SEBU8733-01

September 2013

Operation and
Maintenance
Manual
C7.1 Industrial Engine
881 1-Up (Engine)

SAFETY.CAT.COM
 i05296198

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

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

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU8733 3
Table of Contents

Table of Contents Maintenance Section

Foreword.............................. ............................. 4 Refill Capacities....................... ....................... 76

Maintenance Recommendations.......... .......... 83

Safety Section
Maintenance Interval Schedule ........... ........... 87
Safety Messages....................... ....................... 5

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

Warranty Section

Burn Prevention....................... ....................... 12 Warranty Information .................. .................. 131

Fire Prevention and Explosion Prevention ... .. 13 Reference Information Section

Crushing Prevention and Cutting Prevention . 15 Engine Ratings ....................... ...................... 132

Mounting and Dismounting............... .............. 15 Customer Service ..................... .................... 133

High Pressure Fuel Lines ................ ............... 15 Reference Materials .................. ................... 135

Before Starting Engine ................. .................. 17 Index Section

Engine Starting ........................ ....................... 17 Index............................... .............................. 138

Engine Stopping ....................... ...................... 18

Electrical System ...................... ...................... 18

Engine Electronics..................... ..................... 19

Product Information Section

General Information.................... .................... 21

Product Identification Information.......... ......... 30

Operation Section

Lifting and Storage..................... ..................... 33

Features and Controls .................. .................. 37

Engine Diagnostics..................... .................... 59

Engine Starting ........................ ....................... 64

Engine Operation...................... ...................... 67

Cold Weather Operation................. ................ 69

Engine Stopping ....................... ...................... 74

4 SEBU8733
Foreword

Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
This manual contains safety, operation instructions, wet or freezing cold operating conditions, more
lubrication and maintenance information. This manual frequent lubrication and maintenance than is
should be stored in or near the engine area in a specified in the Maintenance Interval Schedule may
literature holder or literature storage area. Read, be necessary.
study and keep it with the literature and engine
information. The maintenance schedule items are organized for a
preventive maintenance management program. If the
English is the primary language for all Cat preventive maintenance program is followed, a
publications. The English used facilitates translation periodic tune-up is not required. The implementation
and consistency in electronic media delivery. of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures.
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing Maintenance Intervals
improvement and advancement of product design
may have caused changes to your engine which are Perform maintenance on items at multiples of the
not included in this manual. Whenever a question original requirement. Each level and/or individual
arises regarding your engine, or this manual, please items in each level should be shifted ahead or back
consult with your Cat dealer for the latest available depending upon your specific maintenance practices,
information. operation and application. We recommend that the
maintenance schedules be reproduced and displayed
Safety near the engine as a convenient reminder. We also
recommend that a maintenance record be maintained
This safety section lists basic safety precautions. In as part of the engine's permanent record.
addition, this section identifies hazardous, warning
situations. Read and understand the basic See the section in the Operation and Maintenance
precautions listed in the safety section before Manual, “Maintenance Records” for information
operating or performing lubrication, maintenance and regarding documents that are generally accepted as
repair on this product. proof of maintenance or repair. Your authorized Cat
dealer can assist you in adjusting your maintenance
schedule to meet the needs of your operating
Operation environment.
Operating techniques outlined in this manual are
basic. They assist with developing the skills and Overhaul
techniques required to operate the engine more Major engine overhaul details are not covered in the
efficiently and economically. Skill and techniques Operation and Maintenance Manual except for the
develop as the operator gains knowledge of the interval and the maintenance items in that interval.
engine and its capabilities. Major repairs are best left to trained personnel or an
authorized Cat dealer. Your Cat dealer offers a
The operation section is a reference for operators. variety of options regarding overhaul programs. If you
Photographs and illustrations guide the operator experience a major engine failure, there are also
through procedures of inspecting, starting, operating numerous after failure overhaul options available
and stopping the engine. This section also includes a from your Cat dealer. Consult with your dealer for
discussion of electronic diagnostic information. information regarding these options.
Maintenance California Proposition 65 Warning
The maintenance section is a guide to engine care. Diesel engine exhaust and some of its constituents
The illustrated, step-by-step instructions are grouped are known to the State of California to cause cancer,
by fuel consumption, service hours and/or calendar birth defects, and other reproductive harm.
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that Battery posts, terminals and related accessories
follow. contain lead and lead compounds. Wash hands after
Use fuel consumption or service hours to determine handling.
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals if
they provide more convenient schedules and
approximate the indicated service meter reading.
SEBU8733 5
Safety Section
Safety Messages

Safety Section
i04889628

Safety Messages
SMCS Code: 1000; 7405
There may be several specific warning signs on your
engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become familiar with all warning signs.
Ensure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if the
words cannot be read or if the illustrations are not
visible. Use a cloth, water, and soap to clean the
warning signs. Do not use solvents, gasoline, or other
harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning signs. The warning signs that are loosened
could drop off the engine.
Replace any warning sign that is damaged or
missing. If a warning sign is attached to a part of the
engine that is replaced, install a new warning sign on
the replacement part. Your Caterpiller dealer can
provide new warning signs.

Universal Warning 1

Do not operate or work on this equipment unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or heed
the warnings could result in serious injury or
death.
6 SEBU8733
Safety Section
Safety Messages

Illustration 1 g03022899
Typical example

The universal warning label is install in two positions

on the engine. On the valve mechanism cover and on
the intake manifold, refer to illustration 1 .

Ether Warning 2

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.

Illustration 2 g03023096
Typical example
SEBU8733 7
Safety Section
Safety Messages

The ether warning label is installed on the intake

manifold, refer to illustration 2 .

Hand (High Pressure) 3

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

Illustration 3 g03023097
Typical example

The hand high-pressure warning label is a rap around

label installed on the main injection line, refer to
illustration 3 .
8 SEBU8733
Safety Section
General Hazard Information

i05474090 • Tampering with the engine installation or tampering

with the OEM supplied wiring can be dangerous.
General Hazard Information Personal injury, death and/or engine damage
could result.
SMCS Code: 1000; 4450; 7405
• Vent the engine exhaust to the outside when the
engine is operated in an enclosed area.

• If the engine is not running, do not release the

secondary brake or the parking brake systems
unless the vehicle is blocked or unless the vehicle
is restrained.
• Wear a hard hat, protective glasses, and other
protective equipment, as required.
• When work is performed around an engine that is
operating, wear protective devices for ears in order
to help prevent damage to hearing.
• Do not wear loose clothing or jewelry that can snag
Illustration 4 g00104545
on controls or on other parts of the engine.

Attach a “Do Not Operate” warning tag or a similar • Ensure that all protective guards and all covers are
warning tag to the start switch or to the controls secured in place on the engine.
before the engine is serviced or before the engine is
repaired. These warning tags (Special Instruction, • Never put maintenance fluids into glass
SEHS7332) are available from your Cat dealer. containers. Glass containers can break.
Attach the warning tags to the engine and to each
operator control station. When appropriate, • Use all cleaning solutions with care.
disconnect the starting controls.
• Report all necessary repairs.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being Unless other instructions are provided, perform the
serviced. maintenance under the following conditions:
SEBU8733 9
Safety Section
General Hazard Information

• The engine is stopped. Ensure that the engine • Filler caps

cannot be started.
• Grease fittings
• The protective locks or the controls are in the
applied position. • Pressure taps

• Engage the secondary brakes or parking brakes. • Breathers

• Block the vehicle or restrain the vehicle before • Drain plugs

maintenance or repairs are performed.
Use caution when cover plates are removed.
• Disconnect the batteries when maintenance is Gradually loosen, but do not remove the last two bolts
performed or when the electrical system is or nuts that are located at opposite ends of the cover
plate or the device. Before removing the last two bolts
serviced. Disconnect the battery ground leads. or nuts, pry the cover loose in order to relieve any
Tape the leads in order to help prevent sparks. If spring pressure or other pressure.
equipped, allow the diesel exhaust fluid to be
purged before disconnecting the battery.

• If equipped, disconnect the connectors for the unit

injectors that are located on the valve cover base.
This action will help prevent personal injury from
the high voltage to the unit injectors. Do not come
in contact with the unit injector terminals while the
engine is operating.

• Do not attempt any repairs or any adjustments to

the engine while the engine is operating.
• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment. Illustration 5 g00702020

• For initial start-up of a new engine or for starting an • Wear a hard hat, protective glasses, and other
engine that has been serviced, make provisions to protective equipment, as required.
stop the engine if an overspeed occurs. The
stopping of the engine may be accomplished by • When work is performed around an engine that is
shutting off the fuel supply and/or the air supply to operating, wear protective devices for ears in order
the engine. Ensure that only the fuel supply line is to help prevent damage to hearing.
shut off. Ensure that the fuel return line is open.
• Do not wear loose clothing or jewelry that can snag
• Start the engine from the operators station (cab). on controls or on other parts of the engine.
Never short across the starting motor terminals or
the batteries. This action could bypass the engine • Ensure that all protective guards and all covers are
neutral start system and/or the electrical system secured in place on the engine.
could be damaged.
• Never put maintenance fluids into glass
Engine exhaust contains products of combustion containers. Glass containers can break.
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated • Use all cleaning solutions with care.
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside. • Report all necessary repairs.

Cautiously remove the following parts. To help Unless other instructions are provided, perform
prevent spraying or splashing of pressurized fluids, the maintenance under the following conditions:
hold a rag over the part that is being removed.
10 SEBU8733
Safety Section
General Hazard Information

• The engine is stopped. Ensure that the engine

cannot be started.

• Disconnect the batteries when maintenance is

performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.

• Do not attempt any repairs that are not

understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or
hot water to be blown out. This action could result in Illustration 6 g00687600
personal injury.
Always use a board or cardboard when you check for
When pressurized air and/or pressurized water is a leak. Leaking fluid that is under pressure can
used for cleaning, wear protective clothing, protective penetrate body tissue. Fluid penetration can cause
shoes, and eye protection. Eye protection includes serious injury and possible death. A pin hole leak can
goggles or a protective face shield. cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
The maximum air pressure for cleaning purposes from a doctor that is familiar with this type of injury.
must be below 205 kPa (30 psi). The maximum water
pressure for cleaning purposes must be below Containing Fluid Spillage
275 kPa (40 psi).
Care must be taken to ensure that fluids are
Fluid Penetration contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
Pressure can be trapped in the hydraulic circuit long product. Be prepared to collect the fluid with suitable
after the engine has been stopped. The pressure can containers before opening any compartment or
cause hydraulic fluid or items such as pipe plugs to disassembling any component containing fluids.
escape rapidly if the pressure is not relieved correctly.
Refer to Special Publication, NENG2500, “Cat
Do not remove any hydraulic components or parts Dealer Service Tool Catalog” for tools and supplies
until pressure has been relieved or personal injury suitable to collect and contain fluids on Cat products.
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved Dispose of all fluids according to local regulations and
or personal injury may occur. Refer to the OEM mandates.
information for any procedures that are required to
relieve the hydraulic pressure.
SEBU8733 11
Safety Section
General Hazard Information

Inhalation • Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up 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.
Illustration 7 g00702022
• Comply with applicable rules and regulations for
Exhaust the work place. In the United States , use
Occupational Safety and Health Administration
Use caution. Exhaust fumes can be hazardous to (OSHA) requirements. These OSHA
health. If you operate the equipment in an enclosed requirements can be found in 29 CFR 1910.1001.
area, adequate ventilation is necessary.
• Obey environmental regulations for the disposal of
Asbestos Information asbestos.

Cat equipment and replacement parts that are • Stay away from areas that might have asbestos
shipped from Caterpillar are asbestos free. particles in the air.
Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when Dispose of Waste Properly
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there are
several guidelines that should be followed:

Illustration 8 g00706404

Improperly disposing of waste can threaten the

environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
12 SEBU8733
Safety Section
Burn Prevention

i04891356 Coolant
Burn Prevention When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
SMCS Code: 1000; 4450; 7405 pressure. The radiator and all lines to the heaters,
aftertreatment system or to the engine contain hot
Do not touch any part of an operating engine system. coolant.
The engine, the exhaust, and the engine
aftertreatment system can reach temperatures as Any contact with hot coolant or with steam can cause
high as 650° C (1202° F) under normal operating severe burns. Allow cooling system components to
conditions. cool before the cooling system is drained.

Allow the engine system to cool before any Check that the coolant level after the engine has
maintenance is performed. Relieve all pressure in the stopped and the engine has been allowed to cool.
air system, hydraulic system, lubrication system, fuel
system, and the cooling system before the related Ensure that the filler cap is cool before removing the
items are disconnected. filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
Contact with high pressure fuel may cause fluid cause personal injury. Do not allow alkali to contact
penetration and burn hazards. High pressure fuel the skin, the eyes, or the mouth.
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in- Oils
structions may cause personal injury or death.
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
After the engine has stopped, you must wait for 10 skin. Also, do not allow hot components to contact the
minutes in order to allow the fuel pressure to be skin.
purged from the high-pressure fuel lines before any
service or repair is performed on the engine fuel lines. Batteries
Allow the pressure to be purged in the air system, in Electrolyte is an acid. Electrolyte can cause personal
the hydraulic system, in the lubrication system, or in injury. Do not allow electrolyte to contact the skin or
the cooling system before any lines, fittings, or related the eyes. Always wear protective glasses for
items are disconnected. servicing batteries. Wash hands after touching the
batteries and connectors. Use of gloves is
Induction System recommended.

Aftertreatment System
Allow the aftertreatment to cool down before any
Sulfuric Acid Burn Hazard may cause serious per- maintenance or repair is performed.
sonal injury or death.
The exhaust gas cooler may contain a small
amount of sulfuric acid. The use of fuel with sulfur
levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid
may spill from the cooler during service of the en-
gine. The sulfuric acid will burn the eyes, skin and
clothing on contact. Always wear the appropriate
personal protective equipment (PPE) that is noted
on a material safety data sheet (MSDS) for sulfuric
acid. Always follow the directions for first aid that
are noted on a material safety data sheet (MSDS)
for sulfuric acid.
SEBU8733 13
Safety Section
Fire Prevention and Explosion Prevention

i05408756 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
Fire Prevention and Explosion thoroughly with a nonflammable solvent prior to
Prevention welding or flame cutting.
SMCS Code: 1000; 4450; 7405 Wiring must be kept in good condition. All electrical
wires must be properly routed and securely attached.
Check all electrical wires daily. Repair any wires that
are loose or frayed before you operate the engine.
Clean all electrical connections and tighten all
electrical connections.
Eliminate all wiring that is unattached or unnecessary.
Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.

Illustration 9 g00704000
Contact with high pressure fuel may cause fluid
All fuels, most lubricants, and some coolant mixtures penetration and burn hazards. High pressure fuel
are flammable.
spray may cause a fire hazard. Failure to follow
Flammable fluids that are leaking or spilled onto hot these inspection, maintenance and service in-
surfaces or onto electrical components can cause a structions may cause personal injury or death.
fire. Fire may cause personal injury and property
damage.
After the engine has stopped, you must wait for 10
A flash fire may result if the covers for the engine minutes in order to allow the fuel pressure to be
crankcase are removed within 15 minutes after an purged from the high-pressure fuel lines before any
emergency shutdown. service or repair is performed on the engine fuel lines.
Determine whether the engine will be operated in an Inspect all lines and hoses for wear or for
environment that allows combustible gases to be deterioration. The hoses must be properly routed.
drawn into the air inlet system. These gases could The lines and hoses must have adequate support
cause the engine to overspeed. Personal injury, and secure clamps. Tighten all connections to the
property damage, or engine damage could result. recommended torque. Leaks can cause fires.
If the application involves the presence of Oil filters and fuel filters must be properly installed.
combustible gases, consult your Caterpillar dealer for The filter housings must be tightened to the proper
additional information about suitable protection torque.
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.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in a case of a line, a
tube, or a seal failure. Exhaust shields must be
installed correctly.
14 SEBU8733
Safety Section
Fire Prevention and Explosion Prevention

Illustration 10 g00704059 Illustration 11 g00704135

Use caution when you are refueling an engine. Do not Gases from a battery can explode. Keep any open
smoke while you are refueling an engine. Do not flames or sparks away from the top of a battery. Do
refuel an engine near open flames or sparks. Always not smoke in battery charging areas.
stop the engine before refueling.
Never check the battery charge by placing a metal
Avoid static electricity risk when fueling. Ultra low object across the terminal posts. Use a voltmeter or a
sulfur diesel (ULSD) poses a greater static ignition hydrometer.
hazard that earlier diesel formulation with a higher
sulfur content. Avoid death or serious injury from the Improper jumper cable connections can cause an
fire or explosion. Consult with your fuel or fuel system explosion that can result in injury. Refer to the
supplier to ensure that the delivery system is in Operation Section of this manual for specific
compliance with fueling standards for proper instructions.
grounding and bonding practices.
Do not charge a frozen battery. A frozen battery may
cause an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.

Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations on
the instruction plate.

Ether
Ether is flammable and poisonous.
Do not smoke while you are replacing an ether
cylinder or while you are using an ether spray.
Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49 °C
(120 °F). Keep ether cylinders away from open
flames or sparks.
SEBU8733 15
Safety Section
Crushing Prevention and Cutting Prevention

Dispose of used ether cylinders properly. Do not When objects are struck, wear protective glasses in
puncture an ether cylinder. Keep ether cylinders away order to avoid injury to the eyes.
from unauthorized personnel.
Chips or other debris may fly off objects when objects
Lines, Tubes, and Hoses are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent or i04016709
damaged.
Repair any lines that are loose or damaged. Leaks Mounting and Dismounting
can cause fires. Consult your Caterpillar dealer for SMCS Code: 1000; 4450; 7405
repair or for replacement parts.
Do not climb on the engine or the engine
Check lines, tubes, and hoses carefully. Do not use aftertreatment. The engine and aftertreatment have
your bare hand to check for leaks. Use a board or not been designed with mounting or dismounting
cardboard to check for leaks. Tighten all connections locations.
to the recommended torque.
Refer to the OEM for the location of foot and hand
Replace the parts if any of the following conditions holds for your specific application.
are present:
• High-pressure fuel line or lines are removed. i03550790

• End fittings are damaged or leaking. High Pressure Fuel Lines

• Outer coverings are chafed or cut. SMCS Code: 1274

• Wires are exposed.

• Outer coverings are ballooning.
Contact with high pressure fuel may cause fluid
• Flexible part of the hose is kinked. penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
• Outer covers have embedded armoring. these inspection, maintenance and service in-
structions may cause personal injury or death.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.

i01359666

Crushing Prevention and

Cutting Prevention
SMCS Code: 1000; 4450; 7405
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
16 SEBU8733
Safety Section
High Pressure Fuel Lines

Illustration 12 g01877473

(1) High pressure line (4) High pressure line (7) High pressure fuel manifold (rail)
(2) High pressure line (5) High pressure line (8) High pressure line
(3) High pressure line (6) High pressure line (9) Fuel transfer line that is high pressure

The high pressure fuel lines are the fuel lines that are Visually inspect the high pressure fuel lines before
between the high pressure fuel pump and the high the engine is started. This inspection should be each
pressure fuel manifold and the fuel lines that are day.
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel If you inspect the engine in operation, always use the
systems. proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
This is because of the following items: Maintenance Manual, “General hazard Information”.
• The high pressure fuel lines are constantly • Inspect the high pressure fuel lines for damage,
charged with high pressure. deformation, a nick, a cut, a crease, or a dent.
• The internal pressures of the high pressure fuel • Do not operate the engine with a fuel leak. If there
lines are higher than other types of fuel system. is a leak do not tighten the connection in order to
stop the leak. The connection must only be
• The high pressure fuel lines are formed to shape tightened to the recommended torque. Refer to
and then strengthened by a special process. Disassembly and Assembly, “Fuel injection lines -
Remove and Fuel injection lines - Install”.
Do not step on the high pressure fuel lines. Do not
deflect the high pressure fuel lines. Do not bend or • If the high pressure fuel lines are torqued correctly
strike the high pressure fuel lines. Deformation or
and the high pressure fuel lines are leaking the
damage of the high pressure fuel lines may cause a
point of weakness and potential failure. high pressure fuel lines must be replaced.

Do not check the high pressure fuel lines with the • Ensure that all clips on the high pressure fuel lines
engine or the starting motor in operation. After the are in place. Do not operate the engine with clips
engine has stopped, you must wait for 10 minutes in that are damaged, missing or loose.
order to allow the fuel pressure to be purged from the
high pressure fuel lines before any service or repair is • Do not attach any other item to the high pressure
performed on the engine fuel lines. fuel lines.

Do not loosen the high pressure fuel lines in order to • Loosened high pressure fuel lines must be
remove air from the fuel system. This procedure is not replaced. Also removed high pressure fuel lines
required. must be replaced. Refer to Disassembly and
assembly manual, “Fuel Injection Lines - Install”.
SEBU8733 17
Safety Section
Before Starting Engine

i03560601 i03635086

Before Starting Engine Engine Starting

SMCS Code: 1000 SMCS Code: 1000

NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make Do not use aerosol types of starting aids such as
provision to shut the engine off should an overspeed ether. Such use could result in an explosion and
occur. This may be accomplished by shutting off the personal injury.
air and/or fuel supply to the engine.
If a warning tag is attached to the engine start switch
or to the controls DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start All protective guards and all protective covers must
and operate the engine in a well ventilated area be installed if the engine must be started in order to
and, if in an enclosed area, vent the exhaust to the perform service procedures. To help prevent an
outside. accident that is caused by parts in rotation, work
around the parts carefully.

Inspect the engine for potential hazards. Start the engine from the operator's compartment or
from the engine start switch.
Do not start the engine or move any of the controls if
there is a “DO NOT OPERATE” warning tag or Always start the engine according to the procedure
similar warning tag attached to the start switch or to that is described in the Operation and Maintenance
the controls. Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
Before starting the engine, ensure that no one is on, prevent major damage to the engine components.
underneath, or close to the engine. Ensure that the Knowing the procedure will also help to prevent
area is free of personnel. personal injury.

If equipped, ensure that the lighting system for the To ensure that the jacket water heater (if equipped)
engine is suitable for the conditions. Ensure that all and/or the lube oil heater (if equipped) is working
lights work properly, if equipped. correctly, check the water temperature gauge and/or
the oil temperature gauge during the heater
All protective guards and all protective covers must operation.
be installed if the engine must be started in order to
perform service procedures. To help prevent an Engine exhaust contains products of combustion
accident that is caused by parts in rotation, work which can be harmful to your health. Always start the
around the parts carefully. engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area, vent
Do not bypass the automatic shutoff circuits. Do not the engine exhaust to the outside.
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The These engines are equipped with a glow plug starting
circuits are also provided in order to help prevent aid in each individual cylinder that heats the intake air
engine damage. in order to improve starting. Some Caterpillar
engines may have a cold starting system that is
See the Service Manual for repairs and for controlled by the ECM that allows a controlled flow of
adjustments. ether into the engine. The ECM will disconnect the
glow plugs before the ether is introduced. This
system would be installed at the factory.
18 SEBU8733
Safety Section
Engine Stopping

i03648639 Grounding Practices

Engine Stopping
SMCS Code: 1000
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to this Operation and Maintenance Manual,
“Engine Stopping” topic (Operation Section).
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.
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop the
engine if an overspeed condition occurs.

i04891806

Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit is
operating. A spark can cause the combustible gases
that are produced by some batteries to ignite.
Illustration 13 g01888534
To help prevent sparks from igniting combustible Typical example
gases that are produced by some batteries, the
negative “−” cable should be connected last from the (1) Ground to battery
(2) Ground to starting motor
external power source to the primary position for (3) Starting motor to engine block
grounding.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical
connections 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.
SEBU8733 19
Safety Section
Engine Electronics

i05206178

Engine Electronics
SMCS Code: 1000; 1900

Tampering with the electronic system installation

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

Electrical Shock Hazard. The electronic unit injec-

tors use DC voltage. The ECM sends this voltage
to the electronic unit injectors. Do not come in
contact with the harness connector for the elec-
tronic unit injectors while the engine is operating.
Failure to follow this instruction could result in
personal injury or death.

This engine has a comprehensive, programmable

Engine Monitoring System. The Electronic Control
Module (ECM) has the ability to monitor the engine
Illustration 14 g03027396 operating conditions. If any of the engine parameters
Typical example extend outside an allowable range, the ECM will
initiate an immediate action.
(5) Ground to the battery
(6) Ground to the engine block The following actions are available for engine
(7) Primary position for grounding monitoring control:
Correct grounding for the engine electrical system is • Warning
necessary for optimum engine performance and
reliability. Incorrect grounding will result in • Derate
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths. • Shutdown
Uncontrolled electrical circuit paths can result in The following monitored engine operating conditions
damage to the crankshaft bearing journal surfaces and components can limit engine speed and/or the
and to aluminum components. engine power:
Engines that are installed without engine-to-frame • Engine Coolant Temperature
ground straps can be damaged by electrical
discharge. • Engine Oil Pressure
To ensure that the engine and the engine electrical • Engine Speed
systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be • Intake Manifold Air Temperature
used. This path may be provided by way of a direct
engine ground to the frame. • Wastegate Regulator
The connections for the grounds should be tight and • Supply Voltage to Sensors
free of corrosion. The engine alternator must be
grounded to the negative “-” battery terminal. The • Fuel Temperature
wire used must be adequate to handle the full
charging current of the alternator. • Fuel Pressure in Manifold (Rail)
The power supply connections and the ground • NOxReduction System
connections for the engine electronics should always
be from the isolator to the battery. • Engine Aftertreatment System
20 SEBU8733
Safety Section
Engine Electronics

The Engine Monitoring package can vary for different

engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.

Note: Many of the engine control systems and

display modules that are available for Caterpillar
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to Troubleshooting for more
information on the Engine Monitoring System.
SEBU8733 21
Product Information Section
Model View Illustrations

Product Information
Section

General Information
i05347319

Model View Illustrations

SMCS Code: 1000
The following model views show typical features of
the engine. Due to individual applications, your
engine may appear different from the illustrations.
Single Turbocharged Engine with Installed Aftertreatment

Illustration 15 g03393436
Typical example
22 SEBU8733
General Information
Model View Illustrations

Engine Views with Series Turbochargers

Illustration 16 g03387645
Typical example
(1) Rear engine lifting eye (4) Alternator (7) Back pressure valve
(2) High-pressure turbocharger (5) Low-pressure turbocharger
(3) Front engine lifting eye (6) Oil drain plug
SEBU8733 23
General Information
Model View Illustrations

Illustration 17 g03387666
Typical example
(8) Secondary fuel filter (12) Flywheel housing (17) Oil level gauge (Dipstick)
(9) Primary fuel filter (13) Flywheel (18) Oil drain tap
(10) Crankcase breather (14) Solenoid for starting motor (19) location for the oil sampling valve
(11) Engine Electronic Control Module (15) Starting motor (20) High-pressure fuel pump
(ECM) (16) Oil filter
24 SEBU8733
General Information
Model View Illustrations

Illustration 18 g03387667
Typical example
(21) NOx Reduction system (NRS) (24) Oil filler cap (27) Crankshaft damper
(22) Air intake (25) Water pump (28) Belt tensioner
(23) Coolant outlet (26) Coolant intake (29) Belt
SEBU8733 25
General Information
Model View Illustrations

Off Engine Components

Illustration 19 g03387619
Items that can be supplied loose.
(1) Clean emission module (5) NOx sensors (9) Flexible exhaust pipe assembly
(2) Pump electronics tank unit (6) In-line fuel filter (9 A) Protection sleeve for flexible exhaust
(3) Heated line (7) Priming/tranfer fuel pump pipe
(4) Soot sensor control (8) Primary fuel filter (10) Inlet air temperature sensor

Note: Use the sleeve (9 A) for transportation only.

26 SEBU8733
General Information
Model View Illustrations

Engine Aftertreatment System

Illustration 20 g03027726
Typical example
(1) Clean Emission Module (CEM) (3) Exhaust intake connection (5) Diesel Exhaust Fluid (DEF) injector
(2) Lifting eyes for CEM (4) Exhaust outlet connection
SEBU8733 27
General Information
Product Description

Illustration 21 g03034176
Typical example
(1) Pump Electronics Tank Unit (PETU) (4) Coolant outlet (7) Heated DEF line
(2) Diesel Exhaust Fluid (DEF) tank filler cap (5) Dosing Control Module (DCU) (8) Harness connections
(3) Coolant inlet (6) DEF Tank (9) DEF drain plug

The size of the DEF tank will depend on the • In-line Six cylinder
application. For more information on the
aftertreatment system, refer to this Operation and • Four stroke cycle
Maintenance Manual, “Sensors and Electrical
Components”. • Four valves in each cylinder

• Series turbocharged charge cooled/or Single

i05352909
turbocharged charge cooled
Product Description • Aftertreatment System
(Engine and Aftertreatment) The Clean Emissions Module (CEM) is constructed of
SMCS Code: 1000; 4450; 4491 three main items, the diesel oxidation catalyst, the
diesel particulate filter, and the Selective Catalytic
There are two variants of the C7.1 industrial engine Reduction (SCR). The SCR requires the use of Diesel
the single turbocharged engine and the series Exhaust Fluid (DEF) to be injected into the system in
turbocharged engine. order to lower the emissions from the engine. The
(DEF) is stored and controlled by the pump electronic
The Caterpillar C7.1 Industrial Engine has the tank unit. The DEF tank can be installed separate
following characteristics. from the electronic pump unit.
28 SEBU8733
General Information
Product Description

Engine Specifications (Table 2, contd)

Power 151 to 205 kW
Note: The front end of the engine is opposite the (202.5 to 274.9 hp)
flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel Aspiration Turbocharged charge cooled
end. The number 1 cylinder is the front cylinder.
Compression Ratio 16.4:1

Displacement 7.01 L (428 in3)

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

Rotation (flywheel end) Counterclockwise

(1) The operating rpm is dependent on the engine rating, the appli-
cation, and the configuration of the throttle.

