Dokumen - Tips - Engine Manual c7 t3 PDF

SEBU8089-02
August 2008
Operation and
Maintenance
Manual
C7 Industrial Engine
JRA1-Up (Engine)
JTF1-Up (Engine)
SAFETY.CAT.COM
i01658146
Important Safety Information

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

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

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SEBU8089-02 3
Table of Contents
Table of Contents Warranty Section

Warranty Information ............................................ 89
Foreword ................................................................. 4
Reference Information Section
Safety Section
Engine Ratings ..................................................... 90
Safety Messages .................................................... 6
Customer Service ................................................. 92
General Hazard Information ................................... 7
Reference Materials .............................................. 94
Burn Prevention ...................................................... 9
Index Section
Fire Prevention and Explosion Prevention ............ 10
Index ..................................................................... 98
Crushing Prevention and Cutting Prevention ........ 12
Mounting and Dismounting ................................... 12
Before Starting Engine .......................................... 12
Engine Starting ..................................................... 12
Engine Stopping ................................................... 13
Electrical System .................................................. 13
Engine Electronics ................................................ 14
Product Information Section

Model Views ......................................................... 15
Product Identification Information ........................ 18
Operation Section
Lifting and Storage ................................................ 19
Gauges and Indicators .......................................... 20
Features and Controls .......................................... 24
Engine Diagnostics ............................................... 27
Engine Starting ..................................................... 32
Engine Operation .................................................. 37
Engine Stopping ................................................... 38
Cold Weather Operation ....................................... 40
Maintenance Section
Refill Capacities .................................................... 42
Maintenance Recommendations .......................... 47
Maintenance Interval Schedule ............................ 49

4 SEBU8089-02
Foreword
Foreword Use fuel consumption or service hours to determine

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

Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating Major engine overhaul details are not covered in the
and stopping the engine. This section also includes a Operation and Maintenance Manual except for the
discussion of electronic diagnostic information. interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
Maintenance an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
The maintenance section is a guide to engine care. programs. If you experience a major engine failure,
The illustrated, step-by-step instructions are grouped there are also numerous after failure overhaul options
by fuel consumption, service hours and/or calendar available from your Caterpillar dealer. Consult with
time maintenance intervals. Items in the maintenance your dealer for information regarding these options.
schedule are referenced to detailed instructions that
follow.
SEBU8089-02 5
Foreword
California Proposition 65 Warning

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

contain lead and lead compounds. Wash hands
after handling.
6 SEBU8089-02
Safety Section
Safety Messages
Safety Section
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Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on

your engine. The exact location and a description of
the safety messages are reviewed in this section.
Please become familiar with all safety messages.
Ensure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water,
and soap to clean the safety messages. Do not
use solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off
of the engine.
Replace any safety message that is damaged or

missing. If a safety message is attached to a part
of the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
g00986753
Illustration 1
(1) Universal warning label
SEBU8089-02 7
Safety Section
General Hazard Information
(1) Universal Warning Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar
Do not operate or work on this equipment unless dealer. Attach the warning tags to the engine and to
you have read and understand the instructions each operator control station. When it is appropriate,
and warnings in the Operation and Maintenance disconnect the starting controls.
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con- Do not allow unauthorized personnel on the engine,
tact any Caterpillar dealer for replacement manu- or around the engine when the engine is being
als. Proper care is your responsibility. serviced.
Engine exhaust contains products of combustion

which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
Cautiously remove the following parts. To help

prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps
• Grease fittings
g00934493
Illustration 2 • Pressure taps
The Universal warning label is typically located on • Breathers
each side of the valve cover base.
• Drain plugs
i02566298
Use caution when cover plates are removed.
General Hazard Information Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
SMCS Code: 1000; 7405 the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
g00104545
Illustration 3
g00702020
Illustration 4
• Wear a hard hat, protective glasses, and other

protective equipment, as required.
• When work is performed around an engine that is

operating, wear protective devices for ears in order
to help prevent damage to hearing.
8 SEBU8089-02
Safety Section
General Hazard Information
• Do not wear loose clothing or jewelry that can snag Always use a board or cardboard when you check
on controls or on other parts of the engine. for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
• Ensure that all protective guards and all covers are serious injury and possible death. A pin hole leak can
secured in place on the engine. cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
• Never put maintenance fluids into glass containers. from a doctor that is familiar with this type of injury.
Glass containers can break.
Containing Fluid Spillage
• Use all cleaning solutions with care.
Care must be taken in order to ensure that fluids
• Report all necessary repairs. are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
Unless other instructions are provided, perform
engine. Prepare to collect the fluid with suitable
the maintenance under the following conditions:
containers before opening any compartment or
disassembling any component that contains fluids.
• The engine is stopped. Ensure that the engine
cannot be started.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tools Catalog” for the following items:
• Disconnect the batteries when maintenance
is performed or when the electrical system is
serviced. Disconnect the battery ground leads. • Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
Tape the leads in order to help prevent sparks.
• Tools that are suitable for containing fluids and
• Do not attempt any repairs that are not understood. equipment that is suitable for containing fluids
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
Obey all local regulations for the disposal of liquids.
Pressurized Air and Water Asbestos Information

Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.
When pressurized air and/or pressurized water is

used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi) when the air nozzle
is deadheaded. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
g00702022
Fluid Penetration Illustration 6
Caterpillar equipment and replacement parts that are

shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
g00687600
Illustration 5
SEBU8089-02 9
Safety Section
Burn Prevention
Use caution. Avoid inhaling dust that might be Dispose of Waste Properly
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:
• Never use compressed air for cleaning.

g00706404
• Avoid brushing materials that contain asbestos. Illustration 7
• Avoid grinding materials that contain asbestos. Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
• Use a wet method in order to clean up asbestos disposed of according to local regulations.
materials.
Always use leakproof containers when you drain
• A vacuum cleaner that is equipped with a high fluids. Do not pour waste onto the ground, down a
efficiency particulate air filter (HEPA) can also be drain, or into any source of water.
used.
i01480768
• Use exhaust ventilation on permanent machining
jobs. Burn Prevention
• Wear an approved respirator if there is no other SMCS Code: 1000; 7405
way to control the dust.
Do not touch any part of an operating engine.
• Comply with applicable rules and regulations Allow the engine to cool before any maintenance
for the work place. In the United States, use is performed on the engine. Relieve all pressure
Occupational Safety and Health Administration in the air system, in the hydraulic system, in the
(OSHA) requirements. These OSHA requirements lubrication system, in the fuel system, or in the
can be found in “29 CFR 1910.1001”. cooling system before any lines, fittings or related
items are disconnected.
• Obey environmental regulations for the disposal
of asbestos.
Coolant
• Stay away from areas that might have asbestos
particles in the air. When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause

severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level after the engine has stopped

and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the

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.
10 SEBU8089-02
Safety Section
Fire Prevention and Explosion Prevention
Cooling system conditioner contains alkali. Alkali can If the application involves the presence of combustible
cause personal injury. Do not allow alkali to contact gases, consult your Caterpillar dealer for additional
the skin, the eyes, or the mouth. information about suitable protection devices.
Remove all flammable materials such as fuel, oil, and

Oils debris from the engine. Do not allow any flammable
Hot oil and hot lubricating components can cause materials to accumulate on the engine.
personal injury. Do not allow hot oil to contact the
Store fuels and lubricants in properly marked
skin. Also, do not allow hot components to contact
the skin. containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
Batteries storing flammable materials.
Electrolyte is an acid. Electrolyte can cause personal Do not expose the engine to any flame.
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing Exhaust shields (if equipped) protect hot exhaust
batteries. Wash hands after touching the batteries components from oil or fuel spray in case of a line,
and connectors. Use of gloves is recommended. a tube, or a seal failure. Exhaust shields must be
installed correctly.
i02469590
Do not weld on lines or tanks that contain flammable
Fire Prevention and Explosion fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
Prevention thoroughly with a nonflammable solvent prior to
welding or flame cutting.
SMCS Code: 1000; 7405
Wiring must be kept in good condition. All electrical
wires must be properly routed and securely attached.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and properly
g00704000
maintained battery cables will help to prevent arcing
Illustration 8 or sparking.
All fuels, most lubricants, and some coolant mixtures Inspect all lines and hoses for wear or for
are flammable. deterioration. The hoses must be properly routed.
The lines and hoses must have adequate support
Flammable fluids that are leaking or spilled onto hot and secure clamps. Tighten all connections to the
surfaces or onto electrical components can cause recommended torque. Leaks can cause fires.
a fire. Fire may cause personal injury and property
damage. Oil filters and fuel filters must be properly installed.
The filter housings must be tightened to the proper
A flash fire may result if the covers for the engine torque.
crankcase are removed within fifteen minutes after
an emergency shutdown.
Determine whether the engine will be operated in an

environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
SEBU8089-02 11
Safety Section
Fire Prevention and Explosion Prevention
Improper jumper cable connections can cause an

explosion that can result in injury. Refer to this
Operation and Maintenance Manual, “Starting with
Jump Start Cables” for specific instructions.
Do not charge a frozen battery. This 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.
g00704059
Illustration 9
Ether
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not Ether is flammable and poisonous.
refuel an engine near open flames or sparks. Always
stop the engine before refueling. Use ether in well ventilated areas. 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.
Dispose of used ether cylinders properly. Do not

puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Do not spray ether into an engine if the engine is

equipped with a thermal starting aid for cold weather
starting.
Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
Illustration 10
g00704135 or damaged.
Gases from a battery can explode. Keep any open Repair any lines that are loose or damaged. Leaks
flames or sparks away from the top of a battery. Do can cause fires. Consult your Caterpillar dealer for
not smoke in battery charging areas. repair or for replacement parts.
Never check the battery charge by placing a metal Check lines, tubes and hoses carefully. Do not use
object across the terminal posts. Use a voltmeter or your bare hand to check for leaks. Use a board or
a hydrometer. cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions

are present:
12 SEBU8089-02
Safety Section
Crushing Prevention and Cutting Prevention
• End fittings are damaged or leaking. Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
• Outer coverings are chafed or cut. climb on the engine, and do not jump off the engine.
• Wires are exposed. Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
• Outer coverings are ballooning. with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
• Flexible part of the hoses are kinked. controls as handholds.
• Outer covers have embedded armoring. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
• End fittings are displaced. platform. Secure the climbing equipment so that the
equipment will not move.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this Do not carry tools or supplies when you mount the
will help to prevent vibration, rubbing against other engine or when you dismount the engine. Use a hand
parts, and excessive heat. line to raise and lower tools or supplies.
i01359666 i00911989
Crushing Prevention and Before Starting Engine

Cutting Prevention SMCS Code: 1000
SMCS Code: 1000; 7405
Inspect the engine for potential hazards.
Support the component properly when work beneath Before starting the engine, ensure that no one is on,
the component is performed.
underneath, or close to the engine. All protective
guards and all protective covers must be installed
Unless other maintenance instructions are provided, if the engine must be started in order to perform
never attempt adjustments while the engine is
service procedures. To help prevent an accident that
running.
is caused by parts in rotation, work around the parts
carefully.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
Do not bypass the automatic shutoff circuits. Do not
is performed. After the maintenance is performed, disable the automatic shutoff circuits. The circuits are
reinstall the guards.
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
Keep objects away from moving fan blades. The fan engine damage.
blades will throw objects or cut objects.
On the initial start-up of a new engine or an engine
When objects are struck, wear protective glasses in that has been serviced, prepare to stop the engine
order to avoid injury to the eyes.
if an overspeed condition occurs. This may be
accomplished by shutting off the fuel supply to the
Chips or other debris may fly off objects when objects engine and/or shutting off the air supply to the engine.
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
See the Service Manual for repairs and for
adjustments.
i01372247
Mounting and Dismounting i02136012
SMCS Code: 1000; 7405

Engine Starting
SMCS Code: 1000
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
If a warning tag is attached to the engine start switch
and keep these items in good repair.
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.
SEBU8089-02 13
Safety Section
Engine Stopping
All protective guards and all protective covers must i01489749

be installed if the engine must be started in order
to perform service procedures. To help prevent an Electrical System
accident that is caused by parts in rotation, work
around the parts carefully. SMCS Code: 1000; 1400
If there is a possibility that unburned gas remains in Never disconnect any charging unit circuit or battery
the exhaust system, refer to the purge procedure in circuit cable from the battery when the charging unit
this Operation and Maintenance Manual, “Engine is operating. A spark can cause the combustible
Starting” topic in the Operation Section. gases that are produced by some batteries to ignite.
Start the engine from the operator’s compartment or To help prevent sparks from igniting combustible
from the engine start switch. gases that are produced by some batteries, the
negative “−” jump start cable should be connected
Always start the engine according to the procedure last from the external power source to the negative
that is described in the Operation and Maintenance “−” terminal of the starting motor. If the starting motor
Manual, “Engine Starting” topic in the Operation is not equipped with a negative “−” terminal, connect
Section. Knowing the correct procedure will help to the jump start cable to the engine block.
prevent major damage to the engine components.
Knowing the procedure will also help to prevent Check the electrical wires daily for wires that are
personal injury. loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
To ensure that the jacket water heater (if equipped) electrical wires before the engine is started. See
and/or the lube oil heater (if equipped) is working the Operation and Maintenance Manual for specific
properly, check the water temperature and the oil starting instructions.
temperature during heater operation.
Grounding Practices
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
i01462046
Engine Stopping
SMCS Code: 1000
Stop the engine according to the procedure in

the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
the engine components.
Use the Emergency Stop Button (if equipped) ONLY

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

during the initial start-up of a new engine or an engine
that has been overhauled. This may be accomplished
g00774062
by shutting off the fuel supply to the engine and/or Illustration 11
shutting off the air supply to the engine. Typical example
Grounding Stud To Battery Ground
To stop an electronically controlled engine, cut the
power to the engine.
14 SEBU8089-02
Safety Section
Engine Electronics
i02784356
Engine Electronics
SMCS Code: 1000; 1400; 1900
Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine damage.
This engine has a comprehensive, programmable

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

monitoring control: WARNING, DERATE, and
SHUTDOWN. These engine monitoring modes have
the ability to limit engine speed and/or the engine
power.
Many of the parameters that are monitored by the

g00774088
Illustration 12 ECM can be programmed for the engine monitoring
Typical example functions. The following parameters can be monitored
Alternate Grounding Stud To Battery Ground
as a part of the Engine Monitoring System:
Proper grounding for the engine electrical system • Operating Altitude

is necessary for optimum engine performance
and reliability. Improper grounding will result in • Engine Coolant Level
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths. • Engine Coolant Temperature
Uncontrolled electrical circuit paths can result in • Engine Oil Pressure

damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components. • Engine Speed
Engines that are installed without engine-to-frame • Fuel Temperature

ground straps can be damaged by electrical
discharge. • Intake Manifold Air Temperature
To ensure that the engine and the engine electrical • System Voltage
systems function properly, an engine-to-frame ground
strap with a direct path to the battery must be used. The Engine Monitoring package can vary for different
This path may be provided by way of a starting motor engine models and different engine applications.
ground, a starting motor ground to the frame, or a However, the monitoring system and the engine
direct engine ground to the frame. monitoring control will be similar for all engines.
All grounds should be tight and free of corrosion. The Note: Many of the engine control systems and display
engine alternator must be grounded to the negative modules that are available for Caterpillar Engines
“-” battery terminal with a wire that is adequate to will work in unison with the Engine Monitoring
handle the full charging current of the alternator. System. Together, the two controls will provide the
engine monitoring function for the specific engine
application. Refer to the Troubleshooting Manual for
more information.
SEBU8089-02 15
Model Views
Product Information
Section
Model Views
i02112288
Model View Illustrations

SMCS Code: 1000
g01075656
Illustration 14
Right side view
(12) Exhaust manifold
(13) Turbocharger
(14) Engine oil filter
(15) Alternator
i02920111
Engine Description
SMCS Code: 1000
Illustration 13
g01075652 The Caterpillar C7 Engine has the following
Left side view characteristics:
(1) Belt tensioner
(2) Lifting eyes • In-Line 6 cylinder
(3) Engine oil level gauge
(4) Air inlet heater relay • Four stroke cycle
(5) Engine control module (ECM)
(6) Engine oil filler
(7) Fuel priming pump • Hydraulically Actuated Electronic Unit Injection
(8) Fuel filter (HEUI)
(9) Unit injector hydraulic pump
(10) Air compressor • Turbocharged
(11) Crankcase breather
• Air-to-air aftercooled
Engine Specifications
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.
16 SEBU8089-02
Model Views
• System diagnostics
For more information on electronic engine features,
refer to the Operation and Maintenance Manual,
“Engine Features and Controls” topic (Operation
Section).
Additional Features
The following additional features provide increased
engine fuel economy and serviceability:
• Cold starting capability
Illustration 15
g00407141 • Tampering detection
Cylinder and valve location
• Diagnostics
(A) Exhaust valve
(B) Inlet valve
Hydraulic Electronic Unit Injectors
Table 1
Hydraulically Actuated Electronic Unit Injectors
C7 Industrial Engine Specifications
(HEUI) perform the following functions: pumping of
Arrangement and fuel, fuel metering, and fuel timing.
In-Line 6 cylinder
Cylinders
The unit injectors are controlled by the ECM which
Bore 110 mm (4.3 inch)
uses the camshaft position and the engine speed
Stroke 127 mm (5.0 inch) signals from the engine speed/timing sensors and
the inlet air pressure sensors. The engine’s rated rpm
Aspiration Turbocharged
ATAAC(1) is identified on the Information Plate.
Displacement 7.2 L (440 in3) Engine Diagnostics

Firing Order 1-5-3-6-2-4
The engine has built-in diagnostics in order to ensure
Rotation (flywheel end) Counterclockwise that all of the components are functioning properly.
Valve Lash (inlet) 0.38 mm (0.015 inch) In the event of a deviation from the programmed
limits, the operator will be alerted to the condition
Valve Lash (exhaust) 0.64 mm (0.025 inch) by a “DIAGNOSTIC” lamp that is mounted on the
(1) Air-to-air aftercooled control panel. Under certain conditions, the engine
horsepower may be limited. A Caterpillar electronic
service tool may be used to display the diagnostic
Electronic Engine Features code.
The Caterpillar C7 Industrial Engines are designed for
There are three types of diagnostic codes: active,
electronic controls. The integral on board computer
logged, and event.
controls the operation of the engine. Current
operating conditions are monitored. The Electronic
Most of the diagnostic codes are logged and stored
Control Module (ECM) controls the response of the
in the ECM. For additional information, refer to
engine to these conditions and to the demands of the
the Operation and Maintenance Manual, “Engine
operator. These conditions and operator demands
Diagnostics” topic (Operation Section).
determine the precise control of fuel injection by the
ECM. The electronic engine control system provides
The ECM provides an electronic governor that
the following features:
controls the injector output in order to maintain the
desired engine rpm. The functionality of electronic
• Engine speed governor governor is similar to the Caterpillar mechanical
governor.
• Automatic air/fuel ratio control
• Torque rise shaping Engine Cooling and Lubrication
• Injection timing control The cooling system consists of the following
components:
SEBU8089-02 17
Model Views
• Centrifugal pump that is driven by belts However, failures that result from the installation
or use of other manufacturers’ devices,
• Water temperature regulator which regulates the accessories, or consumables are NOT Caterpillar
engine coolant temperature defects. Therefore, the defects are NOT covered
under the Caterpillar warranty.
• Oil cooler and radiator which incorporates a shunt
system Welding and Caterpillar Electronic
The engine lubricating oil that is supplied is cooled. Engines
The engine lubricating oil is also filtered. Bypass
valves provide unrestricted flow of lubrication oil NOTICE
to the engine components during the following Because the strength of the frame may decrease,
conditions: some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
• High oil viscosity ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
• Plugged oil cooler or plugged oil filter elements
(paper cartridge)
To help avoid damage to the electronic controls,
proper welding procedures are necessary. Before
Engine Service Life welding on an engine that is equipped with electronic
controls, observe the following precautions:
Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper 1. Turn off the engine. Place the key start switch in
operation and maintenance recommendations. In the OFF position.
addition, use recommended fuels, coolants and
lubricants. Use the Operation and Maintenance 2. If the machine has a battery disconnect switch,
Manual as a guide for required engine maintenance. open the switch. Otherwise, disconnect the
negative “-” battery cable from the battery of the
Expected engine life is generally predicted by the vehicle.
average power that is demanded. The average power
that is demanded is based on fuel consumption of
the engine over a period of time. Reduced hours of NOTICE
operation at full throttle and/or operating at reduced Do not ground the welder to electrical components
throttle settings result in a lower average power such as the ECM or sensors. Improper grounding can
demand. Reduced hours of operation will increase cause damage to the drive train bearings, hydraulic
the length of operating time before an engine components, electrical components, and other com-
overhaul is required. For more information, refer to ponents.
the Operation and Maintenance Manual, “Overhaul
Considerations” topic (Maintenance Section). Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
Aftermarket Products and sibility of damage.
Caterpillar Engines
3. Clamp the ground cable from the welder to the
NOTICE component that will be welded. Place the clamp
In order to maximize fuel system life and prevent pre- as close as possible to the weld.
mature wear out from abrasive particles in the fuel, a
four micron[c] absolute high efficiency fuel filter is re- 4. Protect wiring harnesses from welding debris and
quired for all Caterpillar Hydraulic Electronic Unit In- spatter. Use proper welding procedures.
jectors. Caterpillar High Efficiency Fuel Filters meet
these requirements. Consult your Caterpillar dealer
for the proper part numbers.
When auxiliary devices, accessories, or consumables

(filters, additives, catalysts, etc) which are made
by other manufacturers are used on Caterpillar
products, the Caterpillar warranty is not affected
simply because of such use.
18 SEBU8089-02
Product Identification Information
Product Identification Information Plate

Information
i02414123
Plate Locations and Film

Locations
SMCS Code: 1000
Engine Identification
Caterpillar engines are identified with serial numbers,
with performance specification numbers, and with Illustration 17
g00764335
arrangement numbers. In some of the cases,
Typical example
modification numbers are used. These numbers
are shown on the Serial Number Plate and the
The Information Plate is on the front valve cover.
Information Plate that are mounted on the engine.
The following information is on the Information
Plate: engine serial number, engine model, engine
Caterpillar dealers need these numbers in order to
arrangement number, maximum altitude of the
determine the components that were included with
engine that is possible to achieve the rated power,
the engine. This permits accurate identification of
horsepower, high idle, full load rpm, fuel settings, and
replacement part numbers.
other information.
Serial Number Plate Emission Certification
g00764267
Illustration 16 g00284658
Illustration 18
The Serial Number Plate is located on the right side Film for EPA Emission Certification
of the cylinder block.
The following information is stamped on the Serial

Number Plate: engine serial number, engine model,
and arrangement number.
g00415538
Illustration 19
Film for European Emission Certification
The film for the EPA Emission Certification (if

equipped) and/or the film for the European Emission
Certification (if equipped) is located on the side of
the engine.
SEBU8089-02 19
Operation Section
Lifting and Storage
Operation Section Engine Lifting with a Fuel Tank
Lifting and Storage Lift eyes or tank can fail when lifting tank con-
taining fluids resulting in possible personal injury.
i02055889 Drain tank of all fluids before lifting.
Product Lifting Lifting the engine with a fuel tank that is mounted
SMCS Code: 1000; 1404; 7002 to the engine requires special equipment and
procedures. Do not lift the unit with fuel in the fuel
tank. Consult your Caterpillar dealer for information
regarding fixtures for proper lifting of your complete
package.
i02068367
Product Storage
SMCS Code: 1000; 1404; 7002
If the engine will not be started for several weeks, the

lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface. Rust on the cylinder liner surface will
g00103219
Illustration 20 cause increased engine wear and a reduction in
engine service life.
NOTICE
Never bend the eyebolts and the brackets. Only load To help prevent excessive engine wear, use the
the eyebolts and the brackets under tension. Remem- following guidelines:
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be- • Complete all of the lubrication recommendations
comes less than 90 degrees. that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
When it is necessary to remove a component at an (Maintenance Section).
angle, only use a link bracket that is properly rated for
the weight. • If freezing temperatures are expected, check the
cooling system for adequate protection against
freezing. See this Operation and Maintenance
Use a hoist to remove heavy components. Use Manual, “Refill Capacities and Recommendations”
an adjustable lifting beam to lift the engine. All (Maintenance Section).
supporting members (chains and cables) should be
parallel to each other. The chains and cables should If an engine is out of operation and if use of the engine
be perpendicular to the top of the object that is being is not planned, special precautions should be made.
lifted. If the engine will be stored for more than one month,
a complete protection procedure is recommended.
Some removals require lifting the fixtures in order to
obtain proper balance and safety. For more detailed information on engine storage, see
Special Instruction, SEHS9031, “Storage Procedure
To remove the engine ONLY, use the lifting eyes that For Caterpillar Products”.
are on the engine.
Your Caterpillar dealer can assist in preparing the
Lifting eyes are designed and installed for the specific engine for extended storage periods.
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.
20 SEBU8089-02
Operation Section
Gauges and Indicators
Gauges and Indicators 3. Check the oil level. Maintain the oil level at the
proper amount.
i01465281 If the gauge continues to fluctuate, consult your

