524” corrosion of internal components. Fuel sulfur levels above 1.0
Residue on percent may significantly shorten the oil change interval. For
10% Bottoms additional information, see this publication, “Engine Oil” topic
(Maintenance Section).
40 minimum (DI engines) “D613” (2) The values of the fuel viscosity are the values as the fuel
Cetane Number is delivered to the fuel injection pumps. If a fuel with a low
35 minimum (PC engines) viscosity is used, cooling of the fuel may be required to maintain
- a 1.4 cSt viscosity at the fuel injection pump. Fuels with a high
The cloud point must
viscosity might require fuel heaters in order to bring down the
not exceed the lowest viscosity to a 20 cSt viscosity. For additional information, see
Cloud Point
expected ambient Special Publication, SEBD0717, “Diesel Fuel and Your Engine”.
temperature. (3) Follow the test conditions and procedures for gasoline (motor).
(4) The lubricity of a fuel is a concern with low sulfur fuel. To
Copper Strip No. 3 maximum “D130”
determine the lubricity of the fuel, use either the “ASTM D6078
Corrosion Scuffing Load Wear Test (SBOCLE)” or the “ASTM D6079 High
(continued) Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a
fuel does not meet the minimum requirements, consult your
fuel supplier. Do not treat the fuel without consulting the fuel
supplier. Some additives are not compatible. These additives
can cause problems in the fuel system.
64
Maintenance Section
Fuel Specifications

There are many other diesel fuel specifications that

NOTICE are published by governments and by technological
Operating with fuels that do not meet Caterpillar’s rec- societies. Usually, those specifications do not
ommendations can cause the following effects: start- review all the requirements that are addressed
ing difficulty, poor combustion, deposits in the fuel in- in this specification. To ensure optimum engine
jectors, reduced service life of the fuel system, de- performance, a complete fuel analysis should be
posits in the combustion chamber, and reduced ser- obtained before engine operation. The fuel analysis
vice life of the engine. should include all of the properties that are listed
in Table 14.
In the USA, 0.05 percent diesel fuels have been
used in all on-highway truck engines since 1
January 1994. This low sulfur diesel fuel was
mandated as a means of directly reducing
particulate emissions from diesel truck engines.
This low sulfur fuel will also be used in Caterpillar
commercial diesel engines when low emissions are
required or when the fuel supply sources provide
this type of fuel. Caterpillar has not seen any
detrimental effects with 0.05 percent sulfur fuel in
Caterpillar diesel engines.

NOTICE
Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel
must NOT be used in Caterpillar diesel engines (ex-
cept in 3600 Series HFO engines). Severe component
wear and component failures will result if HFO type fu-
els are used in engines that are configured to use dis-
tillate fuel.

In extreme cold ambient conditions, you may

use the distillate fuels that are specified in Table
15. However, the fuel that is selected must meet
the requirements that are specified in Table 14.
These fuels are intended to be used in operating
temperatures that are down to −54 C (−65 F).
Table 15
Distillate Fuels (1)

Specification Grade
“MIL-T-5624R” JP-5
“ASTM D1655” Jet-A-1
“MIL-T-83133D” JP-8
(1) The fuels that are listed in this Table may not meet the
requirements that are specified in the “Caterpillar Specifications
for Distillate Diesel Fuel” Table. Consult the supplier for the
recommended additives in order to maintain the proper fuel
lubricity.

These fuels are lighter than the No. 2 grades of fuel.

The cetane number of the fuels in Table 15 must be
at least 40. If the viscosity is below 1.4 cSt at 38 C
(100 F), use the fuel only in temperatures below
0 C (32 F). Do not use any fuels with a viscosity
of less than 1.2 cSt at 38 C (100 F). Fuel cooling
may be required in order to maintain the minimum
viscosity of 1.4 cSt at the fuel injection pump.
 65
Maintenance Section
Cooling System Specifications

Cooling System Many engine failures are related to the cooling

system. The following problems are related to
Specifications cooling system failures: overheating, leakage of the
water pump, plugged radiators or heat exchangers,
and pitting of the cylinder liners.
i01646523
These failures can be avoided with proper cooling
General Coolant Information system maintenance. Cooling system maintenance
is as important as maintenance of the fuel system
SMCS Code: 1350; 1395 and the lubrication system. Quality of the coolant
is as important as the quality of the fuel and the
NOTICE lubricating oil.
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first. Coolant is normally composed of three elements:
water, additives, and glycol.

NOTICE
If the engine is to be stored in, or shipped to an area Water
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temper- NOTICE
ature or drained completely to prevent damage. All Caterpillar diesel engines equipped with air-to-air
aftercooling (ATAAC) require a minimum of 30 percent
glycol to prevent water pump cavitation.
NOTICE
Frequently check the specific gravity of the coolant for
proper freeze protection or for anti-boil protection. NOTICE
Never use water alone without Supplemental Coolant
Additives (SCA) or without inhibited coolant. Water
Clean the cooling system for the following reasons: alone is corrosive at engine operating temperatures.
Water alone does not provide adequate protection
• Contamination of the cooling system against boiling or freezing.

• Overheating of the engine

Water is used in the cooling system in order to
• Foaming of the coolant transfer heat.

Note: Air pockets can form in the cooling system if Distilled water or deionized water is
the cooling system is filled at a rate that is greater recommended for use in engine cooling systems.
than 20 L (5 US gal) per minute.
DO NOT use the following types of water in cooling
After you drain the cooling system and after you systems: hard water, softened water that has been
refill the cooling system, operate the engine. conditioned with salt, and sea water.
Operate the engine without the filler cap until the
coolant reaches normal operating temperature and If distilled water or deionized water is not available,
the coolant level stabilizes. Ensure that the coolant use water with the properties that are listed in Table
is maintained to the proper level. 16.

NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.

Refer to Special Instruction, SEBD0518, “Know

Your Cooling System” and Special Instruction,
SEBD0970, “Coolant and Your Engine” for more
detailed information.
66
Maintenance Section
Cooling System Specifications

Table 16 • Formation of gel compounds

Caterpillar Minimum Acceptable Water Requirements
• Reduction of heat transfer
Property Maximum Limit ASTM Test
40 mg/L “D512”, • Leakage of the water pump seal
Chloride (Cl)
(2.4 grains/US gal) “D4327”
• Plugging of radiators, coolers, and small
100 mg/L passages
Sulfate (SO4) “D516”
(5.9 grains/US gal)

Total Hardness
170 mg/L
“D1126” Glycol
(10 grains/US gal)
340 mg/L Glycol in the coolant helps to provide protection
Total Solids “D1888” against the following conditions:
(20 grain/US gal)
Acidity pH of 5.5 to 9.0 “D1293” • Boiling
For a water analysis, consult one of the following • Freezing
sources:
For optimum performance, Caterpillar recommends
• Caterpillar dealer a 1:1 mixture of a water/glycol solution.

• Local water utility company Note: Use a mixture that will provide protection
against the lowest ambient temperature.
• Agricultural agent
Note: 100 percent pure glycol will freeze at a
• Independent laboratory temperature of −23 C (−9 F).

Most conventional heavy-duty coolant/antifreezes

Additives use ethylene glycol. Propylene glycol may also be
used. In a 1:1 mixture with water, ethylene and
Additives help to protect the metal surfaces of propylene glycol provide similar protection against
the cooling system. A lack of coolant additives freezing and boiling. See Tables 17 and 18.
or insufficient amounts of additives enable the
following conditions to occur: Table 17
Ethylene Glycol
• Corrosion
Freeze Boil
Concentration
• Formation of mineral deposits Protection Protection
50 Percent −36 C (−33 F) 106 C (223 F)
• Rust
60 Percent −51 C (−60 F) 111 C (232 F)
• Scale
• Pitting and erosion from cavitation of the cylinder NOTICE
liner Do not use propylene glycol in concentrations that ex-
ceed 50 percent glycol because of propylene glycol’s
• Foaming of the coolant reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against
Many additives are depleted during engine boiling or freezing.
operation. These additives must be replaced
periodically. This can be done by adding
Supplemental Coolant Additives (SCA) to Diesel
Engine Antifreeze/Coolant (DEAC) or by adding
ELC Extender to Extended Life Coolant (ELC).

Additives must be added at the proper

concentration. Overconcentration of additives can
cause the inhibitors to drop out-of-solution. The
deposits can enable the following problems to
occur:
 67
Maintenance Section
Cooling System Specifications

Table 18
Propylene Glycol NOTICE
All Caterpillar diesel engines equipped with air-to-air
Freeze Boil aftercooling (ATAAC) require a minimum of 30 percent
Concentration
Protection Protection glycol to prevent water pump cavitation.
50 Percent −29 C (−20 F) 106 C (223 F)
Table 19
To check the concentration of glycol, use the Coolant Service Life
1U-7298 Coolant/Battery Tester (Degree Celsius)
or use the 1U-7297 Coolant/Battery Tester (Degree Coolant Type Service Life
Fahrenheit). The testers give readings that are 6000 Service Hours or
immediate and accurate. The testers can be used Caterpillar ELC
Six Years
with ethylene or propylene glycol.
3000 Service Hours or
Caterpillar DEAC
Three Years
i01096597
Commercial Heavy-Duty
3000 Service Hours or
Coolant Recommendations Coolant/Antifreeze that
meets “ASTM D5345”
Two Years

SMCS Code: 1350; 1395 Commercial Heavy-Duty

3000 Service Hours or
Coolant/Antifreeze that
One Year
The following two coolants are used in Caterpillar meets “ASTM D4985”
diesel engines: Caterpillar SCA and 3000 Service Hours or
Water Two Years
Preferred – Caterpillar Extended Life Coolant (ELC)
or a commercial extended life coolant that meets Commercial SCA and 3000 Service Hours or
the Caterpillar EC-1 specification Water One Year

Acceptable – A Caterpillar Diesel Engine

Antifreeze/Coolant (DEAC) or a commercial i01200209
heavy-duty coolant/antifreeze that meets “ASTM
D4985” or “ASTM D5345” specifications
S·O·S Coolant Analysis
SMCS Code: 1352; 1395; 7542
NOTICE
Do not use a commercial coolant/antifreeze that only Testing the engine coolant is important to ensure
meets the ASTM D3306 or D4656 specification. This that the engine is protected from internal cavitation
type of coolant/antifreeze is made for light duty auto- and from corrosion. The analysis also tests the
motive applications. ability of the coolant to protect the engine from
boiling and from freezing. The S·O·S Coolant
Analysis can be done at your Caterpillar dealer.
Caterpillar recommends a 1:1 mixture of water
Caterpillar S·O·S Coolant Analysis is the best
and glycol. This mixture of water and glycol will
way to monitor the condition of your coolant and
provide optimum heavy-duty performance as a
your cooling system. S·O·S Coolant Analysis is a
coolant/antifreeze.
program that is based on periodic samples.
Note: Caterpillar DEAC DOES NOT require a
treatment with an SCA at the initial fill. Commercial NOTICE
heavy-duty coolant/antifreeze that meets “ASTM Do not use the same vacuum sampling pump for ex-
D4985” or “ASTM D5345” specifications MAY tracting oil samples that is used for extracting coolant
require a treatment with an SCA at the initial fill. samples.
Read the label or the instructions that are provided
by the OEM of the product. A small residue of either type sample may remain in
the pump and may cause a false positive analysis for
In stationary engine applications and marine engine the sample being taken.
applications that do not require anti-boil protection
or freeze protection, a mixture of SCA and water is Always use a designated pump for oil sampling and a
acceptable. Caterpillar recommends a six percent designated pump for coolant sampling.
to eight percent concentration of SCA in those
cooling systems. Distilled water or deionized water Failure to do so may cause a false analysis which
is preferred. Water which has the recommended could lead to customer and dealer concerns.
properties may be used.
68
Maintenance Section
Cooling System Specifications

New Systems, Refilled Systems, • Identification of buildup of the impurities that

cause corrosion
and Converted Systems
Perform a coolant analysis (Level 2) at 500 service • Identification of buildup of the impurities that
cause scaling
hours for new systems, for refilled systems, or for
converted systems that use ELC or use DEAC. This
500 hour check will also check for any residual • Determination of possible electrolysis within the
engines’ cooling system
cleaner that may have contaminated the system.
The results are reported, and appropriate
Recommended Interval for S·O·S recommendations are made.
Coolant Sample For more information on S·O·S Coolant Analysis,
Perform a coolant analysis (Level 1) at every 500 consult your Caterpillar dealer.
service hour interval. Perform a coolant analysis
(Level 2) annually. i01096605

Note: Check the standard coolant’s Supplemental Extended Life Coolant (ELC)
Coolant Additive at every oil change.
SMCS Code: 1350; 1395
S·O·S Coolant Analysis (Level 1) Caterpillar provides Extended Life Coolant (ELC) for
use in the following applications:
A coolant analysis (Level 1) is a test of the
properties of the coolant.
• Heavy-duty spark ignited gas engines
The following properties of the coolant are tested:
• Heavy-duty diesel engines
• Glycol Concentration for freeze protection • Automotive applications
• Ability to protect from erosion and corrosion The anti-corrosion package for Caterpillar ELC is
different from the anti-corrosion package for other
• pH coolants. Caterpillar ELC is an ethylene glycol
base coolant. However, Caterpillar ELC contains
• Conductivity organic corrosion inhibitors and antifoam agents
with low amounts of nitrite. Caterpillar ELC has
• Water hardness been formulated with the correct amount of these
additives in order to provide superior corrosion
• Visual analysis protection for all metals in engine cooling systems.
• Odor analysis ELC extends the service life of the coolant to 6000
service hours or six years. ELC does not require
The results are reported, and appropriate
a frequent addition of a Supplemental Coolant
recommendations are made.
Additive (SCA). An Extender is the only additional
maintenance that is needed at 3000 service hours
S·O·S Coolant Analysis (Level 2) or one half of the ELC service life.

Level 2 coolant analysis is a comprehensive ELC is available in a 1:1 premixed cooling solution
chemical evaluation of the coolant. This analysis is with distilled water. The Premixed ELC provides
also a check of the overall condition of the inside of freeze protection to −36 C (−33 F). The Premixed
the cooling system. ELC is recommended for the initial fill of the cooling
system. The Premixed ELC is also recommended
The S·O·S Coolant Analysis has the following five for topping off the cooling system.
features:
ELC Concentrate is also available. ELC Concentrate
• Full analysis of Level 1 can be used to lower the freezing point to −51 C
(−60 F) for arctic conditions.
• Identification of the source of metal corrosion and
of contaminants Containers of several sizes are available. Consult
your Caterpillar dealer for the part numbers.
 69
Maintenance Section
Cooling System Specifications

Note: Caterpillar developed the EC-1 specification. Caterpillar ELC Extender

The EC-1 specification is an industry standard. The
EC-1 specification defines all of the performance Caterpillar ELC Extender is added to the cooling
requirements that are needed for an engine coolant system halfway through the ELC service life. Treat
to be sold as an extended life coolant for Caterpillar the cooling system with ELC Extender at 3000 hours
engines. ELC can be used in most OEM engines of or one half of the coolant service life. Use Table 20
the following types: diesel, gasoline, and natural in order to determine the proper amount of ELC
gas. ELC meets the performance requirements of Extender that is required.
“ASTM D4985” and “ASTM D5345” for heavy-duty
low silicate antifreeze/coolants. ELC also meets the Containers of several sizes are available. Consult
performance requirements of “ASTM D3306” and your Caterpillar dealer for the part numbers.
“ASTM D4656” for automotive applications.
Table 20

i01111712
Caterpillar ELC Extender Additions by
Cooling System Capacity
Extended Life Coolant (ELC) Addition of ELC
Cooling System Capacity
Cooling System Maintenance Extender
22 to 30 L (6 to 8 US gal) 0.57 L (20 fl oz)
SMCS Code: 1350; 1352; 1395
31 to 38 L (9 to 10 US gal) 0.71 L (24 fl oz)

Proper additions to the Extended 39 to 49 L (11 to 13 US gal) 0.95 L (32 fl oz)

Life Coolant 50 to 64 L (14 to 17 US gal) 1.18 L (40 fl oz)

65 to 83 L (18 to 22 US gal) 1.60 L (54 fl oz)
NOTICE
Use only Caterpillar products or commercial products 84 to 114 L (23 to 30 US gal) 2.15 L (72 fl oz)
that have passed Caterpillar’s EC-1 specification for 115 to 163 L (31 to 43 US gal) 3.00 L (100 fl oz)
pre-mixed or concentrated coolants.
164 to 242 L (44 to 64 US gal) 4.40 L (148 fl oz)
Use only Caterpillar Extender with Extended Life
Coolant. For cooling system capacities that exceed the
capacities that are specified in Table 20, use the
Mixing Extended Life Coolant with other products re- equation that is in Table 21 in order to determine
duces the Extended Life Coolant service life. Failure to the proper amount of ELC Extender that is required.
follow the recommendations can reduce cooling sys-
tem components life unless appropriate corrective ac- Table 21
tion is performed. Equation For Adding ELC Extender To ELC
V × 0.02 = X
In order to maintain the correct balance between
the antifreeze and the additives, you must maintain V is the total volume of the cooling system.
the recommended concentration of Extended Life X is the amount of ELC Extender that is required.
Coolant (ELC). Lowering the proportion of antifreeze
lowers the proportion of additive. This will lower
the ability of the coolant to protect the system from Table 22 is an example for using the equation that
pitting, from cavitation, from erosion, and from is in Table 21.
deposits.
Table 22

NOTICE Example Of The Equation For Adding ELC

Extender To ELC
Do not use a conventional coolant to top-off a cooling
system that is filled with Extended Life Coolant (ELC). Total Volume Multiplication Amount of ELC
of the Cooling Factor Extender that is
Do not use standard supplemental coolant additive System (V) Required (X)
(SCA). Only use ELC Extender in cooling systems that 946 L × 0.02 19 L
are filled with ELC. (250 US gal) (5 US gal)
70
Maintenance Section
Cooling System Specifications

NOTICE NOTICE
When using Caterpillar ELC, do not use standard Do not leave an empty SCA filter on an ELC system.
SCA’s or SCA filters. To avoid SCA contamination of
an ELC system, remove the SCA filter base and plug The filter housing may corrode and leak causing an
off or by-pass the coolant lines. engine failure.

Remove the SCA filter base and plug off or by-pass

ELC Cooling System Cleaning the coolant lines.

Note: If the cooling system is already using ELC, 3. Remove the empty SCA filter and remove the
cleaning agents are not required to be used at filter base. Plug the coolant lines or bypass the
the specified coolant change interval. Cleaning coolant lines.
agents are only required if the system has been
contaminated by the addition of some other type of 4. Flush the system with clean water in order to
coolant or by cooling system damage. remove any debris.
Clean water is the only cleaning agent that is 5. Use Caterpillar cleaner to clean the system.
required when ELC is drained from the cooling Follow the instruction on the label.
system.
6. Drain the cleaner into a suitable container. Flush
ELC can be recycled. The drained coolant mixture the cooling system with clean water.
can be distilled in order to remove the ethylene
glycol and the water. The ethylene glycol and the 7. Fill the cooling system with clean water and
water can be reused. Consult your Caterpillar dealer operate the engine until the engine is warmed to
for more information. 49 to 66C (120 to 150F).
After the cooling system is drained and after the
cooling system is refilled, operate the engine while NOTICE
the cooling system filler cap is removed. Operate Improper or incomplete rinsing of the cooling system
the engine until the coolant level reaches the normal can result in damage to copper and other metal com-
operating temperature and until the coolant level ponents.
stabilizes. As needed, add the coolant mixture in
order to fill the system to the proper level. To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
Changing to Caterpillar ELC cleaning agent are gone.
To change from heavy-duty coolant/antifreeze to the
Caterpillar ELC, perform the following steps: 8. Drain the cooling system into a suitable container
and flush the cooling system with clean water.
NOTICE
Note: The cooling system cleaner must be
Care must be taken to ensure that fluids are contained
thoroughly flushed from the cooling system. Cooling
during performance of inspection, maintenance, test-
system cleaner that is left in the system will
ing, adjusting and repair of the product. Be prepared to
contaminate the coolant. The cleaner may also
collect the fluid with suitable containers before open-
corrode the cooling system.
ing any compartment or disassembling any compo-
nent containing fluids.
9. Repeat Steps 7 and 8 until the system is
completely clean.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
10. Fill the cooling system with the Caterpillar
suitable to collect and contain fluids on Caterpillar
premixed ELC.
products.
11. Attach the Special Publication, PEEP5027,
Dispose of all fluids according to local regulations and
“Label” to the cooling system filler for the engine
mandates.
in order to indicate the use of Caterpillar ELC.

