CAT C13 Engine Manual SEBU7901-09

SEBU7901-09 (en-us)
November 2020
Operation and
Maintenance
Manual
C11 and C13 Industrial Engines
GLS 1-UP (Engine)
HRA 1-UP (Engine)
LGK 1-UP (Engine)
RRA 1-UP (Engine)
PBZ 1-UP (Package)
PBY 1-UP (Package)
PDY 1-UP (Package)
PDN 1-UP (Package)
Scan to find and purchase genuine Cat® parts and related

service information.
i07966018
Important Safety Information

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

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
NOTICE
When replacement parts are required for this product Caterpillar recommends using original Cater-
pillar® replacement parts.
Other parts may not meet certain original equipment specifications.
When replacement parts are installed, the machine owner/user should ensure that the machine re-
mains in compliance with all applicable requirements.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7901-09 3
Table of Contents
Table of Contents Refill Capacities............................................... 50
Maintenance Recommendations .................... 59

Foreword ........................................................... 4
Maintenance Interval Schedule (Engines Which
Safety Section
Have Deep Oil Pans)..................................... 62
Safety Messages............................................... 6
Have Shallow Oil Pans)................................. 64
General Hazard Information.............................. 7
Burn Prevention................................................11 Warranty Section
Fire Prevention and Explosion Prevention.......11 Warranty Information..................................... 104
Crushing Prevention and Cutting Prevention.. 13 Reference Information Section
Mounting and Dismounting ............................. 14 Engine Ratings .............................................. 105
Before Starting Engine .................................... 14 Customer Service.......................................... 106
Engine Starting................................................ 14 Reference Materials ...................................... 108
Engine Stopping .............................................. 15 Index Section
Electrical System............................................. 15 Index............................................................... 111
Engine Electronics........................................... 16
Product Information Section
General Information ........................................ 17
Product Identification Information ................... 21
Operation Section
Lifting and Storage .......................................... 23
Features and Controls..................................... 26
Engine Diagnostics ......................................... 31
Engine Starting................................................ 41
Engine Operation ............................................ 44
Cold Weather Operation ................................. 46
Engine Stopping .............................................. 48
Maintenance Section
4 SEBU7901-09
Foreword
Foreword Some photographs or illustrations in this manual

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

expose you to chemicals
including ethylene glycol, which This safety section lists basic safety precautions. In
is known to the State of California to addition, this section identifies hazardous, warning
cause birth defects or other reproductive situations. Read and understand the basic
harm. For more information go to: precautions listed in the safety section before
operating or performing lubrication, maintenance,
and repair on this product.
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands Operation
after handling to avoid incidental Operating techniques outlined in this manual are
ingestion. basic. They assist with developing the skills and
techniques required to operate the engine more
WARNING – This product can efficiently and economically. Skill and techniques
expose you to chemicals develop as the operator gains knowledge of the
including lead and lead engine and its capabilities.
compounds, which are known to the
The operation section is a reference for operators.
State of California to cause cancer, birth Photographs and illustrations guide the operator
defects, or other reproductive harm. For through procedures of inspecting, starting, operating,
more information go to: and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
www.P65Warnings.ca.gov
Maintenance
Wash hands after handling components
that may contain lead. The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
Literature Information by fuel consumption, service hours and/or calendar
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that
This manual contains safety, operation instructions, follow.
lubrication, and maintenance information. This
manual should be stored in or near the engine area in Use fuel consumption or service hours to determine
a literature holder or literature storage area. Read, intervals. Calendar intervals shown (daily, annually,
study, and keep it with the literature and engine etc.) may be used instead of service meter intervals if
information. they provide more convenient schedules and
approximate the indicated service meter reading.
English is the primary language for all Cat
publications. The English used facilitates translation Recommended service should be performed at the
and consistency in electronic media delivery. appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
freezing cold operating conditions, more frequent
lubrication, and maintenance than is specified in the
Maintenance Interval Schedule may be necessary.
SEBU7901-09 5
Foreword
The maintenance schedule items are organized for a

preventive maintenance management program. If the
preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. We recommend that the
maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engine's permanent record.
See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information
regarding documents that are accepted as proof of
maintenance or repair. Your authorized Cat dealer
can assist you in adjusting your maintenance
schedule to meet the needs of your operating
environment.
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
authorized Cat dealer. Your Cat dealer offers various
options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available
from your Cat dealer. Consult with your dealer for
information regarding these options.
6 SEBU7901-09
Safety Section
Safety Messages
Safety Section
i04334670
Safety Messages
SMCS Code: 1000; 7405
Illustration 1 g02490123
Location of safety messages on a C11 Industrial Engine
Location of safety messages on C13 Industrial Engine
SEBU7901-09 7
Safety Section
General Hazard Information
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.
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 the
engine.
Replace any safety message that is damaged or Illustration 3 g01370904
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 Cat dealer
can provide new safety messages.
Do not operate or work on this engine unless you
have read and understand the instructions and
Universal Warning (1) warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the
The safety messages for the universal warning are warnings could result in injury or death. Contact
located toward the front of the engine on both sides any Caterpillar dealer for replacement manuals.
of the valve cover base. Proper care is your responsibility.
i06300340

SMCS Code: 1000; 4450; 7405
Attach a “Do Not Operate” warning tag to the start

switch or controls before the engine is serviced or
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each
operator control station. When appropriate,
disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
8 SEBU7901-09
Safety Section
Cautiously remove the following parts. To help • The protective locks or the controls are in the
prevent spraying or splashing of pressurized fluids, applied position.
hold a rag over the part that is being removed.
• Disconnect the batteries when maintenance is
• Filler caps performed or when the electrical system is
serviced. Disconnect the battery ground leads.
• Grease fittings Tape the leads in order to help prevent sparks.
• Pressure taps • When starting a new engine, make provisions to
stop the engine if an overspeed occurs. If an
• Breathers
engine has not been started since service has
• Drain plugs been performed, make provisions to stop the
engine if an overspeed occurs. Shutting down the
Use caution when cover plates are removed. engine may be accomplished by shutting off the
Gradually loosen, but do not remove the last two fuel supply and/or the air supply to the engine.
bolts or nuts that are located at opposite ends of the
cover plate or the device. Before removing the last • Do not attempt any repairs that are not
two bolts or nuts, pry the cover loose in order to understood. Use the proper tools. Replace any
relieve any spring pressure or other pressure. equipment that is damaged or repair the
equipment.
• Start the engine with the operator controls. Never

short across the starting motor terminals or the
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the
electrical system could be damaged.
Pressurized Air and Water

Pressurized air and/or water can cause debris and/or
hot water to be blown out which could result in
personal injury.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
Illustration 5 g00702020 nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective
• Wear a hard hat, protective glasses, and other equipment. The maximum water pressure for
protective equipment, as required. cleaning purposes must be below 275 kPa (40 psi).
• When work is performed around an engine that is When pressurized air and/or pressurized water is
operating, wear protective devices for ears in used for cleaning, wear protective clothing, protective
order to help prevent damage to hearing. shoes, and eye protection. Eye protection includes
goggles or a protective face shield. Always wear eye
• Do not wear loose clothing or jewelry that can protection for cleaning the cooling system.
snag on controls or on other parts of the engine.
• Ensure that all protective guards and all covers
are secured in place on the engine.
• Never put maintenance fluids into glass
containers. Glass containers can break.
• Use all cleaning solutions with care.

• Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
• The engine is stopped. Ensure that the engine

cannot be started.
SEBU7901-09 9
Safety Section
Avoid direct spraying of water on electrical Static Electricity Hazard when

connectors, connections, and components. When
using air for cleaning, allow the machine to cool to Fueling with Ultra-low Sulfur Diesel
reduce the possibility of fine debris igniting when Fuel
redeposited on hot surfaces.
The removal of sulfur and other compounds in ultra-
Fluid Penetration low sulfur diesel fuel (ULSD fuel) decreases the
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.
Avoid static electricity risk when fueling. Ultra-
Always use a board or cardboard when you check for low sulfur diesel fuel (ULSD fuel) poses a greater
a leak. Leaking fluid that is under pressure can static ignition hazard than earlier diesel formula-
penetrate body tissue. Fluid penetration can cause tions with a higher sulfur contents. Avoid death
serious injury and possible death. A pin hole leak can or serious injury from fire or explosion. Consult
cause severe injury. If fluid is injected into your skin, with your fuel or fuel system supplier to ensure
you must get treatment immediately. Seek treatment the delivery system is in compliance with fueling
from a doctor that is familiar with this type of injury. standards for proper grounding and bonding
practices.
Containing Fluid Spillage
NOTICE Lines, Tubes, and Hoses
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Do not bend or strike high-pressure lines. Do not
nance, testing, adjusting, and repair of the product. install lines, tubes, or hoses that are damaged.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Repair any fuel lines, oil lines, tubes, or hoses that
bling any component containing fluids. are loose or damaged. Leaks can cause fires.
Refer to Special Publication, NENG2500, “Cat Dealer Inspect all lines, tubes, and hoses carefully. Do not
Service Tool Catalog” or refer to Special Publication, use bare hands to check for leaks. Always use a
PECJ0003, “Cat Shop Supplies and Tools Catalog” board or cardboard for checking engine components
for tools and supplies suitable to collect and contain for leaks. Tighten all connections to the
fluids on Cat products. recommended torque.
Dispose of all fluids according to local regulations Check for the following conditions:
and mandates.
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering
10 SEBU7901-09
Safety Section
Ensure that all of the clamps, the guards, and the • A vacuum cleaner that is equipped with a high
heat shields are installed correctly. Correct efficiency particulate air filter (HEPA) can also be
installation of these components will help to prevent used.
these effects: vibration, rubbing against other parts
and excessive heat during operation. • Use exhaust ventilation on permanent machining
jobs.
Inhalation • Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos

particles in the air.
Softwrap
Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
Exhaust approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate
Use caution. Exhaust fumes can be hazardous to protective clothing in order to minimize direct contact.
your health. If you operate the equipment in an Use good hygiene practices and wash hands
enclosed area, adequate ventilation is necessary. thoroughly after handling Softwrap material. Do not
smoke until washing hands thoroughly after handling
Asbestos Information Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean
Cat equipment and replacement parts that are up debris.
shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is 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.

• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos
materials.
SEBU7901-09 11
Safety Section
Burn Prevention
Reference: The applicable material safety data Check that the coolant level after the engine has
sheets can be found at the following web site by stopped and the engine has been allowed to cool.
searching using part number or the name: Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
https://catmsds.cat.com/MSDSSearch/servlet/ with a bare hand. Remove the filler cap slowly to
cat.cis.ecs. relieve pressure.
msdsSearch.controller.
UserIdentificationDisplayServlet Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Dispose of Waste Properly
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot
components to contact the skin.
If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
Improperly disposing of waste can threaten the explode.
environment. Potentially harmful fluids should be Always wear protective glasses when you work with
disposed of according to local regulations. batteries. Wash hands after touching batteries. The
Always use leakproof containers when you drain use of gloves is recommended.
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water. i07254650
i08159513 Fire Prevention and Explosion

Prevention
Burn Prevention
SMCS Code: 1000; 4450; 7405
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
appropriate system before any lines, fittings, or
related items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the
cooling system is drained.
Use of personal protection equipment (PPE) may be

needed.
12 SEBU7901-09
Safety Section
Fire Prevention and Explosion Prevention
All fuels, most lubricants, and some coolant mixtures Arcing or sparking could cause a fire. Secure
are flammable. connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
Always perform a Walk-Around Inspection, which or sparking.
may help you identify a fire hazard. Do not operate a
product when a fire hazard exists. Contact your Cat Inspect all lines and hoses for wear or for
dealer for service. deterioration. Properly route all hoses. The lines and
hoses must have adequate support and secure
Flammable fluids that are leaking or spilled onto hot clamps. Tighten all connections to the recommended
surfaces or onto electrical components can cause a torque. Leaks can cause fires.
fire. Fire may cause personal injury and property
damage. Properly install all oil filters and fuel filters. The filter
housings must be tightened to the proper torque.
A flash fire may result if the covers for the engine
crankcase are removed within 15 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.
If the application involves the presence of
combustible gases, consult your Cat dealer for
additional information about suitable protection
devices.
Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
All fluids that are captured in the fluid spill
containment basin should be cleaned up
immediately. Failure to clean up spilled fluids can
cause a fire. Fire may cause personal injury and
property damage.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store Use caution when you are refueling an engine. Do
oily rags and any flammable materials in protective not smoke while you are refueling an engine. Do not
containers. Do not smoke in areas that are used for refuel an engine near open flames or sparks. Always
storing flammable materials.
stop the engine before refueling.
Do not expose the engine to any flame.
Avoid static electricity risk when fueling. Ultra Low
Exhaust shields (if equipped) protect hot exhaust Sulfur Diesel (ULSD) poses a greater static ignition
components from oil or fuel spray in a line, a tube, or hazard than earlier diesel formulations with a higher
a seal failure. Exhaust shields must be installed Sulfur content. Avoid death or serious injury from fire
correctly. or explosion. Consult with your fuel or fuel system
supplier to ensure that the delivery system is in
Do not weld on lines or tanks that contain flammable compliance with fueling standards for proper
fluids. Do not use flame to cut lines or tanks that grounding and bonding practices.
contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Properly route
and attach all electrical wires. Check all electrical
wires daily. Repair any wires that are loose or frayed
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.
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.
SEBU7901-09 13
Safety Section
Crushing Prevention and Cutting Prevention
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
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Cat dealer for repair or
for replacement parts.
Check lines, tubes, and hoses carefully. Do not use
Gases from a battery can explode. Keep any open your bare hand to check for leaks. Use a board or
flames or sparks away from the top of a battery. Do cardboard to check for leaks. Tighten all connections
not smoke in battery charging areas. to the recommended torque.
Never check the battery charge by placing a metal Replace the parts if any of the following conditions
object across the terminal posts. Use a voltmeter or a are present:
hydrometer.
• End fittings are damaged or leaking.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the • Outer coverings are chafed or cut.
Operation Section of this manual for specific
instructions. • Wires are exposed.
Do not charge a frozen battery. Charging a frozen • Outer coverings are ballooning.
battery may result in an explosion.
• Flexible parts of the hoses are kinked.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the • Outer covers have embedded armoring.
recommended cables, connections, and battery box
covers when the engine is operated. • End fittings are displaced.
Fire Extinguisher Make sure that all clamps, guards, and heat shields
are installed correctly to prevent vibration, rubbing
Make sure that a fire extinguisher is available. Be against other parts, and excessive heat.
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire i08162291
extinguisher regularly. Obey the recommendations
on the instruction plate. Crushing Prevention and
Ether Cutting Prevention
SMCS Code: 1000; 4450; 7405
Ether is flammable and poisonous.
Support the component properly when work beneath
Use ether in ventilated areas. Do not smoke while the component is performed.
you are replacing an ether cylinder or while you are
using an ether spray. Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
14 SEBU7901-09
Safety Section
Mounting and Dismounting
Stay clear of all rotating parts and of all moving parts. Inspect the engine for potential hazards.
Leave the guards in place until maintenance is
performed. After the maintenance is performed, Do not start the engine if there is a “DO NOT
reinstall the guards. OPERATE” warning tag or similar warning tag
attached to the start switch. Do not move any of the
Keep objects away from moving fan blades. The fan controls if there is a “DO NOT OPERATE” warning
blades will throw objects or cut objects. tag or similar warning tag attached to the controls.
When objects are struck, wear protective glasses to Before starting the engine, ensure that no one is on,
avoid injury to the eyes. underneath, or close to the engine. Ensure that the
area is free of personnel.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no If equipped, ensure that the lighting system for the
one will be injured by flying debris. engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
i08159517
All protective guards and all protective covers must
be installed if the engine must be started to perform
Mounting and Dismounting service procedures. To help prevent an accident that
SMCS Code: 1000; 4450; 7405 is caused by parts in rotation, work around the parts
carefully.
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean Do not bypass the automatic shutoff circuits. Do not
and keep these items in good repair. disable the automatic shutoff circuits. The circuits are
provided to help prevent personal injury. The circuits
Mount the engine and dismount the engine only at are also provided to help prevent engine damage.
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine. See the Service Manual for repairs and for
adjustments.
Face the engine to mount the engine or dismount the
engine. With your feet and hands, always maintain a i08162293
three-point contact with the steps and designated
handholds. Do not use any controls as handholds. Engine Starting
Do not stand on components which cannot support SMCS Code: 1000
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the If a warning tag is attached to the engine start switch
equipment will not move. or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
Do not carry tools or supplies when you mount the the warning tag before the engine is started.
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies. All protective guards and all protective covers must
be installed if the engine must be started to perform
i08258438
service procedures. To help prevent an accident that
is caused by parts in rotation, work around the parts
carefully.
Before Starting Engine
SMCS Code: 1000 If there is a possibility that unburned gas remains in
the exhaust system, refer to the purge procedure in
this Operation and Maintenance Manual, “Engine
NOTICE Starting” topic in the Operation Section.
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make Start the engine from the operator' compartment or
provision to shut the engine off should an overspeed from the engine start switch.
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine. Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
Engine exhaust contains products of combustion personal injury.
which may be harmful to your health. Always
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust
to the outside.
SEBU7901-09 15
Safety Section
Engine Stopping
To ensure that the jacket water heater (if equipped) is Check the electrical wires daily for wires that are
working properly, check the water temperature during loose or frayed. Tighten all loose electrical wires
operation. To ensure that the lube oil heater (if before the engine is started. Repair all frayed
equipped) is working properly, check the oil electrical wires before the engine is started. Refer to
temperature during heater operation. the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well-ventilated Grounding Practices
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
i07668288
Engine Stopping
SMCS Code: 1000
• Remove the load in increments.

• Open the circuit breaker.
• Allow the engine to run for five minutes to cool.

• Stop the engine.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled. This may be
accomplished by shutting off the fuel supply to the
engine and/or shutting off the air supply to the
engine.
To stop an electronically controlled engine, cut the Illustration 12 g00771448
power to the engine. Typical example
Grounding Stud To Battery Ground
i02469632
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” jump start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
16 SEBU7901-09
Safety Section
Engine Electronics
All grounds should be tight and free of corrosion. The

engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.
i02784356
Engine Electronics
SMCS Code: 1000; 1900
Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.
This engine has a comprehensive, programmable
Engine Monitoring System. The Engine Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine
monitoring control: WARNING, DERATE and
SHUTDOWN. These engine monitoring modes have
the ability to limit engine speed and/or the engine
power.
Typical example Many of the parameters that are monitored by the
Alternate Grounding Stud To Battery Ground ECM can be programmed for the engine monitoring
functions. The following parameters can be
Proper grounding for the engine electrical system is monitored as a part of the Engine Monitoring System:
necessary for optimum engine performance and
reliability. Improper grounding will result in • Operating Altitude
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths. • Engine Coolant Level
Uncontrolled electrical circuit paths can result in • Engine Coolant Temperature

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

ground straps can be damaged by electrical
discharge. • Fuel Temperature
To ensure that the engine and the engine electrical • Intake Manifold Air Temperature
systems function properly, an engine-to-frame
ground strap with a direct path to the battery must be • System Voltage
used. This path may be provided by way of a starting
motor ground, a starting motor ground to the frame, The Engine Monitoring package can vary for different
or a direct engine ground to the frame. engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: Many of the engine control systems and
display modules that are available for Caterpillar
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting
Manual for more information.
SEBU7901-09 17
General Information
Product Information
Section
General Information
i04336830
Model View Illustrations