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

potential gauge or engine problems. Problems may Jacket Water Coolant Temperature –
Typical temperature range is 88 to 102 °C
also be indicated by gauge readings that change
even if the readings are within specifications. (190 to 215 °F). The maximum allowable
Determine the cause of any significant change in the temperature with the pressurized cooling system is
105 °C (220 °F). Higher temperatures may occur
readings. Then, correct any cause of any significant
change in the readings. Consult your Caterpillar under certain conditions. The water temperature
dealer for assistance. reading may vary according to load. The reading
should never exceed the boiling point for the
Caterpillar requires one lamp in addition to the gauge pressurized system that is being used.
package that is normally provided. The “Diagnostic”
lamp is yellow or amber. The “Diagnostic” lamp will If the engine is operating above the normal range
communicate the status of the engine’s electronic or steam becomes apparent, perform the following
system. The optional red “Warning” lamp is also procedure:
available. This red “Warning” lamp warns the operator
of engine problems. 1. Reduce the load and the engine rpm.
The following conditions are some examples of the 2. Inspect the cooling system for leaks.
engine problems:
3. Determine if the engine must be shut down
• Low oil pressure immediately or if the engine can be cooled by
reducing the load.
• High coolant temperature
• Low coolant level
Pressurized System: Hot coolant can cause seri-
• High inlet air temperature ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
Engine Oil Pressure – Typical oil
components are cool. Loosen the cooling system
pressure for an engine at rated speed
pressure cap slowly in order to relieve the pres-
with SAE 10W30 or with SAE 15W40 is
sure.
240 to 480 kPa (35 to 70 psi).
A lower oil pressure is normal at low idle. If the load 4. Check the coolant level.
is stable and the gauge reading changes, perform
the following procedure: Tachometer – This gauge indicates engine
speed. When the throttle control lever is
1. Remove the load. moved to the full throttle position without
load, the engine is running at high idle. The engine is
2. Reduce engine speed to low idle. running at the full load rpm when the throttle control
lever is at the full throttle position with maximum
rated load.
SEBU8089-02 21
Operation Section
Note: The default high idle rpm and the full load rpm
are stamped on the Information Plate.
Ammeter – This gauge indicates the

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

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

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

level of fuel in the fuel tank. The fuel level
gauge registers the fuel level only when the
ignition switch is in the ON position.
i02238470
Engine Monitoring System

(EMS)
SMCS Code: 7490
g00788015
Illustration 21
(1) Main unit (2) Tachometer (unit) (3) Quad gauge
22 SEBU8089-02
Operation Section
The Caterpillar Engine Monitoring System (EMS) is Table 2

an option. The engine parameters are displayed in Abbreviation Parameter
both digital display and analog. The EMS display is
for electronically controlled engines. Spd Engine Speed
GA-1 Engine Oil Pressure
The EMS includes three individual gauge units. The
units can be installed in various combinations. The GA-2 Coolant Temperature
main unit must be used if any of the units are used. GA-3 Battery Voltage
For information on installation and troubleshooting, GA-4 Fuel Pressure
refer to Installation Guide, REHS0871. Boost Boost Pressure
IAirT Inlet Air Temperature
EMS Main Unit
FuelT Fuel Temperature
AccrP Auxiliary Pressure
AccrT Auxiliary Temperature
Fuel Fuel Rate
Hrs Engine Hours
Load Percent of Engine Load
(speed and derate)
Note: For detailed information on the exact

parameters for your engine, refer to the Operation
and Maintenance Manual, “Gauges and Indicators”.
Quad Gauge Unit
g00595165
Illustration 22
(4) Engine oil pressure
(5) Engine coolant temperature
(6) Fuel pressure
(7) Inlet manifold temperature
(8) Fuel temperature
(9) Engine coolant level
(10) Battery voltage
(11) Active engine derate
(12) Auxiliary temperature
(13) Auxiliary pressure
The Engine Monitoring System provides warning

lamps. Refer to Illustration 22. The Engine
Monitoring System provides a LCD display for engine
parameters. When the scroll switch is depressed,
the parameters will scroll on the screen. The EMS
displays the real time value for the parameter that is
g00595166
selected. The default is engine speed. Illustration 23
(14) Engine oil pressure
The parameters are abbreviated on the LCD display. (15) Engine coolant temperature
Table 2 lists the parameters. (16) Battery voltage
(17) Fuel pressure
The quad gauge unit displays the following

information: engine oil pressure, engine coolant
temperature, battery voltage, and fuel pressure
SEBU8089-02 23
Operation Section
Note: The gauge needles may not always return to

zero position when the engine is not running.

Tachometer Unit
g00788023
Illustration 24
(18) Tachometer
The tachometer displays the engine speed (rpm) on

an analog gauge.

Communication Data Link

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

Troubleshooting Manual, “Cat Data Link
Circuit-Test”.
24 SEBU8089-02
Operation Section
Features and Controls

i02414027
Sensors and Electrical

Components
SMCS Code: 1439; 1900; 7400
Sensor Locations
Illustration 25 shows the typical locations of the
sensors for a C7 Industrial Engine. Specific engines
may appear different from the illustration due to
differences in applications.
g00805525
Illustration 25
Typical example
Left side view
(1) Injection actuation pressure sensor (4) Boost pressure sensor (7) Coolant temperature sensor
(2) Inlet air temperature sensor (5) Engine oil temperature sensor (8) Engine oil pressure sensor
(3) Atmospheric pressure sensor (6) Engine speed/timing sensor
Failure of Sensors • Sensor output is shorted to “- battery” or “+ battery”.
All Sensors • Measured reading of the sensor is out of the

specification.
A failure of any of the sensors may be caused by one
of the following malfunctions:
• Sensor output is open.

SEBU8089-02 25
Operation Section
Atmospheric Pressure Sensor Failure of the Coolant Temperature

Sensor
Atmospheric pressure sensor (3) measures the
atmospheric pressure in the crankcase. A signal is The ECM will detect a failure of the coolant
sent to the Electronic Control Module (ECM). temperature sensor. The diagnostic lamp will
warn the operator about the status of the coolant
Table 3
temperature sensor. A failure of the coolant
Atmospheric Pressure Sensor temperature sensor will not cause a shutdown of the
engine or any horsepower change.
Operating pressure
0 to 116 kPa (0 to 16.8 psi)
range
Engine Oil Pressure Sensor
Boost Pressure Sensor Engine oil pressure sensor (8) is an absolute pressure
sensor that measures the engine oil pressure in
Boost pressure sensor (4) provides a signal which the main oil gallery. The engine oil pressure sensor
corresponds to turbocharger outlet pressure to the detects engine oil pressure for diagnostic purposes.
ECM. The air/fuel ratio control utilizes the actual The engine oil pressure sensor sends a signal to the
engine speed and the turbocharger outlet pressure in ECM.
order to control the transient smoke level. The ECM
can control injection timing and the amount of fuel Table 5
that is injected. When the throttle is increased and Engine Oil Pressure Sensor
when the engine demands more fuel, the fuel limit is
controlled in order to reduce overall smoke levels of Operating pressure
0 to 690 kPa (0 to 100 psi)
the engine exhaust. range
Failure of the Boost Pressure Sensor Low Oil Pressure Warning

The ECM will detect failure of the boost pressure The setpoint is dependent upon the engine speed.
sensor. The operator will be warned of the problem The fault will be active and logged only if the engine
through the diagnostic lamp. The strategies that are has been running for more than 15 seconds.
related to the boost will be disabled. Engine power
will be severely reduced in the event of a failure of the
boost pressure sensor. A failure of the boost pressure
Very Low Oil Pressure Warning
sensor will not cause a shutdown of the engine.
The very low oil pressure setpoint is dependent upon
the engine speed. If the DERATE mode of the engine
Coolant Temperature Sensor monitoring system is selected, the ECM will derate
the engine power. The engine horsepower will be
Coolant temperature sensor (7) monitors engine limited.
coolant temperature. The output of the ECM can
indicate a high coolant temperature through a relay Failure of the Engine Oil Pressure Sensor
or a lamp. The coolant temperature sensor is used
by the ECM to determine initiation of the Cold Start The ECM will detect failure of the engine oil pressure
Strategy. sensor. The diagnostic lamp warns the user about the
status of the engine oil pressure sensor. The engine
Table 4
oil pressure related strategies will be disabled in the
Coolant Temperature Sensor event of a failure of the engine oil pressure sensor. A
Activation temperature for the high failure of the engine oil pressure sensor will not cause
103°C (217°F) a shutdown of the engine or any horsepower change.
coolant temperature fault
Activation temperature for the very
high coolant temperature fault
106°C (229°F) Engine Oil Temperature Sensor
Engine oil temperature sensor (5) monitors the
temperature of the engine oil. The ECM uses the
information from the engine oil temperature sensor
in order to adjust the timing of the fuel injection and
the pressure of the fuel injection.
26 SEBU8089-02
Operation Section
Table 6 Note: The throttle position sensor is not shown in

Engine Oil Temperature Sensor
the illustration.
Operating temperature Failure of the Throttle Position Sensor

−40 to 120°C (−40 to 258°F)
range
An intermittent failure in the TPS causes the engine
speed to vary erratically. The ECM will perform the
Engine Speed/Timing Sensor following process:
If the ECM does not receive a signal from primary
speed/timing sensor (6), the “DIAGNOSTIC” lamp • The ECM will detect the failure of the TPS.
will indicate a diagnostic fault code which will be
logged in the ECM memory. • The ECM will warn the operator of the failure
through the diagnostic lamp.
If the ECM does not receive a signal from the primary
speed/timing sensor, the ECM will read the signal • The ECM will set the desired engine speed to low
idle.
from the secondary speed/timing sensor. The ECM
continually checks in order to determine if there is a
signal from both sensors. If either sensor fails, the
faulty sensor should be replaced.
Intermittent failure of the sensors will cause erratic

engine control.
Injection Actuation Pressure

Sensor
Injection actuation pressure sensor (1) provides
a signal of the injection actuation pressure to the
ECM. The ECM modifies the current to the injection
actuation pressure control valve (not shown) in
order to control the injection actuation pressure. The
desired actuation pressure is based on the following
engine parameters: quantity of fuel, injection timing,
engine speed, and engine operating mode.
Inlet Air Temperature Sensor

Inlet air temperature sensor (2) measures the inlet air
temperature. A signal is sent to the Electronic Control
Module (ECM). The inlet air temperature sensor is
also used by the ECM to determine initiation of the
Cold Start Strategy.
Table 7
Inlet Air Temperature Sensor
Operating temperature
−40 to 120°C (−40 to 258°F)
range
Throttle Position Sensor

The Throttle Position Sensor (TPS) sends a signal to
the ECM. The signal from the TPS is required in order
to govern engine speed. The throttle position sensor
signal is used by the ECM in order to calculate the
desired engine speed. The TPS is calibrated during
the initial installation of the engine.
SEBU8089-02 27
Operation Section
Engine Diagnostics
Engine Diagnostics The “DIAGNOSTIC” lamp blinks on and off at five

second intervals.
i01463253 • When the ignition key is in the ON position, the

lamp is checked for proper operation. If there
Diagnostic Lamp are any active codes except for Code 34, the
codes are displayed at this time.
SMCS Code: 1000; 1900; 1901; 1902; 7451
Note: The “DIAGNOSTIC” lamp will illuminate for five
The “DIAGNOSTIC” lamp is used to indicate the seconds. The lamp will stay on if there is an active
existence of an active fault by flashing codes. diagnostic code.
When the ignition switch is first turned on, the 2. The Active Diagnostic codes will always be
“DIAGNOSTIC” lamp will go through the following flashed. There is no toggle switch that will shut
procedure: off the lamp.
• The “DIAGNOSTIC” lamp will come on and 3. The “DIAGNOSTIC” lamp will flash in order to
the “DIAGNOSTIC” lamp will remain on for five indicate a two-digit code. The sequence of flashes
seconds. This checks the operation of the lamp. represents the system diagnostic message.
Each digit of the two-digit code is determined by
• The “DIAGNOSTIC” lamp will turn off. counting the number of flashes. The lamp flashes
at a rate of two times per second. The lamp will
• The “DIAGNOSTIC” lamp will come on again and pause for one second between digits. The lamp
the “DIAGNOSTIC” lamp will flash codes for any will pause for two seconds between codes.
active diagnostic codes. Not all diagnostic codes
have a unique flash code. Table 8 indicates the potential effect on the engine
performance with active flash codes. Table 8 also
• The “DIAGNOSTIC” lamp will turn off for five forms a list of Electronic diagnostic codes and
seconds. descriptions.
• The “DIAGNOSTIC” lamp repeats all active

diagnostic codes.
A fault diagnostic code will remain active until the

problem is repaired. The electronic control module
will continue flashing the flash code at five second
intervals until the problem is repaired.
i02414604
Diagnostic Flash Code

Retrieval
SMCS Code: 1000; 1900; 1901; 1902
“Diagnostic” Lamp
Use the “DIAGNOSTIC” Lamp or Caterpillar
Electronic Technician (ET) in order to determine the
diagnostic flash code.
Use the following procedure to retrieve the diagnostic

codes if the engine is equipped with a “DIAGNOSTIC”
lamp:
1. Turn the ignition key to the ON position. The

engine does not need to be started in order to view
codes. The engine does not need to be running
while the ignition switch is in the ON position.
28 SEBU8089-02
Operation Section
Engine Diagnostics
Table 8
Diagnostic Flash Codes for C7 Industrial Engine
Suggested Action by the
Effect On Engine Performance
Operator
Diagnostic Flash Code Schedule

Reduced Engine Shut
Engine Low Service
Engine Shut down the Service(2)
Misfire Power for the
Speed Down Engine(1)
Engine.(3)
Open or Short Circuit of Injection
15 X X
Actuation Pressure Sensor
High Injection Actuation
17 X X
Pressure
Open or Short for the Injection
18 Actuation Pressure Control X X
Valve
Sensor Supply Voltage Above
21 X X
Normal or Below Normal (4)
24 Oil Pressure Sensor Fault (4) X
Inlet Manifold Air Pressure
25 X
Sensor Fault(5)
Atmospheric Pressure Sensor
26 X X
Fault(4)
Coolant Temperature Sensor
27 X X X
Fault(4)
Check the Adjustments for the
28 X X X
Throttle Position Sensor.
34 Loss Of Engine RPM Signal X X X
35 Event for Engine Overspeed X X
37 Fuel Pressure Sensor Fault(4) X
Inlet Manifold Air Temperature
38 X X X
Sensor Fault(4)
Mechanical Failure of the
39 Injection Actuation Pressure X X
Sensor
Check the Calibration of the
42 X X X X X
Timing Sensor.
46 Low Oil Pressure Event X X X
Intermittent Battery Power to the
51 X X X X X
ECM
52 Personality Module Fault X X X X X
The following parameters must
56 be checked: Customer and X X X
System
59 Incorrect Engine Software X X X X
Event for High Coolant
61 X X X X
Temperature
62 Event for Low Coolant Level X X X X
63 Low Fuel Pressure Event X X X X
(continued)
SEBU8089-02 29
Operation Section
Engine Diagnostics
(Table 8, contd)
Diagnostic Flash Codes for C7 Industrial Engine
Suggested Action by the
Effect On Engine Performance
Operator
Diagnostic Flash Code Schedule

Reduced Engine Shut
Engine Low Service
Engine Shut down the Service(2)
Misfire Power for the
Speed Down Engine(1)
Engine.(3)
Even for High Inlet Manifold Air
64 X X X
Temperature
72 Fault of Cylinder 1 or Cylinder 2 X X X
(1) Shut down the Engine: Operate the engine cautiously. Get immediate service. Severe engine damage may result.
(2) The operator should go to the nearest location for service.
(3) The operator should investigate the problem at a convenient time.
(4) The Diagnostic Flash Codes reduce the effectiveness of the Engine Monitoring feature.
(5) These Diagnostic Flash Codes may affect the system only under specific environmental conditions such as engine start-up at cold
temperatures, etc.
i02512380 i02784364
Fault Logging Engine Operation with Active

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

The cause of the problem should be corrected as
soon as possible. Operation of the engine and
performance of the engine can be limited as a result
of the active diagnostic code that is generated. If
the cause of the active diagnostic code is repaired
and there is only one active diagnostic code, the
diagnostic lamp will turn off.
30 SEBU8089-02
Operation Section
Engine Diagnostics
i01456915 • First Password ___________________________________________

Engine Operation with • Second Password ______________________________________
Intermittent Diagnostic Codes Power Rating (hp at rpm) ______________________________
SMCS Code: 1000; 1900; 1901; 1902
Rating Selection (A-E) __________________________________
If the diagnostic lamp starts to flash codes during
normal engine operation and the diagnostic lamp PTO Governor Parameters
shuts off, an intermittent fault may have occurred. If
a fault has occurred, the fault will be logged into the • PTO Engine Speed Ramp Rate____________rpm/sec
memory of the Electronic Control Module (ECM).
Engine Parameters
In most cases, it is not necessary to stop the engine
because of an intermittent code. However, the • Top Engine Limit (TEL) at 100 percent load (If
operator should retrieve the logged fault codes Applicable) _______________________________________________
and the operator should reference the appropriate
information in order to identify the nature of the event. • Torque Limit ______________________________________________
The operator should log any observation that could
have caused the lamp to light. • High Idle (If Applicable) ________________________________
• Low power • Low Idle ___________________________________________________
• Limits of the engine speed • Intermediate Speed ____________________________________
• Excessive smoke, etc Engine Monitoring Mode
This information can be useful to help troubleshoot • “OFF” ______________________________________________________

the situation. The information can also be used for
future reference. For more information on diagnostic • “Warning” _________________________________________________
codes, refer to the Troubleshooting Guide for this
engine. • “Warning/Derate” ________________________________________
• “Warning/Derate/Shutdown” __________________________
i02918535
Configuration Parameters • “Coolant Level Sensor Enable/Disable” ____________

• “Fuel Pressure Sensor Enable/Disable” ___________
SMCS Code: 1000; 1900; 1901; 1902
• “Inlet Manifold Air Temperature Sensor
Customer specified parameters that will enhance Enable/Disable” _________________________________________
the fuel efficiency and the operator’s convenience
can be programmed into the Electronic Control Equipment ID
Module (ECM). Some parameters may affect
engine operation. This may lead to complaints from Maintenance Indicator
the operator about power or about performance.
The following engine related parameters may be
• Manual-Hours
programmed by the customer by using Caterpillar
electronic service tools in order to influence the
• Auto-Hours
operation of the engine:
• Manual-Fuel
Customer password
• Auto-Fuel
This parameter allows the customer to lock out
certain parameters by entering a password. Customer Auxiliary Pressure
passwords must be used to unlock any parameters
that are protected by customer passwords before the • High Warning Set Point ________________________________
parameter can be changed. Factory passwords are
required if this password is lost. Auxiliary Temperature
Customer Passwords • High Warning Set Point ________________________________

SEBU8089-02 31
Operation Section
Engine Diagnostics
The customer specified parameters can be changed

as often as needed. Password protection is provided
so that the customer can change the parameters. The
customer can authorize someone else to change the
parameters. Ensure that a record of the parameters
is kept in the Operation and Maintenance Manual.
For detailed instructions on programming the engine
for optimum performance and for optimum fuel
economy, consult your Caterpillar dealer.
32 SEBU8089-02
Operation Section
Engine Starting
Engine Starting • Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
i01486758 to the controls.
Before Starting Engine • Ensure that the areas around the rotating parts are
clear.
SMCS Code: 1000; 1400; 1450
• All of the guards must be put in place. Check for
Perform the required daily maintenance and other damaged guards or for missing guards. Repair
periodic maintenance before the engine is started. any damaged guards. Replace damaged guards
Inspect the engine compartment. This inspection can and/or missing guards.
help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, “Maintenance • Disconnect any battery chargers that are not
Interval Schedule” for more information. protected against the high current drain that
is created when the electric starting motor (if
• For the maximum service life of the engine, make equipped) is engaged. Check electrical cables
a thorough inspection before the engine is started. and check the battery for poor connections and
Look for the following items: oil leaks, coolant for corrosion.
leaks, loose bolts, and trash buildup. Remove trash
buildup and arrange for repairs, as needed. • Reset all of the shutoffs or alarm components.
• Inspect the cooling system hoses for cracks and • Check the engine lubrication oil level. Maintain the
for loose clamps. oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage. • Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
• Inspect the wiring for loose connections and for the coolant level to the “FULL” mark on the coolant
worn wires or frayed wires. recovery tank.
• Check the fuel supply. Drain water from the water • If the engine is not equipped with a coolant
separator (if equipped). Open the fuel supply valve. recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If
NOTICE the engine is equipped with a sight glass, maintain
All valves in the fuel return line must be open before the coolant level in the sight glass.
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing • Observe the air cleaner service indicator (if
failure or other damage. equipped). Service the air cleaner when the yellow
diaphragm enters the red zone, or when the red
piston locks in the visible position.
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air • Ensure that any driven equipment has been
may have entered the filter housing. Also, when fuel disengaged. Minimize electrical loads or remove
filters have been changed, some air pockets will be any electrical loads.
trapped in the engine. In these instances, prime the
fuel system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information i03203474
on priming the fuel system.
Starting the Engine
SMCS Code: 1000; 1450

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
which may be harmful to your health. Always start
outside.
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
SEBU8089-02 33
Operation Section
Engine Starting
Initial Inspection • Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
Perform the required daily maintenance and other the coolant level to the “FULL” mark on the coolant
periodic maintenance before you start the engine. recovery tank.
Inspect the engine compartment. This inspection can
help prevent major repairs at a later date. Refer to the • If the engine is not equipped with a coolant
Operation and Maintenance Manual, “Walk-Around recovery tank maintain the coolant level within
Inspection” topic (Maintenance Section) for more 13 mm (.5 inch) of the bottom of the filler pipe. If
information. the engine is equipped with a sight glass, maintain
the coolant level in the sight glass.
• For the maximum service life of the engine, make
a thorough inspection before you start the engine. • Observe the air cleaner service indicator (if
Look for the following items: oil leaks, coolant equipped). Service the air cleaner when the yellow
leaks, loose bolts, and trash buildup. Remove trash diaphragm enters the red zone, or when the red
buildup and arrange for repairs, as needed. piston locks in the visible position.
• Inspect the cooling system hoses for cracks and • Ensure that any driven equipment has been
for loose clamps. disengaged. Remove any electrical loads.
• Inspect the alternator and accessory drive belts for Cold Weather Starting
cracks, breaks, and other damage.
Starting the engine and operation in cold weather
• Inspect the wiring for loose connections and for is dependent on the type of fuel that is used, the oil
worn wires or frayed wires. viscosity, and other optional starting aids. For more
information, refer to the Operation and Maintenance
• Check the fuel supply. Drain water from the water Manual, “Cold Weather Operation” topic (Operation
separator (if equipped). Open the fuel supply valve. Section).
NOTICE
All valves in the fuel return line must be open before
Air Inlet Heater
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.
DO NOT USE ETHER (starting fluids) unless
specifically instructed to do so. If the engine is
• Do not start the engine or do not move any of the equipped with an Air Inlet Heater (electrically or
controls if there is a “DO NOT OPERATE” warning fuel ignited manifold heater), DO NOT use ether
tag or similar warning tag attached to the start (starting fluids) at any time. The use could result
switch or to the controls. in engine damage and/or personal injury.
• Ensure that the areas around the rotating parts are
clear. Note: There will be an indicator lamp on the control
panel that is marked “AIR INLET HEATER”.
• All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair For detailed information on the operation of the Air
any damaged guards. Replace damaged guards Inlet Heater, refer to Troubleshooting Manual, “Air
and/or missing guards. Inlet Heater Circuit - Test”.
• Disconnect any battery chargers that are not Refer to the Owner’s Manual of the OEM for your
protected against the high current drain that type of controls. Use the following procedure to start
is created when the electric starting motor (if the engine.
equipped) is engaged. Check electrical cables
and check the battery for poor connections and 1. Place the transmission in NEUTRAL. Disengage
for corrosion. the flywheel clutch in order to allow the engine to
start faster. This also reduces the draining of the
• Reset all of the shutoffs or alarm components. battery.
• Check the engine lubrication oil level. Maintain the 2. Turn the ignition switch to the ON position.
oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
34 SEBU8089-02
Operation Section
Engine Starting
The “WARNING and DIAGNOSTIC” lamp (if Note: Oil pressures and fuel pressures should be in
equipped) will flash while the engine is cranking. the normal range on the instrument panel. Engines
The lamp should turn off after proper engine that are equipped with “WARNING” lamps do not
oil pressure is achieved. If the lamp fails to have an operating range. The “WARNING and
flash, notify your authorized Caterpillar dealer. DIAGNOSTIC” lamp (if equipped) will flash while
If the lamp continues to flash, the Electronic the engine is cranking. The lamp should turn off
Control Module (ECM) has detected a problem after proper engine oil pressure or fuel pressure
in the system. For more information, refer to the is achieved. Do not apply a load to the engine or
Operation and Maintenance Manual, “Diagnostic increase engine rpm until the oil pressure gauge
Flash Code Retrieval” (Operation Section). indicates at least normal pressure. Inspect the engine
for leaks and/or unusual noises.
NOTICE
Do not engage the starting motor when flywheel is After the engine has started, the air inlet heater may
turning. Do not start the engine under load. continue to operate in a “Continuous” mode and/or in
an “Intermittent” mode. The air inlet heater will turn
If the engine fails to start within 30 seconds, release OFF when the sum of the coolant temperature and
the starter switch or button and wait two minutes to the air inlet temperature exceeds 35 °C or 127 °F.
allow the starting motor to cool before attempting to
start the engine again. If the engine is operated with a low load, the engine
will reach normal operating temperature sooner than
idling the engine with no load. When the engine is
3. Push the start button or turn the ignition switch to idled in cold weather, increase the engine rpm to
the START position in order to crank the engine. approximately 1000 to 1200 rpm. This will warm
up the engine more quickly. Do not exceed the
Do not push down or hold the throttle down recommended rpm in order to increase the speed
while the engine is cranked. The system will of the warm-up. Limit unnecessary idle time to ten
automatically provide the correct amount of fuel minutes.
that is needed to start the engine.
4. If the engine fails to start within 30 seconds,