1. Drain the coolant into a suitable container.

2. Dispose of the coolant according to local

regulations.
 71
Maintenance Section
Cooling System Specifications

ELC Cooling System i01111753

Contamination Diesel Engine Antifreeze/

NOTICE
Coolant (DEAC)
Mixing ELC with other products reduces the effective-
SMCS Code: 1350; 1395
ness of the ELC and shortens the ELC service life.
Use only Caterpillar products or commercial products
Caterpillar recommends using Caterpillar
that have passed the Caterpillar EC-1 specification for
Diesel Engine Antifreeze/Coolant (DEAC) for
premixed or concentrate coolants. Use only Caterpillar
cooling systems that require a heavy-duty
ELC Extender with Caterpillar ELC. Failure to follow
coolant/antifreeze. Caterpillar DEAC is an alkaline
these recommendations can result in shortened cool-
single-phase ethylene glycol type antifreeze that
ing system component life.
contains corrosion inhibitors and antifoam agents.

ELC cooling systems can withstand contamination Caterpillar DEAC is formulated with the correct
to a maximum of ten percent of conventional amount of Caterpillar Supplemental Coolant Additive
heavy-duty coolant/antifreeze or SCA. If the (SCA). Do no use SCA at the initial fill when DEAC
contamination exceeds ten percent of the total is used.
system capacity, perform ONE of the following
procedures: Containers of several sizes are available. Consult
your Caterpillar dealer for the part numbers.
• Drain the cooling system into a suitable container.
Dispose of the coolant according to local If concentrated DEAC is used, Caterpillar
regulations. Flush the system with clean water. Fill recommends mixing the concentrate with distilled
the system with the Caterpillar ELC. water or with deionized water. If distilled water is
not available or deionized water is not available,
• Drain a portion of the cooling system into a use water which has the required properties. For
suitable container according to local regulations. the water properties, see this publication, “General
Then, fill the cooling system with premixed ELC. Coolant Information” topic (Maintenance Section).
This should lower the contamination to less than
10 percent.
i01069295

• Maintain the system as a conventional Diesel

Engine Antifreeze/Coolant (DEAC). Treat the
Supplemental Coolant Additive
system with an SCA. Change the coolant at the (SCA)
interval that is recommended for the conventional
Diesel Engine Antifreeze/Coolant (DEAC). SMCS Code: 1350; 1352; 1395

The use of SCA helps to prevent the following

Commercial ELC conditions from occurring:
If Caterpillar ELC is not used, then select a
commercial ELC that meets the Caterpillar
• Corrosion
specification of EC-1 and either the “ASTM D5345”
specification or the “ASTM D4985” specification. Do
• Formation of mineral deposits
not use an extended life coolant that does not meet
the EC-1 specification. Follow the maintenance
• Cavitation erosion of the cylinder liners
guide for the coolant from the supplier of the
commercial ELC. Follow the Caterpillar guidelines
• Foaming of the coolant
for the quality of water and the specified coolant Caterpillar Diesel Engine Antifreeze/Coolant (DEAC)
change interval. is formulated with the correct level of Caterpillar
SCA. When the cooling system is initially filled with
DEAC, adding more SCA is not necessary until the
concentration of SCA has been depleted. To ensure
that the correct amount of SCA is in the cooling
system, the concentration of SCA must be tested
on a scheduled basis. Refer to the specific engine’s
Operation and Maintenance Manual, “Maintenance
Interval Schedule”.
72
Maintenance Section
Cooling System Specifications

Containers of SCA are available in several sizes.

Consult your Caterpillar dealer for the part numbers. NOTICE
Never use water alone without Supplemental Coolant
Additives (SCA) or without inhibited coolant. Water
i01164588
alone is corrosive at engine operating temperatures.
Commercial Heavy-Duty Water alone does not provide adequate protection
against boiling or freezing.
Coolant/Antifreeze and SCA
SMCS Code: 1350; 1395 Note: Premix the coolant solution in order to provide
protection to the lowest ambient temperature that
If Caterpillar DEAC is not used, select a is expected.
coolant/antifreeze with low silicate content for
heavy-duty applications that meets “ASTM D5345” Note: Pure undiluted antifreeze freezes at −23 C
or “ASTM D4985” specifications. (−9 F).

Note: When you are not using Caterpillar DEAC the In engine cooling systems that use water alone,
cooling system must be drained one time during Caterpillar recommends the use of SCA. SCA helps
every year. The cooling system must be flushed at to prevent the following conditions from occurring:
this time as well.
• Corrosion
When a heavy-duty coolant/antifreeze is used,
treat the cooling system with three to six • Formation of mineral deposits
percent Caterpillar SCA by volume. For more
information, see this publication, “Conventional • Cavitation erosion of the cylinder liner
Coolant/Antifreeze Cooling System Maintenance”
topic (Maintenance Section). • Foaming of the coolant
If Caterpillar SCA is not used, select a commercial If Caterpillar SCA is not used, select a commercial
SCA. The commercial SCA must provide a minimum SCA. The commercial SCA must provide a minimum
of 1200 mg/L or 1200 ppm (70 grains/US gal) of of 2400 mg/L or 2400 ppm (140 grains/US gal) of
nitrites in the final coolant mixture. nitrites in the final coolant mixture.

Coolant/antifreeze that meets “ASTM D5345” or The quality of the water is a very important factor
“ASTM D4985” specifications MAY require treatment in this type of cooling system. Distilled water
with SCA at the initial fill. These coolants WILL or deionized water is recommended for use in
require treatment with SCA on a maintenance basis. cooling systems. If distilled water or deionized
water is not available, use water that meets the
When concentrated coolant/antifreeze is mixed, minimum requirements that are listed in the table for
Caterpillar recommends mixing the concentrate with recommended water properties in this publication,
distilled water or with deionized water. If distilled “General Coolant Information” topic (Maintenance
water or deionized water is not available, water Section).
which has the required properties may be used. For
the water properties, see this publication, “General A cooling system that uses a mixture of SCA
Coolant Information” topic (Maintenance Section). and water only needs more SCA than a cooling
system that uses a mixture of glycol and water. The
SCA concentration in a cooling system that uses
i01318169 SCA and water should be six to eight percent by
volume. Refer to Table 23 for the amount of SCA
Water/Supplemental Coolant that is required for various capacities of the cooling
Additive (SCA) system.

SMCS Code: 1350; 1352; 1395

NOTICE
All Caterpillar diesel engines equipped with air-to-air
aftercooling (ATAAC) require a minimum of 30 percent
glycol to prevent water pump cavitation.
 73
Maintenance Section
Cooling System Specifications

Table 23 Cooling Systems with Larger

Caterpillar SCA Requirements for SCA and Capacities
Water Cooling Systems
Cooling System Caterpillar SCA Caterpillar SCA Adding the SCA to Water at the Initial Fill
Capacity at Initial Fill at 250 Hours
Use the equation that is in Table 25 to determine
22 to 30 L
(6 to 8 US gal)
1.75 L (64 fl oz) 0.44 L (15 fl oz) the amount of Caterpillar SCA that is required at
the initial fill. This equation is for a mixture of only
31 to 38 L
2.30 L (80 fl oz) 0.57 L (20 fl oz) SCA and water.
(9 to 10 US gal)
Table 25
39 to 49 L
3.00 L (100 fl oz) 0.75 L (25 fl oz)
(11 to 13 US gal) Equation For Adding The SCA To Water
At The Initial Fill
50 to 64 L
3.90 L (128 fl oz) 0.95 L (32 fl oz) V × 0.07 = X
(14 to 17 US gal)
65 to 83 L V is the total volume of the cooling system.
5.00 L (168 fl oz) 1.25 L (42 fl oz)
(18 to 22 US gal)
X is the amount of SCA that is required.
84 to 110 L
6.60 L (224 fl oz) 1.65 L (56 fl oz)
(23 to 29 US gal)
Table 26 is an example for using the equation that
111 to 145 L is in Table 25.
8.75 L (296 fl oz) 2.19 L (74 fl oz)
(30 to 38 US gal)
Table 26
146 to 190 L 11.50 L
2.88 L (98 fl oz)
(39 to 50 US gal) (392 fl oz) Example Of The Equation For Adding The SCA
To Water At The Initial Fill
191 to 250 L 15.00 L
3.75 L (128 fl oz)
(51 to 66 US gal) (512 fl oz) Total Volume Multiplication Amount of SCA
of the Cooling Factor that is Required
System (V) (X)
Refer to Table 24 for part numbers and for quantities
of SCA. 946 L × 0.07 66 L
(250 US gal) (18 US gal)
Table 24
Caterpillar Liquid SCA Adding the SCA to Water for Maintenance
Part Number Quantity
For the recommended service interval, refer to the
6V-3542 0.24 L (8 oz) Operation and Maintenance Manual, “Maintenance
111-2372 0.36 L (12 oz) Interval Schedule” for your engine.
8T-1589 0.47 L (16 oz) Use the 8T-5296 Coolant Conditioner Test Kit to
3P-2044 0.94 L (32 oz) test the concentration of SCA. Make the following
modifications to Steps 3 and 5 of the 8T-5296
8C-3680 19 L (5 US gal) Coolant Conditioner Test Kit instructions:
5P-2907 208 L (55 US gal)
STEP 3 – Add tap water to the vial up to the “20
ml” mark.
Maintain the SCA in the same way as you would
maintain a cooling system that uses heavy-duty STEP 5 – When the defined procedure is used,
coolant/antifreeze. Adjust the maintenance for the a concentration of six to eight percent will yield
amount of SCA additions. See Table 23 for the between 20 drops and 27 drops. If the number of
amount of SCA that is required. drops is below 20 drops, the concentration of SCA
is low. If the number of drops is above 27 drops, the
concentration of SCA is high. Make the appropriate
adjustments to the concentration of SCA.

Test the concentration of SCA or submit a

coolant sample to your Caterpillar dealer. See
this publication, “S·O·S Coolant Analysis” topic
(Maintenance Section).
74
Maintenance Section
Cooling System Specifications

Additions of SCA are based on the results of the Check the coolant/antifreeze (glycol concentration)
test or based on the results of the coolant analysis. in order to ensure adequate protection against
The size of the cooling system determines the boiling or freezing. Caterpillar recommends the
amount of SCA that is required. use of a refractometer for checking the glycol
concentration. Use the 1U-7298 Coolant/Battery
Use the equation that is in Table 25 to determine Tester (Degree Celsius) or use the 1U-7297
the amount of Caterpillar SCA that is required for Coolant/Battery Tester (Degree Fahrenheit). The
maintenance, if necessary: testers give readings that are immediate and
accurate. The testers can be used with ethylene
Table 27 or with propylene glycol.
SCA To Water Addition Equation For Maintenance
Caterpillar engine cooling systems should be
V × 0.023 = X tested at 250 hour intervals for the concentration of
V is the total volume of the cooling system. Supplemental Coolant Additive (SCA). SCA test kits
are available from your Caterpillar dealer. Test the
X is the amount of SCA that is required. concentration of SCA or submit a coolant sample to
your Caterpillar dealer at 250 hour intervals. Refer
Table 28 is an example for using the equation that to S·O·S Coolant Analysis for more information on
is in Table 25. this topic.

Table 28 Additions of SCA are based on the results of the

test or based on the results of the coolant analysis.
SCA To Water Addition Equation Example
For Maintenance An SCA that is liquid or a maintenance element for
an SCA (if equipped) may be needed at 250 hour
Total Volume Multiplication Amount of SCA intervals.
of the Cooling Factor that is Required
System (V) (X) Table 29 lists the amount of Caterpillar SCA
946 L × 0.023 22 L that is needed at the initial fill in order to treat
(250 US gal) (6 US gal) coolant/antifreeze. These amounts of SCA are for
systems that use heavy-duty coolant/antifreeze.
Note: Specific engine applications may require Table 29 also lists additions of SCA for liquid
maintenance practices to be periodically evaluated and for maintenance elements at 250 hours. The
in order to properly maintain the engine’s cooling additions are required for Caterpillar DEAC and for
system. commercial coolant/antifreezes.
Table 24 lists part numbers and quantities of SCA
that is available from your Caterpillar dealer.

i01570193

Conventional Coolant/
Antifreeze Cooling System
Maintenance
SMCS Code: 1350; 1352; 1395

NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.
 75
Maintenance Section
Cooling System Specifications

Table 29
Caterpillar SCA Requirements for Heavy-Duty Coolant/Antifreeze
Spin-on
250 Service Element at 250
Cooling System
Initial Fill(1) Hour Service Hour
Capacity
Maintenance(2) Maintenance
(If Equipped)(3)
22 to 30 L
0.95 L (32 fl oz) 0.24 L (8 fl oz) 111-2370 (1)
(6 to 8 US gal)
31 to 38 L
1.18 L (40 fl oz) 0.36 L (12 fl oz) 111-2369 (1)
(9 to 10 US gal)
39 to 49 L
1.42 L (48 fl oz) 0.36 L (12 fl oz) 111-2369 (1)
(11 to 13 US gal)
50 to 64 L
1.90 L (64 fl oz) 0.47 L (16 fl oz) 9N-3368 (1)
(14 to 17 US gal)
65 to 83 L
2.37 L (80 fl oz) 0.60 L (20 fl oz) 111-2371 (1)
(18 to 22 US gal)
84 to 114 L
3.32 L (112 fl oz) 0.95 L (32 fl oz) 9N-3718 (1)
(23 to 30 US gal)
115 to 163 L
4.75 L (160 fl oz) 1.18 L (40 fl oz) 111-2371 (2)
(31 to 43 US gal)
164 to 242 L
7.60 L (256 fl oz) 1.90 L (64 fl oz) 9N-3718 (2)
(44 to 64 US gal)
(1) When the coolant system is first filled, the SCA is not required to be used with
Caterpillar DEAC.
(2) Do not exceed the six percent maximum concentration. Check the concentration
of SCA with a SCA test kit.
(3) Do not use the maintenance element for the SCA and the liquid for the SCA at the
same time.

Note: Specific engine applications may require Cooling Systems with Larger
maintenance practices to be periodically evaluated
in order to properly maintain the engine’s cooling
Capacities
system.
Adding the SCA to Conventional
Refer to Table 30 for part numbers and for quantities Coolant/Antifreeze at the Initial Fill
of SCA.
Note: Caterpillar DEAC DOES NOT require an
Table 30 addition of SCA when the cooling system is initially
Caterpillar Liquid SCA filled.
Part Number Quantity Commercial heavy-duty coolant/antifreeze
6V-3542 0.24 L (8 oz) that meets “ASTM D4985” or “ASTM D5345”
specifications MAY require an addition of SCA at
111-2372 0.36 L (12 oz) the initial fill. Read the label or the instructions that
8T-1589 0.47 L (16 oz) are provided by the OEM of the product.

3P-2044 0.94 L (32 oz) Use the equation that is in Table 31 to determine
8C-3680 19 L (5 US gal) the amount of Caterpillar SCA that is required when
the cooling system is initially filled with the following
5P-2907 208 L (55 US gal) fluids:

• “ASTM D4985”
• “ASTM D5345”
76
Maintenance Section
Cooling System Specifications

Table 31 Table 34
Equation For Adding The SCA To Conventional Example Of The Equation For Adding The SCA To
Coolant/Antifreeze At The Initial Fill Conventional Coolant/Antifreeze For Maintenance
V × 0.045 = X Total Volume Multiplication Amount of SCA
of the Cooling Factor that is Required
V is the total volume of the cooling system. System (V) (X)
X is the amount of SCA that is required. 946 L × 0.014 9 L
(250 US gal) (4 US gal)
Table 32 is an example for using the equation that
is in Table 31. Note: Specific engine applications may require
maintenance practices to be periodically evaluated
Table 32
in order to properly maintain the engine’s cooling
Example Of The Equation For Adding The SCA To system.
Conventional Coolant/Antifreeze At The Initial Fill
Total Volume Multiplication
Table 30 lists part numbers and quantities of SCA
Amount of SCA
of the Cooling Factor that is Required that is available from your Caterpillar dealer.
System (V) (X)
946 L × 0.045 43 L Cleaning the System of Heavy-Duty
(250 US gal) (11 US gal) Coolant/Antifreeze
Caterpillar cooling system cleaners are designed
Adding the SCA to Conventional to clean the cooling system of harmful scale and
Coolant/Antifreeze For Maintenance corrosion. Caterpillar cooling system cleaners
dissolve mineral scale, corrosion products, light oil
Heavy duty coolant/antifreeze of all types REQUIRE contamination and sludge.
periodic additions of an SCA.
• Clean the cooling system after used coolant is
Test the coolant/antifreeze periodically for the drained or before the cooling system is filled with
concentration of SCA. For the interval, see the new coolant.
Operation and Maintenance Manual, “Maintenance
Interval Schedule” (Maintenance Section). SCA • Clean the cooling system whenever the coolant is
test kits are available from your Caterpillar contaminated or whenever the coolant is foaming.
dealer. Test the concentration of SCA or submit
a coolant sample to your Caterpillar dealer. See • For the recommended service interval, refer
this publication, “S·O·S Coolant Analysis” topic to the Operation and Maintenance Manual,
(Maintenance Section). “Maintenance Interval Schedule” for your engine.
Additions of SCA are based on the results of the
test or based on the results of the coolant analysis.
The size of the cooling system determines the
amount of SCA that is needed.

Use the equation that is in Table 33 to determine

the amount of Caterpillar SCA that is required, if
necessary:
Table 33
Equation For Adding The SCA To Conventional
Coolant/Antifreeze For Maintenance
V × 0.014 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.

Table 34 is an example for using the equation that

is in Table 33.
 77
Maintenance Section
Refill Capacities

Refill Capacities Table 35

Approximate Refill Capacities of the C-10 and
C-12 Engine Lubrication System
i01570098
Compartment
Liters Quarts
Refill Capacities or System
Deep Oil Sump(1) 34 36
SMCS Code: 1348; 1395; 7560
Shallow Oil
30 32
Sump(1)
Lubrication System
Center Oil
30 32
The refill capacities for the engine crankcase Sump(1)
reflect the approximate capacity of the crankcase Capacity of the
or sump plus standard oil filters. Auxiliary oil filter Auxiliary Oil
systems will require additional oil. Refer to the Filter System(2)
OEM specifications for the capacity of the auxiliary
oil filter. Refer to the Operation and Maintenance Total Capacity
Manual, “Maintenance Section” for more information of the
Lubrication
on Lubricant Specifications. System(3)
(1) Approximate sump capacity of the crankcase includes standard
C-10 and C-12 Industrial Engines oil filters that are factory installed. Engines with auxiliary oil
filters will require additional oil. Optional bypass oil filters that
are supplied by Caterpillar require an additional 2.5 L (2.6 qt)
of oil. If the engine is equipped with another type of auxiliary
oil filter, refer to the OEM specifications for the capacity of the
auxiliary oil filter.
(2) Fill in the capacity of the auxiliary oil filter system (if equipped)
in the space that is provided.
(3) Fill in the total capacity of the lubrication system. Add the
auxiliary oil filter system to the correct capacity of the oil sump
in order to find the total capacity of the lubrication system.