SMCS Code: 1000
Left side view of C11 and C13 industrial engine
(1) Oil filler (5) Air inlet from aftercooler (9) Heater inlet
(2) Lifting eye (6) Fuel priming pump (10) Oil drain
(3) Water outlet (7) Electronic control module (ECM) (11) Fuel inlet
(4) Oil level gauge (8) Fuel filter
18 SEBU7901-09
Product Description
Right side view of C11 and C13 industrial engine
(1) Oil pressure connection and location for (4) Air inlet (8) Oil drain
oil sampling (5) Air outlet to aftercooler (9) Mounting block for an oil filter bypass
(2) Lifting eye (6) Water inlet (10) Oil filter
(3) Jacket water heater (7) Heater inlet for lubrication
i04227689 Table 2
C13 Engine Specifications
Product Description
Cylinders and Arrangement In-line six-cylinder
SMCS Code: 1000; 4450; 4491
Bore 130 mm (5.2 inch)
Table 1
Stroke 157 mm (6.2 inch)
C11 Engine Specifications
Displacement 12.5 L (763 in3)
Cylinders and Arrangement In-line six-cylinder
Firing Order 1-5-3-6-2-4
Bore 130 mm (5.2 inch)
Rotation (flywheel end) Counterclockwise
Stroke 140 mm (5.5 inch)
Displacement 11.1 L (677 in3) The electronic engines that are covered by this
Firing Order 1-5-3-6-2-4
manual have the following characteristics: direct fuel
injection, electronic unit injection that is mechanically
Rotation (flywheel end) Counterclockwise actuated, turbocharged and air-to-air aftercooled
(ATAAC).
The electronic engine control system provides the
following functions: electronic governing, automatic
air to fuel ratio control, torque rise shaping, injection
timing control and system diagnostics.
SEBU7901-09 19
Product Description
An electronic governor controls the output of the unit Engine efficiency, efficiency of emission controls, and
injectors in order to maintain the engine rpm that is engine performance depend on adherence to proper
desired. The functions of the governor include a operation and maintenance recommendations
programmable low idle and a 20 rpm to 200 rpm including recommended fuels, coolants, and
governor overrun. lubrication oils.
Very high injection pressures are produced by
electronically controlled, mechanically actuated unit Aftermarket Products and Cat
injectors. The injectors combine the pumping and the Engines
electronic fuel metering (duration and timing) during
injection. The unit injectors accurately control smoke
limiting, white smoke, and engine acceleration rates. NOTICE
In order to maximize fuel system life and prevent pre-
There is one unit injector per cylinder. Individual unit mature wear out from abrasive particles in the fuel, a
injectors meter the fuel. The individual unit injectors two micron absolute high efficiency fuel filter is re-
also pump the fuel. The metering and the pumping is quired for all Caterpillar Electronic Unit Injectors. Cat-
done under high pressure. High injection pressures erpillar High Efficiency Fuel Filters meet these
help to reduce fuel consumption and emissions. The requirements. Consult your Caterpillar dealer for the
use of this type of unit injector provides total proper part numbers.
electronic control of injection timing. The injection
timing varies with engine operating conditions. The The use of auxiliary devices, accessories, or
engine performance is optimized in the following consumables which are made by other
areas: manufacturers on Cat products does not affect the
Caterpillar warranty simply because of such use.
• Starting
However, failures that result from the installation
• Emissions or use of devices, accessories, or consumables
which are made by other manufacturers are NOT
• Noise Caterpillar defects. Therefore, the defects are
NOT covered under the Caterpillar warranty.
• Fuel consumption
The timing advance is achieved through precise
Welding and Cat Electronic
control of the injector firing. Engine speed is Engines
controlled by adjusting the firing duration. The
information is provided to the Electronic Control
Module (ECM) by an engine speed/timing sensor. NOTICE
The information is for detection of cylinder position Because the strength of the frame may decrease,
and engine speed. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
The engines have built-in diagnostics in order to ment or your Cat dealer regarding welding on a chas-
ensure that all of the components are functioning and sis frame or rail.
operating properly. If a system component deviates
from the programmed limits, the operator is alerted to To help avoid damage to the electronic controls,
the condition by a DIAGNOSTIC lamp mounted on proper welding procedures are necessary. Before
the control panel. An electronic service tool that is welding on a vehicle that is equipped with an
provided by Cat may be used to read the numerical electronic engine, observe the following precautions:
code of the diagnostic flash code. There are three 1. Turn off the engine. Place the key start switch in
types of diagnostic codes: ACTIVE, LOGGED and
EVENT. These codes are logged and stored in the the OFF position.
ECM. Refer to the Operation and Maintenance 2. If the application has a battery disconnect switch,
Manual, “Engine Diagnostics” for additional open the switch. Otherwise, disconnect the
information.
negative “-” battery cable from the battery of the
The cooling system consists of the following items: a vehicle.
centrifugal pump that is driven by a gear, water
temperature regulator, an oil cooler and a radiator
that incorporates a shunt system.
The engine lubricating oil is supplied by a gear type
pump. The engine lubricating oil is cooled and
filtered. Bypass valves provide unrestricted flow of
lubrication oil to the engine when the oil viscosity is
high and when the oil cooler or the oil filter elements
(paper cartridge) become plugged.
20 SEBU7901-09
Product Description
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding
can cause damage to the drive train bearings, hy-
draulic components, electrical components, and oth-
er components.
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-
sibility of damage.
3. Clamp the ground cable from the welder to the

component that will be welded. Place the clamp as
close as possible to the weld.
4. Protect wiring harnesses from welding debris and
from spatter. Use proper welding procedures.
SEBU7901-09 21
Product Identification Information
Product Identification Engine Modification Number
Information The engine identification plate also contains other

important information about the engine.
i02495907
i00844066
Plate Locations and Film Emissions Certification Film

Locations SMCS Code: 1000; 7405
SMCS Code: 1000; 4450
EPA Emissions Certification Film
Caterpillar engines are identified by serial numbers

and by arrangement numbers. These numbers are
shown on the engine serial number plate and on the Illustration 18 g00415538
engine information plate. Caterpillar dealers need
these numbers in order to determine the components European Emissions Certification Film
that were included with the engine. This permits
accurate identification of replacement part numbers. The EPA Emissions Certification Film (if equipped)
and/or the European Emissions Certification Film (if
equipped) is located on the side of the engine.
Serial Number Plate (1)
i04128675
The engine serial number plate is located on the rear
right side of the engine block.
Reference Information
Engine serial number SMCS Code: 1000; 4450
Engine model Information for the following items may be needed to
Arrangement number order parts. Locate the information for your engine.
Record the information on the appropriate space.
Make a copy of this list for a record. Retain the
Information Plate (2) information for future reference.
The engine information plate is located on the intake

manifold near the front of the right side of the engine.
Engine Serial Number
Engine Arrangement Number
22 SEBU7901-09
Reference Information
Record for Reference

Table 3
System or Component Information
Chassis serial number

Engine model
Engine serial number
Engine arrangement
number
Modification number
Engine low idle rpm
Engine full load rpm
Performance specification
number
Engine horsepower
Primary fuel filter part

number
Water separator element
part number
Secondary fuel filter ele-

ment part number
Lubrication oil filter ele-

ment part number
Auxiliary oil filter element

part number
Supplemental coolant ad-

ditive maintenance ele-
ment part number (if
equipped)
Total lubrication system

capacity
Total cooling system

capacity
Engine air cleaner ele-

ment part number
Fan drive belt part

number
Alternator belt part
number
SEBU7901-09 23
Operation Section
Lifting and Storage
Operation Section i05260537
Product Storage
Lifting and Storage SMCS Code: 7002
i01988813 Storage (Less Than One Year)

Product Lifting If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls,
SMCS Code: 7000; 7002 piston rings, main bearings, connecting rod bearings,
crankshaft and gears.
This lack of lubricant allows corrosion to begin to
appear on the metal. This condition is worse in areas
of high humidity.
When the engine is started again, metal to metal
contact will cause wear before the surfaces receive
oil. To minimize this wear, use the starter to turn the
engine with the throttle in the FUEL OFF position.
When oil pressure is shown on the pressure gauge,
start the engine.
1. Clean the engine of any dirt, rust, grease, and oil.
Inspect the exterior. Paint areas that contain paint
damage with a good quality paint.
2. Remove dirt from the air cleaners. Check all seals,
gaskets, and the filter element for damage.
3. Apply lubricant to all points in this Operation and
NOTICE
Never bend the eyebolts and the brackets. Only load Maintenance Manual, “Maintenance Interval
the eyebolts and the brackets under tension. Re- Schedule”.
member that the capacity of an eyebolt is less as the
angle between the supporting members and the ob- 4. Drain the crankcase oil. Replace the crankcase oil
ject becomes less than 90 degrees. and change the oil filters. For the proper
procedure, refer to this Operation and
When it is necessary to remove a component at an Maintenance Manual.
angle, only use a link bracket that is properly rated for
the weight. 5. If the engine is equipped with an air starting motor,
fill the reservoir with the following mixture: 50
Use a hoist to remove heavy components. Use an percent volatile corrosion inhibitor oil
adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be (<nomen>VCI oil</nomen>) and 50 percent
parallel to each other. The chains and cables should engine oil.
be perpendicular to the top of the object that is being
lifted. 6. Add VCI oil to the crankcase oil. The volume of
VCI oil in the crankcase oil should be 3 to 4
Some removals require lifting the fixtures in order to percent.
obtain proper balance and safety.
Note: If the engine crankcase is full, drain enough
To remove the engine ONLY, use the lifting eyes that engine oil so the mixture can be added.
are on the engine.
7. Remove the air filter elements. Turn the engine at
Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting cranking speed with the throttle control in FUEL
eyes and/or the engine make the lifting eyes and the OFF position. Use a sprayer to add a mixture of 50
lifting fixtures obsolete. If alterations are made, percent VCI oil and 50 percent engine oil into the
ensure that proper lifting devices are provided. air inlet or turbocharger inlet.
Consult your Caterpillar dealer for information
regarding fixtures for proper engine lifting.
24 SEBU7901-09
Operation Section
Product Storage
Note: The mixture of VCI oil can be added to the inlet Ensure that all covers are airtight and
by removing the plug for checking turbocharger boost weatherproof. Use a waterproof weather resistant
pressure. The minimum application rate for the VCI tape such as Kendall No. 231 or an equivalent. Do
oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of not use duct tape. Duct tape will only seal for a
engine displacement. short time.
8. Use a sprayer to apply a mixture of 50 percent VCI 13. Under most conditions, removing the batteries is
oil and 50 percent crankcase oil into the exhaust the best procedure. As an alternative, place the
openings. The minimum application rate for the oil batteries in storage. As needed, periodically
mixture is 5.5 mL per L (3 oz per 1000 cu in) of charge the batteries while the batteries are in
engine displacement. Seal the exhaust pipe and storage.
seal any drain holes in the muffler.
If the batteries are not removed, wash the tops of
9. Remove the fuel from the secondary fuel filter the batteries until the tops are clean. Apply an
housing. Alternately, empty and reinstall the spin- electrical charge to the batteries in order to obtain
on fuel filter element in order to remove any dirt a specific gravity of 1.225.
and water. Drain any sleeve metering fuel pump.
Disconnect the battery terminals. Place a plastic
Clean the primary fuel filter. Fill with calibration cover over the batteries.
fluid or kerosene. Install the primary fuel filter and
operate the priming pump. This procedure will Note: For additional information, refer to Special
send clean oil to the secondary filter and the Instruction, SEHS7633, “Battery Test Procedure”.
engine.
14. Loosen all belts.
Open the fuel tank drain valve in order to drain any
15. Place a waterproof cover over the engine. Ensure
water and dirt from the fuel tank. Apply a spray of
that the engine cover is secure. The cover should
calibration fluid or kerosene at the rate of
be loose enough to allow air to circulate around
30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank
the engine in order to prevent damage from
capacity in order to prevent rust in the fuel tank.
condensation.
Add 0.15 mL per L (.02 oz per 1 gal US) of
commercial biocide such as Biobor JF to the fuel. 16. Attach a tag with the storage date to the engine.
Apply a small amount of oil to the threads on the 17. Remove the waterproof cover at 2 month or 3
fuel tank filler neck and install the cap. Seal all month intervals in order to check the engine for
openings to the tank in order to prevent corrosion. If the engine has signs of corrosion,
evaporation of the fuel and as a preservative. repeat the protection procedure.
10. Remove the fuel nozzles or spark plugs. Apply Coolant System
30 mL (1 oz) of the mixture of oils (50 percent VCI
oil and 50 percent engine oil) into each cylinder. Completely fill the cooling system before storage.
Use a bar or a turning tool in order to turn over the Refer to this Operation and Maintenance Manual,
engine slowly. This procedure puts the oil on the “Fluid Recommendations” for more information about
cylinder walls. Install all fuel nozzles or spark plugs coolants.
and tighten to the correct torque.
11. Spray a thin amount of a mixture of 50 percent
Removal from Storage
VCI oil and 50 percent engine oil onto the following 1. Remove all outside protective covers.
components: flywheel, ring gear teeth and starter
pinion. Install the covers in order to prevent 2. Change the oil and filters.
evaporation of the vapors from the VCI oil. 3. Check the condition of the fan and alternator belts.
12. Apply a heavy amount of Cat Multipurpose Replace the belts, if necessary. Refer to this
Grease (MPGM) to all outside parts that move, Operation and Maintenance Manual, “Belts -
such as rod threads, ball joints, linkage. Inspect/Adjust/Replace” for the correct procedure.
Note: Install all covers. Ensure that tape has been 4. Replace the fuel filter elements.
installed over all openings, air inlets, exhaust 5. Remove the plastic covers from the air cleaner
openings, the flywheel housing, the crankcase elements.
breathers, the dipstick tubes.
SEBU7901-09 25
Operation Section
Product Storage
6. Use a bar or a turning tool in order to turn the

engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
resistance exist.
7. Before starting the engine, remove the valve cover
or covers. Put a large amount of engine oil on the
camshaft, cam followers, and valve mechanism in
order to prevent damage to the mechanism.
8. Pressure-lubricate the engine before starting the
engine. Pressure lubricating the engine ensures
immediate lubrication and prevents damage to the
engine during the first few minutes of engine
operation. If the engine is not equipped with a
prelube pump, contact your Cat dealer for
information about lubrication of the engine before
starting the engine.
9. Check the condition of all rubber hoses. Replace
any worn hoses. Replace any damaged hoses.
10. Before start-up, test the cooling system for a 3
percent to a 6 percent concentration of coolant
conditioner. Add liquid coolant conditioner or a
coolant conditioner element, if equipped.
Test the coolant mixture for proper nitrite level. If
necessary, adjust the coolant mixture.
Prime the engine with clean diesel fuel before
starting.
11. Ensure that the cooling system is clean. Ensure
that the system is full. Ensure that the system has
the correct amount of supplemental cooling
system conditioner.
12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.
13. If the engine was removed from storage in which
temperatures of less than -12°C (10°F) were
encountered, refer to Service Manual, SEBU5898,
“Cold Weather Recommendations Operation and
Maintenance”.
26 SEBU7901-09
Operation Section
Features and Controls
Features and Controls The diagnostic lamp will turn on if the oil pressure
drops below 35 kPa (5 psi) at low idle rpm. The
diagnostic code will be logged in the Engine Control
i01465281 Module (ECM).
Gauges and Indicators Engine Oil Temperature – This gauge
indicates the engine oil temperature. An
SMCS Code: 7450
oil temperature that is higher than
Your engine may not have the same gauges or all of normal indicates a heat problem in the lubrication
the gauges that are described. For more information system and/or the cooling system. This problem
about the gauge package, see the literature that is can damage the cylinder heads, the cylinder
provided by the OEM. liners, the pistons, and the crankshaft bearings.
Gauges provide indications of engine performance. Jacket Water Coolant Temperature –

Ensure that the gauges are in good working order. Typical temperature range is
Determine the normal operating range by observing 88 to 102 °C (190 to 215 °F). The
the gauges over a period of time. maximum allowable temperature with the
pressurized cooling system is 105 °C (220 °F).
Noticeable changes in gauge readings indicate Higher temperatures may occur under certain
potential gauge or engine problems. Problems may
conditions. The water temperature reading may
also be indicated by gauge readings that change
even if the readings are within specifications. vary according to load. The reading should never
Determine the cause of any significant change in the exceed the boiling point for the pressurized
readings. Then, correct any cause of any significant system that is being used.
change in the readings. Consult your Caterpillar
dealer for assistance. If the engine is operating above the normal range or
steam becomes apparent, perform the following
Caterpillar requires one lamp in addition to the gauge procedure:
package that is normally provided. The “Diagnostic”
lamp is yellow or amber. The “Diagnostic” lamp will 1. Reduce the load and the engine rpm.
communicate the status of the engine's electronic 2. Inspect the cooling system for leaks.
system. The optional red “Warning” lamp is also
available. This red “Warning” lamp warns the 3. Determine if the engine must be shut down
operator of engine problems. immediately or if the engine can be cooled by
reducing the load.
The following conditions are some examples of the
engine problems:
• Low oil pressure

Pressurized System: Hot coolant can cause seri-
• High coolant temperature ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
• Low coolant level components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
• High inlet air temperature pressure.
Engine Oil Pressure – Typical oil 4. Check the coolant level.
pressure for an engine at rated speed
with SAE 10W30 or with SAE 15W40 is Tachometer – This gauge indicates
240 to 480 kPa (35 to 70 psi). engine speed. When the throttle control
lever is moved to the full throttle
A lower oil pressure is normal at low idle. If the load is
stable and the gauge reading changes, perform the position without load, the engine is running at
following procedure: high idle. The engine is running at the full load
rpm when the throttle control lever is at the full
1. Remove the load. throttle position with maximum rated load.
2. Reduce engine speed to low idle. Note: The default high idle rpm and the full load rpm
are stamped on the Information Plate.
3. Check the oil level. Maintain the oil level at the
proper amount. Ammeter – This gauge indicates the
amount of charge or of discharge in the
If the gauge continues to fluctuate, consult your
Caterpillar dealer. battery charging circuit. Operation of
the indicator should be to the right side of “ 0””
(zero).
SEBU7901-09 27
Operation Section
Monitoring System
Service Hour Meter – This gauge Diagnostic Lamp (1) – The diagnostic
indicates the total number of clock lamp is used to indicate the existence of
hours of engine operation. Hours of a fault by flashing a fault code. For a
operation are logged in the ECM. A service tool is more detailed discussion of the diagnostic lamp,
needed to retrieve the hours from the ECM. A please see this Operation and Maintenance
Service Hour Meter may be installed on the Manual, “Diagnostic Lamp” topic.
engine.
Engine Oil Pressure (2) – The oil
Fuel Pressure – This gauge indicates pressure should be greatest after a cold
fuel pressure to the electronic unit engine is started. The pressure will
injectors from the fuel filter. The decrease as the engine warms up. The pressure
indicator should indicate the “ NORMAL”” range. A will increase when the engine rpm is increased.
decrease in fuel pressure usually indicates a The pressure will stabilize when the engine rpm
plugged fuel filter. is stable.
Fuel Level – This gauge indicates the A lower oil pressure is normal at low idle. If the load is
level of fuel in the fuel tank. The fuel stable and the gauge reading changes, perform the
level gauge registers the fuel level only following procedure:
when the ignition switch is in the ON position. 1. Remove the load.
i07504949 2. Reduce engine speed to low idle.

3. Check and maintain the oil level.
Monitoring System
SMCS Code: 1900; 7400; 7450; 7451 Tachometer (3) – This gauge indicates
engine speed (rpm). When the throttle
The Monitoring System is designed to alert the control lever is moved to the full throttle
operator to an immediate problem with any of the position without load, the engine is running at
engine systems that are monitored. The Monitoring high idle. The engine is running at the full load
System is also designed to alert the operator to an rpm when the throttle control lever is at the full
impending problem with any of the engine systems throttle position with maximum rated load.
that are monitored.
NOTICE
Indicators and Gauges To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
damage to the engine. The engine can be operated
at high idle without damage, but should never be al-
lowed to exceed high idle rpm.
Note: The high idle rpm and the full load rpm are
stamped on the Information Plate.
Coolant Temperature (4) – When the
coolant temperature is above the normal
operating value, the coolant
temperature gauge will be in the red zone. Refer
to the Messenger display for any additional
information that may be available.
Warning Lamp (5) – There is a general
fault in the engine. Refer to the
Messenger display for any additional
information that may be available.
Fuel Pressure (6) – This gauge indicates

fuel pressure to the fuel injection pump
from the fuel filter. A decrease in fuel
pressure usually indicates a dirty fuel filter or a
Gauge cluster and indicators plugged fuel filter. As the fuel filter becomes
plugged, there will be a noticeable reduction in
the engine's performance.
28 SEBU7901-09
Operation Section
Monitoring System
System Voltage (7) – This gauge

indicates the voltage of the electrical
system. Caterpillar Messenger Display
Circuit Breaker (8) – Reset the circuit breaker if a
circuit breaker trips. Press the button in order to reset
the circuit breaker. If the electrical system is working
properly, the button will remain pressed. If the button
does not remain pressed or if the circuit breaker trips
soon after being reset, check the appropriate
electrical circuit. Repair the electrical circuit, if
necessary.
Start Switch (9) – The start switch has three
positions: OFF, RUN and START. When the start
switch is turned clockwise to the RUN position, the
lamps will flash for five seconds during the system
test. The lamps will then shut off. In the RUN
position, the ECM and electronic systems are
powered up.
Idle Speed Switch (10) – When the
switch is in the up position, the engine Digital display area (15) – The Messenger system
speed increases to HIGH IDLE. When shows information on the digital display area.
the switch is in the down position, the engine
speed decreases to LOW IDLE. Previous button (16) – Use the previous button to
return to information that was previously shown on
Maintenance Lamp (11) – The ECM the digital display area.
records data that is related to equipment
maintenance. The ECM will activate the
maintenance indicator lamp when scheduled “ Scroll up/scroll left button”” (17) – This button is
maintenance is due. The maintenance indicator used to scroll up through information that is shown on
lamp can be reset by actuating the maintenance the display area. The button can also be used to
clear switch. The maintenance interval may be scroll to the left through information that is shown on
based on operating hours or fuel consumption. the display area.
The ECM provides information that pertains to
maintenance intervals and the last maintenance “ Scroll down/scroll right button”” (18) – This button
that was performed. is used to scroll down through information that is
shown on the display area. The button can also be
Maintenance Clear Switch (12) – The used to scroll to the right through information that is
maintenance clear switch is required to shown on the display area.
reset the maintenance lamp after
maintenance on the engine is performed.
OK button (19) – This button may be used in order to
Shutdown Switch (13) – Use the engine confirm the selections that were selected with the
“scroll up/scroll left” buttonand with the “scroll down/
shutdown switch in order to stop the scroll right” button.
engine. Push the shutdown switch in
order to put the switch in the OFF position. This
will stop the engine. After the engine stops, turn Performance Monitor Screen
the knob clockwise. This will reset the engine
shutdown switch to the ON position. The following options are available through the
performance monitor screen:
Service Tool Connector (14) – For more information
regarding the use of Caterpillar Electronic Technician Engine Speed – When you scroll to this option, the
(ET) and the PC requirements for Cat ET, refer to the performance monitor screen will show the engine
documentation that accompanies your Cat ET RPM.
software.
Engine Coolant Temperature – When you scroll to
this option, the performance monitor screen will show
the engine coolant temperature in degrees fahrenheit
or in degrees celsius.
SEBU7901-09 29
Operation Section
Monitoring System
Fuel Level – When you scroll to this option, the

performance monitor screen will show the amount of
fuel that remains in the fuel tank as a percentage of a Clear All Diagnostics – If you use an authorized
full tank. password, you can select this option in order to clear
all logged events.
Display Screen for Totals SYSTEM PARAMETERS