Ether Injection System
release the start button, or the ignition switch. Wait
for two minutes in order to allow the starting motor
to cool before attempting to start the engine again.
Personal injury or property damage can result
Note: The “WARNING and DIAGNOSTIC” lamps (if from alcohol or starting fluids.
equipped) may come on after the engine is started. If
this occurs, the ECM has detected a problem with the Alcohol or starting fluids are highly flammable and
system. For more information, refer to the Operation toxic and if improperly stored could result in injury
and Maintenance Manual, “Diagnostic Flash Code or property damage.
Retrieval” (Operation Section) .
NOTICE
Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine rpm until the oil DO NOT USE ETHER (starting fluids) unless
pressure gauge indicates normal. If oil pressure is not specifically instructed to do so. If the engine is
indicated on the gauge within 15 seconds, DO NOT equipped with an Air Inlet Heater (electrically or
operate the engine. STOP the engine, investigate and fuel ignited manifold heater), DO NOT use ether
correct the cause. (starting fluids) at any time. The use could result
in engine damage and/or personal injury.
5. Allow the engine to idle for approximately
three minutes. Idle the engine until the water Starting Problems
temperature gauge has begun to rise. Check all
gauges during the warm-up period. An occasional starting problem may be caused by
one of the following items:
• Low battery charge

• Lack of fuel
• Problem with the wiring harness
SEBU8089-02 35
Operation Section
Engine Starting
If the engine fuel system has been run dry, fill the i02308903
fuel tank and prime the fuel system. Refer to the
Operation and Maintenance Manual, “Fuel System - Starting with Jump Start
Prime” topic (Maintenance Section). Cables
If the other problems are suspected, perform the SMCS Code: 1000; 1401; 1402; 1900
appropriate procedure in order to start the engine.
Problems with the Wiring Harness

Improper jump start cable connections can cause
an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could

cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
If the installation is not equipped with a backup

battery system, it may be necessary to start the
engine from an external electrical source.
For information on troubleshooting the charging

system, refer to Special Instruction, REHS0354,
“Charging System Troubleshooting”.
Many batteries which are considered unusable are

still rechargeable. After jump starting, the alternator
may not be able to fully recharge batteries that
are severely discharged. The batteries must be
charged to the proper voltage with a battery charger.
g01248812 For information on testing and charging, refer to
Illustration 26 the Special Instruction, SEHS7633, “Battery Test
ECM Connector J2/P2 Procedure”.
Locate the ECM. Check the connector in order to NOTICE

ensure that the connector is secure. Lightly pull each Using a battery source with the same voltage as the
of the wires in the chassis harness. electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
1. Pull each wire with approximately 4.5 kg (10 lb) of the electrical system.
force. The wire should remain in the connector.
Do not reverse the battery cables. The alternator can
2. If a wire is loose, push the wire back into the be damaged. Attach ground cable last and remove
connector. Pull the wire again in order to ensure first.
that the wire is secure.
When using an external electrical source to start the
3. Start the engine. If the engine does not start, engine, turn the generator set control switch to the
consult the nearest Caterpillar dealer for “OFF” position. Turn all electrical accessories OFF be-
assistance. fore attaching the jump start cables.
Ensure that the main power switch is in the OFF posi-

tion before attaching the jump start cables to the en-
gine being started.
1. Turn the start switch on the stalled engine to the

OFF position. Turn off all accessories.
36 SEBU8089-02
Operation Section
Engine Starting
2. Connect one positive end of the jump start cable

to the positive cable terminal of the discharged
battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the
electrical source.
3. Connect one negative end of the jump start cable

to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.
4. Charge the batteries. The engine will not continue

to run after starting if the batteries have not been
charged.
5. Start the engine.
6. Immediately after the stalled engine is started,

disconnect the jump start cables in reverse order.
Refer to the Electrical Schematic for your engine.

Consult your Caterpillar dealer for more information.
i01646248
After Starting Engine

SMCS Code: 1000
Note: In temperatures from 0 to 60°C (32 to 140°F),

the warm-up time is approximately three minutes. In
temperatures below 0°C (32°F), additional warm-up
time may be required.
Note: Ensure that the self test for the monitoring

system (if equipped) is completed before operating
the engine under load.
When the engine idles during warm-up, observe the

following conditions:
• Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
possible in some applications.
• Operate the engine at low idle until all systems

achieve operating temperatures. Check all gauges
during the warm-up period.
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 determine normal readings for each
gauge. Comparing data over time will also help
detect abnormal operating developments. Significant
changes in the readings should be investigated.
SEBU8089-02 37
Operation Section
Engine Operation
Engine Operation i01646335
Engaging the Driven

i00718869 Equipment
Engine Operation SMCS Code: 1000
SMCS Code: 1000
1. Operate the engine at one-half of the rated rpm,
when possible.
Proper operation and maintenance are key factors
in obtaining the maximum life and economy of
2. Engage the driven equipment without a load on
the engine. If the directions in the Operation and
the equipment, when possible.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized.
Interrupted starts put excessive stress on the drive
train. Interrupted starts also waste fuel. To get the
The time that is needed for the engine to reach
driven equipment in motion, engage the clutch
normal operating temperature can be less than the
smoothly with no load on the equipment. This
time needed for a walk-around inspection of the
method should produce a start that is smooth and
engine.
easy. The engine rpm should not increase and the
clutch should not slip.
After the engine is started and after the engine
reaches normal operating temperature, the engine
3. Ensure that the ranges of the gauges are normal
can be operated at the rated rpm. The engine will
when the engine is operating at one-half of
reach normal operating temperature faster when
the rated rpm. Ensure that all gauges operate
the engine is at rated speed. The engine will reach
properly.
normal operating temperature faster when the engine
is at low power demand. This procedure is more
4. Increase the engine rpm to the rated rpm. Always
effective than idling the engine at no load. The engine
increase the engine rpm to the rated rpm before
should reach operating temperature in a few minutes.
the load is applied.
Gauge readings should be observed and the data
5. Apply the load. Begin operating the engine at low
should be recorded frequently while the engine
load. Check the gauges and equipment for proper
is operating. Comparing the data over time will
operation. After normal oil pressure is reached
help to determine normal readings for each gauge.
and the temperature gauge begins to move,
Comparing data over time will also help detect
the engine may be operated at full load. Check
abnormal operating developments. Significant
the gauges and equipment frequently when the
changes in the readings should be investigated.
engine is operated under load.
Extended operation at low idle or at reduced load

may cause increased oil consumption and carbon
buildup in the cylinders. This carbon buildup
results in a loss of power and/or poor performance.
38 SEBU8089-02
Operation Section
Engine Stopping
Engine Stopping i02255774
Emergency Stopping
i01428739
SMCS Code: 1000; 7418
Stopping the Engine
NOTICE
SMCS Code: 1000; 7000 Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
NOTICE controls for normal stopping procedure.
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
Ensure that any components for the external system
celerated wear of the engine components.
that support the engine operation are secured after
the engine is stopped.
If the engine has been operating at high rpm and/or
high loads, run at low idle for at least three minutes
to reduce and stabilize internal engine temperature Emergency Stop Button
before stopping the engine.
Avoiding hot engine shutdowns will maximize tur-

bocharger shaft and bearing life.
Prior to stopping an engine that is being operated

at low loads, operate the engine at low idle for 30
seconds before stopping. If the engine has been
operating at highway speeds and/or at high loads,
operate the engine at low idle for at least three
minutes. This procedure will cause the internal
engine temperature to be reduced and stabilized.
Ensure that the engine stopping procedure is

understood. Stop the engine according to the shutoff Illustration 27
g00104303
system on the engine or refer to the instructions that
Typical emergency stop button
are provided by the OEM.
The emergency stop button is in the OUT position for
• To stop the engine, turn the ignition key switch to normal engine operation. Push the emergency stop
the OFF position.
button. The engine will not start when the button is
locked. Turn the button clockwise in order to reset.
Refer to Operation and Maintenance Manual,

“Features and Controls” for the location and the
operation of the emergency stop button.
SEBU8089-02 39
Operation Section
Engine Stopping
i01646416 i01465494
Manual Stop Procedure After Stopping Engine

SMCS Code: 1000 SMCS Code: 1000
Note: Individual applications will have different Note: Before you check the engine oil, do not operate
control systems. Ensure that the shutoff procedures the engine for at least 10 minutes in order to allow
are understood. Use the following general guidelines the engine oil to return to the oil pan.
in order to stop the engine.
• Check the crankcase oil level. Maintain the oil level
1. Remove the load, when possible. Reduce the between the “ADD” mark and the “FULL” mark on
engine speed (rpm) to low idle. the oil level gauge.
2. Increase the engine speed (rpm) to no more than • If necessary, perform minor adjustments. Repair
one-half of the rated rpm. Perform this procedure any leaks and tighten any loose bolts.
for three to five minutes in order to cool the engine.
Reduce the engine speed (rpm) to low idle. • Note the service hour meter reading. Perform
the maintenance that is in the Operation and
3. After the cool down period, turn the key switch to Maintenance Manual, “Maintenance Interval
the OFF position. Schedule”.
• Fill the fuel tank in order to help prevent

accumulation of moisture in the fuel. Do not overfill
the fuel tank.
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Coolant Specifications that are in the Operation
and Maintenance Manual. Failure to do so can cause
engine damage.
• Allow the engine to cool. Check the coolant level.

• If freezing temperatures are expected, check
the coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in
the instructions from the OEM.
40 SEBU8089-02
Operation Section
Cold Weather Operation
Cold Weather Operation Quantities of No. 1 diesel fuel are limited. No. 1 diesel
fuels are usually available during the months of the
winter in the colder climates. During cold weather
i01457051 operation, if No. 1 diesel fuel is not available, use No.
2 diesel fuel, if necessary.
Radiator Restrictions
There are three major differences between No. 1 and
SMCS Code: 1353; 1396 No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow • Lower cloud point
restriction can cause the following conditions:
• Lower pour point
• High exhaust temperatures
• Lower rating of kJ (BTU) per unit volume of fuel
• Power loss
When No. 1 diesel fuel is used, a decrease in power
• Excessive fan usage and in fuel efficiency may be noticed. Other operating
effects should not be experienced.
• Reduction in fuel economy
The cloud point is the temperature when a cloud of
If an airflow restriction device must be used, the wax crystals begins to form in the fuel. These crystals
device should have a permanent opening directly can cause the fuel filters to plug. The pour point is
in line with the fan hub. The device must have a the temperature when diesel fuel will thicken. The
minimum opening dimension of at least 770 cm2 diesel fuel becomes more resistant to flow through
(120 in2). fuel pumps and through fuel lines.
A centered opening that is directly in line with the fan Be aware of these values when diesel fuel is
hub is specified in order to prevent an interrupted purchased. Anticipate the average ambient
airflow on the fan blades. Interrupted airflow on the temperature of the area. Engines that are fueled in
fan blades could cause a fan failure. one climate may not operate well if the engines are
moved to another climate. Problems can result due
Caterpillar recommends a warning device for the to changes in temperature.
inlet manifold temperature and/or the installation of
an inlet air temperature gauge. The warning device Before troubleshooting for low power or for poor
for the inlet manifold temperature should be set at performance in the winter, check the type of fuel that
75 °C (167 °F). The inlet manifold air temperature is being used.
should not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential When No. 2 diesel fuel is used the following
engine damage. components provide a means of minimizing problems
in cold weather:
i02237624
• Starting aids
Fuel and the Effect from Cold
• Engine oil pan heaters
Weather
• Engine coolant heaters
SMCS Code: 1000; 1250
• Fuel heaters
The following fuels are the grades that are available
for Caterpillar engines: • Fuel line insulation
• No. 1 For more information on cold weather operation,
see Special Publication, SEBU5898, “Cold Weather
• No. 2 Recommendations”.
• Blend of No. 1 and No. 2

No. 2 diesel fuel is the most commonly used fuel.
Either No. 1 diesel fuel or a blend of No. 1 and No. 2
is best suited for cold weather operation.
SEBU8089-02 41
Operation Section
Cold Weather Operation
i02775524 These engines are equipped with a primary

filter/water separator. The primary filter/water
Fuel Related Components in separator must use a 10 micron filter to a 15 micron
Cold Weather filter. The filters are becoming more critical as fuel
injection pressures increase to 209 MPa (30000 psi)
SMCS Code: 1000; 1250 and higher psi. For more information on priming the
fuel system, see the Operation and Maintenance
Manual, “Fuel System - Prime” topic (Maintenance
Fuel Tanks Section).
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after operating the engine. Fuel Heaters
Fuel tanks should contain some provision for draining Fuel heaters help to prevent fuel filters from plugging
water and sediment from the bottom of the tanks. in cold weather due to waxing. A fuel heater should
Some fuel tanks use supply pipes that allow water be installed in order for the fuel to be heated before
and sediment to settle below the end of the fuel the fuel enters the primary fuel filter.
supply pipe.
Select a fuel heater that is mechanically simple, yet
Some fuel tanks use supply lines that take fuel adequate for the application. The fuel heater should
directly from the bottom of the tank. If the engine is also help to prevent overheating of the fuel. High fuel
equipped with this system, regular maintenance of temperatures reduce engine performance and the
the fuel system filter is important. availability of engine power. Choose a fuel heater
with a large heating surface. The fuel heater should
Drain the water and sediment from any fuel storage be practical in size. Small heaters can be too hot due
tank at the following intervals: to the limited surface area.
• Weekly Disconnect the fuel heater in warm weather.
• Oil changes Note: Fuel heaters that are controlled by the water
temperature regulator or self-regulating fuel heaters
• Refueling of the fuel tank should be used with this engine. Fuel heaters that
are not controlled by the water temperature regulator
This will help prevent water and/or sediment from can heat the fuel in excess of 65° C (149° F). A
being pumped from the fuel storage tank and into loss of engine power can occur if the fuel supply
the engine fuel tank. temperature exceeds 37° C (100° F).
Note: Heat exchanger type fuel heaters should have

Fuel Filters a bypass provision in order to prevent overheating of
the fuel in warm weather operation.
NOTICE
Do not fill the fuel filters with fuel before installing them. For further information on fuel heaters, consult your
The fuel would not be filtered and could be contami- Caterpillar dealer.
nated. Contaminated fuel will cause accelerated wear
to fuel system parts.
NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a
four micron[c] absolute high efficiency fuel filter is re-
quired for all Caterpillar Hydraulic Electronic Unit In-
jectors. Caterpillar High Efficiency Fuel Filters meet
these requirements. Consult your Caterpillar dealer
for the proper part numbers.
42 SEBU8089-02
Maintenance Section
Refill Capacities
Maintenance Section Table 9

API Classifications
Current Obsolete
Refill Capacities CI-4(1)
CH-4(1)
CE
CG-4(2)
i03174163 CF-4(3)
Refill Capacities and CF (4) CC, CD
Recommendations CF-2(5) CD-2(5)
(1) API CH-4 and CI-4 oils are acceptable if the requirements
SMCS Code: 1348; 1395; 7560 of Caterpillar’s ECF-1 (Engine Crankcase Fluid
specification-1) are met. CH-4 and CI-4 oils that have not
met the requirements of Caterpillar’s ECF-1 Specification
Engine Oil may cause reduced engine life.
(2) API CG-4 oils are acceptable for all Caterpillar diesel engines.
When the API CG-4 oils are used, the oil drain interval should
API Oils not exceed 75 Percent of the standard oil drain interval for
your engine.
The Engine Oil Licensing and Certification System by (3) API CF-4 oils are no longer recommended for Caterpillar
the American Petroleum Institute (API) is recognized on-highway diesel engines.
by Caterpillar. For detailed information about this (4) API CF oils are not recommended for Caterpillar on-highway
system, see the latest edition of the “API publication diesel engines.
(5) API CF-2 and CD-2 oils are classifications for two-cycle diesel
No. 1509”. Engine oils that bear the API symbol are
engines. Caterpillar does not sell engines that utilize the CD-2
authorized by API. and the API CF-2 oils.
Cat DEO (Diesel Engine Oil)

Caterpillar Oils have been developed and tested in
order to provide the full performance and service
life that has been designed and built into Caterpillar
Engines. Caterpillar Oils are currently used to fill
diesel engines at the factory. These oils are offered
by Caterpillar dealers for continued use when the
engine oil is changed. Consult your Caterpillar dealer
for more information on these oils.
Due to significant variations in the quality and in

the performance of commercially available oils,
Illustration 28
g00546535 Caterpillar makes the following recommendations:
Typical API symbol
• Cat DEO (Diesel Engine Oil) (10W-30)
Diesel engine oils CC, CD, CD-2, and CE have
not been API authorized classifications since 1 • Cat DEO (Diesel Engine Oil) (15W-40)
January 1996. Table 9 summarizes the status of the
classifications. Commercial Oils
• API CH-4 oils and API CI-4 oils are acceptable if
the requirements of Caterpillar’s ECF-1 (Engine
Crankcase Fluid specification-1) are met. CH-4 oils
and CI-4 oils that have not met the requirements
of Caterpillar’s ECF-1 Specification may cause
reduced engine life.
• API CG-4 oils are acceptable for all Caterpillar

diesel engines. When the API CG-4 oils are used,
the oil drain interval should not exceed 75 Percent
of the standard oil drain interval for your engine.
• API CF-4 oils are no longer recommended.

SEBU8089-02 43
Maintenance Section
Refill Capacities
If ambient temperature conditions at engine start-up

NOTICE require the use of multigrade SAE 0W oil, SAE
In selecting oil for any engine application, both the oil 0W-40 viscosity grade is preferred over SAE 0W-20
viscosity and oil performance classification/specifica- or SAE 0W-30.
tion as specified by the engine manufacturer must be
defined and satisfied. Using only one of these param- Note: SAE 10W-30 is the preferred viscosity grade
eters will not sufficently define oil for an engine appli- for the following diesel engines when the ambient
cation. temperature is above −18 °C (0 °F) and below 40 °C
(104 °F).
In order to make the proper choice of a commercial Table 10
oil, refer to the following explanations:
Engine Oil Viscosities for Ambient Temperatures
API CI-4 – API CI-4 oils were developed in order Ambient Temperature
to meet the requirements of high performance
diesel engines that use cooled Exhaust Gas Viscosity Grade Minimum Maximum
Recirculation (EGR). API CI-4 oils are acceptable SAE 0W-20 −40 °C (−40 °F) 10 °C (50 °F)
if the requirements of Caterpillar’s ECF-1 (Engine
Crankcase Fluid specification-1) are met. SAE 0W-30 −40 °C (−40 °F) 30 °C (86 °F)
SAE 0W-40 −40 °C (−40 °F) 40 °C (104 °F)
API CH-4 – API CH-4 oils were developed in order
to protect low emissions diesel engines that use a SAE 5W-30 −30 °C (−22 °F) 30 °C (86 °F)
0.05 percent level of fuel sulfur. However, API CH-4 SAE 5W-40 −30 °C (−22 °F) 50 °C (122 °F)
oils may be used with higher sulfur fuels. API CH-4
oils are acceptable if the requirements of Caterpillar’s SAE 10W-30(1) −18 °C (0 °F) 40 °C (104 °F)
ECF-1 (Engine Crankcase Fluid specification-1) are SAE 10W-40 −18 °C (0 °F) 50 °C (122 °F)
met.
SAE 15W-40 −9.5 °C (15 °F) 50 °C (122 °F)
Note: CH-4 oils and CI-4 oils that have not met the (1) SAE 10W-30 is the preferred viscosity grade for the C7 diesel
requirements of Caterpillar’s ECF-1 Specification engine when the ambient temperature is above −18 °C (0 °F)
may cause reduced engine life. and below 40 °C (104 °F).
Note: Supplemental heat is recommended below the

NOTICE minimum recommended ambient temperature.
Failure to follow these oil recommendations can cause
shortened engine service life due to deposits and/or
excessive wear.
S·O·S Oil Analysis
Caterpillar has developed a tool for maintenance
Note: Refer to Special Publication, SEBU6251, management that evaluates oil degradation and the
“Caterpillar Commercial Diesel Engine Fluids tool also detects the early signs of wear on internal
Recommendations” for additional information that components. The Caterpillar tool for oil analysis is
relates to lubrication for your engine. called S·O·S Oil Analysis and the tool is part of the
S·O·S Services program. S·O·S Oil Analysis divides
Lubricant Viscosity Recommendations oil analysis into three categories:
The proper SAE viscosity grade of oil is determined • Wear Analysis

by the minimum ambient temperature during
cold engine start-up, and the maximum ambient • Oil condition
temperature during engine operation.
• Additional tests
Refer to Table 10 (minimum temperature) in order
to determine the required oil viscosity for starting a The wear analysis monitors metal particles, some oil
cold engine. additives, and some contaminants.
Refer to Table 10 (maximum temperature) in order Oil condition uses infrared (IR) analysis to evaluate
to select the oil viscosity for engine operation at the the chemistry of the oil. Infrared analysis is also used
highest ambient temperature that is anticipated. to detect certain types of contamination.
Note: Generally, use the highest oil viscosity that is Additional tests are used to measure contamination
available to meet the requirement for the temperature levels from water, fuel, or coolant. Oil viscosity and
at start-up. corrosion protection can be evaluated, as needed.
44 SEBU8089-02
Maintenance Section
Refill Capacities
Refer to Special Publication, SEBU6251, “Caterpillar

Commercial Diesel Engine Fluids Recommendations”
or contact your local Caterpillar dealer for additional
information concerning the S·O·S Oil Analysis
program.
Refill Capacities (Engine Oil)