Cooling System
To maintain the cooling system, the Total Cooling
System capacity must be known. The approximate
capacity for the Engine cooling system is listed.
External System capacities will vary among
applications. Refer to the OEM specifications for the
External System capacity. This capacity information
will be needed in order to determine the amount
of coolant/antifreeze that is required for the Total
Cooling System.
g00479249
Illustration 35
Table 36
(1) Deep Oil Sump
(A) Depth 278 mm (11.00 inch) C-10 and C-12 Industrial Engine
(2) Shallow Oil Sump Refill Capacities (Approximate Capacity)
(B) Depth 235 mm (9.25 inch)
(3) Center Oil Sump Compartment or System Liters Quarts
Engine Only 10.2 10.8
External System(1)
Total Cooling System(2)
(1) The External System includes a radiator with the following
components: aftercooler and piping. Refer to the Specifications
Manual or the OEM. Enter the capacity for the External System
in this row.
(2) The Total Cooling System includes the capacity for the Engine
plus the capacity for the External System. Enter the total in
this row.
78
Maintenance Section
Maintenance Interval Schedule

i01660574 Between 250 Service Hours and 1000 Service

Hours
Maintenance Interval Schedule
Electronic Unit Injector - Inspect/Adjust ................ 94
(C-10 Industrial Engines) Engine Valve Lash - Inspect/Adjust .................... 104
Engine Valve Rotators - Inspect .......................... 105
SMCS Code: 1000; 7500
S/N: BCX1-Up Every 6000 Service Hours or 6 Years

Operating conditions and oil API Classifications Cooling System Coolant (ELC) - Change ............. 89
will determine the amount of service hours for the
PM Level 1 Maintenance Interval Schedule. Refer PM Level 1 - Every 8500 L (2250 US gal) of
to Operation and Maintenance Manual, “Engine Oil Fuel or 250 Service Hours or 6 Months
and Filter - Change” for your specific oil change
Air Compressor Filter - Clean/Replace ................. 83
interval.
Alternator - Inspect ............................................... 84
Battery Electrolyte Level - Check .......................... 85
Note: Ensure that the Safety Information, warnings,
Cooling System Supplemental Coolant Additive
and instructions are read and understood
before operation or maintenance procedures are (SCA) - Test/Add ................................................. 91
Cylinder Head Grounding Stud - Inspect/Clean/
performed.
Tighten ................................................................ 93
Note: Use fuel consumption, service hours, or Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 94
calendar time, whichever occurs first , in order to
Engine Air Cleaner Element - Clean/Replace ....... 97
determine the maintenance intervals. Engines that
operate in severe operating conditions may require Engine Crankcase Breather - Clean ..................... 99
Engine Oil Sample - Obtain ................................ 100
more frequent maintenance.
Engine Oil and Filter - Change ........................... 101
Before each consecutive interval is performed, all Fan Drive Bearing - Lubricate ............................. 106
Fuel System Primary Filter/Water Separator Element
of the maintenance requirements from the previous
- Replace ........................................................... 108
interval must also be performed.
Fuel System Secondary Filter - Replace ............ 109
Fuel Tank Water and Sediment - Drain ............... 110
When Required Hoses and Clamps - Inspect/Replace ................ 110
Battery - Replace .................................................. 84 Radiator - Clean .................................................. 115
Battery or Battery Cable - Disconnect .................. 85
Engine Air Cleaner Element (Dual Element) - PM Level 1 - Every 17 000 L (4500 US gal) of
Clean/Replace .................................................... 94 Fuel or 500 Service Hours or 6 Months
Engine Air Cleaner Element - Clean/Replace ....... 97
Engine Storage Procedure - Check .................... 104 Air Compressor Filter - Clean/Replace ................. 83
Ether Starting Aid Cylinder - Replace ................. 105 Alternator - Inspect ............................................... 84
Fuel System - Prime ........................................... 106 Battery Electrolyte Level - Check .......................... 85
Severe Service Application - Check .................... 115 Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 91
Cylinder Head Grounding Stud - Inspect/Clean/
Daily
Tighten ................................................................ 93
Air Starting Motor Lubricator Oil Level - Check .... 83 Engine Air Cleaner Element (Dual Element) -
Air Tank Moisture and Sediment - Drain ............... 84 Clean/Replace .................................................... 94
Cooling System Coolant Level - Check ................ 90 Engine Air Cleaner Element - Clean/Replace ....... 97
Driven Equipment - Check .................................... 94 Engine Crankcase Breather - Clean ..................... 99
Engine Air Cleaner Service Indicator - Inspect ..... 98 Engine Oil Sample - Obtain ................................ 100
Engine Air Precleaner - Clean .............................. 98 Engine Oil and Filter - Change ........................... 101
Engine Oil Level - Check ...................................... 99 Fan Drive Bearing - Lubricate ............................. 106
Fuel System Primary Filter/Water Separator - Fuel System Primary Filter/Water Separator Element
Drain ................................................................. 107 - Replace ........................................................... 108
Power Take-Off Clutch - Check/Adjust/ Fuel System Secondary Filter - Replace ............ 109
Lubricate ........................................................... 114 Fuel Tank Water and Sediment - Drain ............... 110
Walk-Around Inspection ...................................... 117 Hoses and Clamps - Inspect/Replace ................ 110
Radiator - Clean .................................................. 115
Initial 20 to 40 Service Hours
Belt - Inspect ......................................................... 86
 79
Maintenance Section
Maintenance Interval Schedule

PM Level 2 - Every 68 000 L (18 000 US gal)

of Fuel or 2000 Service Hours or 1 Year
Aftercooler Core - Clean/Test ............................... 82
Alternator - Inspect ............................................... 84
Engine Crankcase Breather - Clean ..................... 99

PM Level 3 - Every 102 200 L (27 000 US gal)

of Fuel or 3000 Service Hours or 2 Years
Aftercooler Core - Clean/Test ............................... 82
Air Compressor - Inspect ...................................... 82
Belt Tensioner - Inspect ........................................ 87
Cooling System Coolant (DEAC) - Change .......... 87
Cooling System Coolant Extender (ELC) - Add .... 90
Cooling System Water Temperature Regulator -
Replace ............................................................... 92
Crankshaft Vibration Damper - Inspect ................. 93
Electronic Unit Injector - Inspect/Adjust ................ 94
Engine - Clean ...................................................... 94
Engine Mounts - Inspect ....................................... 99
Engine Valve Lash - Inspect/Adjust .................... 104
Engine Valve Rotators - Inspect .......................... 105

Every 170 400 L (45 000 US gal) of Fuel or

5000 Service Hours
Starting Motor - Inspect ...................................... 116
Turbocharger - Inspect ........................................ 116
Water Pump - Inspect ......................................... 118

Every 340 500 L (90 000 US gal) of Fuel or

10 000 Service Hours
Overhaul Considerations .................................... 111
80
Maintenance Section
Maintenance Interval Schedule

i01660576 Initial 20 to 40 Service Hours

Maintenance Interval Schedule Belt - Inspect ......................................................... 86
(C-12 Industrial Engines) Between 250 Service Hours and 1000 Service
SMCS Code: 1000; 7500 Hours

S/N: BDL1-Up Electronic Unit Injector - Inspect/Adjust ................ 94

Engine Valve Lash - Inspect/Adjust .................... 104
S/N: 866; BDL1-Up Engine Valve Rotators - Inspect .......................... 105

Operating conditions and oil API Classifications Every 6000 Service Hours or 6 Years
will determine the amount of service hours for the
PM Level 1 Maintenance Interval Schedule. Refer Cooling System Coolant (ELC) - Change ............. 89
to Operation and Maintenance Manual, “Engine Oil
and Filter - Change” for your specific oil change PM Level 1 - Every 10 400 L (2750 US gal) of
interval. Fuel or 250 Service Hours or 6 Months

Note: Ensure that the Safety Information, warnings, Air Compressor Filter - Clean/Replace ................. 83
and instructions are read and understood Alternator - Inspect ............................................... 84
before operation or maintenance procedures are Battery Electrolyte Level - Check .......................... 85
performed. Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 91
Note: Use fuel consumption, service hours, or Cylinder Head Grounding Stud - Inspect/Clean/
calendar time, whichever occurs first , in order to Tighten ................................................................ 93
determine the maintenance intervals. Engines that Engine Air Cleaner Element (Dual Element) -
operate in severe operating conditions may require Clean/Replace .................................................... 94
more frequent maintenance. Engine Air Cleaner Element - Clean/Replace ....... 97
Engine Crankcase Breather - Clean ..................... 99
Before each consecutive interval is performed, all Engine Oil Sample - Obtain ................................ 100
of the maintenance requirements from the previous Engine Oil and Filter - Change ........................... 101
interval must also be performed. Fan Drive Bearing - Lubricate ............................. 106
Fuel System Primary Filter/Water Separator Element
- Replace ........................................................... 108
When Required
Fuel System Secondary Filter - Replace ............ 109
Battery - Replace .................................................. 84 Fuel Tank Water and Sediment - Drain ............... 110
Battery or Battery Cable - Disconnect .................. 85 Hoses and Clamps - Inspect/Replace ................ 110
Engine Air Cleaner Element (Dual Element) - Radiator - Clean .................................................. 115
Clean/Replace .................................................... 94
Engine Air Cleaner Element - Clean/Replace ....... 97 PM Level 1 - Every 20 800 L (5500 US gal) of
Engine Storage Procedure - Check .................... 104 Fuel or 500 Service Hours or 6 Months
Ether Starting Aid Cylinder - Replace ................. 105
Fuel System - Prime ........................................... 106 Air Compressor Filter - Clean/Replace ................. 83
Severe Service Application - Check .................... 115 Alternator - Inspect ............................................... 84
Battery Electrolyte Level - Check .......................... 85
Daily Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 91
Air Starting Motor Lubricator Oil Level - Check .... 83 Cylinder Head Grounding Stud - Inspect/Clean/
Air Tank Moisture and Sediment - Drain ............... 84 Tighten ................................................................ 93
Cooling System Coolant Level - Check ................ 90 Engine Air Cleaner Element (Dual Element) -
Driven Equipment - Check .................................... 94 Clean/Replace .................................................... 94
Engine Air Cleaner Service Indicator - Inspect ..... 98 Engine Air Cleaner Element - Clean/Replace ....... 97
Engine Air Precleaner - Clean .............................. 98 Engine Crankcase Breather - Clean ..................... 99
Engine Oil Level - Check ...................................... 99 Engine Oil Sample - Obtain ................................ 100
Fuel System Primary Filter/Water Separator - Engine Oil and Filter - Change ........................... 101
Drain ................................................................. 107 Fan Drive Bearing - Lubricate ............................. 106
Power Take-Off Clutch - Check/Adjust/ Fuel System Primary Filter/Water Separator Element
Lubricate ........................................................... 114 - Replace ........................................................... 108
Walk-Around Inspection ...................................... 117 Fuel System Secondary Filter - Replace ............ 109
Fuel Tank Water and Sediment - Drain ............... 110
Hoses and Clamps - Inspect/Replace ................ 110
Radiator - Clean .................................................. 115
 81
Maintenance Section
Maintenance Interval Schedule

PM Level 2 - Every 83 250 L (22 000 US gal)

of Fuel or 2000 Service Hours or 1 Year
Aftercooler Core - Clean/Test ............................... 82
Alternator - Inspect ............................................... 84
Engine Crankcase Breather - Clean ..................... 99

Every 208 000 L (55 000 US gal) of Fuel or

5000 Service Hours
Starting Motor - Inspect ...................................... 116
Turbocharger - Inspect ........................................ 116
Water Pump - Inspect ......................................... 118

PM Level 3 - Every 125 000 L (33 000 US gal)

of Fuel or 3000 Service Hours or 2 Years
Aftercooler Core - Clean/Test ............................... 82
Air Compressor - Inspect ...................................... 82
Belt Tensioner - Inspect ........................................ 87
Cooling System Coolant (DEAC) - Change .......... 87
Cooling System Coolant Extender (ELC) - Add .... 90
Cooling System Water Temperature Regulator -
Replace ............................................................... 92
Crankshaft Vibration Damper - Inspect ................. 93
Electronic Unit Injector - Inspect/Adjust ................ 94
Engine - Clean ...................................................... 94
Engine Mounts - Inspect ....................................... 99
Engine Valve Lash - Inspect/Adjust .................... 104
Engine Valve Rotators - Inspect .......................... 105

Every 380 000 L (100 000 US gal) of Fuel or

10 000 Service Hours
Overhaul Considerations .................................... 111
82
Maintenance Section
Aftercooler Core - Clean/Test

i01546702 7. Inspect the core in order to ensure cleanliness.

Pressure test the core. Many shops that service
Aftercooler Core - Clean/Test radiators are equipped to perform pressure tests.
If necessary, repair the core.
SMCS Code: 1064-070; 1064-081
8. Install the core. Refer to the Service Manual for
1. Remove the core. Refer to the Service Manual the procedure.
for the procedure.
For more information on cleaning the core, consult
2. Turn the aftercooler core upside-down in order your Caterpillar dealer.
to remove debris.

i01183385
NOTICE
Do not use a high concentration of caustic cleaner to Air Compressor - Inspect
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause SMCS Code: 1803-040
leakage. Only use the recommended concentration of
cleaner.

3. Back flush the core with cleaner. Do not disconnect the air line from the air com-
pressor governor without purging the air brake
Caterpillar recommends the use of Hydrosolv and the auxiliary air systems. Failure to purge the
liquid cleaner. Table 37 lists Hydrosolv liquid air brake and the auxiliary air systems before re-
cleaners that are available from your Caterpillar moving the air compressor and/or the air lines
dealer. could cause personal injury.
Table 37
Hydrosolv Liquid Cleaners(1)
Part
Description Size
Number
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner
at temperatures up to 93C (200F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more
information.

4. Steam clean the core in order to remove any

residue. Flush the fins of the aftercooler core.
Remove any other trapped debris. g00633741
Illustration 36
(1) Air compressor pressure relief valve
5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.

If the air compressor pressure relief valve that is

mounted in the air compressor cylinder head is
Personal injury can result from air pressure. bypassing compressed air, there is a malfunction
in the air system, possibly ice blockage. Under
Personal injury can result without following prop- these conditions, your engine may have insuffi-
er procedure. When using pressure air, wear a pro- cient air for normal brake operation.
tective face shield and protective clothing.
Do not operate the engine until the reason for the
Maximum air pressure at the nozzle must be less air bypass is identified and corrected. Failure to
than 205 kPa (30 psi) for cleaning purposes. heed this warning could lead to property damage,
personal injury, or death to the operator or by-
6. Dry the core with compressed air. Direct the air standers.
in the reverse direction of the normal flow.
 83
Maintenance Section
Air Compressor Filter - Clean/Replace

The function of the air compressor pressure relief

valve is to bypass air when there is a malfunction in
the air compressor system.

The air compressor pressure relief valve releases

air at 1723 kPa (250 psi). It is very important that
all personnel stand clear of the air compressor
pressure relief valve when compressed air is
released. All personnel should also stay clear of the
air compressor when the engine is operating and
the air compressor is exposed.

Refer to the Service Manual or refer to the OEM

specifications in order to find information concerning
the air compressor. Consult your Caterpillar dealer g00381232
for assistance. Illustration 37
(1) Air valve
(2) Lubricator bowl
i01491325 (3) Adjustment knob

Air Compressor Filter - 1. The vanes of the air starting motor are lubricated
Clean/Replace with a fine mist of oil from the air starting motor
lubricator. Check the level of oil in lubricator bowl
SMCS Code: 1803-070-FQ; 1803-510-FQ (2). If the oil level is less than 1/2, add oil to the
lubricator bowl.
One of the single most important aspects of
preventive maintenance for the air compressor is 2. Ensure that the air supply to the lubricator is OFF.
the induction of clean air. The type of maintenance
that is required for the air compressor and the 3. Remove the plug. Pour oil into lubricator bowl
maintenance interval depends on the type of air (2). Use “10W” oil for temperatures that are
induction system that is used. Operating conditions greater than 0 C (32 F). Use air tool oil for
(dust, dirt and debris) may require more frequent temperatures that are below 0 C (32 F).
service.
4. Install the plug.
Refer to the Service Manual for the type of
air compressor that is installed on the engine. Oiler Feed Adjustment
Follow the maintenance recommendations that are
provided by the OEM of the air compressor. Some If necessary, adjust the lubricator in order to release
engines use boost air pressure so the engine air approximately two drops of fluid per 30 seconds
cleaner will require servicing. into the starting motor air stream.

1. Ensure that the fuel supply to the engine is OFF.

i00805129

Air Starting Motor Lubricator 2. Turn adjustment knob (3) clockwise until the
adjustment knob locks.
Oil Level - Check
(If Equipped) 3. Turn adjustment knob (3) counterclockwise for
1/4 turns.
SMCS Code: 1451-535
NOTICE
NOTICE Do not crank the engine continuously for more than
Never allow the lubricator bowl to become empty. The 30 seconds. Allow the starting motor to cool for two
air starting motor will be damaged by a lack of lubrica- minutes before cranking the engine again.
tion. Ensure that sufficient oil is in the lubricator bowl.
4. Crank the starting motor for ten seconds and
observe the exhaust air from the mufflers of the
starting motor. Look for oil mist. A slight oil mist
should be barely visible.
84
Maintenance Section
Air Tank Moisture and Sediment - Drain

If no mist is observed, or if the mist is excessive, i00072207

rotate adjustment knob (3) in increments of 1/16 in
order to increase or decrease the oil mist. Repeat Alternator - Inspect
the starting motor cranking and observe until the
mist is satisfactory. SMCS Code: 1405-040

Note: Drip rates should only be made under an Caterpillar recommends a scheduled inspection
average steady flow condition. Once a steady of the alternator. Inspect the alternator for loose
flow condition is established, the lubricator will connections and proper battery charging. Inspect
automatically adjust the drip rate in proportion to the ammeter (if equipped) during engine operation
the variations in air flow. in order to ensure proper battery performance
and/or proper performance of the electrical system.
Make repairs, as required. Refer to the Service
i00847451 Manual.
Air Tank Moisture and Check the alternator and the battery charger for
Sediment - Drain proper operation. If the batteries are properly
charged, the ammeter reading should be very near
(If Equipped) zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
SMCS Code: 1466-543-M&S affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
Moisture and sediment in the air starting system not crank the engine, even if the engine is warm.
can cause the following conditions: When the engine is not run for long periods of time
or if the engine is run for short periods, the batteries
• Freezing may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
• Corrosion of internal parts
• Malfunction of the air starting system i01492550

Battery - Replace
SMCS Code: 1401-510
When opening the drain valve, wear protective
gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal
Batteries give off combustible gases which can
injury.
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
1. Open the drain valve that is on the bottom of jury or death.
the air tank. Allow the moisture and sediment
to drain. Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
2. Close the drain valve. der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
3. Check the air supply pressure. The air starting serviced.
motor requires a minimum of 620 kPa (90 psi) of
air pressure to operate properly. The maximum
air pressure must not exceed 1550 kPa (225 psi).
The normal air pressure will be 758 to 965 kPa
(110 to 140 psi). The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion
resulting in personal injury.
 85
Maintenance Section
Battery Electrolyte Level - Check

1. Turn the key start switch to the OFF position. If the addition of water is necessary, use distilled
Remove the key and all electrical loads. water. If distilled water is not available use
clean water that is low in minerals. Do not use
2. Turn OFF the battery charger. Disconnect the artificially softened water.
charger.
2. Check the condition of the electrolyte with the
3. The NEGATIVE “-” cable connects the NEGATIVE 1U-7298 Coolant/Battery Tester (C) or the
“-” battery terminal to the ground plane. 1U-7297 Coolant/Battery Tester (F).
Disconnect the cable from the NEGATIVE “-”
battery terminal. 3. Keep the batteries clean.