Electronic Engine Features

The engine and aftertreatment operating conditions
are monitored. The Electronic Control Module (ECM)
controls the response of the engine to these
conditions and to the demands of the operator. These
conditions and operator demands determine the
Illustration 22 g01127295
precise control of fuel injection by the ECM. The
Cylinder and valve location electronic engine control system provides the
(A) Exhaust valves following features:
(B) Inlet valves
• Engine monitoring
Table 1
C7.1 Single Turbocharged Engine Specifications
• Engine speed governing

Operating Range (rpm) 800 to 2500(1) • Control of the injection pressure

Number of Cylinders 6 In-Line • Cold start strategy
Bore 105 mm (4.13 inch) • Automatic air/fuel ratio control
Stroke 127 mm (5 inch)
• Torque rise shaping
Power 116 to 151 kW
(155.5 to 202.5 hp) • Injection timing control
Aspiration Turbocharged charge cooled • System diagnostics
Compression Ratio 16.4:1 • NOx reduction system control
Displacement 7.01 L (428 in3)
• Aftertreatment system control
Firing Order 1-5-3-6-2-4
The ECM provides an electronic governor that
Rotation (flywheel end) Counterclockwise controls the injector output in order to maintain the
(1) The operating rpm is dependent on the engine rating, the appli- desired engine rpm.
cation, and the configuration of the throttle.
For more information on electronic engine features,
Table 2 refer to the Operation and Maintenance Manual,
“Features and Controls” topic (Operation Section).
C7.1 Series Turbocharged Engine Specifications

Operating Range (rpm) 800 to 2500(1) Engine Diagnostics

Number of Cylinders 6 In-Line The engine has built-in diagnostics in order to ensure
that the engine systems are functioning correctly. The
Bore 105 mm (4.13 inch) operator will be alerted to the condition by a “Stop or
Stroke 135 mm (5.31495 inch)
Warning” lamp. Under certain conditions, the engine
horsepower and the vehicle speed may be limited.
The electronic service tool may be used to display the
diagnostic codes.
(continued)
SEBU8733 29
General Information
Product Description

There are three types of diagnostic codes: active, When auxiliary devices, accessories, or consumables
logged and event. (filters, additives, catalysts,) which are made by other
manufacturers are used on Caterpillar products, the
Most of the diagnostic codes are logged and stored in Caterpillar warranty is not affected simply because
the ECM. For additional information, refer to the of such use.
Operation and Maintenance Manual, “Engine
Diagnostics” topic (Operation Section). However, failures that result from the installation
or use of other manufacturers devices,
Engine Cooling and Lubrication accessories, or consumables are NOT Caterpillar
defects. Therefore, the defects are NOT covered
The cooling system and lubrication system consists under the Caterpillar warranty.
of the following components:
Aftertreatment System
• Gear-driven centrifugal water pump
The aftertreatment system is approved for use by
• Water temperature regulator which regulates the Caterpillar . In order to be emission-compliant only
engine coolant temperature the approved Caterpillar aftertreatment system must
be used on a Caterpillar engine.
• Gear-driven gerotor type oil pump

• Oil cooler
The engine lubricating oil is supplied by a gerotor
type oil pump. The engine lubricating oil is cooled and
the engine lubricating oil is filtered. The bypass valve
can provide unrestricted flow of lubrication oil to the
engine if the oil filter element should become
plugged.
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to proper
operation and maintenance recommendations.
Engine performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and
coolants. Refer to this Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
information on maintenance items.

Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants, and
lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
Expected engine life is generally predicted by the
average power that is demanded. The average power
that is demanded is based on fuel consumption of the
engine over time. Reduced hours of operation at full
throttle and/or operating at reduced throttle settings
result in a lower average power demand. Reduced
hours of operation will increase the length of
operating time before an engine overhaul is required.
For more information, refer to the Operation and
Maintenance Manual, “Overhaul Considerations”
topic (Maintenance Section).

Aftermarket Products and

Caterpillar Engines
Caterpillar does not warrant the quality or
performance of non-Caterpillar fluids and filters.
30 SEBU8733
Product Identification Information
Plate Locations and Film Locations

Product Identification
Information
i04897160

Plate Locations and Film

Locations
SMCS Code: 1000; 4450

Illustration 24 g03047463
Typical example

i05349518

Plate Locations and Film

Locations
(Aftertreatment System)
SMCS Code: 1000; 4450

Clean Emission Module (CEM)

Illustration 23 g03046077
(1) Location of the engine serial number plate

Serial Number Plate

The engine serial number plate (1) is located on the
left side of the cylinder block to the rear of the front
engine mounting.
Caterpiller dealers need all of these numbers in order
to determine the components that were included with
the engine. The full serial number permits accurate
identification of replacement part numbers.

Illustration 25 g03047499
Typical example

The identification plate (1) is located on the intake

end of the CEM.
SEBU8733 31
Product Identification Information
Emissions Certification Film

Illustration 26 g03388367 Illustration 28 g03418749

Typical example CEM identification plate Typical example PETU serial plate

Record all the information on the CEM and PETU

Pump Electronic Tank Unit (PETU) serial plates. The information will be required by your
Cat dealer in order to identify replacement part
numbers.

i04274710

Emissions Certification Film

SMCS Code: 1000; 7405
The label for the emission is installed on the front
gear cover.
Note: A second emission label will be supplied with
the engine. If necessary, the second emission label
will be installed on the application by the original
equipment manufacturer.

Illustration 27 g03419905
Typical example

The location of the PETU serial plate (2).

32 SEBU8733
Product Identification Information
Reference Information

Secondary Fuel Filter Element

Lubrication Oil Filter Element
Auxiliary Oil Filter Element
Total Lubrication System Capacity
Total Cooling System Capacity
Air Cleaner Element
Drive Belt

Clean Emission Module

Part Number
Serial Number

Pump Electronics Tank Unit

Part Number
Serial Number

Illustration 29 g02443539
Typical example

i05362542

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

Record for Reference

Engine Model
Engine Serial number
Engine Low Idle rpm
Engine Full Load rpm
In Line Fuel Filter
Primary Fuel Filter
SEBU8733 33
Operation Section
Product Lifting

Operation Section Engine and Clean Emission Module

(CEM)
Lifting and Storage
i05350494

Product Lifting
SMCS Code: 7000; 7002

NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.

Read all the information within produce lifting before

any lifting is attempted. Ensure that the correct set of
lifting eyes for the assembly to be lifted have been
selected.
Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the assembly. 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.

Illustration 30 g03051657
Typical example
(1) Lifting eyes for engine and aftertreatment.

Refer to illustration 30 for the location of the lifting

eyes in order to lift the assembly.

CEM Only
Ensure that the exhaust inlet for the CEM is not
damaged during removal and installation. Do not
allow the weigh of the CEM to act on the exhaust
inlet.
34 SEBU8733
Lifting and Storage
Product Lifting

Illustration 32 g03419909
Typical example
(3) Lifting eyes for PETU

Refer to illustration 32 for the location of the lifting

eyes in order to lift the PETU.
Illustration 31 g03051677
Typical example
(2) Lifting eyes for the CEM

Refer to illustration 31 for the location of the lifting

eyes in order to lift the CEM. The lifting eyes (2) are
designed only to lift the CEM. The lifting eyes (2)
must not be used to lift any other parts of the
application.

Note: If the CEM is removed from the application, the

inlet and outlet connections must be protected in
order to prevent damage.

Pump Electronics Tank Unit (PETU) Only

The tank on the PETU should be empty before the
assembly is lifted.
SEBU8733 35
Lifting and Storage
Product Storage

Engine Only • Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).
• If freezing temperatures are expected, check the
cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
(Maintenance Section).
If an engine is out of operation and if use of the
engine is not planned, special precautions should be
made. If the engine will be stored for more than 1
month, a complete protection procedure is
recommended.
Ensure that the outlets on the Clean Emission Module
(CEM) are capped Ensure that the Diesel Exhaust
Fluid (DEF) injector connections are capped.
In order to prevent damage to the exhaust outlet
connection during storage, the weight of the CEM
must not act on the exhaust outlet.
For more detailed information on engine storage, see
Special Instruction, SEHS9031, “Storage Procedure
For Caterpillar Products”.
Your Cat dealer can assist in preparing the engine for
extended storage periods.

Aftertreatment
Illustration 33 g03051679
Typical example The engine must be allowed to perform a DEF purge
before the battery disconnect switch is turned off.
(4) Lifting eyes for the engine
Some applications, the engine can be equipped with
Refer to illustration 32 for the location of the lifting delayed engine shutdown. Allow 2 minutes after the
eyes in order to lift the engine. engine has stopped before disconnecting the battery
disconnect switch.

i05359242 The exhaust outlet of the aftertreatment must be

capped. In order to prevent damage to the exhaust
outlet connection during storage, the weight of the
Product Storage CEM must not act on the exhaust outlet.
SMCS Code: 7002
DEF Tank Storage
If the engine will not be started for several weeks, the
lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder 1. Ensure normal engine shutdown, allow the DEF to
liner surface. Rust on the cylinder liner surface will be purged. Do not disconnect the battery
cause increased engine wear and a reduction in disconnect switch, allow 2 minutes after key off
engine service life. before disconnection.
To help prevent excessive engine wear, use the 2. Fill the tank with DEF that meet all the requirement
following guidelines:
defined in ISO 22241-1.
3. Ensure that all DEF lines and electrical connection
are connected prior to prevent crystal from
forming.

4. Ensure that the DEF filler cap is correctly installed.

36 SEBU8733
Lifting and Storage
Product Storage

Removal from Storage

DEF has a limited life, refer to table 3 for the time and
temperature range. DEF that is outside this range
MUST be replaced.
On removal from storage the DEF quality in the tank
must be tested with a refractometer. The DEF in the
tank must meet the requirements defined in ISO
22241-1 and comply with table 3 .

1. If necessary, drain the tank and fill with DEF that

meet ISO 22241-1.
2. Replace the DEF filter, refer to this Operation and
Maintenance Manual, “Diesel Exhaust Fluid Filter-
Clean/Replace”.

3. Ensure that the drive belt is correctly installed.

Ensure that all engine coolant and engine oil has
the correct specification and grade. Ensure that the
coolant and the engine oil are at the correct level.
Start the engine. If a fault becomes active turn off
the engine, allow 2 minutes for the DEF system to
purge, then restart the engine.

4. If the fault continues to stay active, refer to

Troubleshooting for more information.
Table 3
Temperature Duration

10° C (50° F) 36 months

25° C (77° F) 18 months

30° C (86° F) 12 months

35° C (95° F)(1) 6 months

(1) At 35° C, significant degradation can occur. Check every batch
before use.
SEBU8733 37
Features and Controls
Alarms and Shutoffs

Features and Controls Intake manifold pressure – The intake manifold

pressure sensor checks the rated pressure in the
engine manifold.
i05416516
Fuel rail pressure – The fuel rail pressure sensor
Alarms and Shutoffs measures the high pressure or low pressure in the
fuel rail. The ECM will Check the pressure.
SMCS Code: 7400
Engine oil pressure – The engine oil pressure
sensor indicates when oil pressure drops below rated
Shutoffs system pressure, at a set engine speed.
The shutoffs are electrically operated or mechanically Engine overspeed – If, the engine rpm exceeds the
operated. The electrically operated shutoffs are overspeed setting the alarm will be activated.
controlled by the ECM.
Air filter restriction – The switch checks the air filter
Shutoffs are set at critical levels for the following when the engine is operating.
items:
User-defined switch – This switch can shut down
• Operating temperature the engine remotely.
Water in fuel switch – This switch checks for water
• Operating pressure in the primary fuel filter when the engine is operating.
• Operating level Fuel temperature – The fuel temperature sensor
monitors the pressurized fuel in the high-pressure fuel
• Operating rpm pump.
The particular shutoff may need to be reset before the
engine will start. Note: The sensing element of the coolant
temperature switch must be submerged in coolant in
NOTICE order to operate.
Always determine the cause of the engine shutdown.
Make necessary repairs before attempting to restart Engines may be equipped with alarms in order to
alert the operator when undesirable operating
the engine.
conditions occur.

Be familiar with the following items: NOTICE

When an alarm is activated, corrective measures
• Types and locations of shutoff must be taken before the situation becomes an emer-
gency in order to avoid possible engine damage.
• Conditions which cause each shutoff to function

• The resetting procedure that is required to restart If corrective measures are not taken within a
the engine reasonable time, engine damage could result. The
alarm will continue until the condition is corrected.
Alarms The alarm may need to be reset.

The alarms are electrically operated. The operations Note: If installed, the coolant level switch and the oil
of the alarms are controlled by the ECM. level switch are indicators. Both switches operate
when the application is on level ground and the
The alarm is operated by a sensor or by a switch. engine RPM at zero.
When the sensor or the switch is activated, a signal is
sent to the ECM. An event code is created by the
ECM. The ECM will send a signal in order to Clean Emission Module (CEM)
illuminate the lamp.
• Diesel Oxidation Catalyst (DOC)
Your engine may be equipped with the following
sensors or switches: • Selective Catalyst Reduction (SCR)
Coolant temperature – The coolant temperature Soot Sensors – The soot sensors monitor the soot
sensor indicates high jacket water coolant level within the CEM
temperature.
NOx Sensors – Two NOx sensors monitor the NOx
Intake manifold air temperature – The intake concentration within the exhaust gas before and after
manifold air temperature sensor indicates high intake the selective catalyst reduction module.
air temperature.
Temperature Sensors – A temperature sensor after
the engine exhaust gas exit, after the DOC and
38 SEBU8733
Features and Controls
Selective Catalytic Reduction Warning System

before the SCR module monitor the temperatures Warning Strategy

within the system.
The Electronic Control Module (ECM) will have either
a world-wide warning strategy or a European union
Pump Electronics Tank Unit (PETU) warning strategy enabled within the ECM software.
Alarms and Shutoff The European union warning strategy is comprised of
two different options. The two options will give
Diesel Exhaust Fluid (DEF) Level Sensor – The different response times for the operated to act and
DEF level sensor monitors the volume of fluid in the different de-rates to the engine. Only one option will
tank and signals the ECM if the level drops below a be enabled.
given point.
Dosing Control Unit (DCU) – The DCU controls the DEF Level Warning Strategy
injection of the DEF and will signal the ECM if the
injection has been interrupted. The DEF level world-wide warning strategy and the
DEF level European union warning strategy both offer
two options. Only one option will be enabled. These
Testing warning strategy options will give different response
times and different derate to the engine.
Turning the keyswitch to the ON position will check
the indicator lights on the control panel. All the Warning Indicators
indicator lights will be illuminated for 2 seconds after
the keyswitch is operated. Replace suspect bulbs The warning indicators consist of a level gauge for
immediately. the DEF, a low-level lamp for the DEF, an emission
malfunction lamp, and the application stop lamp.
Refer to Troubleshooting for more information.

i05406889

Selective Catalytic Reduction

Warning System
SMCS Code: 1091-WXX; 7400
The Selective Catalytic Reduction (SCR) system is a
system used to reduce NOx emissions from the
engine. Diesel Exhaust Fluid (DEF) is pumped from
the DEF tank and is sprayed into the exhaust stream.
The DEF reacts with the SCR catalyst to reduce NOx
and leaves a nitrogen and water vapor.
Illustration 34 g03069862
NOTICE (1) DEF gauge
Stopping the engine immediately after the engine has (A) Low-level warning lamp
been working under load can result in overheating of
DEF system components.
Refer to the Operation and Maintenance Manual, “En-
gine Stopping” procedure to allow the engine to cool
and to prevent excessive temperatures in the turbo-
charger housing and the DEF injector.

NOTICE
Allow at least 2 minutes after the engine has stopped Illustration 35 g02852336
before you turn the battery disconnect switch to OFF. Emission malfunction lamp
Disconnecting the battery power too soon will prevent
purging of the DEF lines after the engine is shut
down. Warning Levels
The SCR has three levels of warning. Depending on
the fault that has been detected and software enabled
will govern the time that the system will stay at each
warning level.
SEBU8733 39
Features and Controls
Selective Catalytic Reduction Warning System

Any warning should be investigated immediately,

contact your Cat dealer. The system is equipped with
an override option. Once the override option has
been used and the fault still exist, the engine will be
locked in de-rate or shutdown mode.

World-Wide SCR Warnings

• At Level 1 the emission malfunction lamp will be on
solid.

• At Level 2 the emission malfunction lamp will flash.

• At Level 3 the emission malfunction lamp will flash
and the stop lamp will activate.

• At Level 3 the engine may shut down or operate at

1000 Revolutions Per Minute (RPM).

• At Level 3 cycling the keyswitch will give 20

minutes override at full power, before the
shutdown or idle is triggered. The emission
malfunction lamp will continue to flash .If installed,
an audible warning will sound.
Table 4
World-Wide
DEF Quality Tampering and Dosing Interruption

- Normal operation Level 1 Level 2 Level 3 Override

Inducement Time None 2.5 Hours 70 minutes Shut down or idle Cycling the keyswitch
First occurrence Until fault heals will give 20 minutes
of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then the
repeat inducement time will be triggered.
The override can only be used once

Repeat Inducement None 5 minutes 5 minutes Shut down or idle Cycling the keyswitch
time Until fault heals will give 20 minutes
of full power
Inducement None None None
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will be
on solid
Contact your Cat dealer at level 1 warning, do not let the fault develop.

Table 5
World-Wide
NOx Reduction System Fault

- Normal operation Level 1 Level 2 Level 3 Override

Inducement Time None 35 Hours 60 minutes Shut down or idle Cycling the keyswitch
First occurrence Until fault heals will give 20 minutes
of full power

(continued)
40 SEBU8733
Features and Controls
Selective Catalytic Reduction Warning System

(Table 5, contd)
The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then the
repeat inducement time will be triggered.
The override can only be used once.

Repeat Inducement None 48 minutes 60 minutes Shut down or idle Cycling the keyswitch
time Until fault heals will give 20 minutes
of full power
Inducement None None None
Notification None Emission malfunction Emission malfunction Emission malfunction Emission malfunction
lamp will be on solid lamp will flash lamp will flash lamp will flash
The stop lamp will
activate
Contact your Cat dealer at level 1 warning, do not let the fault develop.

World-Wide DEF Level Warnings

Two options are available but only one option will be
enabled.
• The low-level warning lamp will operate when DEF
level reaches the trigger point of below 19 percent.

• At Level 1 the low-level warning lamp in the DEF

gauge will illuminate and the emission malfunction
lamp will be on solid.

• At Level 2 the low-level warning lamp for the DEF

is active and the emission malfunction lamp will
flash.

• At Level 3 all level 2 warning are operating, plus

the stop lamp will become activate. The engine will
shut down or will only operate at 1000 RPM. If
installed, an audible warning will sound.
Filling the DEF tank will remove the warning from the
system.
Table 6
World-Wide DEF Level Option 1

- Normal operation Initial indication Level 1 Level 2 Level 3

Inducement Trigger Above 19 percent Below 19 percent Below 12.5 percent 0 Percent reading Empty tank

Inducement None None None 25 percent torque de- Shut down or idle only
rate
Notification None Low-level lamp Low-level lamp Low-level lamp Low-level lamp
illuminated illuminated illuminated illuminated
Emission malfunction Emission malfunction Emission malfunction
lamp on solid lamp flashing lamp flashing
Stop lamp on solid

Table 7
World-Wide DEF Level Option 2

- Normal operation Initial indication Level 1 Level 2 Level 3

Inducement Trigger Above 19 percent Below 19 percent Below 12.5 percent 6 Percent reading 0 Percent reading

(continued)
SEBU8733 41
Features and Controls
Battery Disconnect Switch

(Table 7, contd)
Inducement None None None None Shut down or idle only

Notification None Low-level lamp Low-level lamp Low-level lamp Low-level lamp
illuminated illuminated illuminated illuminated
Emission malfunction Emission malfunction Emission malfunction
lamp on solid lamp flashing lamp flashing
Stop lamp on solid

i05408886
NOTICE
Never move the battery disconnect switch to the OFF
Battery Disconnect Switch position while the engine is operating. Serious dam-
(If Equipped) age to the electrical system could result.
SMCS Code: 1411
Allow at least 2 minutes after the engine has stopped i05353501
before you turn the battery disconnect switch to OFF.
Disconnecting the battery power too soon will prevent Gauges and Indicators
purging of the Diesel Exhaust Fluid (DEF) lines after
the engine is shut down. Also, during the 2 minutes SMCS Code: 7450
the engine Electronic Control Module (ECM) is active
storing information from the engine and Your engine may not have the same gauges or all of
aftertreatment sensors. the gauges that are described. For more information
about the gauge package, see the OEM information.
Not allowing the DEF purge to be performed can
damage the DEF system. Not allowing the engine Gauges provide indications of engine performance.
ECM time to store the information from the sensors Ensure that the gauges are in good working order.
can damage to emission control system. Determine the normal operating range by observing
the gauges over a period.
Some applications, the engine can be equipped with
a wait to disconnect lamp. The wait to disconnect Noticeable changes in gauge readings indicate
lamp will be illuminated during engine operation and potential gauge or engine problems. Problems may
will be extinguished approximately 2 minutes after the also be indicated by gauge readings that change
engine has stopped. even if the readings are within specifications.
Determine and correct the cause of any significant
change in the readings. Consult your Cat dealer for
assistance.
Some engine applications are equipped with Indicator
Lamps. Indicator lamps can be used as a diagnostic
aid. There are two lamps. One lamp has an orange
lens and the other lamp has a red lens.
These indicator lamps can be used in two ways:
• The indicator lamps can be used to identify the
current operational status of the engine. The
indicator lamps can also indicate that the engine
has a fault. This system is automatically operated
via the ignition switch.
Illustration 36 g03265058
• The indicator lamps can be used to identify active
Battery disconnect switch label diagnostic codes. This system is activated by
pressing the Flash Code button.
NOTICE
Do not turn off the battery disconnect switch until the Refer to the Troubleshooting Guide, “Indicator
Lamps” for further information.
indicator lamp has turned off. If the switch is turned off
when the indicator lamp is illuminated the Diesel Ex-
haust Fluid (DEF) system will not purge the DEF. If NOTICE
the DEF does not purge, DEF could freeze and dam- If no oil pressure is indicated, STOP the engine. If
age the pump and lines. maximum coolant temperature is exceeded, STOP
the engine. Engine damage can result.
42 SEBU8733
Features and Controls
Gauges and Indicators

Engine Oil Pressure – The oil pressure Ammeter – This gauge indicates the
should be greatest after a cold engine is amount of charge or discharge in the
started. The typical engine oil pressure battery charging circuit. Operation of the
with SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) at indicator should be to the “ +”” side of “ 0”” (zero).
rated rpm.
Fuel Level – This gauge indicates the
A lower oil pressure is normal at low idle. If the engine fuel level in the fuel tank. The fuel level
speed and load are stable and the gauge reading gauge operates when the “ START/
changes, perform the following procedure: STOP”” switch is in the “ on”” position.
1. Remove the load. Service Hour Meter – The gauge
indicates total operating hours of the
2. Stop the engine. engine.
3. Check and maintain the oil level.
Indicator Lamps
Jacket Water Coolant Temperature –
• Shutdown lamp
Typical temperature range is 82° to 94°C
(179.6° to 169.2°F). This temperature • Warning lamp
range will vary according to engine load and the
ambient temperature. • Wait to start lamp (Glow plug warning lamp)
A 100 kPa (14.5 psi) radiator cap must be installed • Low oil pressure lamp
on the cooling system. The maximum temperature for
the cooling system is 108° C (226.4° F). This For information, refer to this manual, “Monitoring
temperature is measured at the outlet for the water System (Table for the Indicator Lamps)” for the
temperature regulator. The engine coolant sequence of operation of the shutdown lamp and the
temperature is regulated by the engine sensors and warning lamp.
the engine ECM. This programming cannot be
altered. Derates can occur if the maximum engine The function of the wait to start lamp is automatically
coolant temperature is exceeded. controlled at engine start-up.
If the engine is operating above the normal range, The function of the low oil pressure lamp is controlled
reduce the engine load. If high coolant temperatures by the engine ECM. If low oil pressure is detected, the
are a frequent event, perform the following lamp will be illuminated. The reason for the
procedures: illumination of the low-pressure lamp should be
investigated immediately.
1. Reduce the load on the engine.
All lamps will illuminate for 2 seconds in order to
2. Determine if the engine must be shut down check that the lamps are functioning when the
immediately or if the engine can be cooled by keyswitch is turned to the ON position. If any of the
lamps stay illuminated, or a lamp fails to be
reducing the load. illuminated the reason should be investigated
immediately.
3. Inspect the cooling system for leaks. If necessary,
consult your Caterpillar dealer for assistance. The glow plug warning lamp will flash in order to show
that the engine is been held at low speed. This
Tachometer – This gauge indicates function will be performed at engine starting and the
engine speed (rpm). When the throttle duration will depend on ambient temperature and
control lever is moved to the full throttle engine temperature.
position without load, the engine is running at
high idle. The engine is running at the full load Aftertreatment Lamps and gauges
rpm when the throttle control lever is at the full
throttle position with maximum rated load. All applications will require the following lamps and
gauges:
NOTICE • Emission malfunction lamp
To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious • Action indicator lamp
damage to the engine. Operation at speeds exceed-
ing high idle rpm should be kept to a minimum. • Gauge for Diesel Exhaust Fluid (DEF)

• Low warning lamp for DEF

• Wait to disconnect lamp (optional)
SEBU8733 43
Features and Controls
Monitoring System

The wait to disconnect lamp will be illuminated during

engine operation and will be extinguished
approximately 2 minutes after the engine has
stopped. Do not disconnect the battery disconnect
switch during the period the lamp is illuminated. The
DEF system will be purged during this time. Also,
during the 2 minutes the engine electronic control
module is active storing information from the engine
and aftertreatment sensors.
Note: The wait to disconnect lamp will not be
checked at key on. The wait to disconnect lamp will
illuminate at key on.

i04901303

Monitoring System
(Engine Indicators and
Aftertreatment Indicators)
SMCS Code: 1900; 7400; 7450; 7451

Engine Indicator Lamps

Note: When in operation the amber warning lamp has
three states, solid, flashing, and fast flashing. The
sequence is to give a visual indication of the
importance of the warning. Some application can
have an audible warning installed.
Ensure that the engine maintenance is carried out at
the correct intervals. A lack of maintenance can result
in illumination of the warning lamp. For the correct
intervals of maintenance, refer to the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
Table 8
Indicator Lamp Table

Warning Shutdown Lamp State Description of the Indication Engine Status

Lamp Action Indi-
cator Lamp
On On Lamp Check When the keyswitch is moved to the ON po- The keyswitch is in the ON position but the en-
sition, the lamps come on for 2 seconds and gine has not yet been cranked.
the lamps will then go off.

If any of the indicators will not illuminate during indicator check, the fault must be investigated immediately
If any Indicators stay illuminated or flash, the fault must be investigated immediately.

Off Off No Faults With the engine in operation, there are no The engine is operating with no detected faults.
active warnings, diagnostic codes, or event
codes.
On Solid Off Warning Level 1 warning The engine is operating normally but there is
one or more faults with the electronic manage-
ment system for the engine.

As soon as possible the fault should be investigated.

(continued)
44 SEBU8733
Features and Controls
Overspeed

(Table 8, contd)
Indicator Lamp Table

Warning Shutdown Lamp State Description of the Indication Engine Status

Lamp Action Indi-
cator Lamp
Flashing Off Warning Level 2 warning The engine continues to be operated, but the
level of importance of the warning has
increased.
Depending on the particular fault and the se-
verity the engine may be de-rated.
The engine could be damaged if continued to
be operated.

Stop the engine. Investigate the code.

Flashing On Engine Shutdown Level 3 warning The engine is either shutdown or an engine
If both the warning lamp and the shutdown shutdown is imminent. One or more monitored
lamp are in operation, this issue indicates engine parameters have exceeded the limit for
one of the following conditions. an engine shutdown. This pattern of lamps can
be caused by the detection of a serious active
1. One or more of the shutdown values for diagnostic code.
the engine protection strategy has been
exceeded. Contact your Cat dealer.

2. A serious active diagnostic code has been

detected.

If install, the audible warning will sound.

After a short time period, the engine may
shut down.

Flash Codes An overspeed is detected by the speed/timing

sensors.
Some applications may support flash codes. A flash
code can be viewed by an indicator lamp that when The default setting for an overspeed is 3000 rpm. The
asked will flash in a particular sequence. The ECM will cut the power to the electronic unit injectors,
indicator lamp used to view the codes is the warning until the rpm drops below 200 rpm of the overspeed
lamp, the lamp can then be refer to as a diagnostic setting. A diagnostic fault code will be logged into the
lamp. For more information refer to this Operation and ECM memory and a warning lamp will indicate a
Maintenance Manual, “Diagnostic Lamp”. diagnostic fault code.
An overspeed can be set from 2600 rpm to 3000 rpm.
Aftertreatment System This setting depends on the application.