The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will
require additional oil. Refer to the OEM specifications
for the capacity of the auxiliary oil filter.
Table 11
C7 Industrial Engine
Approximate Refill Capacities
Refill Capacity for
Changing the Oil
and the Filter
Liters Quarts
Shallow Oil Sump(1) 18.0 19.0
Deep Oil Sump(1) 25.0 26.5
g00808467
(1)
Illustration 29
These values should be inserted by the customer as
approximate capacities for the crankcase oil sump which (1) Shallow oil sump
include the standard oil filters that are installed at the factory. (2) Deep oil sump (Aluminum)
Engines with auxiliary oil filters will require additional oil. Refer (3) Deep oil sump (Stamped steel)
to the OEM specifications for the capacity of the auxiliary oil
filter.
Lubricating Grease
Caterpillar provides a range of moderate greases
to extremely high performance greases in order to
service the entire line of Caterpillar products that
operate throughout the wide variety of climates. From
this variety of Caterpillar grease products, you will
find at least one of the Caterpillar greases that will
meet the performance requirements for any machine
or equipment application.
Before selecting a grease product for any application,

the performance requirements must be determined.
Consult the grease recommendations that are made
by the OEM for the equipment when the equipment is
operated in the expected conditions. Then, consult
with your Caterpillar dealer for a list of greases and
the following related characteristics.
• Performance specifications
• Available sizes of containers
• Part numbers
Always choose a grease that meets the
recommendations that are specified by the
equipment manufacturer for the application.
SEBU8089-02 45
Maintenance Section
Refill Capacities
If it is necessary to choose a single grease to use Coolant

for all of the equipment at one site, always choose
a grease that meets the requirements of the most NOTICE
demanding application. Products that meet the Do not use a commercial coolant/antifreeze that on-
minimum performance requirements can be expected ly meets the ASTM D3306 specification. This type of
to produce minimum parts’ life. Instead, use the coolant/antifreeze is made for light duty automotive
grease that yields the lowest total operating cost. applications.
This cost is based on an analysis that includes the
costs of parts, labor, and downtime. Also, include the
cost of the amount of grease that is actually used. The following two coolants are used in Caterpillar
diesel engines:
Note: Consult your supplier in order to determine if
the greases are compatible. Preferred – Caterpillar Extended Life Coolant (ELC)
or a commercial extended life coolant that meets the
If the technician is in doubt, purge the grease! Caterpillar EC-1 specification
Note: All Caterpillar brand name greases are Acceptable – A Caterpillar Diesel Engine
compatible with each other. Antifreeze/Coolant (DEAC) or a commercial
heavy-duty antifreeze/coolant that meets “ASTM
Note: Refer to Special Publication, SEBU6251, D4985”, or “ASTM D6210” specifications
“Caterpillar Commercial Diesel Engine Fluids
Recommendations” for additional information that Note: Caterpillar DEAC does not require a treatment
relates to lubrication for your engine. with an SCA at the initial fill. A commercial heavy-duty
antifreeze/coolant that meets “ASTM D4985”
or “ASTM D6210” specifications MAY require a
Fuel treatment with an SCA at the initial fill. These
coolants WILL require a treatment with an SCA on a
Distillate Diesel Fuel maintenance basis.
In North America, diesel fuel that is identified as No. Table 12

1-D or No. 2-D in “ASTM D975” generally meet the Service Life Before Flushing and Before Refilling
specifications. Caterpillar recommends diesel fuels
that are distilled from crude oil. Diesel fuels from Coolant Service Life(1)(2)
other sources could exhibit detrimental properties .
that are not defined or controlled by this specification. Cat ELC 12,000 Service Hours
or 6 Years
NOTICE Commercial coolant that 6,000 Service Hours
Operating with fuels that do not meet Caterpillar’s rec- meets the Caterpillar EC-1 or 6 Years
ommendations can cause the following effects: start- specification
ing difficulty, poor combustion, deposits in the fuel in-
jectors, reduced service life of the fuel system, de- Cat DEAC 3,000 Service Hours
or 3 Years
posits in the combustion chamber, and reduced ser-
vice life of the engine. Commercial Heavy-Duty
3,000 Service Hours
Antifreeze/Coolant that meets
or 2 Years
“ASTM D4985”
Note: Refer to Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engine Fluids Commercial Heavy-Duty
3,000 Service Hours
Recommendations” for the Caterpillar Specification Antifreeze/Coolant that meets
or 1 Year
“ASTM D4985”
for distillate fuel and for additional information that
relates to fuel for your engine. (1) Use the interval that occurs first.
(2) Refer to the specific engine Operation and Maintenance
Manual, “Maintenance Interval Schedule” for the interval for the
Refill Capacities (Fuel System) Cooling System Water Temperature Regulator.
Refer to the Operation and Maintenance Manual that

is provided by the OEM for capacities of the fuel
Glycol
system.
Glycol in the coolant helps to provide protection
against the following conditions:
• Boiling
• Freezing
46 SEBU8089-02
Maintenance Section
Refill Capacities
• Cavitation of the water pump and cylinder liners S·O·S Coolant Analysis
For optimum performance, Caterpillar recommends a Testing the engine coolant is important to ensure that
1:1 mixture of a water/glycol solution. the engine is protected from internal cavitation and
from corrosion. The analysis also tests the ability of
Note: Use a mixture that will provide protection the coolant to protect the engine from boiling and
against the lowest ambient temperature. from freezing. The S·O·S Coolant Analysis can be
done at your Caterpillar dealer. Caterpillar S·O·S
Note: 100 percent pure glycol will freeze at a Coolant Analysis is the best way to monitor the
temperature of −23 °C (−9 °F). condition of your coolant and your cooling system.
S·O·S Coolant Analysis is a program that is based
Refer to tables 13 and 14for additional information. on periodic samples.
Most conventional heavy-duty antifreeze/coolants Refer to Special Publication, SEBU6251, “Caterpillar

use ethylene glycol. Propylene glycol may also be Commercial Diesel Engine Fluids Recommendations”
used. In a 1:1 mixture with water, ethylene and for additional information.
propylene glycol provide similar protection against
freezing and boiling. Refer to tables 13 and 14 for Refill Capacity (Coolant System)
additional information.
The total cooling system capacity will vary depending
Table 13
on the radiator that is provided by the OEM. The
Ethylene Glycol table for the capacity of the cooling system is blank.
The customer should fill in the table.
Freeze Boil
Concentration
Protection Protection
Table 15
50 Percent −37 °C (−34 °F) 106 °C (223 °F) Approximate Capacity of the Cooling System
60 Percent −51 °C (−60 °F) 111 °C (232 °F) Compartment
Liters Quarts
or System
NOTICE Total Cooling
Do not use propylene glycol in concentrations that ex- System(1)
ceed 50 percent glycol because of propylene glycol’s (1) The total cooling system capacity includes the following
reduced heat transfer capability. Use ethylene glycol components:the engine block, the radiator, and all coolant
in conditions that require additional protection against hoses and lines.
boiling or freezing.
Note: Refer to Special Publication, SEBU6251,
Table 14
“Caterpillar Commercial Diesel Engine Fluids
Recommendations” for additional information that
Propylene Glycol relates to coolant for your engine.
Freeze Boil
Concentration
Protection Protection
50 Percent −32 °C (−26 °F) 106 °C (223 °F)
To check the concentration of glycol, use the

1U-7298 Coolant/Battery Tester (Degree Celsius)
or use the 1U-7297 Coolant/Battery Tester (Degree
Fahrenheit). The testers give readings that are
immediate and accurate. The testers can be used
with ethylene or propylene glycol.
Note: Propylene glycol coolant that is used in

Caterpillar Diesel Engine cooling systems must meet
“ASTM D6211-98a "Fully-Formulated Propylene
Glycol-Based Engine Coolant for Heavy-Duty
Engines”. When Propylene glycol is used in
heavy-duty diesel engines, a regular addition of
Supplemental Coolant Additive (SCA) is required
for protection against liner cavitation. Consult your
Caterpillar dealer for more information.
SEBU8089-02 47
Maintenance Section
Maintenance Recommendations
Maintenance 1. Stop the engine.
Recommendations 2. Wait for ten minutes.
Do not loosen the high pressure fuel lines in order to

i02909163 remove air pressure from the fuel system.
System Pressure Release
Engine Oil
SMCS Code: 1250; 1300; 1350; 5050
To relieve pressure from the lubricating system, turn
Coolant System off the engine.
i03091592
Welding on Engines with

Pressurized system: Hot coolant can cause seri-
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
NOTICE
To relieve the pressure from the coolant system, turn
Because the strength of the frame may decrease,
off the engine. Allow the cooling system pressure cap
some manufacturers do not recommend welding onto
to cool. Remove the cooling system pressure cap
a chassis frame or rail. Consult the OEM of the equip-
slowly in order to relieve pressure.
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
Fuel System
Proper welding procedures are necessary in order
To relieve the pressure from the fuel system, turn off to avoid damage to the engine’s ECM, sensors,
the engine. and associated components. When possible,
remove the component from the unit and then
High Pressure Fuel Lines (If Equipped) weld the component. If removal of the component
is not possible, the following procedure must be
followed when you weld on a unit that is equipped
with a Caterpillar Electronic Engine. The following
procedure is considered to be the safest procedure to
Contact with high pressure fuel may cause fluid
weld on a component. This procedure should provide
penetration and burn hazards. High pressure fu-
a minimum risk of damage to electronic components.
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death. NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
The high pressure fuel lines are the fuel lines that cause damage to the drive train bearings, hydraulic
are between the high pressure fuel pump and the components, electrical components, and other com-
high pressure fuel manifold and the fuel lines that are ponents.
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel Clamp the ground cable from the welder to the com-
systems. ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
This is because of the following differences: sibility of damage.
• The high pressure fuel lines are constantly charged
with high pressure. Note: Perform the welding in areas that are free from
explosive hazards.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system. 1. Stop the engine. Turn the switched power to the
OFF position.
Before any service or repair is performed on the
engine fuel lines, perform the following tasks:
48 SEBU8089-02
Maintenance Section
Maintenance Recommendations
2. Disconnect the negative battery cable from the Note: If electrical/electronic components are used
battery. If a battery disconnect switch is provided, as a ground for the welder, or electrical/electronic
open the switch. components are located between the welder ground
and the weld, current flow from the welder could
3. Disconnect the J1/P1 and J2/P2 connectors from severely damage the component.
the ECM. Move the harness to a position that will
not allow the harness to accidentally move back 5. Protect the wiring harness from welding debris
and make contact with any of the ECM pins. and spatter.
6. Use standard welding practices to weld the

materials.
g01075639
Illustration 30
Use the example above. The current flow from the welder to
the ground clamp of the welder will not cause damage to 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
4. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to bearings,
hydraulic components, electrical components, and
ground straps.
SEBU8089-02 49
Maintenance Section
Maintenance Interval Schedule
i03194073 Every 250 Service Hours

Maintenance Interval Schedule Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 62
SMCS Code: 1000; 7500
Initial 500 Service Hours
Ensure that all safety information, warnings and
instructions are read and understood before any Engine Valve Lash - Inspect/Adjust ...................... 74
operation or any maintenance procedures are
performed. Every Year
The user is responsible for the performance of Cooling System Coolant Sample (Level 2) -
maintenance, including all adjustments, the use of Obtain ................................................................. 62
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure Every 3000 Service Hours or 3 Years
to adhere to proper maintenance intervals and Cooling System Coolant (DEAC) - Change .......... 57
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Every 6000 Service Hours or 3 Years
Use mileage, fuel consumption, service hours, or Cooling System Coolant Extender (ELC) - Add .... 60
calendar time, WHICH EVER OCCURS FIRST,
in order to determine the maintenance intervals. Every 12 000 Service Hours or 6 Years
Products that operate in severe operating conditions
may require more frequent maintenance. Cooling System Coolant (ELC) - Change ............. 59
Note: Before each consecutive interval is performed, PM Level 1 - Every 6625 L (1750 US gal) of
all maintenance from the previous interval must be Fuel or 250 Service Hours or 6 Months
performed.
Air Compressor - Inspect ...................................... 52
When Required Air Compressor Filter - Clean/Replace ................. 52
Alternator - Inspect ............................................... 53
Battery - Replace .................................................. 53 Battery Electrolyte Level - Check .......................... 55
Battery or Battery Cable - Disconnect .................. 55 Belts - Inspect/Adjust ............................................ 56
Engine Air Cleaner Element (Dual Element) - Cooling System Supplemental Coolant Additive
Clean/Replace .................................................... 66 (SCA) - Test/Add ................................................. 63
Engine Storage Procedure - Check ...................... 74 Cylinder Head Grounding Stud - Inspect/Clean/
Fuel System - Prime ............................................. 75 Tighten ................................................................ 65
Severe Service Application - Check ..................... 85 Engine Crankcase Breather - Clean ..................... 69
Engine Oil Sample - Obtain .................................. 71
Daily Engine Oil and Filter - Change ............................. 72
Fan Drive Bearing - Lubricate ............................... 75
Air Tank Moisture and Sediment - Drain ............... 53 Fuel System Primary Filter (Water Separator)
Cooling System Coolant Level - Check ................ 61 Element - Replace .............................................. 77
Driven Equipment - Check .................................... 66 Fuel System Secondary Filter - Replace .............. 78
Engine Air Cleaner Service Indicator - Inspect ..... 69 Fuel Tank Water and Sediment - Drain ................. 79
Engine Oil Level - Check ...................................... 70 Hoses and Clamps - Inspect/Replace .................. 80
Fuel System Primary Filter/Water Separator - Radiator - Clean .................................................... 84
Drain ................................................................... 78
Power Take-Off Clutch - Check/Adjust/Lubricate .. 84
Every 22 700 L (6000 US gal) of Fuel or 250
Walk-Around Inspection ........................................ 87
Service Hours or 1 Year
Initial 20 to 40 Service Hours Aftercooler Core - Inspect ..................................... 51
Belts - Inspect/Adjust ............................................ 56
PM Level 2 - Every 52 990 L (14 000 US gal)
Every Week of Fuel or 2000 Service Hours or 1 Year
Aftercooler Core - Clean/Test ............................... 51
Battery Charger - Check ....................................... 54
Engine Valve Lash - Inspect/Adjust ...................... 74
Jacket Water Heater - Check ................................ 81
50 SEBU8089-02
Maintenance Section
Maintenance Interval Schedule
PM Level 3 - Every 105 980 L (28 000 US gal)

of Fuel or 4000 Service Hours or 2 Years
Belt Tensioner - Inspect ........................................ 55
Cooling System Water Temperature Regulator -
Replace ............................................................... 64
Crankshaft Vibration Damper - Inspect ................. 65
Engine - Clean ...................................................... 66
Engine Mounts - Inspect ....................................... 70
Every 132 475 L (35 000 US gal) of Fuel or

5000 Service Hours
Starting Motor - Inspect ........................................ 86
Turbocharger - Inspect .......................................... 86
Water Pump - Inspect ........................................... 88
Overhaul
Overhaul Considerations ...................................... 81
SEBU8089-02 51
Maintenance Section
Aftercooler Core - Clean/Test
i01546702 7. Inspect the core in order to ensure cleanliness.

Pressure test the core. Many shops that service
Aftercooler Core - Clean/Test radiators are equipped to perform pressure tests.
If necessary, repair the core.
SMCS Code: 1064-070; 1064-081
8. Install the core. Refer to the Service Manual for
1. Remove the core. Refer to the Service Manual the procedure.
for the procedure.
For more information on cleaning the core, consult
2. Turn the aftercooler core upside-down in order to your Caterpillar dealer.
remove debris.
i01468985
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
Aftercooler Core - Inspect
can attack the internal metals of the core and cause SMCS Code: 1064-040
leakage. Only use the recommended concentration of
cleaner. Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
3. Back flush the core with cleaner.
Inspect the aftercooler for these items: damaged fins,
Caterpillar recommends the use of Hydrosolv corrosion, dirt, grease, insects, leaves, oil, and other
liquid cleaner. Table 16 lists Hydrosolv liquid debris. Clean the aftercooler, if necessary.
cleaners that are available from your Caterpillar
dealer. For air-to-air aftercoolers, use the same methods that
are used for cleaning radiators.
Table 16
Hydrosolv Liquid Cleaners(1)

Part
Description Size Personal injury can result from air pressure.
Number
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
Personal injury can result without following prop-
174-6854 Hydrosolv 100 19 L (5 US gallon) er procedure. When using pressure air, wear a pro-
(1) Use a two to five percent concentration of the cleaner
tective face shield and protective clothing.
at temperatures up to 93°C (200°F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more Maximum air pressure at the nozzle must be less
information. than 205 kPa (30 psi) for cleaning purposes.
4. Steam clean the core in order to remove any

residue. Flush the fins of the aftercooler core. Pressurized air is the preferred method for removing
Remove any other trapped debris. loose debris. Direct the air in the opposite direction
of the fan’s air flow. Hold the nozzle approximately
5. Wash the core with hot, soapy water. Rinse the 6 mm (.25 inch) away from the fins. Slowly move the
core thoroughly with clean water. air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.
Pressurized water may also be used for cleaning.

The maximum water pressure for cleaning purposes
Personal injury can result from air pressure. must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
Personal injury can result without following prop- both sides.
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing. Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
Maximum air pressure at the nozzle must be less with detergent and hot water. Thoroughly rinse the
than 205 kPa (30 psi) for cleaning purposes. core with clean water.
6. Dry the core with compressed air. Direct the air in

the reverse direction of the normal flow.
52 SEBU8089-02
Maintenance Section
Air Compressor - Inspect
After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
If the air compressor pressure relief valve that is
Use a light bulb behind the core in order to inspect
mounted in the air compressor cylinder head is
the core for cleanliness. Repeat the cleaning, if
bypassing compressed air, there is a malfunction
necessary.
in the air system, possibly ice blockage. Under
these conditions, your engine may have insuffi-
Inspect the fins for damage. Bent fins may be opened
cient air for normal brake operation.
with a “comb”.
Do not operate the engine until the reason for the
Note: If parts of the aftercooler system are repaired
air bypass is identified and corrected. Failure to
or replaced, a leak test is highly recommended. The
heed this warning could lead to property damage,
FT1984 Aftercooler Testing Group is used to perform
personal injury, or death to the operator or by-
leak tests on the aftercooler. Refer to the Systems
standers.
Operation/Testing and Adjusting, “Aftercooler - Test”
and the Special Instruction, SEHS8622 for the proper
testing procedure. The function of the pressure relief valve is to bypass
air when there is a malfunction in the air compressor
Inspect these items for good condition: welds, system.
mounting brackets, air lines, connections, clamps,
and seals. Make repairs, if necessary. The pressure relief valve releases air at 1723 kPa
(250 psi). Do not stand near the pressure relief
For more detailed information on cleaning and valve. Compressed air may be released without
inspection, see Special Publication, SEBD0518, warning. All personnel should also stay clear of the
“Know Your Cooling System”. air compressor when the engine is operating and the
air compressor is exposed.
i02113479
Refer to the Service Manual or refer to the OEM
Air Compressor - Inspect specifications in order to find information concerning
the air compressor. Consult your Caterpillar dealer
SMCS Code: 1803-040 for assistance.
i01544231
Do not disconnect the air line from the air com- Air Compressor Filter -
pressor governor without purging the air brake Clean/Replace
and the auxiliary air systems. Failure to purge the
air brake and the auxiliary air systems before re- (If Equipped)
moving the air compressor and/or the air lines
could cause personal injury. SMCS Code: 1803-070-FQ; 1803-510-FQ
One of the single most important aspects of

preventive maintenance for the air compressor is the
induction of clean air. The type of maintenance that is
required for the air compressor and the maintenance
interval depends on the type of air induction system
that is used. Operating conditions (dust, dirt and
debris) may require more frequent service.
Refer to the Service Manual for the type of air

compressor that is installed on the engine. Follow
the maintenance recommendations that are provided
by the OEM of the air compressor. Some engines
use boost air pressure so the engine air cleaner will
require servicing.
g01076630
Illustration 31
(1) Pressure relief valve
SEBU8089-02 53
Maintenance Section
Air Tank Moisture and Sediment - Drain
i00847451 Check the alternator and the battery charger for

proper operation. If the batteries are properly
Air Tank Moisture and charged, the ammeter reading should be very near
Sediment - Drain zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
(If Equipped) affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
SMCS Code: 1466-543-M&S not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time
Moisture and sediment in the air starting system can or if the engine is run for short periods, the batteries
cause the following conditions: may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
• Freezing
• Corrosion of internal parts i02153996
• Malfunction of the air starting system

Battery - Replace
SMCS Code: 1401-510
When opening the drain valve, wear protective

gloves, a protective face shield, protective cloth- Batteries give off combustible gases which can
ing, and protective shoes. Pressurized air could explode. A spark can cause the combustible gas-
cause debris to be blown and result in personal es to ignite. This can result in severe personal in-
injury. jury or death.
1. Open the drain valve that is on the bottom of the Ensure proper ventilation for batteries that are in
air tank. Allow the moisture and sediment to drain. an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
2. Close the drain valve. near batteries. Do not smoke when batteries are
serviced.
3. Check the air supply pressure. The air starting
motor requires a minimum of 620 kPa (90 psi) of
air pressure to operate properly. The maximum
air pressure must not exceed 1550 kPa (225 psi).
The normal air pressure will be 758 to 965 kPa The battery cables or the batteries should not be
(110 to 140 psi). removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
i02676048
Removing the battery cables or the batteries with
Alternator - Inspect the cover in place may cause a battery explosion
resulting in personal injury.
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection 1. Turn the key start switch to the OFF position.
of the alternator. Inspect the alternator for loose Remove the key and all electrical loads.
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in 2. Turn OFF the battery charger. Disconnect the
order to ensure proper battery performance and/or charger.
proper performance of the electrical system. Make
repairs, as required. 3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the ground plane. Disconnect
the cable from the NEGATIVE “-” battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE

“+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+”
battery terminal.
54 SEBU8089-02
Maintenance Section
Battery Charger - Check
Note: Always recycle a battery. Never discard a 3. Connect the POSITIVE “+” lead of the charger
battery. Return used batteries to an appropriate to the POSITIVE “+” battery terminal. Connect
recycling facility. the NEGATIVE “-” lead of the charger to the
NEGATIVE “-” battery terminal.
5. Remove the used battery.
4. Turn ON the battery charger.
6. Install the new battery.
Overcharging of Batteries
Note: Before the cables are connected, ensure that
the key start switch is OFF. Overcharging reduces the service life of batteries.
Use a battery charger that will not overcharge the
7. Connect the cable from the starting motor to the battery. DO NOT charge the battery if the meter of
POSITIVE “+” battery terminal. the battery charger is in the RED zone.
8. Connect the cable from the ground plane to the Overcharging is indicated by the following symptoms:
NEGATIVE “-” battery terminal.
• The battery is very warm to the touch.
i01039758
• A strong odor of acid is present.
Battery Charger - Check
• The battery emits smoke or a dense vapor (gas).
SMCS Code: 1401-535
Perform one of the following procedures if the battery
shows symptoms of overcharging:
Checking Before Start-Up
• Reduce the rate of charging by a significant
Check the battery charger for proper operation. If amount. Complete the charging at the reduced
the batteries are properly charged, the needle of the rate.
ammeter will register near “0” (zero).
• Turn OFF the charger.
The battery charger must not produce excessive
current during start-up. Alternatively, the charger Table 17 describes the effects of overcharging on
must be automatically disconnected for start-up. different types of batteries.
If the engine has an alternator, the charger must
be automatically disconnected during start-up and Table 17
during engine operation. Effects of Overcharging Batteries
Charging the Battery Type of Battery Effect
Caterpillar General Service All of the battery cells have

Batteries a low level of electrolyte.
Caterpillar Premium High
Never disconnect any charging unit circuit or bat-
Output Batteries
tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an explo-
sion from the flammable vapor mixture of hydro-
gen and oxygen that is released from the elec-
When the plates of the
trolyte through the battery outlets. Injury to per- battery are inspected
sonnel can be the result. through the filler holes, the
plates may appear to be
warped. This is caused by
Perform the following procedure to charge the
an excessive temperature.
battery:
The battery may not pass
1. Ensure that the charger is turned OFF. a load test.
Caterpillar Maintenance The battery may not accept
2. Adjust the voltage of the charger in order to match Free Batteries a charging current.
the voltage of the battery.
The battery may not pass
a load test.
SEBU8089-02 55
Maintenance Section
Battery Electrolyte Level - Check
Checking After Stopping i01492654
Ensure that the battery charger is connected Battery or Battery Cable -

properly. Observe the meter of the charger. Record Disconnect
the amperage.
SMCS Code: 1402-029
i02601752
Battery Electrolyte Level -

Check The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
SMCS Code: 1401-535 tery cover should be removed before any servic-
ing is attempted.
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries Removing the battery cables or the batteries with
may not fully recharge. Ensure a full charge in order the cover in place may cause a battery explosion
to help prevent the battery from freezing. resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the

ignition switch (if equipped) to the OFF position
All lead-acid batteries contain sulfuric acid which and remove the key and all electrical loads.
can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or 2. Disconnect the negative battery terminal at the
near batteries. battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
1. Remove the filler caps. Maintain the electrolyte two batteries must be disconnected.
level to the “FULL” mark on the battery.
3. Tape the leads in order to help prevent accidental
If the addition of water is necessary, use distilled starting.
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially 4. Proceed with necessary system repairs. Reverse
softened water. the steps in order to reconnect all of the cables.
2. Check the condition of the electrolyte with the

245-5829 Coolant Battery Tester Refractometer. i01555583
3. Keep the batteries clean.