The following information is available through the MONITORING SYSTEM
display:
• Battery Voltage When you scroll to this option,
Service Hours – When you scroll to this option, the the battery voltage is displayed.
display shows the total amount of service hours that
the engine has accumulated. • Fuel Level When you scroll to this option, the
fuel level is displayed.
Total Time – When you scroll to this option, the
display shows the total hours for the engine ECM. • Status of the Alternator When you scroll to this
option, the status of the alternator is displayed.
Total Fuel – When you scroll to this option, the • Engine Speed When you scroll to this option,
display shows the total amount of fuel that has been the engine RPM is displayed.
consumed.
• Desired Engine Speed When you scroll to this
option, the desired engine speed is displayed.
Display Screen for Settings This parameter is used by the Automatic Retarder
Control to prevent the engine from overspeeding.
The following options are available through the If you have an approved password, you can
payload display: change this parameter.
Language – Select this option in order to change the • Throttle Position When you scroll to this option,
language that is shown on the display. the throttle position is displayed.
Units – Select this option in order to choose the • Coolant Temperature When you scroll to this
desired system of measurement. The choices are option, the coolant temperature is displayed.
metric or English.
• Coolant Flow When you scroll to this option, the
amount of coolant flow is displayed.
Adjust Contrast – Select this option in order to
adjust the contrast of the display so that visibility will • Boost Pressure When you scroll to this option,
be improved. the boost pressure is displayed.
• Atmospheric Pressure When you scroll to this
Adjust the Backlight – Select this option in order to
adjust the backlighting of the display so that visibility option, the atmospheric pressure is displayed.
will be improved. • Turbocharger Inlet Pressure When you scroll
to this option, the turbocharger inlet pressure is
Equipment ID – Select this option in order to view displayed.
the product identification number.
• Oil Pressure When you scroll to this option, the
absolute engine oil pressure is displayed.
Product Identification – Select this option in order
to view the product identification number. • Oil Pressure When you scroll to this option, the
engine oil pressure gauge is displayed.
Service Display • Fuel Temperature When you scroll to this
option, the fuel temperature is displayed.
The following options are password protection. You
must enter a password in order to change the SYSTEMS TESTS
settings.
“ SYSTEM SELF TEST””
View – Select this option in order to view events that
have been logged by the monitoring system. If you
use an authorized password, you can clear individual
events.
30 SEBU7901-09
Operation Section
Monitoring System
If you select this option, the monitoring system will • Fuel Level When this option is selected, all
initiate the self test. The self test is similar to the indicators will display the maximum values that
functional test that occurs when you turn the start were reached during operation. The fuel level
switch from the OFF position to the ON position. gauge will also show the minimum value that was
reached during operation.
INFORMATION on MONITORING and ENGINE
SYSTEMS • Clear If you have an approved password, you
can clear the maximum values that have been
MONITORING SYSTEM
stored by the monitoring system.
• Software Part Number When you scroll to this
option, the software part number is displayed.
• ECM Part Number When you scroll to this
option, the ECM part number is displayed.
• “ Software Release Date”” When you scroll to
this option, the release date of the software is
displayed.
• “ Software Description”” When you scroll to this
option, the description of the software is displayed.
ENGINE
• ECM Serial Number When you scroll to this

option, the ECM serial number is displayed.
• Software Part Number When you scroll to this
option, the software part number is displayed.
• “ Software Release Date”” When you scroll to
this option, the release date of the software is
displayed.
• “ Software Description”” When you scroll to this
option, the description of the software is displayed.
• Engine Serial Number When you scroll to this
option, the engine serial number is displayed.
TATTLETALE
• “ Full Tattletale Readout”” When this option is

selected, all displays and gauges will display the
maximum values that have been reached during
operation.
• Engine Coolant Temperature When this option

is selected, all indicators will display the maximum
values that have been reached during operation.
The engine coolant temperature gauge will also
show the maximum value that was reached during
operation.
• Tachometer When this option is selected, all

indicators will display the maximum values that
have been reached during operation. The
tachometer will also show the maximum value that
was reached during operation.
SEBU7901-09 31
Operation Section
Engine Diagnostics
Engine Diagnostics • The “DIAGNOSTIC” lamp will come on and the

“DIAGNOSTIC” lamp will remain on for five
seconds. This checks the operation of the lamp.
i01563934
• The “DIAGNOSTIC” lamp will turn off.
Self-Diagnostics
• The “DIAGNOSTIC” lamp will come on again and
SMCS Code: 1000; 1900; 1901; 1902 the “DIAGNOSTIC” lamp will flash codes for any
active diagnostic codes. Not all diagnostic codes
Caterpillar Electronic Engines have the capability to
have a unique flash code.
perform a self-diagnostics test. When the system
detects an active problem, the “DIAGNOSTIC” lamp • The “DIAGNOSTIC” lamp will turn off for five
is activated. Diagnostic codes will be stored in
seconds.
permanent memory in the Electronic Control Module
(ECM). The diagnostic codes can be retrieved by • The “DIAGNOSTIC” lamp repeats all active
using the following components:
diagnostic codes.
• Caterpillar electronic service tools A fault diagnostic code will remain active until the
problem is repaired. The electronic control module
• “DIAGNOSTIC” lamp
will continue flashing the flash code at five second
Note: The “DIAGNOSTIC” lamp must be installed by intervals until the problem is repaired.
the OEM or by the customer.
i02496338
Some installations have electronic displays that
provide direct readouts of the engine diagnostic Diagnostic Flash Code
codes. Refer to the manual that is provided by the
OEM for more information on retrieving engine Retrieval
diagnostic codes. SMCS Code: 1000; 1900; 1901; 1902
Active codes represent problems that currently exist. Problems with the electronic control system are
These problems should be investigated first. If a code reported via these types of codes: flash codes, SPN/
is active, the “DIAGNOSTIC” lamp will flash the flash FMI codes, diagnostic codes and event codes.
code at five second intervals.
Logged codes represent the following items:
• Intermittent problems
• Recorded events
• Performance history
The problems may have been repaired since the
logging of the code. These codes do not indicate that
a repair is needed. The codes are guides or signals
when a situation exists. Codes may be helpful to
troubleshoot problems.
When the problems have been corrected, the
corresponding logged fault codes should be cleared.
i01463253
Diagnostic Lamp
SMCS Code: 1000; 1900; 1901; 1902; 7451
The “DIAGNOSTIC” lamp is used to indicate the
existence of an active fault by flashing codes.
When the ignition switch is first turned on, the
“DIAGNOSTIC” lamp will go through the following
procedure:
32 SEBU7901-09
Operation Section
Diagnostic Flash Code Retrieval
Table 4
Cross Reference for Diagnostic Codes
Diagnostic Code
Flash Code SPN(1)/FMI Code or Description of Code
Event Code
1387-15 High Auxiliary Pressure Warning
1387-16 E443(2) High Auxiliary Pressure Derate
1387-00 High Auxiliary Pressure Shutdown
0441-15 High Auxiliary Temperature Warning
0441-16 E445(2) High Auxiliary Temperature Derate
0441-00 High Auxiliary Temperature Shutdown
545-05 Ether Start Relay open/short to +batt

626-05
N/A 2417-05 Ether Injection Control Solenoid open/short to +batt
545-06 Ether Start Relay short to ground

626-06
2417-06 Ether Injection Control Solenoid short to ground
1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt
1835-04 1835-04 Auxiliary Pressure Sensor short to ground
1836-03 1836-03 Auxiliary Temperature Sensor open/short to +batt
1836-04 1836-04 Auxiliary Temperature Sensor short to ground
111-02 111-02 Engine Coolant Level Sensor Loss of Signal
174-03 174-03 Fuel Temperature open/short to +batt

13
174-04 174-04 Fuel Temperature short to ground
678-03 41-03 8 Volt DC Supply short to +batt
678-04 41-04 8 Volt DC Supply short to ground
620-03
21 262-03 5 Volt Sensor DC Power Supply short to +batt
1079-03
620-04
262-04 5 Volt Sensor DC Power Supply short to ground
1079-04
100-03 100-03 Engine Oil Pressure open/short to +batt
24 100-04 100-04 Engine Oil Pressure short to ground
100-10 100-10 Engine Oil Pressure abnormal rate of change
102-03 102-03 Boost Pressure Sensor short to +batt
25 102-04 102-04 Boost Pressure Sensor short to ground
102-10 102-10 Boost Pressure Sensor abnormal rate of change
108-03 274-03 Atmospheric Pressure open/short to +batt

26
108-04 274-04 Atmospheric Pressure short to ground
110-03 110-03 Engine Coolant Temperature open/short to +batt

27
110-04 110-04 Engine Coolant Temperature short to ground
(continued)
SEBU7901-09 33
Operation Section
Diagnostic Flash Code Retrieval
(Table 4, contd)
Diagnostic Code
Event Code
28 91-13 91-13 Throttle Position calibration required
32 91-08 91-08 Throttle Position signal abnormal
190-08 190-08 Engine Speed signal abnormal

34
723-08 342-08 Secondary Engine Speed signal abnormal
190-15 Engine Overspeed Warning

35 E362(2)
190-00 Engine Overspeed Shutdown
94-03 94-03 Fuel Pressure open/short to +batt

37
94-04 94-04 Fuel Pressure short to ground
105-03 172-03 Intake Manifold Air Temp open/short to +batt

38
105-04 172-04 Intake Manifold Air Temp short to ground
42 637-13 261-13 Engine Timing calibration required
100-17 Low Engine Oil Pressure Warning
46 100-18 E360(2) Low Engine Oil Pressure Derate
100-01 Low Engine Oil Pressure Shutdown
168-00 168-00 System Voltage high
51 168-01 168-01 System Voltage low
168-02 168-02 System Voltage intermittent/erratic
56 630-02 268-02 Check Programmable Parameters
58 639-09 247-09 J1939 Data Link communications
110-15 High Engine Coolant Temperature Warning
61 110-16 E361(2) High Engine Coolant Temperature Derate
110-00 High Engine Coolant Temperature Shutdown
111-17 Low Engine Coolant Level Warning
62 111-18 E2143(2) Low Engine Coolant Level Derate
111-01 Low Engine Coolant Level Shutdown
63 94-15 E096 High Fuel Pressure Warning
1636-15 High Inlet Air Temperature Warning

64 E539(2)
1636-00 High Inlet Air Temperature Shutdown
174-15 High Fuel Temperature Warning
65 174-16 E363(2) High Fuel Temperature Derate
174-00 High Fuel Temperature Shutdown
651-05 001-05 Injector Cylinder 1 open circuit

71
651-06 001-06 Injector Cylinder 1 short
(continued)
34 SEBU7901-09
Operation Section
Fault Logging
(Table 4, contd)
Diagnostic Code
Event Code
651-11 001-11 Injector Cylinder #1 fault
72 652-06 002-06 Injector Cylinder 2 short
75 655-05 005-05 Injector Cylinder 5 open circuit
655-06 005-06 Injector Cylinder 5 short

(1) Suspect Parameter Number
(2) Caterpillar Electronic Technician (ET) will display the number 1, 2, or 3 after the event code in order to designate a warning, a derate, or a
shutdown.
For further information, see the troubleshooting guide i01797045

for your engine.
Engine Operation with Active
i03840813
Diagnostic Codes
Fault Logging SMCS Code: 1000; 1900; 1901; 1902
SMCS Code: 1000; 1900; 1901; 1902 If a diagnostic lamp illuminates during normal engine
operation, the system has identified a situation that is
The system provides the capability of Fault Logging. not within the specification. Use Caterpillar electronic
When the Electronic Control Module (ECM) service tools to check the active diagnostic codes.
generates an active diagnostic code, the code will be
logged in the memory of the ECM. The codes that Note: If the customer has selected “DERATE” and if
have been logged in the memory of the ECM can be there is a low oil pressure condition, the Electronic
retrieved with Caterpillar electronic service tools. The Control Module (ECM) will limit the engine power
codes that have been logged can be cleared with until the problem is corrected. If the oil pressure is
Caterpillar electronic service tools. The codes that
within the normal range, the engine may be operated
have been logged in the memory of the ECM will be
automatically cleared from the memory after 100 at the rated speed and load. However, maintenance
hours. The following faults cannot be cleared from should be performed as soon as possible.
the memory of the ECM without using a factory The active diagnostic code should be investigated.
password: overspeed, low engine oil pressure and The cause of the problem should be corrected as
high engine coolant temperature. soon as possible. If the cause of the active diagnostic
code is repaired and there is only one active
diagnostic code, the diagnostic lamp will turn off.
SEBU7901-09 35
Operation Section
Engine Operation with Intermittent Diagnostic Codes
Operation of the engine and performance of the “ Engine Serial Number””

engine can be limited as a result of the active
diagnostic code that is generated. Acceleration rates Program the “Engine Serial Number” to match the
may be significantly slower. Refer to the engine serial number that is stamped on the engine
Troubleshooting Guide for more information on the information plate. If the ECM is replaced, the engine
relationship between these active diagnostic codes serial number from the engine information plate must
and engine performance. be programmed into the new ECM.
i01456915 Note: When you are requesting factory passwords,

always use the engine serial number that is
Engine Operation with programmed in the ECM.
Intermittent Diagnostic Codes “ Rating Number””

SMCS Code: 1000; 1900; 1901; 1902
The “Rating Number” corresponds to the selected set
If the diagnostic lamp starts to flash codes during of performance maps for the application. This
normal engine operation and the diagnostic lamp selected set of performance maps comes out of
shuts off, an intermittent fault may have occurred. If a several unique sets of maps that are resident in the
fault has occurred, the fault will be logged into the flash file. The dealer and/or the OEM will need to
memory of the Electronic Control Module (ECM). select the appropriate rating tier, if more than one
rating tier is present. The rating tiers are “A” through
In most cases, it is not necessary to stop the engine “E” .
because of an intermittent code. However, the
operator should retrieve the logged fault codes and Refer to this Operation and Maintenance Manual,
the operator should reference the appropriate “Engine Rating Definitions” for more information
information in order to identify the nature of the event. about engine ratings.
The operator should log any observation that could
have caused the lamp to light. Note: Factory passwords are required in order to
change the “Rating Number” .
• Low power
“ Top Engine Limit”” (TEL)
• Limits of the engine speed
• Excessive smoke, etc
This information can be useful to help troubleshoot
the situation. The information can also be used for
future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this
engine.
i04228059
Configuration Parameters
SMCS Code: 1000; 1900; 1901; 1902
System configuration parameters are parameters
that affect the emissions and the power of the engine.
Default values for the parameters are programmed at
the factory. Some parameters may be changed by
the customer in order to suit the needs of the specific
application.
Parameter Descriptions
“ Equipment ID””
“TEL” is a customer programmable parameter that
defines the maximum allowable engine speed for
“Equipment ID” allows the customer to enter a
description into the Electronic Control Module (ECM) maximum power. “TEL” can be programmed up to
the maximum rated engine speed. “TEL” is defined
in order to identify the machine. A maximum of 17
along the engine's lug curve.
characters may be entered in the field. This
parameter is only for reference by the customer. This
parameter is not required.
36 SEBU7901-09
Operation Section
“ Engine Accel. Rate”” “ Intermediate Engine Speed””

“Engine Accel. Rate” determines the rate of change “Intermediate Engine Speed” defines the speed for
of the engine speed (acceleration or deceleration) the engine when the intermediate engine speed
during PTO operation. This rate of change is also switch is activated. This parameter can be
used to achieve intermediate engine speed. programmed to any engine speed between “Low Idle
Speed” and “TEL” . Engine speed will increase or
“ Low Idle Speed”” engine speed will decrease at the rate that is defined
by the programmed value for “Engine Accel. Rate” .
“Low Idle Speed” is the minimum allowable operating
speed for the engine. This parameter can be “ Maximum Engine Torque Limit””
programmed between 600 and 1400 rpm.
“ PTO Mode””
“PTO Mode” allows the ECM to be programmed to
either one of the two PTO configurations that are
available.
“ Ramp Up/Ramp Down”” – When “PTO Mode” is
programmed to “Ramp Up/Ramp Down” , the ECM
allows PTO operation with traditional features.
“ Set/Resume”” – When “PTO Mode” is programmed
to “Set/Resume” , the ECM allows PTO operation
with enhanced features.
“ High Idle Speed””
“Engine Torque Limit” can be used to limit torque

output to the programmed value when the torque limit
switch is activated.
“ FLS”” (Full Load Setting)

“FLS” is a number that represents the adjustment to
the fuel system that was made at the factory in order
to fine tune the fuel system. The correct value for this
parameter is stamped on the engine information
plate. Factory passwords are required in order to
change this parameter.
“ FTS”” (Full Torque Setting)
Illustration 23 g00763900 “FTS” is similar to “FLS” . Factory passwords are

required in order to change this parameter.
“High Idle Speed” is the maximum no-load engine
speed when the throttle or the PTO switch is in the “ Ether Control””
maximum position.
Program the “Ether Control” to “Enabled” if an ether
Note: “High Idle Speed” cannot be programmed injection system is installed on the engine. This
lower than “TEL” . allows the ECM to control ether injection. If the
engine is not equipped with ether, program this
parameter to “Disabled” .
SEBU7901-09 37
Operation Section
“ Air Shutoff””
“Air Shutoff” allows the ECM to be programmed for
operation of an air shutoff system. If this parameter is
programmed to “Installed” , the ECM will activate the
air shutoff solenoid in the event of an engine
overspeed condition.
Note: If an engine overspeed condition occurs and
“Air Shutoff” is programmed to “Enabled” , the
switched power to the ECM must be cycled and the
air shutoff solenoid must be manually reset before
the engine will restart.
“ Maintenance Indicator Mode””

The ECM records data that is related to equipment
maintenance. The ECM will activate the maintenance
indicator lamp when scheduled maintenance is due.
The maintenance indicator lamp can be reset by
actuating the maintenance clear switch. The
maintenance interval may be based on operating
hours or on fuel consumption. The ECM provides
information that pertains to maintenance intervals
and the last maintenance that was performed.
“ PM1 Interval””
“PM1 Interval” allows the customer to define the
maintenance interval if “Maintenance Indicator Mode”
is programmed to one of the manual options. Refer to
the engine's Operation and Maintenance Manual for
more information.
“ Throttle Position Sensor””

Program the “Throttle Position Sensor” to “Installed” if
a throttle position sensor is used for desired speed
control. Otherwise program this parameter to “Not
Installed” .
“ Coolant Level Sensor””

Program the “Coolant Level Sensor” to “Installed” if a
coolant level sensor is installed on the engine.
Otherwise program this parameter to “Not Installed” .
“ Aux Press Sensor Installation Status””

Program “Aux Press Enable” to “Installed” if an
auxiliary pressure sensor is installed. This will allow
the Caterpillar Messenger Driver Information Display
to monitor the pressure of another system. Program
this parameter to “Not Installed” if an auxiliary
pressure sensor is not installed.
38 SEBU7901-09
Operation Section
“ Aux Temp Sensor Installation Status””

Program “Aux Temp Enable” to “Installed” if an
auxiliary temperature sensor is installed. This will
allow the Caterpillar Messenger Driver Information
Display to monitor the temperature of another
system. Program this parameter to “Not Installed” if
an auxiliary temperature sensor is not installed.
System Configuration Parameters

Table 5
Available Range or Options Required

Parameter Default
Password
ECM Identification Parameters
“Equipment ID” 17 alphanumeric characters “NOT PROGRAMMED” None
“Engine Serial Number” 0XX00000 or XXX00000 0XX00000 None
“ECM Serial Number” “Read Only” (1)
“Software Gp Part Number” Software Dependent Read Only (1)
“Software Gp Release Date” Software Dependent Read Only (1)
Selected Engine Rating
“Rating Number” Software Dependent Customer
“Rated Power” Software Dependent Read Only (1)
“Rated Peak Torque” Software Dependent Read Only (1)
“Top Engine Speed Range” Software Dependent Read Only (1)
“Test Spec” Software Dependent Read Only (1)
“Top Engine Limit” Software Dependent Customer
“Speed Control”
“Engine Governor Primary Mode” “Speed Control” None
“Min/Max”
“Engine Accel. Rate” 50 to 1000 50 None
“Low Idle Speed” 600 to 1400 700 None
“Ramp Up/Ramp Down”