The aftertreatment indicators should illuminate at key

i05350563
on for 2 seconds in order to test the system. If any of
the indicators do not illuminate, the fault must be
investigated immediately. Sensors and Electrical
For more information on the illumination of the Components
aftertreatment indicators refer to this Operation and SMCS Code: 1900; 7400
Maintenance Manual, “Selective Catalytic Reduction
Warning System”. The illustrations within the following sections are
typical location of the sensors or electrical
i03554501 components for an industrial engine. Specific engines
may appear different due to differences in
Overspeed applications.

SMCS Code: 1900; 1907; 1912; 7427

• ECM Electronic Control Module

• RPM Revolutions Per Minute

SEBU8733 45
Features and Controls
Sensors and Electrical Components

Engine Components

Illustration 37 g03389319
Typical example
(1) Coolant Temperature Sensor (6) Inlet Manifold Air Temperature Sensor (13) Primary Speed/Timing Sensor
(2) Injector Connector for Number One and (7) Inlet Manifold Air Pressure Sensor (14) Starter Solenoid
Two Injectors (8) Glow Plug Connection (15) Starter relay
(3) Injector Connector for Number three and (9) Diagnostic Connector (16) Starting Motor
Four Injectors (10) Electronic Control Module (17) Oil Level Switch
(4) Injector Connector for Number Five and (11) Atmospheric Pressure Sensor (18) Fuel Temperature Sensor
Six Injectors (Barometric Pressure sensor) (19) Solenoid for High Pressure Fuel Pump
(5) Fuel Pressure Sensor (12) Oil Pressure Sensor
46 SEBU8733
Features and Controls
Sensors and Electrical Components

Illustration 38 g03389322
Typical example
(20) Wastegate Regulator (22) Temperature Sensor for the NRS (25) Back Pressure Valve
(21) Control Valve for the NOx Reduction (23) Intake Pressure for the NRS
System (NRS) (24) Differential Pressure for the NRS
SEBU8733 47
Features and Controls
Sensors and Electrical Components

Illustration 39 g03389323
Typical example
(26) Alternator (27) Secondary Speed/Timing sensor (28) Exhaust Temperature Sensor
48 SEBU8733
Features and Controls
Sensors and Electrical Components

Illustration 40 g03393046
Typical example
(29) Water in Fuel Switch
(30) Inlet Air Temperature

Some applications do not require a diagnostic

connector (9) installed in the engine wiring harness.
The Inlet air temperature sensor (30) will be installed
in the induction system between the air cleaner and
the inlet manifold.

Illustration 41 g03058119
Typical example
(1) Coolant Temperature Sensor (4) Injector Connector (7) Inlet Manifold Pressure Sensor
(2) Injector connector (5) Fuel Pressure Sensor (8) Glow Plug Connection
(3) Injector Connector (6) Inlet Manifold Temperature Sensor
SEBU8733 49
Features and Controls
Sensors and Electrical Components

Illustration 42 g03393011
Typical example
(9) Diagnostic connector
(10) Electronic Control Module
(11) Atmospheric Pressure Sensor (Barometric Pressure sensor)
(12) Oil pressure sensor

Illustration 43 g03392999
Typical example
(13) Primary Speed/Timing Sensor
50 SEBU8733
Features and Controls
Sensors and Electrical Components

Illustration 44 g03393000
Typical example
(14) Starter Solenoid (16) Starter Relay
(15) Starting Motor (17) Oil Level Switch

Illustration 45 g03393004
Typical example
(18) Fuel Temperature Sensor
(19) Solenoid for High Pressure Fuel Pump
SEBU8733 51
Features and Controls
Sensors and Electrical Components

Illustration 46 g03393005
Typical example
(20) Wastegate Regulator (22) Temperature Sensor for the NRS (24) Differential Pressure for the NRS
(21) Control Valve for NRS (23) Intake Pressure for the NRS
52 SEBU8733
Features and Controls
Sensors and Electrical Components

Illustration 47 g03393010
Typical example
(25) Back Pressure valve
(26) Alternator
SEBU8733 53
Features and Controls
Sensors and Electrical Components

Illustration 48 g03393006
Typical example
(27) Secondary Speed/Timing sensor
(28) Exhaust Temperature Sensor
54 SEBU8733
Features and Controls
Sensors and Electrical Components

Aftertreatment Components

Illustration 49 g03393078

Clean Emissions Module (CEM)

Illustration 50 g03393624
(1) Clean Emission Module
(2) Gas Intake Temperature Sensor
(3) Soot Sensor Antenna
(4) Location for NOx Sensing Element
(5) Soot Sensor Antenna
(6) Diesel Exhaust Fluid Injector
(7) Temperature Sensor Connector
(8) Identification Module
(9) Gas Temperature Sensor before Selective Catalytic Reduction
SEBU8733 55
Features and Controls
Sensors and Electrical Components

CEM Sensors

Illustration 51 g03393632

(2) Gas Intake Temperature Sensor (4) Location for NOx Sensing Element (6) Diesel Exhaust Fluid Injector
(3) Soot Sensor Antenna (5) Soot Sensor Antenna

Illustration 52 g03393634

(7) Temperature Sensor Connector (9) Gas Temperature Sensor before

(8) Identification Module Selective Catalytic Reduction
56 SEBU8733
Features and Controls
Sensors and Electrical Components

Soot and NOx Sensors

Illustration 53 g03393956

(10) Soot Sensor (11) NOx Sensors

The location of the soot sensor (10) and NOx sensor

(11) will depend on the application.
SEBU8733 57
Features and Controls
Sensors and Electrical Components

Pump Electronic Tank Unit (PETU)

Illustration 54 g03393959

(1) DEF Level Sensor and DEF Temperature (3) Customer Connections (6) Voltage Limiting Protection Module
Sensor (4) Dosing Control Module
(2) Coolant Diverter Valve (5) Relays
58 SEBU8733
Features and Controls
Sensors and Electrical Components

Heated Line

Illustration 55 g03393960
Typical example
(7) Heated line
SEBU8733 59
Engine Diagnostics
Self-Diagnostics

Engine Diagnostics
1. Move the keyswitch from the on/off two times within
3 seconds.
i01796959
2. The shutdown warning lamp will flash once.
Self-Diagnostics
3. A flashing YELLOW lamp indicates a 3-digit
SMCS Code: 1000; 1900; 1901; 1902
diagnostic code for the engine. The sequence of
Caterpillar Electronic Engines have the capability to flashes represents the system diagnostic
perform a self-diagnostics test. When the system message. Count the first sequence of flashes in
detects an active problem, a diagnostic lamp is order to determine the first digit of the flash code.
activated. Diagnostic codes will be stored in After a two second pause, the second sequence of
permanent memory in the Electronic Control Module
(ECM). The diagnostic codes can be retrieved by flashes will identify the second digit of the flash
using Caterpillar electronic service tools. code. After the second pause, the third sequence
of flashes will identify the flash code.
Some installations have electronic displays that
provide direct readouts of the engine diagnostic 4. After the diagnostic codes have been displayed,
codes. Refer to the manual that is provided by the the shutdown lamp will flash twice and the
OEM for more information on retrieving engine indicator lamp will start to flash the logged
diagnostic codes.
diagnostic codes.
Active codes represent problems that currently exist.
These problems should be investigated first. 5. After the logged diagnostic codes have been
displayed, the shutdown lamp will flash three times
Logged codes represent the following items: in order to indication that the code sequences have
finished.
• Intermittent problems
Note: If there are no diagnostic codes or logged
• Recorded events
diagnostic codes, the system will flash the code 551.
• Performance history
i05406659
The problems may have been repaired since the
logging of the code. These codes do not indicate that
a repair is needed. The codes are guides or signals Fault Logging
when a situation exists. Codes may be helpful to SMCS Code: 1000; 1900; 1901; 1902
troubleshoot problems.
The system provides the capability of Fault Logging.
When the problems have been corrected, the When the Electronic Control Module (ECM)
corresponding logged fault codes should be cleared. generates an active diagnostic code, the code will be
logged in the memory of the ECM. The codes that
i03554520
have been logged by the ECM can be identified by
the electronic service tool. The active codes that have
been logged will be cleared when the fault has been
Diagnostic Lamp rectified or the fault is no longer active. The following
SMCS Code: 1000; 1900; 1901; 1902; 7451 logged faults cannot be cleared from the memory of
the ECM without using a factory password:
A diagnostic lamp is used to indicate the existence of Overspeed, low engine oil pressure, high engine
an active fault. A fault diagnostic code will remain coolant temperature, and aftertreatment codes.
active until the problem is repaired. The diagnostic
code may be retrieved by using the electronic service i03554534
tool.
Engine Operation with Active
i04907245
Diagnostic Codes
Diagnostic Flash Code SMCS Code: 1000; 1900; 1901; 1902
Retrieval If a diagnostic lamp illuminates during normal engine
SMCS Code: 1000; 1900; 1901; 1902 operation, the system has identified a situation that is
not within the specification. Use electronic service
Use the following procedure to retrieve the flash tools to check the active diagnostic codes.
codes if the engine is equipped with a
“DIAGNOSTIC” lamp:
60 SEBU8733
Engine Diagnostics
Engine Operation with Intermittent Diagnostic Codes

Note: If the customer has selected “DERATE” and if The electronic service tool is required in order to alter
there is a low oil pressure condition, the Electronic the configuration parameters.
Control Module (ECM) will limit the engine power until
the problem is corrected. If the oil pressure is within System Configuration Parameters
the normal range, the engine may be operated at the
rated speed and load. However, maintenance should System configuration parameters affect the emissions
be performed as soon as possible. of the engine or the power of the engine. System
configuration parameters are programmed at the
The active diagnostic code should be investigated. factory. Normally, system configuration parameters
The cause of the problem should be corrected as would never require changing through the life of the
soon as possible. If the cause of the active diagnostic engine. System configuration parameters must be
code is repaired and there is only one active reprogrammed if an ECM is replaced. System
diagnostic code, the diagnostic lamp will turn off. configuration parameters do not require
reprogrammed if the ECM software is changed.
Operation of the engine and performance of the Factory passwords are required to change these
engine can be limited as a result of the active parameters.
diagnostic code that is generated. Acceleration rates
may be significantly slower. Refer to the
Troubleshooting Guide for more information on the
relationship between these active diagnostic codes
and engine performance.

i01797063

Engine Operation with

Intermittent Diagnostic Codes
SMCS Code: 1000; 1900; 1901; 1902
If a diagnostic lamp illuminates during normal engine
operation and the diagnostic lamp shuts off, an
intermittent fault may have occurred. If a fault has
occurred, the fault will be logged into the memory of
the Electronic Control Module (ECM).
In most cases, it is not necessary to stop the engine
because of an intermittent code. However, the
operator should retrieve the logged fault codes and
the operator should reference the appropriate
information in order to identify the nature of the event.
The operator should log any observation that could
have caused the lamp to light.

• Low power
• Limits of the engine speed
• Excessive smoke, etc
This information can be useful to help troubleshoot
the situation. The information can also be used for
future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this
engine.

i05402551

Configuration Parameters
SMCS Code: 1000; 1900; 1901; 1902
The engine electronic control module (ECM) has two
types of configuration parameters. The system
configuration parameters and the customer specified
parameters.
SEBU8733 61
Engine Diagnostics
Configuration Parameters

Table 9
System Configuration Parameters

Configuration Parameters Record

Engine Serial Number

Factory Installed Aftertreatment #1 Identification Number

DPF #1 Soot Loading Sensing System Configuration Code

Limp Home Engine Speed Ramp Rate

System Operating Voltage Configuration

Rating Number

CAN Communication Protocol Write Security

Engine Emissions Operator Inducement Progress Configuration

Engine Emissions Operator Inducement Regulation Configuration

Customer Specified Parameters

Customer specified parameters allow the engine to
be configured to the exact needs of the application.
The electronic service tool is required in order to alter
the customer configuration parameters.
Customer parameters may be changed repeatedly as
operational requirements change.
Table 10
Customer Specified Parameters

Specified Parameters Record

Throttle Type Channel 1

Throttle Type Channel 2

IVS Channel 1
IVS Channel 2
Continuous Position Throttle Configuration 1

Continuous Position Throttle Configuration 2

Multi Position Throttle Switch Configuration

Throttle Arbitration
Equipment ID

Low Idle Speed

Delay Engine Shutdown

Ether Solenoid Configuration

Engine Idle Shutdown Minimum Ambient Air Temperature

Engine Idle Shutdown Maximum Ambient Air Temperature

Engine Idle Shutdown Enable Status

Engine Idle Shutdown Delay Time

(continued)
62 SEBU8733
Engine Diagnostics
Configuration Parameters

(Table 10, contd)

Engine Idle Shutdown Ambient Temperature Override Enable Status

High Soot Load Aftertreatment Protection Enable Status

Air Shutoff
Throttle Lock Feature Installation Status
PTO Mode
Throttle Lock Engine Set Speed #1

Throttle Lock Engine Set Speed #2

Throttle Lock Increment Speed Ramp Rate

Throttle Lock Decrement Speed Ramp Rate

Throttle Lock Engine Set Speed Increment

Throttle Lock Engine Set Speed Decrement

Monitoring Mode Shutdowns

Monitoring Mode Derates

Limp Home Desired Engine Speed

Engine Acceleration Rate

Engine Speed Decelerating Ramp Rate

Intermediate Engine Speed

Fan
Engine Fan Control

Engine Fan Type Configuration

Engine Cooling Fan Temperature Error Increasing Hysteresis

Engine Cooling Fan Temperature Error Decreasing Hysteresis

Engine Cooling Fan Current Ramp Rate

Engine Cooling Fan Speed

Top Engine Fan Speed

Minimum Desired Engine Cooling Fan Speed

Engine Cooling Fan Solenoid Minimum Current

Engine Cooling Fan Solenoid Maximum Current

Engine cooling Fan solenoid Dither Frequency

Engine Cooling Fan Solenoid Dither Amplitude

Fan Temperatures

Engine Fan Control Charge Air Cooler Outlet Temperature Input Enable

Engine Cooling Fan Maximum Air Flow Charge Air Cooler Outlet Temperature

Engine Cooling Fan Minimum Air Flow Charge Air Cooler Outlet Temperature

Engine Cooling Fan Control Coolant Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Coolant Temperature

(continued)
SEBU8733 63
Engine Diagnostics
Configuration Parameters

(Table 10, contd)

Engine Cooling Fan Minimum Air Flow Coolant Temperature

Engine Cooling Fan Control Transmission Oil Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Transmission Oil Temperature

Engine Cooling Fan Minimum Air Flow Transmission Oil Temperature

Engine Cooling Fan Control Hydraulic Oil Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Hydraulic Oil Temperature

Engine Cooling Fan Minimum Air Flow Hydraulic Oil Temperature

Engine Cooling Fan Control Auxiliary #1 Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Auxiliary #1 Temperature

Engine Cooling Fan Minimum Air Flow Auxiliary #1 Temperature

Engine Cooling Fan Control Auxiliary #2 Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Auxiliary #2 Temperature

Engine Cooling Fan Minimum Air Flow Auxiliary #2 Temperature

Other Parameters
Maintenance Indicator Mode
Maintenance Level 1 Cycle Interval Hours

Coolant Level Sensor

Air Filter Restriction Switch Installation Status
Air Filter Restriction Switch Configuration

Fuel/Water Separator Switch Installation Status

User Defined Switch Installation Status

Auxiliary Temperature Sensor Installation Status

Auxiliary Pressure Sensor Installation Status

Remote Torque Speed Control Enable Status

Number of Engine Operating Mode Switches

Engine Operating Mode Configuration

Glow Plug Start Aid Installation Status

High Idle Configuration

Throttle Channel 1 Droop %

Throttle Channel 2 Droop %

TSC 1 Droop %

Min Max / All Speed Governing

Rated Speed Configuration

64 SEBU8733
Engine Starting
Before Starting Engine

Engine Starting i05354321

i04935860
Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Before Starting Engine
SMCS Code: 1000; 1400; 1450
Perform the required daily maintenance and other Do not use aerosol types of starting aids such as
periodic maintenance before the engine is started. ether. Such use could result in an explosion and
Inspect the engine compartment. This inspection can personal injury.
help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, “Maintenance
Interval Schedule” for more information. Startability will be improved at temperatures below
−18 °C (0 °F) from the use of a jacket water heater or
• Ensure that the engine has an adequate fuel extra battery capacity.
supply.
The following items provide a means of minimizing
• Ensure that the engine has an adequate diesel starting problems and fuel problems in cold weather:
exhaust fluid supply Engine oil pan heaters, jacket water heaters, fuel
heaters and fuel line insulation. For more information,
• Open the fuel supply valve (if equipped). refer to Commercial Diesel Engine Fluids
Recommendations , SEBU6251.
NOTICE Use the procedure that follows for cold weather
All valves in the fuel return line must be open and fuel starting.
supply lines must be open. Damage to the fuel sys-
tem can occur if fuel lines are closed with the engine Note: Do not adjust the engine speed control during
in operation. start-up. The electronic control module (ECM) will
control the engine speed during start-up.
If the engine has not been started for several weeks, 1. Disengage any driven equipment.
fuel may have drained from the fuel system. Air may
have entered the filter housing. Also, when fuel filters 2. Turn the keyswitch to the RUN position. Leave the
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel keyswitch in the RUN position until the warning
system. Refer to the Operation and Maintenance light for the glow plugs is extinguished.
Manual, “Fuel System - Prime” for more information
on priming the fuel system. Also, check that the fuel
specification is correct and that the fuel condition is NOTICE
correct. Refer to the Operation and Maintenance Do not engage the starting motor when flywheel is
Manual, “Fuel Recommendations”. turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to al-
low the starting motor to cool before attempting to
Engine exhaust contains products of combustion start the engine again.
which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the 3. When the warning light for the glow plugs is
outside. extinguished cycle the keyswitch. Turn the
keyswitch to the OFF position and then to the
START position in order to engage the electric
• Do not start the engine or move any of the controls starting motor and crank the engine.
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
to the controls. Note: The operating period of the warning light for the
glow plugs will change due to the temperature of the
• Reset all of the shutoffs or alarm components. engine.
4. Allow the keyswitch to return to the RUN position
• Ensure that any driven equipment has been after the engine starts.
disengaged. Minimize electrical loads or remove
any electrical loads. 5. Repeat step 2 through step 4 if the engine fails to
start.
SEBU8733 65
Engine Starting
Starting the Engine

Note: After starting, the engine may be held at low Note: The operating period of the warning light for the
speed for a duration between 1 and 25 seconds to glow plugs will change due to the temperature of the
allow engine systems to stabilize. The duration will engine.
depend on ambient temperature, time since last run
and other factors. The glow plug warning lamp will NOTICE
flash in order to indicate that the engine is been held Do not engage the starting motor when flywheel is
at low speed. turning. Do not start the engine under load.
6. The engine should not be “raced” in order to speed
up the warm-up process. Allow the engine to idle If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to al-
for 3 to 5 minutes, or allow the engine to idle until low the starting motor to cool before attempting to
the water temperature indicator begins to rise. start the engine again.
When idling after the engine has started in cold
weather, increase the engine rpm from 1000 to
4. Allow the keyswitch to return to the RUN position
1200 rpm. This procedure will warm up the engine
after the engine starts.
more quickly.
5. Repeat step 2 through step 4 if the engine fails to
7. Operate the engine at low load until all systems
start.
reach operating temperature. Check the gauges
during the warm-up period. 6. After starting, the engine may be held at low speed
for a duration between 1 and 25 seconds to allow
Following a cold start white smoke can be seen from
the tailpipe. This smoke is normal and caused by engine systems to stabilize. The duration will
condensation leaving the exhaust system after depend on ambient temperature, time since last
warming up. The white smoke should clear following run and other factors. The glow plug warning light
working of the engine. will flash in order to indicate that the engine is been
held at low speed.
i05354322
i03653722
Starting the Engine
SMCS Code: 1000; 1450 Starting with Jump Start
Note: Do not adjust the engine speed control during
Cables
start-up. The electronic control module (ECM) will SMCS Code: 1000; 1401; 1402; 1900
control the engine speed during start-up.

Starting the Engine

Improper jump start cable connections can cause
1. Disengage any equipment that is driven by the an explosion resulting in personal injury.
engine.
Prevent sparks near the batteries. Sparks could
2. Turn the keyswitch to the RUN position. Leave the cause vapors to explode. Do not allow jump start
keyswitch in the RUN position until the warning cable ends to contact each other or the engine.
light for the glow plugs is extinguished.
If the installation is not equipped with a backup
Note: During the key on, the indicator lamps will be battery system, it may be necessary to start the
engine from an external electrical source.
illuminated for 2 seconds in order to check lamp
operation. If any of the lamps do not illuminate, check For information on troubleshooting the charging
the bulb. If any indicator lamps stay illuminated or system, refer to Special Instruction, REHS0354,
flash, refer to Troubleshooting, “Indicator Lamp “Charging System Troubleshooting”.
Circuit - Test”.
3. When the warning light for the glow plugs is Many batteries which are considered unusable are
extinguished cycle the keyswitch. Turn the still rechargeable. After jump starting, the alternator
may not be able to fully recharge batteries that are
keyswitch to the OFF position and then to the severely discharged. The batteries must be charged
START position in order to engage the electric to the proper voltage with a battery charger. For
starting motor and crank the engine. information on testing and charging, refer to the
Special Instruction, SEHS7633, “Battery Test
Procedure”.
66 SEBU8733
Engine Starting
After Starting Engine

i05354355
NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
After Starting Engine
jump starting. The use of higher voltage will damage SMCS Code: 1000
the electrical system.
After starting, the engine may be held at low speed
Do not reverse the battery cables. The alternator can for a duration between 1 and 25 seconds to allow
be damaged. Attach ground cable last and remove engine systems to stabilize. The duration will depend
first. on ambient temperature, time since last run and other
factors.
When using an external electrical source to start the
engine, turn the generator set control switch to the Note: In ambient temperatures from 0 to 60°C
“OFF” position. Turn all electrical accessories OFF (32 to 140°F), the warm-up time is approximately 3
before attaching the jump start cables. minutes. In temperatures below 0°C (32°F),
additional warm-up time may be required.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en- When the engine idles during warm-up, observe the
gine being started. following conditions:
Do not check the high-pressure fuel lines with the
1. Turn the start switch on the stalled engine to the engine or the starting motor in operation. If you
OFF position. Turn off all the engine's accessories. inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid
2. Connect one positive end of the jump start cable to penetration hazard. Refer to Operation and
the positive cable terminal of the discharged Maintenance Manual, “General hazard Information”.
battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the • Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
electrical source.
before operating the engine under load. This check
3. Connect one negative end of the jump start cable may not possible in some applications.
to the negative cable terminal of the electrical
• Allow the engine to idle for 3 to 5 minutes, or allow
source. Connect the other negative end of the the engine to idle until the water temperature
jump start cable to the engine block or to the indicator begins to rise. Check all gauges during
chassis ground. This procedure helps to prevent the warm-up period.
potential sparks from igniting the combustible
gases that are produced by some batteries. Note: 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
Note: The engine ECM must be powered before the determine normal readings for each gauge.
starting motor is operated or damage can occur. Comparing data over time will also help detect
4. Start the engine in the normal operating procedure. abnormal operating developments. Significant
Refer to this Operation and Maintenance Manual, changes in the readings should be investigated.
“Starting the Engine”.

5. Immediately after the engine is started, disconnect

the jump start cables in reverse order.
After jump starting, the alternator may not be able to
fully recharge batteries that are severely discharged.
The batteries must be replaced or charged to the
proper voltage with a battery charger after the engine
is stopped. Many batteries which are considered
unusable are still rechargeable. Refer to Operation
and Maintenance Manual, “Battery - Replace” and
Testing and Adjusting Manual, “Battery - Test”.
Refer to the Electrical Schematic for your engine.
Consult your Caterpillar dealer for more information.
SEBU8733 67
Engine Operation
Engine Operation

Engine Operation The DPF may require the exhaust gas temperature to
rise in order to remove the soot. If necessary, the
back pressure valve operates in order to create the
i04907268 rise in temperature. In some applications, the
operation of the back pressure valve will make the
Engine Operation engine tone different.
SMCS Code: 1000 The engine software will control the amount of DEF
that will be required in order to keep the exhaust
Proper operation and maintenance are key factors in emission compliant.
obtaining the maximum life and economy of the
engine. If the directions in the Operation and This design of DPF will not require a service
Maintenance Manual are followed, costs can be maintenance interval. The DPF can be expected to
minimized and engine service life can be maximized. function properly for the useful life of the engine
(emissions durability period), as defined by
The time that is needed for the engine to reach regulation, subject to prescribed maintenance
normal operating temperature can be less than the requirements being followed.
time taken for a walk-around inspection of the engine.
The engine can be operated at the rated rpm after the i01646335
engine is started and after the engine reaches
operating temperature. The engine will reach normal Engaging the Driven
operating temperature sooner during a low engine
speed (rpm) and during a low-power demand. This Equipment
procedure is more effective than idling the engine at SMCS Code: 1000
no load. The engine should reach operating
temperature in a few minutes.
1. Operate the engine at one-half of the rated rpm,
Avoid excess idling. Excessive idling causes carbon when possible.
buildup, engine slobber and soot loading of the
Diesel Particulate Filter (DPF). These issues are 2. Engage the driven equipment without a load on the
harmful to the engine. equipment, when possible.
Gauge readings should be observed and the data Interrupted starts put excessive stress on the drive
should be recorded frequently while the engine is train. Interrupted starts also waste fuel. To get the
operating. Comparing the data over time will help to driven equipment in motion, engage the clutch
determine normal readings for each gauge. smoothly with no load on the equipment. This
Comparing data over time will also help detect method should produce a start that is smooth and
abnormal operating developments. Significant easy. The engine rpm should not increase and the
changes in the readings should be investigated. clutch should not slip.

Engine Operation and the 3. Ensure that the ranges of the gauges are normal
Aftertreatment System when the engine is operating at one-half of the
rated rpm. Ensure that all gauges operate properly.
The exhaust gases and hydrocarbon particles from
the engine first pass through Diesel Oxidation 4. Increase the engine rpm to the rated rpm. Always
Catalyst (DOC). Some of the gasses and matter are increase the engine rpm to the rated rpm before
oxidized as they pass through the DOC. The gasses the load is applied.
then pass through the Diesel Particulate Filter (DPF).
The DPF collects the soot and any ash that is 5. Apply the load. Begin operating the engine at low
produced by the combustion in the engine. During load. Check the gauges and equipment for proper
regeneration, the soot is converted into a gas and the
ash remains in the DPF. The gasses finally pass operation. After normal oil pressure is reached and
through the Selective Catalytic Reduction (SCR). the temperature gauge begins to move, the engine
Before the gasses pass through the SCR, Diesel may be operated at full load. Check the gauges
Exhaust Fluid (DEF) is injected into the gas stream. and equipment frequently when the engine is
The DEF is stored and controlled by the Pump operated under load.
Electronic Tank Unit (PETU). The mixtures of DEF
and the exhaust gas pass through the SCR reducing Extended operation at low idle or at reduced load
the NOx in the exhaust emissions. may cause increased oil consumption and carbon
buildup in the cylinders. This carbon buildup
results in a loss of power and/or poor performance.
68 SEBU8733
Engine Operation
Fuel Conservation Practices

i04018250

Fuel Conservation Practices

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

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
• Be aware of the properties of the different fuels.
Use only the recommended fuels. Refer to the
Operations and Maintenance Manual, “Fuel
Recommendations”for further information.
• Avoid unnecessary idling.
Shut off the engine rather than idle for long periods of
time.
• Observe the service indicator frequently. Keep the
air cleaner elements clean.

• Ensure that the turbocharger is operating correctly.

For more information refer to this Operation and
Maintenance Manual, “Turbocharger - Inspect”.

• Maintain a good electrical system.

One faulty battery cell will overwork the alternator.
This fault will consume excess power and excess
fuel.
• The belt should be in good condition. Refer to the
Systems Operation, Testing and Adjusting, “V -
Belt Test” for further information.
• Ensure that all of the connections of the hoses are
tight. The connections should not leak.

• Ensure that the driven equipment is in good

working order.

• Cold engines consume excess fuel. Utilize heat

from the jacket water system and the exhaust
system, when possible. Keep cooling system
components clean and keep cooling system
components in good repair. Never operate the
engine without water temperature regulators. All of
these items will help maintain operating
temperatures.
SEBU8733 69
Cold Weather Operation
Cold Weather Operation

Cold Weather Operation Hints for Cold Weather Operation

• After starting the engine, the engine speed will be
i05353504 governed for up to a maximum of 25 seconds.
After this period, the engine should be operated at
Cold Weather Operation low loads until a minimum operating temperature
of 80° C (176° F) is achieved
SMCS Code: 1000; 1250
• Achieving operating temperature will help prevent
Caterpillar Diesel Engines can operate effectively in
cold weather. During cold weather, the starting and the intake valves and exhaust valves from sticking.
the operation of the diesel engine is dependent on the
following items: • The cooling system and the lubrication system for
the engine do not lose heat immediately upon
• The type of fuel that is used shutdown. This means that an engine can be shut
down for a period and the engine can still start
• The viscosity of the engine oil readily.