4. The POSITIVE “+” cable connects the POSITIVE Clean the battery case with one of the following
“+” battery terminal to the starting motor. cleaning solutions:
Disconnect the cable from the POSITIVE “+”
battery terminal. • A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate • A mixture of 0.1 L (0.11 qt) of ammonia and
recycling facility. 1 L (1 qt) of clean water

5. Remove the used battery. Thoroughly rinse the battery case with clean
water.
6. Install the new battery.
Use a fine grade of sandpaper to clean the
Note: Before the cables are connected, ensure that terminals and the cable clamps. Clean the items
the key start switch is OFF. until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
7. Connect the cable from the starting motor to the of material can cause the clamps to not fit
POSITIVE “+” battery terminal. properly. Coat the clamps and the terminals with
5N-5561 Silicone Lubricant, petroleum jelly or
8. Connect the cable from the ground plane to the MPGM grease.
NEGATIVE “-” battery terminal.
i01492654
i01639002
Battery or Battery Cable -
Battery Electrolyte Level - Disconnect
Check
SMCS Code: 1402-029
SMCS Code: 1401-535

When the engine is not run for long periods of

time or when the engine is run for short periods, The battery cables or the batteries should not be
the batteries may not fully recharge. Ensure a full removed with the battery cover in place. The bat-
charge in order to help prevent the battery from tery cover should be removed before any servic-
freezing. If batteries are properly charged, ammeter ing is attempted.
reading should be very near zero.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face 1. Turn the start switch to the OFF position. Turn the
shield and protective clothing when working on or ignition switch (if equipped) to the OFF position
near batteries. and remove the key and all electrical loads.

1. Remove the filler caps. Maintain the electrolyte 2. Disconnect the negative battery terminal at the
level to the “FULL” mark on the battery. battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side
of two batteries must be disconnected.
86
Maintenance Section
Belt - Inspect

3. Tape the leads in order to help prevent accidental Adjustment

starting.
Alternator Belt
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.

i00951407

Belt - Inspect
SMCS Code: 1357-040; 1357; 1397-040; 1397

Inspection
Belt tension should be checked initially between
the first 20 to 40 hours of engine operation.

After the initial check, the belt tension should be Illustration 38 g00485289
checked at Every PM Level 1 or Three Months. Typical alternator mounting
(1) Adjusting nuts
To maximize the engine performance, inspect the (2) Mounting bolts
belts for wear and for cracking. Replace belts that
are worn or damaged. 1. Slightly loosen mounting bolt (2) and adjusting
nut (1).
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only 2. Move the pulley in order to adjust the belt
one belt of a matched set will cause the new belt to tension.
carry more load because the older belt is stretched.
The additional load on the new belt could cause the 3. Tighten adjusting nuts (1) and mounting bolts (2).
new belt to break. Refer to the Operation and Maintenance Manual,
“Torque Specifications” topic (Maintenance
If the belts are too loose, vibration causes Section).
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating. 4. Install the belt guard.
If the belts are too tight, unnecessary stresses are If new belts are installed, check the belt tension
placed on the pulley bearings and on the belts. This again after 30 minutes of engine operation at the
may shorten the service life of the components. rated rpm.
Remove the belt guard. Inspect the condition and
adjustment of the alternator belts and accessory
drive belts (if equipped).

To check the belt tension, apply 110 N (25 lb ft)

of force midway between the pulleys. A correctly
adjusted belt will deflect 9 mm (0.35 inch) to 15 mm
(0.59 inch).

If the belt does not require replacement or

adjustment, install the belt guard. If the belt requires
adjustment or replacement, perform the following
procedure to adjust the belt tension.

• If the engine is equipped with a refrigerant

compressor (air conditioner), the belt for the fan
drive, the alternator, and the accessories will have
an automatic belt tensioner.

• If the engine is not equipped with a refrigerant

compressor, the alternator is used to adjust the
belt tension.
 87
Maintenance Section
Belt Tensioner - Inspect

i01555583 Note: Inspect the water pump and the water

temperature regulator after the cooling system has
Belt Tensioner - Inspect been drained. This is a good opportunity to replace
(If Equipped) the water pump, the water temperature regulator
and the hoses, if necessary.
SMCS Code: 1358-040
Drain

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.

1. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly
g00426964 in order to relieve any pressure. Remove the
Illustration 39
cooling system filler cap.
Belt tensioner
2. Open the cooling system drain valve (if
Inspect the belt tensioner for unusual noise, equipped). If the cooling system is not equipped
excessive looseness and/or shaking of the bearings. with a drain valve, remove one of the drain plugs.
If the belt tensioner should require disassembly, Allow the coolant to drain.
refer to the Service Manual for the procedure.
NOTICE
i01206425 Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
Cooling System Coolant coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
(DEAC) - Change Caterpillar to reclaim the used coolant.
SMCS Code: 1350-070; 1395-044
For information regarding the disposal and the
Clean the cooling system and flush the cooling recycling of used coolant, consult your Caterpillar
system before the recommended maintenance dealer or consult Caterpillar Service Technology
interval if the following conditions exist: Group:

• The engine overheats frequently. Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
• Foaming is observed. Canada: 1-800-523-TOOL

• The oil has entered the cooling system and the Flush
coolant is contaminated.
1. Flush the cooling system with clean water in
• The fuel has entered the cooling system and the order to remove any debris.
coolant is contaminated.
2. Close the drain valve (if equipped). Clean the
NOTICE drain plugs. Install the drain plugs. Refer to the
Use of commercially available cooling system clean- Operation and Maintenance Manual, “Torque
ers may cause damage to cooling system compo- Specifications” topic (Maintenance Section) for
nents. Use only cooling system cleaners that are ap- more information on the proper torques.
proved for Caterpillar engines.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
88
Maintenance Section
Cooling System Coolant (DEAC) - Change

3. Fill the cooling system with a mixture of clean 4. Start and run the engine at low idle for a
water and Caterpillar Fast Acting Cooling System minimum of 90 minutes. The coolant temperature
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L should be at least 82 C (180 F).
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap. NOTICE
Improper or incomplete rinsing of the cooling system
4. Start and run the engine at low idle for a can result in damage to copper and other metal com-
minimum of 30 minutes. The coolant temperature ponents.
should be at least 82 C (180 F).
To avoid damage to the cooling system, make sure
NOTICE to completely flush the cooling system with clear wa-
Improper or incomplete rinsing of the cooling system ter. Continue to flush the system until all signs of the
can result in damage to copper and other metal com- cleaning agent are gone.
ponents.

To avoid damage to the cooling system, make sure 5. Stop the engine and allow the engine to cool.
to completely flush the cooling system with clear wa- Loosen the cooling system filler cap slowly
ter. Continue to flush the system until all signs of the in order to relieve any pressure. Remove the
cleaning agent are gone. cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system
drain plugs. Allow the water to drain. Flush the
5. Stop the engine and allow the engine to cool. cooling system with clean water. Close the drain
Loosen the cooling system filler cap slowly valve (if equipped). Clean the drain plugs. Install
in order to relieve any pressure. Remove the the drain plugs. Refer to the Operation and
cooling system filler cap. Open the drain valve Maintenance Manual, “Torque Specifications”
(if equipped) or remove the cooling system topic (Maintenance Section) for more information
drain plugs. Allow the water to drain. Flush the on the proper torques.
cooling system with clean water. Close the drain
valve (if equipped). Clean the drain plugs. Install
the drain plugs. Refer to the Operation and
Fill
Maintenance Manual, “Torque Specifications”
topic (Maintenance Section) for more information NOTICE
on the proper torques. Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Cooling Systems with Heavy
1. Fill the cooling system with coolant/antifreeze.
Deposits or Plugging Refer to the Operation and Maintenance
Manual, “Cooling System Specifications” topic
Note: For the following procedure to be effective, (Maintenance Section) for more information on
there must be some active flow through the cooling cooling system specifications. Do not install the
system components. cooling system filler cap.
1. Flush the cooling system with clean water in 2. Start and run the engine at low idle. Increase the
order to remove any debris. engine rpm to 1500 rpm. Run the engine at high
idle for one minute in order to purge the air from
2. Close the drain valve (if equipped). Clean the the cavities of the engine block. Stop the engine.
drain plugs. Install the drain plugs. Refer to the
Operation and Maintenance Manual, “Torque 3. Check the coolant level. Maintain the coolant
Specifications” topic (Maintenance Section) for level within 13 mm (0.5 inch) below the bottom
more information on the proper torques. of the pipe for filling. Maintain the coolant level
within 13 mm (0.5 inch) to the proper level on the
NOTICE sight glass (if equipped).
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

3. Fill the cooling system with a mixture of clean

water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the cooling system filler cap.
 89
Maintenance Section
Cooling System Coolant (ELC) - Change

4. Clean the cooling system filler cap. Inspect the 1. Stop the engine and allow the engine to cool.
gasket that is on the cooling system filler cap. If Loosen the cooling system filler cap slowly
the gasket that is on the cooling system filler cap in order to relieve any pressure. Remove the
is damaged, discard the old cooling system filler cooling system filler cap.
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler 2. Open the cooling system drain valve (if
cap is not damaged, perform a pressure test. A equipped). If the cooling system is not equipped
9S-8140 Pressurizing Pump is used to perform with a drain valve, remove the cooling system
the pressure test. The correct pressure for the drain plugs.
cooling system filler cap is stamped on the face
of the cooling system filler cap. If the cooling Allow the coolant to drain.
system filler cap does not retain the correct
pressure, install a new cooling system filler cap. NOTICE
Dispose of used engine coolant properly or recycle.
5. Start the engine. Inspect the cooling system for Various methods have been proposed to reclaim used
leaks and for proper operating temperature. coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
i01206445
Caterpillar to reclaim the used coolant.

Cooling System Coolant (ELC) For information regarding the disposal and the
- Change recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology
SMCS Code: 1350-070; 1395-044 Group:

Clean the cooling system and flush the cooling Outside Illinois: 1-800-542-TOOL
system before the recommended maintenance Inside Illinois: 1-800-541-TOOL
interval if the following conditions exist: Canada: 1-800-523-TOOL

• The engine overheats frequently. Flush

• Foaming is observed. 1. Flush the cooling system with clean water in
order to remove any debris.
• The oil has entered the cooling system and the
coolant is contaminated. 2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the
• The fuel has entered the cooling system and the Operation and Maintenance Manual, “Torque
coolant is contaminated. Specifications” topic (Maintenance Section) for
more information on the proper torques.
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained
and replaced. NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
Note: Inspect the water pump and the water per minute to avoid air locks.
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace 3. Fill the cooling system with clean water. Install
the water pump, the water temperature regulator the cooling system filler cap.
and the hoses, if necessary.
4. Start and run the engine at low idle until the
Drain temperature reaches 49 to 66 C (120 to 150 F).

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
90
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

5. Stop the engine and allow the engine to cool. i00259474

Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the Cooling System Coolant
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system
Extender (ELC) - Add
drain plugs. Allow the water to drain. Flush the SMCS Code: 1352-045; 1395-081
cooling system with clean water. Close the drain
valve (if equipped). Clean the drain plugs. Install Caterpillar Extended Life Coolant (ELC) does not
the drain plugs. Refer to the Operation and require the frequent Supplemental Coolant Additive
Maintenance Manual, “Torque Specifications” (SCA) additions associated with the present
topic (Maintenance Section) for more information conventional coolants. The Extender only needs to
on the proper torques. be added once.

Fill Check the cooling system only when the engine is

stopped and cool.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) 1. Loosen the cooling system filler cap slowly in
per minute to avoid air locks. order to relieve pressure. Remove the cooling
system filler cap.

1. Fill the cooling system with Extended Life Coolant 2. It may be necessary to drain enough coolant
(ELC). Refer to the Operation and Maintenance from the cooling system in order to add the
Manual, “Cooling System Specifications” topic Extender.
(Maintenance Section) for more information on
cooling system specifications. Do not install the 3. Add Extender according to the requirements for
cooling system filler cap. your engine’s cooling system capacity. Refer to
the Operation and Maintenance Manual, “Refill
2. Start and run the engine at low idle. Increase the Capacities” in the Maintenance Section for the
engine rpm to high idle. Run the engine at high capacity of the cooling system for your engine.
idle for one minute in order to purge the air from Refer to the Operation and Maintenance Manual,
the cavities of the engine block. Stop the engine. “Cooling System Specifications” information for
the Caterpillar ELC Extender additions.
3. Check the coolant level. Maintain the coolant
level within 13 mm (0.5 inch) below the bottom 4. Clean the cooling system filler cap. Inspect the
of the pipe for filling. Maintain the coolant level cooling system filler cap gaskets. Replace the
within 13 mm (0.5 inch) to the proper level on the cooling system filler cap if the cooling system
sight glass (if equipped). filler cap gaskets are damaged. Install the
cooling system filler cap.
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
i01197583
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
Cooling System Coolant Level
the gasket that is on the cooling system filler cap - Check
is not damaged, use a 9S-8140 Pressurizing
Pump in order to pressure test the cooling SMCS Code: 1395-082
system filler cap. The correct pressure for the
cooling system filler cap is stamped on the face Check the coolant level when the engine is stopped
of the cooling system filler cap. If the cooling and cool.
system filler cap does not retain the correct
pressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system for

leaks and for proper operating temperature.
 91
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i01463635

Cooling System Supplemental

Coolant Additive (SCA) -
Test/Add
SMCS Code: 1352-045; 1395-081

Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact with
the skin and the eyes. Do not drink cooling system
Illustration 40
g00285520 coolant additive.
Cooling system filler cap
Note: Test the concentration of the Supplemental
Coolant Additive (SCA) or test the SCA concentration
as part of an S·O·S Coolant Analysis.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, Test for SCA Concentration
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system Coolant/Antifreeze and SCA
pressure cap slowly in order to relieve the pres-
sure. NOTICE
Do not exceed the recommended six percent supple-
1. Remove the cooling system filler cap slowly in mental coolant additive concentration.
order to relieve pressure.
Use the 8T-5296 Coolant Conditioner Test Kit or
2. Maintain the coolant level within 13 mm (0.5 inch) use the 4C-9301 Coolant Conditioner Test Kit in
of the bottom of the filler pipe. If the engine is order to check the concentration of the SCA. Refer
equipped with a sight glass, maintain the coolant to the Operation and Maintenance Manual for more
level to the proper level in the sight glass. information.

Water and SCA

NOTICE
Do not exceed the recommended eight percent sup-
plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296

Coolant Conditioner Test Kit. Refer to the Operation
and Maintenance Manual, “Water/Supplemental
Coolant Additive (SCA)” topic (Maintenance
Section). Refer to the Operation and Maintenance
Manual, “Conventional Coolant/Antifreeze Cooling
g00103639 System Maintenance” topic (Maintenance Section).
Illustration 41
Typical filler cap gaskets
S·O·S Coolant Analysis
3. Clean the cooling system filler cap and check the
condition of the filler cap gaskets. Replace the S·O·S coolant samples can be analyzed at your
cooling system filler cap if the filler cap gaskets Caterpillar dealer. S·O·S Coolant Analysis is a
are damaged. Reinstall the cooling system filler program that is based on periodic samples.
cap.

4. Inspect the cooling system for leaks.

92
Maintenance Section
Cooling System Water Temperature Regulator - Replace

Level 1 Note: Always discard drained fluids according to

local regulations.
Level 1 is a basic analysis of the coolant. The
following items are tested: 2. If necessary, drain some coolant from the cooling
system into a suitable container in order to allow
• Glycol Concentration space for the extra SCA.

• Concentration of SCA 3. Add the proper amount of SCA. Refer to the

Operation and Maintenance Manual for more
• pH information on SCA requirements.

• Conductivity 4. Clean the cooling system filler cap. Inspect the

gaskets of the cooling system filler cap. If the
The results are reported, and recommendations gaskets are damaged, replace the old cooling
are made according to the results. Consult your system filler cap with a new cooling system filler
Caterpillar dealer for information on the benefits of cap. Install the cooling system filler cap.
managing your equipment with an S·O·S Coolant
Analysis.
i00912898

Level 2 Cooling System Water

This level coolant analysis is recommended Temperature Regulator -
when the engine is overhauled. Refer to the Replace
Operations and Maintenance Manual, “Overhaul
Considerations” for further information. SMCS Code: 1355-510

Add the SCA, If Necessary Replace the water temperature regulator before
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
NOTICE Replacing the water temperature regulator reduces
Do not exceed the recommended amount of sup- the chances for unscheduled downtime.
plemental coolant additive concentration. Excessive
supplemental coolant additive concentration can form A water temperature regulator that fails in a
deposits on the higher temperature surfaces of the partially opened position can cause overheating or
cooling system, reducing the engine’s heat transfer overcooling of the engine.
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high temper- A water temperature regulator that fails in the
ature components. Excessive supplemental coolant closed position can cause excessive overheating.
additive concentration could also result in radiator Excessive overheating could result in cracking of
tube blockage, overheating, and/or accelerated water the cylinder head or piston seizure problems.
pump seal wear. Never use both liquid supplemental
coolant additive and the spin-on element (if equipped) A water temperature regulator that fails in the open
at the same time. The use of those additives together position will cause the engine operating temperature
could result in supplemental coolant additive concen- to be too low during partial load operation. Low
tration exceeding the recommended maximum. 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.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.

1. Slowly loosen the cooling system filler cap in

order to relieve the pressure. Remove the cooling
system filler cap.
 93
Maintenance Section
Crankshaft Vibration Damper - Inspect

Visconic Damper
NOTICE
Failure to replace your water temperature regulator The visconic damper has a weight that is located
on a regularly scheduled basis could cause severe inside a fluid filled case. The weight moves in the
engine damage. case in order to limit torsional vibration. Inspect
the damper for evidence of dents, cracks or leaks
Caterpillar engines incorporate a shunt design cooling of the fluid.
system and require operating the engine with a water
temperature regulator installed. Replace the damper if the damper is dented,
cracked or leaking. Refer to the Service Manual
If the water temperature regulator is installed incor- or consult your Caterpillar dealer for damper
rectly, the engine may overheat, causing cylinder head replacement.
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
i01400784
the water temperature regulator vent hole is open.
Cylinder Head Grounding Stud
Do not use liquid gasket material on the gasket or
cylinder head surface. - Inspect/Clean/Tighten
SMCS Code: 7423-040; 7423-070; 7423-079
Refer to the Service Manual for the replacement
procedure of the water temperature regulator, or
consult your Caterpillar dealer.

Note: If only the water temperature regulators are

replaced, drain the coolant from the cooling system
to a level that is below the water temperature
regulator housing.

i00072369

Crankshaft Vibration Damper

- Inspect
SMCS Code: 1205-040 g00738038
Illustration 42
(1) Cylinder head grounding stud
Damage to the crankshaft vibration damper or
failure of the crankshaft vibration damper can Inspect the wiring harness for good connections.
increase torsional vibrations. This can result in
damage to the crankshaft and to other engine The cylinder head grounding stud must have a wire
components. A deteriorating damper can cause ground to the battery. Tighten the cylinder head
excessive gear train noise at variable points in the grounding stud at every oil change. Ground wires
speed range. and straps should be combined at engine grounds.
All grounds should be tight and free of corrosion.
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the • Clean the cylinder head grounding stud and the
engine. terminals with a clean cloth.

