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Operation and Maintenance Manual: C7.1 Industrial Engine
Operation and Maintenance Manual: C7.1 Industrial Engine
September 2013
Operation and
Maintenance
Manual
C7.1 Industrial Engine
881 1-Up (Engine)
SAFETY.CAT.COM
i05296198
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
Crushing Prevention and Cutting Prevention . 15 Engine Ratings ....................... ...................... 132
High Pressure Fuel Lines ................ ............... 15 Reference Materials .................. ................... 135
Operation Section
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
Illustration 1 g03022899
Typical example
Ether Warning 2
Illustration 2 g03023096
Typical example
SEBU8733 7
Safety Section
Safety Messages
Illustration 3 g03023097
Typical example
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
• 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
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
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
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
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
i01359666
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
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
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
Product Information
Section
General Information
i05347319
Illustration 15 g03393436
Typical example
22 SEBU8733
General Information
Model View Illustrations
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
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
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
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.
Product Identification
Information
i04897160
Illustration 24 g03047463
Typical example
i05349518
Illustration 23 g03046077
(1) Location of the engine serial number plate
Illustration 25 g03047499
Typical example
i04274710
Illustration 27 g03419905
Typical example
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.
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.
Illustration 30 g03051657
Typical example
(1) Lifting eyes for engine and aftertreatment.
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
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.
• 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
i05406889
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
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
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.
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
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)
i04901303
Monitoring System
(Engine Indicators and
Aftertreatment Indicators)
SMCS Code: 1900; 7400; 7450; 7451
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.
(continued)
44 SEBU8733
Features and Controls
Overspeed
(Table 8, contd)
Indicator Lamp Table
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.
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
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
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
Illustration 53 g03393956
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
• 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
Rating Number
IVS Channel 1
IVS Channel 2
Continuous Position Throttle Configuration 1
Throttle Arbitration
Equipment ID
(continued)
62 SEBU8733
Engine Diagnostics
Configuration Parameters
Air Shutoff
Throttle Lock Feature Installation Status
PTO Mode
Throttle Lock Engine Set Speed #1
Fan
Engine Fan Control
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
(continued)
SEBU8733 63
Engine Diagnostics
Configuration Parameters
Engine Cooling Fan Control Transmission Oil Temperature Input Enable Status
Engine Cooling Fan Control Hydraulic Oil Temperature Input Enable Status
Other Parameters
Maintenance Indicator Mode
Maintenance Level 1 Cycle Interval Hours
TSC 1 Droop %
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.
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”.
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
• 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
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
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
Fuel and the Effect from Cold • Engine oil pan heaters
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
Fluid Recommendations
Refill Capacities SMCS Code: 1280; 1348; 1395; 7560
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.
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.
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
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.
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
• Water hardness
• Identification of buildup of the impurities that cause
corrosion
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
• ECM
• Sensors
• Relays
• 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
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)
Every 250 Service Hours “Alternator and Fan Belts - Replace” .......................89
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.
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
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
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.
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.
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.
Illustration 62 g03075756
Illustration 64 g03081697
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
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.
i05360509
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
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
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.
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
i05436397
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.
• 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
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.
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
Illustration 69 g03379943
Lockable type DEF Filler cap
Illustration 71 g03097598
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.
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
Illustration 74 g00281693
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
Top Service
Illustration 79 g03090963
Illustration 78 g03090965
Illustration 80 g03090938
(A) Alignment position
(B) Alignment position
108 SEBU8733
Maintenance Recommendations
Engine Crankcase Breather Element - Replace
Illustration 82 g02346498
Typical example
(X) Alignment mark
(Y) Alignment mark
Illustration 84 g02346500
Typical example
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
i03996035
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 .
Illustration 88 g02351361
Typical example
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.
Illustration 89 g02173847
“L” Low
“H” High
i05404932
Illustration 90 g03414037
Typical example
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.
i04921313
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.
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.
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.
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.
Illustration 95 g02148370
Typical example
SEBU8733 119
Maintenance Recommendations
Fuel System Secondary Filter - Replace
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.
Illustration 98 g03088837
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
• Anticipated expansion and contraction of the 10. Start the engine. Inspect the cooling system for
fittings leaks.
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.
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.
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
i02348493
i04922217
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.
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.
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
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.
Warranty Section
Warranty Information
i04141951
Emissions Warranty
Information
SMCS Code: 1000
Caterpillar Inc. (Caterpillar ) warrants to the ultimate
purchaser and each subsequent purchaser that:
NOTICE
Operating engines above the rating definitions can re-
sult in shorter service life before overhaul.
i04650089
• 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:
• Maintenance log
136 SEBU8733
Reference Materials
Maintenance Log
i01176304
Maintenance Log
SMCS Code: 1000; 4450
Table 20
Engine Model Customer Identifier
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
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
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
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:
Transmission
Serial Number:
Attachment Information:
Dealer Equipment
Number:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
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