• The operation of the glow plugs • Install the correct specification of engine lubricant
before the beginning of cold weather.
• Optional Cold starting aid
• Check all rubber parts (hoses, fan drive belts)
• Battery condition weekly.
• Ambient air temperature • Check all electrical wiring and connections for any
fraying or damaged insulation.
Refer to Special Publication, SEBU5898, Cold
Weather Recommendations for Caterpillar • Keep all batteries fully charged and warm.
Machines.
• Fill the fuel tank at the end of each shift.
This section will cover the following information:
• Drain the water from the fuel system. Refer to this
• Potential problems that are caused by cold-
Operation and Maintenance Manual, “Fuel System
weather operation
Primary Filter/Water Separator - Drain”.
• Suggest steps which can be taken in order to
• Check the air cleaners and the air intake daily.
minimize starting problems and operating
Check the air intake more often when you operate
problems when the ambient air temperature is
in snow.
between “0° to −40 °C (32° to -40 °F)”.
The operation and maintenance of an engine in • Ensure that the glow plugs are in working order.
freezing temperatures is complex . This complexity is Refer to Troubleshooting, “Glow Plug Starting Aid -
because of the following conditions: Test”.

• Weather conditions

• Engine applications Personal injury or property damage can result

Recommendations from your Caterpillar dealer are from alcohol or starting fluids.
based on past proven practices. The information that
Alcohol or starting fluids are highly flammable
is contained in this section provides guidelines for
cold-weather operation. and toxic and if improperly stored could result in
injury or property damage.

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.

• For jump starting with cables in cold weather, refer

to the Operation and Maintenance Manual,
“Starting with Jump Start Cables.” for instructions.
70 SEBU8733
Cold Weather Operation
Cold Weather Operation

Viscosity of the Engine Lubrication Recommendations for Coolant

Oil Warm Up
Correct engine oil viscosity is essential. Oil viscosity Warm up an engine that has cooled below normal
affects the amount of torque that is needed to crank operating temperatures due to inactivity. This
the engine. Refer to this Operation and Maintenance procedure should be performed before the engine is
Manual, “Fluid Recommendations” for the returned to full operation. During operation in very
recommended viscosity of oil. cold temperature conditions, damage to engine valve
mechanisms can result from engine operation for
Recommendations for the Coolant short intervals. This damage can happen if the engine
is started and the engine is stopped many times
Provide cooling system protection for the lowest without being operated in order to warm up
expected outside temperature. Refer to this completely.
Operation and Maintenance Manual, “Fluid
Recommendations” for the recommended coolant When the engine is operated below normal operating
mixture. temperatures, fuel and oil are not completely burned
In cold weather, check the coolant often for the in the combustion chamber. This fuel and oil causes
correct glycol concentration in order to ensure soft carbon deposits to form on the valve stems.
adequate freeze protection. Generally, the deposits do not cause problems and
the deposits are burned off during operation at normal
engine operating temperatures.
Engine Block Heaters
When the engine is started and the engine is stopped
Engine block heaters (if equipped) heat the engine many times without being operated in order to warm
jacket water that surrounds the combustion up completely, the carbon deposits become thicker.
chambers. This heat provides the following functions: This carbon can cause the following problems:

• Startability is improved. • Free operation of the valves is prevented.

• Warm up time is reduced. • Valves become stuck.

An electric block heater can be activated once the • Pushrods may become bent.
engine is stopped. A block heater can be 110V dc or
240V dc. The output can be 750/1000W. Consult your • Other damage to valve train components can
Cat dealer for more information. result.

Idling the Engine For this reason, when the engine is started, the
engine must be operated until the coolant
After starting the engine, the engine speed will be temperature is 80° C (176° F) minimum. Carbon
governed for a maximum period of 25 seconds. When deposits on the valve stems will be kept at a minimum
idling after the engine is started in cold weather, and the free operation of the valves and the valve
increase the engine rpm from 1000 to 1200 rpm. This components will be maintained.
increase in RPM will warm up the engine more
quickly. Maintaining an elevated low idle speed for The engine must be thoroughly warmed in order to
extended periods will be easier with the installation of keep other engine parts in better condition. Also, the
a hand throttle. The engine should not be “raced” in service life of the engine will be generally extended.
order to speed up the warm-up process. Lubrication will be improved. There will be less acid
and less sludge in the oil. This improvement will
While the engine is idling, the application of a light provide longer service life for the engine bearings, the
load (parasitic load) will assist in achieving the piston rings, and other parts. However, limit
minimum operating temperature. The minimum unnecessary idle time to 10 minutes in order to
operating temperature is 80° C (176° F). reduce wear and unnecessary fuel consumption.
SEBU8733 71
Cold Weather Operation
Radiator Restrictions

The Water Temperature Regulator and Recommendation for Crankcase Breather

Insulated Heater Lines Protection
The engine is equipped with a water temperature Crankcase ventilation gases contain a large quantity
regulator. When the engine coolant is below the of water vapor. This water vapor can freeze in cold
correct operating temperature, jacket water circulates ambient conditions and can plug or damage the
through the engine cylinder block and into the engine crankcase ventilation system. If the engine is
cylinder head. The coolant then returns to the cylinder operated in temperatures below −25° C (−13° F),
block via an internal passage that bypasses the valve measures must be taken to prevent freezing and
of the coolant temperature regulator. This coolant plugging of the breather system. Insulated hoses and
return circuit ensures that coolant flows around the a heated canister assembly should be installed.
engine under cold operating conditions. The water
temperature regulator begins to open when the Consult with your Cat dealer for the recommended
engine jacket water has reached the correct minimum breather components for operation from
operating temperature. As the jacket water coolant −25° to -40°C (−13° to -40.°F).
temperature rises above the minimum operating
temperature the water temperature regulator opens
i04156663
further allowing more coolant through the radiator to
dissipate excess heat.
Radiator Restrictions
The progressive opening of the water temperature
regulator operates the progressive closing of the SMCS Code: 1353; 1396
bypass passage between the cylinder block and
Caterpillar discourages the use of airflow restriction
head. This process ensures maximum coolant flow to
the radiator in order to achieve maximum heat devices that are mounted in front of radiators. Airflow
dissipation. restriction can cause the following conditions:

Note: Do not restrict the air flow. Restriction to the air • High exhaust temperatures
flow can damage the fuel system. Caterpillar strongly • Power loss
discourages the use of all air flow restriction devices
such as radiator shutters. Restriction of the air flow • Excessive fan usage
can result in the following: high exhaust
temperatures, power loss, excessive fan usage and • Reduction in fuel economy
reduction in fuel economy.
Reducing air flow over components will also affect
A cab heater is beneficial in very cold weather. The under hood temperatures. Reducing air flow can
feed from the engine and the return lines from the cab increase surface temperatures during an
should be insulated in order to reduce heat loss to the aftertreatment regeneration and could affect
outside air. component reliability.
Reducing air flow can increase surface temperatures
Insulating the Air Inlet and Engine during an aftertreatment regeneration and could
Compartment affect component reliability.

When temperatures below −18 °C (−0 °F) will be If an airflow restriction device must be used, the
frequently encountered, an air cleaner inlet that is device should have a permanent opening directly in
located in the engine compartment may be specified. line with the fan hub. The device must have a
minimum opening dimension of at least 770 cm2
An air cleaner that is located in the engine
(120 in2).
compartment may also minimize the entry of snow
into the air cleaner. Also, heat that is rejected by the A centered opening that is directly in line with the fan
engine helps to warm the intake air. hub is specified in order to prevent an interrupted
Additional heat can be retained around the engine by airflow on the fan blades. Interrupted airflow on the
insulating the engine compartment. fan blades could cause a fan failure.
Caterpillar recommends a warning device for the
inlet manifold temperature and/or the installation of an
inlet air temperature gauge. The warning device for
the inlet manifold temperature should be set at 75 °C
(167 °F). The inlet manifold air temperature should
not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential
engine damage.
72 SEBU8733
Cold Weather Operation
Fuel and the Effect from Cold Weather

i05385898 • Starting aids

Fuel and the Effect from Cold • Engine oil pan heaters

Weather • Engine coolant heaters

SMCS Code: 1000; 1250; 1280 • Fuel heaters
The following fuels are the grades that are available • Fuel line insulation
for Cat engines:
For more information on cold-weather operation, see
• NO. 1 is ASTM D975 grade 1D S15 Special Publication, SEBU5898, “Cold Weather
Recommendations”.
• NO. 2 is ASTM D975 grade 2D S15
No. 2 diesel fuel is the most commonly used fuel. i05354369
Either No. 1 diesel fuel or a blend of No. 1 and No. 2
is best suited for cold-weather operation. Fuel Related Components in
Quantities of No. 1 diesel fuel are limited. No. 1 diesel Cold Weather
fuels are usually available during the months of the
winter in the colder climates. During cold-weather SMCS Code: 1000; 1250; 1280
operation, if No. 1 diesel fuel is not available, use No.
2 diesel fuel, if necessary. Fuel Tanks
There are three major differences between No. 1 and Condensation can form in partially filled fuel tanks.
No. 2 diesel fuel. No. 1 diesel fuel has the following Top off the fuel tanks after you operate the engine.
properties:
Fuel tanks should contain some provision for draining
• Lower cloud point water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
• Lower pour point and sediment to settle below the end of the fuel
supply pipe.
• Lower rating of kJ (BTU) per unit volume of fuel
Some fuel tanks use supply lines that take fuel
When No. 1 diesel fuel is used, a decrease in power directly from the bottom of the tank. If the engine is
and in fuel efficiency may be noticed. Other operating equipped with this system, regular maintenance of
effects should not be experienced. the fuel system filter is important.
The cloud point is the temperature when a cloud of Drain the water and sediment from any fuel storage
wax crystals begins to form in the fuel. These crystals tank at the following intervals: weekly, service
can cause the fuel filters to plug. The pour point is the intervals and refueling of the fuel tank. This procedure
temperature when diesel fuel will thicken. The diesel will help prevent water and/or sediment from being
fuel becomes more resistant to flow through fuel pumped from the fuel storage tank and into the
pumps and through fuel lines. engine fuel tank.
Be aware of these values when diesel fuel is
purchased. Anticipate the average ambient
Fuel Filters
temperature of the area. Engines that are fueled in After you change the fuel filter, always prime the fuel
one climate may not operate well if the engines are system in order to remove air bubbles from the fuel
moved to another climate. Problems can result due to system. Refer to the Operation and Maintenance
changes in temperature. Manual in the Maintenance Section for more
information on priming the fuel system.
Before troubleshooting for low power or for poor
performance in the winter, check the type of fuel that The micron rating and the location of a primary fuel
is being used. filter is important in cold-weather operation. The In-
line filter, primary fuel filter, and the fuel supply line
When No. 2 diesel fuel is used, the following are the most common components that are affected
components provide a means of minimizing problems by cold fuel.
in cold weather:
SEBU8733 73
Cold Weather Operation
Diesel Exhaust Fluid in Cold Weather

NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a
four micron[c] absolute high efficiency fuel filter is re-
quired for all Caterpillar Electronic Unit Injectors.
Caterpillar High Efficiency Fuel Filters meet these re-
quirements. Consult your Cat dealer for the proper
part numbers.

Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in the fuel system before the electric fuel
pump.
For further information on fuel heaters, consult your
Cat dealer.

i04928593

Diesel Exhaust Fluid in Cold

Weather
SMCS Code: 108K
Due to the freezing point of Diesel Exhaust Fluid
(DEF) the aftertreatment system is equipped with
electrically heated DEF lines. The system also has a
coolant heated element in the DEF tank. For
information on DEF refer to this Operation and
Maintenance Manual, “Fluid Recommendations”.
74 SEBU8733
Engine Stopping
Stopping the Engine

Engine Stopping Note: There may be regulations that define the

requirements for the operator and/or support
personnel to be present when the engine is running.
i05406628

Stopping the Engine

SMCS Code: 1000 Leaving the machine unattended when the engine
is running may result in personal injury or death.
NOTICE Before leaving the machine operator station, neu-
Stopping the engine immediately after the engine has tralize the travel controls, lower the work tools to
been working under load, can result in overheating the ground and deactivate all work tools, and
and accelerated wear of the engine components. place the lever for the hydraulic lockout control in
the LOCKED position.
Avoid accelerating the engine prior to shutting down
the engine.
Leaving the engine unattended while running may
Avoiding hot engine shutdowns will maximize turbo- result in property damage in the event of a
charger shaft and bearing life. Also, selective catalytic malfunction.
reduction component life.
Note: An authorized dealer can change the maximum
run time value up to 30 minutes but the default setting
Note: Individual applications will have different is 10 minutes.
control systems. Ensure that the shutoff procedures
An override can be enabled so that the delayed
are understood. Use the following general guidelines engine shutdown will not operate. Overriding delayed
in order to stop the engine. engine shutdown may reduce engine and system
component life. The override is operated by the
1. Remove the load from the engine. Reduce the keyswitch.
engine speed to low idle. Allow the engine to idle
for 5 minutes in order to cool the engine. At any time during a delayed engine shutdown, the
engine start switch may be turned to the ON position.
2. Stop the engine after the cool down period The engine may be placed back into service.
according to the shutoff system on the engine and
turn the ignition keyswitch to the OFF position. If i03554860
necessary, refer to the instructions that are
provided by the OEM. Emergency Stopping
SMCS Code: 1000; 7418
Note: Some applications the engine will continue to
operate after the keyswitch is turned to the OFF NOTICE
position. The engine will operate for a short time in Emergency shutoff controls are for EMERGENCY
order to allow engine components to cool. use ONLY. DO NOT use emergency shutoff devices
3. Allow at least 2 minutes after the engine has or controls for normal stopping procedure.
stopped before you turn the battery disconnect
switch to OFF. Disconnecting the battery power too
Ensure that any components for the external system
soon will prevent purging of the DEF fluid lines that support the engine operation are secured after
after the engine is shut down. Also, during the 2 the engine is stopped.
minutes the engine electronic control module is
active, storing information from the engine and
aftertreatment sensors.

Delayed Engine Shutdown (if

Equipped)
The delayed engine shutdown allows the engine to
run for a time after the engine start switch is turned to
the OFF position in order to cool the system
components. The engine start switch key may be
removed.
SEBU8733 75
Engine Stopping
After Stopping Engine

Emergency Stop Button • Diesel Exhaust Fluid (DEF) purge, do not

disconnect the battery disconnect switch until the
DEF purge has been completed. The procedure is
automatically controlled and will take
approximately 2 minutes.
• After the engine has stopped, you must wait for 10
minutes in order to allow the fuel pressure to be
purged from the high-pressure fuel lines before
any service or repair is performed on the engine
fuel lines. If necessary, perform minor adjustments.
Repair any leaks from the low-pressure fuel
system and from the cooling, lubrication, or air
systems. Replace any high-pressure fuel line that
has leaked. Refer to Disassembly and Assembly
Manual, “Fuel Injection Lines - Install”.
Illustration 56 g00104303 • Check the crankcase oil level. Maintain the oil level
Typical emergency stop button between the “MIN” mark and the “MAX” mark on
the engine oil level gauge.
The emergency stop button is in the OUT position for
normal engine operation. Push the emergency stop • If the engine is equipped with a service hour meter,
button. The engine will not start when the button is note the reading. Perform the maintenance that is
locked. Turn the button clockwise in order to reset. in the Operation and Maintenance Manual,
“Maintenance Interval Schedule”.
Refer to Operation and Maintenance Manual,
“Features and Controls” for the location and the • Fill the fuel tank, in order to help prevent
operation of the emergency stop button.
accumulation of moisture in the fuel. Do not overfill
the fuel tank.
i05402556
• Fill the DEF tank, a low level of DEF in the tank
After Stopping Engine can result in engine de-rate.
SMCS Code: 1000 NOTICE
Only use antifreeze/coolant mixtures recommended
Note: Before you check the engine oil, do not operate
in this Operation and Maintenance Manual, “Refill Ca-
the engine. Wait for at least 10 minutes after the
pacities and Recommendations” topic or in this Oper-
engine has stopped in order to allow the engine oil to
ation and Maintenance Manual, “Fluid
return to the oil pan.
Recommendations” topic. Failure to do so can cause
engine damage.

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow Pressurized System: Hot coolant can cause seri-
these inspection, maintenance and service in- ous burns. To open the cooling system filler cap,
structions may cause personal injury or death. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.

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

• Check the coolant for correct antifreeze protection
and the correct corrosion protection. Add the
correct coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.
76 SEBU8733
Maintenance Section
Refill Capacities

Maintenance Section i04907693

Fluid Recommendations
Refill Capacities SMCS Code: 1280; 1348; 1395; 7560

i04907690 Engine Lubrication Oil

Refill Capacities NOTICE
These recommendations are subject to change with-
SMCS Code: 1000; 1348; 1395; 7560 out notice. Contact your local Caterpillar dealer for
the most up-to-date fluids recommendations.
Lubrication System
The refill capacities for the engine crankcase reflect • EMA Engine Manufacturers Association
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will • API American Petroleum Institute
require additional oil. Refer to the OEM specifications
for the capacity of the auxiliary oil filter. Refer to the • SAE Society Of Automotive Engineers Inc.
Operation and Maintenance Manual, “Maintenance
Section” for more information on Lubricant • DEO-ULS Diesel Engine Oil-Ultra Low
Specifications. Sulfur
Table 11
Engine Cat DEO-ULS
Refill Capacities
Cat DEO-ULS is developed and tested in order to
Compartment or System Minimum Maximum provide superior protection and life for your Caterpillar
engines.
13.5 L 16.5 L
Crankcase Oil Sump(1)
(3.56 US gal) (4.36 US gal) • Better Detergents
(1) These values are the approximate capacities for the crankcase
oil sump (aluminum) which includes the standard factory in- • Advanced Additive Package
stalled oil filters. Engines with auxiliary oil filters will require addi-
tional oil. Refer to the OEM specifications for the capacity of the • Enhanced Dispersants
auxiliary oil filter. The design of the oil pan can change the oil ca-
pacity of the oil pan. • Improved Protection from Thermal breakdown and
Oxidation Breakdown
Cooling System Due to significant variations in the quality and in the
performance of commercially available oils,
Refer to the OEM specifications for the External Caterpillar makes the following recommendations:
System capacity. This capacity information will be
needed in order to determine the amount of coolant/ • Cat DEO-ULS (SAE 10W-30)
antifreeze that is required for the Total Cooling
System. • Cat DEO-ULS (SAE 15W-40)
Table 12
Cat DEO-ULS Multigrade oil is available in various
Engine viscosity grades that include SAE 10W-30 and SAE
Refill Capacities 15W-40. To choose the correct viscosity grade for the
Compartment or System ambient temperature, see illustration 57 . Multigrade
Liters
oils provide the correct viscosity for a broad range of
15 L operating temperatures. Multigrade oils are also
Engine Only
(3.96 US gal) effective in maintaining low oil consumption and low
levels of piston deposits.
External System Per OEM(1)
(1) The External System includes a radiator or an expansion tank
Consult your Caterpillar dealer for part numbers and
with the following components: heat exchanger and piping. Re- for available sizes of containers.
fer to the OEM specifications. Enter the value for the capacity of
the External System in this row.
SEBU8733 77
Refill Capacities
Fluid Recommendations

Note: Cat DEO-ULS in SAE 15W-40 passes the Refer to illustration 57 (maximum temperature) in
following proprietary tests: sticking of the piston ring, order to select the oil viscosity for engine operation at
oil control tests , wear tests and soot tests . the highest ambient temperature that is anticipated.
Proprietary tests help ensure that Caterpillar
multigrade oil provides superior performance in Note: Generally, use the highest oil viscosity that is
Caterpillar Diesel Engines. In addition, Cat DEO- available to meet the requirement for the temperature
ULS Multigrade oil exceeds many of the performance at start-up.
requirements of other manufacturers of diesel If ambient temperature conditions at engine start-up
engines. Therefore, this oil is an excellent choice for require the use of multigrade SAE 0W oil, SAE 0W-40
many mixed fleets. True high performance oil is viscosity grade is preferred.
produced with a combination of the following
factors: industry standard tests, proprietary tests,
field tests and prior experience with similar
formulations. The design and the development of
Caterpillar lubricants that are both high
performance and high quality are based on these
factors.

Commercial Oils
Note: Non-Caterpillar commercial oils are second
choice oils.

NOTICE
Caterpillar require the use of the following specifica-
tion of engine oil. Failure to use the appropriate speci-
fication of engine oil will reduce the life of your
engine. Failure to use the correct specification of en-
gine will also reduce the life and the effectiveness of
your aftertreatment system .

Table 13
Illustration 57 g03329687
API Classifications for the Industrial Engine Supplemental heat is recommended for cold soaked
Oil Specification
starts below the minimum ambient temperature.
Supplemental heat may be required for cold soaked
ECF-3 starts that are above the minimum temperature that is
CJ-4 stated, depending on the parasitic load and other
AECA E9 factors. Cold soaked starts occur when the engine
has not been operated for a period of time. This will
allow the oil to become more viscous due to cooler
NOTICE ambient temperatures.
Failure to follow these oil recommendations can
cause shortened engine service life due to deposits S·O·S Oil Analysis
and/or excessive wear.
Caterpillar has developed a tool for maintenance
management that evaluates oil degradation and the
Note: Refer to Special Publication, SEBU6251, tool also detects the early signs of wear on internal
“Caterpillar Commercial Diesel Engine Fluids components. The Caterpillar tool for oil analysis is
Recommendations ” for additional information that called S·O·S Oil Analysis and the tool is part of the
relates to lubrication for your engine. S·O·S Services program. S·O·S Oil Analysis divides
oil analysis into three categories:
Lubricant Viscosity Recommendations • Wear Analysis
The proper SAE viscosity grade of oil is determined • Oil condition
by the minimum ambient temperature during cold
engine start-up, and the maximum ambient • Additional tests
temperature during engine operation.
The wear analysis monitors metal particles, some oil
Refer to illustration 57 (minimum temperature) in additives, and some contaminants.
order to determine the required oil viscosity for
starting a cold engine.
78 SEBU8733
Refill Capacities
Fluid Recommendations

Oil condition uses infrared (IR) analysis to evaluate Note: Refer to Special Publication, SEBU6251,
the chemistry of the oil. Infrared analysis is also used “Caterpillar Commercial Diesel Engine Fluids
to detect certain types of contamination. Recommendations ” for additional information that
relates to lubrication for your engine.
Additional tests are used to measure contamination
levels from water, fuel, or coolant. Oil viscosity and
corrosion protection can be evaluated, as needed. Fuel
Refer to Special Publication, SEBU6251, “Caterpillar
Refer to Special Publication, SEBU6251, Caterpillar
Commercial Diesel Engine Fluids Recommendations
Commercial Diesel Engine Fluids Recommendations
” for the Caterpillar Specification for distillate fuel and
or contact your local Caterpillar dealer for additional
for additional information that relates to fuel for your
information concerning the S·O·S Oil Analysis
program. engine.
Ultra low Sulfur Diesel (ULSD)
Lubricating Grease
Your Caterpillar Diesel Engine must use ultra low
Caterpillar provides a range of moderate greases to sulfur diesel fuel. This fuel complies with the
extremely high performance greases in order to emissions regulations that are prescribed by the
service the entire line of Caterpillar products that Environmental Protection Agency of the United
operate throughout the wide variety of climates. You States.
will always be able to find a grease that will meet your
machines requirements for a certain application. Engines that are manufactured by Caterpillar are
Caterpillar grease products often exceed Caterpillar certified with the fuel that is prescribed by the United
specifications. States Environmental Protection Agency . Engines
that are manufactured by Caterpillar are certified with
Before selecting a grease products for any the fuel that is prescribed by the European
application, the performance requirements must be Certification. Caterpillar does not certify diesel
determined. Consult the grease recommendations engines on any other fuel.
that are made by the OEM for the equipment when
the equipment is operated in the expected conditions. Note: The owner and the operator of the engine has
Then, consult with your Caterpillar dealer for a list of the responsibility of using the fuel that is prescribed
greases and the following related characteristics. by the United States Environmental Protection
Agency and other appropriate regulatory agencies.
• Performance specifications
Fuel tank inlet labels are installed in order to ensure
• Available sizes of containers that the correct fuels are used. Illustration 58 is an
example of one of the labels designs that will be
• Part numbers installed.
Always choose a grease that meets the
recommendations that are specified by the equipment
manufacturer for the application, or choose a grease
that exceeds the recommendations that are specified
by the equipment manufacturer for the application.
If it is necessary to choose a single grease for use on
all of the equipment at one site, always choose a
grease that meets the requirements of the most
demanding application. A product that barely meets
the minimum performance requirements will shorten
the life of the part. Use the grease that yields the least
total operating cost. Base this cost on an analysis that
includes the costs of the parts, the labor, the
downtime, and the cost of the grease that is used.
Some greases are not chemically compatible. Illustration 58 g02157153
Consult your supplier in order to determine if two or Typical example
more greases are compatible.
Purge the grease from a joint at the following times: Fuel Additives
• Switching from one grease to another grease Many types of fuel additives are available. Caterpillar
does not generally recommend the use of fuel
• Switching from one supplier to another supplier additives.

Note: All Caterpillar brand name greases are

compatible with each other.
SEBU8733 79
Refill Capacities
Fluid Recommendations

In special circumstances, Caterpillar recognizes the Outside of North America , commercial DEF that
need for fuel additives. Fuel additives need to be meets all requirements defined in ISO 22241-1 may
used with caution. The additive may not be be used in Cat engines that are equipped with SCR
compatible with the fuel. Some additives may systems.
precipitate. This action causes deposits in the fuel
system. The deposits may cause seizure. Some The supplier should provide documentation to prove
additives may be corrosive and some additives may the DEF is compliant with the requirements of ISO
be harmful to the elastomers in the fuel system. 22241-1.

Some additives may damage emission control NOTICE

systems. Some additives may cause the amount of Cat does not warrant the quality or performance of
sulfur in the fuel to be greater than 15 ppm. non-Cat fluids.
Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier
can recommend the best additives for your NOTICE
application and for the proper level of treatment. Do not use agriculture grade urea solutions. Do
not use any fluids that do not meet ISO 22241-1 Re-
Note: For the best results, your fuel supplier should quirements in SCR emissions reduction systems.
treat the fuel when additives are necessary. Use of these fluids can result in numerous problems
including damage to SCR equipment and a reduction
Diesel Exhaust Fluid in NOx conversion efficiency.

General Information DEF is a solution of solid urea that is dissolved in

demineralized water to produce a final concentration
Diesel Exhaust Fluid (DEF) is a liquid that is injected of 32.5% urea. DEF concentration of 32.5% is optimal
into the exhaust system of engines equipped with for use in SCR systems. DEF solution of 32.5% urea
Selective Catalytic Reduction (SCR) systems. SCR has the lowest attainable freeze point of −11.5° C
reduces emissions of nitrogen oxides (NOx) in diesel (11.3° F). DEF concentrations that are higher or lower
engine exhaust. than 32.5% have higher freeze points. DEF dosing
systems and ISO 22241-1 specifications are
In engines equipped with SCR emissions reduction
designed for a solution that is approximately 32.5%.
system, DEF is injected in controlled amounts into the
engine exhaust stream. At the elevated exhaust Caterpillar offers a refractometer, Cat part number
temperature, urea in DEF is converted to ammonia. 360-0774, that can be used to measure DEF
The ammonia chemically reacts with NOx in diesel concentration. Follow the instructions provided with
exhaust in the presence of the SCR catalyst. The the instrument. Appropriate commercial portable
reaction converts NOx into harmless nitrogen (N2) refractometers can be used to determine urea
and water (H2O). concentration. Follow the instructions from the
manufacturer.
DEF is known by many brands including those that
carry the AdBlue or API certification.
DEF Guidelines
DEF Recommendations DEF solution is typically colorless and clear. Changes
to color or clarity are indicators of quality issues.
For use in Cat engines, DEF must meet all the Quality of DEF can degrade when stored and
requirements defined by ISO 22241-1 Requirements. handled inappropriately or if DEF is not protected
from contamination. Details are provided below.
Caterpillar recommends the use of DEF available
through the Cat parts ordering system for use in Cat If quality issues are suspected, testing of DEF should
engines equipped with SCR systems. Refer to Table focus on urea percentage, alkalinity as NH3 and
14 for part number information: biuret content. DEF that does not pass all these tests
Table 14 or that is no longer clear should not be used.
Cat Part Number Container Size
Materials compatibility
350-8733 2.5 gal bottle

350-8734 1000-L tote

DEF is corrosive. Due to the corrosion caused, DEF
must be stored in tanks constructed of approved
materials. Recommended storage materials:
In North America , commercial DEF that is API
approved and meets all the requirements defined in Stainless Steels:
ISO 22241-1 may be used in Cat engines that are
equipped with SCR systems.
80 SEBU8733
Refill Capacities
Fluid Recommendations

• 304 (S30400) • Nitrile Rubber (NBR)

• 304L (S30403) • Fluoroelastomer (FKM)

• 316 (S31600) • Ethylene Propylene Diene Monomer (EPDM)

• 316L (S31603) The condition of hoses and other nonmetallics that
are used with DEF should be monitored for signs of
Alloys and metals: degradation. DEF leaks are easily recognizable by
white urea crystals that accumulate at the site of the
• Chromium Nickel (CrNi) leak. Solid urea can be corrosive to galvanized or
unalloyed steel, aluminum, copper, and brass. Leaks
• Chromium Nickel Molybdenum (CrNiMo) should be repaired immediately to avoid damage to
surrounding hardware.
• Titanium
Non-metallic materials: Cleanliness
• Polyethylene Contaminants can degrade the quality and life of
DEF. Filtering DEF is recommended when dispensed
• Polypropylene into the DEF tank. Filters should be compatible with
DEF and should be used exclusively with DEF. Check
• Polyisobutylene with the filter supplier to confirm compatibility with
DEF before using. Mesh-type filters using compatible
• Teflon (PFA) metals, such as stainless steel, are recommended.
Paper (cellulose) media and some synthetic filter
• Polyfluoroethylene (PFE) media are not recommended because of degradation
during use.
• Polyvinylidene fluoride (PVDF)
Care should be taken when dispensing DEF. Spills
• Polytetrafluoroethylene (PTFE) should be cleaned immediately. Machine or engine
surfaces should be wiped clean and rinsed with
Materials NOT compatible with DEF solutions include water. Caution should be used when dispensing DEF
Aluminum, Magnesium, Zinc, Nickel coatings, Silver near an engine that has recently been running.
and Carbon steel and Solders containing any of the Spilling DEF onto hot components will cause harmful
above. Unexpected reactions may occur if DEF vapors.
solutions come in contact with any non-compatible
material or unknown materials. Stability
Bulk storage DEF fluid is stable when stored and handled properly.
The quality of DEF rapidly degrades when stored at
Follow all local regulations covering bulk storage high temperatures. The ideal storage temperature for
tanks. Follow proper tank construction guidelines. DEF is between −9° C (15.8° F) and 25° C (77° F).
Tank volume typically should be 110% of planned DEF that is stored above 35° C (95° F) for longer
capacity. Appropriately vent indoor tanks. Plan for than 1 month must be tested before use. Testing
control of overflow of the tank. Heat tanks that should evaluate Urea Percentage, Alkalinity as NH3
dispense DEF in cold climates. and Biuret content.