“PTO Mode” “Ramp Up/Ramp Down” None
“Set/Resume”
“High Idle Speed” 1800 to 2310 2310 Customer
“Intermediate Engine Speed” Programmed “Low Idle” to “TEL” 1100 None
“Maximum Engine Torque Limit” Software Dependent None
“Customer Password #1” 8 alphanumeric characters Blank Customer
“Customer Password #2” 8 alphanumeric characters Blank Customer
“FLS” (Full Load Setting) - 128 to 127 0 Factory
“FTS” (Full Torque Setting) -128 to 127 0 Factory
“No Ether”
“Ether Control” “No Ether” None
“Continuous Flow”
(continued)
SEBU7901-09 39
Operation Section
(Table 5, contd)
Available Range or Options Required

Parameter Default
Password
“Enabled”
“Air Shutoff” “Disabled” None
“Disabled”
“OFF”
“Auto Fuel”
“Maintenance Indicator Mode” “Auto Hour” “OFF” None
“Man Fuel”
“Man Hour”
100 to 750 Hours 250 Hours
“PM1 Interval” or or None
3785 to 28390 L (1000 to 7500 US gal) 9463 L (2500 US gal)
“Installed”
“Throttle Position Sensor” “Not Installed” None
“Not Installed”
“Installed”
“Coolant Level On” “Not Installed” None
“Not Installed”
“Last Tool to change Customer
Read Only (1)
Parameters”
“Last Tool to change System
Read Only (1)
Parameters”
“On”
“Aux Temp Sensor Installation Status” “Off” None
“Off”
“Aux Press Sensor Installation “On”
“Off” None
Status” “Off”
“Total Tattletale” Read Only (1)

(1) The parameter can only be viewed. No changes are allowed.
Parameters Worksheet (Table 6, contd)

Engine Parameters
Note: A mistake in recording this information will
result in incorrect passwords. “Rated Power”
Table 6
“Rated Peak Torque”
Engine Parameters
ECM Identification Parameters “Top Engine Speed Range”
“Equipment ID”
“Test Spec”
“Engine Serial Number”

“Top Engine Limit”
“ECM Serial Number”

“Engine Accel Rate”
“Software Gp Part Number”

“Low Idle Speed”
“Software Gp Release Date”

“PTO Mode”
Selected Engine Rating

“High Idle Speed”
“Rating Number”
(continued)
(continued)
40 SEBU7901-09
Operation Section
(Table 6, contd)
Engine Parameters (Table 6, contd)
“Intermediate Engine Speed” Injector Code (3)
“Maximum Engine Torque Limit” Injector Code (4)
“Customer Password #1” Injector Code (5)
“Customer Password #2” Injector Code (6)
“FLS”
Note: Compare the FLS and the FTS from the ECM
“FTS” with the values that are listed on the engine
information plate. Only change the FLS and the FTS
because of a mechanical change in the engine. The
“Ether Control”
use of the wrong parameters could cause damage to
the engine. The use of the wrong parameters may
“Air Shutoff” also void the Caterpillar warranty.
“Maintenance Indicator Mode”
“PM1 Interval”
“Throttle Position Sensor”
“Coolant Level Sensor”
“Last Tool to change Customer

Parameters”
“Last Tool to change System
Parameters”
“Aux Press Temp Installation
Status”
“Aux Press Sensor Installation
Status”
“Total Tattletale”
Information from Engine Information Plate
“Engine Serial Number”
“FLS”
“FTS”
Injector Codes
Injector Code (1)
Injector Code (2)
(continued)
SEBU7901-09 41
Operation Section
Engine Starting
Engine Starting • Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
i02109067 to the controls.
Before Starting Engine • Ensure that the areas around the rotating parts are
clear.
SMCS Code: 1000; 1400; 1450
• All of the guards must be put in place. Check for
Perform the required daily maintenance and other
damaged guards or for missing guards. Repair
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can any damaged guards. Replace damaged guards
help prevent major repairs at a later date. Refer to and/or missing guards.
the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for more • Disconnect any battery chargers that are not
information. protected against the high current drain that is
created when the electric starting motor (if
• For the maximum service life of the engine, make equipped) is engaged. Check electrical cables and
a thorough inspection before the engine is started. check the battery for poor connections and for
Look for the following items: oil leaks, coolant corrosion.
leaks, loose bolts and trash buildup. Remove trash
buildup and arrange for repairs, as needed. • Reset all of the shutoffs or alarm components.
• Inspect the aftercooler for loose connections and • Check the engine lubrication oil level. Maintain the
for debris buildup. oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• Inspect the cooling system hoses for cracks and
for loose clamps. • Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
• Inspect the alternator and accessory drive belts for the coolant level to the “FULL” mark on the coolant
cracks, breaks, and other damage. recovery tank.
• Inspect the wiring for loose connections and for • If the engine is not equipped with a coolant
worn wires or frayed wires. recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If
• Check the fuel supply. Drain water from the water the engine is equipped with a sight glass, maintain
separator (if equipped). Open the fuel supply the coolant level in the sight glass.
valve.
• Observe the air cleaner service indicator (if
NOTICE equipped). Service the air cleaner when the yellow
All valves in the fuel return line must be open before diaphragm enters the red zone, or when the red
and during engine operation to help prevent high fuel piston locks in the visible position.
pressure. High fuel pressure may cause filter housing
failure or other damage. • Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove
any electrical loads.
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air may i01797227
have entered the filter housing. Also, when fuel filters
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel Cold Weather Starting
system. Refer to the Operation and Maintenance SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Manual, “Fuel System - Prime” for more information
on priming the fuel system.
Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
Engine exhaust contains products of combustion personal injury.
which may be harmful to your health. Always
start and operate the engine in a well ventilated Startability will be improved at temperatures below
area and, if in an enclosed area, vent the exhaust −18 °C (0 °F) from the use of a jacket water heater or
to the outside. extra battery capacity.
42 SEBU7901-09
Operation Section
Starting the Engine
When No. 2 diesel fuel is used, the following items 2. Turn the keyswitch to the RUN position. Leave the
provide a means of minimizing starting problems and keyswitch in the RUN position for 15 seconds.
fuel problems in cold weather: engine oil pan heaters,
jacket water heaters, fuel heaters and fuel line 3. Turn the keyswitch to the START position in order
insulation. to engage the electric starting motor and crank the
engine.
Use the procedure that follows for cold weather
starting.
NOTICE
Note: Do not adjust the engine speed control during Do not engage the starting motor when flywheel is
start-up. The electronic control module (ECM) will turning. Do not start the engine under load.
control the engine speed during start-up. If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
1. Disengage any driven equipment. allow the starting motor to cool before attempting to
start the engine again.
2. Turn the keyswitch to the RUN position. Leave the
keyswitch in the RUN position for 20 seconds.
4. Allow the keyswitch to return to the RUN position
NOTICE after the engine starts.
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load. 5. Repeat step 2 through step 4 if the engine fails to
start.
If the engine fails to start within 30 seconds, release
allow the starting motor to cool before attempting to Starting a Warm Engine
start the engine again.
1. Disengage any equipment that is driven by the
engine.
3. Turn the keyswitch to the START position in order
to engage the starting motor and crank the engine. 2. Turn the keyswitch to the START position in order
to engage the electric starting motor and crank the
engine.
after the engine starts.
5. Repeat step 2 through step 4 if the engine fails to NOTICE
start. Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
6. Allow the engine to idle for three to five minutes, or
allow the engine to idle until the water temperature If the engine fails to start within 30 seconds, release
indicator begins to rise. The engine should run at allow the starting motor to cool before attempting to
low idle smoothly until speed is gradually start the engine again.
increased to high idle. Allow the white smoke to
disperse before proceeding with normal operation.
7. Operate the engine at low load until all systems after the engine starts.
reach operating temperature. Check the gauges
4. Repeat step 2 and step 3 if the engine fails to start.
during the warm-up period.
i08203805
i01903151
Starting the Engine Starting with Jump Start

SMCS Code: 1000; 1450
Cables
SMCS Code: 1000; 1401; 1402; 1900
Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will
control the engine speed during start-up.
Improper jump start cable connections can cause
Starting a Cold Engine an explosion resulting in personal injury.
1. Disengage any equipment that is driven by the Prevent sparks near the batteries. Sparks could
engine. cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
SEBU7901-09 43
Operation Section
After Starting Engine
If the installation is not equipped with a backup Note: Ensure that the self test for the monitoring
battery system, an external electrical source may be system (if equipped) is completed before operating
necessary to start the engine. the engine under load.
NOTICE When the engine idles during warm-up, observe the

Using a battery source with the same voltage as the following conditions:
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage • Check for any fluid or for any air leaks at idle rpm
the electrical system. and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
Do not reverse the battery cables. The alternator can possible in some applications.
be damaged. Attach the negative cable last and re-
move first. • Operate the engine at low idle until all systems
achieve operating temperatures. Check all gauges
When using an external electrical source to start the
engine, turn the generator set control switch to the during the warm-up period.
“OFF” position. Turn all electrical accessories OFF Note: Gauge readings should be observed and the
before attaching the jump-start cables.
data should be recorded frequently while the engine
Ensure that the main power switch is in the OFF posi- is operating. Comparing the data over time will help
tion before attaching the jump-start cables to the en- to determine normal readings for each gauge.
gine being started. Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
1. Turn the start switch to the OFF position. Turn off
all accessories.
2. Connect one positive end of the jump-start cable to
the positive cable terminal of the discharged
battery. Connect the other positive end of the
jump-start cable to the positive cable terminal of
the electrical source.
3. Connect one negative end of the jump-start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump-start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.
4. Start the engine.
5. Immediately after the stalled engine is started,
disconnect the jump-start cables in reverse order.
Note: If there is a problem with the alternator or the
battery charger, the engine will not continue to run
after starting. The engine may continue to run if
power to the engine control module is supplied by a
separate source.
i01646248
After Starting Engine

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

the warm-up time is approximately three minutes. In
temperatures below 0°C (32°F), additional warm-up
time may be required.
44 SEBU7901-09
Operation Section
Engine Operation
Engine Operation Engines rated for constant speed use are allowed to
complete a starting sequence, an operation at a
single constant speed, and a shutdown sequence.
i06545691 Every time the engine is run, each of these
operations should occur only once. The starting
Engine Operation sequence and shutdown sequence can include a
short period of operation at the low idle speed for
SMCS Code: 1000 purposes of warming up and cooling down the engine
or driven equipment. The emissions type approval is
Correct operation and maintenance are key factors in not valid for operation of a constant speed engine in
obtaining the maximum life and economy of the a manner different from that described above.
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be i01196062
minimized and engine service life can be maximized.
The engine can be operated at the rated rpm after Engaging the Driven
the engine reaches operating temperature. The
engine will reach normal operating temperature Equipment
sooner during a low engine speed (rpm) and during a SMCS Code: 1000
low-power demand. This procedure is more effective
than idling the engine at no load. The engine should If the load varies, or if the load is cyclic, the governor
reach operating temperature in a few minutes. will adjust the engine rpm, as needed.
Gauge readings should be observed and the data Extended operation at low idle or extended operation
should be recorded frequently while the engine is at a reduced load may cause increased oil
operating. Comparing the data over time will help to consumption and carbon buildup in the cylinders.
determine normal readings for each gauge. This carbon buildup results in a loss of power and/or
Comparing data over time will also help detect poor performance. When the engine is operated at a
abnormal operating developments. Significant reduced load, the engine should be fully loaded at
changes in the readings should be investigated. every four hours in order to burn excess carbon from
the cylinders.
Minimum Engine Run Time
Industrial Engines
Changes to the operating cycle may be required
when the engines are applied in a manner that will 1. When the engine is operating, check the engine
result in repeated occurrences of less than one hour gauges. The engine gauges should be in the
of continuous run time. normal range before you engage the driven
In order for the exhaust aftertreatment to function equipment.
properly, the engine must complete a DPF
regeneration to 0 percent soot load once in every 24 2. Engage the driven equipment. Begin operating the
hours of engine run time. engine at low load. Check the gauges and check
the equipment for proper operation. Check the
After this regeneration to 0 percent soot has finished, gauges and check the equipment frequently while
an additional 70 minutes of run time is needed for Cat
Regeneration System fuel nozzle maintenance. Both the engine is operating under load.
of these requirements can be run with or without load
on the engine. i05893104
Fuel Conservation Practices

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

Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
SEBU7901-09 45
Operation Section
Fuel Conservation Practices
• Be aware of the properties of the different fuels.

Use only the recommended fuels.
• Avoid unnecessary operation at no load.

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

belts should be in good condition.
• Ensure that all of the connections of the hoses are

tight. The connections should not leak.
• Ensure that the driven equipment is in good
working order.
• Cold engines consume excess fuel. Keep cooling
system components clean and keep cooling
system components in good repair. Never operate
the engine without water temperature regulators.
All of these items will help maintain operating
temperatures.
46 SEBU7901-09
Operation Section
Cold Weather Operation
Cold Weather Operation There are three major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
i01646447
• Lower cloud point
Radiator Restrictions • Lower pour point
SMCS Code: 1353; 1396
• Lower rating of kJ (BTU) per unit volume of fuel
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow When No. 1 diesel fuel is used, a decrease in power
restriction can cause the following conditions: and in fuel efficiency may be noticed. Other operating
effects should not be experienced.
• High exhaust temperatures
The cloud point is the temperature when a cloud of
• Power loss wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is the
• Excessive fan usage temperature when diesel fuel will thicken. The diesel
fuel becomes more resistant to flow through fuel
• Reduction in fuel economy pumps and through fuel lines.
If an airflow restriction device must be used, the Be aware of these values when diesel fuel is
device should have a permanent opening directly in purchased. Anticipate the average ambient
line with the fan hub. A centered opening that is temperature for the engine area. Engines that are
directly in line with the fan hub is specified in order to fueled in one climate may not operate well if the
prevent an interrupted airflow on the fan blades. engines are moved to another climate. Problems can
Interrupted airflow on the fan blades could cause a result due to changes in temperature.
fan failure.
Before troubleshooting for low power or for poor
Caterpillar recommends a warning device for the inlet performance during cold weather, check the type of
manifold temperature and/or the installation of an fuel that is being used.
inlet air temperature gauge. The warning device for
the inlet manifold temperature should be set at 75 °C
(167 °F). The inlet manifold air temperature should i02469608
not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential Fuel Related Components in
engine damage.
Cold Weather
i01872912 SMCS Code: 1000; 1250; 1280
Fuel and the Effect from Cold Fuel Tanks

Weather Condensation can form in partially filled fuel tanks.
SMCS Code: 1000; 1250; 1280 Top off the fuel tanks after you operate the engine.
The following fuels are the grades that are available Fuel tanks should contain some provision for draining
for Caterpillar engines: water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
• No. 1 and sediment to settle below the end of the fuel
supply pipe.
• No. 2
Some fuel tanks use supply lines that take fuel
• Blend of No. 1 and No. 2 directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
No. 2 diesel fuel is the most commonly used fuel. the fuel system filter is important.
Either No. 1 diesel fuel or a blend of No. 1 and No. 2
is best suited for cold weather operation.
Quantities of No. 1 diesel fuel are limited. No. 1
diesel fuels are usually available during the months
of the winter in the colder climates. During cold
weather operation, if No. 1 diesel fuel is not available,
use No. 2 diesel fuel, if necessary.
SEBU7901-09 47
Operation Section
Fuel Related Components in Cold Weather
Drain the water and sediment from any fuel storage

tank at the following intervals: weekly, oil changes
and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.
Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information.
The micron rating and the location of a primary fuel
filter is important in cold weather operation. The
primary fuel filter and the fuel supply line are the most
common components that are affected by cold fuel.
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in the fuel system before the primary fuel
filter.
For further information on fuel heaters, consult your
Caterpillar dealer.
Disconnect the fuel heater in warm weather.
Note: Fuel heaters that are controlled by the water
temperature regulator or self-regulating fuel heaters
should be used with this engine. Fuel heaters that are
not controlled by the water temperature regulator can
heat the fuel in excess of 65°C (149°F). A loss of
engine power can occur if the fuel supply
temperature exceeds 37°C (100°F).
Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
the fuel in warm weather operation.
48 SEBU7901-09
Operation Section
Engine Stopping
Engine Stopping Refer to Operation and Maintenance Manual,

“Features and Controls” for the location and the
operation of the emergency stop button.
i06171418
i08257497
Emergency Stopping
SMCS Code: 1000; 7418 Manual Stop Procedure
SMCS Code: 1000; 7418
NOTICE
Emergency shutoff controls are for EMERGENCY NOTICE
use ONLY. DO NOT use emergency shutoff devices Stopping the engine immediately after it has been
or controls for normal stopping procedure. working under load can result in overheating and ac-
celerated wear of the engine components.
Ensure that any components for the external system
that support the engine operation are secured after If the engine has been operating at high rpm and/or
the engine is stopped. high loads, run at low idle for at least three minutes to
reduce and stabilize internal engine temperature be-
Emergency Stop Button (If fore stopping the engine.
Equipped) Avoiding hot engine shutdowns will maximize turbo-
charger shaft and bearing life.
Note: Individual applications have different control

systems. Ensure that the shutoff procedures are
understood. Use the following general guidelines to
stop the engine.
1. Remove the load from the engine so that the

engine has no more than 30% power.
2. Run the engine at the programmed low idle speed
for at least 3 minutes.
3. After the cool down period, turn the start switch to
the OFF position.
i04137729
After Stopping Engine

SMCS Code: 1000
Note: After operation, allow 10 minutes for the

engine oil to return to the oil pan before checking the
Typical emergency stop symbol located near the engine oil level.
emergency stop button
• Check the crankcase oil level. Maintain the oil
The emergency stop button is in the OUT position for level between the “ADD” mark and the “FULL”
normal engine operation. Push the emergency stop mark on the oil level gauge.
button. The engine will not start when the button is
locked. Turn the button clockwise in order to reset. Note: Only use oil that is recommended in this
Operation and Maintenance Manual, “Fluid
Recommendations” article. Failure to do so may
result in engine damage.
• If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.
• Note the service hour meter reading. Perform the
maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
SEBU7901-09 49
Operation Section
After Stopping Engine
• Fill the fuel tank to prevent accumulation of

moisture in the fuel. Do not overfill the fuel tank.
• Allow the engine to cool. Check the coolant level.

Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling.
Note: Only use coolant that is recommended in this

Operation and Maintenance Manual, “Fluid
Recommendations” article. Failure to do so may
result in engine damage.
• 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.
50 SEBU7901-09
Maintenance Section
Refill Capacities
Maintenance Section Table 7

Approximate Refill Capacities of the Engine Lubrication
System
Refill Capacities Compartment or System C11 and C13
Standard Oil Pan(1) 34 L (36 qt)

i04228154
Deep Oil Pan(1) 40 L (42 qt)
Refill Capacities Capacity of the Auxiliary Oil Filter System(2)
SMCS Code: 1000; 1348; 1395; 7560 Total Capacity of the Lubrication System(3)
Refer to this Operation and Maintenance Manual, (1) Approximate sump capacity of the crankcase includes the
“Fluid Recommendations” for information about standard oil filters that are factory installed. Engines with auxili-
choosing the correct fluids for your engine. ary oil filters will require additional oil. Optional bypass oil filters
that are supplied by Caterpillar require an additional 3 L
(3.2 qt)of oil. If the engine is equipped with another type of aux-
Engine Oil iliary oil filter, refer to the OEM specifications for the capacity of
the auxiliary oil filter.
(2) Fill in the capacity of the auxiliary oil filter system (if equipped)
The capacity of the engine lubrication system
in the space that is provided.
includes the capacity of the oil filters that are installed (3) Fill in the total capacity of the lubrication system. Add the auxili-
at the factory. Auxiliary oil filter systems (if equipped) ary oil filter system to the correct capacity of the oil sump in or-
will require additional oil. Refer to the specifications der to find the total capacity of the lubrication system.
that are provided by the OEM of the auxiliary oil filter
system.
Coolant
To maintain the cooling system, the total cooling
system capacity must be known. The capacity of the
total cooling system will vary. The capacity will
depend on the size of the radiator (capacity) that is
provided by the vehicle manufacturer. Table 8 should
be completed by the customer for the maintenance of
the cooling system.
Table 8
Approximate Capacity of the Cooling System
Compartment or
Liters Quarts
System
Total Cooling Sys-

Illustration 26 g01011620 tem(1)
C11 and C13 standard oil pan (1) The total cooling system capacity includes the following compo-
nents:the engine block, the radiator and all coolant hoses and
lines.
i04327214
Fluid Recommendations
SMCS Code: 1280; 1348; 1395; 7560
Refer to this Operation and Maintenance Manual,
“Severe Service Application” for information about
operating an engine in a severe service application.
Note: The interval for changing the coolant varies

depending on the type of coolant being replaced.
Refer to this article, “Coolant Recommendations”, for
the intervals for changing the coolant.
C11 and C13 deep oil pan
SEBU7901-09 51
Maintenance Section
Diesel Engine Oil Table 10

Cat Engine Crankcase Fluids (ECF) Definitions
For more information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids Cat Performance
Cat ECF Specifications Requirements
Recommendations”. Requirement
API CJ-4 Oil Category performance

Cat Diesel Engine Oil (Cat DEO) Cat ECF-3
requirements
Cat oils have been developed and tested in order to API CI-4 / CI-4 PLUS Oil Category per-
provide the full performance and service life that has formance requirements
been designed and built into Cat engines. Cat oils
Passing standard Cat C13 engine test
are currently used to fill Cat Diesel Engines at the Cat ECF-2
per API requirements
factory. These oils are offered by Cat dealers for
continued use when the engine oil is changed. Oils of sulfated ash > 1.50 percent are
Consult your Cat dealer for more information on not allowed
these oils.
API CH-4 Oil Category performance
Due to significant variations in the quality and in the requirements
performance of commercially available oils,
Caterpillar makes the following recommendations: For oils that are between 1.30 percent
and 1.50 percent sulfated ash, passing
Table 9 Cat ECF-1-a
one additional Cat 1P SCOTE test
Cat Lubricants Viscosity Grade (“ASTM D6681”) is required
SAE 15W-40 Oils of sulfated ash > 1.50 percent are

Cat DEO-ULS not allowed
Diesel Engine SAE 10W-30
Oil-Ultra Low Cat DEO-ULS SYN SAE 5W-40 In selecting oil for any engine application, both of the
Sulfur following must be satisfied: the oil viscosity and the
Cat Cold Weather
DEO-ULS
SAE 0W-40 category of oil performance or the specification for oil
performance . Using only one of these parameters
SAE 15W-40 will not sufficiently define oil for an engine
Diesel Engine Cat DEO application.
SAE 10W-30
Oil
Cat DEO SYN SAE 5W-40 The proper SAE viscosity grade of oil is determined
by the following temperatures: minimum ambient
temperature during cold engine start-up and
Note: Cat DEO and Cat DEO-ULS multigrade oils maximum ambient temperature during engine
are the preferred oils for use in this Cat Diesel operation.
Engine.
Refer to Table 11 (minimum temperature) in order to
Commercial Oil determine the required oil viscosity for starting a cold
engine.
Note: Non-Cat commercial oils are second choice Refer to Table 11 (maximum temperature) in order to
oils for your engine. select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
NOTICE
Caterpillar does not warrant the quality or perform- Note: Generally, use the highest oil viscosity that is
ance of non-Cat fluids. available to meet the requirement for the temperature
at start-up.
The three current Caterpillar ECF specifications are:
Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each Table 11
higher Cat ECF specification provides increased
Lubricant Viscosities for Ambient Temperatures
performance over lower Cat ECF specifications. for Cat Diesel Engines
A commercial oil must meet the following standards Oil Type and Per- °C °F
to be considered an equivalent of a Cat Diesel formance
Viscosity
Engine Oil: Grade Min Max Min Max
Requirements
(continued)
52 SEBU7901-09
Maintenance Section
(Table 11, contd) Table 12

Lubricant Viscosities for Ambient Temperatures TBN recommendations for applications in Cat engines
for Cat Diesel Engines (1)
Cat ECF-1-a TBN of Com-

Fuel Sulfur Level per-
Cat ECF-2 SAE 0W-30 −40 30 −40 86 Cat Engine Oils mercial Engine
cent (ppm)
Cat ECF-3 Oils
Cat Cold Weather ≤0.05 percent (≤500 Cat DEO-ULS

Min 7
DEO-ULS ppm) Cat DEO
Cat ECF-1-a SAE 0W-40 −40 40 −40 104
Cat ECF-2 0. 1- 0.05 percent Cat DEO-ULS
Min 7
Cat ECF-3 (1000-500 ppm) Cat DEO
Cat DEO-ULS Above 0.1 percent

Cat DEO(3) Min 10
Cat ECF-1-a (above 1000 ppm)(2)
SAE 5W-30 −30 30 −22 86
Cat ECF-2 (1) When using fuel with 0.10% sulfur (1000 ppm) or higher, refer
Cat ECF-3 to this Operation and Maintenance Manual, “Severe Service
Cat DEO-ULS SYN Application” for more information.
(2) For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
Cat DEO
refer to TBN and engine oil guidelines given in this section.
Cat ECF-1-a SAE 5W-40 −30 50 −22 122 (3) Cat DEO-ULS may be used if an oil analysis program is fol-
Cat ECF-2 lowed. Base the oil change interval on the analysis.
Cat ECF-3
Cat ECF-1-a
SAE 10W- S·O·S Services Oil Analysis
Cat ECF-2 −18 40 0 104
30
Cat ECF-3 Caterpillar has developed a maintenance tool that
SAE 10W- evaluates oil degradation. the maintenance
−18 50 0 122 management also detects the early signs of wear on
Cat DEO-ULS 40
Cat DEO
internal components. The Caterpillar tool for oil
SAE 15W- analysis is called S·O·S oil analysis and the tool is
−9.5 50 15 122
40 part of the S·O·S Services program. S·O·S oil
analysis divides oil analysis into four categories:
Note: A cold soaked start occurs when the engine
has not been operated recently, allowing the oil to • Component wear rate
become more viscous due to cooler ambient • Oil condition
temperatures. Supplemental heat is recommended
for cold soaked starts below the minimum ambient • Oil contamination
temperature. Supplemental heat may be necessary
for cold soaked starts that are above the minimum • Identification of oil
temperature depending on factors such as parasitic
load. These four types of analysis are used to monitor the
condition of your equipment. The four types of
analysis will also help you identify potential problems.
Total Base Number (TBN) and Fuel Sulfur A properly administered S·O·S oil analysis program
Levels will reduce repair costs and the program will lessen
the impact of downtime.
The use of Cat S·O·S Services oil analysis is
recommended strongly for determining oil life. The S·O·S Oil Analysis program uses a wide range
of tests to determine the condition of the oil and the
The minimum required Total Base Number (TBN) for crankcase. Guidelines that are based on experience
oil depends on the fuel sulfur level. The TBN for new and a correlation to failures have been established
oil is typically determined by the “ASTM D2896” for these tests. Exceeding one or more of these
procedure. For direct injection engines that use guidelines could indicate serious fluid degradation or
distillate fuel, the following guidelines apply: a pending component failure. A trained person at
your Cat dealership should make the final analysis.
SEBU7901-09 53
Maintenance Section
The preferred fuels provide maximum engine

NOTICE service life and performance. The preferred fuels
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam- are distillate fuels. These fuels are commonly called
pling. Using the same pump for both types of sam- diesel fuel, furnace oil, gas oil, or kerosene. These
ples may contaminate the samples that are being fuels must meet the “Cat Specification for Distillate
drawn. This contaminate may cause a false analysis Diesel Fuel for Off-Highway Diesel Engines” found in
and an incorrect interpretation that could lead to con- this Special Publication, “Distillate Diesel Fuel”
cerns by both dealers and customers. article.
Note: The permissible fuels are some crude oils,
Refer to Special Publication, SEBU6251, “Cat some blends of crude oil with distillate fuel, some
Commercial Diesel Engine Fluids biodiesel, and some marine diesel fuel. These fuels
Recommendations” in order to obtain additional are not suitable for use in all engine applications.
information about S·O·S Services oil analysis. You The acceptability of these fuels for use is determined
can also contact your local Cat dealer. on a case by case basis. A complete fuel analysis is
required. Consult your Cat dealer for further
Fuel information.
Note: Caterpillar strongly recommends the filtration NOTICE

of fuel through a fuel filter with a rating of four The footnotes are a key part of the “Caterpillar Speci-
microns(c) absolute or less. This filtration should be fication for Distillate Diesel Fuel for Off-Highway Die-
located on the device that dispenses the fuel to the sel Engines” Table. Read ALL of the footnotes.
fuel tank for the engine. This filtration should also be
located on the device that dispenses fuel from the Table 13
bulk storage tank. Series filtration is recommended. Caterpillar Specification for Distillate Fuel for Nonroad
Diesel Engines
NOTICE
In order to meet expected fuel system component life, ASTM
4 micron (c) absolute or less secondary fuel filtration Specifications Requirements Test ISO Test
is required for all Cat Diesel Engines that are Aromatics 35% maximum “D1319” “ISO 3837”
equipped with unit injected fuel systems. All current
Cat Diesel Engines are factory equipped with Cat Ad- 0.01% maximum
Ash “D482” “ISO 6245”
vanced Efficiency 4 micron(c) absolute fuel filters. (weight)
Carbon Residue 0.35% maximum

Caterpillar does not warrant the quality or perform- “D524” “ISO 4262”
on 10% Bottoms (weight)
ance of non-Cat fluids and filters.
40 minimum (DI
Diesel engines can burn a wide variety of fuels. engines) “D613”
These fuels are divided into two general groups. The Cetane Number (1) or “ISO 5165”
two groups are called the preferred fuels and the 35 minimum (PC “D6890”
permissible fuels. engines)
Note: The permissible fuels are some crude oils, The cloud point
must not exceed
some blends of crude oil with distillate fuel, some
Cloud Point the lowest ex- “D2500” “ISO 3015”
biodiesel, and some marine diesel fuel. These fuels pected ambient
are not suitable for use in all engine applications. The temperature.
acceptability of these fuels for use is determined on
an individual basis. A complete fuel analysis is Copper Strip
No. 3 maximum “D130” “ISO 2160”
required. Corrosion
10% at 282 °C
For more information, refer to Special Publication, (540 °F)
SEBU6251, “Cat Commercial Diesel Engine Fluids maximum
Recommendations” or consult your Cat dealer for Distillation “D86” “ISO 3405”
further information. 90% at 360 °C
(680 °F)
maximum
Diesel Distillate Fuel
Flash Point legal limit “D93” “ISO 2719”
Diesel engines may burn a wide variety of fuels.
These fuels are divided into two general groups. The
two groups are called the preferred fuels and the
(continued)
permissible fuels.
54 SEBU7901-09
Maintenance Section
(Table 13, contd) (Table 13, contd)

(4) Certain Cat fuel systems and engine components can operate
Caterpillar Specification for Distillate Fuel for Nonroad
on fuel with a maximum sulfur content of 3%. Contact your Cat
Diesel Engines dealer for guidance about appropriate maintenance intervals
and fluids for engines operating on fuel with sulfur levels be-
ASTM tween 0.1% and 3%.
Specifications Requirements Test ISO Test (5) An engine which operates on fuel with 0.1% (1000 ppm) of sul-
fur or more is operating in a severe service application. Refer to
Minimum of 80%
this Operation and Maintenance Manual, “Severe Service Ap-
reflectance after plication” for information about operating an engine in a severe
No equiva-
Thermal Stability aging for 180 mi- “D6468” service application.
lent test
nutes at 150 °C (6) Follow the test conditions and procedures for gasoline (motor).
(302 °F)
30 minimum No equiva- Biodiesel

API Gravity (2) “D287”
45 maximum lent test
A biodiesel blend of up to 20 percent may be used in
6 °C (10 °F) mini- the engine when the fuel blend meets the
Pour Point mum below ambi- “D97” “ISO 3016” recommendations in table 14 and meets the
ent temperature recommendations in Special Publication, SEBU6251,
“Biodiesel”.
“D5453” ISO 20846
Sulfur (3)(4)(5) or or Note: A complete Cat S·O·S Services oil analysis
“D2622” ISO 20884 program is recommended strongly when using
1.4 cSt minimum
biodiesel blends above 5 percent.
and 20.0 cSt max-
Table 14
imum as delivered
to the fuel injec- Biodiesel Blends for Cat Commercial Diesel Engines
Kinematic tion pumps
- - Distillate diesel fuel
Viscosity Biodiesel blend stock Final blend
1.4 cSt minimum used for blend
and 4.5 cSt maxi-
Caterpillar distillate
mum as delivered Caterpillar biodiesel B20: “ASTM
diesel fuel specifica-
to the rotary fuel specification, “ASTM D7467” and “API”
tion, “ASTM D975” or
injection pumps D6751” or “EN14214” gravity 30-45
“EN590”
“D1796”
Water and
0.05% maximum or “ISO 3734”
Sediment
“D2709” Fuel Additives
No equiva- Cat Diesel Fuel Conditioner
Water 0.05% maximum “D6304”
lent test
0.05% maximum Cat Diesel Fuel Conditioner is a proprietary
Sediment “D473” “ISO 3735” formulation that has been extensively tested for use
(weight)
with distillate diesel fuels for use in Cat Diesel
Gums and Resins 10 mg per 100 mL Engines. Cat Diesel Fuel Conditioner is a high
“D381” “ISO 6246”
(6) maximum performance diesel fuel conditioner for use with lower
quality fuels that do not meet the minimum
0.52 mm
requirements of any of the following:
(0.0205 inch) No equiva-
Lubricity “D6079”
maximum at 60 °C lent test • “Caterpillar Specification for Distillate Diesel Fuel”
(140 °F)
(1) Alternatively, to ensure a minimum cetane number of 35 (PC • National Conference on Weights and Measures
engines), and 40 (DI engines), distillate diesel fuel should have (NCWM) Premium Diesel definition (refer to the
a minimum cetane index of 37.5 (PC engines), and 44.2 (DI en- 2004 or newer National Institute of Standards &
gines) when the “ASTM D4737-96a” test method is used. A fuel
with a higher cetane number may be required for operation at a Technology (NIST) Handbook).
higher altitude or in cold weather.
(2) Via standards tables, the equivalent kg/m3 (kilograms per cubic • EN590 (non-arctic)
meter) using the “ASTM D287” test method temperature of
15.56° C (60° F) for the minimum API gravity of 30 is 875.7 kg/ • ASTM D975
m3, and for the maximum API gravity of 45 is 801.3 kg/m3.
(3) ULSD 0.0015% (<15 ppm S) is required by law for Tier 4 en- Cat Diesel Fuel Conditioner is the only fuel
gines and engines with aftertreatment devices. conditioner/additive available to the end user that is
tested and approved by Caterpillar for use in Cat
Diesel Engines.
(continued)
SEBU7901-09 55
Maintenance Section
Refer to Special Publication, SEBU6251, “Cat Note: For best results, your fuel supplier should treat
Commercial Diesel Engine Fluids the fuel when additives are needed.
Recommendations” for information about the use of
Cat Diesel Fuel Conditioner.
Cooling System
Cat Diesel Fuel System Cleaner
Note: Refer to Special Publication , SEBU6251, “Cat
Note: Cat Diesel Fuel System Cleaner is the only fuel Commercial Diesel Engine Fluids
system cleaner available to the end user that is Recommendations” for complete information about
tested and approved by Caterpillar for use in Cat the proper fluids for use in the cooling system.
Diesel Engines.
Cat Diesel Fuel System Cleaner is a proven high
performance detergent product designed specifically The cooling system operates under pressure
for cleaning deposits that form in the fuel system. which is controlled by the radiator pressure cap.
Deposits in the fuel system reduce system Removing the cap while the system is hot may al-
performance and can increase fuel consumption. Cat low the escape of hot coolant and steam, causing
Diesel Fuel System Cleaner addresses the deposits serious burns.
formed due to the use of degraded diesel fuel, poor
quality diesel fuel, and diesel fuel containing high Before you remove the radiator cap, allow the
quantities of high molecular weight compounds. Cat system to cool. Use a thick cloth and turn the ra-
Diesel Fuel System Cleaner addresses deposits diator cap slowly to the first stop to allow pres-
formed due to the use of biodiesel, biodiesel blends, sure to escape before fully removing the cap.
and biodiesel that does not meet the appropriate
quality specifications. Continued use of Cat Diesel Avoid contact with coolant.
Fuel System Cleaner is proven to inhibit the growth of
new deposits.
Caterpillar strongly recommends that Cat Diesel NOTICE
Never add coolant to an overheated engine. Engine
Fuel System Cleaner be used with biodiesel and damage could result. Allow the engine to cool first.
biodiesel blends. Cat Diesel Fuel System Cleaner is
suitable for use with biodiesel/biodiesel blends that
meet Caterpillar biodiesel recommendations and
requirements. Not all fuel cleaners are suitable for NOTICE
use with biodiesel/biodiesel blends. Read and follow If the engine is to be stored in, or shipped to an area
all applicable label usage instructions. Also, refer to with below freezing temperatures, the cooling system
Special Publication, SEBU6251, “Cat Commercial must be either protected to the lowest outside tem-
Diesel Engine Fluids Recommendations” “Distillate perature or drained completely in order to prevent
Diesel Fuel”, article and also refer to the “Biodiesel” damage caused by freezing coolant.
article, which includes Caterpillar biodiesel
recommendations and requirements. Never operate an engine without water temperature
regulators in the cooling system. Water temperature
Aftermarket Fuel Additives regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system
There are many different types of fuel additives that problems can develop without water temperature
are available to use. Caterpillar does not generally regulators. Removing the regulators allows some
recommend the use of fuel additives. coolant to bypass the radiator, potentially causing
overheating.
In special circumstances, Caterpillar recognizes the
need for fuel additives. Use fuel additives with Coolant Recommendations
caution. The additive may not be compatible with the
fuel. Some additives may precipitate. This action
causes deposits in the fuel system. The deposits may Note: A Cat Diesel Engine equipped with air-to-air
cause seizure. Some additives may plug fuel filters. aftercooling (ATAAC) requires a minimum of 30
Some additives may be corrosive, and some percent glycol to help prevent water pump cavitation.
additives may be harmful to the elastomers in the fuel
system. Some additives may damage emission
control systems. Some additives may raise fuel sulfur
levels above the maximum levels that are allowed by
the following agencies: EPA and other regulatory
agencies. Contact your fuel supplier for those
circumstances when fuel additives are required. Your
fuel supplier can make recommendations for
additives to use and for the proper level of treatment.
56 SEBU7901-09
Maintenance Section
Table 15
Coolant Recommendations for use in Cat Diesel Engines
Service Hours
Recommendations Product (1)(2)(3)
Required Maintenance
Add Cat ELC Extender at

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

3000 hours or 3
Acceptable Cat DEAC (Cat Diesel Engine Antifreeze/Coolant) ant additive) at mainte-
years
nance intervals
“ASTM D6210” and
Min requirements for fully Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US
3000 hours or 2 SCA at maintenance
formulated Heavy Duty gal) and maximum of 2400 ppm (140 grains/US gal)
years intervals
Commercial coolants Silicon concentration: minimum of 100 ppm and maximum of 275
ppm
“ASTM D4985” and(1)

Min requirements for Com- Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US
3000 hours or 1 SCA at initial fill and SCA
mercial coolants requiring gal) and maximum of 2400 ppm (140 grains/US gal)
year at maintenance intervals
SCA precharge Silicon concentration: minimum of 100 ppm and maximum of 275
ppm
(1) New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets
Reagent 4 “ASTM D1193” requirements.
(2) Maintain the in-service coolant at the given limits.
(3) When referring to the service hours, use the interval that occurs first. These coolant change intervals are only achievable with annual S·O·S
Services Level 2 coolant sampling analysis.
Table 16
Special Requirements
Cat C7-C32 Marine Engines with heat exchangers
Minimum of 30% glycol is required. 50% Glycol is recommended.
Cat diesel engines equipped with air-to-air aftercooling (ATAAC) Water alone or water with SCA or with ELI is NOT allowed.
SEBU7901-09 57
Maintenance Section
The following properties of the coolant are tested:

NOTICE
Use Only Approved SCAs and Extenders
• Glycol concentration for freeze protection and boil
Conventional coolants require the maintenance addi- protection
tion of SCA throughout the expected life of the cool-
ants. Do NOT use an SCA with a coolant unless • Ability to protect from erosion and corrosion
approved specifically by the coolant supplier. The
coolant manufacturer is responsible for ensuring • pH
compatibility and acceptable performance.
• Conductivity
To help ensure expected performance, EC-1 coolants
require the one time maintenance addition of an ex- • Visual analysis
tender at coolant service mid-life. Do not use an ex-
tender with a coolant unless the extender has been • Odor analysis
approved specifically for use by the coolant manufac-
turer. The coolant manufacturer is responsible for en- The results are reported, and appropriate
suring compatibility and acceptable performance. recommendations are made.
Failure to follow these recommendations can result in S·O·S Services Coolant Analysis (Level 2)
shortened cooling system component life.
A coolant analysis (Level 2) is a comprehensive
Cat ELC can be recycled into conventional coolants. chemical evaluation of the coolant. This analysis is
also a check of the overall condition of the cooling
For more information, refer to Special Publication, system.
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”. The S·O·S coolant analysis (Level 2) has the
following features:
S·O·S Services Coolant Analysis
• Full coolant analysis (Level 1)
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and • Identification of metal corrosion and of
corrosion. The analysis also tests the ability of the contaminants
coolant to protect the engine from boiling and
freezing. S·O·S coolant analysis can be done at your • Identification of buildup of the impurities that
Cat dealer. Cat S·O·S coolant analysis is the best cause corrosion
way to monitor the condition of your coolant and your
cooling system. S·O·S coolant analysis is a program • Identification of buildup of the impurities that
that is based on periodic samples. cause scaling
Table 17 • Determination of the possibility of electrolysis
within the cooling system of the engine
Recommended Interval
The results are reported, and appropriate
Type of recommendations are made.
Level 1 Level 2
Coolant
For more information on S·O·S coolant analysis,
Cat DEAC consult your Cat dealer.
Conventional Heavy- Every 250 hours Yearly(1)
Duty Coolants
Greases
Cat ELC
Cat ELI
Optional Yearly(1)
If it is necessary to choose a single grease, always
Commercial EC-1 choose a grease that meets or exceeds the
Coolants requirements of the most demanding application.
(1) The Level 2 Coolant Analysis should be performed sooner if a Remember that the products which barely meet the
problem is suspected or identified. minimum performance requirements can be
expected to barely produce the minimum lives of your
Note: Check the SCA (Supplemental Coolant parts. False economy is being used if a grease is
Additive) of the conventional coolant at every oil purchased with the lowest cost as the only
consideration. Instead, use the grease that yields the
change or at every 250 hours. Perform this check at
lowest total operating cost. The cost should be based
the interval that occurs first. on an analysis that includes the costs of parts, labor,
downtime, and the cost of the amount of grease that
S·O·S Services Coolant Analysis (Level 1)
is required.
A coolant analysis (Level 1) is a test of the properties
of the coolant.
58 SEBU7901-09
Maintenance Section
For more information, refer to Special Publication,

SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.
SEBU7901-09 59
Maintenance Section
Maintenance Recommendations
Maintenance Do not loosen the high-pressure fuel lines to remove

air pressure from the fuel system.
Recommendations
Engine Oil
i08186078
To relieve pressure from the lubricating system, turn
System Pressure Release off the engine.
SMCS Code: 1250; 1300; 1350; 5050 i08254042
Coolant System Welding on Engines with

Electronic Controls
SMCS Code: 1000
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra- NOTICE
diator is cool. Then loosen cap slowly to relieve Because the strength of the frame may decrease,
the pressure. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Cat dealer regarding welding on a chas-
off the engine. Allow the cooling system pressure cap sis frame or rail.
to cool. Remove the cooling system pressure cap
slowly to relieve pressure. Proper welding procedures are necessary to avoid
damage to the engine ECM, sensors, and associated
Fuel System components. When possible, remove the component
from the unit and then weld the component. If
removal of the component is not possible, the correct
To relieve the pressure from the fuel system, turn off
procedure must be followed. When welding on a unit
the engine.
that is equipped with a Cat Electronic Engine, the
following is considered to be the safest procedure:
High-Pressure Fuel Lines (If Equipped)
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding
Contact with high pressure fuel may cause fluid can cause damage to the drive train, the bearings,
penetration and burn hazards. High pressure fuel hydraulic components, electrical components, and
other components.
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in- Do not ground the welder across the centerline of the
structions may cause personal injury or death. package. Improper grounding could cause damage
to the bearings, the crankshaft, the rotor shaft, and
The high-pressure fuel lines are between the high- other components.
pressure fuel pump and the high-pressure fuel
manifold. The high-pressure fuel lines are also Clamp the ground cable from the welder to the com-
between the fuel manifold and cylinder head. These ponent that will be welded. Place the clamp as close
fuel lines are different from fuel lines on other fuel as possible to the weld. This will help reduce the pos-
systems. sibility of damage.
The following are the differences:
• The high-pressure fuel lines are constantly Note: Perform the welding in areas that are free from
charged with high pressure. explosive hazards.
• The internal pressures of the high-pressure fuel 1. Stop the engine. Turn the switched power to the
lines are higher than other types of fuel system. OFF position.
Before any service or repair is performed on the 2. Disconnect the negative battery cable from the
engine fuel lines, perform the following tasks: battery. If a battery disconnect switch is provided,
open the switch.
1. Stop the engine.
2. Wait for 10 minutes.
60 SEBU7901-09
Maintenance Section
Severe Service Application
3. Disconnect the J1/P1 and J2/P2 connectors from 5. Connect the welding ground cable directly to the
the ECM. Move the harness to a position that will part that will be welded. Place the ground cable as
not allow the harness to move back accidentally, close as possible to the weld. This location will
and contact any of the ECM pins. reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
4. Disconnect any component with a microprocessor
components, and ground straps.
from the engine harness, such as:
Note: If electrical/electronic components are used as
• Engine ECM a ground for the welder, current flow from the welder
could severely damage the component. Current flow
• Product Link
from the welder could also severely damage
electrical/electronic components that are located
• Cell/Sat Radio
between the welder ground and the weld.
• DOC Identity Modules
6. Protect the wiring harness from welding debris and
spatter.
7. Use standard welding practices to weld the
materials.
i05083249

SMCS Code: 1000
An engine which operates outside of normal
conditions is operating in a severe service
application.
An engine that operates in a severe service
application may need more frequent maintenance
intervals in order to maximize the following
conditions:
• Reliability
• Service life
The number of individual applications cause the
impossibility of identifying all of the factors which may
contribute to severe service operation. Consult your
Caterpillar dealer for the unique maintenance that
may be necessary for your engine.
An application is a severe service application if any of
Illustration 28 g01075639 the following conditions apply:
Use the example above. The current flow from the
welder to the ground clamp of the welder will not Severe Environmental Factors
damage any associated components.
(1) Engine • Frequent operation in dirty air
(2) Welding electrode
(3) Keyswitch in the OFF position • Frequent operation at an altitude which is above
(4) Battery disconnect switch in the open position 1525 m (5000 ft)
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
• Frequent operation in ambient temperatures which
(8) Minimum distance between the component that is being are above 32° C (90° F)
welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
SEBU7901-09 61
Maintenance Section
• Frequent operation in ambient temperatures which • Extending maintenance intervals for changing the
are below 0° C (32° F) engine oil and engine coolant without S·O·S
validation
Severe Operating Conditions • Extending maintenance intervals for changing air
filters, oil filters, and fuel filters
• Frequent operation with inlet air which has a
corrosive content • Failure to use a water separator
• Operation with inlet air which has a combustible • Using filters which are not recommended by
content Special Publication, PEWJ0074, “2008 Cat Filter
and Fluid Application Guide”
• Operation which is outside of the intended
application • Storing the engine for more than 3 months but less
than 1 yr (For information about engine storage,
• Operation with a plugged fuel filter
refer to Special Publication, SEHS9031, “Storage
• Extended operation at low idle (more than 20% of Procedure for Caterpillar Products”)
hours)
• Storing the engine for 1 yr to 2 years (For
• Frequent cold starts at temperatures below 0° C information about engine storage, refer to Special
(32° F) Instruction, REHS5001, “The Long Term Storage
and Recovery of Certain Commercial Engines”)
• Frequent dry starts (starting after more than 72
hours of shutdown)
• Frequent hot shutdowns (shutting down the
engine without the minimum of 2 minutes to 5
minutes of cool down time)
• Operation above the engine rated speed
• Operation below the peak torque speed

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

1000 ppm (0.1%) sulfur
• Operating with a blend of distillate fuel which

contains more than 5 percent biodiesel
Improper Maintenance Procedures

(Maintenance Procedures Which
May Contribute to a Severe Service
Application)
• Inadequate maintenance of fuel storage tanks
from causes such as excessive water, sediment,
and microorganism growth.
• Extending maintenance intervals beyond the
recommended intervals
• Using fluids which are not recommended in
Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids
Recommendations”
62 SEBU7901-09
Maintenance Section
Maintenance Interval Schedule
i08291877 “ Walk-Around Inspection“ . . . . . . . . . . . . . . . . . . . 102
Maintenance Interval Schedule Every Week

(Engines Which Have Deep Oil “ Jacket Water Heater - Check“. . . . . . . . . . . . . . . . 95
Pans)
SMCS Code: 1000; 4450; 7500 Every 250 Service Hours
Ensure that all safety information, warnings, and “ Battery Electrolyte Level - Check“ . . . . . . . . . . . . 67
instructions are read and understood before any
operation or any maintenance procedures are “ Coolant Sample (Level 1) - Obtain“ . . . . . . . . . . . 73
performed. The user is responsible for the
performance of maintenance, including all “ Cooling System Supplemental Coolant Additive
adjustments, the use of proper lubricants, fluids, and (SCA) - Test/Add“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
filters. The user is also responsible for the
replacement of components due to normal wear and “ Engine Crankcase Breather - Clean“ . . . . . . . . . . 81
aging. Failure to adhere to proper maintenance “ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . . 82
intervals and procedures may result in diminished
performance of the product and/or accelerated wear “ Fuel System Primary Filter (Water Separator)
of components. Use fuel consumption, service hours, Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 89
or calendar time, WHICH EVER OCCURS FIRST, to
determine the maintenance intervals. Products that “ Fuel System Secondary Filter - Replace“. . . . . . . 90
operate in severe operating conditions may require
more frequent maintenance. Before each “ Fuel Tank Water and Sediment - Drain“ . . . . . . . . 91
consecutive interval is performed, all maintenance
from the previous interval must be performed. “ Grounding Stud - Inspect/Clean/Tighten“. . . . . . . 92
When Required “ Hoses and Clamps - Inspect/Replace“. . . . . . . . . 93

“ Radiator - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . 100
“ Battery - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 67
“ Battery or Battery Cable - Disconnect“ . . . . . . . . . 68 Initial 500 Service Hours (or at first
“ Coolant - Change“ . . . . . . . . . . . . . . . . . . . . . . . . . 69 oil change)
“ Coolant Extender (ELC) - Add“ . . . . . . . . . . . . . . . 71 “ Engine Valve Lash - Check“ . . . . . . . . . . . . . . . . . 86
“ Engine Air Cleaner Element (Dual Element) - “ Engine Valve Rotators - Inspect“ . . . . . . . . . . . . . 86
Inspect/Clean/Replace“ . . . . . . . . . . . . . . . . . . . . . . 77
“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . . 83
Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
“ Engine Storage Procedure - Check“. . . . . . . . . . . 85
Systems)
“ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . . 87
“ Coolant Sample (Level 2) - Obtain“ . . . . . . . . . . . 73
Daily
Every 500 Service Hours
“ Coolant Level - Check“ . . . . . . . . . . . . . . . . . . . . . 72
“ Air Shutoff - Test“ . . . . . . . . . . . . . . . . . . . . . . . . . . 66
“ Engine Air Cleaner Service Indicator - Inspect“ . . 80
“ Belts - Inspect/Adjust/Replace“. . . . . . . . . . . . . . . 68
“ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . . 82
“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . . 83
“ Fuel System Primary Filter/Water Separator -
Drain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 “ Starting Motor - Inspect“ . . . . . . . . . . . . . . . . . . . 101
“ Power Take-Off Clutch - Check“ . . . . . . . . . . . . . 100 “ Turbocharger - Inspect“ . . . . . . . . . . . . . . . . . . . . 101
SEBU7901-09 63
Maintenance Section
Engines Which Have Deep Oil Pans
“ Water Pump - Inspect“. . . . . . . . . . . . . . . . . . . . . 103
Every 2000 Service Hours or 1 Year

“ Alternator - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . 67
Every Year
Every 3000 Service Hours or 3

Years
“ Aftercooler Core - Clean/Test“ . . . . . . . . . . . . . . . 66
“ Coolant Temperature Regulator - Replace“ . . . . . 74
“ Crankshaft Vibration Damper - Inspect“ . . . . . . . . 76
“ Driven Equipment - Check“ . . . . . . . . . . . . . . . . . . 76
“ Electronic Unit Injector - Check/Replace“ . . . . . . 77
“ Engine - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
“ Engine Mounts - Inspect“ . . . . . . . . . . . . . . . . . . . 82
“ Engine Protective Devices - Check“ . . . . . . . . . . . 85
“ Engine Speed/Timing Sensor - Clean/Inspect“ . . 85
“ Engine Valve Lash - Check“ . . . . . . . . . . . . . . . . . 86
“ Engine Valve Rotators - Inspect“ . . . . . . . . . . . . . 86
“ Fan Drive Bearing - Lubricate“ . . . . . . . . . . . . . . . 86
Every 416 400 L (110 000 US gal) of

Fuel
“ Overhaul Considerations“ . . . . . . . . . . . . . . . . . . . 95
Every 492 100 L (130 000 US gal) of

Fuel
Overhaul
“ Fan Drive Bearing - Replace“ . . . . . . . . . . . . . . . . 87
64 SEBU7901-09
Maintenance Section
Maintenance Interval Schedule
i08291878 “ Jacket Water Heater - Check“. . . . . . . . . . . . . . . . 95
Maintenance Interval Schedule Initial 250 Service Hours (or at first

(Engines Which Have Shallow oil change)
Oil Pans) “ Engine Valve Lash - Check“ . . . . . . . . . . . . . . . . . 86
SMCS Code: 1000; 4450; 7500
Ensure that all safety information, warnings, and
instructions are read and understood before any Every 250 Service Hours
operation or any maintenance procedures are
performed. The user is responsible for the “ Battery Electrolyte Level - Check“ . . . . . . . . . . . . 67
performance of maintenance, including all
adjustments, the use of proper lubricants, fluids, and “ Coolant Sample (Level 1) - Obtain“ . . . . . . . . . . . 73
filters. The user is also responsible for the
replacement of components due to normal wear and “ Cooling System Supplemental Coolant Additive
aging. Failure to adhere to proper maintenance (SCA) - Test/Add“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
intervals and procedures may result in diminished
performance of the product and/or accelerated wear “ Engine Crankcase Breather - Clean“ . . . . . . . . . . 81
of components. Use fuel consumption, service hours,
or calendar time, WHICH EVER OCCURS FIRST, to “ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . . 82
determine the maintenance intervals. Products that
operate in severe operating conditions may require “ Engine Oil and Filter - Change“. . . . . . . . . . . . . . . 83
more frequent maintenance. Before each
consecutive interval is performed, all maintenance “ Fuel System Primary Filter (Water Separator)
from the previous interval must be performed. Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 89
“ Fuel Tank Water and Sediment - Drain“ . . . . . . . . 91
When Required
“ Grounding Stud - Inspect/Clean/Tighten“. . . . . . . 92
“ Battery - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 67
“ Hoses and Clamps - Inspect/Replace“. . . . . . . . . 93
“ Battery or Battery Cable - Disconnect“ . . . . . . . . . 68
“ Radiator - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . 100
“ Coolant - Change“ . . . . . . . . . . . . . . . . . . . . . . . . . 69
“ Coolant Extender (ELC) - Add“ . . . . . . . . . . . . . . . 71 Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
“ Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace“ . . . . . . . . . . . . . . . . . . . . . . 77 Systems)
“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . . 83 “ Coolant Sample (Level 2) - Obtain“ . . . . . . . . . . . 73
“ Engine Storage Procedure - Check“. . . . . . . . . . . 85
Every 500 Service Hours
“ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . . 87
“ Belts - Inspect/Adjust/Replace“. . . . . . . . . . . . . . . 68
Daily “ Starting Motor - Inspect“ . . . . . . . . . . . . . . . . . . . 101
“ Coolant Level - Check“ . . . . . . . . . . . . . . . . . . . . . 72 “ Turbocharger - Inspect“ . . . . . . . . . . . . . . . . . . . . 101
“ Engine Air Cleaner Service Indicator - Inspect“ . . 80
“ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . . 82
“ Fuel System Primary Filter/Water Separator -
Drain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
“ Power Take-Off Clutch - Check“ . . . . . . . . . . . . . 100
“ Walk-Around Inspection“ . . . . . . . . . . . . . . . . . . . 102
Every Week
“ Fuel Tank Water and Sediment - Drain“ . . . . . . . . 91
SEBU7901-09 65
Maintenance Section
Engines Which Have Shallow Oil Pans
“ Water Pump - Inspect“. . . . . . . . . . . . . . . . . . . . . 103
Every 2000 Service Hours or 1 Year

“ Alternator - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . 67
Every Year
Every 3000 Service Hours or 3

Years
“ Aftercooler Core - Clean/Test“ . . . . . . . . . . . . . . . 66
“ Coolant Temperature Regulator - Replace“ . . . . . 74
“ Crankshaft Vibration Damper - Inspect“ . . . . . . . . 76
“ Driven Equipment - Check“ . . . . . . . . . . . . . . . . . . 76
“ Electronic Unit Injector - Check/Replace“ . . . . . . 77
“ Engine - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
“ Engine Mounts - Inspect“ . . . . . . . . . . . . . . . . . . . 82
“ Engine Protective Devices - Check“ . . . . . . . . . . . 85
“ Engine Speed/Timing Sensor - Clean/Inspect“ . . 85
“ Engine Valve Lash - Check“ . . . . . . . . . . . . . . . . . 86
“ Fan Drive Bearing - Lubricate“ . . . . . . . . . . . . . . . 86
Every 416 400 L (110 000 US gal) of

Fuel
Every 492 100 L (130 000 US gal) of

Fuel
Overhaul
“ Fan Drive Bearing - Replace“ . . . . . . . . . . . . . . . . 87
66 SEBU7901-09
Maintenance Section
Aftercooler Core - Clean/Test
i01188617 Note: If parts of the aftercooler system are repaired

or replaced, a leak test is highly recommended. The
Aftercooler Core - Clean/Test FT1984 Aftercooler Testing Group is used to
perform leak tests on the aftercooler. Refer to the
(Air-To-Air Aftercooler) Systems Operation/Testing and Adjusting,
SMCS Code: 1064-081; 1064-070 “Aftercooler - Test” and the Special Instruction,
SEHS8622 for the proper testing procedure.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. Inspect these items for good condition: welds,
mounting brackets, air lines, connections, clamps
Inspect the cooling air side of the aftercooler for and seals. Make repairs, if necessary.
these items: damaged fins, corrosion, dirt, grease,
insects, leaves, oil and other debris. Clean the For more detailed information on cleaning and
cooling air side of the aftercooler, if necessary. inspection, see Special Publication, SEBD0518,
“Know Your Cooling System”.
For air-to-air aftercoolers, use the same methods that
are used for cleaning the outside of radiators. i05341564
Air Shutoff - Test

Personal injury can result from air pressure. SMCS Code: 1078-081
To ensure that the air shutoff valve always shuts
Personal injury can result without following prop-
down when the engine ingests gaseous fumes,
er procedure. When using pressure air, wear a
perform the test below at each oil change. A test
protective face shield and protective clothing.
failure can indicate wear in the block off plate to valve
Maximum air pressure at the nozzle must be less body interface and/or the bearing system.
than 205 kPa (30 psi) for cleaning purposes. 1. Place engine at low idle speed. Ensure all
accessories that are normally used for the
Pressurized air is the preferred method for removing application are in use, like a fan, or power takeoffs.
loose debris. Direct the air in the opposite direction of
the fan's air flow. Hold the nozzle approximately 2. Actuate the air shutoff manually. On electrical
6 mm (0.25 inch) away from the fins. Slowly move operator air shutoffs, utilize an applicable power
the air nozzle in a direction that is parallel with the supply or jumper cables from the battery to
tubes. This will remove debris that is between the energize the air shut-off solenoid. Ensure that the
tubes. solenoid receives only a momentary signal to
Pressurized water may also be used for cleaning. prevent overheating. On hydraulic operator air
The maximum water pressure for cleaning purposes shutoffs, found on some hazardous location units,
must be less than 275 kPa (40 psi). Use pressurized actuate by pulling the emergency stop handle.
water in order to soften mud. Clean the core from
both sides. 3. Ensure that air shutoff was actuated and that the
engine comes to a complete stop.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core Note: As every application has different parasitic
with detergent and hot water. Thoroughly rinse the loads and inertia, the duration for the problem to
core with clean water.
occur cannot be specified. However, if the engine
After cleaning, start the engine and accelerate the stumbles or attempts to continue running, these
engine to high idle rpm. This will help in the removal symptoms may be an indication that worn
of debris and drying of the core. Stop the engine. Use components may need replacement.
a light bulb behind the core in order to inspect the
core for cleanliness. Repeat the cleaning, if If additional help is needed, contact the Dealer
necessary. Solution Network.
Inspect the fins for damage. Bent fins may be opened NOTICE
with a “comb”. Actuating the air shutoff valve may result in oil leak-
age past the shaft seal in some cases. Repeated ac-
tuation of the air shutoff valve during loaded
operation of the engine can result in mechanical
damage to the turbocharger and reduce turbocharger
life.
SEBU7901-09 67
Maintenance Section
Alternator - Inspect
i08259468 3. The NEGATIVE “-” cable connects the NEGATIVE