Belt Tensioner - Inspect
(If Equipped)
Clean the battery case with one of the following
cleaning solutions: SMCS Code: 1358-040
• A mixture of 0.1 kg (0.2 lb) of baking soda and

1 L (1 qt) of clean water
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L

(1 qt) of clean water
Thoroughly rinse the battery case with clean water.
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
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561 g00426964
Silicone Lubricant, petroleum jelly or MPGM. Illustration 32
Belt tensioner
56 SEBU8089-02
Maintenance Section
Belts - Inspect/Adjust
Inspect the belt tensioner for unusual noise, • If the engine is not equipped with a refrigerant
excessive looseness and/or shaking of the bearings. compressor, the alternator is used to adjust the
belt tension.
If the belt tensioner should require disassembly, refer
to the Service Manual for the procedure.
Adjustment
i02436685 Alternator Belt
Belts - Inspect/Adjust
SMCS Code: 1357-025; 1357-040
Inspection
Belt tension should be checked initially between
the first 20 to 40 hours of engine operation. Check
the tension when the engine is stopped.
After the initial check, the belt tension should be

checked at Every 250 Service Hours or Six Months.
To maximize the engine performance, inspect the g00285332

Illustration 33
belts for wear and for cracking. Replace belts that are
worn or damaged. (1) Adjusting bolt
(2) Mounting bolts
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only 1. Slightly loosen mounting bolts (2) and adjusting
one belt of a matched set will cause the new belt to bolt (1).
carry more load because the older belt is stretched.
The additional load on the new belt could cause the 2. Move the pulley in order to adjust the belt tension.
new belt to break.
3. Tighten adjusting bolt (1) and mounting bolts (2).
If the belts are too loose, vibration causes Refer to the Operation and Maintenance Manual,
unnecessary wear on the belts and pulleys. Loose “Torque Specifications” topic (Maintenance
belts may slip enough to cause overheating. Section).
If the belts are too tight, unnecessary stresses are 4. Install the belt guard.
placed on the pulley bearings and on the belts. This
may shorten the service life of the components. If new belts are installed, check the belt tension again
after 30 minutes of engine operation at the rated rpm.
Remove the belt guard. Inspect the condition and
adjustment of the alternator belts and accessory
drive belts (if equipped).
To check the belt tension, apply 110 N (25 lb ft)

of force midway between the pulleys. A correctly
adjusted belt will deflect 9 mm (0.35 inch) to 15 mm
(0.59 inch).
If the belt does not require replacement or adjustment,

install the belt guard. If the belt requires adjustment
or replacement, perform the following procedure to
adjust the belt tension.
• If the engine is equipped with a refrigerant

compressor (air conditioner), the belt for the fan
drive, the alternator, and the accessories will have
an automatic belt tensioner.
SEBU8089-02 57
Maintenance Section
Cooling System Coolant (DEAC) - Change
Water Pump Belt (IF EQUIPPED)

NOTICE
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
Note: Inspect the water pump and the water

temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
Drain
g00426869
Illustration 34
Exploded view of the drive assembly for a water pump belt
(1) Mounting bolt Pressurized System: Hot coolant can cause seri-
(2) Square hole
(3) Adjusting bolt ous burns. To open the cooling system filler cap,
1. Slightly loosen mounting bolts (1) and adjusting components are cool. Loosen the cooling system
bolt (3). pressure cap slowly in order to relieve the pres-
sure.
2. Adjust the belt tension with a square drive in
square hole (2). 1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
3. Tighten adjusting bolt (3) and mounting bolt (1). order to relieve any pressure. Remove the cooling
Refer to the Operation and Maintenance Manual, system filler cap.
“Torque Specifications” topic (Maintenance
Section). 2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
4. Install the belt guard. valve, remove one of the drain plugs.
Check the belt tension again after 30 minutes of Note: If equipped, be sure to drain the heater and
engine operation at the rated rpm if new belts are any related supply and return lines.
installed.
Allow the coolant to drain.
i02139869
NOTICE
Cooling System Coolant Dispose of used engine coolant properly or recycle.
(DEAC) - Change Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
SMCS Code: 1350-070; 1395-044 distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
Clean the cooling system and flush the cooling
system before the recommended maintenance For information regarding the disposal and the
interval if the following conditions exist: recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tool
• The engine overheats frequently. Group:
• Foaming is observed. Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
• The oil has entered the cooling system and the Canada: 1-800-523-TOOL
coolant is contaminated.
• The fuel has entered the cooling system and the Flush
coolant is contaminated.
1. Flush the cooling system with clean water in order
to remove any debris.
58 SEBU8089-02
Maintenance Section
Cooling System Coolant (DEAC) - Change
2. Close the drain valve (if equipped). Clean the 2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to drain plugs. Install the drain plugs. Refer to
the Specifications Manual, SENR3130, “Torque the Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper Specifications” for more information on the proper
torques. torques.
NOTICE NOTICE
Fill the cooling system no faster than 19 L (5 US gal) Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks. per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean 3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L Cleaner. Add 0.5 L (1 pint) of cleaner per
(4 US gal) of the cooling system capacity. Install 3.8 to 7.6 L (1 to 2 US gal) of the cooling system
the cooling system filler cap. capacity. Install the cooling system filler cap.
4. Start and run the engine at low idle for a minimum 4. Start and run the engine at low idle for a minimum
of 30 minutes. The coolant temperature should be of 90 minutes. The coolant temperature should be
at least 82 °C (180 °F). at least 82 °C (180 °F).
NOTICE NOTICE
Improper or incomplete rinsing of the cooling system Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com- can result in damage to copper and other metal com-
ponents. ponents.
To avoid damage to the cooling system, make sure To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa- to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the ter. Continue to flush the system until all signs of the
cleaning agent are gone. cleaning agent are gone.
5. Stop the engine and allow the engine to cool. 5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system drain (if equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling plugs. Allow the water to drain. Flush the cooling
system with clean water. If equipped, be sure to system with clean water. Close the drain valve
flush the heater and any related supply and return (if equipped). Clean the drain plugs. Install the
lines. Close the drain valve (if equipped). Clean drain plugs. Refer to the Specifications Manual,
the drain plugs. Install the drain plugs. Refer to SENR3130, “Torque Specifications” for more
the Specifications Manual, SENR3130, “Torque information on the proper torques.
Specifications” for more information on the proper
torques. Fill
Cooling Systems with Heavy NOTICE
Deposits or Plugging Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Note: For the following procedure to be effective,
there must be some active flow through the cooling 1. Fill the cooling system with coolant/antifreeze.
system components. Refer to the Operation and Maintenance Manual,
“Refill Capacitites and Recommendations” topic
1. Flush the cooling system with clean water in order (Maintenance Section) for more information on
to remove any debris. cooling system specifications. Do not install the
cooling system filler cap.
Note: If equipped, be sure to flush the heater and
any related supply and return lines.
SEBU8089-02 59
Maintenance Section
Cooling System Coolant (ELC) - Change
2. Start and run the engine at low idle. Increase the Drain
engine rpm to 1500 rpm. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level ous burns. To open the cooling system filler cap,
within 13 mm (0.5 inch) below the bottom of the stop the engine and wait until the cooling system
pipe for filling. Maintain the coolant level within components are cool. Loosen the cooling system
13 mm (0.5 inch) to the proper level on the sight pressure cap slowly in order to relieve the pres-
glass (if equipped). sure.
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If 1. Stop the engine and allow the engine to cool.
the gasket that is on the cooling system filler cap Loosen the cooling system filler cap slowly in
is damaged, discard the old cooling system filler order to relieve any pressure. Remove the cooling
cap and install a new cooling system filler cap. system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, perform a pressure test. A 2. Open the cooling system drain valve (if equipped).
9S-8140 Pressurizing Pump is used to perform If the cooling system is not equipped with a drain
the pressure test. The correct pressure for the valve, remove the cooling system drain plugs.
cooling system filler cap is stamped on the face of
the cooling system filler cap. If the cooling system Allow the coolant to drain.
filler cap does not retain the correct pressure,
install a new cooling system filler cap. NOTICE
Dispose of used engine coolant properly or recycle.
5. Start the engine. Inspect the cooling system for Various methods have been proposed to reclaim used
leaks and for proper operating temperature. coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
i02056152
Caterpillar to reclaim the used coolant.
Cooling System Coolant (ELC) For information regarding the disposal and the
- Change recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tool
SMCS Code: 1350-070; 1395-044 Group:
Clean the cooling system and flush the cooling Outside Illinois: 1-800-542-TOOL
system before the recommended maintenance Inside Illinois: 1-800-541-TOOL
interval if the following conditions exist: Canada: 1-800-523-TOOL
• The engine overheats frequently. Flush

• Foaming is observed. 1. Flush the cooling system with clean water in order
to remove any debris.
• The oil has entered the cooling system and the
coolant is contaminated. 2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to
• The fuel has entered the cooling system and the the Specifications Manual, SENR3130, “Torque
coolant is contaminated. Specifications” for more information on the proper
torques.
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and
replaced. NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
Note: Inspect the water pump and the water per minute to avoid air locks.
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace 3. Fill the cooling system with clean water. Install the
the water pump, the water temperature regulator and cooling system filler cap.
the hoses, if necessary.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
60 SEBU8089-02
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
5. Stop the engine and allow the engine to cool. i02482066

Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the Cooling System Coolant
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system drain
Extender (ELC) - Add
plugs. Allow the water to drain. Flush the cooling SMCS Code: 1352-045; 1395-081
system with clean water. Close the drain valve
(if equipped). Clean the drain plugs. Install the Cat ELC (Extended Life Coolant) does not require
drain plugs. Refer to the Specifications Manual, the frequent additions of any supplemental cooling
SENR3130, “Torque Specifications” for more additives which are associated with the present
information on the proper torques. conventional coolants. The Cat ELC Extender only
needs to be added once.
Fill
NOTICE
NOTICE Use only Cat Extended Life Coolant (ELC) Extender
Fill the cooling system no faster than 19 L (5 US gal) with Cat ELC.
per minute to avoid air locks.
Do NOT use conventional supplemental coolant addi-
tive (SCA) with Cat ELC. Mixing Cat ELC with conven-
1. Fill the cooling system with Extended Life Coolant tional coolants and/or conventional SCA reduces the
(ELC). Refer to the Operation and Maintenance Cat ELC service life.
Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information
on cooling system specifications. Do not install the Check the cooling system only when the engine is
cooling system filler cap. stopped and cool.
2. Start and run the engine at low idle. Increase the

engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from Personal injury can result from hot coolant, steam
the cavities of the engine block. Stop the engine. and alkali.
3. Check the coolant level. Maintain the coolant level At operating temperature, engine coolant is hot
within 13 mm (0.5 inch) below the bottom of the and under pressure. The radiator and all lines
pipe for filling. Maintain the coolant level within to heaters or the engine contain hot coolant or
13 mm (0.5 inch) to the proper level on the sight steam. Any contact can cause severe burns.
glass (if equipped).
Remove cooling system pressure cap slowly to
4. Clean the cooling system filler cap. Inspect the relieve pressure only when engine is stopped and
gasket that is on the cooling system filler cap. If cooling system pressure cap is cool enough to
the gasket that is on the cooling system filler cap touch with your bare hand.
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If Do not attempt to tighten hose connections when
the gasket that is on the cooling system filler cap is the coolant is hot, the hose can come off causing
not damaged, use a 9S-8140 Pressurizing Pump burns.
in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system Cooling System Coolant Additive contains alkali.
filler cap is stamped on the face of the cooling Avoid contact with skin and eyes.
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
cooling system filler cap.
5. Start the engine. Inspect the cooling system for

leaks and for proper operating temperature.
SEBU8089-02 61
Maintenance Section
Cooling System Coolant Level - Check
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and g00285520

Illustration 35
mandates.
Cooling system filler cap
1. Loosen the cooling system filler cap slowly in

order to relieve pressure. Remove the cooling
system filler cap.
2. It may be necessary to drain enough coolant from ous burns. To open the cooling system filler cap,
the cooling system in order to add the Cat ELC stop the engine and wait until the cooling system
Extender. components are cool. Loosen the cooling system
3. Add Cat ELC Extender according to the sure.
requirements for your engine’s cooling system
capacity. Refer to the Operation and Maintenance 1. Remove the cooling system filler cap slowly in
Manual, “Refill Capacities and Recommendations” order to relieve pressure.
article for more information.
2. Maintain the coolant level within 13 mm (0.5 inch)
4. Clean the cooling system filler cap. Inspect the of the bottom of the filler pipe. If the engine is
gaskets on the cooling system filler cap. Replace equipped with a sight glass, maintain the coolant
the cooling system filler cap if the gaskets are level to the proper level in the sight glass.
damaged. Install the cooling system filler cap.
i01197583
Cooling System Coolant Level

- Check
SMCS Code: 1395-082
Check the coolant level when the engine is stopped

and cool.
g00103639
Illustration 36
Typical filler cap gaskets
3. Clean the cooling system filler cap and check the

condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.
4. Inspect the cooling system for leaks.

62 SEBU8089-02
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
i02837191 Obtain the sample of the coolant as close as possible

to the recommended sampling interval. In order
Cooling System Coolant to receive the full effect of S·O·S analysis, you
Sample (Level 1) - Obtain must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
Note: Obtaining a Coolant Sample (Level 1) is your Caterpillar dealer.
optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems that Use the following guidelines for proper sampling of
are filled with Cat ELC should have a Coolant Sample the coolant:
(Level 2) that is obtained at the recommended interval
that is stated in the Maintenance Interval Schedule. • Complete the information on the label for the
sampling bottle before you begin to take the
Note: Obtain a Coolant Sample (Level 1) if the samples.
cooling system is filled with any other coolant
instead of Cat ELC. This includes the following • Keep the unused sampling bottles stored in plastic
types of coolants: bags.
• Commercial long life coolants that meet the • Obtain coolant samples directly from the coolant
Caterpillar Engine Coolant Specification -1 sample port. You should not obtain the samples
(Caterpillar EC-1) from any other location.
• Cat DEAC (Diesel Engine Antifreeze/Coolant) • Keep the lids on empty sampling bottles until you
are ready to collect the sample.
• Commercial heavy-duty coolant/antifreeze
• Place the sample in the mailing tube immediately
Table 18 after obtaining the sample in order to avoid
contamination.
Recommended Interval
Type of Coolant Level 1 Level 2 • Never collect samples from expansion bottles.
Every 250
Cat DEAC
Hours(1)
Yearly(1)(2) • Never collect samples from the drain for a system.
Cat ELC Optional(2) Yearly(2) Submit the sample for Level 1 analysis.
(1) This is the recommended interval for coolant samples for all
conventional heavy-duty coolant/antifreeze. This is also the For additional information about coolant analysis,
recommended interval for coolant samples of commercial see this Operation and Maintenance Manual, “Refill
coolants that meet the Cat EC-1 specification for engine Capacities and Recommendations” or consult your
coolant.
(2) The Level 2 Coolant Analysis should be performed sooner if a
Caterpillar dealer.
problem is suspected or identified.
i01987714
NOTICE
Always use a designated pump for oil sampling, and Cooling System Coolant
use a separate designated pump for coolant sampling. Sample (Level 2) - Obtain
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This SMCS Code: 1350-008; 1395-008; 1395-554; 7542
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers. NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Note: Level 1 results may indicate a need for Using the same pump for both types of samples may
Level 2 Analysis. contaminate the samples that are being drawn. This
dealers and customers.
Refer to Operation and Maintenance Manual,

“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.
SEBU8089-02 63
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
Submit the sample for Level 2 analysis. Cooling Systems that Use
For additional information about coolant
Conventional Coolant
analysis, see Special Publication, SEBU6251,
This maintenance procedure is required for
“Caterpillar Commercial Diesel Engines Fluids
conventional coolants such as DEAC.This
Recommendations” or consult your Caterpillar dealer.
maintenance is NOT required for cooling systems
that are filled with Extended Life Coolant.
i02839449
Test the Concentration of the SCA
Cooling System Supplemental
Coolant Additive (SCA) - NOTICE
Test/Add Do not exceed the recommended six percent supple-
mental coolant additive concentration.
SMCS Code: 1352-045; 1395-081
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit.
Cooling system coolant additive contains alkali. Add the SCA, If Necessary
To help prevent personal injury, avoid contact with
the skin and eyes. Do not drink cooling system
coolant additive.
ous burns. To open the cooling system filler cap,
NOTICE
Excessive supplemental coolant additive concentra-
components are cool. Loosen the cooling system
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine’s
sure.
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components. 1. Remove the cooling system filler cap slowly.
Excessive supplemental coolant additive concentra- 2. If necessary, drain some coolant in order to allow
tion could also result in blockage of the heat exchang- space for the addition of the SCA.
er, overheating, and/or accelerated wear of the water
pump seal. 3. Add the proper amount of SCA. For the
proper amount of SCA, refer to this Operation
Do not exceed the recommended amount of supple- and Maintenance Manual, “Refill Capacities
mental coolant additive concentration. and Recommendations” topic. The proper
concentration of SCA depends on the type of
coolant that is used. For the proper concentration
NOTICE of SCA, refer to Special Publication, SEBU6251,
Care must be taken to ensure that fluids are contained “Caterpillar Commercial Diesel Engine Fluids
during performance of inspection, maintenance, test- Recommendations”.
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- 4. Clean the cooling system filler cap. Install the
ing any compartment or disassembling any compo- cooling system filler cap.

Dealer Service Tool Catalog” and to Special Publica-
tion, GECJ0003, “Cat Shop Supplies and Tools” for
tools and supplies suitable to collect and contain flu-
ids on Caterpillar products.
Dispose of all fluids according to applicable regula-

tions and mandates.
Note: Caterpillar recommends an S·O·S coolant

analysis (Level 1).
64 SEBU8089-02
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Cooling Systems that Use Water i02623972
and SCA Cooling System Water

Test the Concentration of the SCA Temperature Regulator -
Replace
Test the concentration of the SCA with a 298-5311
Coolant Nitrite Test Kit for SCA or perform an S·O·S SMCS Code: 1355-510
Coolant Analysis. The test kit includes the following
items: a tool for the testing, 30 ampoules for testing Replace the water temperature regulator before
nitrite, instructions, and a case. 294-7420 Test the water temperature regulator fails. This is a
Kit contains the refill ampoules for the 298-5311 recommended preventive maintenance practice.
Coolant Nitrite Test Kit. Use the instructions that are Replacing the water temperature regulator reduces
included with the test kit in order to properly conduct the chances for unscheduled downtime.
the testing.
A water temperature regulator that fails in a
Refer to this Operation and Maintenance Manual, partially opened position can cause overheating or
“Maintenance Interval Schedule” for the times at overcooling of the engine.
which the procedures should be conducted. Test the
concentration of the SCA more frequently if more A water temperature regulator that fails in the closed
frequent testing is indicated by the results of the position can cause excessive overheating. Excessive
S·O·S Coolant Analysis. overheating could result in cracking of the cylinder
head or piston seizure problems.
NOTICE
Do not exceed the recommended eight percent sup- A water temperature regulator that fails in the open
plemental coolant additive concentration. position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
Add the SCA, If Necessary could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner.

ous burns. To open the cooling system filler cap, NOTICE
stop the engine and wait until the cooling system Failure to replace your water temperature regulator
components are cool. Loosen the cooling system on a regularly scheduled basis could cause severe
pressure cap slowly in order to relieve the pres- engine damage.
sure.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water
1. Remove the cooling system filler cap slowly. temperature regulator installed.
2. If necessary, drain some coolant in order to allow If the water temperature regulator is installed incor-
space for the addition of the SCA. rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
3. Add the proper amount of SCA. For the proper ulator is installed in the original position. Ensure that
amount of SCA, refer to this Operation and the water temperature regulator vent hole is open.
Maintenance Manual, “Refill Capacities and
Recommendations” topic. For the proper Do not use liquid gasket material on the gasket or
concentration of SCA, refer to Special Publication, cylinder head surface.
SEBU6251, “Caterpillar Commercial Diesel
Engine Fluids Recommendations”.
Refer to two articles in the Disassembly and
4. Clean the cooling system filler cap. Install the Assembly Manual, “Water Temperature Regulators
cooling system filler cap. - Remove and Water Temperature Regulators -
Install” for the replacement procedure of the water
temperature regulator, or consult your Caterpillar
dealer.
SEBU8089-02 65
Maintenance Section
Crankshaft Vibration Damper - Inspect
Note: If only the water temperature regulators are • The damper is bent.
replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator • The bolt holes are worn or there is a loose fit for
housing. the bolts.
i03175962
• The engine has had a crankshaft failure due to
torsional forces.
Crankshaft Vibration Damper Replace the damper if any of these conditions exist.
- Inspect
SMCS Code: 1205-040
Removal and Installation
Refer to this Operation and Maintenance Manual,
Damage to the crankshaft vibration damper or failure
“Belts - Inspect/Adjust/Replace” for information
of the crankshaft vibration damper can increase
on removing and on installing the belt. Refer to
torsional vibrations. This can result in damage to
the Disassembly and Assembly Manual, “Vibration
the crankshaft and to other engine components. A
Damper and Pulley - Remove and Install” for
deteriorating damper can cause excessive gear train
information on removing and installing the damper.
noise at variable points in the speed range.
The damper is mounted to the crankshaft which is i01473487

located behind the belt guard on the front of the
engine. Cylinder Head Grounding Stud
- Inspect/Clean/Tighten
SMCS Code: 7423-040; 7423-070; 7423-079
g01134779
Illustration 37
Viscous vibration damper
Typical example
g00768411
(1) Crankshaft pulley Illustration 38
(2) Weight Typical example
(3) Case
Inspect the OEM harness for good connections and
Inspection condition.
Inspect the damper for the following conditions: The electrical grounding stud must have a wire
ground to the battery. Tighten the electrical grounding
• The damper is dented, cracked, or fluid is leaking stud at every oil change. Ground wires and straps
from the damper. should be combined at engine grounds. All grounds
should be tight and free of corrosion.
• The paint on the damper is discolored from
excessive heat.
66 SEBU8089-02
Maintenance Section
Driven Equipment - Check
• If the connections are corroded, clean the • Maximum heat transfer characteristics
connections with a solution of baking soda and
water. • Ease of maintenance
• Keep the electrical grounding stud and the strap Note: Caution must be used in order to prevent
clean and coated with MPGM grease or petroleum electrical components from being damaged by
jelly. excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
starter, and the ECM.
i00174798
Driven Equipment - Check i01553486
SMCS Code: 3279-535 Engine Air Cleaner Element

Refer to the OEM specifications for more information
(Dual Element) - Clean/Replace
on the following maintenance recommendations for
SMCS Code: 1054-037; 1054-510
the driven equipment:
• Inspection NOTICE
Never run the engine without an air cleaner element
• Adjustment installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
• Lubrication damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
• Other maintenance recommendations components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
Perform any maintenance for the driven equipment
which is recommended by the OEM.
NOTICE
Never service the air cleaner element with the engine
i01646701 running since this will allow dirt to enter the engine.
Engine - Clean
SMCS Code: 1000-070
Servicing the Air Cleaner Elements
If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
Personal injury or death can result from high volt- wear. Your Caterpillar dealer has the proper air
age. cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.
Moisture can create paths of electrical conductiv-
ity. • Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt
Make sure that the electrical system is OFF. Lock and debris, as needed.
out the starting controls and tag the controls “DO
NOT OPERATE”. • Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner
element.
NOTICE
Accumulated grease and oil on an engine is a fire haz- • The air cleaner element may be cleaned up to
ard. Keep the engine clean. Remove debris and fluid six times if the element is properly cleaned and
spills whenever a significant quantity accumulates on inspected.
the engine.
• The air cleaner element should be replaced at least
Periodic cleaning of the engine is recommended. one time per year. This replacement should be
Steam cleaning the engine will remove accumulated performed regardless of the number of cleanings.
oil and grease. A clean engine provides the following
benefits:
• Easy detection of fluid leaks

SEBU8089-02 67
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Replace the dirty paper air cleaner elements with 5. Remove the tape for the turbocharger air inlet.
clean air cleaner elements. Before installation, the Install the secondary air cleaner element. Install a
air cleaner elements should be thoroughly checked primary air cleaner element that is new or cleaned.
for tears and/or holes in the filter material. Inspect
the gasket or the seal of the air cleaner element for 6. Install the air cleaner cover.
damage. Maintain a supply of suitable air cleaner
elements for replacement purposes. 7. Reset the air cleaner service indicator.
Dual Element Air Cleaners Cleaning the Primary Air Cleaner