Bulk tank breathers should be fitted with filtration to The length of storage of DEF is listed in the following
keep airborne debris from entering the tank. table:
Desiccant breathers should not be used because Table 15
water will be absorbed, which potentially can alter
DEF concentration. Storage Temperature Expected DEF Life
Below 25° C (77° F) 18 months
Handling
25° C (77° F) to 30° C (86° F) 12 months
Follow all local regulations covering transport and 30° C (86° F) to 35° C (95° F) 6 months
handling. DEF transport temperature is
recommended to be −5° C (23° F) to 25° C (77° F). Above 35° C (95° F) test quality before use
All transfer equipment and intermediate containers
should be used exclusively for DEF. Containers
should not be reused for any other fluids. Ensure that Refer to ISO 22241 document series for more
information about DEF quality control.
transfer equipment is made from DEF-compatible
materials. Recommended material for hoses and Note: Dispose of all fluids according to applicable
other non-metallic transfer equipment include:
regulations and mandates.
SEBU8733 81
Refill Capacities
Fluid Recommendations

Coolant (Table 16, contd)

The following two coolants are used in Caterpillar 3000 Service Hours or Three
Cat DEAC
diesel engines: Years
Commercial Heavy-Duty Cool-
Preferred – Cat ELC (Extended Life Coolant) or a ant/Antifreeze that meets 3000 Service Hours or Two Years
commercial extended life coolant that meets the ASTM D6210
Caterpillar EC-1 specification
(1) Use the interval that occurs first. The cooling system must also
be flushed out at this time.
Acceptable – A Cat DEAC (Diesel Engine (2) Cat ELC Extender must be added at 6000 service hours or one
Antifreeze/Coolant) or a commercial heavy-duty half of the service life of the Cat ELC. Refer to your machine
antifreeze that meets ASTM D6210 specifications Operation and Maintenance Manual for exceptions.
(3) An extender must be added at 3000 service hours or one half of
the service life of the coolant.

NOTICE Note: Refer to Special Publication, SEBU6251,

The Caterpillar industrial engine must be oper- “Caterpillar Commercial Diesel Engine Fluids
ated with a 1:1 mixture of water and glycol. This Recommendations ” for additional information that
concentration allows the NOx reduction system to relates to coolant for your engine.
operate correctly at high ambient temperatures.
S·O·S Coolant Analysis
NOTICE Table 17
Do not use a commercial coolant/antifreeze that only
meets the ASTM D3306 or equivalent specification.
Recommended Interval
This type of coolant/antifreeze is made for light duty Type of
automotive applications.
Coolant Level 1 Level 2
Use only the coolant/antifreeze that is recommended. DEAC Every 250 Hours (1) Yearly(1)

ELC Optional (1) Yearly

Caterpillar recommends a 1:1 mixture of water and
(1) The Level 2 Coolant Analysis should be performed sooner if a
glycol. This mixture of water and glycol will provide
problem is identified by a Level 1 Coolant Analysis.
optimum heavy-duty performance as an antifreeze.
Note: Cat DEAC does not require a treatment with S·O·S Coolant Analysis (Level 1)
an SCA at the initial fill. Commercial heavy-duty A coolant analysis (Level 1) is a test of the properties
antifreeze that meets ASTM D6210 specifications of the coolant.
MAY require a treatment with an SCA at the initial fill.
Read the label or the instructions that are provided by The following properties of the coolant are tested:
the OEM of the product.
• Glycol concentration for freeze protection and boil
In stationary engine applications that do not require protection
anti-boil protection or freeze protection, a mixture of
SCA and water is acceptable. Caterpillar • Ability to protect from erosion and corrosion
recommends a 6 percent to 8 percent concentration
of SCA in those cooling systems. Distilled water or • pH
deionized water is preferred. Water which has the
recommended properties may be used. • Conductivity
Table 16
• Visual analysis
Coolant Service Life
Coolant Type
• Odor analysis
Service Life (1)

12000 Service Hours or Six Years The results are reported, and appropriate
Cat ELC (2) recommendations are made.

Commercial coolant that meets Refer to the Maintenance Interval Schedule in this
6000 Service Hours or Six Years Operation and Maintenance Manual in order to find
the Caterpillar EC-1 (3)
Specification the maintenance interval for collecting the coolant
samples.
S·O·S Coolant Analysis (Level 2)
(continued)
82 SEBU8733
Refill Capacities
Fluid Recommendations

A coolant analysis (Level 2) is a comprehensive

chemical evaluation of the coolant. This analysis is
also a check of the overall condition of the inside of
the cooling system.
The S·O·S Coolant Analysis has the following
features:
• Full coolant analysis (Level 1)

• Identification of the source of metal corrosion and

of contaminants

• Water hardness
• Identification of buildup of the impurities that cause
corrosion

• Identification of buildup of the impurities that cause

scaling
The results are reported, and appropriate
recommendations are made.
Refer to the Maintenance Interval Schedule in this
Operation and Maintenance Manual, “Cooling
System Coolant Sample (Level 2) - Obtain” for the
maintenance interval for collecting the coolant
samples.
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and
from corrosion. The analysis also tests the 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 S·O·S
Coolant Analysis is the best way to monitor the
condition of your coolant and your cooling system.
S·O·S Coolant Analysis is a program that is based on
periodic samples.
Refer to Special Publication, SEBU6251, Caterpillar
Commercial Diesel Engine Fluids Recommendations
for additional information.
SEBU8733 83
Maintenance Recommendations
System Pressure Release

Maintenance
1. Stop the engine.
Recommendations
2. Wait for 10 minutes.
i03648938
Do not loosen the high pressure fuel lines in order to
remove air from the fuel system.
System Pressure Release
SMCS Code: 1250; 1300; 1350; 5050 Engine Oil
To relieve pressure from the lubricating system, turn
Coolant System off the engine.

i05354374

Pressurized system: Hot coolant can cause seri- Welding on Engines with
ous burn. To open cap, stop engine, wait until ra- Electronic Controls
diator is cool. Then loosen cap slowly to relieve
the pressure. SMCS Code: 1000

The engine can have the ability to auto start. Ensure NOTICE
that the power supply is isolated before any service or Because the strength of the frame may decrease,
repair is performed. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Caterpillar dealer regarding welding on
off the engine. Allow the cooling system pressure cap a chassis frame or rail.
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure.
Proper welding procedures are necessary in order to
Fuel System avoid damage to the engines ECM, sensors, and
associated components. When possible, remove the
To relieve the pressure from the fuel system, turn off component from the unit and then weld the
the engine. component. If removal of the component is not
possible, the following procedure must be followed
High Pressure Fuel Lines when you weld on a unit equipped with an Electronic
Engine. The following procedure is considered to be
the safest procedure to weld on a component. This
procedure should provide a minimum risk of damage
to electronic components.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel NOTICE
spray may cause a fire hazard. Failure to follow Do not ground the welder to electrical components
these inspection, maintenance and service in- such as the ECM or sensors. Improper grounding can
structions may cause personal injury or death. cause damage to the drive train bearings, hydraulic
components, electrical components, and other
components.
The high pressure fuel lines are the fuel lines that are
between the high pressure fuel pump and the high Clamp the ground cable from the welder to the com-
pressure fuel manifold and the fuel lines that are ponent that will be welded. Place the clamp as close
between the fuel manifold and cylinder head. These as possible to the weld. This will help reduce the pos-
fuel lines are different from fuel lines on other fuel sibility of damage.
systems.
This is because of the following differences: Note: Perform the welding in areas that are free from
explosive hazards.
• The high pressure fuel lines are constantly
charged with high pressure. 1. Stop the engine. Turn the switched power to the
OFF position.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system. 2. Ensure that the fuel supply to the engine is turned
Before any service or repair is performed on the off.
engine fuel lines, perform the following tasks:
84 SEBU8733
Maintenance Recommendations
Welding on Engines with Electronic Controls

3. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is provided,
open the switch.

4. Disconnect all electronic components from the

wiring harnesses. Include the following
components:

• Electronic components for the driven equipment

• ECM

• Sensors

• Electronically controlled valves

• Relays

• Electric fuel pump

• Aftertreatment ID module

NOTICE
Do not use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.

Illustration 59 g01075639
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage any associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being welded
and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder

5. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to the
following components. Bearings, hydraulic
components, electrical components, and ground
straps.
Note: If electrical/electronic components are used as
a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.

6. Protect the wiring harness from welding debris and

spatter.
SEBU8733 85
Maintenance Recommendations
Severe Service Application

7. Use standard welding practices to weld the Severe Operating Conditions

materials.
• Frequent operation with inlet air which has a
corrosive content
i04807435

• Operation with inlet air which has a combustible

Severe Service Application content
SMCS Code: 1000
• Operation which is outside of the intended
An engine which operates outside of normal application
conditions is operating in a severe service
application. • Operation with a plugged fuel filter

An engine that operates in a severe service • Extended operation at low idle (more than 20% of
application may need more frequent maintenance hours)
intervals in order to maximize the following
conditions: • Frequent cold starts at temperatures below 0° C
(32° F)
• Reliability
• Frequent dry starts (starting after more than 72
• Service life hours of shutdown)
The number of individual applications cause the • Frequent hot shutdowns (shutting down the engine
impossibility of identifying all of the factors which may without the minimum of 2 minutes to 5 minutes of
contribute to severe service operation. Consult your cool down time)
Caterpillar dealer for the unique maintenance that
may be necessary for your engine. • Operation above the engine rated speed
An application is a severe service application if any of • Operation below the peak torque speed
the following conditions apply:
• Operating with fuel which does not meet the
Severe Environmental Factors standards for distillate diesel fuel as stated in
Special Publication, SEBU6250, Caterpillar
• Frequent operation in dirty air Machine Fluids Recommendations, “Distillate
• Frequent operation at an altitude which is above Diesel Fuel”
1525 m (5000 ft) • Operating with a blend of distillate fuel which
• Frequent operation in ambient temperatures which contains more than 20 percent biodiesel
are above 32° C (90° F)

• Frequent operation in ambient temperatures which

are below 0° C (32° F)
86 SEBU8733
Maintenance Recommendations
Severe Service Application

Improper Maintenance Procedures

(Maintenance Procedures Which
May Contribute to a Severe Service
Application)
• Inadequate maintenance of fuel storage tanks from
causes such as excessive water, sediment, and
microorganism growth.

• Extending maintenance intervals beyond the

recommended intervals

• Using fluids which are not recommended in

Special Publication, SEBU6250, Caterpillar
Machine Fluids Recommendations

• Extending maintenance intervals for changing the

engine oil and engine coolant without S·O·S
validation

• Extending maintenance intervals for changing air

filters, oil filters, and fuel filters
• Failure to use a water separator

• Using filters which are not recommended by

Special Publication, PEWJ0074, 2008 Cat Filter
and Fluid Application Guide
• Storing the engine for more than 3 months but less
than 1 yr (For information about engine storage,
refer to Special Publication, SEHS9031, Storage
Procedure for Caterpillar Products)
SEBU8733 87
Maintenance Recommendations
Maintenance Interval Schedule

i05354411 “Crankshaft Vibration Damper - Inspect”.............. 100

Maintenance Interval Schedule “Engine Air Cleaner Element (Dual Element) -

Inspect/Clean/Replace” ........................................ 102
SMCS Code: 1000; 4450; 7500
“Engine Air Cleaner Element (Single Element) -
Inspect/Replace”................................................... 105
When Required
“Engine Oil and Filter - Change”............................ 111
“Battery - Replace”...................................................89
“Fuel Filter (In-Line) - Replace”..............................114
“Battery or Battery Cable - Disconnect”...................90
“Fuel System Primary Filter (Water Separator)
“Diesel Exhaust Fluid - Fill”................................... 101 Element - Replace”................................................116
“Engine - Clean”.................................................... 102 “Fuel System Secondary Filter - Replace” ............118
“Engine Air Cleaner Element (Dual Element) - “Radiator - Clean” ................................................. 125
Inspect/Clean/Replace” ........................................ 102
“Engine Air Cleaner Element (Single Element) - Every 1000 Service Hours
Inspect/Replace”................................................... 105
“Belt Tensioner - Check” ..........................................90
“Fuel System - Prime”............................................115 “Belt - Inspect”..........................................................91
Daily “Water Pump - Inspect”......................................... 129
“Coolant Level - Check”...........................................97 Every 1500 Service Hours
“Driven Equipment - Check” ................................. 102
“Engine Crankcase Breather Element - Replace” 106
“Engine Air Cleaner Service Indicator - Inspect” .. 105
Every 2000 Service Hours
“Engine Air Precleaner - Check/Clean” ................ 106
“Aftercooler Core - Inspect” .....................................88
“Engine Oil Level - Check”.....................................110
“Engine Mounts - Inspect” .................................... 109
“Fuel System Primary Filter/Water Separator -
Drain” .....................................................................118 “Starting Motor - Inspect” ...................................... 126
“Walk-Around Inspection”..................................... 128 “Turbocharger - Inspect” .......................................126

Every Week Every Year

“Hoses and Clamps - Inspect/Replace”................ 120 “Coolant Sample (Level 2) - Obtain”........................98

Every 50 Service Hours or Weekly Every 3000 Service Hours

“Fuel Tank Water and Sediment - Drain” .............. 120 “Alternator - Inspect” ................................................88

Every 250 Service Hours “Alternator and Fan Belts - Replace” .......................89

“Coolant Sample (Level 1) - Obtain”........................97 Every 3000 Service Hours or 2

“Engine Oil Sample - Obtain”.................................110 Years
“Coolant (DEAC) - Change”.....................................91
Every 500 Service Hours
“Fan Clearance - Check” .......................................113
Every 4000 Service Hours
“Aftercooler Core - Clean/Test”................................88
Every 500 Service Hours or 1 Year
“Battery Electrolyte Level - Check” ..........................89
Every 5000 Service Hours
“Cooling System Supplemental Coolant Additive “Diesel Exhaust Fluid Filter - Clean/Replace” ...... 101
(SCA) - Test/Add”.....................................................99 “Injector (Diesel Exhaust Fluid) - Replace”........... 121
88 SEBU8733
Maintenance Recommendations
Aftercooler Core - Clean/Test

Every 6000 Service Hours or 3 Pressurized water may also be used for cleaning. The
maximum water pressure for cleaning purposes must
Years be less than 275 kPa (40 psi). Use pressurized water
“Coolant Extender (ELC) - Add” ..............................96 in order to soften mud. Clean the core from both
sides.
Every 12 000 Service Hours or 6 Use a degreaser and steam for removal of oil and
Years grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
“Coolant (ELC) - Change”........................................94 core with clean water.
After cleaning, start the engine and accelerate the
Overhaul engine to high idle rpm. This will help in the removal
“Overhaul Considerations” ................................... 123 of debris and drying of the core. Stop the engine. Use
a light bulb behind the core in order to inspect the
core for cleanliness. Repeat the cleaning, if
i01807350 necessary.

Aftercooler Core - Clean/Test Inspect the fins for damage. Bent fins may be opened
with a “comb”.
(Air-To-Air Aftercooler)
Note: If parts of the aftercooler system are repaired
SMCS Code: 1064-070; 1064-081 or replaced, a leak test is highly recommended. For
The air-to-air aftercooler is OEM installed in many more information, refer to OEM specification for the
applications. Please refer to the OEM specifications aftercooler.
for information that is related to the aftercooler.
Inspect these items for good condition: welds,
mounting brackets, air lines, connections, clamps and
i04380914 seals. Make repairs, if necessary.

Aftercooler Core - Inspect i03641972

SMCS Code: 1064-040
Alternator - Inspect
Note: Adjust the frequency of cleaning according to
SMCS Code: 1405-040
the effects of the operating environment.
Caterpillar recommends a scheduled inspection of
Inspect the aftercooler for these items: damaged fins, the alternator. Inspect the alternator for loose
corrosion, dirt, grease, insects, leaves, oil and other connections and proper battery charging. Inspect the
debris. Clean the aftercooler, if necessary. ammeter (if equipped) during engine operation in
For air-to-air aftercoolers, use the same methods that order to ensure proper battery performance and/or
are used for cleaning radiators. proper performance of the electrical system. Make
repairs, as required.
Check the alternator and the battery charger for
proper operation. If the batteries are properly
Personal injury can result from air pressure. charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
Personal injury can result without following prop- batteries should be kept warm because temperature
er procedure. When using pressure air, wear a affects the cranking power of the battery. If the battery
protective face shield and protective clothing. is too cold, the battery will not crank the engine.

Maximum air pressure at the nozzle must be less When the engine is not run for long periods of time or
than 205 kPa (30 psi) for cleaning purposes. if the engine is run for short periods, the batteries may
not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction of
the fans air flow. Hold the nozzle approximately 6 mm
(.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes.
The pressurized air will remove debris that is between
the tubes.
SEBU8733 89
Maintenance Recommendations
Alternator and Fan Belts - Replace

i02320208 Note: Always recycle a battery. Never discard a

battery. Dispose of used batteries to an appropriate
Alternator and Fan Belts - recycling facility.
6. Remove the used battery.
Replace
SMCS Code: 1357-510 7. Install the new battery.

Refer to Disassembly and Assembly Manual,

“Alternator Belt - Remove and Install”. Note: Before the cables are connected, ensure that
the battery disconnect switch is in the OFF position.
i05425759
8. Connect the POSITIVE “+” cable to the POSITIVE
“+” battery terminal.
Battery - Replace 9. Connect the NEGATIVE “-” cable to the
SMCS Code: 1401-510 NEGATIVE “-” battery terminal.

10. Turn the battery disconnect switch to the ON

position.
Batteries give off combustible gases which can
explode. A spark can cause the combustible i02724529
gases to ignite. This can result in severe personal
injury or death. Battery Electrolyte Level -
Ensure proper ventilation for batteries that are in Check
an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks SMCS Code: 1401-535-FLV
near batteries. Do not smoke when batteries are
serviced. When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries
are properly charged, ammeter reading should be
very near zero,when the engine is in operation.
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.
All lead-acid batteries contain sulfuric acid which
Removing the battery cables or the batteries with can burn the skin and clothing. Always wear a
the cover in place may cause a battery explosion face shield and protective clothing when working
resulting in personal injury. on or near batteries.

1. Switch the engine to the OFF position. Remove all 1. Remove the filler caps. Maintain the electrolyte
electrical loads. level to the “FULL” mark on the battery.
Note: After the engine has stopped, allow 2 minutes If the addition of water is necessary, use distilled
in order for the diesel exhaust fluid lines to be purged water. If distilled water is not available use clean
before disconnecting the power. water that is low in minerals. Do not use artificially
softened water.
2. Turn off any battery chargers. Disconnect any
2. Check the condition of the electrolyte with the
battery chargers.
245-5829 Coolant Battery Tester Refractometer.
3. Ensure that the battery disconnect switch is in the
3. Keep the batteries clean.
OFF position.
Clean the battery case with one of the following
4. Disconnect the NEGATIVE “-” cable from the cleaning solutions:
NEGATIVE “-” battery terminal.
• Use a solution of 0.1 kg (0.2 lb) baking soda
5. Disconnect the POSITIVE “+” cable from the and 1 L (1 qt) of clean water.
POSITIVE “+” battery terminal.
• Use a solution of ammonium hydroxide .
90 SEBU8733
Maintenance Recommendations
Battery or Battery Cable - Disconnect

Thoroughly rinse the battery case with clean water. 8. In order to connect the battery, connect the positive
connection before the negative connector.
Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT i04907925
remove material excessively. Excessive removal of
material can cause the clamps to not fit properly. Belt Tensioner - Check
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM. SMCS Code: 1358-535

i05424317

Battery or Battery Cable -

Disconnect
SMCS Code: 1401; 1402-029

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.

1. Turn the start switch to the OFF position. Turn the

ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads. Illustration 60 g03074016
Typical example
Note: After the engine has stopped, allow 2 minutes
in order for the diesel exhaust fluid lines to be purged Remove the belt. Refer to Disassembly and
before disconnecting the power. Assembly, “Alternator Belt - Remove and Install”.

2. Disconnect the negative battery terminal. Ensure Ensure that the belt tensioner is securely installed.
that the cable cannot contact the terminal. When Visually inspect the belt tensioner (1) for damage.
Check that the pulley on the tensioner rotates freely
four 12 V batteries are involved, 2 negative and that the bearing is not loose. Some engines have
connections must be disconnected. an idler pulley (2). Ensure that the idler pulley is
securely installed. Visually inspect the idler pulley for
3. Remove the positive connection. damage. Ensure that the idler pulley can rotate freely
and that the bearing is not loose. If necessary,
4. Clean all disconnected connection and battery replace damaged components.
terminals.
Install the belt. Refer to Disassembly and Assembly,
5. Use a fine grade of sandpaper to clean the “Alternator Belt - Remove and Install”.
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal of
material can cause the clamps to fit incorrectly.
Coat the clamps and the terminals with a suitable
silicone lubricant or petroleum jelly.

6. Tape the cable connections in order to help prevent

accidental starting.

7. Proceed with necessary system repairs.

SEBU8733 91
Maintenance Recommendations
Belt - Inspect

i04907868 • The engine overheats frequently.

Belt - Inspect • Foaming is observed.

SMCS Code: 1357-040; 1357; 1397-040; 1397 • The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.

NOTICE
Use of commercially available cooling system
cleaners may cause damage to cooling system com-
ponents. Use only cooling system cleaners that are
approved for Caterpillar engines.

NOTICE
When any servicing or repair of the engine cooling
system is performed, the procedure must be per-
formed with the engine on level ground. Level ground
will allow you to check accurately the coolant level.
This procedure will also help in avoiding the risk of in-
troducing an air lock into the coolant system.

Note: Inspect the water pump and the water

temperature regulator after the cooling system has
Illustration 61 g03073936
been drained. This inspection is a good opportunity to
Typical example replace the water pump, the water temperature
regulator, and the hoses, if necessary.
To maximize the engine performance, inspect the belt
(1) for wear and for cracking. Replace the belt if the Drain
belt is worn or damaged.
• Inspect the belt for cracks, splits, glazing, grease,
displacement of the cord and evidence of fluid
contamination. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
The belt must be replaced if the following conditions stop the engine and wait until the cooling system
are present. components are cool. Loosen the cooling system
• The belt has a crack in more than one rib. pressure cap slowly in order to relieve the
pressure.
• More than one section of the belt is displaced in
one rib of a maximum length of 50.8 mm (2 inch). 1. Stop the engine and allow the engine to cool.
To replace the belt, refer to Disassembly and Loosen the cooling system filler cap slowly in order
Assembly, “Alternator Belt - Remove and Install”. If to relieve any pressure. Remove the cooling
necessary, replace the belt tensioner. Refer to system filler cap.
Disassembly and Assembly, “Alternator Belt -
Remove and Install” for the correct procedure.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
i05425761
Containing Fluid Spillage.
Coolant (DEAC) - Change
SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
92 SEBU8733
Maintenance Recommendations
Coolant (DEAC) - Change

NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable
by Caterpillar to reclaim the used coolant.

Alternative Drain Plug

The cylinder coolant can be drained from the plug
below the oil cooler. Refer to illustration 64 . If the
alternative drain plug (3) is removed, the O ring seal
must be replaced. Tighten the drain plug to a torque
of 35 N·m (25 lb ft).

Illustration 62 g03075756

Illustration 64 g03081697

Flush
1. Flush the cooling system with clean water in order
to remove any debris.

2. Install connection hose. Clean the drain plugs.

Illustration 63 g02350785
Install the drain plugs and tighten securely.

2. Remove connection hose (1) on the engine. Also NOTICE

remove the drain plug (2). Open the drain cock or Do not fill the cooling system faster than 5 L
remove the drain plug on the radiator. (1.3 US gal) per minute to avoid air locks.
Allow the coolant to drain into a suitable container. Cooling system air locks may result in engine
damage.
3. Properly dispose of the drained material. Obey
local regulations for the disposal of the material.
3. Fill the cooling system with a mixture of clean water
and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pt) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
SEBU8733 93
Maintenance Recommendations
Coolant (DEAC) - Change

4. Start and run the engine at low idle for a minimum

of 30 minutes. The coolant temperature should be NOTICE
at least 82 °C (180 °F). Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal
components.
NOTICE
Improper or incomplete rinsing of the cooling system To avoid damage to the cooling system, make sure to
can result in damage to copper and other metal completely flush the cooling system with clear water.
Continue to flush the system until all signs of the
components. cleaning agent are gone.
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water. 5. Stop the engine and allow the engine to cool.
Continue to flush the system until all signs of the
cleaning agent are gone. Loosen the cooling system filler cap slowly in order
to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if
5. Stop the engine and allow the engine to cool. equipped) or remove the cooling system drain
Loosen the cooling system filler cap slowly in order plugs. Allow the water to drain. Flush the cooling
to relieve any pressure. Remove the cooling system with clean water. Install the connection
system filler cap. Remove the connection hose or hose.
remove the cooling system drain plugs. Allow the
water to drain. Flush the cooling system with clean 6. The drain plug O rings on the engine block must be
water. Install the connection hose. replaced. Clean the drain plugs and install new O
ring seal. Install the drain plugs and tighten to a
6. The drain plug O rings on the engine block must be torque of 35 N·m (25 lb ft).
replaced. Clean the drain plugs and install new O
ring seal. Install the drain plugs and tighten to a Fill
torque of 35 N·m (25 lb ft).

Cooling Systems with Heavy NOTICE

Do not fill the cooling system faster than 5 L
Deposits or Plugging (1.3 US gal) per minute to avoid air locks.
Note: For the following procedure to be effective, Cooling system air locks may result in engine
there must be some active flow through the cooling damage.
system components.

1. Flush the cooling system with clean water in order 1. Fill the cooling system with the coolant/antifreeze.
to remove any debris. Refer to this Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic
2. Install the connection hose. Clean the drain plugs. (Maintenance Section) for more information on
Install the drain plugs and tighten securely. cooling system specifications. Do not install the
cooling system filler cap.
NOTICE 2. Start and run the engine at low idle. Increase the
Do not fill the cooling system faster than 5 L engine rpm to high idle. Operate the engine in
(1.3 US gal) per minute to avoid air locks. order to open the engine thermostat. This
Cooling system air locks may result in engine operation will allow any air in the system to be
damage. purged. Decrease the engine speed to low idle.
Stop the engine.
3. Fill the cooling system with a mixture of clean water 3. Maintain the coolant level at the maximum mark
and Caterpillar Fast Acting Cooling System that is correct for your application.
Cleaner. Add 0.5 L (1 pt) 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.

4. Start and run the engine at low idle for a minimum

of 90 minutes. The coolant temperature should be
at least 82 °C (180 °F).
94 SEBU8733
Maintenance Recommendations
Coolant (ELC) - Change

4. Clean the cooling system filler cap. Inspect the Drain

gasket that is on the cooling system filler cap. If the
gasket that is on the cooling system filler cap is
damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the Pressurized System: Hot coolant can cause seri-
gasket that is on the cooling system filler cap is not ous burns. To open the cooling system filler cap,
damaged, perform a pressure test. A 9S-8140 stop the engine and wait until the cooling system
Pressurizing Pump is used to perform the pressure components are cool. Loosen the cooling system
test. The correct pressure for the cooling system pressure cap slowly in order to relieve the
pressure.
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new 1. Stop the engine and allow the engine to cool.
cooling system filler cap. Loosen the cooling system filler cap slowly in order
to relieve any pressure. Remove the cooling
5. Start the engine. Inspect the cooling system for system filler cap.
leaks and for the correct operating temperature.

i05360509

Coolant (ELC) - Change

SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and the

coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and
replaced.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. Replace the water pump, the water
temperature regulator, and the hoses, if necessary.