“-” battery terminal to the NEGATIVE “-” terminal
Alternator - Inspect on the starter motor. Disconnect the cable from the
SMCS Code: 1405-040 NEGATIVE “-” battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE
Caterpillar recommends a scheduled inspection of
the alternator. Inspect the alternator for loose “+” battery terminal to the POSITIVE “+” terminal
connections and proper battery charging. Inspect the on the starting motor. Disconnect the cable from
ammeter (if equipped) during engine operation to the POSITIVE “+” battery terminal.
ensure proper battery performance and/or proper
performance of the electrical system. Make repairs, Note: Always recycle a battery. Never discard a
as required. battery. Return used batteries to an appropriate
recycling facility.
Check the alternator and the battery charger for
proper operation. If the batteries are properly 5. Remove the used battery.
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The 6. Install the new battery.
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold, Note: Before the cables are connected, ensure that
the battery will not crank the engine. The battery will the engine start switch is OFF.
not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time or 7. Connect the cable from the starting motor to the
if the engine is run for short periods, the batteries POSITIVE “+” battery terminal.
may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge. 8. Connect the cable from the NEGATIVE “-” terminal
on the starter motor to the NEGATIVE “-” battery
i01878164 terminal.
Battery - Replace i08265744
SMCS Code: 1401-510

Battery Electrolyte Level -
Check
SMCS Code: 1401-535-FLV
Batteries give off combustible gases which can
explode. A spark can cause the combustible When the engine has not run for long or short periods
gases to ignite. This can result in severe personal of time, the batteries may not fully recharge. Ensure a
injury or death. full charge to help prevent the battery from freezing.
Ensure proper ventilation for batteries that are in In warmer climates, check the electrolyte level more
an enclosure. Follow the proper procedures in or- frequently.
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are Ensure that the electrolyte level is 13 mm (0.5 inch)
serviced. above the top of the separators.
All lead-acid batteries contain sulfuric acid which

The battery cables or the batteries should not be can burn the skin and clothing. Always wear a
removed with the battery cover in place. The bat- face shield and protective clothing when working
tery cover should be removed before any servic- on or near batteries.
ing is attempted.
Removing the battery cables or the batteries with 1. Remove the filler caps. Maintain the electrolyte
the cover in place may cause a battery explosion level to the “FULL” mark on the battery.
resulting in personal injury.
If the addition of water is necessary, use distilled
water. If distilled water is not available, use clean
1. Switch the engine to the OFF position. Remove all
water that is low in minerals. Do not use artificially
electrical loads.
softened water.
2. Turn off any battery chargers. Disconnect any
2. Check the condition of the electrolyte with the
battery chargers.
245-5829 Coolant Battery Tester Refractometer.
68 SEBU7901-09
Maintenance Section
Battery or Battery Cable - Disconnect
3. Keep the batteries clean. 2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
Clean the battery case with one of the following
the cable cannot contact the terminal. When four
cleaning solutions:
12 volt batteries are involved, the negative side of
• A mixture of 0.1 kg (0.2 lb) of baking soda and two batteries must be disconnected.
1 L (1 qt) of clean water 3. Tape the leads in order to help prevent accidental
starting.
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water 4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.
Thoroughly rinse the battery case with clean
water. i08257469
Use the 1U-9921 Battery Service Tool to clean

the battery terminals. Use a wire brush to clean Belts - Inspect/Adjust/Replace
the cable clamps. Clean the items until the SMCS Code: 1357-510; 1357-040; 1357-025
surfaces are bright or shiny. DO NOT remove
material excessively. Excessive removal of Inspection
material can cause the clamps to fit improperly.
Coat the clamps and the terminals with the Loctite Inspect the alternator belt and the fan drive belts for
®
product listed below, petroleum jelly or MPGM. wear and for cracking. Replace the belts if the belts
are not in good condition.
• For Americas North - Loctite LB8632
Check the belt tension according to the information in
• For Europe and Africa, Middle East, CIS the Service Manual, “Specifications”.
(AMEC) - Loctite LB8104
Slippage of loose belts can reduce the efficiency of
• For Asia Pacific - Loctite LB8801 the driven components. Vibration of loose belts can
cause unnecessary wear on the following
• For Americas South - Loctite LB Superlube components:
• Belts
For ordering the products listed above, go to the
following address. • Pulleys
http://www.loctite.com/en/meta/meta-nav/ • Bearings
location-selector.html
i06738663
Battery or Battery Cable -

Disconnect
SMCS Code: 1401; 1402-029
The battery cables or the batteries should not be

removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the

ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
SEBU7901-09 69
Maintenance Section
Coolant - Change
If the belts are too tight, unnecessary stress is placed 4. Move the pulley to adjust the belt tension.
on the components. This stress reduces the service
life of the components. 5. Tighten the adjusting nut.
6. Tighten the mounting bolt.
Replacement
7. Reinstall the belt guard.
For applications that require multiple drive belts, If new drive belts are installed, check the drive belt
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new tension again after 30 minutes of engine operation
drive belt to carry more load because the older drive at the rated rpm.
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail. i04538352
Alternator Belt Adjustment Coolant - Change

SMCS Code: 1350-044; 1352; 1395; 1395-044
“Fluid Recommendations” for the correct intervals for
changing the coolant.
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.
• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.
Drain the Cooling System
Pressurized System: Hot coolant can cause seri-
1. Remove the belt guard. ous burns. To open the cooling system filler cap,
2. Loosen mounting bolts (1) and adjusting bolt (2). components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
3. Move the assembly to increase or decrease the pressure.
belt tension.
4. Tighten adjusting bolt (2). Tighten mounting bolts
(1). NOTICE
5. Reinstall the belt guard. tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
If new drive belts are installed, check the drive belt Be prepared to collect the fluid with suitable contain-
tension again after 30 minutes of engine operation ers before opening any compartment or disassem-
at the rated rpm. bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Adjustment of the Fan Drive Belt Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
1. Remove the belt guard. for tools and supplies suitable to collect and contain
fluids on Cat products.
2. Loosen the mounting bolt for the pulley.
Dispose of all fluids according to local regulations
3. Loosen the adjusting nut for the pulley. and mandates.
70 SEBU7901-09
Maintenance Section
Coolant - Change
1. Stop the engine and allow the engine to cool. 5. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the Loosen the cooling system filler cap slowly in
cooling system is drained. order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if
2. Loosen the cooling system filler cap slowly in order
equipped) or remove the cooling system drain
to relieve any pressure. Remove the cooling
plugs. Allow the water to drain. Flush the cooling
system filler cap.
system with clean water. Close the drain valve (if
3. Open the cooling system drain valve (if equipped). equipped). Clean the drain plugs. Install the drain
If the cooling system is not equipped with a drain plugs. Refer to the Specifications Manual,
valve, remove one of the drain plugs. SENR3130, “Torque Specifications” for more
information on the proper torques.
Note: If equipped, be sure to drain the heater and
any related supply and return lines. Systems Filled with Cat DEAC,
Allow the coolant to drain. Conventional Coolant which does not
Meet the Cat EC-1 Requirements, or
NOTICE Supplemental Coolant Additive (SCA)
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim and Water
used coolant for reuse in engine cooling systems.
The full distillation procedure is the only method ac- 3. Flush the cooling system with clean water in order
ceptable by Caterpillar to reclaim the used coolant. to remove any debris.
4. Close the drain valve (if equipped). Clean the drain
For information regarding the disposal and the plugs. Install the drain plugs. Refer to the
recycling of used coolant, consult your Cat dealer or Specifications Manual, SENR3130, “Torque
consult Cat Dealer Service Tool Group: Specifications” for more information on the proper
Inside USA 1-800-542-TOOL torques.
Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL NOTICE
International 1-309-578-7372 Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Flush
5. Fill the cooling system with a mixture of clean
Systems Filled with Cat ELC, Cat ELI, or water and Cat Fast Acting Cooling System
a Conventional Coolant that Meets the Cleaner.
Cat EC-1 Requirements and the 6. Choose 1 of the following options.
Standards of ASTM D6210
• Add 0.5 L (1 pint) of cleaner per 15 L
1. Flush the cooling system with clean water in order (4 US gal) of the cooling system capacity.
to remove any debris. • For cooling systems with heavy deposits or
2. Close the drain valve (if equipped). Clean the drain plugging, add 0.5 L (1 pint) of cleaner per
plugs. Install the drain plugs. Refer to the 3.8 to 7.6 L (1 to 2 US gal) of the cooling
Specifications Manual, SENR3130, “Torque system capacity.
Specifications” for more information on the proper
torques. 7. Install the cooling system filler cap.
8. Start and run the engine at low idle for a minimum
NOTICE of 30 minutes. For cooling systems with heavy
Fill the cooling system no faster than 19 L (5 US gal)
deposits or plugging, run the engine for 90
minutes. The coolant temperature should be at
least 82 °C (180 °F).
3. Fill the cooling system with clean water. Install the
cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
SEBU7901-09 71
Maintenance Section
Coolant Extender (ELC) - Add
4. Clean the cooling system filler cap. Inspect the

NOTICE
Improper or incomplete rinsing of the cooling system gasket that is on the cooling system filler cap. Only
can result in damage to copper and other metal install the used filler cap if the gasket is not
components. damaged. Use a 9S-8140 Pressurizing Pump to
pressure test a reinstalled cooling system filler
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water. cap. The correct pressure for the cooling system
Continue to flush the system until all signs of the filler cap is stamped on the face of the cooling
cleaning agent are gone. system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
9. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in 5. Start the engine. Inspect the cooling system for
order to relieve any pressure. Remove the cooling leaks and for proper operating temperature.
system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain i04862631
plugs. Allow the water to drain. Flush the cooling
system with clean water. If equipped, be sure to Coolant Extender (ELC) - Add
flush the heater and any related supply and return SMCS Code: 1352-544-NL
lines. Close the drain valve (if equipped). Clean
the drain plugs. Install the drain plugs. Refer to the Note: Refer to this Operation and Maintenance
Specifications Manual, SENR3130, “Torque Manual, “Fluid Recommendations” (Cooling System)
Specifications” for more information on the proper for the maintenance interval for the addition of the
torques. coolant extender.
Cat ELC (Extended Life Coolant) and Cat ELI
Fill the Cooling System (Extended Life Inhibitor) do not require the frequent
additions of any supplemental cooling additives. The
Cat ELC Extender will only be added one time.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) Note: Do not use conventional supplemental coolant
additive (SCA) with Cat ELC or with Cat ELI.
1. Fill the cooling system. Refer to this Operation and Check the cooling system only when the engine is
stopped and cool.
Maintenance Manual, “Fluid Recommendations”
for more information on cooling system
specifications Refer to this Operation and
Maintenance Manual, “Refill Capacities” for
Personal injury can result from hot coolant,
information about the capacity of the cooling steam and alkali.
system. Do not install the cooling system filler cap.
At operating temperature, engine coolant is hot
2. Start and run the engine at low idle. Increase the and under pressure. The radiator and all lines to
engine rpm to high idle. Run the engine at high heaters or the engine contain hot coolant or
idle for 1 minute in order to purge the air from the steam. Any contact can cause severe burns.
cavities of the engine block. Stop the engine.
Remove cooling system pressure cap slowly to
3. Check the coolant level. Maintain the coolant level relieve pressure only when engine is stopped and
within 13 mm (0.5 inch) below the bottom of the cooling system pressure cap is cool enough to
touch with your bare hand.
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight Do not attempt to tighten hose connections when
glass (if equipped). the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
72 SEBU7901-09
Maintenance Section
Coolant Level - Check
NOTICE
tained during performance of inspection, mainte-
ers before opening any compartment or disassem-
bling any component containing fluids.
Service Tool Catalog” or refer to Special Publication,
for tools and supplies suitable to collect and contain
and 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. If necessary, drain enough coolant from the Pressurized System: Hot coolant can cause seri-
cooling system in order to add the Cat ELC ous burns. To open the cooling system filler cap,
Extender. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
3. Add Cat ELC Extender according to the pressure cap slowly in order to relieve the
requirements for the cooling system capacity. pressure.
“Refill Capacities” for the coolant capacity. 1. Remove the cooling system filler cap slowly in
order to relieve pressure.
4. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace 2. Maintain the coolant level within 13 mm (0.5 inch)
the cooling system filler cap if the gaskets are of the bottom of the filler pipe. If the engine is
damaged. Install the cooling system filler cap. equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
For further information, refer to this Operation and
Maintenance Manual, , “Fluid Recommendations”.
i04156593
Coolant Level - Check

SMCS Code: 1395-082
Check the coolant level when the engine is stopped
and cool.
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.
SEBU7901-09 73
Maintenance Section
Coolant Sample (Level 1) - Obtain
i08254010 • Never collect samples from the drain for a system.
Coolant Sample (Level 1) - Timing of the Sampling

Obtain Table 18
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Recommended Interval
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and Type of
corrosion. The analysis also tests the ability of the Level 1 Level 2
Coolant
coolant to protect the engine from boiling and
freezing. S·O·S Systems Coolant Analysis can be Cat DEAC
done at your Cat dealer. Cat S·O·S coolant analysis Cat SCA
Every 250 hours Yearly(1)
is the best way to monitor the condition of your Conventional Heavy-
coolant and your cooling system. S·O·S coolant Duty Coolants
analysis is a program that is based on periodic Cat ELC
samples. Cat ELI
Optional(1) Yearly(1)
Commercial EC-1
Note: Obtaining a Coolant Sample (Level 1) is Coolants
optional if the cooling system is filled with one of
(1) The Level 2 Coolant Analysis should be performed sooner if a
the following coolants: Cat ELC (Extended Life
problem is suspected or identified.
Coolant)., Cat ELI (Extended Life Inhibitor) and
Conventional Heavy-Duty Coolant.
Note: Check the SCA (Supplemental Coolant
Note: Obtain a Coolant Sample (Level 1) if the Additive) of the conventional coolant at every oil
cooling system is filled with any of the following change or at every 250 hours. Perform this check at
coolants: Cat DEAC, Cat SCA, and Conventional the interval that occurs first.
Heavy-Duty Coolants. Obtain the sample of the coolant as close as possible
to the recommended sampling interval. To receive
For additional information about coolant analysis and the full effect of S·O·S analysis, establish a
about other coolants, see this Operation and consistent trend of data. To establish a pertinent
Maintenance Manual, “Fluid Recommendations” or history of data, perform consistent samplings that are
consult your Cat dealer.
evenly spaced. Supplies for collecting samples can
be obtained from your Cat dealer.
Sampling Conditions
NOTICE
If the engine is equipped with a sampling port, the Always use a designated pump for oil sampling, and
engine should be running at operating temperature use a separate designated pump for coolant sam-
when the sample is obtained. pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
If the engine is not equipped with a sampling port, the drawn. This contaminate may cause a false analysis
coolant should be warm. and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
Use the following guidelines for proper sampling of
the coolant:
Submit the sample for Level 1 analysis.
• Complete the information on the label for the
sampling bottle before you begin to take the Note: Level 1 results may indicate a need for Level 2
samples. Analysis.
• Keep the unused sampling bottles stored in plastic
i04638756
bags.
• Obtain coolant samples directly from the coolant Coolant Sample (Level 2) -
sample port. You should not obtain the samples Obtain
from any other location.
SMCS Code: 1350-008; 1395-554; 1395-008; 7542
• Keep the lids on empty sampling bottles until you
are ready to collect the sample. An S·O·S Coolant Analysis (Level 2) is a
comprehensive chemical evaluation of the coolant.
• Place the sample in the mailing tube immediately This analysis is also a check of the overall condition
after obtaining the sample to avoid contamination. of the cooling system. The S·O·S Coolant Analysis
(Level 2) has the following features:
• Never collect samples from expansion bottles.
74 SEBU7901-09
Maintenance Section
Coolant Temperature Regulator - Replace
• Full coolant analysis (Level 1)

NOTICE
Failure to replace your water temperature regulator
• Identification of metal corrosion and contaminants
on a regularly scheduled basis could cause severe
• Identification of buildup of the impurities that engine damage.
cause corrosion and scaling Cat engines incorporate a shunt bypass design cool-
ing system and require operating the engine with a
• Determination of the possibility of electrolysis water temperature regulator installed.
within the cooling system of the engine
If the water temperature regulator is installed incor-
The results are reported and appropriate rectly, the engine may overheat, causing cylinder
recommendations are made. head damage. Ensure that the new water tempera-
ture regulator is installed in the original position. En-
Obtaining the Sample sure that the water temperature regulator vent hole is
open.
Refer to Operation and Maintenance Manual,
“Coolant Sample (Level 1) - Obtain” for the guidelines Do not use liquid gasket material on the gasket or cyl-
for proper sampling of the coolant. inder head surface.
Submit the sample for Level 2 analysis.

NOTICE
For further information, refer to this Operation and Care must be taken to ensure that fluids are con-
Maintenance Manual, “Fluid Recommendations”. tained during performance of inspection, mainte-
i08272084
Coolant Temperature
Regulator - Replace Refer to Special Publication, NENG2500, “Cat Dealer
SMCS Code: 1355-510 PECJ0003, “Cat Shop Supplies and Tools Catalog”
Replace the water temperature regulator before the fluids on Cat products.
water temperature regulator fails. Replacing the
water temperature regulator reduces the chances for Dispose of all fluids according to local regulations
unscheduled downtime. and mandates.
A water temperature regulator that fails in a partially
opened position can cause overheating or Note: If replacing only the water temperature
overcooling of the engine. regulator, only drain the coolant to a level that is
below the water temperature regulator housing.
A water temperature regulator that fails in the open
position will cause the engine operating temperature Refer to two articles in the Disassembly and
to be too low during partial load operation. Low Assembly Manual, “Water Temperature Regulator -
engine operating temperatures during partial loads Remove and Water Temperature Regulator - Install”
could cause an excessive carbon buildup inside the for the replacement procedure or consult your Cat
cylinders. This excessive carbon buildup could result dealer.
in an accelerated wear of the piston rings and wear of
the cylinder liner.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.
SEBU7901-09 75
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
i04269112
NOTICE
Cooling System Supplemental tained during performance of inspection, mainte-
Coolant Additive (SCA) - Test/ Be prepared to collect the fluid with suitable contain-
Add ers before opening any compartment or disassem-
(Systems Which are Filled with
Conventional Coolant) Service Tool Catalog” and to Special Publication,
SMCS Code: 1352-045; 1395-081 GECJ0003, “Cat Shop Supplies and Tools” for tools
and supplies suitable to collect and contain fluids on
This maintenance procedure is required for Cat products.
conventional coolants such as DEAC.Do not
perform this maintenance for cooling systems Dispose of all fluids according to applicable regula-
that are filled with Cat Extended Life Coolant (Cat tions and mandates.
ELC) or Cat Extended Life Inhibitor (Cat ELI).
Note: Caterpillar recommends that an S·O·S Coolant
Analysis (Level 1) be performed to check the
concentration of SCA.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact
with the skin and eyes. Do not drink cooling sys- Maintain the Proper Concentration
tem coolant additive. of SCA in the Coolant
NOTICE
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur- Pressurized System: Hot coolant can cause seri-
faces of the cooling system, reducing the engine's ous burns. To open the cooling system filler cap,
heat transfer characteristics. Reduced heat transfer stop the engine and wait until the cooling system
could cause cracking of the cylinder head and other components are cool. Loosen the cooling system
high temperature components. pressure cap slowly in order to relieve the
pressure.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat ex- 1. Remove the cooling system filler cap slowly.
changer, overheating, and/or accelerated wear of the
water pump seal. 2. Test the concentration of the SCA with a
286-2578 Nitrite Test Strip or review the results
Do not exceed the recommended amount of supple- of the S·O·S Coolant Analysis (Level 1).
mental coolant additive concentration.
3. If necessary, drain some coolant in order to allow
space for the addition of the SCA.
NOTICE
Do NOT mix brands or types of SCA. Do NOT mix 4. Add the amount of SCA required to maintain a
SCAs and extenders. concentration of 3 percent to 6 percent SCA in the
coolant.
Failure to follow the recommendations can result in
shortened cooling system component life. 5. Clean the cooling system filler cap. Install the
NOTICE
Use Only Approved SCAs. Conventional coolants
require the maintenance addition of SCA throughout
their expected life. Do NOT use an SCA with a cool-
ant unless specifically approved by the coolant sup-
plier for use with their coolant. It is the responsibility
of the coolant manufacturer to ensure compatibility
and acceptable performance.
Failure to follow the recommendations can result in
shortened cooling system component life.
76 SEBU7901-09
Maintenance Section
Crankshaft Vibration Damper - Inspect
For further information, refer to Special Publication, Refer to the Disassembly and Assembly Manual,
SEBU6251, “Cat Commercial Diesel Engine Fluids “Vibration Damper and Pulley - Remove and Install”
Recommendations”. or consult your Cat dealer for information about
damper replacement.
i05264144
i08269146
Crankshaft Vibration Damper -
Inspect Driven Equipment - Check
SMCS Code: 3279-535
SMCS Code: 1205-040
Damage to the crankshaft vibration damper or failure Check the Alignment
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to the To minimize bearing problems and vibration of the
crankshaft and to other engine components. A engine crankshaft and the driven equipment, the
damper that is damaged can cause excessive gear alignment between the engine and driven equipment
train noise at variable points in the speed range. must be properly maintained.
The damper is mounted to the crankshaft which is Check the alignment according to the instructions
located behind the belt guard on the front of the that are provided by the following manufacturers:
engine.
• Caterpillar
Visconic Damper
• OEM of the drive coupling
The visconic damper has a weight that is located
inside a fluid filled case. The weight moves in the • OEM of the driven equipment
case in order to limit torsional vibration. Torque all fasteners to the proper specifications.
Inspect the damper for evidence of fluid leaks. If a
fluid leak is found, determine the type of fluid. The Inspect the Drive Coupling
fluid in the damper is silicone. Silicone has the
following characteristics: transparent, viscous, Inspect the drive coupling according to the
smooth and adhering. instructions that are provided by the OEM of the
coupling. For the following service information, see
If the fluid leak is oil, inspect the crankshaft seals for the literature that is provided by the OEM of the
leaks. If a leak is observed, replace the crankshaft coupling:
seals.
Inspect the damper and repair or replace the damper • Lubrication requirements
for any of the following reasons:
• Specifications for the end play
• The damper is dented, cracked, or leaking.
• “Reusability Guidelines”
• The paint on the damper is discolored from heat.
• Replacement instructions
• The engine has had a failure because of a broken
crankshaft. Inspect the Rear Gear Train
• Analysis of the oil has revealed that the front main Inspect the crankshaft gear. If excessive wear is
bearing is badly worn. found, replace the crankshaft gear and the large
cluster idler.
• There is a large amount of gear train wear that is
not caused by a lack of oil. If any gear damages the other gears through failure,
replace the entire rear gear train.
SEBU7901-09 77
Maintenance Section
Electronic Unit Injector - Check/Replace
For the correct parts, see the Parts Manual for the i08267616
engine. For removal and replacement instructions,
see the Service Manual, “Disassembly and
Assembly” module. Consult your Cat dealer for
Engine - Clean
assistance. SMCS Code: 1000-070
i06826449
Electronic Unit Injector - Personal injury or death can result from high
voltage.
Check/Replace
SMCS Code: 1251-535; 1251-510; 1290-510; 1290- Moisture can create paths of electrical
conductivity.
535
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “ DO
NOT OPERATE”” .
Be sure the engine cannot be started while this
maintenance is being performed. To prevent pos-
sible injury, do not use the starting motor to turn NOTICE
the flywheel. Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and
Hot engine components can cause burns. Allow fluid spills whenever a significant quantity accumu-
additional time for the engine to cool before lates on the engine.
measuring/adjusting the unit injectors.
Periodic cleaning of the engine is recommended.
The electronic unit injectors use high voltage. Steam cleaning the engine will remove accumulated
Disconnect the unit injector enable circuit con- oil and grease. A clean engine provides the following
nector in order to prevent personal injury. Do not benefits:
come in contact with the injector terminals while
the engine is running. • Easy detection of fluid leaks
The operation of a Cat Engine with an electronic unit • Maximum heat transfer characteristics
injector which is improperly adjusted may reduce
engine efficiency. This reduced efficiency may result • Ease of maintenance
in excessive fuel usage and/or shortened engine
component life. Note: Caution must be used to prevent electrical
components from being damaged by excessive water
Note: Only qualified service personnel should when you clean the engine. Avoid electrical
perform this maintenance. components such as the alternator, the starter, and
the ECM.
Refer to the Systems Operation, Testing and
Adjusting, “Electronic Unit Injector - Test” for the test
i04322011
procedure. Refer to Systems Operation, Testing and
Adjusting, “Engine Valve Lash — Inspect/Adjust” for
the adjustment procedure. Engine Air Cleaner Element
Refer to the Disassembly and Assembly Manual for (Dual Element) - Inspect/Clean/
the procedure applicable for the removal and
replacement of the injector.
Replace
SMCS Code: 1051; 1054-070; 1054-510; 1054-040
NOTICE
The camshafts must be correctly timed with the NOTICE
crankshaft before an adjustment of the lash for the Never run the engine without an air cleaner element
fuel injector is made. The timing pins must be reinstalled. Never run the engine with a damaged air
moved from the camshafts before the crankshaft is cleaner element. Do not use air cleaner elements
turned or damage to the cylinder block will be the with damaged pleats, gaskets or seals. Dirt entering
result. the engine causes premature wear and damage to
engine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.
78 SEBU7901-09
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
engine wear. Your Cat dealer has the proper air
cleaner elements for your application. Consult your
Cat dealer for the correct air cleaner element.
• Check the precleaner (if equipped) daily for