Removal and Installation • If the connections are corroded, clean the

connections with a solution of baking soda and
Refer to the Service Manual for the damper water.
removal procedure and for the damper installation
procedure. • Keep the cylinder head grounding stud and the
strap clean and coated with MPGM grease or
petroleum jelly.
94
Maintenance Section
Driven Equipment - Check

i00174798 i01646701

Driven Equipment - Check Engine - Clean

SMCS Code: 3279-535 SMCS Code: 1000-070

Refer to the OEM specifications for more information

on the following maintenance recommendations for
the driven equipment: Personal injury or death can result from high volt-
age.
• Inspection
Moisture can create paths of electrical conductiv-
• Adjustment ity.
• Lubrication Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “DO
• Other maintenance recommendations NOT OPERATE”.
Perform any maintenance for the driven equipment
which is recommended by the OEM. NOTICE
Accumulated grease and oil on an engine is a fire haz-
i01117091
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
Electronic Unit Injector - the engine.
Inspect/Adjust
Periodic cleaning of the engine is recommended.
SMCS Code: 1251-025; 1251-040; 1290-025; Steam cleaning the engine will remove accumulated
1290-040 oil and grease. A clean engine provides the
following benefits:

• Easy detection of fluid leaks

Be sure the engine cannot be started while this
maintenance is being performed. To prevent pos- • Maximum heat transfer characteristics
sible injury, do not use the starting motor to turn
the flywheel. • Ease of maintenance
Note: Caution must be used in order to prevent
Hot engine components can cause burns. Allow
electrical components from being damaged by
additional time for the engine to cool before mea-
excessive water when you clean the engine. Avoid
suring/adjusting the unit injectors.
electrical components such as the alternator, the
starter, and the ECM.
The electronic unit injectors use high voltage. Dis-
connect the unit injector enable circuit connector
in order to prevent personal injury. Do not come i01553486
in contact with the injector terminals while the en-
gine is running. Engine Air Cleaner Element
(Dual Element) - Clean/Replace
Adjust the electronic unit injector at the same
interval as the valve lash adjustment. The operation SMCS Code: 1054-037; 1054-510
of Caterpillar engines with improper adjustments
of the electronic unit injector can reduce engine NOTICE
efficiency. This reduced efficiency could result in Never run the engine without an air cleaner element
excessive fuel usage and/or shortened engine installed. Never run the engine with a damaged air
component life. cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
 95
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

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

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the
air can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
engine wear. Your Caterpillar dealer has the proper
air cleaner elements for your application. Consult
your Caterpillar dealer for the correct air cleaner
element. Illustration 43
g00736431

(1) Cover
• Check the precleaner (if equipped) daily for (2) Primary air cleaner element
accumulation of dirt and debris. Remove any dirt (3) Secondary air cleaner element
and debris, as needed. (4) Turbocharger air inlet

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

Replace the dirty paper air cleaner elements with 4. Clean the inside of the air cleaner cover and
clean air cleaner elements. Before installation, the body with a clean, dry cloth.
air cleaner elements should be thoroughly checked
for tears and/or holes in the filter material. Inspect 5. Remove the tape for the turbocharger air inlet.
the gasket or the seal of the air cleaner element for Install the secondary air cleaner element. Install
damage. Maintain a supply of suitable air cleaner a primary air cleaner element that is new or
elements for replacement purposes. cleaned.

Dual Element Air Cleaners 6. Install the air cleaner cover.

The dual element air cleaner contains a primary 7. Reset the air cleaner service indicator.
air 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.
96
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

Cleaning the Primary Air Cleaner Pressurized Air

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

Observe the following guidelines if you attempt to

clean the filter element:

Do not tap or strike the filter element in order to remove

dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage g00281692
Illustration 44
to the pleats.
Note: When the primary air cleaner elements are
Do not use air filters with damaged pleats, gaskets, or cleaned, always begin with the clean side (inside)
seals. Dirt entering the engine will cause damage to in order to force dirt particles toward the dirty side
engine components. (outside).

The primary air cleaner element can be used up Aim the hose so that the air flows inside the element
to six times if the element is properly cleaned and along the length of the filter in order to help prevent
inspected. When the primary air cleaner element is damage to the paper pleats. Do not aim the stream
cleaned, check for rips or tears in the filter material. of air directly at the primary air cleaner element. Dirt
The primary air cleaner element should be replaced could be forced further into the pleats.
at least one time per year. This replacement
should be performed regardless of the number of Note: Refer to “Inspecting the Primary Air Cleaner
cleanings. Elements”.

Use clean primary air cleaner elements while dirty Vacuum Cleaning
elements are being cleaned.
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
NOTICE cleaning because of a dry, dusty environment.
Do not clean the air cleaner elements by bumping or Cleaning with pressurized air is recommended
tapping. This could damage the seals. Do not use el- prior to vacuum cleaning. Vacuum cleaning will not
ements with damaged pleats, gaskets or seals. Dam- remove deposits of carbon and oil.
aged elements will allow dirt to pass through. Engine
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 damage to the seal, the gaskets, and the outer
cover. Discard any damaged air cleaner elements.

There are two common methods that are used to

clean primary air cleaner elements:

• Pressurized air
• Vacuum cleaning
 97
Maintenance Section
Engine Air Cleaner Element - Clean/Replace

Inspecting the Primary Air Cleaner Do not use paint, a waterproof cover, or plastic as a
Elements protective covering for storage. An airflow restriction
may result. To protect against dirt and damage,
wrap the primary air cleaner elements in Volatile
Corrosion Inhibited (VCI) paper.

Place the primary air cleaner element into a box

for storage. For identification, mark the outside of
the box and mark the primary air cleaner element.
Include the following information:

• Date of cleaning
• Number of cleanings
Store the box in a dry location.
g00281693
Illustration 45
i00857000

Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a
Engine Air Cleaner Element -
similar facility. Place the blue light in the primary Clean/Replace
air cleaner element. Rotate the primary air cleaner
element. Inspect the primary air cleaner element for SMCS Code: 1054-070; 1054-510
tears and/or holes. Inspect the primary air cleaner
element for light that may show through the filter NOTICE
material. If it is necessary in order to confirm the Never service the air cleaner element with the engine
result, compare the primary air cleaner element running since this will allow dirt to enter the engine.
to a new primary air cleaner element that has the
same part number.
If the air cleaner element becomes plugged, the
Do not use a primary air cleaner element that has air can split the material of the air cleaner element.
any tears and/or holes in the filter material. Do not Unfiltered air will drastically accelerate internal
use a primary air cleaner element with damaged engine wear.
pleats, gaskets or seals. Discard damaged primary
air cleaner elements. • Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner
Storing Primary Air Cleaner Elements element.

If a primary air cleaner element that passes • The air cleaner element should be replaced
inspection will not be used, the primary air cleaner at least one time per year. This replacement
element can be stored for future use. should be performed regardless of the number
of cleanings.

Replace the dirty paper air cleaner elements with

clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked
for tears and/or holes in the filter material. Inspect
the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner
elements for replacement purposes.

Your Caterpillar dealer has the proper air cleaner

elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element
or follow the instructions that are provided by the
OEM.
g00281694
Illustration 46
98
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

i01175055 If the service indicator does not reset easily, or if the

yellow core does not latch at the greatest vacuum,
Engine Air Cleaner Service the service indicator should be replaced. If the
Indicator - Inspect new service indicator will not reset, the hole for the
service indicator may be plugged.
SMCS Code: 7452-040
The service indicator may need to be replaced
Some engines may be equipped with a different frequently in environments that are severely dusty, if
service indicator. necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
Some engines are equipped with a differential service indicator when the engine is overhauled,
gauge for inlet air pressure. The differential gauge and whenever major engine components are
for inlet air pressure displays the difference in the replaced.
pressure that is measured before the air cleaner
element and the pressure that is measured after Note: When a new service indicator is installed,
the air cleaner element. As the air cleaner element excessive force may crack the top of the service
becomes dirty, the pressure differential rises. If your indicator. Tighten the service indicator to a torque
engine is equipped with a different type of service of 2 N·m (18 lb in).
indicator, follow the OEM recommendations in order
to service the air cleaner service indicator. i01397717

The service indicator may be mounted on the air Engine Air Precleaner - Clean
cleaner element or in a remote location.
SMCS Code: 1055-070

g00103777
Illustration 47
g00736588
Typical service indicator Illustration 48
Typical precleaner
Observe the service indicator. The air cleaner (1) Wing nut
element should be cleaned or the air cleaner (2) Cover
element should be replaced when one of the (3) Body
following conditions occur:
Remove wing nut (1) and cover (2). Check for an
• The yellow diaphragm enters the red zone. accumulation of dirt and debris in body (3). Clean
the body, if necessary.
• The red piston locks in the visible position.
After cleaning the precleaner, install cover (2) and
wing nut (1).
Test the Service Indicator
Note: When the engine is operated in dusty
Service indicators are important instruments.
applications, more frequent cleaning is required.
• Check for ease of resetting. The service indicator
should reset in less than three pushes.

• Check the movement of the yellow core when the

engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.
 99
Maintenance Section
Engine Crankcase Breather - Clean

i00951415 i00687861

Engine Crankcase Breather - Engine Mounts - Inspect

Clean SMCS Code: 1152-040
SMCS Code: 1317-070
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 Service Manual for the
recommended torques. Refer to your Caterpillar
dealer for more information.

i01400963

Illustration 49 g00485291
Engine Oil Level - Check
(1) Bolts. (2) Hose clamp. (3) Breather cover.
SMCS Code: 1348-535-FLV
NOTICE
Perform this maintenance with the engine stopped.

Hot oil and hot components can cause personal

If the crankcase breather is not maintained on a injury. Do not allow hot oil or hot components to
regular basis, the crankcase breather will become contact the skin.
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.

1. Loosen hose clamp (2) and remove the hose

from breather cover (3).

2. Loosen four bolts (1) for the breather cover and

remove breather cover (3).

3. Remove the breather element and wash the

breather element in solvent that is clean and
nonflammable. Allow the breather element to dry.

4. Install a breather element that is clean and dry.

Install breather cover (3) and install bolts (1). g00123045
Illustration 50
Refer to the Operation and Maintenance Manual
for the proper torques. (1) Oil filler cap. (2) Oil level gauge.

5. Install the hose. Install hose clamp (2). Refer to

the Operation and Maintenance Manual for the
proper torques.

g00110310
Illustration 51
(Y) “ADD” mark. (X) “FULL” mark.
100
Maintenance Section
Engine Oil Sample - Obtain

To ensure that the sample is representative of the

NOTICE oil in the crankcase, obtain a warm, well mixed oil
Perform this maintenance with the engine stopped. sample.

To avoid contamination of the oil samples, the tools

Note: Before you perform this maintenance, do not and the supplies that are used for obtaining oil
operate the engine for at least 10 minutes in order samples must be clean.
to allow the engine oil to return to the oil pan.
Caterpillar recommends using the sampling valve
1. Maintain the oil level between “ADD” mark (Y) in order to obtain oil samples. The quality and the
and “FULL” mark (X) on oil level gauge (1). Do consistency of the samples are better when the
not fill the crankcase above “FULL” mark (X). sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
NOTICE obtained during normal engine operation.
Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into The 169-8373 Fluid Sampling Bottle is
the oil. The air bubbles created from the crankshaft recommended for use with the sampling valve. The
dipping into the oil reduces the oil’s lubricating char- fluid sampling bottle includes the parts that are
acteristics and could result in the loss of power. needed for obtaining oil samples. Instructions are
also provided.
2. Remove oil filler cap (2) and add oil, if necessary.
Clean the oil filler cap. Reinstall the oil filler cap. NOTICE
Do not use the same vacuum sampling pump for ex-
tracting oil samples that is used for extracting coolant
i01534451 samples.
Engine Oil Sample - Obtain A small residue of either type sample may remain in
the pump and may cause a false positive analysis for
SMCS Code: 1000-008; 1348-554-SM; the sample being taken.
7542-554-OC, SM
Always use a designated pump for oil sampling and a
In addition to a good preventive maintenance designated pump for coolant sampling.
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order Failure to do so may cause a false analysis which
to monitor the condition of the engine and the could lead to customer and dealer concerns.
maintenance requirements of the engine.
If the engine is not equipped with a sampling valve,
Obtain the Sample and the Analysis use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
Hot oil and hot components can cause personal
For instructions, see Special Publication, PEHP6001,
injury. Do not allow hot oil or hot components to
“How To Take A Good Oil Sample”. Consult your
contact the skin.
Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for
Before you take the oil sample, complete the Label, your engine.
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:

• Engine model
• Service hours on the engine
• The number of hours that have accumulated
since the last oil change

• The amount of oil that has been added since the

last oil change
 101
Maintenance Section
Engine Oil and Filter - Change

i01556104 Abnormally harsh operating cycles or harsh

environments can shorten the service life of
Engine Oil and Filter - Change the engine oil. Arctic temperatures, corrosive
environments, or extremely dusty conditions may
SMCS Code: 1318-510; 1348-044 require a reduction in engine oil change intervals
from the recommendations in Table 38 and Table
Selection of Oil Change Interval 39. Poor maintenance of air filters or of fuel filters
requires reduced oil change intervals. See your
Caterpillar dealer for more information if this product
NOTICE will experience abnormally harsh operating cycles
This engine meets EPA Tier 2, Euro Stage II, or MOC or harsh environments.
Step 2 emission regulations. A 500 hour engine oil
change interval is available, provided that operating
conditions and recommended multigrade oil types are
met. When these requirements are not met, shorten
the oil change interval to 250 hours, or use an S·O·S
oil sampling and analysis program to determine an
acceptable oil change interval.

If you select an interval for oil and filter change that is

too long, you may damage the engine.

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.

Caterpillar oil filters are recommended for oil

changes. Recommended multigrade oil types are
listed in Table 38 and Table 39. Do not use single
grade oils.

g00783061
Illustration 52
API Trademark
Commercial oils that are licensed by the American Petroleum
Institute (API) bear this trademark. Commercial oils that do
not bear this trademark are not licensed and these oils are not
recommended. Oils that are not listed in Table 38 or Table 39 are
not recommended.
102
Maintenance Section
Engine Oil and Filter - Change

Table 38 Table 39
Oil Change Interval for C-10 Industrial Engines (1) Oil Change Interval for C-12 Industrial Engines (1)

Operating Conditions Operating Conditions

Severe Severe
Normal(2) High Fuel Altitude Normal(2) High Fuel Altitude
Load Sulfur above Load Sulfur above
Multigrade Factor from 1830 m Multigrade Factor from 1830 m
Oil Type above 0.3% to (6000 ft) Oil Type above 0.3% to (6000 ft)
34 L 0.5% 43 L 0.5%
(9 US (4)
(11 US (4)
gal per gal per
hour of hour of
fuel) fuel)
(3) (3)

Cat DEO Cat DEO

500 hr 500 hr 500 hr 250 hr(6) 500 hr 500 hr 500 hr 250 hr(6)
Preferred Preferred
API CH-4 API CH-4
11.0 11.0
minimum 500 hr 500 hr 500 hr 250 hr(6) minimum 500 hr 500 hr 500 hr 250 hr(6)
TBN(4) TBN(4)
Preferred Preferred
API CH-4 API CH-4
TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6) TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6)
below 11.0 below 11.0
API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6) API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6)
API CF-4 250 hr(5) 250 hr(6) 250 hr(6) 250 hr(6) API CF-4 250 hr(5) 250 hr(6) 250 hr(6) 250 hr(6)
(1) The standard oil change interval in this engine is 500 hours, if (1) The standard oil change interval in this engine is 500 hours, if
the operating conditions and recommended oil types that are the operating conditions and recommended oil types that are
listed in this table are met. The traditional oil change interval for listed in this table are met. The traditional oil change interval for
engines is 250 hours. Improvements in the engine allow this engines is 250 hours. Improvements in the engine allow this
engine oil change interval. This new standard interval is not engine oil change interval. This new standard interval is not
permitted for other engines. Refer to the applicable Operation permitted for other engines. Refer to the applicable Operation
and Maintenance Manuals for the other engines. and Maintenance Manuals for the other engines.
(2) Normal conditions include these factors: Fuel sulfur below (2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and 0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments. load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine oil. (3) High load factors can shorten the service life of your engine oil.
Continuous heavy load cycles and very little idle time result Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average factors deplete the oil additives more rapidly. If the average
fuel consumption of your engine exceed 34 L (9 US gal) per fuel consumption of your engine exceed 43 L (11 US gal) per
hour, follow the “High Load Factor” recommendations in Table hour, follow the “High Load Factor” recommendations in Table
38. To determine average fuel consumption for your engine, 39. To determine average fuel consumption for your engine,
measure average fuel consumption for a period of 50 to 100 measure average fuel consumption for a period of 50 to 100
hours. If the application of the engine is changed, the average hours. If the application of the engine is changed, the average
fuel consumption may change. fuel consumption may change.
(4) For sulfur content above 0.5%, refer to Operation and (4) For sulfur content above 0.5%, refer to Operation and
Maintenance Manual, “Total Base Number (TBN) and Fuel Maintenance Manual, “Total Base Number (TBN) and Fuel
Sulfur Levels for Direct Injection (DI) Diesel Engines” in the Sulfur Levels for Direct Injection (DI) Diesel Engines” in the
“Lubricant” section of this manual. Also, you may refer to this “Lubricant” section of this manual. Also, you may refer to this
topic in Manual, SEBU6251. topic in Manual, SEBU6251.
(5) In order to verify an oil change interval of 500 hours, refer to (5) In order to verify an oil change interval of 500 hours, refer to
“Program A” below. “Program A” below.
(6) Use “Program B” below to determine an appropriate interval. (6) Use “Program B” below to determine an appropriate interval.

Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additional
information on these programs.
 103
Maintenance Section
Engine Oil and Filter - Change

Program A 2. After the oil has drained, the oil drain plug should
be cleaned and installed.
Verification for a 500 Hour Oil Change Interval

This program consists of three oil change intervals

Replace the Oil Filter
of 500 hours. Oil sampling and analysis is done
at 250 hours and 500 hours for each of the three NOTICE
intervals for a total of six oil samples. The analysis Caterpillar oil filters are built to Caterpillar speci-
includes oil viscosity and infrared (IR) analysis of fications. Use of an oil filter not recommended by
the oil. If all of the results are satisfactory, the 500 Caterpillar could result in severe engine damage to
hour oil change interval is acceptable for the engine the engine bearings, crankshaft, etc., as a result of
in that application. Repeat Program A if you change the larger waste particles from unfiltered oil entering
the application of the engine. the engine lubricating system. Only use oil filters
recommended by Caterpillar.
If a sample does not pass the oil analysis, take one
of these actions:
1. Remove the oil filter with a 1U-8760 Chain
Wrench.
• Shorten the oil change interval to 250 hours.
• Proceed to Program B.
• Change to a preferred oil type in Table 38 or
Table 39.

Program B

Optimizing Oil Change Intervals

Begin with a 250 hour oil change interval. The

oil change intervals are adjusted by increments.
Each interval is adjusted an additional 50 hours.
Periodic oil sampling and analysis is done during
each interval. The analysis includes oil viscosity and Illustration 53
g00588944
infrared (IR) analysis of the oil. Repeat Program B if
Element with debris
you change the application of the engine.
2. Cut the oil filter open with a 4C-5084 Oil Filter
If an oil sample does not pass the analysis, shorten
Cutter. Break apart the pleats and inspect the oil
the oil change interval, or change to a preferred
filter for metal debris. An excessive amount of
multigrade oil type in the listing above.
metal debris in the oil filter may indicate early
wear or a pending failure.
References
Use a magnet to differentiate between the
Reference: Form, PEDP7035, “Optimizing Oil
ferrous metals and the nonferrous metals that
Change Intervals”
are found in the oil filter element. Ferrous metals
may indicate wear on the steel and cast iron
Reference: Form, PEDP7036, “S·O·S Fluid Analysis”
parts of the engine.
Reference: Form, PEDP7076, “Understanding the
Nonferrous metals may indicate wear on the
S·O·S Oil Analysis Tests”
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
Drain the Engine Oil the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
After the engine has been run at the normal
operating temperature, stop the engine. Attach a Due to normal wear and friction, it is not
“DO NOT OPERATE” or a similar warning tag to the uncommon to find small amounts of debris in the
ignition key switch before the engine is serviced. oil filter. Consult your Caterpillar dealer in order
Catch the oil in a suitable container. Recycle the to arrange for a further analysis if an excessive
used oil, or dispose of the used oil properly. amount of debris is found in the oil filter.

1. Remove the oil drain plug in order to allow the

oil to drain.
104
Maintenance Section
Engine Storage Procedure - Check

2. Start the engine and run the engine at “LOW

IDLE” for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.