NOTICE
Service or repair of the engine cooling system must
be performed on level ground. The engine must be
level in order to check the coolant level. The engine
must be level in order to avoid the risk of introducing
an air lock into the coolant system.
SEBU8733 95
Maintenance Recommendations
Coolant (ELC) - Change

For information regarding the disposal and the

recycling of used coolant, consult your Caterpillar
dealer or consult Dealer Service Tools .

Flush
1. Flush the cooling system with clean water in order
to remove any debris.

2. Install the connection hose. Clean the drain plugs.

Install the drain plugs. Refer to Torque
Specifications, SENR3130 for more information on
the correct torques.

NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine
damage.

Illustration 65 g03075756 3. Fill the cooling system with clean water. Install the
cooling system filler cap.

4. Start and run the engine at low idle until the

temperature reaches 49 to 66 °C (120 to 150 °F).

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

Loosen the cooling system filler cap slowly in order
to relieve any pressure. Remove the cooling
system filler cap. Remove the connection hose
and remove the cooling system drain plugs. Allow
the water to drain. Flush the cooling system with
clean water. Install the connection hose. Clean the
drain plugs. Install the drain plugs. Refer to Torque
Specifications, SENR3130 for more information on
the correct torques.

Fill

NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Illustration 66 g02350785
Cooling system air locks may result in engine
2. Remove connection hose (1) on the engine. Also damage.
remove the drain plug (2). Open the drain cock or
remove the drain plug on the radiator. 1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to this Operation and Maintenance
Allow the coolant to drain. Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information
NOTICE
on cooling system specifications. Do not install the
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used cooling system filler cap.
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable
by Caterpillar to reclaim the used coolant.
96 SEBU8733
Maintenance Recommendations
Coolant Extender (ELC) - Add

2. Start and run the engine at low idle. Increase the

engine rpm to high idle. Operate the engine in
order to open the engine thermostat. An open Personal injury can result from hot coolant, steam
thermostat will allow any air in the system to be and alkali.
purged. Decrease the engine speed to low idle.
Stop the engine. At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
3. Maintain the coolant level at the maximum mark steam. Any contact can cause severe burns.
that is correct for your application.
Remove cooling system pressure cap slowly to
4. Clean the cooling system filler cap. Inspect the relieve pressure only when engine is stopped and
gasket that is on the cooling system filler cap. If the cooling system pressure cap is cool enough to
gasket that is on the cooling system filler cap is touch with your bare hand.
damaged, discard the old cooling system filler cap Do not attempt to tighten hose connections when
and install a new cooling system filler cap. If the the coolant is hot, the hose can come off causing
gasket that is on the cooling system filler cap is not burns.
damaged, use a 9S-8140 Pressurizing Pump in
Cooling System Coolant Additive contains alkali.
order to pressure test the cooling system filler cap.
Avoid contact with skin and eyes.
The correct pressure for the cooling system filler
cap is stamped on the face of the cooling system
filler cap. If the cooling system filler cap does not NOTICE
retain the correct pressure, install a new cooling Care must be taken to ensure that fluids are con-
system filler cap. tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
5. Start the engine. Inspect the cooling system for Be prepared to collect the fluid with suitable contain-
leaks and for proper operating temperature. ers before opening any compartment or disassem-
bling any component containing fluids.
i04913503
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
Coolant Extender (ELC) - Add PECJ0003, “Cat Shop Supplies and Tools Catalog”
SMCS Code: 1352-544-NL for tools and supplies suitable to collect and contain
fluids on Cat products.
Cat ELC (Extended Life Coolant) does not require
the frequent additions of any supplemental cooling Dispose of all fluids according to local regulations and
additives which are associated with the present mandates.
conventional coolants. The Cat ELC Extender only
needs adding once.
NOTICE
NOTICE When any servicing or repair of the engine cooling
Use only Cat Extended Life Coolant (ELC) Extender system is performed, the procedure must be per-
with Cat ELC. formed with the engine on level ground. This proce-
dure will allow you to check accurately the coolant
Do NOT use conventional supplemental coolant addi- level. This procedure will also help in avoiding the risk
tive (SCA) with Cat ELC. Mixing Cat ELC with con- of introducing an air lock into the coolant system.
ventional coolants and/or conventional SCA reduces
the Cat ELC service life.
1. Loosen the cooling system filler cap slowly in order
Check the cooling system only when the engine is to relieve pressure. Remove the cooling system
stopped and cool. filler cap.

2. If necessary, drain enough coolant from the cooling

system in order to add the Cat ELC Extender .

3. Add Cat ELC Extender according to the

requirements for your engines cooling system
capacity. Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
article for more information.
SEBU8733 97
Maintenance Recommendations
Coolant Level - Check

4. Clean the cooling system filler cap. Inspect the

gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.

i05436397

Coolant Level - Check

SMCS Code: 1395-082

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
pressure.

Check the coolant level when the engine is stopped Illustration 67 g02590196
and cool.
Typical filler cap gaskets
NOTICE
When any servicing or repair of the engine cooling 3. Clean the cooling system filler cap and check the
system is performed, the procedure must be per- condition of the filler cap gaskets. Replace the
formed with the engine on level ground. This proce- cooling system filler cap if the filler cap gaskets are
dure will allow you to check accurately the coolant damaged. Reinstall the cooling system filler cap.
level. This procedure will also help in avoiding the risk
of introducing an air lock into the coolant system. 4. Inspect the cooling system for leaks.

Note: The Diesel Exhaust Fluid (DEF) tank requires

1. Remove the cooling system filler cap slowly in coolant flow around the tank. The Coolant Diverter
order to relieve pressure. Valve (CDV) will turn the flow on or off. If the coolant
system has been filled with the CDV in the closed
2. Maintain the coolant level at the maximum mark position, coolant level will drop because of the
that is correct for your application. If the engine is opening of the CDV.
equipped with a sight glass, maintain the coolant
level to the correct level in the sight glass. i04913603

Coolant Sample (Level 1) -

Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Obtaining a Coolant Sample (Level 1) is

optional if the cooling system is filled with Cat
ELC (Extended Life Coolant).Cooling systems
filled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended
interval as stated in the maintenance interval
schedule.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant
instead of Cat ELC including the following
coolants:
98 SEBU8733
Maintenance Recommendations
Coolant Sample (Level 2) - Obtain

• Commercial long life coolants that meet the • Complete the information on the label for the
Caterpillar Engine Coolant Specification -1 sampling bottle before you begin to take the
(Caterpillar EC-1) samples.

• Cat DEAC (Diesel Engine Antifreeze/Coolant) • Keep the unused sampling bottles stored in plastic
bags.
• Commercial heavy-duty coolant/antifreeze
Table 18 • Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
Recommended Interval
from any other location.
Type of Coolant Level 1 Level 2
• Keep the lids on empty sampling bottles until you
Cat DEAC are ready to collect the sample.
Conventional heavy
duty-coolant • Place the sample in the mailing tube immediately
Every 250 service after obtaining the sample in order to avoid
Commercial coolant Every year(1) contamination.
hours
that meets the re-
quirements of the • Never collect samples from expansion bottles.
Caterpillar EC-1
standard • Never collect samples from the drain for a system.
Cat ELC or conven-
Optional Every year(1) Submit the sample for Level 1 analysis.
tional EC-1 coolant
(1) The Level 2 Coolant Analysis should be performed sooner if a For additional information about coolant analysis, see
problem is suspected or identified. this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” or consult your
Caterpillar dealer.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam- i04913805
pling. Using the same pump for both types of samples
may contaminate the samples that are being drawn. Coolant Sample (Level 2) -
This contaminate may cause a false analysis and an Obtain
incorrect interpretation that could lead to concerns by
both dealers and customers. SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Level 1 results may indicate a need for NOTICE

Level 2 Analysis. Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
Obtain the sample of the coolant as close as possible pling. Using the same pump for both types of samples
to the recommended sampling interval. In order to may contaminate the samples that are being drawn.
receive the full effect of S·O·S analysis, establish a This contaminate may cause a false analysis and an
consistent trend of data. In order to establish a incorrect interpretation that could lead to concerns by
pertinent history of data, perform consistent both dealers and customers.
samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your
Caterpillar dealer.
Use the following guidelines for proper sampling of
the coolant:
SEBU8733 99
Maintenance Recommendations
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Use the 8T-5296 Coolant Conditioner Test Kit or

NOTICE use the 4C-9301 Coolant Conditioner Test Kit in
Care must be taken to ensure that fluids are con- order to check the concentration of the SCA. Refer to
tained during performance of inspection, mainte- this Operation and Maintenance Manual, “Refill
nance, testing, adjusting and repair of the product. Be Capacities and Recommendations” for more
prepared to collect the fluid with suitable containers information.
before opening any compartment or disassembling
any component containing fluids. Water and SCA
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” or refer to Special Publi- NOTICE
cation, PECJ0003, “Caterpillar Shop Supplies and Do not exceed the recommended eight percent sup-
Tools Catalog” for tools and supplies suitable to col- plemental coolant additive concentration.
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and Test the concentration of the SCA with the 8T-5296
mandates. Coolant Conditioner Test Kit. Refer to the Special
Publication, SEBU6251, Caterpillar Commercial
Diesel Engine Fluids Recommendations for more
Refer to Operation and Maintenance Manual, information.
“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant. S·O·S Coolant Analysis
Submit the sample for Level 2 analysis. S·O·S coolant samples can be analyzed at your
Caterpillar dealer. S·O·S Coolant Analysis is a
For additional information about coolant analysis, see program that is based on periodic samples.
Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engines Fluids
Recommendations” or consult your Caterpillar Level 1
dealer.
Level 1 is a basic analysis of the coolant. The
following items are tested:
i03644817
• Glycol Concentration
Cooling System Supplemental
• Concentration of SCA
Coolant Additive (SCA) - Test/
Add • pH

SMCS Code: 1352-045; 1395-081 • Conductivity

The results are reported, and recommendations are
made according to the results. Consult your
Caterpillar dealer for information on the benefits of
Cooling system coolant additive contains alkali. managing your equipment with an S·O·S Coolant
To help prevent personal injury, avoid contact Analysis.
with the skin and the eyes. Do not drink cooling
system coolant additive. Level 2
This level coolant analysis is recommended when the
Note: Test the concentration of the Supplemental engine is overhauled. Refer to this Operations and
Coolant Additive (SCA) or test the SCA concentration Maintenance Manual, “Overhaul Considerations” for
as part of an S·O·S Coolant Analysis. further information.

Test for SCA Concentration

Coolant and SCA

NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
100 SEBU8733
Maintenance Recommendations
Crankshaft Vibration Damper - Inspect

Add the SCA, If Necessary 4. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
NOTICE gaskets are damaged, replace the old cooling
Do not exceed the recommended amount of supple- system filler cap with a new cooling system filler
mental coolant additive concentration. Excessive sup- cap. Install the cooling system filler cap.
plemental coolant additive concentration can form
deposits on the higher temperature surfaces of the
i03634651
cooling system, reducing the engine's heat transfer
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high tempera- Crankshaft Vibration Damper -
ture components. Excessive supplemental coolant
additive concentration could also result in radiator
Inspect
tube blockage, overheating, and/or accelerated water SMCS Code: 1205-040
pump seal wear. Never use both liquid supplemental
coolant additive and the spin-on element (if equipped) Viscous Damper
at the same time. The use of those additives together
could result in supplemental coolant additive concen- The viscous damper has a inertia weight that is
tration exceeding the recommended maximum. located inside a fluid filled case. The inertia weight
moves in the case in order to limit torsional vibration.
Visually inspect the crankshaft damper. Ensure that
the cooling fins (1) on the crankshaft damper are
clean and free from dirt.
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
pressure.

NOTICE
When any servicing or repair of the engine cooling
system is performed the procedure must be per-
formed with the engine on level ground. This will allow
you to accurately check the coolant level. This will al-
so help in avoiding the risk of introducing an air lock
into the coolant system.

1. Slowly loosen the cooling system filler cap in order

to relieve the pressure. Remove the cooling
system filler cap.

Note: Always discard drained fluids according to local Illustration 68 g01950241

regulations. Typical example
2. If necessary, drain some coolant from the cooling
system into a suitable container in order to allow Inspect the damper and replace the damper for any of
space for the extra SCA. the following reasons:

3. Add the proper amount of SCA. Refer to the • The damper is dented, cracked, or leaking.
Special Publication, SEBU6251, Caterpillar For information on removal of the crankshaft damper,
Commercial Diesel Engines Fluids refer to Disassembly and Assembly, “Vibration
Recommendations for more information on SCA Damper and Pulley - Remove and Install”.
requirements.
SEBU8733 101
Maintenance Recommendations
Diesel Exhaust Fluid - Fill

i05413412 4. The opening on the DEF tank (2) is a special

diameter. Ensure that the correct nozzle is used
Diesel Exhaust Fluid - Fill when filling the DEF tank.
SMCS Code: 108K-544
5. Install the DEF cap.
Refer to the original equipment manufacture
information for the Diesel Exhaust Fluid (DEF) tank i04928595
capacity.
Diesel Exhaust Fluid Filter -
Clean/Replace
SMCS Code: 108K-070-FI; 108K-510-FI

Illustration 69 g03379943
Lockable type DEF Filler cap

Illustration 71 g03097598

1. Ensure that the area around the Diesel Exhaust

Fluid (DEF) filter is clean and free from dirt. Use a
27mm Bi-Hex socket in order to remove filter cap
(3).

2. Remove the expansion device (2). Use tool

supplied with new filter element in order to remove
expansion device. Remove filter element (1) from
main body (4).
Illustration 70 g03417998 3. Install new filter element (1) into main body (4).
Typical example Install expansion device (2) into filter element (1).
Install filter cap (3) and tighten cap to 20 N·m
1. Ensure that the DEF cap (1) and the surrounding (15 lb ft).
area is clean and free from dirt.
2. Remove the DEF cap from the tank.

3. Fill the tank with the required amount of DEF.

Ensure that dirt is not introduced into the tank
during filling. Do not over fill the tank. The DEF
may require room for expansion.
102 SEBU8733
Maintenance Recommendations
Driven Equipment - Check

i00174798 Note: Caution must be used in order to prevent

electrical components from being damaged by
Driven Equipment - Check excessive water when the engine is cleaned.
Pressure washers and steam cleaners should not be
SMCS Code: 3279-535 directed at any electrical connectors or the junction of
Refer to the OEM specifications for more information cables into the rear of the connectors. Avoid electrical
on the following maintenance recommendations for components such as the alternator, the starter, and
the driven equipment: the ECM. Protect the fuel injection pump from fluids in
order to wash the engine.
• Inspection
Aftertreatment
• Adjustment
During the engine cleaning process, ensure that
• Lubrication water or cleaning fluids cannot enter the
aftertreatment system. If cleaning fluids enters the
• Other maintenance recommendations aftertreatment system, damage could occur.
Perform any maintenance for the driven equipment
which is recommended by the OEM. i04932800

i03991933
Engine Air Cleaner Element
(Dual Element) - Inspect/Clean/
Engine - Clean Replace
SMCS Code: 1000-070
SMCS Code: 1051; 1054-040; 1054-070; 1054-510

NOTICE
Never run the engine without an air cleaner element
Personal injury or death can result from high
installed. Never run the engine with a damaged air
voltage.
cleaner element. Do not use air cleaner elements with
Moisture can create paths of electrical damaged pleats, gaskets or seals. Dirt entering the
conductivity. engine causes premature wear and damage to en-
gine components. Air cleaner elements help to pre-
Make sure that the electrical system is OFF. Lock vent airborne debris from entering the air inlet.
out the starting controls and tag the controls “ DO
NOT OPERATE”” .
NOTICE
Never service the air cleaner element with the engine
NOTICE running since this will allow dirt to enter the engine.
Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and
fluid spills whenever a significant quantity accumu- Servicing the Air Cleaner Elements
lates on the engine.
Note: The air filter system may not have been
provided by Caterpillar. The procedure that follows is
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated for a typical air filter system. Refer to the OEM
oil and grease. A clean engine provides the following information for the correct procedure.
benefits: If the air cleaner element becomes plugged, the air
• Easy detection of fluid leaks can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
• Maximum heat transfer characteristics wear. Refer to the OEM information for the correct air
cleaner elements for your application.
• Ease of maintenance
SEBU8733 103
Maintenance Recommendations
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

• Check the precleaner (if equipped) and the dust 2. The secondary air cleaner element should be
bowl daily for accumulation of dirt and debris. removed and discarded for every three cleanings
Remove any dirt and debris, as needed. of the primary air cleaner element.
• Operating in dirty conditions may require more Note: Refer to “Cleaning the Primary Air Cleaner
frequent service of the air cleaner element. Elements”.
• The air cleaner element should be replaced at 3. Cover the air inlet with tape in order to keep out
least one time per year. This replacement should dirt.
be performed regardless of the number of
cleanings. 4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
Replace the dirty air cleaner elements with clean air
cleaner elements. Before installation, the air cleaner 5. Remove the tape from the air inlet. Install the
elements should be thoroughly checked for tears and/
or holes in the filter material. Inspect the gasket or the secondary air cleaner element. Install a primary air
seal of the air cleaner element for damage. Maintain a cleaner element that is new or cleaned.
supply of suitable air cleaner elements for
replacement purposes. 6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.
Dual Element Air Cleaners
Cleaning the Primary Air Cleaner
The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner Elements
element.
Refer to the OEM information in order to determine
The primary air cleaner element can be used up to six the number of times that the primary filter element
times if the element is properly cleaned and properly can be cleaned. When the primary air cleaner
inspected. The primary air cleaner element should be element is cleaned, check for rips or tears in the filter
replaced at least one time per year. This replacement material. The primary air cleaner element should be
should be performed regardless of the number of replaced at least one time per year. This replacement
cleanings. should be performed regardless of the number of
cleanings.
The secondary air cleaner element is not serviceable.
Refer to the OEM information for instructions in order NOTICE
to replace the secondary air cleaner element. Do not tap or strike the air cleaner element.
When the engine is operating in environments that Do not wash the primary air cleaner element.
are dusty or dirty, air cleaner elements may require
more frequent replacement. Use low pressure (207 kPa 30 psi maximum) pressur-
ized air or vacuum cleaning to clean the primary air
cleaner element.
Take extreme care in order to avoid damage to the air
cleaner elements.
Do not use air cleaner elements that have damaged
pleats, gaskets, or seals.

Refer to the OEM information in order to determine

the number of times that the primary air cleaner
element can be cleaned. Do not clean the primary air
filter element more than three times. The primary air
cleaner element must be replaced at least one time
per year.

Illustration 72 g00736431 Cleaning the air filter element will not extend the life
(1) Cover of the air filter element.
(2) Primary air cleaner element
(3) Secondary air cleaner element Visually inspect the primary air cleaner element
(4) Air inlet before cleaning. Inspect air cleaner elements for
damage to the pleats, the seals, the gaskets, and the
outer cover. Discard any damaged air cleaner
1. Remove the cover. Remove the primary air cleaner element.
element.
104 SEBU8733
Maintenance Recommendations
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

Two methods may be used in order to clean the Vacuum Cleaning

primary air cleaner element:
Vacuum cleaning is a good method for removing
• pressurized air accumulated dirt from the dirty side (outside) of a
primary air cleaner element. Vacuum cleaning is
• Vacuum cleaning especially useful for cleaning primary air cleaner
elements which require daily cleaning because of a
Pressurized Air dry, dusty environment.
Cleaning from the clean side (inside) with pressurized
air is recommended prior to vacuum cleaning the dirty
side (outside) of a primary air cleaner element.
Personal injury can result from air pressure.
Note: Refer to “Inspecting the Primary Air Cleaner
Personal injury can result without following prop- Elements”.
er procedure. When using pressure air, wear a
protective face shield and protective clothing. Inspecting the Primary Air Cleaner
Maximum air pressure at the nozzle must be less Elements
than 205 kPa (30 psi) for cleaning purposes.

Pressurized air can be used to clean primary air

cleaner elements that have not been cleaned more
than three times. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi). Pressurized air will not
remove deposits of carbon and oil.

Illustration 74 g00281693

Inspect the clean, dry primary air cleaner element.

Use a 60 W blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears and/
Illustration 73 g00281692
or holes. Inspect the primary air cleaner element for
light that may show through the filter material. If it is
Note: When the primary air cleaner elements are necessary in order to confirm the result, compare the
cleaned, always begin with the clean side (inside) in primary air cleaner element to a new primary air
order to force dirt particles toward the dirty side cleaner element that has the same part number.
(outside).
Do not use a primary air cleaner element that has any
Aim the air hose so that air flows along the length of tears and/or holes in the filter material. Do not use a
the filter. Follow the direction of the paper pleats in primary air cleaner element with damaged pleats,
order to prevent damage to the pleats. Do not aim the gaskets, or seals. Discard damaged primary air
air directly at the face of the paper pleats. cleaner elements.

Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.
SEBU8733 105
Maintenance Recommendations
Engine Air Cleaner Element (Single Element) - Inspect/Replace

i01432811
5. Remove the seal from the opening of the air inlet.
Engine Air Cleaner Element
6. Install a clean, undamaged air filter element (2).
(Single Element) - Inspect/
Replace 7. Install air cleaner cover (1).
SMCS Code: 1051; 1054-040; 1054-510 8. Reset the air cleaner service indicator.
Perform the Operation and Maintenance Manual,
“Engine Air Cleaner Service Indicator-Inspect” i02335405
procedure and perform the Operation and
Maintenance Manual, “Engine Air Precleaner Check/ Engine Air Cleaner Service
Clean” procedure (if equipped) before performing the
following procedure. Indicator - Inspect
SMCS Code: 7452-040
NOTICE
Never run the engine without an air cleaner element Some engines may be equipped with a different
installed. Never run the engine with a damaged air service indicator.
cleaner element. Do not use air cleaner elements with Some engines are equipped with a differential gauge
damaged pleats, gaskets or seals. Dirt entering the for inlet air pressure. The differential gauge for inlet
engine causes premature wear and damage to en- air pressure displays the difference in the pressure
gine components. Air cleaner elements help to pre- that is measured before the air cleaner element and
vent airborne debris from entering the air inlet. the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
NOTICE equipped with a different type of service indicator,
Never service the air cleaner element with the engine follow the OEM recommendations in order to service
the air cleaner service indicator.
running since this will allow dirt to enter the engine.
The service indicator may be mounted on the air
cleaner element or in a remote location.

Illustration 75 g00310664
Illustration 76 g00103777
(1) Air cleaner cover
(2) Air filter element Typical service indicator
(3) Air inlet
Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element
1. Remove air cleaner cover (1) and remove air filter should be replaced when one of the following
element (2). conditions occur:

2. Cover air inlet (3) with tape or a clean cloth so that • The yellow diaphragm enters the red zone.
debris cannot enter the air inlet.
• The red piston locks in the visible position.
3. Clean the inside of air cleaner cover (1). Clean the
body that holds the air cleaner element. Test the Service Indicator
Service indicators are important instruments.
4. Inspect the replacement element for the following
items:damage, dirt and debris.
106 SEBU8733
Maintenance Recommendations
Engine Air Precleaner - Check/Clean

• Check for ease of resetting. The service indicator i04923813

should reset in less than three pushes.
Engine Crankcase Breather
• Check the movement of the yellow core when the
engine is accelerated to the engine rated speed. Element - Replace
The yellow core should latch at the greatest SMCS Code: 1317-510-FQ
vacuum that is attained.
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new Hot oil and hot components can cause personal
service indicator will not reset, the hole for the service injury. Do not allow hot oil or hot components to
indicator may be restricted.
contact the skin.
The service indicator may need to be replaced
frequently in environments that are severely dusty.
NOTICE
i02927289
Ensure that the engine is stopped before any servic-
ing or repair is performed.
Engine Air Precleaner - Check/
Clean NOTICE
Care must be taken to ensure that fluids are con-
SMCS Code: 1055-070; 1055-535
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.

The crankcase breather is a very important

component in order to keep your engine emissions
Illustration 77 g01453058 compliant .
Typical engine air precleaner
(1) Wing nut • The filter element within the crankcase breather
(2) Cover must be serviced at the prescribed service interval.
(3) Body
• The correct filter element must be installed before
Remove wing nut (1) and cover (2). Check for an the engine is operated.
accumulation of dirt and debris in body (3). Clean the
body, if necessary. • The installation of the filter element is very
important.
After cleaning the precleaner, install cover (2) and
wing nut (1). • The quality of the filter element that is installed is
very important.
Note: When the engine is operated in dusty
applications, more frequent cleaning is required. For information on aftermarket products, refer to
Operation and Maintenance Manual, “Engine
Description”. Within that section, refer to the title
“Aftermarket Products and Caterpillar Engines”.
The breather element can be serviced from the top
position or the breather element can be serviced from
the bottom position.
SEBU8733 107
Maintenance Recommendations
Engine Crankcase Breather Element - Replace

Top Service

Illustration 79 g03090963

3. Remove the old seal (4) and install a new seal.

Note: The cut away from section (5) in the top cap
allows access to the seal.

Illustration 78 g03090965

1. Ensure that dirt cannot enter the breather

assembly. Ensure that the outside body of the
breather assembly is clean and free from damage.
Place a container under the breather assembly.

2. Rotate the top cap (1) counterclockwise into the

unlocked position. Remove the top cap from the
body of the breather (3) and remove the filter
element (2).

Illustration 80 g03090938
(A) Alignment position
(B) Alignment position
108 SEBU8733
Maintenance Recommendations
Engine Crankcase Breather Element - Replace

4. Install a new filter element into the breather body

(3). Ensure the correct position of the element,
refer to illustration 80 . Align position (A) on the top
cap to position (B) on the filter element.

Illustration 82 g02346498
Typical example
(X) Alignment mark
(Y) Alignment mark

Illustration 81 g02346577 1. Ensure that the outside body of the breather

Typical example assembly is clean and free from damage. Place a
container under the breather.
5. Install the top cap (1). Rotate the top cap by hand
clockwise until the top cap locks into the locked 2. Remove the tube connection (1). Ensure that dirt
position (C) on the breather body. cannot enter the tube connection. Note the position
of the alignment marks (X and Y). Rotate the
6. Remove the container. bottom cap (2) counterclockwise in order to
release the cap and the filter element (4) from the
Bottom Service breather body (3).
Ensure that dirt cannot enter the breather assembly.
SEBU8733 109
Maintenance Recommendations
Engine Mounts - Inspect

Check the System

Illustration 84 g02346500
Typical example

Inspect the breather tube (1) for damage. Ensure that

the outlet (2) is clean and free from any obstructions.
Illustration 83 g03090968 Ice can cause obstructions in adverse weather
conditions.
Typical example
(A) Alignment postion
i02456872
(B) Alignment postion

3. Remove the filter element (4). Remove the seal (5). Engine Mounts - Inspect
SMCS Code: 1152-040; 1152
Note: The bottom cap has a section that allows
access in order to remove the seal. Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused by
4. Install a new seal (5). Install a new filter element the following conditions:
into the bottom cap (2).
• Improper mounting of the engine
5. Align position (A) on the top cap to position (B) on
the filter element. Refer to illustration 83 . • Deterioration of the engine mounts

6. Install the assembly of the filter element and the Any engine mount that shows deterioration should be
bottom cap (2). Rotate the bottom cap by hand replaced. Refer to Special Publication, SENR3130,
Torque Specifications for the recommended torques.
clockwise until the bottom cap locks into the locked Refer to the OEM recommendations for more
position on the breather body. Ensure that the information.
alignment marks (X and Y) are correctly aligned.
Refer to illustration 82 .
7. Install tube connection (1). Ensure that the
retaining clips on the tube connection are correctly
engaged. Remove the container.
110 SEBU8733
Maintenance Recommendations
Engine Oil Level - Check

i05300117 i04237495

Engine Oil Level - Check Engine Oil Sample - Obtain

SMCS Code: 1348-535-FLV SMCS Code: 1348-554-SM
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil
Hot oil and hot components can cause personal analysis provides infrared analysis, which is required
injury. Do not allow hot oil or hot components to for determining nitration and oxidation levels.
contact the skin.
Obtain the Sample and the Analysis

Hot oil and hot components can cause personal

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

Before you take the oil sample, complete the Label,

PEEP5031 for identification of the sample. In order to
help obtain the most accurate analysis, provide the
following information:
• Engine model

Illustration 85 g02173847 • Service hours on the engine

“L” Low • The number of hours that have accumulated since
“H” High the last oil change
• The amount of oil that has been added since the
NOTICE last oil change
Perform this maintenance with the engine stopped.
To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, mixed oil sample.
Note: Ensure that the engine is either level or that the
engine is in the normal operating position in order to To avoid contamination of the oil samples, the tools
obtain a true level indication. and the supplies that are used for obtaining oil
samples must be clean.
Note: After the engine has been switched OFF, wait
for 10 minutes in order to allow the engine oil to drain Caterpillar recommends using the sampling valve in
to the oil pan before checking the oil level. order to obtain oil samples. The quality and the
consistency of the samples are better when the
1. Maintain the oil level between the mark (L) and the sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
mark (H) on the engine oil dipstick. Do not fill the
obtained during normal engine operation.
crankcase above the “H” .
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
NOTICE fluid sampling bottle includes the parts that are
Operating your engine when the oil level is above the needed for obtaining oil samples. Instructions are
“H” mark could cause your crankshaft to dip into the also provided.
oil. The air bubbles created from the crankshaft dip-
ping into the oil reduces the oils lubricating character-
istics and could result in the loss of power.