The dual element air cleaner contains a primary Elements
air cleaner element and a secondary air cleaner
element. The primary air cleaner element can be NOTICE
used up to six times if the element is properly cleaned Caterpillar recommends certified air filter cleaning ser-
and inspected. The primary air cleaner element vices that are available at Caterpillar dealers. The
should be replaced at least one time per year. This Caterpillar cleaning process uses proven procedures
replacement should be performed regardless of the to assure consistent quality and sufficient filter life.
number of cleanings.
Observe the following guidelines if you attempt to
The secondary air cleaner element is not serviceable clean the filter element:
or washable. The secondary air cleaner element
should be removed and discarded for every three Do not tap or strike the filter element in order to re-
cleanings of the primary air cleaner element. When move dust.
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more Do not wash the filter element.
frequent replacement.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or

seals. Dirt entering the engine will cause damage to
engine components.
The primary air cleaner element can be used up

to six times if the element is properly cleaned and
inspected. When the primary air cleaner element is
Illustration 39
g00736431 cleaned, check for rips or tears in the filter material.
The primary air cleaner element should be replaced
(1) Cover
(2) Primary air cleaner element
at least one time per year. This replacement should
(3) Secondary air cleaner element be performed regardless of the number of cleanings.
(4) Turbocharger air inlet
Use clean primary air cleaner elements while dirty
1. Remove the cover. Remove the primary air elements are being cleaned.
cleaner element.
NOTICE
2. The secondary air cleaner element should be Do not clean the air cleaner elements by bumping or
removed and discarded for every three cleanings tapping. This could damage the seals. Do not use el-
of the primary air cleaner element. ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
Note: Refer to “Cleaning the Primary Air Cleaner damage could result.
Elements”.
3. Cover the turbocharger air inlet with tape in order Visually inspect the primary air cleaner elements
to keep dirt out. before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
4. Clean the inside of the air cleaner cover and body Discard any damaged air cleaner elements.
with a clean, dry cloth.
68 SEBU8089-02
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
There are two common methods that are used to Inspecting the Primary Air Cleaner
clean primary air cleaner elements: Elements
• Pressurized air
• Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
g00281693
Illustration 41
Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears
and/or holes. Inspect the primary air cleaner element
for light that may show through the filter material. If it
is necessary in order to confirm the result, compare
the primary air cleaner element to a new primary air
cleaner element that has the same part number.
g00281692
Illustration 40
Do not use a primary air cleaner element that has
Note: When the primary air cleaner elements are any tears and/or holes in the filter material. Do not
cleaned, always begin with the clean side (inside) use a primary air cleaner element with damaged
in order to force dirt particles toward the dirty side pleats, gaskets or seals. Discard damaged primary
(outside). air cleaner elements.
Aim the hose so that the air flows inside the element Storing Primary Air Cleaner Elements
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream If a primary air cleaner element that passes inspection
of air directly at the primary air cleaner element. Dirt will not be used, the primary air cleaner element can
could be forced further into the pleats. be stored for future use.
Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not remove
deposits of carbon and oil.
Note: Refer to “Inspecting the Primary Air Cleaner

Elements”. g00281694
Illustration 42
SEBU8089-02 69
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Do not use paint, a waterproof cover, or plastic as a Observe the service indicator. The air cleaner
protective covering for storage. An airflow restriction element should be cleaned or the air cleaner element
may result. To protect against dirt and damage, wrap should be replaced when one of the following
the primary air cleaner elements in Volatile Corrosion conditions occur:
Inhibited (VCI) paper.
• The yellow diaphragm enters the red zone.
Place the primary air cleaner element into a box
for storage. For identification, mark the outside of • The red piston locks in the visible position.
the box and mark the primary air cleaner element.
Include the following information: Test the Service Indicator
• Date of cleaning Service indicators are important instruments.
• Number of cleanings • Check for ease of resetting. The service indicator
should reset in less than three pushes.
Store the box in a dry location.
• Check the movement of the yellow core when the
i01900118 engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
Engine Air Cleaner Service greatest vacuum that is attained.
Indicator - Inspect If the service indicator does not reset easily, or if the
(If Equipped) yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
SMCS Code: 7452-040 service indicator will not reset, the hole for the service
indicator may be plugged.
Some engines may be equipped with a different
service indicator. The service indicator may need to be replaced
frequently in environments that are severely dusty, if
Some engines are equipped with a differential gauge necessary. Replace the service indicator annually
for inlet air pressure. The differential gauge for inlet regardless of the operating conditions. Replace the
air pressure displays the difference in the pressure service indicator when the engine is overhauled, and
that is measured before the air cleaner element and whenever major engine components are replaced.
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty, Note: When a new service indicator is installed,
the pressure differential rises. If your engine is excessive force may crack the top of the service
equipped with a different type of service indicator, indicator. Tighten the service indicator to a torque
follow the OEM recommendations in order to service of 2 N·m (18 lb in).
the air cleaner service indicator.
i01724662
The service indicator may be mounted on the air
cleaner housing or in a remote location. Engine Crankcase Breather -
Clean
SMCS Code: 1317-070
NOTICE
Perform this maintenance with the engine stopped.
NOTICE
If the crankcase breather is not maintained on a regu-
lar basis, it can become plugged. A plugged breather
will cause excessive crankcase pressure that may
cause crankshaft seal leakage.
g00103777
Illustration 43
Typical service indicator
70 SEBU8089-02
Maintenance Section
Engine Mounts - Inspect
• Deterioration of the engine mounts

• Loose mounting bolts
Any engine mount that shows deterioration should
be replaced. Refer to the Specifications Manual,
SENR3130, “Torque Specifications”. Refer to your
Caterpillar dealer for more information.
i02108396
Engine Oil Level - Check

SMCS Code: 1348-535-FLV
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
g00768439
Illustration 44
(1) Breather assembly
(2) Bolt
(3) Hose clamp
(4) Hose
1. Loosen hose clamp (3) and remove hose (4) from

breather assembly (1).
g00110310
Illustration 45
2. Remove bolt (2) and the washer. Remove the
breather assembly (1) and the seal. (Y) “ADD” mark
(X) “FULL” mark
3. Wash the breather element in solvent that is clean
and nonflammable. Allow the breather element to NOTICE
dry before installation. Perform this maintenance with the engine stopped.
4. Install a breather element that is clean and dry.

Install breather assembly (1) and the seal. 1. Maintain the oil level between “ADD” mark (Y) and
“FULL” mark (X) on the oil level gauge. Do not fill
5. Install bolt (2) and the washer. Refer the crankcase above “FULL” mark (X).
to Specifications, SENR3130, “Torque
Specifications” for the correct torque.
6. Install hose (4) on breather assembly (1).

Tighten hose clamp (3). Refer to Specifications,
SENR3130, “Torque Specifications” for the correct
torques.
i02436689
Engine Mounts - Inspect

SMCS Code: 1152-040
Inspect the engine mounts for deterioration and for

proper bolt torque. Engine vibration can be caused
by the following conditions:
• Improper mounting of the engine

SEBU8089-02 71
Maintenance Section
Engine Oil Sample - Obtain
Obtain the Sample and the Analysis

NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip-
stick).
Hot oil and hot components can cause personal
An overfull crankcase can enable the crankshaft to
contact the skin.
dip into the oil. This will reduce the power that is de-
veloped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re- Before you take the oil sample, complete the Label,
duction of the oil’s ability to lubricate, reduction of oil PEEP5031 for identification of the sample. In order
pressure, inadequate cooling of the pistons, oil blow- to help obtain the most accurate analysis, provide
ing out of the crankcase breathers, and excessive oil the following information:
consumption.
• Engine model
Excessive oil consumption will enable deposits to form
on the pistons and in the combustion chamber. De- • Service hours on the engine
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon • The number of hours that have accumulated since
under the piston rings, and wear of the cylinder liner. the last oil change
If the oil level is above the “FULL” mark on the oil level • The amount of oil that has been added since the
gauge, drain some of the oil immediately. last oil change
To ensure that the sample is representative of the

2. Remove the oil filler cap and add oil, if necessary.
oil in the crankcase, obtain a warm, well mixed oil
For the correct oil to use, see this Operation
sample.
and Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section).
To avoid contamination of the oil samples, the tools
Do not fill the crankcase above “FULL” mark (X)
and the supplies that are used for obtaining oil
on the oil level gauge. Clean the oil filler cap.
samples must be clean.
Install the oil filler cap.
Caterpillar recommends using the sampling valve
3. Record the amount of oil that is added. For the
in order to obtain oil samples. The quality and the
next oil sample and analysis, include the total
consistency of the samples are better when the
amount of oil that has been added since the
sampling valve is used. The location of the sampling
previous sample. This will help to provide the most
valve allows oil that is flowing under pressure to be
accurate oil analysis.
obtained during normal engine operation.
i01935337 The 169-8373 Fluid Sampling Bottle is

recommended for use with the sampling valve. The
Engine Oil Sample - Obtain fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
SMCS Code: 1000-008; 1348-554-SM; also provided.
7542-554-OC, SM
NOTICE
In addition to a good preventive maintenance
Always use a designated pump for oil sampling, and
program, Caterpillar recommends using S·O·S oil
use a separate designated pump for coolant sampling.
analysis at regularly scheduled intervals in order
Using the same pump for both types of samples may
to monitor the condition of the engine and the
contaminate the samples that are being drawn. This
maintenance requirements of the engine. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
dealers and customers.
If the engine is not equipped with a sampling valve,

use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
72 SEBU8089-02
Maintenance Section
Engine Oil and Filter - Change
For instructions, see Special Publication, PEHP6001, Abnormally harsh operating cycles or harsh
“How To Take A Good Oil Sample”. Consult your environments can shorten the service life of
Caterpillar dealer for complete information and the engine oil. Arctic temperatures, corrosive
assistance in establishing an S·O·S program for your environments, or extremely dusty conditions may
engine. require a reduction in engine oil change intervals from
the recommendations in Table 19. Poor maintenance
of air filters or of fuel filters requires reduced oil
i03194069
change intervals. See your Caterpillar dealer for more
Engine Oil and Filter - Change information if this product will experience abnormally
harsh operating cycles or harsh environments.
SMCS Code: 1318-510; 1348-044 Table 19
Oil Change Interval for C7 Industrial Engine (1)
Selection of Oil Change Interval
Operating Conditions
NOTICE Severe
This engine meets EPA Tier 3, Euro Stage III, or MOC Normal(2) High Fuel Altitude
Step 3 emission regulations. The standard oil change Load Sulfur above
interval is 250 hours. Oil change intervals of 500 hours Factor from 1830 m
Multigrade
are available, provided that operating conditions, rec- above 0.3% to (6000 ft)
Oil Type
ommended multigrade oil types, SOS oil sampling, 43 L 0.5%
analysis program , and IR (infrared) are used to de- (11 US (4)
termine the acceptable oil change interval. Refer to gal per
the "Optimizing Oil Change Intervals", PEDP7035 in hour of
order to determine oil changes. fuel)
(3)
If you select an interval for oil and filter change that is Cat DEO
250 hr 250 hr 250 hr 250 hr(6)
too long, you may damage the engine. Preferred
API CH-4
11.0
minimum 250 hr 250 hr 250 hr 250 hr(6)
TBN(4)
Hot oil and hot components can cause personal Preferred
contact the skin. API CH-4
TBN(4) 250 hr 250 hr 250 hr(5) 250 hr(6)
below 11.0
Caterpillar oil filters are recommended for oil API CG-4 250 hr 250 hr(5) 250 hr(5) 250 hr(6)
changes. Recommended multigrade oil types are
(1) The standard oil change interval in this engine is 250 hours,
listed in Table 19. Do not use single grade oils.
if the operating conditions and recommended oil types that
are listed in this table are met. Oil change intervals may be
increased to 500 hours, depending on the type of oil, quality and
operating conditions. Refer to Special Publication, PEDP7035,
“Optimizing Oil Change Intervals” in order to determine if the oil
change interval can be extended beyond 250 hours.
(2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine
oil. Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average
fuel consumption of your engine exceed 43 L (11 US gal) per
hour, follow the “High Load Factor” recommendations in Table
19. To determine average fuel consumption for your engine,
measure average fuel consumption for a period of 50 to 100
g00783061 hours. If the application of the engine is changed, the average
Illustration 46
fuel consumption may change.
API Trademark (4) For sulfur content above 0.5%, refer to, “Total Base Number
Commercial oils that are licensed by the American Petroleum (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel
Institute (API) bear this trademark. Commercial oils that do Engines” in Special Publication, SEBU6251, “Caterpillar
not bear this trademark are not licensed and these oils are Commercial Diesel Engine Fluids Recommendations”.
(5) In order to verify an oil change interval of 500 hours, refer to
not recommended. Oils that are not listed in Table19 are not
recommended. “Program A” below.
(6) Use “Program B” below to determine an appropriate interval.
SEBU8089-02 73
Maintenance Section
Engine Oil and Filter - Change
Adjustment of the Oil Change Interval Replace the Oil Filter

Note: Your Caterpillar dealer has additional
NOTICE
information on these programs.
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Program A
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
• Proceed to Program B. the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
• Change to a preferred oil type in Table 19. recommended by Caterpillar.
Program B
1. Remove the oil filter with a 185-3630 Strap
Optimizing Oil Change Intervals Wrench.
Begin with a 250 hour oil change interval. The oil

change intervals are adjusted by increments. Each
interval is adjusted an additional 50 hours. Periodic oil
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change
the application of the engine.
If an oil sample does not pass the analysis, shorten

the oil change interval, or change to a preferred
multigrade oil type in the listing above.
References
g00588944
Reference: Form, PEDP7035, “Optimizing Oil Illustration 47
Change Intervals” Element with debris
Reference: Form, PEDP7036, “S·O·S Fluid Analysis” 2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter . Break apart the pleats and inspect the
Reference: Form, PEDP7076, “Understanding the oil filter for metal debris. An excessive amount
S·O·S Oil Analysis Tests” of metal debris in the oil filter may indicate early
wear or a pending failure.
Drain the Engine Oil Use a magnet to differentiate between the ferrous
After the engine has been run at the normal operating metals and the nonferrous metals that are found in
temperature, stop the engine. Attach a “DO NOT the oil filter element. Ferrous metals may indicate
OPERATE” or a similar warning tag to the ignition wear on the steel and cast iron parts of the engine.
keyswitch before the engine is serviced. Catch the
oil in a suitable container. Recycle the used oil, or Nonferrous metals may indicate wear on the
dispose of the used oil properly. aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
1. Remove the oil drain plug in order to allow the oil the following items: main bearings, rod bearings,
to drain. turbocharger bearings, and cylinder heads.
2. After the oil has drained, the oil drain plug should Due to normal wear and friction, it is not
be cleaned and installed. uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
74 SEBU8089-02
Maintenance Section
Engine Storage Procedure - Check
2. Start the engine and run the engine at “LOW

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

the sump for a minimum of ten minutes.
4. Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the “ENGINE STOPPED”
side of the oil level gauge.
g00103713
Illustration 48 i02703023
Typical filter mounting base and filter gasket
Engine Storage Procedure -
3. Clean the sealing surface of the filter mounting Check
base. Ensure that all of the old oil filter gasket is
removed. SMCS Code: 1000-535
4. Apply clean engine oil to the new oil filter gasket. Caterpillar recommends storage procedures and
start-up procedures for all engines that are stored
NOTICE for more than 1 month. These procedures provide
Do not fill the oil filters with oil before installing them. maximum protection to internal engine components.
This oil would not be filtered and could be contaminat- Refer to Special Instruction, SEHS9031, “Storage
ed. Contaminated oil can cause accelerated wear to Procedure For Caterpillar Products” for information
engine components. on these procedures.
An extension of the oil change interval to 12 months

5. Install the oil filter. Tighten the oil filter until the is permitted if you follow the required procedures for
oil filter gasket contacts the base. Tighten the oil storage and start-up. This extension is permitted if the
filter by hand according to the instructions that are following intervals in the Operation and Maintenance
shown on the oil filter. Do not overtighten the oil Manual, “Maintenance Interval Schedule” have not
filter. been reached:
Fill the Engine Crankcase • Operating hours
1. Remove the oil filler cap. Fill the crankcase with • Fuel consumption
the proper amount of oil. Refer to the Operation
and Maintenance Manual, “Refill Capacities and i00869628
Recommendations” topic (Maintenance Section)
for more information. Engine Valve Lash -
Inspect/Adjust
NOTICE
If equipped with an auxiliary oil filter or system, extra SMCS Code: 1102-025
oil must be added when filling the crankcase. Follow
the OEM or filter manufacturer’s recommendations. If The initial valve lash adjustment on new engines,
the extra oil is not added, the engine may starve for rebuilt engines, or remanufactured engines is
oil. recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of
NOTICE the valve train components and to the seating of the
To help prevent crankshaft or bearing damage, crank valve train components.
engine to fill all filters before starting. Do not crank
engine for more than 30 seconds. This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
SEBU8089-02 75
Maintenance Section
Fan Drive Bearing - Lubricate
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
Operation of Caterpillar engines with improper valve

adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.
g00746166
Illustration 49
Ensure that the engine can not be started while
this maintenance is being performed. To help pre- Typical location of the grease fitting (if equipped) that is for the fan
drive bearing
vent possible injury, do not use the starting motor
to turn the flywheel. The pulley is shown with the belt guards that have been removed.
Hot engine components can cause burns. Allow Lubricate the grease fitting that is on the fan drive
additional time for the engine to cool before mea- bearing with High Speed Ball Bearing Grease or the
suring/adjusting valve lash clearance. equivalent.
Inspect the fan drive pulley assembly for wear or for

Ensure that the engine is stopped before measuring damage. If the shaft is loose, an inspection of the
the valve lash. To obtain an accurate measurement, internal components should be performed. Refer to
allow the valves to cool before this maintenance is the Systems Operation Testing and Adjusting Manual
performed. for additional information.
Refer to the Service Manual for more information.

i02113137
i02784507 Fuel System - Prime

Fan Drive Bearing - Lubricate SMCS Code: 1258-548
SMCS Code: 1359-086-BD
Some of the fan drives have grease fittings and some

Fuel leaked or spilled onto hot surfaces or elec-
of the fan drives do not have grease fittings. If there is
no grease fitting, periodic lubrication is not required. trical components can cause a fire. To help pre-
The fan drive requires grease only if the fan drive vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
is equipped with a zerk.
Clean up fuel spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
Prime the fuel system in order to fill the fuel filter.

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

• Storage
76 SEBU8089-02
Maintenance Section
Fuel System - Prime
• Replacement of the fuel filter
Engines that are Equipped with a

Fuel Priming Pump
NOTICE
Do not loosen the fuel lines at the fuel manifold. The
fittings may be damaged and/or a loss of priming pres-
sure may occur when the fuel lines are loosened.
1. Open the fuel priming pump and operate the fuel

priming pump until a strong pressure is felt. This
procedure will require considerable strokes. Lock g01076450
the fuel priming pump. Illustration 50
(1) Plug
(2) Fuel filter
NOTICE
Do not crank the engine continuously for more than 1. Remove plug (1) in order to fill fuel filter (2).
30 seconds. Allow the starting motor to cool for two Ensure that air is able to vent from the fitting of
minutes before cranking the engine again. the plug while the fuel filter is being filled. Clean
up any spilled fuel immediately. Clean plug (1).
2. Promptly start the engine. If the engine runs Install plug (1).
rough, continue to operate the engine at low idle.
Do not raise the engine rpm above an idle, until NOTICE
the engine operates smoothly. Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
3. If the engine does not start, open the fuel priming minutes before cranking the engine again.
pump and repeat Steps 1 and 2 in order to start
the engine.
2. Start the engine and operate the engine at low
idle. Do not raise the engine speed above an idle,
Engines that are Not Equipped with until the engine operates smoothly.
a Fuel Priming Pump
Fuel Filter Bases that are Not Equipped
If the engine is not equipped with a fuel priming with a Plug
pump, you can use the following procedures to prime
the fuel system. These procedures will allow only
filtered fuel to enter the fuel system. NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
Fuel Filter Bases that are Equipped with minutes before cranking the engine again.
a Plug
1. Operate the starting motor. This will fill the fuel
NOTICE filter and the fuel lines with fuel.
clean the area around a fuel system component that 2. Once the engine starts, operate the engine at low
will be disconnected. Fit a suitable cover over any dis- idle. Do not raise the engine speed above an idle,
connected fuel system components. until the engine operates smoothly.
SEBU8089-02 77
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
i02415789
NOTICE
Fuel System Primary Filter Do not allow dirt to enter the fuel system. Thoroughly
(Water Separator) Element - clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
Replace connected fuel system components.
SMCS Code: 1260-510-FQ; 1263-510-FQ
NOTICE
Water in the fuel can cause the engine to run rough. Use a suitable container to catch any fuel that might
Water in the fuel may cause a electronic unit injector spill. Clean up any spilled fuel immediately.
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval. 3. Dispose of the fuel in the fuel filter element.
Remove bowl (2) from element (1). The bowl is
The primary filter/water separator also provides reusable. Do not discard the bowl. Dispose of the
filtration in order to help extend the life of the used element.
secondary fuel filter. The element should be changed
regularly. If a vacuum gauge is installed, the primary 4. Remove the O-ring from the gland of the bowl.
filter/water separator should be changed at 50 to 70 Clean the following components:
kPa (15 to 20 inches hg).
• Bowl
Replace the Element • O-ring
• Mounting base
Fuel leaked or spilled onto hot surfaces or elec- Inspect the O-ring for damage and for
trical components can cause a fire. To help pre- deterioration. Replace the O-ring, if necessary.
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements. 5. Lubricate the O-ring with clean diesel fuel.
6. Install bowl (2) on a new element. Tighten the
bowl by hand. Do not use tools in order to tighten
Note: A 10 to 15 micron absolute high efficiency the bowl.
fuel filter is required for Caterpillar Electronic Unit
Injectors. Caterpillar High Efficiency Fuel Filters meet NOTICE
these requirements. Consult your Caterpillar dealer The primary filter/water separator may be prefilled with
for the proper part number. fuel to avoid rough running/stalling of the engine due
to air. Do not fill the secondary filter with fuel before
1. Close the main fuel supply valve. installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accel-
erated wear to fuel system parts.
7. Lubricate the top seal of element (1) with clean

diesel fuel. The element may be filled with fuel at
this time. Install the new element on the mounting
base. Tighten the element by hand.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the fu-
el system.
g00104012
Illustration 51
(1) Element. (2) Bowl. (3) Drain. 8. Open the main fuel supply valve.
2. Remove element (1) from the element mounting 9. Start the engine and check for leaks. Run the
base while bowl (2) is attached. engine for one minute. Stop the engine and check
for leaks again.
78 SEBU8089-02
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
Detection of leaks is difficult while the engine i03017650

is running. The primary filter/water separator is
under suction. A leak will allow air to enter the fuel. Fuel System Secondary Filter -
The air in the fuel can cause low power due to
aeration of the fuel. If air enters the fuel, check the
Replace
components for overtightening or under tightening. SMCS Code: 1261-510-SE
i00259781
Fuel System Primary Fuel leaked or spilled onto hot surfaces or elec-
Filter/Water Separator - Drain trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
SMCS Code: 1260-543; 1263-543 changing fuel filters or water separator elements.
NOTICE
Fuel leaked or spilled onto hot surfaces or elec- Care must be taken to ensure that fluids are contained
trical components can cause a fire. To help pre- during performance of inspection, maintenance, test-
vent possible injury, turn the start switch off when ing, adjusting and repair of the product. Be prepared to
changing fuel filters or water separator elements. collect the fluid with suitable containers before open-
Clean up fuel spills immediately. ing any compartment or disassembling any compo-

Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and

mandates.
NOTICE
clean the area around a fuel system component that
g00104007 will be disconnected. Fit a suitable cover over any dis-
Illustration 52
connected fuel system components.
(1) Element. (2) Bowl. (3) Drain.
Bowl (2) should be monitored daily for signs of water.