3. Stop the engine and allow the oil to drain back

to the sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the “ENGINE STOPPED”
side of the oil level gauge.

g00103713
Illustration 54 i01430860
Typical filter mounting base and filter gasket
Engine Storage Procedure -
3. Clean the sealing surface of the filter mounting Check
base. Ensure that all of the old oil filter gasket
is removed. SMCS Code: 1000-535

4. Apply clean engine oil to the new oil filter gasket. Caterpillar requires all engines that are stored for
more than 3 months to follow storage procedures
NOTICE and start-up procedures. These procedures provide
Do not fill the oil filters with oil before installing them. maximum protection to internal engine components.
This oil would not be filtered and could be contaminat- Refer to Special Instruction, SEHS9031, “Storage
ed. Contaminated oil can cause accelerated wear to Procedure For Caterpillar Products” for information
engine components. on these procedures.

An extension of the oil change interval to 12

5. Install the oil filter. Tighten the oil filter until the months is permitted if you follow the required
oil filter gasket contacts the base. Tighten the oil procedures for storage and start-up. This extension
filter by hand according to the instructions that is permitted if the following intervals in the Operation
are shown on the oil filter. Do not overtighten the and Maintenance Manual, “Maintenance Interval
oil filter. Schedule” have not been reached:

Fill the Engine Crankcase • Operating hours

1. Remove the oil filler cap. Refer to the • Fuel consumption

Operation and Maintenance Manual, “Lubricant
Specifications” topic (Maintenance Section) for i00869413
more information. Fill the crankcase with the
proper amount of oil. Refer to the Operation and Engine Valve Lash -
Maintenance Manual, “Refill Capacities” topic
(Maintenance Section) for more information.
Inspect/Adjust
SMCS Code: 1102-025
NOTICE
If equipped with an auxiliary oil filter or system, extra The initial valve lash adjustment on new engines,
oil must be added when filling the crankcase. Follow rebuilt engines, or remanufactured engines is
the OEM or filter manufacturer’s recommendations. If recommended at the first scheduled oil change.
the extra oil is not added, the engine may starve for The initial adjustment is necessary due to initial
oil. wear of the valve train components and seating of
the valve train components.
NOTICE This maintenance is recommended by Caterpillar
To help prevent crankshaft or bearing damage, crank as part of a lubrication and preventive maintenance
engine to fill all filters before starting. Do not crank schedule in order to help provide maximum engine
engine for more than 30 seconds. life.
 105
Maintenance Section
Engine Valve Rotators - Inspect

Adjustment of the Electronic Unit 3. Observe the top surface of each valve rotator.
The valve rotators should turn slightly when the
Injector valves close.
Adjust the electronic unit injector (preload) at the
same interval as the valve lash adjustment. The NOTICE
operation of Caterpillar engines with improper valve A valve rotator which does not operate properly will
adjustments and with improper adjustments of the accelerate valve face wear and valve seat wear and
electronic unit injector can reduce engine efficiency. shorten valve life. If a damaged rotator is not replaced,
This reduced efficiency could result in excessive valve face guttering could result and cause pieces of
fuel usage and/or shortened engine component life. the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
NOTICE
Only qualified service personnel should perform this If a valve fails to rotate, consult your Caterpillar
maintenance. Refer to the Service Manual or your dealer.
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
i00805059

Operation of Caterpillar engines with improper valve

adjustments can reduce engine efficiency. This re-
Ether Starting Aid Cylinder -
duced efficiency could result in excessive fuel usage Replace
and/or shortened engine component life. (If Equipped)
SMCS Code: 1456-510-CD

Ensure that the engine can not be started while

this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.

Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.

i01597115

Engine Valve Rotators - Inspect

g00104888
Illustration 55
SMCS Code: 1109-040 Typical example

1. Loosen the ether cylinder clamp. Unscrew and

remove the empty ether cylinder.
When inspecting the valve rotators, protective
glasses or face shield and protective clothing 2. Remove the used gasket. Install the new gasket
must be worn, to help prevent being burned by that is provided with each new ether cylinder.
hot oil or spray.
3. Install the new ether cylinder. Hand tighten the
ether cylinder. Tighten the ether cylinder clamp
Engine valve rotators rotate the valves when the securely.
engine runs. This helps to prevent deposits from
building up on the valves and the valve seats.

Perform the following steps after the engine valve

lash is set, but before the valve covers are installed:

1. Start the engine according to Operation

and Maintenance Manual, “Engine Starting”
(Operation Section) for the procedure.

2. Operate the engine at low idle.

106
Maintenance Section
Fan Drive Bearing - Lubricate

i00175571 • Replacement of the fuel filter

Fan Drive Bearing - Lubricate
Engines that are Equipped with a
SMCS Code: 1359-086-BD Fuel Priming Pump
NOTICE
Do not loosen the fuel lines at the fuel manifold. The
fittings may be damaged and/or a loss of priming pres-
sure may occur when the fuel lines are loosened.

1. Open the fuel priming pump and operate the

fuel priming pump until a strong pressure is felt.
This procedure will require considerable strokes.
Lock the fuel priming pump.

NOTICE
Do not crank the engine continuously for more than
g00123252
Illustration 56 30 seconds. Allow the starting motor to cool for two
Typical Fan Drive Bearing Grease Fitting minutes before cranking the engine again.

Lubricate the fan drive bearing grease fitting with 2. Promptly start the engine. If the engine runs
Bearing Lubricant Special Purpose Grease or the rough, continue to operate the engine at low idle.
equivalent. Do not raise the engine rpm above an idle, until
the engine operates smoothly.
Inspect the fan drive pulley assembly. If the shaft
is loose, an inspection of the internal components 3. If the engine does not start, open the fuel priming
should be performed. Refer to the Service Manual. pump and repeat Steps 1 and 2 in order to start
the engine.
i01091827

Fuel System - Prime Engines that are Not Equipped with

a Fuel Priming Pump
SMCS Code: 1258-548
If the engine is not equipped with a fuel priming
pump, you can use the following procedures to
prime the fuel system. These procedures will allow
only filtered fuel to enter the fuel system.
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when Fuel Filter Bases that are Equipped with
changing fuel filters or water separator elements. a Plug
Clean up fuel spills immediately.
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 dis-
will be disconnected. Fit a suitable cover over any dis- connected fuel system components.
connected fuel system components.

Prime the fuel system in order to fill the fuel filter.

Prime the fuel system in order to purge trapped
air. The fuel system should be primed under the
following conditions:

• Running out of fuel

• Storage
 107
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

i00259781

Fuel System Primary

Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
g00430478
Illustration 57
(1) Plug
(2) Fuel filter

1. Remove plug (1) in order to fill fuel filter (2).

Ensure that air is able to vent from the fitting of
the plug while the fuel filter is being filled. Clean
up any spilled fuel immediately. Clean plug (1).
Install plug (1).

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.
g00104007
Illustration 58
2. Start the engine and operate the engine at low
(1) Element. (2) Bowl. (3) Drain.
idle. Do not raise the engine speed above an
idle, until the engine operates smoothly.
Bowl (2) should be monitored daily for signs of
water. If water is present, drain the water from the
Fuel Filter Bases that are Not Equipped bowl.
with a Plug
1. Open drain (3). The drain is a self-ventilated
drain. Catch the draining water in a suitable
NOTICE
container. Dispose of the water properly.
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
2. Close drain (3).
minutes before cranking the engine again.

NOTICE
1. Operate the starting motor. This will fill the fuel The water separator is under suction during normal
filter and the fuel lines with fuel. engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
2. Once the engine starts, operate the engine at system.
low idle. Do not raise the engine speed above
an idle, until the engine operates smoothly.
108
Maintenance Section
Fuel System Primary Filter/Water Separator Element - Replace

i01488870
NOTICE
Fuel System Primary Do not allow dirt to enter the fuel system. Thoroughly
Filter/Water Separator Element clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
- Replace connected fuel system components.
SMCS Code: 1260-510-FQ; 1263-510-FQ
NOTICE
Water in the fuel can cause the engine to run rough. Use a suitable container to catch any fuel that might
Water in the fuel may cause a electronic unit injector spill. Clean up any spilled fuel immediately.
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval. 3. Dispose of the fuel in the fuel filter element.
Remove bowl (2) from element (1). The bowl is
The primary filter/water separator also provides reusable. Do not discard the bowl. Dispose of
filtration in order to help extend the life of the the used element.
secondary fuel filter. The element should be
changed regularly. If a vacuum gauge is installed, 4. Remove the O-ring from the gland of the bowl.
the primary filter/water separator should be changed Clean the following components:
at 50 to 70 kPa (15 to 20 inches hg).
• Bowl
Replace the Element • O-ring
• Mounting base

Fuel leaked or spilled onto hot surfaces or elec- Inspect the O-ring for damage and for
trical components can cause a fire. To help pre- deterioration. Replace the O-ring, if necessary.
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements. 5. Lubricate the O-ring with clean diesel fuel.
Clean up fuel spills immediately.
6. Install bowl (2) on a new element. Tighten the
bowl by hand. Do not use tools in order to tighten
Note: A 10 to 15 micron absolute high efficiency the bowl.
fuel filter is required for Caterpillar Electronic Unit
Injectors. Caterpillar High Efficiency Fuel Filters NOTICE
meet these requirements. Consult your Caterpillar The primary filter/water separator may be prefilled with
dealer for the proper part number. fuel to avoid rough running/stalling of the engine due
to air. Do not fill the secondary filter with fuel before
1. Close the main fuel supply valve. installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accel-
erated wear to fuel system parts.

7. Lubricate the top seal of element (1) with clean

diesel fuel. The element may be filled with fuel at
this time. Install the new element on the mounting
base. Tighten the element by hand.

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 fu-
el system.
g00104012
Illustration 59
(1) Element. (2) Bowl. (3) Drain. 8. Open the main fuel supply valve.

2. Remove element (1) from the element mounting 9. Start the engine and check for leaks. Run the
base while bowl (2) is attached. engine for one minute. Stop the engine and
check for leaks again.
 109
Maintenance Section
Fuel System Secondary Filter - Replace

Detection of leaks is difficult while the engine 4. Unlock fuel priming pump (2) in order to relieve
is running. The primary filter/water separator is residual pressure in the fuel system.
under suction. A leak will allow air to enter the
fuel. The air in the fuel can cause low power 5. Remove used fuel filter (3). Use a cloth or use a
due to aeration of the fuel. If air enters the fuel, container in order to catch excess fuel.
check the components for overtightening or
under tightening. 6. Clean the gasket sealing surface of the fuel
filter base. Ensure that all of the old gasket is
removed.
i01503553

Fuel System Secondary Filter - NOTICE

In order to maximize fuel system life and prevent pre-
Replace mature wear out from abrasive particles in the fuel,
a two micron absolute high efficiency fuel filter is re-
SMCS Code: 1261-510-SE quired for all Caterpillar Hydraulic Electronic Unit In-
jectors. Caterpillar High Efficiency Fuel Filters meet
these requirements. Consult your Caterpillar dealer for
the proper part numbers.
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
7. Apply clean diesel fuel to the new fuel filter
vent possible injury, turn the start switch off when
gasket.
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.

8. Install new fuel filter (3). Tighten the fuel filter until
the gasket contacts the base. Tighten the fuel
filter by hand according to the instructions that
are shown on the fuel filter. Do not overtighten
the fuel filter.

Note: DO NOT remove plug (1) in the fuel filter base

in order to release air from the fuel system during
g00123061
periodic service of the fuel filter. Periodic removal of
Illustration 60 the plug will result in increased wear of the threads
(1) Plug. (2) Fuel priming pump. (3) Fuel filter. in the fuel filter base.

NOTICE 9. Operate fuel priming pump (2) until a strong

Do not allow dirt to enter the fuel system. Thoroughly pressure is felt on the fuel priming pump and
clean the area around a fuel system component that until the check valve clicks. This procedure
will be disconnected. Fit a suitable cover over any dis- will require considerable strokes. Lock the fuel
connected fuel system components. priming pump.

10. Open the fuel tank supply valve.

1. Stop the engine.
11. Start the engine according to the normal
2. Turn off the start switch or disconnect the battery operating procedures. Immediately increase the
(starting motor) when maintenance is performed engine rpm between 1000 to 1200 rpm with no
on fuel filters. load. The engine will begin to misfire briefly until
air from the fuel filter is purged. No damage to
3. Shut off the fuel tank supply valve to the engine. the engine will occur.

NOTICE NOTICE
Use a suitable container to catch any fuel that might Do not crank the engine continuously for more than
spill. Clean up any spilled fuel immediately. 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
110
Maintenance Section
Fuel Tank Water and Sediment - Drain

12. If the engine stalls during the purging of the air, • Weekly
refer to the Operation and Maintenance Manual,
“Fuel System - Prime” in the Maintenance Section • Oil change
for more information.
• Refill of the tank
i00073301
This will help prevent water or sediment from being
Fuel Tank Water and Sediment pumped from the storage tank into the engine fuel
tank.
- Drain
If a bulk storage tank has been refilled or moved
SMCS Code: 1273-543-M&S recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
Fuel Tank baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
Fuel quality is critical to the performance and to storage tank helps to ensure the quality of the fuel.
the service life of the engine. Water in the fuel can When possible, water separators should be used.
cause excessive fuel system wear. Condensation
occurs during the heating and cooling of fuel. The i00907072
condensation occurs as the fuel passes through
the fuel system and the fuel returns to the fuel tank. Hoses and Clamps -
This causes water to accumulate in fuel tanks.
Draining the fuel tank regularly and obtaining fuel
Inspect/Replace
from reliable sources can help to eliminate water
SMCS Code: 7554-040; 7554-510
in the fuel.
Inspect all hoses for leaks that are caused by the
Drain the Water and the Sediment following conditions:

Fuel tanks should contain some provision for • Cracking

draining water and draining sediment from the
bottom of the fuel tanks. • Softness
Open the drain valve on the bottom of the fuel tank • Loose clamps
in order to drain the water and the sediment. Close
the drain valve. Replace hoses that are cracked or soft. Tighten any
loose clamps.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
NOTICE
the water and sediment from the fuel tank after the
Do not bend or strike high pressure lines. Do not in-
fuel tank has been filled. Allow five to ten minutes
stall bent or damaged lines, tubes or hoses. Repair
before performing this procedure.
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
Fill the fuel tank after operating the engine in
and hoses carefully. Tighten all connections to the rec-
order to drive out moist air. This will help prevent
ommended torque.
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow. Check for the following conditions:

Some fuel tanks use supply pipes that allow water • End fittings that are damaged or leaking
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that • Outer covering that is chafed or cut
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular • Exposed wire that is used for reinforcement
maintenance of the fuel system filter is important.
• Outer covering that is ballooning locally
Fuel Storage Tanks
• Flexible part of the hose that is kinked or crushed
Drain the water and the sediment from the fuel
storage tank during the following conditions: • Armoring that is embedded in the outer covering
 111
Maintenance Section
Overhaul Considerations

A constant torque hose clamp can be used in Note: For the proper coolant to use, see this
place of any standard hose clamp. Ensure that the Operation and Maintenance Manual, “Coolant
constant torque hose clamp is the same size as Recommendations” (Maintenance Section).
the standard clamp.
8. Refill the cooling system.
Due to extreme temperature changes, the hose
will heat set. Heat setting causes hose clamps to 9. Clean the cooling system filler cap. Inspect the
loosen. This can result in leaks. A constant torque cooling system filler cap’s gaskets. Replace
hose clamp will help to prevent loose hose clamps. the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
Each installation application can be different. The
differences depend on the following factors: 10. Start the engine. Inspect the cooling system for
leaks.
• Type of hose
i01452713
• Type of fitting material
Overhaul Considerations
• Anticipated expansion and contraction of the
hose SMCS Code: 7595-043
• Anticipated expansion and contraction of the Reduced hours of operation at full load will result
fittings in a lower average power demand. A decreased
average power demand should increase both the
Replace the Hoses and the Clamps engine service life and the overhaul interval.

The need for an overhaul is generally indicated by

increased fuel consumption and by reduced power.
Pressurized System: Hot coolant can cause seri- The following factors are important when a decision
ous burns. To open the cooling system filler cap, is being made on the proper time for an engine
stop the engine and wait until the cooling system overhaul:
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres- • The need for preventive maintenance
sure.
• The quality of the fuel that is being used
1. Stop the engine. Allow the engine to cool.
• The operating conditions
2. Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the • The results of the S·O·S analysis
cooling system filler cap.
Oil Consumption as an Overhaul
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused. Indicator
3. Drain the coolant from the cooling system to Oil consumption, fuel consumption, and
a level that is below the hose that is being maintenance information can be used to estimate
replaced. the total operating cost for your Caterpillar engine.
Oil consumption can also be used to estimate
4. Remove the hose clamps. the required capacity of a makeup oil tank that is
suitable for the maintenance intervals.
5. Disconnect the old hose.
Oil consumption is in proportion to the percentage
6. Replace the old hose with a new hose. of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
Note: For torques on hose clamps, see this consumed per hour also increases.
Operation and Maintenance Manual, “Torque
Specifications” (Maintenance Section).

7. Install the hose clamps with a torque wrench.

112
Maintenance Section
Overhaul Considerations

The oil consumption rate (brake specific oil Note: Overhaul programs vary according to the
consumption) is measured in grams per kW/h engine application and according to the dealer
(lb per bhp). The brake specific oil consumption that performs the overhaul. Consult your Caterpillar
(BSOC) depends on the engine load. Consult your dealer for specific information about the available
Caterpillar dealer for assistance in determining the overhaul programs and about overhaul services for
typical oil consumption rate for your engine. extending the engine life.

When an engine’s oil consumption has risen to If an overhaul is performed without overhaul service
three times the original oil consumption rate due from your Caterpillar dealer, be aware of the
to normal wear, an engine overhaul should be following maintenance recommendations.
scheduled. There may be a corresponding increase
in blowby and a slight increase in fuel consumption. Rebuild or Exchange
Overhaul Options Cylinder Head Assembly, Cylinder Packs, Oil
Pump, and Fuel Transfer Pump
Before Failure Overhaul
These components should be inspected according
A planned overhaul before failure may be the best to the instructions that are found in various
value for the following reasons: Caterpillar reusability publications. The Special
Publication, SEBF8029 lists the reusability
• Costly unplanned downtime can be avoided. publications that are needed for inspecting the
engine parts.
• Many original parts can be reused according to
the standards for reusable parts. If the parts comply with the established inspection
specifications that are expressed in the reusable
• The engine’s service life can be extended without parts guideline, the parts should be reused.
the risk of a major catastrophe due to engine
failure. Parts that are not within the established inspection
specifications should be dealt with in one of the
• The best cost/value relationship per hour of following manners:
extended life can be attained.
• Salvaging
After Failure Overhaul
• Repairing
If a major engine failure occurs and the engine
must be removed, many options are available. An • Replacing
overhaul should be performed if the engine block
or the crankshaft needs to be repaired. Using out-of-spec parts can result in the following
problems:
If the engine block is repairable and/or the
crankshaft is repairable, the overhaul cost should • Unscheduled downtime
be between 40 percent and 50 percent of the cost
of a new engine with a similar exchange core. • Costly repairs
This lower cost can be attributed to three aspects: • Damage to other engine parts
• Specially designed Caterpillar engine features • Reduced engine efficiency
• Caterpillar dealer exchange components • Increased fuel consumption
• Caterpillar Inc. remanufactured exchange Reduced engine efficiency and increased fuel
components consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts.
Overhaul Recommendation
To minimize downtime, Caterpillar Inc. recommends
a scheduled engine overhaul by your Caterpillar
dealer before the engine fails. This will provide you
with the best cost/value relationship.
 113
Maintenance Section
Overhaul Considerations

Inspection and/or Replacement Oil Cooler Core

Crankshaft Bearings, Valve Rotators, and During an overhaul, Caterpillar Inc. recommends
Crankshaft Seals the removal of the oil cooler core. Clean the oil
cooler core. Then, pressure test the oil cooler core.
The following components may not last until the
second overhaul. NOTICE
Do not use caustic cleaners to clean the core.
• Thrust bearings
Caustic cleaners can attack the internal metals of the
• Main bearings core and cause leakage.
• Rod bearings
Note: Use this cleaning procedure to clean the oil
• Valve rotators cooler core.