2. Remove the oil filler cap and add oil, if necessary.

Clean the oil filler cap. Install the oil filler cap.
If an increase in the oil level is noticed, refer to
Troubleshooting, “Oil Contains Fuel”.
SEBU8733 111
Maintenance Recommendations
Engine Oil and Filter - Change

Failure to follow this recommended procedure will

NOTICE cause the waste particles to be recirculated through
Always use a designated pump for oil sampling, and the engine lubrication system with the new oil.
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of samples Drain the Engine Lubricating Oil
may contaminate the samples that are being drawn.
This contaminate may cause a false analysis and an Note: Ensure that the vessel that will be used is large
incorrect interpretation that could lead to concerns by enough to collect the waste oil.
both dealers and customers.
After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
If the engine is not equipped with a sampling valve, following methods to drain the engine oil pan:
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.
For instructions, see Special Publication, PEGJ0047,
“How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.

i03996035

Engine Oil and Filter - Change

SMCS Code: 1318-510

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
Illustration 86 g01880893
Typical example
NOTICE
Care must be taken to ensure that fluids are con- • If the engine is equipped with a drain valve, turn
tained during performance of inspection, mainte- the drain valve knob counterclockwise in order to
nance, testing, adjusting and repair of the product. Be drain the oil. After the oil has drained, turn the
prepared to collect the fluid with suitable containers drain valve knob clockwise in order to close the
before opening any compartment or disassembling drain valve.
any component containing fluids.
• If the engine is not equipped with a drain valve,
Dispose of all fluids according to local regulations and remove oil drain plug (1) in order to allow the oil to
mandates. drain. If the engine is equipped with a shallow oil
pan, remove the bottom oil drain plugs from both
ends of the oil pan.
NOTICE
Keep all parts clean from contaminants. After the oil has drained, the oil drain plugs should be
cleaned and installed. If necessary, replace the O ring
Contaminants may cause rapid wear and shortened seal. Tighten the drain plug to 34 N·m (25 lb ft).
component life.

Do not drain the engine lubricating oil when the

engine is cold. As the engine lubricating oil cools,
suspended waste particles settle on the bottom of the
oil pan. The waste particles are not removed with
draining cold oil. Drain the oil pan with the engine
stopped. Drain the oil pan with the oil warm. This
draining method allows the waste particles that are
suspended in the oil to be drained properly.
112 SEBU8733
Maintenance Recommendations
Engine Oil and Filter - Change

Replace the Oil Filter Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order to
NOTICE
arrange for a further analysis if an excessive
Caterpillar oil filters are manufactured to Caterpillar amount of debris is found in the oil filter.
specifications. Use of an oil filter that is not recom-
mended by Caterpillar could result in severe damage
to the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters rec-
ommended by Caterpillar .

1. Remove the oil filter with a 1U-8760 Chain

Wrench.
Note: The following actions can be carried out as part
of the preventive maintenance program.

Illustration 88 g02351361
Typical example

3. Clean the sealing surface of the oil filter base (2).

4. Apply clean engine oil to the O ring seal (3) for the
new oil filter.

NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
Illustration 87 g01999595 nated. Contaminated oil can cause accelerated wear
to engine components.
Element with debris

2. Cut the oil filter open with a 175-7546 Oil Filter 5. Install the engine oil filter. Spin on the oil filter until
Cutter. Break apart the pleats and inspect the oil the O ring seal contacts the oil filter base. Rotate
filter for metal debris. An excessive amount of the oil filter ¾ of a full turn.
metal debris in the oil filter may indicate early wear
or a pending failure. Fill the Oil Pan
Use a magnet to differentiate between the ferrous 1. Remove the oil filler cap. Refer to this Operation
metals and the nonferrous metals that are found in and Maintenance Manual, “Fluid
the oil filter element. Ferrous metals may indicate Recommendations” for more information on
wear on the steel and cast iron parts of the engine.
suitable oils. Fill the oil pan with the correct amount
Nonferrous metals may indicate wear on the of new engine lubricating oil. Refer to this
aluminum parts, brass parts or bronze parts of the Operation and Maintenance Manual, “Refill
engine. Parts that may be affected include the Capacities” for more information on refill
following items: main bearings, rod bearings, capacities.
turbocharger bearings and cylinder heads.
SEBU8733 113
Maintenance Recommendations
Fan Clearance - Check

NOTICE
If equipped with an auxiliary oil filter system or a re-
mote filter system, follow the OEM or the filter manu-
factures recommendations. Under filling or over filling
the crankcase with oil can cause engine damage.

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

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

Illustration 89 g02173847
“L” Low
“H” High

4. Remove the engine oil level gauge in order to

check the oil level. Maintain the oil level between
the “L” and “H” marks on the engine oil level
gauge. Do not fill the crankcase above the “H”
mark.

i05404932

Fan Clearance - Check

SMCS Code: 1356; 1359; 1360
There are different types of cooling systems that can
be installed. Refer to the Original Equipment
Manufactory (OEM) for your application for more
information.
Ensure that the engine is stopped and allow 2
minutes before the battery disconnect switch is
turned off. This procedure will allow the Diesel
Exhaust Fluid (DEF) system to purged.
Ensure that the cooling system is full before checking
the fan tip clearance. The fan tip clearance is the
distance between the tip of the fan blade (2) and the
edge of the cover (1).
114 SEBU8733
Maintenance Recommendations
Fuel Filter (In-Line) - Replace

Illustration 90 g03414037
Typical example

The gap (A) must be checked in the vertical position i04921339

and in the horizontal position.
In the vertical position the gap can be checked at the
Fuel Filter (In-Line) - Replace
vertically top position or at the vertically bottom SMCS Code: 1261-510; 1261
position.

• Gap (A) vertical top position 12 ± 1 mm

(0.47244 ± 0.03937 inch).
Fuel leaked or spilled onto hot surfaces or electri-
• Gap (A) vertical bottom position 8 ± 1 mm cal components can cause a fire. To help prevent
(0.31496 ± 0.03937 inch). possible injury, turn the start switch off when
changing fuel filters or water separator elements.
After the gap (A) has been checked in the vertical top Clean up fuel spills immediately.
position or the vertical bottom position, the horizontal
position must be checked.
Note: Refer to Systems Operation, Testing, and
• Gap (A) in the horizontal position must be a Adjusting, “Cleanliness of Fuel System
minimum of 9 mm (0.35433 inch). Components” for detailed information on the
If the fan tip clearance requires adjustment, refer to standards of cleanliness that must be observed
the Disassembly and Assembly manual for more during ALL work on the fuel system.
information.
SEBU8733 115
Maintenance Recommendations
Fuel System - Prime

i03906114
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
Fuel System - Prime
SMCS Code: 1250-548; 1258-548
The location of the in-line fuel filter will depend on the Note: Refer to Systems Operation, Testing, and
application that the engine has been installed. Adjusting, “Cleanliness of Fuel System
Components” for detailed information on the
standards of cleanliness that must be observed
during ALL work on the fuel system.
Ensure that all adjustments and repairs are
performed by authorized personnel that have had the
correct training.

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.

If air enters the fuel system, the air must be purged

from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:
• The fuel tank is empty or the fuel tank has been
partially drained.
• The low-pressure fuel lines are disconnected.
Illustration 91 g03086919
• A leak exists in the low-pressure fuel system.
Typical example
• The fuel filter has been replaced.
1. Turn the fuel supply valve (if equipped) to the OFF
position. Remove any brackets that hold the in-line Use the following procedures in order to remove air
from the fuel system:
fuel filter (1) in place, refer to OEM information.
1. Ensure that the fuel system is in working order.
2. Release the hose clips (3) and remove the hose
Check that the fuel supply valve (if equipped) is in
lines from the in-line fuel filter. Remove the in-line
the “ON” position.
filter.
3. Install a new in-line filter and secure, refer to OEM 2. Turn the keyswitch to the “RUN” position.
information. Ensure that the arrow mark (2) is 3. The keyswitch will allow the electric priming pump
aligned to the direction of fuel flow from the tank to to operate. Operate the electric priming pump. The
the fuel pump. ECM will stop the pump after 2 minutes.
4. Install the fuel hose lines and install the hose clips 4. Turn the keyswitch to the “OFF” position. The fuel
(3). Turn the fuel supply valve (if equipped) to the system should now be primed and the engine
ON position. should be able to start.
5. The in-line fuel filter must be changed with the 5. Operate the engine starter and crank the engine.
primary filter and the secondary fuel filter. After the engine has started, operate the engine at
low idle for a minimum of 5 minutes. Ensure that
the fuel system is free from leaks.

Note: Operating the engine for this period will help

ensure that the fuel system is free of air. DO NOT
loosen the high-pressure fuel lines in order to
purge air from the fuel system. This procedure is
not required.
116 SEBU8733
Maintenance Recommendations
Fuel System Primary Filter (Water Separator) Element - Replace

After the engine has stopped, you must wait for 10

minutes in order to allow the fuel pressure to be
purged from the high-pressure fuel lines before any
service or repair is performed on the engine fuel lines.
If necessary, perform minor adjustments. Repair any
leaks from the low-pressure fuel system and from the
cooling, lubrication, or air systems. Replace any high-
pressure fuel line that has leaked. Refer to
Disassembly and Assembly Manual, “Fuel Injection
Lines - Install”.
If you inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid
penetration hazard . Refer to Operation and
Maintenance Manual, “General hazard Information”.
If the engine will not start, refer to Troubleshooting,
“Engine Cranks but will not Start”.

i04921313

Fuel System Primary Filter

(Water Separator) Element - Illustration 92 g03086757
Replace Typical example
SMCS Code: 1260-510-FQ; 1263-510-FQ
3. Install a suitable tube onto drain (3). Open the drain
valve (2). Rotate the drain valve counterclockwise.
Two full turns are required.

Fuel leaked or spilled onto hot surfaces or electri- 4. Loosen the vent screw (1).
cal components can cause a fire. To help prevent
possible injury, turn the start switch off when 5. Allow the fuel to drain into the container. Remove
changing fuel filters or water separator elements. the tube from the drain valve.
Clean up fuel spills immediately.
6. Tighten the vent screw (1) securely . Remove the
wiring harness from connection (4).
Note: Refer to Systems Operation, Testing, and
Adjusting, “Cleanliness of Fuel System 7. Rotate filter bowl (6) counterclockwise and remove
Components” for detailed information on the the filter bowl from assembly. Refer to your
standards of cleanliness that must be observed caterpillar dealer for the correct tool.
during ALL work on the fuel system.

NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.

Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFF
position before performing this maintenance.

2. Place a suitable container under the water

separator in order to catch any fuel that might spill.
Clean up any spilled fuel. Clean the outside body
of the filter assembly.
SEBU8733 117
Maintenance Recommendations
Fuel System Primary Filter (Water Separator) Element - Replace

Illustration 93 g02148402 Illustration 94 g03086798

Typical example Typical example

8. Rotate the filter element (5) counterclockwise and 1. Locate the thread in the new filter element (8) onto
remove the filter element . Clean the filter bowl. the threads (9). Spin on the filter element and
tighten the drain valve (2) securely.
Install the New Filter Element
2. Lubricate the O ring seal (7) with clean engine oil.
Do NOT fill the bowl with fuel before the assembly
is installed.
3. Do not use a tool in order to install the filter
assembly. Tighten the filter bowl (6) by hand.
Install the filter bowl (6). Turn the filter bowl
clockwise until the filter bowl locks into position
against the stops.

4. Remove the container and dispose of the fuel in a

safe place.

5. The secondary filter element must be replaced at

the same time as the primary filter element. Also,
the in-line filter must be changed. Refer to the
Operation and Maintenance Manual, “Fuel System
Filter - Replace”.
118 SEBU8733
Maintenance Recommendations
Fuel System Primary Filter/Water Separator - Drain

i04925799 3. Install a suitable tube onto drain (3). Open the drain
valve (2). Rotate the drain valve counterclockwise.
Fuel System Primary Filter/ Two full turns are required. Loosen vent screw (1).
Water Separator - Drain 4. Allow the fluid to drain into the container.
SMCS Code: 1260-543; 1263-543
5. Tighten the drain valve clockwise by hand pressure
only. Remove the tube and remove the container.

6. Tighten the vent screw securely.

Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent
i04921888
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately. Fuel System Secondary Filter -
Replace
NOTICE SMCS Code: 1261-510-SE
Ensure that the engine is stopped before any servic-
ing or repair is performed.

Fuel leaked or spilled onto hot surfaces or electri-

NOTICE cal components can cause a fire. To help prevent
The water separator can be under suction during nor- possible injury, turn the start switch off when
mal engine operation. Ensure that the drain valve is changing fuel filters or water separator elements.
tightened securely to help prevent air from entering Clean up fuel spills immediately.
the fuel system.

NOTICE
1. Place a suitable container under the water Ensure that the engine is stopped before any servic-
separator in order to catch any fluid that might spill. ing or repair is performed.
Clean up any spilled fluid.

2. Ensure that the outer body of the filter assembly is Refer to Systems Operation, Testing, and
clean and free from dirt. Adjusting, “Cleanliness of Fuel System
Components” for detailed information on the
standards of cleanliness that must be observed
during ALL work on the fuel system.

Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFF
position before performing this maintenance.

2. Place a suitable container under the fuel filter in

order to catch any fuel that might spill. Clean up
any spilled fuel. Clean the outside body of the filter
assembly.

Illustration 95 g02148370
Typical example
SEBU8733 119
Maintenance Recommendations
Fuel System Secondary Filter - Replace

Illustration 96 g03088718 Illustration 97 g02546456

3. Install a suitable tube onto drain (4). Open the drain 7. Rotate the filter element (5) counterclockwise and
valve (3). Rotate the drain valve counterclockwise. remove the filter element. Clean the filter bowl.
Two full turns are required. Loosen vent screw (1).
Install the Element
4. Allow the fuel to drain into the container and
remove the tube.
5. Tighten the vent screw (1) securely.

6. Remove the filter bowl (2). Rotate the filter

assembly counterclockwise in order to remove the
assembly. Refer to your caterpillar dealer for the
correct tool number.

Illustration 98 g03088837

1. Locate the thread (7) in the filter element onto the

threads (8). Spin on the element and tighten the
drain valve (3) by hand.

2. Lubricate the O ring seal (6) with clean engine oil.

Do NOT fill the filter bowl (2) with fuel before the
filter assembly is installed.
120 SEBU8733
Maintenance Recommendations
Fuel Tank Water and Sediment - Drain

3. Do not use a tool in order to install the filter Open the drain valve on the bottom of the fuel tank in
assembly. Tighten the assembly by hand. Install order to drain the water and the sediment. Close the
the filter bowl (2). Turn the filter bowl clockwise drain valve.
until the filter bowl locks into position against the Check the fuel daily. Allow five minutes after the fuel
stops. tank has been filled before draining water and
sediment from the fuel tank.
4. Turn the fuel supply valve to the ON position.
Fill the fuel tank after operating the engine in order to
5. The primary fuel filter the secondary fuel filter must drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The fuel
be replaced at the same time. Refer to the expands as the fuel gets warm. The tank may
Operation and Maintenance Manual, “Fuel System overflow.
Primary Filter (Water Separator) Element -
Replace”. Also, the in-line fuel must be replaced Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
when the primary and secondary filters are supply pipe. Some fuel tanks use supply lines that
replaced. Refer to Operation and Maintenance take fuel directly from the bottom of the tank. If the
Manual, “Fuel Filter (In-Line)- Replace” engine is equipped with this system, regular
maintenance of the fuel system filter is important.
6. Prime the fuel system. Refer to the Operation and
Maintenance Manual, “Fuel System - Prime” for Fuel Storage Tanks
more information.
Drain the water and the sediment from the fuel
storage tank at the following intervals:
i02348492
• Weekly
Fuel Tank Water and Sediment
• Service intervals
- Drain
• Refill of the tank
SMCS Code: 1273-543-M&S
This will help prevent water or sediment from being
NOTICE pumped from the storage tank into the engine fuel
tank.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- If a bulk storage tank has been refilled or moved
nance, testing, adjusting and repair of the product. Be recently, allow adequate time for the sediment to
prepared to collect the fluid with suitable containers settle before filling the engine fuel tank. Internal
before opening any compartment or disassembling baffles in the bulk storage tank will also help trap
any component containing fluids. sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
Dispose of all fluids according to local regulations and When possible, water separators should be used.
mandates.
i02518232

Fuel Tank Hoses and Clamps - Inspect/

Fuel quality is critical to the performance and to the Replace
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. SMCS Code: 7554-040; 7554-510
Water can be introduced into the fuel tank when the
fuel tank is being filled.
Condensation occurs during the heating and cooling Contact with high pressure fuel may cause fluid
of fuel. The condensation occurs as the fuel passes penetration and burn hazards. High pressure fuel
through the fuel system and the fuel returns to the
spray may cause a fire hazard. Failure to follow
fuel tank. This causes water to accumulate in fuel
tanks. Draining the fuel tank regularly and obtaining these inspection, maintenance and service in-
fuel from reliable sources can help to eliminate water structions may cause personal injury or death.
in the fuel.
If you inspect the engine in operation, always use the
Drain the Water and the Sediment proper inspection procedure in order to avoid a fluid
Fuel tanks should contain some provision for draining penetration hazard. Refer to Operation and
water and draining sediment from the bottom of the Maintenance Manual, “General hazard Information”.
fuel tanks.
SEBU8733 121
Maintenance Recommendations
Injector (Diesel Exhaust Fluid) - Replace

Inspect all hoses for leaks that are caused by the

following conditions:

• Cracking Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
• Softness stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
• Loose clamps pressure cap slowly in order to relieve the
pressure.
Replace hoses that are cracked or soft. Tighten any
loose clamps.
1. Stop the engine. Allow the engine to cool.
Check for the following conditions:
2. Loosen the cooling system filler cap slowly in order
• End fittings that are damaged or leaking
to relieve any pressure. Remove the cooling
• Outer covering that is chafed or cut system filler cap.

• Exposed wire that is used for reinforcement

Note: Drain the coolant into a suitable, clean
• Outer covering that is ballooning locally container. The coolant can be reused.
3. Drain the coolant from the cooling system to a level
• Flexible part of the hose that is kinked or crushed that is below the hose that is being replaced.
• Armoring that is embedded in the outer covering 4. Remove the hose clamps.
A constant torque hose clamp can be used in place of 5. Disconnect the old hose.
any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard 6. Replace the old hose with a new hose.
clamp.
Due to extreme temperature changes, the hose will 7. Install the hose clamps with a torque wrench.
harden. Hardening of the hoses will cause hose
clamps to loosen. This can result in leaks. A constant Note: For the correct coolant, see this Operation and
torque hose clamp will help to prevent loose hose Maintenance Manual, “Fluid Recommendations”.
clamps.
8. Refill the cooling system. Refer to the OEM
Each installation application can be different. The information for further information on refilling the
differences depend on the following factors: cooling system.
• Type of hose 9. Clean the cooling system filler cap. Inspect the
cooling system filler cap's seals. Replace the
• Type of fitting material
cooling system filler cap if the seals are damaged.
• Anticipated expansion and contraction of the hose Install the cooling system filler cap.

• Anticipated expansion and contraction of the 10. Start the engine. Inspect the cooling system for
fittings leaks.

Replace the Hoses and the Clamps i05414590

Refer to the OEM information for further information

on removing and replacing fuel hoses (if equipped). Injector (Diesel Exhaust Fluid) -
The following text describes a typical method of Replace
replacing coolant hoses. Refer to the OEM SMCS Code: 108I-510
information for further information on the coolant
system and the hoses for the coolant system.
122 SEBU8733
Maintenance Recommendations
Injector (Diesel Exhaust Fluid) - Replace

Illustration 99 g03418548 Illustration 101 g03418578

Typical example Typical example

3. Remove gasket (7) and remove the studs (8).

Discard the gasket and the studs.

4. Ensure that the sealing face of the CEM is clean

and free from dirt.
5. Apply bostik pure nickel ant-seize compound to
ends of the new studs (8). Install the coated ends
of the new studs into the CEM, and tighten to a
torque of 5 N·m (44 lb in).

6. Install new gasket (7), ensure that the metal side of

the gasket is to the CEM. Install new DEF injector
(5) to CEM (6).

7. Install washers (9) and apply bostik pure nickel

ant-seize compound to the threads of the studs (8).

8. Install the nuts (4) and tighten the nuts to a torque

of 5 N·m (44 lb in). Retighten the nuts to 5 N·m
(44 lb in). Then, turn the nuts additional 90
Illustration 100 g03418553 degrees.
Typical example 9. Install electrical connection into position (3) and
install DEF line (2). Install coolant lines (1).
1. Drain the coolant in order to remove the coolant
lines (1). Remove the cooling lines (1) and remove 10. Fill cooling system to the correct level. Ensure
Diesel Exhaust Fluid (DEF) line (2). that the correct specification of coolant is used.
2. Remove electrical connect from position (3) and If available, using the electronic service tool (ET)
install protection caps to DEF injector (5). Remove perform DEF Dosing System Verification test.
nuts (4) and washers (9) from DEF injector (5) and
remove DEF injector from Clean Emission Module
(CEM) (6).
SEBU8733 123
Maintenance Recommendations
Overhaul Considerations

i04224312 • Costly unplanned downtime can be avoided.

Overhaul Considerations • Many original parts can be reused according to the

standards for reusable parts.
SMCS Code: 7595-043
• The engines service life can be extended without
Reduced hours of operation at full load will result in a the risk of a major catastrophe due to engine
lower average power demand. A decreased average failure.
power demand should increase both the engine
service life and the overhaul interval. • The best cost/value relationship per hour of
The need for an overhaul is indicated by increased extended life can be attained.
fuel consumption, increased oil consumption,
excessive engine blowby, and reduced power. Arctic After Failure Overhaul
temperatures, extreme high temperatures, corrosive
environments, or extreme dusty conditions contribute If a major engine failure occurs and the engine must
to premature wear and the need for an overhaul. be removed, many options are available. An overhaul
should be performed if the engine block or the
The following factors are important when a decision is crankshaft needs to be repaired.
being made on the proper time for an engine
overhaul: If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost will be less than the
• The need for preventive maintenance cost of a new engine with a similar exchange core.
• The quality of the fuel that is being used This lower cost can be attributed to three aspects:
• The operating conditions • Specially designed Caterpillar engine features
• The results of the S·O·S analysis • Caterpillar dealer exchange components

Oil Consumption as an Overhaul • Caterpillar Inc. remanufactured exchange

components
Indicator
Oil consumption, fuel consumption, and maintenance Overhaul Recommendation
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil To minimize downtime, Caterpillar Inc. recommends
consumption can also be used to estimate the a scheduled engine overhaul by your Caterpillar
required capacity of a makeup oil tank that is suitable dealer before the engine fails. This process will
for the maintenance intervals. provide you with the best cost/value relationship.

Oil consumption is in proportion to the percentage of Note: Overhaul programs vary according to the
the rated engine load. As the percentage of the engine application and according to the dealer that
engine load is increased, the amount of oil that is performs the overhaul. Consult your Caterpillar
consumed per hour also increases. dealer for specific information about the available
overhaul programs and about overhaul services for
The oil consumption rate (brake-specific oil extending the engine life.
consumption) is measured in grams per kW/h (lb per
bhp). The brake-specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar Aftertreatment
dealer for assistance in determining the typical oil
consumption rate for your engine. The aftertreatment system can be expected to
function properly for the useful life of the engine
When an engines oil consumption has risen to three (emissions durability period), as defined by
times the original oil consumption rate due to normal regulation, subject to prescribed maintenance
wear, an engine overhaul should be scheduled. There requirements being followed.
may be a corresponding increase in blowby and a
slight increase in fuel consumption. Rebuild or Exchange
Overhaul Options If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the
following maintenance recommendations.
Before Failure Overhaul
A planned overhaul before failure may be the best
value for the following reasons:
124 SEBU8733
Maintenance Recommendations
Overhaul Considerations

Cylinder Head Assembly, Oil Pump, and Inspect the crankshaft for any of the following
conditions:
Fuel Transfer Pump
• Deflection
These components should be inspected according to
the instructions that are found in various Caterpillar • Damage to the journals
reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are • Bearing material that has seized to the journals
needed for inspecting the engine parts.
Check the journal taper and the profile of the
If the parts comply with the established inspection crankshaft journals. If the wear patterns on the rod
specifications that are expressed in the reusable bearing or the main bearing show a problem, the
parts guideline, the parts should be reused. crankshaft will need to be measured with specialist
equipment.
Parts that are not within the established inspection
specifications should be dealt with in one of the Inspect the camshaft for damage to the journals and
following manners: to the lobes.
• Salvaging Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check for
• Repairing cracks in the camshaft.
• Replacing Inspect the following components for signs of wear or
for signs of scuffing:
Using out-of-spec parts can result in the following
problems: • Camshaft bearings
• Unscheduled downtime • Lifters
• Costly repairs Caterpillar Inc. recommends replacing the crankshaft
vibration damper.
• Damage to other engine parts
• Reduced engine efficiency Oil Cooler Core
• Increased fuel consumption During an overhaul, Caterpillar Inc. recommends the
removal of the oil cooler core. Clean the oil cooler
Reduced engine efficiency and increased fuel core. Then, pressure test the oil cooler core.
consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing out- NOTICE
of-spec parts or replacing out-of-spec parts. Do not use caustic cleaners to clean the core.
Caustic cleaners can attack the internal metals of the
Inspection and/or Replacement core and cause leakage.

Crankshaft Bearings Crankshaft Seals Note: Use this cleaning procedure to clean the oil
and Pistons cooler core.
The following components may not last until the 1. Remove the oil cooler core.
second overhaul.
2. Remove any debris from the oil cooler core. To
• Thrust bearings remove debris from the oil cooler core, turn the oil
cooler core onto one end.
• Main bearings
3. Flush the oil cooler core internally with cleaner in
• Rod bearings order to loosen foreign substances. This flushing
• Crankshaft seals will also help to remove oil from the oil cooler core.

• Piston assembly Note: Caterpillar Inc. recommends the use of

Hydrosolv Liquid Cleaners. Table 19 lists the
Caterpillar Inc. recommends the installation of new Hydrosolv Liquid Cleaners that are available from
parts at each overhaul period. your Caterpillar dealer.
Inspect these parts while the engine is disassembled
for an overhaul.
SEBU8733 125
Maintenance Recommendations
Radiator - Clean

Table 19 A coolant analysis can be conducted in order to verify

Hydrosolv Liquid Cleaners
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
Part Number Description Size by consulting your local water utility company or an
agricultural agent. Private laboratories are also
1U-8812 4 L (1 US gallon) available for water analysis.
1U-5490 Hydrosolv 4165 19 L (5 US gallon) Caterpillar Inc. recommends an S·O·S Coolant
8T-7570 208 L (55 US gallon) Analysis (Level 2).

1U-8804 4 L (1 US gallon)
S·O·S Coolant Analysis (Level 2)
1U-5492 Hydrosolv 100 19 L (5 US gallon)
An S·O·S Coolant Analysis (Level 2) is a
8T-5571 208 L (55 US gallon) comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level 2)
4. Use steam to clean the oil cooler core. The steam provides the following information:
will remove any remaining residue from the
cleaner. Flush the fins of the oil cooler core. • Complete S·O·S Coolant Analysis (Level 1)
Remove any other trapped debris.
• Visual inspection of properties
5. Wash the oil cooler core with hot, soapy water.
• Identification of metal corrosion
Rinse the oil cooler core thoroughly with clean
water. • Identification of contaminants
• Identification of built up impurities (corrosion and
scale)

Personal injury can result from air pressure. S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
Personal injury can result without following prop- recommendations.
er procedure. When using pressure air, wear a
protective face shield and protective clothing. For more information about coolant analysis, see your
Caterpillar dealer.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes. i04020194

6. Dry the oil cooler core with compressed air. Direct Radiator - Clean
the air in the reverse direction of the normal flow.
SMCS Code: 1353-070
7. Inspect the components in order to ensure
cleanliness. The oil cooler core should be pressure Note: Adjust the frequency of cleaning according to
tested. Repair the oil cooler core, if necessary. the effects of the operating environment.
Install the oil cooler core. Inspect the radiator for these items: damaged fins,
For more information about cleaning the cores, corrosion, dirt, grease, insects, leaves, oil and other
consult your Caterpillar dealer. debris. Clean the radiator, if necessary.

Obtain Coolant Analysis

The concentration of supplemental coolant additive Personal injury can result from air pressure.
(SCA) should be checked regularly with test kits or
with S·O·S Coolant Analysis (Level 1). Further Personal injury can result without following prop-
coolant analysis is recommended when the engine is er procedure. When using pressure air, wear a
overhauled. protective face shield and protective clothing.