If water is present, drain the water from the bowl.
Contact with high pressure fuel may cause fluid
1. Open drain (3). The drain is a self-ventilated drain. penetration and burn hazards. High pressure fu-
Catch the draining water in a suitable container. el spray may cause a fire hazard. Failure to fol-
Dispose of the water properly. low these inspection, maintenance and service in-
structions may cause personal injury or death.
2. Close drain (3).
1. Stop the engine. Turn the ignition switch to the
NOTICE OFF position or disconnect the battery. Refer to
The water separator is under suction during normal the Operation and Maintenance Manual, “Battery
engine operation. Ensure that the drain valve is tight- or Battery Cable - Disconnect” topic (Maintenance
ened securely to help prevent air from entering the fuel Section) for more information. Shut off the fuel
system. supply valve (if equipped).
2. Clean the outside of the fuel filter. Remove the

used fuel filter and discard the used fuel filter.
3. Clean the gasket sealing surface of the fuel filter

base. Ensure that all of the old gasket is removed.
SEBU8089-02 79
Maintenance Section
Fuel Tank Water and Sediment - Drain
i03071053
NOTICE
In order to meet expected fuel system component
Fuel Tank Water and Sediment
life, 4 micron(c) absolute or less secondary fuel fil- - Drain
tration is required for all Caterpillar Diesel Engines
that are equipped with unit injected fuel systems. Note SMCS Code: 1273-543-M&S
that all current Caterpillar Diesel Engines are factory
equipped with Caterpillar Advanced Efficiency 4 mi- NOTICE
cron(c) absolute fuel filters. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Caterpillar does not warrant the quality or perfor- ing, adjusting and repair of the product. Be prepared to
mance of non-Caterpillar fluids and filters. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
NOTICE
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be
Dealer Service Tool Catalog” or refer to Special Pub-
contaminated. Contaminated fuel will cause acceler-
lication, PECJ0003, “Caterpillar Shop Supplies and
ated wear to fuel system parts.
Tools Catalog” for tools and supplies suitable to col-
lect and contain fluids on Caterpillar products.
4. Apply clean diesel fuel to the new fuel filter gasket.
Dispose of all fluids according to local regulations and
5. Install the new fuel filter. Spin the fuel filter onto mandates.
the fuel filter base until the gasket contacts
the base. Instructions for the installation of the
filter are printed on the side of each Caterpillar Fuel Tank
spin-on filter. For non-Caterpillar filters, refer to
the installation instructions that are provided by Fuel quality is critical to the performance and to the
the supplier of the filter. service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
6. Open the fuel supply valve. Prime the fuel system. occurs during the heating and cooling of fuel. The
Refer to the Operation and Maintenance Manual, condensation occurs as the fuel passes through the
“Fuel System - Prime” topic (Maintenance Section) fuel system and the fuel returns to the fuel tank. This
for more information. causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
7. Turn on the ignition or reconnect the battery cable. sources can help to eliminate water in the fuel.
Start the engine and inspect the fuel system for
leaks. Drain the Water and the Sediment
NOTICE Fuel tanks should contain some provision for draining
Do not crank the engine continuously for more than water and draining sediment from the bottom of the
30 seconds. Allow the starting motor to cool for two fuel tanks.
minutes before cranking the engine again.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
Check the fuel daily. Drain the water and sediment

from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
Fill the fuel tank after operating the engine in

order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
80 SEBU8089-02
Maintenance Section
Hoses and Clamps - Inspect/Replace
Some fuel tanks use supply pipes that allow water Check for the following conditions:
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that • End fittings that are damaged or leaking
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular • Outer covering that is chafed or cut
maintenance of the fuel system filter is important.
• Exposed wire that is used for reinforcement
Fuel Storage Tanks
• Outer covering that is ballooning locally
Drain the water and the sediment from the fuel
storage tank during the following conditions: • Flexible part of the hose that is kinked or crushed
• Weekly • Armoring that is embedded in the outer covering

A constant torque hose clamp can be used in place
• Oil change of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
• Refill of the tank clamp.
This will help prevent water or sediment from being
Due to extreme temperature changes, the hose will
pumped from the storage tank into the engine fuel
heat set. Heat setting causes hose clamps to loosen.
tank. A four micron(c) absolute filter for the breather
vent on the fuel tank is also recommended. Refer This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
to Special Publication, SENR9620, “Improving Fuel
System Durablity”.
Each installation application can be different. The
differences depend on the following factors:
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal • Type of hose
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the • Type of fitting material
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. • Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the
i02121526 fittings
Hoses and Clamps - Replace the Hoses and the Clamps

Inspect/Replace
SMCS Code: 7554-040; 7554-510
Inspect all hoses for leaks that are caused by the Pressurized System: Hot coolant can cause seri-
following conditions: ous burns. To open the cooling system filler cap,
• Cracking components are cool. Loosen the cooling system
• Softness sure.
• Loose clamps 1. Stop the engine. Allow the engine to cool.

Replace hoses that are cracked or soft. Tighten any 2. Loosen the cooling system filler cap slowly in
loose clamps. order to relieve any pressure. Remove the cooling
system filler cap.
NOTICE
Do not bend or strike high pressure lines. Do not in- Note: Drain the coolant into a suitable, clean
stall bent or damaged lines, tubes or hoses. Repair container. The coolant can be reused.
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes 3. Drain the coolant from the cooling system to a
and hoses carefully. Tighten all connections to the rec- level that is below the hose that is being replaced.
ommended torque.
4. Remove the hose clamps.
SEBU8089-02 81
Maintenance Section
Jacket Water Heater - Check
5. Disconnect the old hose. • The quality of the fuel that is being used
6. Replace the old hose with a new hose. • The operating conditions
7. Install the hose clamps with a torque wrench. • The results of the S·O·S analysis
Note: Refer to the Specifications, SENR3130, Oil Consumption as an Overhaul
“Torque Specifications” in order to locate the proper
torques. Indicator
8. Refill the cooling system. Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
9. Clean the cooling system filler cap. Inspect the operating cost for your Caterpillar engine. Oil
cooling system filler cap’s gaskets. Replace consumption can also be used to estimate the
the cooling system filler cap if the gaskets are required capacity of a makeup oil tank that is suitable
damaged. Install the cooling system filler cap. for the maintenance intervals.
10. Start the engine. Inspect the cooling system for Oil consumption is in proportion to the percentage
leaks. of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
consumed per hour also increases.
i01042517
Jacket Water Heater - Check The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC)
SMCS Code: 1383-535
depends on the engine load. Consult your Caterpillar
Jacket water heaters help to improve startability in dealer for assistance in determining the typical oil
consumption rate for your engine.
ambient temperatures that are below 21 °C (70 °F).
All installations that require automatic starting should
have jacket water heaters. When an engine’s oil consumption has risen to three
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
Check the operation of the jacket water heater. For
an ambient temperature of 0 °C (32 °F), the heater There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
should maintain the jacket water temperature at
approximately 32 °C (90 °F).
Overhaul Options
i02436705 Before Failure Overhaul
Overhaul Considerations A planned overhaul before failure may be the best
value for the following reasons:
SMCS Code: 7595-043
Reduced hours of operation at full load will result in • Costly unplanned downtime can be avoided.
a lower average power demand and reduced fuel
consumption. A decreased average power demand
• Many original parts can be reused according to the
standards for reusable parts.
should increase both the engine service life and the
overhaul interval.
• The engine’s service life can be extended without
the risk of a major catastrophe due to engine
The need for an overhaul is generally indicated failure.
by increased fuel consumption, increased oil
consumption, excessive engine blowby, and
reduced power. Arctic temperatures, extremely high • The best cost/value relationship per hour of
extended life can be attained.
temperatures, corrosive environments, or extremely
dusty conditions contribute to premature wear and After Failure Overhaul
the need for an overhaul.
If a major engine failure occurs and the engine
The following factors are important when a decision must be removed, many options are available. An
is being made on the proper time for an engine overhaul should be performed if the engine block or
overhaul: the crankshaft needs to be repaired.
• The need for preventive maintenance
82 SEBU8089-02
Maintenance Section
Overhaul Considerations
If the engine block is repairable and/or the crankshaft • Costly repairs

is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine • Damage to other engine parts
with a similar exchange core.
• Reduced engine efficiency
This lower cost can be attributed to three aspects:
• Increased fuel consumption
• Specially designed Caterpillar engine features
Reduced engine efficiency and increased fuel
• Caterpillar dealer exchange components consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing
• Caterpillar Inc. remanufactured exchange out-of-spec parts or replacing out-of-spec parts.
components
Inspection and/or Replacement
Overhaul Recommendation
Crankshaft Bearings, Valve Rotators, and
To minimize downtime, Caterpillar Inc. recommends Crankshaft Seals
a scheduled engine overhaul by your Caterpillar
dealer before the engine fails. This will provide you The following components may not last until the
with the best cost/value relationship. second overhaul.
Note: Overhaul programs vary according to the • Thrust bearings

engine application and according to the dealer that
performs the overhaul. Consult your Caterpillar • Main bearings
dealer for specific information about the available
overhaul programs and about overhaul services for • Rod bearings
extending the engine life.
• Valve rotators
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the following • Crankshaft seals
maintenance recommendations.
Caterpillar Inc. recommends the installation of new
parts at each overhaul period.
Rebuild or Exchange
Inspect these parts while the engine is disassembled
Cylinder Head Assembly, Cylinder Packs, Oil
for an overhaul.
Pump, and Fuel Transfer Pump
Inspect the crankshaft for any of the following
These components should be inspected according to
conditions:
the instructions that are found in various Caterpillar
reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are • Deflection
needed for inspecting the engine parts.
• Damage to the journals
If the parts comply with the established inspection
specifications that are expressed in the reusable • Bearing material that has seized to the journals
parts guideline, the parts should be reused.
Check the journal taper and the profile of the
crankshaft journals. Check these components by
Parts that are not within the established inspection
specifications should be dealt with in one of the interpreting the wear patterns on the following
components:
following manners:
• Salvaging • Rod bearing
• Repairing • Main bearings

Inspect the camshaft for damage to the journals and
• Replacing to the lobes.
Using out-of-spec parts can result in the following
Note: If the camshaft is removed for any reason, use
problems:
the magnetic particle inspection process to check for
cracks in the camshaft.
• Unscheduled downtime
SEBU8089-02 83
Maintenance Section
Overhaul Considerations
Inspect the following components for signs of wear or 5. Wash the oil cooler core with hot, soapy water.
for signs of scuffing: Rinse the oil cooler core thoroughly with clean
water.
• Camshaft bearings
• Camshaft followers
Personal injury can result from air pressure.
Caterpillar Inc. recommends replacing the crankshaft
vibration damper. Personal injury can result without following prop-
Oil Cooler Core tective face shield and protective clothing.
During an overhaul, Caterpillar Inc. recommends the Maximum air pressure at the nozzle must be less
removal of the oil cooler core. Clean the oil cooler than 205 kPa (30 psi) for cleaning purposes.
core. Then, pressure test the oil cooler core.
NOTICE 6. Dry the oil cooler core with compressed air. Direct
Do not use caustic cleaners to clean the core. the air in the reverse direction of the normal flow.
Caustic cleaners can attack the internal metals of the 7. Inspect the components in order to ensure
core and cause leakage. cleanliness. The oil cooler core should be
pressure tested. Repair the oil cooler core, if
necessary. Install the oil cooler core.
Note: Use this cleaning procedure to clean the oil
cooler core. For more information about cleaning the cores,
consult your Caterpillar dealer.
1. Remove the oil cooler core.
Obtain Coolant Analysis
2. Remove any debris from the oil cooler core. To
remove debris from the oil cooler core, turn the oil The concentration of supplemental coolant additive
cooler core onto one end. (SCA) should be checked regularly with test kits
or with S·O·S Coolant Analysis (Level 1). Further
3. Flush the oil cooler core internally with cleaner in coolant analysis is recommended when the engine
order to loosen foreign substances. This will also is overhauled.
help to remove oil from the oil cooler core.
For example, considerable deposits are found in the
Note: Caterpillar Inc. recommends the use of water jacket areas on the external cooling system, but
Hydrosolv Liquid Cleaners. Table 20 lists the the concentrations of coolant additives were carefully
Hydrosolv Liquid Cleaners that are available from maintained. The coolant water probably contained
your Caterpillar dealer. minerals that were deposited on the engine over time.
Table 20
A coolant analysis can be conducted in order to verify
HydrosolvLiquid Cleaners the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
Part
Number
Description Size by consulting your local water utility company or
an agricultural agent. Private laboratories are also
1U-8812 4 L (1 US gallon) available for water analysis.
1U-5490 Hydrosolv4165 19 L (5 US gallon)
Caterpillar Inc. recommends an S·O·S Coolant
8T-7570 208 L (55 US gallon) Analysis (Level 2).
1U-8804 4 L (1 US gallon)
S·O·S Coolant Analysis (Level 2)
1U-5492 Hydrosolv100 19 L (5 US gallon)
8T-5571 208 L (55 US gallon)
An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
4. Use steam to clean the oil cooler core. This system. An S·O·S Coolant Analysis (Level 2) provides
removes any remaining residue from the cleaner. the following information:
Flush the fins of the oil cooler core. Remove any
other trapped debris. • Complete S·O·S Coolant Analysis (Level 1)
84 SEBU8089-02
Maintenance Section
Power Take-Off Clutch - Check/Adjust/Lubricate
• Visual inspection of properties Refer to the OEM information and instruction plate
(1) for instructions on lubrication, adjustment, and
• Identification of metal corrosion other recommendations for service. Perform the
maintenance that is specified on the instruction plate.
• Identification of contaminants
• Identification of built up impurities (corrosion and
scale)
Do not operate the engine with the Instruction
S·O·S Coolant Analysis (Level 2) provides a report of Plate cover removed from the clutch. Personal
the results of both the analysis and the maintenance injury may result.
recommendations.
If the clutch is damaged to the point of burst fail-
For more information about coolant analysis, see ure, expelled pieces can cause personal injury to
your Caterpillar dealer. anyone in the immediate area. Proper safeguards
must be followed to help prevent accidents.
i01506009
Power Take-Off Clutch - i02559063
Check/Adjust/Lubricate Radiator - Clean

SMCS Code: 3055-036; 3055-086 SMCS Code: 1353-070
Note: Adjust the frequency of cleaning according to

NOTICE the effects of the operating environment.
New power take-offs should have the clutch adjust-
ment checked before being placed into service. The Inspect the radiator for these items: damaged fins,
clutch adjustment should be checked again after the corrosion, dirt, grease, insects, leaves, oil, and other
first ten hours of operation. New clutch plates have a debris. Clean the radiator, if necessary.
“wear in” period, and the clutch may require several
adjustments until the new plates are “worn in”.
Personal injury can result from air pressure.
Personal injury can result without following prop-

tective face shield and protective clothing.
The maximum air pressure for cleaning purposes

must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction
of the fan’s air flow. Hold the nozzle approximately
g00781502
Illustration 53 6 mm (0.25 inch) away from the fins. Slowly move the
(1) Instruction plate air nozzle in a direction that is parallel with the tubes.
(2) Serial number plate This will remove debris that is between the tubes.
Check the clutch adjustment regularly after “wear in”. Pressurized water may also be used for cleaning.
Heavy-duty applications which have engagements The maximum water pressure for cleaning purposes
that are frequent and relatively long periods of must be less than 275 kPa (40 psi). Use pressurized
clutch slippage require more frequent adjustment water in order to soften mud. Clean the core from
than light-duty applications. The operating torque both sides.
should be measured in order to determine if a clutch
adjustment is required. Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
SEBU8089-02 85
Maintenance Section
Severe Service Application - Check
After cleaning, start the engine and accelerate the The operating environment, improper operating
engine to high idle rpm. This will help in the removal procedures and improper maintenance procedures
of debris and drying of the core. Stop the engine. can be factors which contribute to severe service
Use a light bulb behind the core in order to inspect conditions.
the core for cleanliness. Repeat the cleaning, if
necessary.
Environmental Factors
Inspect the fins for damage. Bent fins may be opened
Ambient temperatures – The engine may be
with a “comb”. Inspect these items for good condition:
exposed to extended operation in extremely
welds, mounting brackets, air lines, connections, cold environments or hot environments. Valve
clamps, and seals. Make repairs, if necessary.
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
For more detailed information on cleaning and cold temperatures. Extremely hot inlet air reduces
inspection, refer to Special Publication, SEBD0518,
engine performance.
“Know Your Cooling System”.
Air Quality – The engine may be exposed to
i00151038 extended operation in an environment that is dirty
or dusty, unless the equipment is cleaned regularly.
Severe Service Application - Mud, dirt and dust can encase components.
Check Maintenance can be very difficult. The buildup can
contain corrosive chemicals.
SMCS Code: 1000-535
Buildup – Compounds, elements, corrosive
chemicals and salt can damage some components.
Severe service is an application of an engine that
exceeds current published standards for that engine.
Altitude – Problems can arise when the engine is
Caterpillar maintains standards for the following
operated at altitudes that are higher than the intended
engine parameters:
settings for that application. Necessary adjustments
should be made.
• Performance (power range, speed range, and fuel
consumption)
Improper Operating Procedures
• Fuel quality
• Extended operation at low idle
• Altitude range
• Frequent hot shutdowns
• Maintenance intervals
• Operating at excessive loads
• Oil selection and maintenance
• Operating at excessive speeds
• Coolant selection and maintenance
• Operating outside the intended application
• Environmental qualities
Improper Maintenance Procedures
• Installation
Refer to the standards for the engine or consult with • Extending the maintenance intervals
your Caterpillar dealer in order to determine if the
engine is operating within the defined parameters. • Failure to use recommended fuel, lubricants and
coolant/antifreeze
Severe service operation can accelerate component
wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention of
full service life.
Due to individual applications, it is not possible to

identify all of the factors which can contribute to
severe service operation. Consult your Caterpillar
dealer for the unique maintenance that is necessary
for the engine.
86 SEBU8089-02
Maintenance Section
Starting Motor - Inspect
i02740889 • Corrosion
Starting Motor - Inspect • Wires that are worn or frayed
(If Equipped)
• Cleanliness
SMCS Code: 1451-040; 1453-040
Make repairs, if necessary.
Note: The OEM may be responsible for the starting
motor for this engine application. Air starting motors Removal and Installation of the
are recommended if an explosive atmosphere may
be present. If the starting motor is supplied by an Starting Motor
OEM, refer to the Service Manual for the starter in
order to locate additional information on the checking Refer to the Service Manual, “Disassembly and
procedure and for specifications. Assembly” module for information on removing the
starting motor and installing the starting motor.
Consult your Caterpillar dealer for assistance.
The connection of battery cables to a battery and

the disconnection of battery cables from a battery i01539769
may cause an explosion which may result in injury

or death. The connection and the disconnection
Turbocharger - Inspect
of other electrical equipment may also cause an SMCS Code: 1052-040; 1052
explosion which may result in injury or death. The
procedures for the connection and the disconnec- Periodic inspection and cleaning is recommended
tion of battery cables and other electrical equip- for the turbocharger compressor housing (inlet side).
ment should only be performed in a nonexplosive Any fumes from the crankcase are filtered through
atmosphere. the air inlet system. Therefore, by-products from oil
and from combustion can collect in the turbocharger
If the starting motor fails, the engine may not start in compressor housing. Over time, this buildup can
an emergency situation. A scheduled inspection of contribute to loss of engine power, increased black
the starting motor is recommended. smoke and overall loss of engine efficiency.
The starting motor pinion and the flywheel ring gear If the turbocharger fails during engine operation,
must be in good condition in order for the engine damage to the turbocharger compressor wheel
to start properly. The engine will not start if the and/or to the engine may occur. Damage to the
starting motor pinion does not engage the flywheel turbocharger compressor wheel can cause additional
ring gear. The teeth of the starting motor pinion and damage to the pistons, the valves, and the cylinder
the flywheel ring gear can be damaged because of head.
irregular engagement.
NOTICE
Inspect the starting motor for proper operation. Listen Turbocharger bearing failures can cause large quan-
for grinding when the engine is started. Inspect the tities of oil to enter the air inlet and exhaust systems.
teeth of the starting motor pinion and the flywheel Loss of engine lubricant can result in serious engine
ring gear. Look for patterns of wear on the teeth. Look damage.
for teeth that are broken or chipped. If damaged teeth
are found, the starting motor pinion and the flywheel Minor leakage of a turbocharger housing under ex-
ring gear must be replaced. tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc-
Electric Starting Motor curred.
Note: Problems with the electric starting motor can When a turbocharger bearing failure is accompanied
be caused by the following conditions: malfunction of by a significant engine performance loss (exhaust
the solenoid and malfunction of the electric starting smoke or engine rpm up at no load), do not continue
system. engine operation until the turbocharger is repaired or
replaced.
Inspect the electrical system for the following
conditions:
• Loose connections
SEBU8089-02 87
Maintenance Section
Walk-Around Inspection
An inspection of the turbocharger can minimize 5. Inspect the bore of the turbine housing for
unscheduled downtime. An inspection of the corrosion.
turbocharger can also reduce the chance for potential
damage to other engine parts. 6. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.
Note: Turbocharger components require precision
clearances. The turbocharger cartridge must 7. Fasten the air inlet piping and the exhaust outlet
be balanced due to high rpm. Severe Service piping to the turbocharger housing.
Applications can accelerate component wear.
Severe Service Applications require more frequent
i01185304
inspections of the cartridge.
Walk-Around Inspection
Removal and Installation
SMCS Code: 1000-040
For options regarding the removal, installation, repair
and replacement, consult your Caterpillar dealer. Inspect the Engine for Leaks and
Refer to the Service Manual for this engine for the
procedure and specifications. for Loose Connections
A walk-around inspection should only take a few
Cleaning and Inspecting minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually For maximum engine service life, make a thorough
inspect the piping for the presence of oil. Clean inspection of the engine compartment before starting
the interior of the pipes in order to prevent dirt the engine. Look for items such as oil leaks or coolant
from entering during reassembly. leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
turbocharger housing. If there is any indication of contamination.
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned. NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
3. Check the compressor wheel for cleanliness. fluid. If leaking is observed, find the source and correct
If only the blade side of the wheel is dirty, dirt the leak. If leaking is suspected, check the fluid levels
and/or moisture is passing through the air filtering more often than recommended until the leak is found
system. If oil is found only on the back side of the or fixed, or until the suspicion of a leak is proved to be
wheel, there is a possibility of a failed turbocharger unwarranted.
oil seal.
NOTICE
The presence of oil may be the result of extended Accumulated grease and/or oil on an engine or deck is
engine operation at low idle. The presence of oil a fire hazard. Remove this debris with steam cleaning
may also be the result of a restriction of the line for or high pressure water.
the inlet air (plugged air filters), which causes the
turbocharger to slobber.
• Ensure that the cooling lines are properly clamped
4. Use a dial indicator to check the end clearance and that the cooling lines are tight. Check for leaks.
on the shaft. If the measured end play is greater Check the condition of all pipes.
than the Service Manual specifications, the
turbocharger should be repaired or replaced. • Inspect the water pumps for coolant leaks.
An end play measurement that is less than the
minimum Service Manual specifications could Note: The water pump seal is lubricated by coolant
indicate carbon buildup on the turbine wheel. The in the cooling system. It is normal for a small amount
turbocharger should be disassembled for cleaning of leakage to occur as the engine cools down and
and for inspection if the measured end play is less the parts contract.
than the minimum Service Manual specifications.
88 SEBU8089-02
Maintenance Section
Water Pump - Inspect
Excessive coolant leakage may indicate the need • Cracks in the cylinder head
to replace the water pump seal. For the removal of
water pumps and the installation of water pumps • A piston seizure
and/or seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer. • Other potential damage to the engine
• Inspect the lubrication system for leaks at the front Visually inspect the water pump for leaks. If any
crankshaft seal, the rear crankshaft seal, the oil leaking is observed, replace the water pump seal
pan, the oil filters and the valve cover. or the water pump assembly. Refer to the Service
Manual for the disassembly and assembly procedure.
• Inspect the fuel system for leaks. Look for loose
fuel line clamps or for loose fuel line tie-wraps. Note: Refer to the Service Manual or consult your
Caterpillar dealer if any repair is needed or any
• Inspect the piping for the air inlet system and the replacement is needed.
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
• Inspect the alternator belt and the accessory drive

belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced as

matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
• Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.
• Inspect the ground strap for a good connection and

for good condition.
• Inspect the ECM to the cylinder head ground strap

for a good connection and for good condition.
• Disconnect any battery chargers that are not

protected against the current drain of the starting
motor. Check the condition and the electrolyte level
of the batteries, unless the engine is equipped with
a maintenance free battery.
• Check the condition of the gauges. Replace any

gauges that are cracked. Replace any gauge that
can not be calibrated.
i01057943
Water Pump - Inspect

SMCS Code: 1361-040; 1361
A failed water pump might cause severe engine

overheating problems that could result in the following
conditions:
SEBU8089-02 89
Warranty Section
Warranty Information
Warranty Section
Warranty Information
i01087950
Emissions Warranty
Information
SMCS Code: 1000
This engine may be certified to comply with exhaust

emission standards and gaseous emission standards
that are prescribed by law at the time of manufacture,
and this engine may be covered by an Emissions
Warranty. A detailed explanation of the Emissions
Warranty that is applicable to emissions certified
engines is found in Supplement, SEBU6981, “Federal
Emissions Control Warranty Information”. Consult
your authorized Caterpillar dealer to determine if your
engine is emissions certified and if your engine is
subject to an Emissions Warranty.
90 SEBU8089-02
Engine Ratings
Reference Information i00819749
Section Engine Rating Definitions