• Crankshaft seals 1. Remove the oil cooler core.

Caterpillar Inc. recommends the installation of new 2. Remove any debris from the oil cooler core. To
parts at each overhaul period. remove debris from the oil cooler core, turn the
oil cooler core onto one end.
Inspect these parts while the engine is disassembled
for an overhaul. 3. Flush the oil cooler core internally with cleaner in
order to loosen foreign substances. This will also
Inspect the crankshaft for any of the following help to remove oil from the oil cooler core.
conditions:
Note: Caterpillar Inc. recommends the use of
• Deflection Hydrosolv Liquid Cleaners. Table 40 lists the
Hydrosolv Liquid Cleaners that are available from
• Damage to the journals your Caterpillar dealer.

• Bearing material that has seized to the journals Table 40

HydrosolvLiquid Cleaners
Check the journal taper and the profile of the
crankshaft journals. Check these components by Part
Description Size
interpreting the wear patterns on the following Number
components: 1U-8812 4 L (1 US gallon)
1U-5490 Hydrosolv4165 19 L (5 US gallon)
• Rod bearing
8T-7570 208 L (55 US gallon)
• Main bearings
1U-8804 4 L (1 US gallon)
Inspect the camshaft for damage to the journals 1U-5492 Hydrosolv100 19 L (5 US gallon)
and to the lobes.
8T-5571 208 L (55 US gallon)
Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check 4. Use steam to clean the oil cooler core. This
for cracks in the camshaft. removes any remaining residue from the cleaner.
Flush the fins of the oil cooler core. Remove any
Inspect the following components for signs of wear other trapped debris.
or for signs of scuffing:
5. Wash the oil cooler core with hot, soapy water.
• Camshaft bearings Rinse the oil cooler core thoroughly with clean
water.
• Camshaft followers
Caterpillar Inc. recommends replacing the
crankshaft vibration damper.
114
Maintenance Section
Power Take-Off Clutch - Check/Adjust/Lubricate

• Identification of metal corrosion

Personal injury can result from air pressure. • Identification of contaminants

Personal injury can result without following prop- • Identification of built up impurities (corrosion and
scale)
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
Maximum air pressure at the nozzle must be less
recommendations.
than 205 kPa (30 psi) for cleaning purposes.
For more information about coolant analysis, see
6. Dry the oil cooler core with compressed air. your Caterpillar dealer.
Direct the air in the reverse direction of the
normal flow.
i01506009

7. Inspect the components in order to ensure

cleanliness. The oil cooler core should be
Power Take-Off Clutch -
pressure tested. Repair the oil cooler core, if Check/Adjust/Lubricate
necessary. Install the oil cooler core.
SMCS Code: 3055-036; 3055-086
For more information about cleaning the cores,
consult your Caterpillar dealer. NOTICE
New power take-offs should have the clutch adjust-
Obtain Coolant Analysis ment checked before being placed into service. The
clutch adjustment should be checked again after the
The concentration of supplemental coolant additive first ten hours of operation. New clutch plates have a
(SCA) should be checked regularly with test kits “wear in” period, and the clutch may require several
or with S·O·S Coolant Analysis (Level 1). Further adjustments until the new plates are “worn in”.
coolant analysis is recommended when the engine
is overhauled.

For example, considerable deposits are found in the

water jacket areas on the external cooling system,
but the concentrations of coolant additives were
carefully maintained. The coolant water probably
contained minerals that were deposited on the
engine over time.

A coolant analysis can be conducted in order

to verify the condition of the water that is being
used in the cooling system. A full water analysis
can be obtained by consulting your local water
utility company or an agricultural agent. Private
laboratories are also available for water analysis. Illustration 61
g00781502

(1) Instruction plate

Caterpillar Inc. recommends an S·O·S Coolant (2) Serial number plate
Analysis (Level 2).
Check the clutch adjustment regularly after
S·O·S Coolant Analysis (Level 2) “wear in”. Heavy-duty applications which have
engagements that are frequent and relatively long
An S·O·S Coolant Analysis (Level 2) is a periods of clutch slippage require more frequent
comprehensive coolant analysis which completely adjustment than light-duty applications. The
analyzes the coolant and the effects on the cooling operating torque should be measured in order to
system. An S·O·S Coolant Analysis (Level 2) determine if a clutch adjustment is required.
provides the following information:
Refer to the OEM information and instruction plate
• Complete S·O·S Coolant Analysis (Level 1) (1) for instructions on lubrication, adjustment, and
other recommendations for service. Perform the
• Visual inspection of properties maintenance that is specified on the instruction
plate.
 115
Maintenance Section
Radiator - Clean

After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Do not operate the engine with the Instruction
Use a light bulb behind the core in order to inspect
Plate cover removed from the clutch. Personal
the core for cleanliness. Repeat the cleaning, if
injury may result.
necessary.
If the clutch is damaged to the point of burst fail-
Inspect the fins for damage. Bent fins may be
ure, expelled pieces can cause personal injury to
opened with a “comb”. Inspect these items for
anyone in the immediate area. Proper safeguards
good condition: welds, mounting brackets, air lines,
must be followed to help prevent accidents.
connections, clamps, and seals. Make repairs, if
necessary.
i01604510 For more detailed information on cleaning and
Radiator - Clean inspection, refer to Special Publication, SEBD0518,
“Know Your Cooling System”.
SMCS Code: 1353-070
i00151038
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. Severe Service Application -
Inspect the radiator for these items: damaged fins,
Check
corrosion, dirt, grease, insects, leaves, oil, and
SMCS Code: 1000-535
other debris. Clean the radiator, if necessary.
Severe service is an application of an engine
that exceeds current published standards for that
engine. Caterpillar maintains standards for the
Personal injury can result from air pressure. following engine parameters:

Personal injury can result without following prop- • Performance (power range, speed range, and
er procedure. When using pressure air, wear a pro- fuel consumption)
tective face shield and protective clothing.
• Fuel quality
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes. • Altitude range

Pressurized air is the preferred method for removing

• Maintenance intervals
loose debris. Direct the air in the opposite direction
of the fan’s air flow. Hold the nozzle approximately
• Oil selection and maintenance
6 mm (0.25 inch) away from the fins. Slowly move
the air nozzle in a direction that is parallel with the
• Coolant selection and maintenance
tubes. This will remove debris that is between the
tubes.
• Environmental qualities

Pressurized water may also be used for cleaning.

• Installation
The maximum water pressure for cleaning purposes Refer to the standards for the engine or consult with
must be less than 275 kPa (40 psi). Use pressurized your Caterpillar dealer in order to determine if the
water in order to soften mud. Clean the core from engine is operating within the defined parameters.
both sides.
Severe service operation can accelerate component
Use a degreaser and steam for removal of oil and wear. Engines that operate under severe conditions
grease. Clean both sides of the core. Wash the core may need more frequent maintenance intervals in
with detergent and hot water. Thoroughly rinse the order to ensure maximum reliability and retention
core with clean water. of full service life.

Due to individual applications, it is not possible to

identify all of the factors which can contribute to
severe service operation. Consult your Caterpillar
dealer for the unique maintenance that is necessary
for the engine.
116
Maintenance Section
Starting Motor - Inspect

The operating environment, improper operating Check the starting motor for proper operation.
procedures and improper maintenance procedures Check the electrical connections and clean the
can be factors which contribute to severe service electrical connections. Refer to the Service Manual
conditions. for more information on the checking procedure and
for specifications or consult your Caterpillar dealer
for assistance.
Environmental Factors
Ambient temperatures – The engine may be i01539769
exposed to extended operation in extremely
cold environments or hot environments. Valve Turbocharger - Inspect
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very SMCS Code: 1052-040
cold temperatures. Extremely hot inlet air reduces
engine performance. Periodic inspection and cleaning is recommended
for the turbocharger compressor housing (inlet
Air Quality – The engine may be exposed to side). Any fumes from the crankcase are filtered
extended operation in an environment that is dirty through the air inlet system. Therefore, by-products
or dusty, unless the equipment is cleaned regularly. from oil and from combustion can collect in the
Mud, dirt and dust can encase components. turbocharger compressor housing. Over time, this
Maintenance can be very difficult. The buildup can buildup can contribute to loss of engine power,
contain corrosive chemicals. increased black smoke and overall loss of engine
efficiency.
Buildup – Compounds, elements, corrosive
chemicals and salt can damage some components. If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
Altitude – Problems can arise when the engine and/or to the engine may occur. Damage to
is operated at altitudes that are higher than the the turbocharger compressor wheel can cause
intended settings for that application. Necessary additional damage to the pistons, the valves, and
adjustments should be made. the cylinder head.

Improper Operating Procedures NOTICE

Turbocharger bearing failures can cause large quan-
• Extended operation at low idle tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
• Frequent hot shutdowns damage.

• Operating at excessive loads Minor leakage of a turbocharger housing under ex-

tended low idle operation should not cause problems
• Operating at excessive speeds as long as a turbocharger bearing failure has not oc-
curred.
• Operating outside the intended application
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
Improper Maintenance Procedures smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
• Extending the maintenance intervals replaced.
• Failure to use recommended fuel, lubricants and
coolant/antifreeze An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for
i00651416
potential damage to other engine parts.
Starting Motor - Inspect Note: Turbocharger components require precision
SMCS Code: 1451-040; 1453-040 clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Caterpillar Inc. recommends a scheduled inspection Applications can accelerate component wear.
of the starting motor. If the starting motor fails, the Severe Service Applications require more frequent
engine may not start in an emergency situation. inspections of the cartridge.
 117
Maintenance Section
Walk-Around Inspection

Removal and Installation i01185304

For options regarding the removal, installation, Walk-Around Inspection

repair and replacement, consult your Caterpillar
dealer. Refer to the Service Manual for this engine SMCS Code: 1000-040
for the procedure and specifications.
Inspect the Engine for Leaks and
Cleaning and Inspecting for Loose Connections
1. Remove the exhaust outlet piping and remove A walk-around inspection should only take a few
the air inlet piping from the turbocharger. Visually minutes. When the time is taken to perform these
inspect the piping for the presence of oil. Clean checks, costly repairs and accidents can be
the interior of the pipes in order to prevent dirt avoided.
from entering during reassembly.
For maximum engine service life, make a thorough
2. Turn the compressor wheel and the turbine inspection of the engine compartment before
wheel by hand. The assembly should turn freely. starting the engine. Look for items such as oil leaks
Inspect the compressor wheel and the turbine or coolant leaks, loose bolts, worn belts, loose
wheel for contact with the turbocharger housing. connections and trash buildup. Make repairs, as
There should not be any visible signs of contact needed:
between the turbine wheel or compressor
wheel and the turbocharger housing. If there is • The guards must be in the proper place. Repair
any indication of contact between the rotating damaged guards or replace missing guards.
turbine wheel or the compressor wheel and the
turbocharger housing, the turbocharger must be • Wipe all caps and plugs before the engine is
reconditioned. serviced in order to reduce the chance of system
contamination.
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty, NOTICE
dirt and/or moisture is passing through the air For any type of leak (coolant, lube, or fuel) clean up the
filtering system. If oil is found only on the back fluid. If leaking is observed, find the source and correct
side of the wheel, there is a possibility of a failed the leak. If leaking is suspected, check the fluid levels
turbocharger oil seal. more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
The presence of oil may be the result of extended unwarranted.
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
for the inlet air (plugged air filters), which causes NOTICE
the turbocharger to slobber. Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
4. Use a dial indicator to check the end clearance or high pressure water.
on the shaft. If the measured end play is greater
than the Service Manual specifications, the
turbocharger should be repaired or replaced. • Ensure that the cooling lines are properly clamped
An end play measurement that is less than the and that the cooling lines are tight. Check for
minimum Service Manual specifications could leaks. Check the condition of all pipes.
indicate carbon buildup on the turbine wheel.
The turbocharger should be disassembled for • Inspect the water pumps for coolant leaks.
cleaning and for inspection if the measured end
play is less than the minimum Service Manual Note: The water pump seal is lubricated by coolant
specifications. in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
5. Inspect the bore of the turbine housing for the parts contract.
corrosion.
Excessive coolant leakage may indicate the need
6. Clean the turbocharger housing with standard to replace the water pump seal. For the removal of
shop solvents and a soft bristle brush. water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
7. Fasten the air inlet piping and the exhaust outlet engine or consult your Caterpillar dealer.
piping to the turbocharger housing.
118
Maintenance Section
Water Pump - Inspect

• Inspect the lubrication system for leaks at the • Other potential damage to the engine
front crankshaft seal, the rear crankshaft seal, the
oil pan, the oil filters and the valve cover. Visually inspect the water pump for leaks. If any
leaking is observed, replace the water pump
• Inspect the fuel system for leaks. Look for loose seal or the water pump assembly. Refer to the
fuel line clamps or for loose fuel line tie-wraps. Service Manual for the disassembly and assembly
procedure.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure Note: Refer to the Service Manual or consult your
that hoses and tubes are not contacting other Caterpillar dealer if any repair is needed or any
hoses, tubes, wiring harnesses, etc. replacement is needed.

• Inspect the alternator belt and the accessory

drive belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced

as matched sets. If only one belt is replaced, the
belt will carry more load than the belts that are
not replaced. The older belts are stretched. The
additional load on the new belt could cause the
belt to break.

• Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.

• 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.

i01057943

Water Pump - Inspect

SMCS Code: 1361-040; 1361

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
 119
Warranty Section
Warranty Information

Warranty Section

Warranty Information
i01087950

Emissions Warranty
Information
SMCS Code: 1000

This engine may be certified to comply with

exhaust emission standards and gaseous emission
standards that are prescribed by law at the time
of manufacture, and this engine may be covered
by an Emissions Warranty. A detailed explanation
of the Emissions Warranty that is applicable to
emissions certified engines is found in Supplement,
SEBU6981, “Federal Emissions Control Warranty
Information”. Consult your authorized Caterpillar
dealer to determine if your engine is emissions
certified and if your engine is subject to an
Emissions Warranty.
120
Reference Information Section
Engine Ratings

Reference Information i00819749

Section Engine Rating Definitions

SMCS Code: 1000

Engine Ratings It is important to know the use of the engine so

that the rating will match the operating profile. The
proper rating selection is also important so that the
i00727327 customer’s perception of price and value is realized.
Engine Rating Conditions In selecting a rating for a specific application, the
most important consideration is the time that is
SMCS Code: 1000 spent at full throttle. These rating definitions identify
the percent of time at full throttle. The definitions
All engine ratings are in compliance with the also identify the corresponding times below rated
following standard ambient air conditions of “SAE rpm.
J1349”:
Note: The examples of the applications are only
• 99 kPa (29.3 inches of Hg) for reference. For an exact determination of the
appropriate rating, follow the OEM specifications or
• 30 percent relative humidity consult your Caterpillar dealer.

• A temperature of 25 C (77 F) A Rating – This rating is used for heavy-duty

applications that are operated at rated load and at
Ratings relate to the standard conditions of rated rpm up to 100 percent. This rating is used
“ISO8665”, of “ISO3046/1”, of “DIN6271”, and of for engines that operate without interruption of load
“BS5514”. cycling. Typical applications include the following
examples: pipeline pumping and ventilation.
The engine ratings are based on the following fuel
specifications: B Rating – This rating is used when power and/or
rpm are cyclic. The engine should be run at full load.
• Low heat value (LHV)of the fuel of 42 780 kJ/kg The engine should not exceed 80 percent of the
(18,390 Btu/lb) at 29 C (84 F) duty cycle. Typical applications include the following
examples: irrigation, operation where normal pump
• Gravity (API) of 35 degrees at 15 C (60 F) demand is 85 percent of the engine rating, oil
pumping/drilling, field mechanical pumping/drilling,
• Specific gravity of .849 at 15 C (60 F) and stationary/plant air compressors.

• Density of 850 kg/m3 (7.085 lb/US gal) C Rating – This rating is used when power and/or
rpm are cyclic. The horsepower and the rpm of the
The engine ratings are gross output ratings. engine can be utilized continuously for one hour.
This is followed by one hour of operation at the A
Gross Output Ratings – The total output capability rating or below the A rating. The engine should
of the engine that is equipped with standard be run at full load. The engine should not exceed
accessories. 50 percent of the duty cycle. Typical applications
include the following examples: agricultural tractors,
Standard accessories include the following harvesters and combines, off-highway trucks, fire
components: pumps, blast hole drills, rock curshers, wood
chippers with high torque rise, and oil field hoisting.
• Oil pumps
D Rating – This rating is used when rated power
• Fuel pumps is required for periodic overloads. The maximum
horsepower and the rpm of the engine can be
• Water pumps utilized continuously for a maximum of 30 minutes.
This is followed by one hour of operation at the C
Subtract the power that is required to drive auxiliary rating. The engine should be run at full load. The
components from the gross output. This will produce engine should not exceed 10 percent of the duty
the net power that is available for the external load cycle. Typical applications include the following
(flywheel). examples: offshore cranes, runway snow blowers,
water well drills, portable air compressors, and fire
pump certification power.
 121
Reference Information Section
Engine Ratings

E Rating – This rating is used when rated power

is required for a short time for initial starting or
for sudden overload. The rating is also used for
emergency service when standard power is not
available. The horsepower and the rpm of the
engine can be utilized continuously for a maximum
of 15 minutes. This is followed by one hour of
operation at the C rating or by the duration of the
emergency. The engine should be run at full load.
The engine should not exceed 5 percent of the duty
cycle. Typical applications include the following
examples: standby centrifugal water pumps, oil
field well servicing, crash trucks, portable air
compressors, and gas turbine starting motors.

NOTICE
Operating engines above the rating definitions can re-
sult in shorter service life before overhaul.
122
Reference Information Section
Customer Service

Customer Service Latin America, Mexico, Carribean

Caterpillar Americas Co.
701 Waterford Way, Suite 200
i01452711 Miami, FL 33126
USA
Customer Assistance Phone: 305-476-6876
Fax: 305-476-6850
SMCS Code: 1000
Europe, Africa, and Middle East
USA and Canada Caterpillar Overseas S.A.
76 Route de Frontenex
When a problem arises concerning the operation of P.O. Box 6000
an engine or concerning the service of an engine, 1211 Geneva 6
the problem will normally be managed by the dealer Switzerland
in your area. Phone: 22-849-4444
Fax: 22-849-4544
Your satisfaction is a primary concern to Caterpillar
and to Caterpillar dealers. If you have a problem Far East
that has not been handled to your complete Caterpillar Asia Pte. Ltd.
satisfaction, follow these steps: 7 Tractor Road
Jurong, Singapore 627968
1. Discuss your problem with a manager from the Republic of Singapore
dealership. Phone: 65-662-8333
Fax: 65-662-8302
2. If your problem cannot be resolved at the dealer
level without additional assistance, use the China
phone number that is listed below to talk with a Caterpillar China Ltd.
Field Service Coordinator: 37/F, The Lee Gardens
33 Hysan Avenue
1-800-447-4986 Causeway Bay, Hong Kong
China
The normal hours are from 8:00 to 4:30 Monday Phone: 852-2848-0333
through Friday Central Standard Time. Fax: 852-2848-0440

3. If your needs have not been met still, submit the Japan
matter in writing to the following address: Shin Caterpillar Mitsubishi Ltd.
Setagaya Business Square Tower
Caterpillar Inc. 10-1, Yoga 4-chome
Manager, Customer Service, Engine Division Setagaya, Tokyo
Mossville Bldg A Japan
P.O. Box 600 Phone: 81-3-5717-1121
Peoria, Illinois 61552-0600 Fax: 81-3-5717-1177

Please keep in mind: probably, your problem will Japan

ultimately be solved at the dealership, using the Caterpillar Power Systems, Inc.
dealership’s facilities, equipment, and personnel. Japan Branch Sanno Grand Bldg.
Therefore, follow the steps in sequence when a 2-14-2 Nagatacho
problem is experienced. Chiyoda-ku, Tokyo, 100
Japan
Phone: 81-335-93-3237
Outside of the USA and of Canada Fax: 81-335-93-3238
If a problem arises outside the USA and outside Australia and New Zealand
Canada, and if the problem cannot be resolved at Caterpillar of Australia Ltd.
the dealer level, consult the appropriate Caterpillar 1 Caterpillar Drive
office. Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9339-9333
Fax: 03-9335-3366
 123
Reference Information Section
Customer Service

i01028392

Ordering Replacement Parts

SMCS Code: 7567

When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers’ parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.