For example, considerable deposits are found in the The maximum air pressure for cleaning purposes
water jacket areas on the external cooling system, but must be reduced to 205 kPa (30 psi) when the air
the concentrations of coolant additives were carefully nozzle is deadheaded.
maintained. The coolant probably contained minerals
that were deposited on the engine over time.
126 SEBU8733
Maintenance Recommendations
Starting Motor - Inspect

Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction of NOTICE
the air flow. Hold the nozzle approximately 6 mm Turbocharger bearing failures can cause large quanti-
(0.25 inch) away from the fins. Slowly move the air ties of oil to enter the air intake and exhaust systems.
nozzle in a direction that is parallel with the tubes. Loss of engine lubricant can result in serious engine
This movement will remove debris that is between the damage.
tubes.
Minor leakage of oil into a turbocharger under ex-
Pressurized water may also be used for cleaning. The tended low idle operation should not cause problems
maximum water pressure for cleaning purposes must as long as a turbocharger bearing failure has not
be less than 275 kPa (40 psi). Use pressurized water occured.
in order to soften mud. Clean the core from both
sides. When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
Use a degreaser and steam for removal of oil and smoke or engine rpm up at no load), do not continue
grease. Clean both sides of the core. Wash the core engine operation until the turbocharger is renewed.
with detergent and hot water. Thoroughly rinse the
core with clean water.
A visual inspection of the turbocharger or
After cleaning, start the engine and accelerate the turbochargers can minimize unscheduled downtime.
engine to high idle rpm. This procedure will help in the A visual inspection of the turbocharger or
removal of debris and drying of the core. Stop the turbochargers can also reduce the chance for
engine. Use a light bulb behind the core in order to potential damage to other engine parts. Do not
inspect the core for cleanliness. Repeat the cleaning, inspect the engine with the engine in operation.
if necessary.
Inspect the fins for damage. Bent fins may be opened Engine Installed with Single
with a “comb”. Inspect these items for good condition: Turbocharger
welds, mounting brackets, air lines, connections,
clamps and seals. Make repairs, if necessary.

i02348493

Starting Motor - Inspect

SMCS Code: 1451-040; 1453-040
Caterpillar recommends a scheduled inspection of
the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
Check the starting motor for correct operation. Check
the electrical connections and clean the electrical
connections. Refer to the Systems Operation, Testing
and Adjusting Manual, “Electric Starting System -
Test” for more information on the checking procedure
and for specifications or consult your Caterpillar
dealer for assistance.

i04922217

Turbocharger - Inspect Illustration 102 g03089297

SMCS Code: 1052-040

1. Ensure that the turbocharger is clean and free from
dirt before removing components for inspection.

2. Remove the pipe from the turbocharger exhaust

Hot engine components can cause injury from
burns. Before performing maintenance on the en- outlet and remove the air intake pipe (1). Visually
gine, allow the engine and the components to inspect the piping for the presence of oil. Clean the
cool. interior of the pipes in order to prevent dirt from
entering during reassembly.
SEBU8733 127
Maintenance Recommendations
Turbocharger - Inspect

3. Check for obvious heat discoloration of the 1. Ensure that the turbochargers are clean and free
turbocharger. Check for any loose bolts or any from dirt before removing components for
missing bolts. Check for damage to the oil supply inspection.
line and the oil drain line. Check for cracks in the
housing of the turbocharger. Ensure that the 2. Remove the pipe from the high-pressure
compressor wheel can rotate freely. turbocharger exhaust outlet and remove the air
intake pipe (3 ) to the turbocharger. Visually
4. Check for the presence of oil. If oil is leaking from inspect the piping for the presence of oil. Clean the
the back side of the compressor wheel, there is a interior of the pipes in order to prevent dirt from
possibility of a failed turbocharger oil seal. entering during reassembly.
The presence of oil may be the result of extended 3. Remove elbow (2) and check for the presence of
engine operation at low idle. The presence of oil engine oil.
may also be the result of a restriction of the line for
the intake air (clogged air filters), which causes the 4. Check for obvious heat discoloration of the
turbocharger to slobber.
turbocharger. Check for any loose bolts or any
5. Install the air intake pipe and the exhaust outlet missing bolts. Check for damage to the oil supply
pipe to the turbocharger housing. Ensure that all line and the oil drain line. Check for cracks in the
clamps are installed correctly and that all clamps housing of the turbocharger. Ensure that the
are tightened securely. For more information, refer compressor wheel can rotate freely.
to Systems Operation, Testing, and Adjusting,
5. Check for the presence of oil. If oil is leaking from
“Turbocharger - Inspect”.
the back side of the compressor wheel, there is a
Engine Installed with High Pressure possibility of a failed turbocharger oil seal.

Turbocharger and Low Pressure The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
Turbocharger may also be the result of a restriction of the line for
the intake air (clogged air filters), which causes the
turbocharger to slobber.

6. Inspect the bore of the housing of the turbine outlet

for corrosion.
7. Install the air intake pipe and the exhaust outlet
pipe to the turbocharger housing. Ensure that all
clamps are installed correctly and that all clamps
are tightened securely. For more information, refer
to Systems Operation, Testing, and Adjusting,
“Turbocharger - Inspect”.

Illustration 103 g03089316

The engine is equipped with a high-pressure

turbocharger (1) and a low-pressure turbocharger (4).
A regular visual inspection of both turbochargers is
recommended. If the turbocharger fails during engine
operation, damage to the turbocharger compressor
wheel and/or to the engine may occur. Damage to the
turbocharger compressor wheel can damage the
pistons, the valves, and the cylinder head.
128 SEBU8733
Maintenance Recommendations
Walk-Around Inspection

i05431557
NOTICE
For any type of leak (coolant, lube, or fuel) clean up
Walk-Around Inspection the fluid. If leaking is observed, find the source and
SMCS Code: 1000-040 correct the leak. If leaking is suspected, check the flu-
id levels more often than recommended until the leak
is found or fixed, or until the suspicion of a leak is
Inspect the Tube of the Crankcase proved to be unwarranted.
Breather
NOTICE
Accumulated grease and/or oil on an engine is a fire
hazard. Remove the accumulated grease and oil. Re-
fer to this Operation and Maintenance Manual, “En-
gine - Clean” for more information.

• Ensure that the cooling system hoses are correctly

clamped and that the cooling system hoses are
tight. Check for leaks. Check the condition of all
pipes.

• Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by the
coolant in the cooling system. It is normal for a small
amount of leakage to occur as the engine cools down
and the parts contract.
Excessive coolant leakage may indicate the need to
replace the water pump. Remove the water pump.
Refer to Disassembly and Assembly, “Water Pump -
Illustration 104 g02351425 Remove and Install”. For more information, consult
Typical example your Caterpillar dealer.

Inspect the breather tube (1) for damage. Ensure that • Inspect the lubrication system for leaks at the front
the outlet (2) is clean and free from any obstructions. crankshaft seal, the rear crankshaft seal, the oil
Ice can cause obstructions in adverse weather pan, the oil filters, and the rocker cover.
conditions.
• Inspect the piping for the air intake system and the
Inspect the Engine for Leaks and elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
for Loose Connections hoses, tubes, wiring harnesses, etc.
A walk-around inspection should only take a few
• Ensure that the areas around the rotating parts are
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided. clear.

For maximum engine service life, make a thorough • Inspect the alternator belts and any accessory
inspection of the engine compartment before starting drive belts for cracks, breaks, or other damage.
the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections, and • Inspect the wiring harness for damage.
trash buildup. Make repairs, as needed:
Belts for multiple groove pulleys must be replaced as
• The guards must be in the correct place. Repair matched sets. If only one belt is replaced, the belt will
damaged guards or replace missing guards. carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
• Wipe all caps and plugs before the engine is the new belt could cause the belt to break.
serviced in order to reduce the chance of system
contamination.
SEBU8733 129
Maintenance Recommendations
Water Pump - Inspect

High Pressure Fuel Lines Engine Aftertreatment

Check the condition of the coolant lines , Diesel
Exhaust Fluid (DEF) lines, and electrical connections.
Check that all clamps, clips, and tie-wraps are secure
Contact with high pressure fuel may cause fluid and in good condition. Check that the DEF filler cap is
penetration and burn hazards. High pressure fuel secure and that cap is clean and free from dirt.
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in- Check the level of DEF in the tank is adequate for
operational purpose, if necessary fill the tank.
structions may cause personal injury or death.

i03570653
After the engine has stopped, you must wait for 10
minutes in order to allow the fuel pressure to be Water Pump - Inspect
purged from the high-pressure fuel lines before any
service or repair is performed on the engine fuel lines. SMCS Code: 1361-040
If necessary, perform minor adjustments. Repair any
leaks from the low-pressure fuel system and from the A failed water pump may cause severe engine
cooling, lubrication, or air systems. Replace any high- overheating problems that could result in the following
pressure fuel line that has leaked. Refer to conditions:
Disassembly and Assembly Manual, “Fuel Injection
Lines - Install”. • Cracks in the cylinder head
If you inspect the engine in operation, always use the • A piston seizure
proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and • Other potential damage to the engine
Maintenance Manual, “General hazard Information”.
Visually inspect the high-pressure fuel lines for
damage or signs of fuel leakage. Replace any
damaged high-pressure fuel lines or high-pressure
fuel lines that have leaked.
Ensure that all clips on the high-pressure fuel lines
are in place and that the clips are not loose.
• Inspect the rest of the fuel system for leaks. Look
for loose fuel line clamps.

• Drain the water and the sediment from the fuel

tank 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. Check for any loose tie-wraps or missing tie-
wraps.
• Inspect the 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.
Illustration 105 g01904773
• Check the condition of the gauges. Replace any
(A) Weep hole
gauges that are cracked. Replace any gauge that (B) Vent hole
cannot be calibrated.
Note: The water pump seals are lubricated by the
coolant in the cooling system. It is normal for a small
amount of leakage to occur. Refer to illustration 105
for the position of the weep hole and the vent hole.
130 SEBU8733
Maintenance Recommendations
Water Pump - Inspect

Visually inspect the water pump for leaks.

Note: If engine coolant enters the engine lubricating
system the lubricating oil and the engine oil filter must
be replaced. This will remove any contamination that
is caused by the coolant and this will prevent any
irregular oil samples.
The water pump is not a serviceable item. In order to
install a new water pump, refer to the Disassembly
and Assembly Manual, “Water Pump - Remove and
Install”.
SEBU8733 131
Warranty Section
Emissions Warranty Information

Warranty Section

Warranty Information
i04141951

Emissions Warranty
Information
SMCS Code: 1000
Caterpillar Inc. (Caterpillar ) warrants to the ultimate
purchaser and each subsequent purchaser that:

1. New non-road diesel engines and stationary diesel

engines less than 10 liters per cylinder operated
and serviced in the United States and Canada ,
including all parts of their emission control systems
(“emission related components”), are:

a. Designed, built, and equipped so as to

conform, at the time of sale, with applicable
emission standards prescribed by the United
States Environmental Protection Agency (EPA
) by way of regulation.

b. Free from defects in materials and

workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.

2. New non-road diesel engines operated and

serviced in the state of California , including all
parts of their emission control systems (“emission
related components”), are:

a. Designed, built, and equipped so as to

conform, at the time of sale, to all applicable
regulations adopted by the California Air
Resources Board (ARB ).

b. Free from defects in materials and

workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the Caterpillar application for
certification for the warranty period.
A detailed explanation of the Emission Control
Warranty that is applicable to new non-road and
stationary diesel engines, including the components
covered and the warranty period, is found in
supplement Special Publication, SELF9001, “Federal
Emission Control Warranty” and “Emission Control
Warranty for California”. Consult your authorized Cat
dealer to determine if your engine is subject to an
Emission Control Warranty.
132 SEBU8733
Reference Information Section
Engine Rating Conditions

Reference Information The engine ratings are gross output ratings.

Section Gross Output Ratings – The total output capability

of the engine that is equipped with standard
accessories.

Engine Ratings Standard accessories include the following

components:
i03579032
• Oil pumps
Engine Rating Conditions • Fuel pumps
SMCS Code: 1000
• Water pumps
It is important to know the use of the engine so that
the rating will match the operating profile. The proper Subtract the power that is required to drive auxiliary
rating selection is also important so that the components from the gross output. This process will
customer's perception of price and value is realized. produce the net power that is available for the
external load (flywheel).
In selecting a rating for a specific application, the
most important consideration is the time that is spent
at full throttle. The rating definitions identify the
percent of time at full throttle. The definitions also
identify the corresponding times below rated rpm.
Note: For an exact determination of the appropriate
rating, follow the OEM specifications or consult your
Caterpillar dealer.
There are five ratings from A to E. The rating for the
C7.1 industrial engine is C.
C – Intermittent service in conjunction with maximum
power and/or speed are cyclic. The engine at full load
should not exceed 50 percent of the duty cycle.

NOTICE
Operating engines above the rating definitions can re-
sult in shorter service life before overhaul.

i04650089

Engine Rating Definitions

SMCS Code: 1000
All engine ratings are in compliance with the following
standard ambient air conditions of ISO14396:2002:

• 100 kPa (29.3 Inches Hg)

• 30 percent relative humidity

• A temperature of 25 °C (77 °F)

The engine ratings are based on the following fuel
specifications:
• The Low Heat Value (LHV) of the fuel at 29 °C
(84.2 °F) at 42780 kJ/kg (18390 Btu/lb)

• Specific gravity of .833 - 837 at 15 °C (60 °F)

SEBU8733 133
Customer Service
Customer Assistance

Customer Service Japan

Shin Caterpillar Mitsubishi Ltd.
SBS Tower
i03996951
10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
Customer Assistance Japan
SMCS Code: 1000; 4450 Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
USA and Canada Japan
When a problem arises concerning the operation or Caterpillar Power Systems, Inc.
the service of an engine, the problem will normally be SBS Tower (14th floor)
managed by the dealer in your area. 4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Outside of the USA and of Canada Phone: 81-3-5797-4300
Fax: 81-3-5797-4359
If a problem arises outside the USA and outside
Canada , and if the problem cannot be resolved at the Australia and New Zealand
dealer level, consult the appropriate Caterpillar Caterpillar of Australia Ltd.
office. 1 Caterpillar Drive
Private Mail Bag 4
Latin America, Mexico, Carribean Tullamarine, Victoria 3043
Caterpillar Americas Co. Australia
701 Waterford Way, Suite 200 Phone: 03-9953-9333
Miami, FL 33126-4670 Fax: 03-9335-3366
USA
Phone: 305-476-6800
i03655027
Fax: 305-476-6801
Europe, Africa, and Middle East Ordering Replacement Parts
Caterpillar Overseas S.A.
SMCS Code: 4450; 7567
76 Route de Frontenex
P.O. Box 6000
CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444 When replacement parts are required for this
Fax: 22-849-4544 product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
Far East specifications including, but not limited to, physi-
Caterpillar Asia Pte. Ltd. cal dimensions, type, strength and material.
7 Tractor Road
Jurong, Singapore 627968 Failure to heed this warning can lead to premature
Republic of Singapore failures, product damage, personal injury or
Phone: 65-662-8333 death.
Fax: 65-662-8302
China Quality Caterpillar replacement parts are available
from Caterpillar dealers throughout the world.
Caterpillar China Ltd.
Caterpillar dealers' parts inventories are up-to-date.
37/F., The Lee Gardens The parts stocks include all of the parts that are
33 Hysan Avenue normally needed to protect your Caterpillar engine
Causeway Bay investment.
G.P.O. Box 3069
Hong Kong When you order parts, please specify the following
Phone: 852-2848-0333 information:
Fax: 852-2848-0440
134 SEBU8733
Customer Service
Ordering Replacement Parts

• When a Caterpillar engine requires maintenance

and/or repair, provide the dealer with all the
information that is stamped on the Information
Plate. Refer to this Operation and Maintenance
Manual, “Plate Locations and Film Locations”.
• 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.
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.
SEBU8733 135
Reference Materials
Maintenance Records

Reference Materials
i05264255

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

• Determine operating costs.

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

Keep the following types of documents as proof of

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

• Owner repair costs

• Owner receipts

• Maintenance log
136 SEBU8733
Reference Materials
Maintenance Log

i01176304

Maintenance Log
SMCS Code: 1000; 4450

Table 20
Engine Model Customer Identifier

Serial Number Arrangement Number

Service Quantity Of
Service Item Date Authorization
Hours Fuel
SEBU8733 137
Reference Materials
Reference Material

i05432178 Miscellaneous
Reference Material • Service Manual, REG1139F, “Service Manual
Contents Microfiche”
SMCS Code: 1000; 4450
• Service Manual, UENR4452, “C7.1 Industrial
The following literature can be obtained through any Engines”
Caterpillar dealer.
• Troubleshooting, UENR0668, “C7.1 Industrial
Lubricants Engines”
• Operation and Maintenance Manual, SEBU5898, • Systems Operation, Testing, and Adjusting,
“Cold Weather Recommendations” UENR0666, “C7.1 Industrial Engines”
• Operation and Maintenance Manual, SEBU6251, • Specifications, UENR0665, “C7.1 Industrial
“Caterpillar Commercial Diesel Engine Fluids Engines.”
Recommendations”
• Disassembly and Assembly, UENR0667, “C7.1
• Special Publication, PEHP6001, “How To Take A Industrial Engines”
Good Oil Sample”
• Specifications, SENR3130, “Torque
Coolants Specifications”

• Special Publication, PEHP4036, “Data Sheet - • Special Publication, PECP9067, “One Safe
Extended Life Coolant” Source” English language for use in NACD

• Special Publication, PEHP7057, “Data Sheet - • Special Publication, SEBF8029, “Index to

S·O·S Coolant Analysis” Guidelines for Reusable Parts and Salvage
Operations”
• Special Publication, SEBD0518, “Know Your
Cooling System” • Special Publication, SEBF8062, “Procedure to
Inspect and Clean Air Filters”
• Label, PEEP5027, “Extended Life Coolant/
Antifreeze” • Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”

• Special Publication, NEHS0526, “Service

Technician Application Guide”

• Special Publication, SEBU6251, “Caterpillar

Commercial Diesel Engine Fluids
Recommendations”

• Special Instruction, SEHS7633, “Battery Test

Procedure”
138 SEBU8733
Index Section

Index
A Coolant (ELC) - Change .................................. 94
Drain ............................................................ 94
After Starting Engine........................................ 66
Fill................................................................. 95
After Stopping Engine...................................... 75
Flush ............................................................ 95
Aftercooler Core - Clean/Test (Air-To-Air
Coolant Extender (ELC) - Add ......................... 96
Aftercooler) .................................................... 88
Coolant Level - Check ..................................... 97
Aftercooler Core - Inspect................................ 88
Coolant Sample (Level 1) - Obtain .................. 97
Alarms and Shutoffs ........................................ 37
Coolant Sample (Level 2) - Obtain .................. 98
Alarms.......................................................... 37
Cooling System Supplemental Coolant
Shutoffs........................................................ 37
Additive (SCA) - Test/Add .............................. 99
Testing.......................................................... 38
Add the SCA, If Necessary ........................ 100
Alternator - Inspect .......................................... 88
S·O·S Coolant Analysis ............................... 99
Alternator and Fan Belts - Replace.................. 89
Test for SCA Concentration ......................... 99
Crankshaft Vibration Damper - Inspect.......... 100
B Viscous Damper......................................... 100
Crushing Prevention and Cutting Prevention .. 15
Battery - Replace............................................. 89
Customer Assistance..................................... 133
Battery Disconnect Switch (If Equipped) ......... 41
Outside of the USA and of Canada ........... 133
Battery Electrolyte Level - Check .................... 89
USA and Canada ...................................... 133
Battery or Battery Cable - Disconnect ............. 90
Customer Service .......................................... 133
Before Starting Engine ...............................17, 64
Belt - Inspect.................................................... 91
Belt Tensioner - Check..................................... 90 D
Burn Prevention............................................... 12
Diagnostic Flash Code Retrieval ..................... 59
Aftertreatment System ................................. 12
Diagnostic Lamp.............................................. 59
Batteries....................................................... 12
Diesel Exhaust Fluid - Fill .............................. 101
Coolant......................................................... 12
Diesel Exhaust Fluid Filter - Clean/Replace.. 101
Induction System ......................................... 12
Diesel Exhaust Fluid in Cold Weather ............. 73
Oils............................................................... 12
Driven Equipment - Check............................. 102

C
E
Cold Weather Operation.................................. 69
Electrical System ............................................. 18
Hints for Cold Weather Operation................ 69
Grounding Practices .................................... 18
Idling the Engine .......................................... 70
Emergency Stopping ....................................... 74
Recommendations for Coolant Warm Up .... 70
Emergency Stop Button............................... 75
Recommendations for the Coolant .............. 70
Emissions Certification Film ............................ 31
Viscosity of the Engine Lubrication Oil......... 70
Emissions Warranty Information.................... 131
Cold Weather Starting ..................................... 64
Engaging the Driven Equipment...................... 67
Configuration Parameters................................ 60
Engine - Clean ............................................... 102
Customer Specified Parameters.................. 61
Aftertreatment ............................................ 102
System Configuration Parameters............... 60
Engine Air Cleaner Element (Dual Element)
Coolant (DEAC) - Change ............................... 91
- Inspect/Clean/Replace .............................. 102
Cooling Systems with Heavy Deposits or
Cleaning the Primary Air Cleaner Elements
Plugging ..................................................... 93
................................................................. 103
Drain ............................................................ 91
Servicing the Air Cleaner Elements ........... 102
Fill................................................................. 93
Engine Air Cleaner Element (Single
Flush ............................................................ 92
Element) - Inspect/Replace ......................... 105
SEBU8733 139
Index Section

Engine Air Cleaner Service Indicator - Maintenance .................................................. 4

Inspect ......................................................... 105 Maintenance Intervals.................................... 4
Test the Service Indicator........................... 105 Operation ....................................................... 4
Engine Air Precleaner - Check/Clean............ 106 Overhaul ........................................................ 4
Engine Crankcase Breather Element - Safety............................................................. 4
Replace........................................................ 106 Fuel and the Effect from Cold Weather............ 72
Bottom Service........................................... 108 Fuel Conservation Practices............................ 68
Check the System...................................... 109 Fuel Filter (In-Line) - Replace .........................114
Top Service ................................................ 107 Fuel Related Components in Cold Weather .... 72
Engine Diagnostics.......................................... 59 Fuel Filters ................................................... 72
Engine Electronics........................................... 19 Fuel Heaters ................................................ 73
Engine Mounts - Inspect................................ 109 Fuel Tanks.................................................... 72
Engine Oil and Filter - Change ....................... 111 Fuel System - Prime .......................................115
Drain the Engine Lubricating Oil .................111 Fuel System Primary Filter (Water
Fill the Oil Pan.............................................112 Separator) Element - Replace ......................116
Replace the Oil Filter...................................112 Install the New Filter Element .....................117
Engine Oil Level - Check ................................110 Remove the Element ..................................116
Engine Oil Sample - Obtain ............................110 Fuel System Primary Filter/Water Separator
Obtain the Sample and the Analysis...........110 - Drain ...........................................................118
Engine Operation............................................. 67 Fuel System Secondary Filter - Replace ........118
Engine Operation and the Aftertreatment Install the Element ......................................119
System ....................................................... 67 Remove the Element ..................................118
Engine Operation with Active Diagnostic Fuel Tank Water and Sediment - Drain.......... 120
Codes ............................................................ 59 Drain the Water and the Sediment............. 120
Engine Operation with Intermittent Fuel Storage Tanks .................................... 120
Diagnostic Codes........................................... 60 Fuel Tank ................................................... 120
Engine Rating Conditions.............................. 132
Engine Rating Definitions .............................. 132
Engine Ratings .............................................. 132 G
Engine Starting ...........................................17, 64 Gauges and Indicators .................................... 41
Engine Stopping .........................................18, 74 Aftertreatment Lamps and gauges............... 42
Indicator Lamps ........................................... 42
General Hazard Information .............................. 8
F Containing Fluid Spillage ............................. 10
Fan Clearance - Check...................................113 Dispose of Waste Properly............................11
Fault Logging................................................... 59 Fluid Penetration.......................................... 10
Features and Controls ..................................... 37 Inhalation ......................................................11
Fire Prevention and Explosion Prevention ...... 13 Pressurized Air and Water ........................... 10
Ether ............................................................ 14 General Information......................................... 21
Fire Extinguisher.......................................... 14
Lines, Tubes, and Hoses ............................. 15
Fluid Recommendations.................................. 76 H
Coolant......................................................... 81 High Pressure Fuel Lines ................................ 15
Diesel Exhaust Fluid .................................... 79 Hoses and Clamps - Inspect/Replace ........... 120
Engine Lubrication Oil.................................. 76 Replace the Hoses and the Clamps .......... 121
Fuel .............................................................. 78
Lubricating Grease....................................... 78
S·O·S Coolant Analysis ............................... 81 I
Foreword............................................................ 4 Important Safety Information ............................. 2
California Proposition 65 Warning ................. 4 Injector (Diesel Exhaust Fluid) - Replace ...... 121
Literature Information..................................... 4
140 SEBU8733
Index Section

L P
Lifting and Storage........................................... 33 Plate Locations and Film Locations................. 30
Serial Number Plate..................................... 30
Plate Locations and Film Locations
M (Aftertreatment System)................................. 30
Maintenance Interval Schedule ....................... 87 Clean Emission Module (CEM).................... 30
Daily ............................................................. 87 Pump Electronic Tank Unit (PETU).............. 31
Every 1000 Service Hours ........................... 87 Product Description (Engine and
Every 12 000 Service Hours or 6 Years ....... 88 Aftertreatment)............................................... 27
Every 1500 Service Hours ........................... 87 Aftermarket Products and Caterpillar Engines
Every 2000 Service Hours ........................... 87 ................................................................... 29
Every 250 Service Hours ............................. 87 Aftertreatment System ................................. 29
Every 3000 Service Hours ........................... 87 Electronic Engine Features.......................... 28
Every 3000 Service Hours or 2 Years .......... 87 Engine Cooling and Lubrication................... 29
Every 4000 Service Hours ........................... 87 Engine Diagnostics ...................................... 28
Every 50 Service Hours or Weekly .............. 87 Engine Service Life ...................................... 29
Every 500 Service Hours ............................. 87 Engine Specifications .................................. 28
Every 500 Service Hours or 1 Year.............. 87 Product Identification Information.................... 30
Every 5000 Service Hours ........................... 87 Product Information Section ............................ 21
Every 6000 Service Hours or 3 Years .......... 88 Product Lifting.................................................. 33
Every Week.................................................. 87 Engine and Clean Emission Module (CEM)
Every Year.................................................... 87 ................................................................... 33
Overhaul ...................................................... 88 Product Storage............................................... 35
When Required............................................ 87 Aftertreatment .............................................. 35
Maintenance Log ........................................... 136
Maintenance Recommendations..................... 83
Maintenance Records.................................... 135
R
Maintenance Section....................................... 76 Radiator - Clean............................................. 125
Model View Illustrations................................... 21 Radiator Restrictions ....................................... 71
Engine Aftertreatment System ..................... 26 Reference Information..................................... 32
Engine Views with Series Turbochargers .... 22 Record for Reference................................... 32
Off Engine Components............................... 25 Reference Information Section ...................... 132
Single Turbocharged Engine with Installed Reference Material ........................................ 137
Aftertreatment ............................................ 21 Coolants..................................................... 137
Monitoring System (Engine Indicators and Lubricants .................................................. 137
Aftertreatment Indicators) .............................. 43 Miscellaneous ............................................ 137
Engine Indicator Lamps ............................... 43 Reference Materials ...................................... 135
Mounting and Dismounting.............................. 15 Refill Capacities............................................... 76
Cooling System............................................ 76
Lubrication System ...................................... 76
O
Operation Section............................................ 33
Ordering Replacement Parts ......................... 133
S
Overhaul Considerations............................... 123 Safety Messages ............................................... 5
Oil Consumption as an Overhaul Indicator Ether Warning 2 ............................................. 6
................................................................. 123 Hand (High Pressure) 3 ................................. 7
Overhaul Recommendation....................... 123 Universal Warning 1....................................... 5
Overspeed....................................................... 44 Safety Section ................................................... 5
Selective Catalytic Reduction Warning
System........................................................... 38
SEBU8733 141
Index Section

Warning Indicators ....................................... 38 Welding on Engines with Electronic Controls .. 83

Warning Levels ............................................ 38
Warning Strategy ......................................... 38
Self-Diagnostics............................................... 59
Sensors and Electrical Components ............... 44
Aftertreatment Components......................... 54
CEM Sensors............................................... 55
Clean Emissions Module (CEM).................. 54
Engine Components .................................... 45
Pump Electronic Tank Unit (PETU).............. 57
Severe Service Application.............................. 85
Improper Maintenance Procedures
(Maintenance Procedures Which May
Contribute to a Severe Service Application)
................................................................... 86
Severe Environmental Factors .................... 85
Severe Operating Conditions....................... 85
Starting Motor - Inspect ................................. 126
Starting the Engine .......................................... 65
Starting the Engine ...................................... 65
Starting with Jump Start Cables ...................... 65
Stopping the Engine ........................................ 74
Delayed Engine Shutdown (if Equipped) ..... 74
System Pressure Release............................... 83
Coolant System............................................ 83
Engine Oil .................................................... 83
Fuel System ................................................. 83

T
Table of Contents............................................... 3
Turbocharger - Inspect .................................. 126
Engine Installed with High Pressure
Turbocharger and Low Pressure
Turbocharger............................................ 127
Engine Installed with Single Turbocharger
................................................................. 126

W
Walk-Around Inspection ................................ 128
Engine Aftertreatment................................ 129
High Pressure Fuel Lines........................... 129
Inspect the Engine for Leaks and for Loose
Connections ............................................. 128
Inspect the Tube of the Crankcase Breather
................................................................. 128
Warranty Information ..................................... 131
Warranty Section ........................................... 131
Water Pump - Inspect .................................... 129
142 SEBU8733
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 Phone Hours

Contact Number

Sales:

Parts:

Service:
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