SMCS Code: 1000
Engine Ratings It is important to know the use of the engine so

that the rating will match the operating profile. The
proper rating selection is also important so that the
i00727327 customer’s perception of price and value is realized.
Engine Rating Conditions In selecting a rating for a specific application, the
most important consideration is the time that is spent
SMCS Code: 1000 at full throttle. These rating definitions identify the
percent of time at full throttle. The definitions also
All engine ratings are in compliance with the following identify the corresponding times below rated rpm.
standard ambient air conditions of “SAE J1349”:
Note: The examples of the applications are only
• 99 kPa (29.3 inches of Hg) for reference. For an exact determination of the
appropriate rating, follow the OEM specifications or
• 30 percent relative humidity consult your Caterpillar dealer.
• A temperature of 25 °C (77 °F) A Rating – This rating is used for heavy-duty

applications that are operated at rated load and at
Ratings relate to the standard conditions of rated rpm up to 100 percent. This rating is used for
“ISO8665”, of “ISO3046/1”, of “DIN6271”, and of engines that operate without interruption of load
“BS5514”. cycling. Typical applications include the following
examples: pipeline pumping and ventilation.
The engine ratings are based on the following fuel
specifications: B Rating – This rating is used when power and/or
rpm are cyclic. The engine should be run at full load.
• Low heat value (LHV) of the fuel of 42 780 kJ/kg The engine should not exceed 80 percent of the
(18,390 Btu/lb) at 29 °C (84 °F) duty cycle. Typical applications include the following
examples: irrigation, operation where normal pump
• Gravity (API) of 35 degrees at 15 °C (60 °F) demand is 85 percent of the engine rating, oil
pumping/drilling, field mechanical pumping/drilling,
• Specific gravity of .849 at 15 °C (60 °F) and stationary/plant air compressors.
• Density of 850 kg/m3 (7.085 lb/US gal) C Rating – This rating is used when power and/or
rpm are cyclic. The horsepower and the rpm of the
The engine ratings are gross output ratings. engine can be utilized continuously for one hour. This
is followed by one hour of operation at the A rating
Gross Output Ratings – The total output capability or below the A rating. The engine should be run at
of the engine that is equipped with standard full load. The engine should not exceed 50 percent
accessories. of the duty cycle. Typical applications include the
following examples: agricultural tractors, harvesters
Standard accessories include the following and combines, off-highway trucks, fire pumps, blast
components: hole drills, rock curshers, wood chippers with high
torque rise, and oil field hoisting.
• Oil pumps
D Rating – This rating is used when rated power
• Fuel pumps is required for periodic overloads. The maximum
horsepower and the rpm of the engine can be utilized
• Water pumps continuously for a maximum of 30 minutes. This is
followed by one hour of operation at the C rating. The
Subtract the power that is required to drive auxiliary engine should be run at full load. The engine should
components from the gross output. This will produce not exceed 10 percent of the duty cycle. Typical
the net power that is available for the external load applications include the following examples: offshore
(flywheel). cranes, runway snow blowers, water well drills,
portable air compressors, and fire pump certification
power.
SEBU8089-02 91
Engine Ratings
E Rating – This rating is used when rated power

is required for a short time for initial starting or
for sudden overload. The rating is also used for
emergency service when standard power is not
available. The horsepower and the rpm of the engine
can be utilized continuously for a maximum of 15
minutes. This is followed by one hour of operation
at the C rating or by the duration of the emergency.
The engine should be run at full load. The engine
should not exceed 5 percent of the duty cycle. Typical
applications include the following examples: standby
centrifugal water pumps, oil field well servicing, crash
trucks, portable air compressors, and gas turbine
starting motors.
NOTICE
Operating engines above the rating definitions can re-
sult in shorter service life before overhaul.
92 SEBU8089-02
Customer Service
Customer Service Latin America, Mexico, Carribean

Caterpillar Americas Co.
701 Waterford Way, Suite 200
i03201484 Miami, FL 33126-4670
USA
Customer Assistance Phone: 305-476-6800
Fax: 305-476-6801
SMCS Code: 1000
Europe, Africa, and Middle East
USA and Canada Caterpillar Overseas S.A.
76 Route de Frontenex
When a problem arises concerning the operation of P.O. Box 6000
an engine or concerning the service of an engine, CH-1211 Geneva 6
the problem will normally be managed by the dealer Switzerland
in your area. Phone: 22-849-4444
Fax: 22-849-4544
Your satisfaction is a primary concern to Caterpillar
and to Caterpillar dealers. If you have a problem that Far East
has not been handled to your complete satisfaction, Caterpillar Asia Pte. Ltd.
follow these steps: 7 Tractor Road
Jurong, Singapore 627968
1. Discuss your problem with a manager from the Republic of Singapore
dealership. Phone: 65-662-8333
Fax: 65-662-8302
2. If your problem cannot be resolved at the dealer
level without additional assistance, use the phone China
number that is listed below to talk with a Field Caterpillar China Ltd.
Service Coordinator: 37/F., The Lee Gardens
33 Hysan Avenue
1-800-447-4986 Causeway Bay
G.P.O. Box 3069
The normal hours are from 8:00 to 4:30 Monday Hong Kong
through Friday Central Standard Time. Phone: 852-2848-0333
Fax: 852-2848-0440
3. If your needs have not been met still, submit the
matter in writing to the following address: Japan
Shin Caterpillar Mitsubishi Ltd.
Caterpillar Inc. SBS Tower
Marine Center of Excellence 10-1, Yoga 4-Chome
Manager, Customer Service Setagaya-Ku, Tokyo 158-8530
111 Southchase Blvd Japan
Fountain Inn, SC 29644 Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Please keep in mind: probably, your problem will
ultimately be solved at the dealership, using the Japan
dealership’s facilities, equipment, and personnel. Caterpillar Power Systems, Inc.
Therefore, follow the steps in sequence when a SBS Tower (14th floor)
problem is experienced. 4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Phone: 81-3-5797-4300
Outside of the USA and of Canada Fax: 81-3-5797-4359
If a problem arises outside the USA and outside Australia and New Zealand
Canada, and if the problem cannot be resolved at the Caterpillar of Australia Ltd.
dealer level, consult the appropriate Caterpillar office. 1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
SEBU8089-02 93
Customer Service
i01028392
Ordering Replacement Parts

SMCS Code: 7567
When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers’ parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following

information:
• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance

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

dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
94 SEBU8089-02
Reference Materials
Reference Materials • Special Publication, PEHP0002, “Data Sheet

- Multipurpose Lithium Complex Grease with
Molybdenum (MPGM)”
i02414607
• Special Publication, PEHP0017, “Data Sheet -
Reference Material Special Purpose Grease (SPG) Bearing Lubricant”
SMCS Code: 1000
• Special Publication, NEHP5621, “How To Select
The Right Grease For Any Job”
The following literature can be obtained through any
Caterpillar dealer.
• Special Publication, PEHP6001, “How To Take A
Good Oil Sample”
Coolants
• Special Publication, SEBD0640, “Oil and Your
• Special Publication, SEBD0970, “Coolant and Your Engine”
Engine”
• Special Publications, PEDP7036, “S·O·S Fluids
• Special Publication, PEHP4036, “Data Sheet- Analysis Cornerstone”
Extended Life Coolant”
Miscellaneous
• Special Publication, SEBD0518, “Know Your
Cooling System”
• Service Manual, RENR9800, “C7 Industrial Engine
Service Manual”
• Special Publication, PEEP5027, “Label - ELC
Radiator Label”
• Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids
• Special Publication, PEHP7057, “S·O·S Coolant Recommendations For Lubricants, Diesel
Analysis” Fuel, and Coolants”
Fuels • Special Publication, PECP9067, “One Safe

Source”
• Special Publication, SENR9620, “Improving Fuel
System Durability” • Special Instruction, SMHS7001, “Assembly of Fan
Drive Pulley Assemblies”
• Special Publication, SEBD0717, “Diesel Fuels and
Your Engine” • Special Instruction, SEHS7633, “Battery Test
Procedure”
Lubricants • Special Publication, SEBF8062, “Guideline for
Reusable Parts - Procedure to Inspect and Clean
• Special Publication, PEDP7035, “Optimizing Oil Air Filters”
Change Intervals”
• Special Publication, SEBF8029, “Index to
• Special Publication, PEHP8038, “Data Sheet - Guidelines for Reusable Parts and Salvage
Caterpillar Diesel Engine Oils (DEO) (CH-4, CG-4, Operations”
CF-4) (North America and Australia)”
• Special Publication, PEDP0026, “Power Analysis
• Special Publication, PEHP7041, “Product Data Report”
Sheet for Caterpillar Diesel Engine Oils (DEO)”
CG-4 engine oils (International markets)
• Special Publication, NEHS0526, “Service
Technology Application Guide”
• Special Publication, PEWP3014, “Cat Fluids
Selector Dial (International)”
• Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”
• Special Publication, PEWP9733, “Cat Fluids
Selector Dial (North America)”
• Specifications, SENR3130, “Torque Specifications
Module”
• Special Publication, NEDG6022, “Data Sheet -
Multipurpose Lithium Complex Grease (MPG)”
• Special Instruction, SEHS8742, “Using the 8T-8697
Electronic Control Analyzer Programmer (ECAP)”
SEBU8089-02 95
Reference Materials
• Special Instruction, SEHS8622, “Using the FT- International Organization for Standardization
1984 Air-To-Air Aftercooler Leak Test Group” (ISO)
1, rue de Varembé
• Special Instruction, SEHS7332, “Warning Tag - Case postale 56
Danger Do Not Operate” CH-1211 Genève 20
Switzerland
• Special Instruction, REHS0871, “Electronic Telephone: +41 22 749 01 11
Installation Guide”. Facsimile: +41 22 733 34 30
E-mail: central@iso.ch
Additional Reference Material Web site: http://www.iso.ch
European classifications are established by the

The “Engine Fluids Data Book” can be obtained from
the following locations: local technological society, Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
local library, and local college. If necessary, consult
Engines).
EMA at the following address:
CIMAC Central Secretariat
Engine Manufacturers Association
Lyoner Strasse 18
Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602 60528 Frankfurt
Germany
E-mail: ema@enginemanufacturers.org
Telephone: +49 69 6603 1567
(312) 827-8700
Facsimile: (312) 827-8737 Facsimile: +49 69 6603 1566
The “Society of Automotive Engineers (SAE) i00912149

Specifications” can be found in your SAE handbook.
This publication can also be obtained from the Maintenance Records
following locations: local technological society, local
library, and local college. If necessary, consult SAE SMCS Code: 1000
at the following address:
Caterpillar Inc. recommends the retention of accurate
SAE International maintenance records. Accurate maintenance records
400 Commonwealth Drive can be used for the following purposes:
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841 • Determine operating costs.
The “American Petroleum Institute Publication No. • Establish maintenance schedules for other engines
1509” can be obtained from the following locations: that are operated in the same environment.
local technological society, local library, and local
college. If necessary, consult API at the following • Show compliance with the required maintenance
address: practices and maintenance intervals.
American Petroleum Institute Maintenance records can be used for a variety of

1220 L St. N.W. other business decisions that are related to engine
Washington, DC, USA 20005 maintenance.
Telephone: (202) 682-8000
Maintenance records are a key element of a
The International Organization for Standardization maintenance program that is well managed. Accurate
(ISO) offers information and customer service maintenance records can help your Caterpillar dealer
regarding international standards and standardizing to fine tune the recommended maintenance intervals
activities. ISO can also supply information on the in order to meet the specific operating situation. This
following subjects that are not controlled by ISO: should result in a lower engine operating cost.
national standards, regional standards, regulations,
certification, and related activities. Consult the Records should be kept for the following items:
member of ISO in your country.
Fuel Consumption – A record of fuel consumption
is essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul
intervals.
96 SEBU8089-02
Reference Materials
Service Hours – A record of service hours is

essential to determine when the speed sensitive
components should be inspected or repaired.
Documents – These items should be easy to

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

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

• Owner’s repair costs
• Owner’s receipts
• Maintenance log
SEBU8089-02 97
Reference Materials
i01176304
Maintenance Log
SMCS Code: 1000
Table 21
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity
Service Item Date Authorization
Hours Of Fuel
98 SEBU8089-02
Index Section
Index
A Cooling System Supplemental Coolant Additive
(SCA) - Test/Add.................................................. 63
After Starting Engine ............................................. 36 Cooling Systems that Use Conventional
After Stopping Engine............................................ 39 Coolant............................................................. 63
Aftercooler Core - Clean/Test ................................ 51 Cooling Systems that Use Water and SCA........ 64
Aftercooler Core - Inspect...................................... 51 Cooling System Water Temperature Regulator -
Air Compressor - Inspect....................................... 52 Replace................................................................ 64
Air Compressor Filter - Clean/Replace (If Crankshaft Vibration Damper - Inspect ................. 65
Equipped) ............................................................ 52 Inspection........................................................... 65
Air Tank Moisture and Sediment - Drain (If Removal and Installation.................................... 65
Equipped) ............................................................ 53 Crushing Prevention and Cutting Prevention ........ 12
Alternator - Inspect ................................................ 53 Customer Assistance............................................. 92
Outside of the USA and of Canada.................... 92
USA and Canada ............................................... 92
B Customer Service .................................................. 92
Cylinder Head Grounding Stud - Inspect/Clean/
Battery - Replace................................................... 53 Tighten................................................................. 65
Battery Charger - Check........................................ 54
Checking After Stopping .................................... 55
Checking Before Start-Up .................................. 54 D
Battery Electrolyte Level - Check .......................... 55
Battery or Battery Cable - Disconnect ................... 55 Diagnostic Flash Code Retrieval ........................... 27
Before Starting Engine .................................... 12, 32 “Diagnostic” Lamp.............................................. 27
Belt Tensioner - Inspect (If Equipped) ................... 55 Diagnostic Lamp.................................................... 27
Belts - Inspect/Adjust............................................. 56 Driven Equipment - Check..................................... 66
Adjustment ......................................................... 56
Inspection........................................................... 56
Burn Prevention....................................................... 9 E
Batteries............................................................. 10
Coolant................................................................. 9 Electrical System ................................................... 13
Oils..................................................................... 10 Grounding Practices .......................................... 13
Emergency Stopping ............................................. 38
Emergency Stop Button ..................................... 38
C Emissions Warranty Information............................ 89
Engaging the Driven Equipment............................ 37
Cold Weather Operation........................................ 40 Engine - Clean....................................................... 66
Configuration Parameters...................................... 30 Engine Air Cleaner Element (Dual Element) -
Customer password .......................................... 30 Clean/Replace ..................................................... 66
Cooling System Coolant (DEAC) - Change........... 57 Cleaning the Primary Air Cleaner Elements ...... 67
Cooling Systems with Heavy Deposits or Servicing the Air Cleaner Elements ................... 66
Plugging ........................................................... 58 Engine Air Cleaner Service Indicator - Inspect (If
Drain .................................................................. 57 Equipped) ............................................................ 69
Fill ...................................................................... 58 Test the Service Indicator................................... 69
Flush .................................................................. 57 Engine Crankcase Breather - Clean...................... 69
Cooling System Coolant (ELC) - Change.............. 59 Engine Description ................................................ 15
Drain .................................................................. 59 Aftermarket Products and Caterpillar Engines... 17
Fill ...................................................................... 60 Electronic Engine Features................................ 16
Flush .................................................................. 59 Engine Cooling and Lubrication ......................... 16
Cooling System Coolant Extender (ELC) - Add..... 60 Engine Service Life ............................................ 17
Cooling System Coolant Level - Check ................. 61 Engine Specifications......................................... 15
Cooling System Coolant Sample (Level 1) - Welding and Caterpillar Electronic Engines....... 17
Obtain .................................................................. 62 Engine Diagnostics................................................ 27
Cooling System Coolant Sample (Level 2) - Engine Electronics................................................. 14
Obtain .................................................................. 62 Engine Monitoring System (EMS) ......................... 21
Communication Data Link.................................. 23
EMS Main Unit ................................................... 22
Quad Gauge Unit ............................................... 22
Tachometer Unit................................................. 23
SEBU8089-02 99
Index Section
Engine Mounts - Inspect........................................ 70 G

Engine Oil and Filter - Change .............................. 72
Drain the Engine Oil........................................... 73 Gauges and Indicators .......................................... 20
Fill the Engine Crankcase .................................. 74 General Hazard Information .................................... 7
Replace the Oil Filter ......................................... 73 Asbestos Information ........................................... 8
Selection of Oil Change Interval ........................ 72 Containing Fluid Spillage ..................................... 8
Engine Oil Level - Check ....................................... 70 Dispose of Waste Properly .................................. 9
Engine Oil Sample - Obtain ................................... 71 Fluid Penetration.................................................. 8
Obtain the Sample and the Analysis.................. 71 Pressurized Air and Water ................................... 8
Engine Operation................................................... 37
Engine Operation with Active Diagnostic Codes ... 29
Engine Operation with Intermittent Diagnostic H
Codes .................................................................. 30
Engine Rating Conditions ...................................... 90 Hoses and Clamps - Inspect/Replace ................... 80
Engine Rating Definitions ...................................... 90 Replace the Hoses and the Clamps .................. 80
Engine Ratings ...................................................... 90
Engine Starting ................................................ 12, 32
Engine Stopping .............................................. 13, 38 I
Engine Storage Procedure - Check....................... 74
Engine Valve Lash - Inspect/Adjust ....................... 74 Important Safety Information ................................... 2
F J
Fan Drive Bearing - Lubricate................................ 75 Jacket Water Heater - Check ................................ 81

Fault Logging......................................................... 29
Features and Controls ........................................... 24
Fire Prevention and Explosion Prevention ............ 10 L
Ether ................................................................... 11
Fire Extinguisher ................................................. 11 Lifting and Storage ................................................ 19
Lines, Tubes and Hoses ..................................... 11
Foreword ................................................................. 5
California Proposition 65 Warning ....................... 5 M
Literature Information........................................... 4
Maintenance ........................................................ 4 Maintenance Interval Schedule ............................. 49
Maintenance Intervals.......................................... 4 Maintenance Log ................................................... 97
Operation ............................................................. 4 Maintenance Recommendations ........................... 47
Overhaul .............................................................. 4 Maintenance Records............................................ 95
Safety................................................................... 4 Maintenance Section ............................................. 42
Fuel and the Effect from Cold Weather ................. 40 Manual Stop Procedure......................................... 39
Fuel Related Components in Cold Weather .......... 41 Model View Illustrations......................................... 15
Fuel Filters ......................................................... 41 Model Views .......................................................... 15
Fuel Heaters ...................................................... 41 Mounting and Dismounting.................................... 12
Fuel Tanks.......................................................... 41
Fuel System - Prime .............................................. 75
Engines that are Equipped with a Fuel Priming O
Pump................................................................ 76
Engines that are Not Equipped with a Fuel Priming Operation Section.................................................. 19
Pump................................................................ 76 Ordering Replacement Parts ................................. 93
Fuel System Primary Filter (Water Separator) Overhaul Considerations ....................................... 81
Element - Replace ............................................... 77 Oil Consumption as an Overhaul Indicator ........ 81
Replace the Element.......................................... 77 Overhaul Recommendation ............................... 82
Fuel System Primary Filter/Water Separator -
Drain .................................................................... 78
Fuel System Secondary Filter - Replace ............... 78 P
Fuel Tank Water and Sediment - Drain ................. 79
Drain the Water and the Sediment..................... 79 Plate Locations and Film Locations....................... 18
Fuel Storage Tanks ............................................ 80 Emission Certification ........................................ 18
Fuel Tank ........................................................... 79 Engine Identification........................................... 18
Information Plate................................................ 18
Serial Number Plate........................................... 18
100 SEBU8089-02
Index Section
Power Take-Off Clutch - Check/Adjust/Lubricate .. 84 System Pressure Release ..................................... 47

Product Identification Information .......................... 18 Coolant System.................................................. 47
Product Information Section .................................. 15 Engine Oil .......................................................... 47
Product Lifting........................................................ 19 Fuel System ....................................................... 47
Engine Lifting with a Fuel Tank .......................... 19
Product Storage..................................................... 19
T
R Table of Contents..................................................... 3
Turbocharger - Inspect .......................................... 86
Radiator - Clean .................................................... 84 Cleaning and Inspecting .................................... 87
Radiator Restrictions ............................................. 40 Removal and Installation.................................... 87
Reference Information Section .............................. 90
Reference Material ................................................ 94
Additional Reference Material............................ 95 W
Coolants............................................................. 94
Fuels .................................................................. 94 Walk-Around Inspection ........................................ 87
Lubricants .......................................................... 94 Inspect the Engine for Leaks and for Loose
Miscellaneous .................................................... 94 Connections ..................................................... 87
Reference Materials .............................................. 94 Warranty Information ............................................. 89
Refill Capacities..................................................... 42 Warranty Section ................................................... 89
Refill Capacities and Recommendations............... 42 Water Pump - Inspect ............................................ 88
Coolant............................................................... 45 Welding on Engines with Electronic Controls ........ 47
Engine Oil .......................................................... 42
Fuel .................................................................... 45
Lubricating Grease............................................. 44
Safety Messages ..................................................... 6

(1) Universal Warning .......................................... 7
Safety Section ......................................................... 6
Sensors and Electrical Components ..................... 24
Atmospheric Pressure Sensor ........................... 25
Boost Pressure Sensor ...................................... 25
Coolant Temperature Sensor ............................. 25
Engine Oil Pressure Sensor............................... 25
Engine Oil Temperature Sensor......................... 25
Engine Speed/Timing Sensor ............................ 26
Failure of Sensors.............................................. 24
Injection Actuation Pressure Sensor.................. 26
Inlet Air Temperature Sensor ............................. 26
Sensor Locations ............................................... 24
Throttle Position Sensor..................................... 26
Severe Service Application - Check ...................... 85
Environmental Factors ....................................... 85
Improper Maintenance Procedures.................... 85
Improper Operating Procedures ........................ 85
Starting Motor - Inspect (If Equipped).................... 86
Electric Starting Motor........................................ 86
Removal and Installation of the Starting Motor .. 86
Starting the Engine ................................................ 32
Air Inlet Heater ................................................... 33
Cold Weather Starting........................................ 33
Ether Injection System ....................................... 34
Initial Inspection ................................................. 33
Problems with the Wiring Harness..................... 35
Starting Problems .............................................. 34
Starting with Jump Start Cables ............................ 35
Stopping the Engine .............................................. 38
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
©2008 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge Printed in U.S.A.
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

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SEBU8089-02

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Warranty Section

Mounting and Dismounting ................................... 12

Before Starting Engine .......................................... 12

Engine Starting ..................................................... 12

Engine Stopping ................................................... 13

Electrical System .................................................. 13

Engine Electronics ................................................ 14

Product Information Section

Product Identification Information ........................ 18

Gauges and Indicators .......................................... 20

Features and Controls .......................................... 24

Engine Diagnostics ............................................... 27

Engine Starting ..................................................... 32

Engine Operation .................................................. 37

Engine Stopping ................................................... 38

Cold Weather Operation ....................................... 40

Maintenance Recommendations .......................... 47

Maintenance Interval Schedule ............................ 49

Foreword Use fuel consumption or service hours to determine

The operation section is a reference for operators. Overhaul

California Proposition 65 Warning

Battery posts, terminals and related accessories

There may be several specific safety messages on

Ensure that all of the safety messages are legible.

Replace any safety message that is damaged or

Engine exhaust contains products of combustion

Cautiously remove the following parts. To help

• Wear a hard hat, protective glasses, and other

• When work is performed around an engine that is

Pressurized Air and Water Asbestos Information

When pressurized air and/or pressurized water is

The maximum air pressure for cleaning purposes

Caterpillar equipment and replacement parts that are

If dust that may contain asbestos is present, there

• Never use compressed air for cleaning.

Any contact with hot coolant or with steam can cause

Check the coolant level after the engine has stopped

Ensure that the filler cap is cool before removing the

Remove all flammable materials such as fuel, oil, and

Eliminate all wiring that is unattached or unnecessary.

Arcing or sparking could cause a fire. Secure

Determine whether the engine will be operated in an

Improper jumper cable connections can cause an

Do not charge a frozen battery. This may cause an

The batteries must be kept clean. The covers

Do not store ether cylinders in living areas or in the

Dispose of used ether cylinders properly. Do not

Do not spray ether into an engine if the engine is

Lines, Tubes and Hoses

Replace the parts if any of the following conditions

Crushing Prevention and Before Starting Engine

Mounting and Dismounting i02136012