When you order parts, please specify the following

information:

• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.

When a Caterpillar engine requires maintenance

and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform the

dealer about the conditions of the problem and
the nature of the problem. Inform the dealer about
when the problem occurs. This will help the dealer
in troubleshooting the problem and solving the
problem faster.
124
Reference Information Section
Reference Materials

Reference Materials • Special Publication, PEHP7057, “S·O·S Coolant

Analysis”

i01452717 • Special Publication, PEEP5027, “Label - ELC

Radiator Label”
Reference Material
SMCS Code: 1000 Miscellaneous
The following literature can be obtained through any • Service Manual, SENR9570, “C10 and C12
Caterpillar dealer. Industrial Engines”

Lubricants • Special Publication, SEHS7654, “Alignment -

General Instructions”
• Operation and Maintenance Manual, SEBU5898, • Special Instruction, SMHS7001, “Assembly of Fan
“Cold Weather Recommendations” Drive Pulley Assemblies”
• Special Publication, SEBU6251, “Caterpillar • Special Instruction, SEHS7633, “Battery Test
Commercial Diesel Engine Fuilds Recomedations” Procedure”
• Special Publication, NEDG6022, “Caterpillar • Tag, SEHS7332, “Do Not Operate”
Lubricating Grease”
• Special Publication, SEBF8062, “Guideline for
• Special Publication, PEHP0002, “Data Sheet Reusable Parts - Cleaning and Inspection of Air
- Multipurpose Lithium Complex Grease with Filters”
Molybdenum (MPGM)”
• Special Publication, SEBF8029, “Index to
• Special Publication, PEHP0017, “Data Sheet - Guidelines for Reusable Parts and Salvage
Special Purpose Grease (SPG) Bearing Lubricant” Operations”
• Special Publication, PEHP6001, “How To Take A • Special Publication, LEBH9324, “Industrial
Good Oil Sample” Application and Installation Guide”
• Special Publication, PEDP7036, “Listen To Your • Service Manual, REG1139F, “Service Manual
Oil” Contents Microfiche”
• Special Publication, SEBD0640, “Oil and Your • Special Publication, NEHS0526, “Service
Engine” Technician Application Guide”
• Special Publication, PECP6026, “One Safe • Special Instruction, SEHS9031, “Storage
Source” Procedure for Caterpillar Products”

Fuels • Special Instruction, NENG2500, “Tools and Shop

Products Guide”
• Special Publication, SEBD0717, “Diesel Fuels and
Your Engine” • Specifications, SENR3130, “Torque Specifications”

Coolants • Special Instruction, SEHS7768, “Use of 6V-2150

Starting/Charging Analyzer”
• Special Publication, SEBD0970, “Coolant and • Special Publication, NEHS0685, “Caterpillar
Your Engine”
Electronic Technician (ET)”
• Special Publication, PEHP4036, “Data Sheet- • Special Instruction, SEHS8622, “Using the FT-
Caterpillar Coolant”
1984 Air-To-Air Aftercooler Leak Test Group”
• Special Publication, SEBD0518, “Knowing Your
Cooling System”

• Special Publication, PECP6026, “One Safe

Source”
 125
Reference Information Section
Reference Materials

Emissions Warranty International Organization for Standardization

(ISO)
This engine may be Certified and this engine 1, rue de Varembé
may be covered by an Emissions Warranty. A Case postale 56
detailed explanation of the Emissions Warranty CH-1211 Genève 20
that is applicable to Certified engines is found in Switzerland
Supplement, SEBU6981, “Federal Emissions Control Telephone: +41 22 749 01 11
Warranty Information”. The Engine is Certified if Facsimile: +41 22 733 34 30
the engine has a special label that states that the E-mail: central@iso.ch
engine is certified. A Caterpillar dealer can also Web site: http://www.iso.ch
inform you if the engine is Certified.
European classifications are established by the
Counseil International Des Machines a Combustion
i01109461
(CIMAC) (International Council on Combustion
Additional Reference Material Engines).

SMCS Code: 1000 CIMAC Central Secretariat

Lyoner Strasse 18
The “EMA Lubricating Oils Data Book” can 60528 Frankfurt
be obtained from the following locations: local Germany
technological society, local library, and local college. Telephone: +49 69 6603 1567
If necessary, consult EMA at the following address: Facsimile: +49 69 6603 1566

Engine Manufacturers Associaton i00912149

401 N. Michigan Ave.
Chicago, IL, USA 60611 Maintenance Records
Telephone: (312) 644-6610 ext. 3626
SMCS Code: 1000
The “Society of Automotive Engineers (SAE)
Specifications” can be found in your SAE handbook. Caterpillar Inc. recommends the retention
This publication can also be obtained from the of accurate maintenance records. Accurate
following locations: local technological society, local maintenance records can be used for the following
library, and local college. If necessary, consult SAE purposes:
at the following address:
• Determine operating costs.
SAE International
400 Commonwealth Drive • Establish maintenance schedules for other
Warrendale, PA, USA 15096-0001 engines that are operated in the same
Telephone: (724) 776-4841 environment.

The “American Petroleum Institute Publication No. • Show compliance with the required maintenance
1509” can be obtained from the following locations: practices and maintenance intervals.
local technological society, local library, and local
college. If necessary, consult API at the following Maintenance records can be used for a variety of
address: other business decisions that are related to engine
maintenance.
American Petroleum Institute
1220 L St. N.W. Maintenance records are a key element of a
Washington, DC, USA 20005 maintenance program that is well managed.
Telephone: (202) 682-8000 Accurate maintenance records can help your
Caterpillar dealer to fine tune the recommended
The International Organization for Standardization maintenance intervals in order to meet the specific
(ISO) offers information and customer service operating situation. This should result in a lower
regarding international standards and standardizing engine operating cost.
activities. ISO can also supply information on the
following subjects that are not controlled by ISO: Records should be kept for the following items:
national standards, regional standards, regulations,
certification, and related activities. Consult the
member of ISO in your country.
126
Reference Information Section
Reference Materials

Fuel Consumption – A record of fuel consumption

is essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines
overhaul intervals.

Service Hours – A record of service hours is

essential to determine when the speed sensitive
components should be inspected or repaired.

Documents – These items should be easy to obtain,

and these items should be kept in the engine
history file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number, and engine serial number. The
following types of documents should be kept as
proof of maintenance or repair for warranty:

Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owner’s repair costs
• Owner’s receipts
• Maintenance log
 127
Reference Information Section
Reference Materials

i01176304

Maintenance Log
SMCS Code: 1000
Table 41
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity
Service Item Date Authorization
Hours Of Fuel
128
Index Section

Index
A Cooling System Coolant (ELC) - Change.............. 89
Drain .................................................................. 89
Additional Reference Material ............................. 125 Fill ...................................................................... 90
After Starting Engine ............................................. 45 Flush .................................................................. 89
After Stopping Engine............................................ 50 Cooling System Coolant Extender (ELC) - Add..... 90
Aftercooler Core - Clean/Test ................................ 82 Cooling System Coolant Level - Check ................. 90
Aftermarket Oil Additives ....................................... 60 Cooling System Specifications .............................. 65
Air Compressor - Inspect....................................... 82 Cooling System Supplemental Coolant Additive
Air Compressor Filter - Clean/Replace.................. 83 (SCA) - Test/Add.................................................. 91
Air Starting............................................................. 46 Add the SCA, If Necessary ................................ 92
Air Starting Motor Lubricator Oil Level - Check (If S·O·S Coolant Analysis...................................... 91
Equipped) ............................................................ 83 Test for SCA Concentration ............................... 91
Oiler Feed Adjustment ....................................... 83 Cooling System Water Temperature Regulator -
Air Tank Moisture and Sediment - Drain (If Replace................................................................ 92
Equipped) ............................................................ 84 Crankshaft Vibration Damper - Inspect ................. 93
Alarm Switches...................................................... 36 Removal and Installation.................................... 93
Alternator - Inspect ................................................ 84 Visconic Damper................................................ 93
Crushing Prevention and Cutting Prevention......... 12
Customer Assistance........................................... 122
B Outside of the USA and of Canada.................. 122
USA and Canada ............................................. 122
Battery - Replace................................................... 84 Customer Service ................................................ 122
Battery Electrolyte Level - Check .......................... 85 Customer Specified Parameters...................... 24, 41
Battery or Battery Cable - Disconnect ................... 85 Programmable Monitoring System (PMS) ......... 25
Before Starting Engine .................................... 13, 42 Cylinder Head Grounding Stud - Inspect/Clean/
Belt - Inspect.......................................................... 86 Tighten................................................................. 93
Adjustment ......................................................... 86
Inspection........................................................... 86
Belt Tensioner - Inspect (If Equipped) ................... 87 D
Burn Prevention..................................................... 10
Batteries............................................................. 10 Diagnostic Flash Code Retrieval ........................... 37
Coolant............................................................... 10 “Diagnostic” Lamp.............................................. 37
Oils..................................................................... 10 Diagnostic Lamp.................................................... 37
Diesel Engine Antifreeze/Coolant (DEAC) ............ 71
Driven Equipment - Check..................................... 94
C

Cold Start Strategy ................................................ 36 E

Cold Weather Lubricants ....................................... 60
Cold Weather Operation........................................ 51 Electrical System................................................... 14
Cold Weather Starting ........................................... 43 Grounding Practices .......................................... 14
Commercial Heavy-Duty Coolant/Antifreeze and Electronic Unit Injector - Inspect/Adjust................. 94
SCA ..................................................................... 72 Emergency Stopping ............................................. 49
Conventional Coolant/Antifreeze Cooling System Emergency Stop Button ..................................... 49
Maintenance ........................................................ 74 Emissions Certification Film .................................. 23
Cleaning the System of Heavy-Duty Emissions Warranty Information.......................... 119
Coolant/Antifreeze ........................................... 76 Engaging the Driven Equipment............................ 48
Cooling Systems with Larger Capacities ........... 75 Engine - Clean....................................................... 94
Coolant Recommendations ................................... 67 Engine Air Cleaner Element - Clean/Replace ....... 97
Cooling System Coolant (DEAC) - Change ........... 87 Engine Air Cleaner Element (Dual Element) -
Cooling Systems with Heavy Deposits or Clean/Replace ..................................................... 94
Plugging ........................................................... 88 Cleaning the Primary Air Cleaner Elements ...... 96
Drain .................................................................. 87 Servicing the Air Cleaner Elements ................... 95
Fill ...................................................................... 88 Engine Air Cleaner Service Indicator - Inspect...... 98
Flush .................................................................. 87 Test the Service Indicator .................................. 98
Engine Air Precleaner - Clean ............................... 98
Engine Crankcase Breather - Clean...................... 99
 129
Index Section

Engine Description ................................................ 19 Fire Prevention and Explosion Prevention............. 10

Engine Service Life ............................................ 20 Ether .................................................................. 12
Engine Specifications......................................... 20 Fire Extinguisher ................................................ 12
Engine Diagnostics................................................ 37 Lines, Tubes and Hoses..................................... 12
Engine Electronics................................................. 15 Foreword.................................................................. 5
Engine Identification .............................................. 22 California Proposition 65 Warning ....................... 5
Engine Lifting......................................................... 27 Literature Information........................................... 4
Engine Monitoring System (EMS) ......................... 29 Maintenance ........................................................ 4
Communication Data Link.................................. 31 Maintenance Intervals.......................................... 4
EMS Main Unit ................................................... 30 Operation ............................................................. 4
Quad Gauge Unit ............................................... 30 Overhaul .............................................................. 4
Tachometer Unit................................................. 31 Safety ................................................................... 4
Engine Mounts - Inspect........................................ 99 Fuel and the Effect from Cold Weather ................. 51
Engine Oil .............................................................. 56 Fuel Conservation Practices.................................. 48
Caterpillar Diesel Engine Oil .............................. 56 Fuel Recommendations......................................... 63
Commercial Oils................................................. 57 Fuel Related Components in Cold Weather .......... 52
Total Base Number (TBN) and Fuel Sulfur Levels Fuel Filters ......................................................... 52
for Direct Injection (DI) Diesel Engines ............ 58 Fuel Heaters ...................................................... 52
Engine Oil and Filter - Change ............................ 101 Fuel Tanks.......................................................... 52
Drain the Engine Oil......................................... 103 Fuel Specifications ................................................ 63
Fill the Engine Crankcase ................................ 104 Fuel System - Prime............................................ 106
Replace the Oil Filter ....................................... 103 Engines that are Equipped with a Fuel Priming
Selection of Oil Change Interval ...................... 101 Pump.............................................................. 106
Engine Oil Level - Check ....................................... 99 Engines that are Not Equipped with a Fuel Priming
Engine Oil Sample - Obtain ................................. 100 Pump.............................................................. 106
Obtain the Sample and the Analysis................ 100 Fuel System Primary Filter/Water Separator -
Engine Operation................................................... 47 Drain .................................................................. 107
Engine Operation with Active Diagnostic Codes ... 40 Fuel System Primary Filter/Water Separator Element
Engine Operation with Intermittent Diagnostic - Replace ........................................................... 108
Codes .................................................................. 40 Replace the Element........................................ 108
Engine Rating Conditions .................................... 120 Fuel System Secondary Filter - Replace............. 109
Engine Rating Definitions .................................... 120 Fuel Tank Water and Sediment - Drain................ 110
Engine Ratings .................................................... 120 Drain the Water and the Sediment................... 110
Engine Shutoff Control .......................................... 36 Fuel Storage Tanks .......................................... 110
Engine Starting................................................ 13, 42 Fuel Tank ......................................................... 110
Ether .................................................................. 13
Engine Stopping .............................................. 14, 49
Engine Storage...................................................... 27 G
Engine Storage Procedure - Check..................... 104
Engine Valve Lash - Inspect/Adjust ..................... 104 Gauges and Indicators .......................................... 28
Adjustment of the Electronic Unit Injector ........ 105 General Coolant Information ................................. 65
Engine Valve Rotators - Inspect .......................... 105 Additives ............................................................ 66
Engine Warm-up.................................................... 47 Glycol ................................................................. 66
Ether Starting Aid Cylinder - Replace (If Water ................................................................. 65
Equipped) .......................................................... 105 General Hazard Information .................................... 7
Extended Life Coolant (ELC)................................. 68 Asbestos Information ........................................... 9
Extended Life Coolant (ELC) Cooling System Containing Fluid Spillage ..................................... 9
Maintenance ........................................................ 69 Dispose of Waste Properly ................................ 10
Caterpillar ELC Extender .................................. 69 Fluid Penetration .................................................. 9
Changing to Caterpillar ELC .............................. 70 Pressure Air and Water........................................ 8
Commercial ELC................................................ 71 General Information............................................... 17
ELC Cooling System Cleaning........................... 70 General Torque Information................................... 53
ELC Cooling System Contamination.................. 71
Proper additions to the Extended Life Coolant .. 69
H

F Hoses and Clamps - Inspect/Replace ................. 110

Replace the Hoses and the Clamps ................ 111
Fan Drive Bearing - Lubricate.............................. 106
Fault Logging......................................................... 39
Features and Controls ........................................... 32
130
Index Section

I Reference Material .............................................. 124

Coolants........................................................... 124
Important Safety Information ................................... 2 Emissions Warranty ......................................... 125
Information Plate ................................................... 22 Fuels ................................................................ 124
Lubricants ........................................................ 124
Miscellaneous .................................................. 124
L Reference Materials ............................................ 124
Reference Numbers .............................................. 22
Lifting and Storage ................................................ 27 Record for Reference......................................... 22
Lubricant Information............................................. 56 Refill Capacities..................................................... 77
API Oils .............................................................. 56 Cooling System.................................................. 77
Engine Manufacturers Association (EMA) Oils .. 56 Lubrication System ............................................ 77
General Information ........................................... 56
Lubricant Specifications ........................................ 56
Lubricating Grease ................................................ 60 S
Caterpillar Premium Grease (CPG) ................... 62
Multipurpose Greases........................................ 61 S·O·S Coolant Analysis ......................................... 67
Special Purpose Grease (SPG)......................... 61 New Systems, Refilled Systems, and Converted
Systems ........................................................... 68
Recommended Interval for S·O·S Coolant
M Sample ............................................................. 68
S·O·S Coolant Analysis (Level 1)....................... 68
Maintenance Interval Schedule (C-10 Industrial S·O·S Coolant Analysis (Level 2)....................... 68
Engines)............................................................... 78 S·O·S Oil Analysis ................................................. 62
Maintenance Interval Schedule (C-12 Industrial Safety Section ......................................................... 6
Engines)............................................................... 80 Safety Signs and Labels.......................................... 6
Maintenance Log ................................................. 127 Self-Diagnostics..................................................... 37
Maintenance Records.......................................... 125 Sensors and Electrical Components ..................... 32
Maintenance Section ............................................. 53 Alarm Lamps (Diagnostic and Warning) ............ 33
Manual Stop Procedure......................................... 49 Auxiliary Pressure Sensor.................................. 34
Model View Illustrations......................................... 18 Auxiliary Temperature Sensor............................ 34
Model Views .......................................................... 18 Coolant Level Sensor......................................... 35
Mounting and Dismounting.................................... 13 Engine Speed/Timing Sensor ............................ 34
Ether Injection System ....................................... 36
Intermediate Engine Speed Switch.................... 34
O Sensor Locations ............................................... 32
Serial Number Plate .............................................. 22
Operation Section.................................................. 27 Severe Service Application - Check .................... 115
Ordering Replacement Parts............................... 123 Environmental Factors ..................................... 116
Overhaul Considerations ..................................... 111 Improper Maintenance Procedures.................. 116
Oil Consumption as an Overhaul Indicator ...... 111 Improper Operating Procedures ...................... 116
Overhaul Recommendation ............................. 112 Standard Torque for Constant Torque Hose
Clamps................................................................. 54
Standard Torque for Inch Fasteners ...................... 53
P Standard Torque for Metric Fasteners ................... 54
Standard Torque for Worm Drive Band Hose
Power Take-Off Clutch - Check/Adjust/Lubricate.. 114 Clamps................................................................. 54
Product Identification Information .......................... 22 Starting Motor - Inspect ....................................... 116
Product Information Section .................................. 17 Starting the Engine................................................ 43
Starting with Jump Start Cables ............................ 44
Supplemental Coolant Additive (SCA)................... 71
R Synthetic Base Stock Oils ..................................... 59

Radiator - Clean .................................................. 115

Radiator Restrictions ............................................. 51 T
Re-refined Base Stock Oils ................................... 59
Reference Information Section ............................ 120 Table of Contents..................................................... 3
Torque Specifications ............................................ 53
Turbocharger - Inspect......................................... 116
Cleaning and Inspecting .................................. 117
Removal and Installation.................................. 117
 131
Index Section

Walk-Around Inspection ...................................... 117

Inspect the Engine for Leaks and for Loose
Connections ................................................... 117
Warranty Information ........................................... 119
Warranty Section ................................................. 119
Water Pump - Inspect .......................................... 118
Water/Supplemental Coolant Additive (SCA) ........ 72
Cooling Systems with Larger Capacities ........... 73
Welding on Engines with Electronic Controls ........ 17
132
Index Section
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the
Operation and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
©2001 Caterpillar
All Rights Reserved Printed in U.S.A.