accumulation of dirt and debris. Remove any dirt Illustration 32 g00736431
and debris, as needed. (1) Cover
(2) Primary air cleaner element
• Operating conditions (dust, dirt, and debris) may (3) Secondary air cleaner element
(4) Turbocharger air inlet
require more frequent service of the air cleaner
element.
1. Remove the cover. Remove the primary air cleaner
• The air cleaner element may be cleaned up to six element.
times if the element is properly cleaned and
inspected. 2. The secondary air cleaner element should be
removed and discarded for every three cleanings
• The air cleaner element should be replaced at of the primary air cleaner element.
least one time per year. This replacement should
be performed regardless of the number of Note: Refer to “Cleaning the Primary Air Cleaner
cleanings. Elements”.
Replace the dirty paper air cleaner elements with 3. Cover the turbocharger air inlet with tape in order
clean air cleaner elements. Before installation, to keep out dirt.
thoroughly check the air cleaner elements for tears
and/or holes in the filter material. Inspect the gasket 4. Clean the inside of the air cleaner cover and body
or the seal of the air cleaner element for damage. with a clean, dry cloth.
Maintain a supply of suitable air cleaner elements for
replacement purposes. 5. Remove the tape for the turbocharger air inlet.
Install the secondary air cleaner element. Install a
Dual Element Air Cleaners primary air cleaner element that is new or cleaned.
The dual element air cleaner contains a primary air 6. Install the air cleaner cover.
cleaner element and a secondary air cleaner
element. The primary air cleaner element can be
used up to six times if the element is properly
cleaned and inspected. The primary air cleaner
element should be replaced at least one time per
year. This replacement should be performed
regardless of the number of cleanings.
The secondary air cleaner element is not serviceable
or washable. The secondary air cleaner element
should be removed and discarded for every three
cleanings of the primary air cleaner element. When
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more
frequent replacement.
SEBU7901-09 79
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
7. Reset the air cleaner service indicator. Pressurized Air
Cleaning the Primary Air Cleaner

Elements Personal injury can result from air pressure.
NOTICE Personal injury can result without following prop-

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

six times if the element is properly cleaned and
inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
The primary air cleaner element should be replaced Illustration 33 g00281692
at least one time per year. This replacement should
be performed regardless of the number of cleanings. Note: When the primary air cleaner elements are
cleaned, always begin with the clean side (inside) in
Use clean primary air cleaner elements while dirty order to force dirt particles toward the dirty side
elements are being cleaned. (outside).
NOTICE To help prevent damage to the paper pleats, aim the

Do not clean the air cleaner elements by bumping or hose so that the air flows inside the element along
tapping. This could damage the seals. Do not use el- the length of the filter. Do not aim the stream of air
ements with damaged pleats, gaskets or seals. Dam- directly at the primary air cleaner element. Dirt could
aged elements will allow dirt to pass through. Engine be forced further into the pleats.
damage could result.
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
Visually inspect the primary air cleaner elements
before cleaning. Inspect the air cleaner elements for Vacuum Cleaning
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
Vacuum cleaning is a good method for cleaning
There are two common methods that are used to primary air cleaner elements which require daily
clean primary air cleaner elements: cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
• Pressurized air to vacuum cleaning. Vacuum cleaning will not
remove deposits of carbon and oil.
• Vacuum cleaning
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
80 SEBU7901-09
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Inspecting the Primary Air Cleaner

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

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inspect the clean, dry primary air cleaner element. Inhibited (VCI) paper.
Use a 60W blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner Place the primary air cleaner element into a box for
element. Rotate the primary air cleaner element. storage. For identification, mark the outside of the
Inspect the primary air cleaner element for tears and/ box and mark the primary air cleaner element.
or holes. Inspect the primary air cleaner element for Include the following information:
light that may show through the filter material. If
necessary, compare the primary air cleaner element • Date of cleaning
to a new primary air cleaner element that has the
same part number. • Number of cleanings
Do not use a primary air cleaner element that has Store the box in a dry location.
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
i06103548
pleats, gaskets, or seals. Discard damaged primary
air cleaner elements.
Engine Air Cleaner Service
Storing Primary Air Cleaner Elements Indicator - Inspect
If a primary air cleaner element that passes (If Equipped)
inspection will not be used, the primary air cleaner SMCS Code: 7452-040
element can be stored for future use.
Some engines may be equipped with a different
service indicator.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before and after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the clean
side of the air cleaner housing or in a remote
location.
SEBU7901-09 81
Maintenance Section
Engine Crankcase Breather - Clean
Note: When a new service indicator is installed,

excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque of
2 N·m (18 lb in).
i02870223
Engine Crankcase Breather -

Clean
SMCS Code: 1317-070
Typical service indicator
Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner element
should be replaced when one of the following
conditions occur:
• The yellow diaphragm enters the red zone.
• The red piston locks in the visible position.
Test the Service Indicator

Service indicators are important instruments. (1) Bolts
(2) Hose
• Check for ease of resetting. The service indicator (3) Breather cover
should reset in less than three pushes.
• Check the movement of the service indicator core NOTICE

Perform this maintenance with the engine stopped.
when the engine is run at full load speed. The core
should latch approximately at the greatest vacuum If the crankcase breather is not maintained on a
that is attained. regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
If the service indicator does not reset easily, or if the excessive crankcase pressure that may cause
core does not latch at the greatest vacuum, the crankshaft seal leakage.
service indicator should be replaced. If the new
service indicator will not reset, the hole for the service 1. Remove the hose from the breather cover.
indicator may be plugged.
2. Loosen the four bolts for the breather cover and
If necessary, replace the service indicator more remove the breather cover .
frequently in environments that are severely dusty.
Replace the service indicator annually regardless of 3. Remove the breather element and wash the
the operating conditions. Replace the service breather element in solvent that is clean and
indicator when the engine is overhauled, and nonflammable. Allow the breather element to dry.
whenever major engine components are replaced.
4. Install a breather element that is clean and dry.
Install the breather cover and install the bolts .
Refer to the Specifications, SENR3130 in order to
locate the proper torques.
5. Install the hose.
82 SEBU7901-09
Maintenance Section
Engine Mounts - Inspect
i02139969
NOTICE
Perform this maintenance with the engine stopped.
Engine Mounts - Inspect
SMCS Code: 1152; 1152-040 1. Maintain the oil level between the “ADD” mark (Y)
Inspect the engine mounts for deterioration and for and the “FULL” mark (X) on the oil level gauge .
proper bolt torque. Engine vibration can be caused Do not fill the crankcase above the “FULL” mark
by the following conditions: (X).
• Improper mounting of the engine NOTICE
Engine damage can occur if the crankcase is filled
• Deterioration of the engine mounts above the “FULL” mark on the oil level gauge
(dipstick).
Any engine mount that shows deterioration should be
replaced. Refer to the Specifications Manual, An overfull crankcase can cause the crankshaft to dip
SENR3130, “Torque Specifications”. Refer to your into the oil. This will reduce the power that is devel-
Caterpillar dealer for more information. oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
i04285621 duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
Engine Oil Level - Check crankcase breathers and excessive oil consumption.
SMCS Code: 1348-535-FLV Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the follow-
ing problems: guttering of the valves, packing of
carbon under the piston rings and wear of the cylin-
Hot oil and hot components can cause personal der liner.
injury. Do not allow hot oil or hot components to
contact the skin. If the oil level is above the “FULL” mark on the oil lev-
el gauge, drain some of the oil immediately.
2. Remove the oil filler cap and add oil, if necessary.

For the correct oil to use, see this Operation and
Maintenance Manual, “Fluid Recommendations”
topic. Do not fill the crankcase above the “FULL”
mark (X) on the oil level gauge. Clean the oil filler
cap. Install the oil filler cap.
3. Record the amount of oil that is added. For the
next oil sample and analysis, include the total
amount of oil that has been added since the
previous sample. This will help to provide the most
accurate oil analysis.
Illustration 38 g01456636 i08234825

(1) Oil level gauge
(2) Oil filler cap
Engine Oil Sample - Obtain
SMCS Code: 1348-554-SM
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
(Y) “ADD” mark
(X) “FULL” mark
SEBU7901-09 83
Maintenance Section
Engine Oil and Filter - Change
Obtain the Sample and the For instructions, see Special Publication, PEGJ0047,
“How To Take A Good S·O·S Oil Sample”. Consult
Analysis your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
Hot oil and hot components can cause personal i04228398

injury. Do not allow hot oil or hot components to
contact the skin. Engine Oil and Filter - Change
Before you take the oil sample, complete the Label, SMCS Code: 1318-510
PEEP5031 for identification of the sample. To help
obtain the most accurate analysis, provide the Caterpillar recommends using S·O·S oil analysis at
following information: regularly scheduled intervals to monitor the condition
and maintenance requirements of the engine. S·O·S
• Engine model oil analysis provides infrared analysis, which is
required for determining nitration and oxidation
• Service hours on the engine levels.
• The number of hours that have accumulated since The maintenance interval is correct if the preferred
the last oil change fluids are being used. Refer to this Operation and
Maintenance Manual, “Severe Service Application ”
• The amount of oil that has been added since the for information about maintenance intervals if the
preferred fluids are not used.
last oil change
To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, mixed oil sample.
Hot oil and hot components can cause personal
To avoid contamination of the oil samples, the tools injury. Do not allow hot oil or hot components to
and the supplies that are used for obtaining oil contact the skin.
samples must be clean.
Caterpillar recommends using the sampling valve to Do not drain the oil when the engine is cold. As the oil
obtain oil samples. The quality and the consistency of cools, suspended waste particles settle on the
the samples are better when the sampling valve is bottom of the oil pan. The waste particles are not
used. The location of the sampling valve allows oil removed with the draining cold oil. Drain the
that is flowing under pressure to be obtained during crankcase with the engine stopped. Drain the
normal engine operation. crankcase with the oil warm. This draining method
allows the waste particles that are suspended in the
The 169-8373 Fluid Sampling Bottle is oil to be drained properly.
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are Failure to follow this recommended procedure will
needed for obtaining oil samples. Instructions are cause the waste particles to be recirculated through
also provided. the engine lubrication system with the new oil.
NOTICE Interval for Engine Oil and Engine

Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam- Oil Filter Change
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being Refer to this Operation and Maintenance Manual,
drawn. This contaminate may cause a false analysis “Refill Capacities” before this procedure is started in
and an incorrect interpretation that could lead to con- order to determine the following:
cerns by both dealers and customers.
• The type of oil pan
If the engine is not equipped with a sampling valve, • The refill capacity for engine oil
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.
84 SEBU7901-09
Maintenance Section
Engine Oil and Filter - Change
Table 19
Intervals for Changing the Engine Oil and Engine Oil Filter(1)
Every 12870 L (3400 US gal) or

Shallow sump
250 service hours or 1 yr
Every 15900 L (4200 US gal) or

Deep sump
500 service hours or 1 yr
(1) Choose the interval that occurs first.
Drain the Engine Oil

After the engine has been run at the normal
operating temperature, stop the engine. Attach a “DO
NOT OPERATE” or a similar warning tag to the
ignition keyswitch before the engine is serviced.
NOTICE
Care must be taken to ensure that fluids are con- Typical filter mounting base and filter gasket
nance, testing, adjusting, and repair of the product. 1. Remove the oil filter with a 185-3630 Strap
Be prepared to collect the fluid with suitable contain- Wrench.
bling any component containing fluids. 2. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket is
Service Tool Catalog” or refer to Special Publication, removed.
PECJ0003, “Cat Shop Supplies and Tools Catalog” 3. Apply clean engine oil to the new oil filter gasket.
NOTICE
Dispose of all fluids according to local regulations Do not fill the oil filters with oil before installing them.
and mandates. This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear
to engine components.
1. Remove the oil drain plug in order to allow the oil
to drain. 4. Install the oil filter. Tighten the oil filter until the oil
2. After the oil has drained, the oil drain plug should filter gasket contacts the base. Tighten the oil filter
be cleaned and installed. by hand according to the instructions that are
shown on the oil filter. Do not overtighten the oil
Replace the Oil Filter filter.
Fill the Engine Crankcase

NOTICE
Caterpillar oil filters are built to Caterpillar specifica-
tions. Use of an oil filter not recommended by Cater- 1. Remove the oil filler cap. Fill the crankcase with
pillar could result in severe engine damage to the the proper amount of oil. Refer to this Operation
engine bearings, crankshaft, etc., as a result of the and Maintenance Manual, “Fluid
larger waste particles from unfiltered oil entering the Recommendations” for information about engine
engine lubricating system. Only use oil filters recom- oils.
mended by Caterpillar.
NOTICE
If equipped with an auxiliary oil filter or system, extra
oil must be added when filling the crankcase. Follow
the OEM or filter manufacturer's recommendations. If
the extra oil is not added, the engine may starve for
oil.
SEBU7901-09 85
Maintenance Section
Engine Protective Devices - Check
Consult your Cat dealer or refer to the Service

NOTICE Manual for more information.
To help prevent crankshaft or bearing damage, crank
engine to fill all filters before starting. Do not crank
engine for more than 30 seconds. i04230693
Engine Speed/Timing Sensor -

2. Start the engine and run the engine at “LOW IDLE”
for 2 minutes. Perform this procedure in order to Clean/Inspect
ensure that the lubrication system has oil and that SMCS Code: 1905-040; 1905-070; 1907-070; 1907-
the oil filters are filled. Inspect the oil filter for oil 040
leaks.
3. Stop the engine and allow the oil to drain back to
the sump for a minimum of 10 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.
i08272025
Engine Protective Devices -

Check
SMCS Code: 7400-535
Visual Inspection Left side view

(1) Secondary speed/timing sensor
(2) Primary speed/timing sensor
Visually check the condition of all gauges, sensors,
and wiring. Look for wiring and components that are
loose, broken, or damaged. Damaged wiring or 1. Remove the speed/timing sensors from the front
components should be repaired or replaced housing. Check the condition of the plastic end of
immediately. the speed/timing sensors for wear and/or
contaminants.
Calibration Check 2. Clean the metal shavings and other debris from
the face of the speed/timing sensors. Install the
NOTICE sensors into the front housing.
During testing, abnormal operating conditions must
be simulated.
i01458399
The tests must be performed correctly in order to pre-
vent possible damage to the engine. Engine Storage Procedure -
Alarms and shutoffs must function properly. Alarms Check
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. Determining if the SMCS Code: 1000-535
engine protective devices are in good working order The oil change interval may be extended to 12
during normal operation is impossible. Malfunctions months for a vehicle that is operated seasonally and
must be simulated to test the engine protective placed in storage for the remainder of the year by
devices. To prevent damage to the engine, only using the required storage procedures and the
authorized service personnel or your Cat dealer required start-up procedures. This extension is
should perform the tests. permitted if the following categories for oil change
intervals in the Operation and Maintenance Manual,
“Maintenance Interval Schedule” have not been
reached:
• Mileage
• Operating hours
86 SEBU7901-09
Maintenance Section
Engine Valve Lash - Check
• Fuel consumption i01597115
If an engine is out of operation and if use of the

engine is not planned, special precautions should be
Engine Valve Rotators -
made. If the engine will be stored for more than three Inspect
months, a complete protection procedure is
recommended. For more detailed information on SMCS Code: 1109-040
engine storage, see Special Instruction, SEHS9031,
“Storage Procedure For Caterpillar Products”.
If the engine will not be started for several weeks, the When inspecting the valve rotators, protective
lubricating oil will drain from the cylinder walls and glasses or face shield and protective clothing
from the piston rings. Rust can form on the cylinder must be worn, to help prevent being burned by
liner surface. Rust on the cylinder liner surface will hot oil or spray.
cause increased engine wear and a reduction in
engine service life. Caterpillar recommends the use Engine valve rotators rotate the valves when the
of volatile corrosion inhibitor (VCI) oil in order to engine runs. This helps to prevent deposits from
prevent internal engine damage due to moisture building up on the valves and the valve seats.
during storage. These inhibitors in the VCI oil act by
evaporating inside the engine. The inhibitors then Perform the following steps after the engine valve
condense over the inside surfaces of the engine. The lash is set, but before the valve covers are installed:
evaporation process and the condensing process
offers full protection to surfaces that cannot be 1. Start the engine according to Operation and
reached with preservatives. 0.9 L (1.0 qt) of Maintenance Manual, “Engine Starting” (Operation
4C-6792 VCI oil will treat 28.4 L (30.0 qt) of engine Section) for the procedure.
oil. This will give a 3 percent concentration of VCI oil.
The engine must be completely sealed when the 2. Operate the engine at low idle.
engine is stored in order for the VCI oil to function
properly. The VCI oil is easily cleaned from the 3. Observe the top surface of each valve rotator. The
engine when you remove the engine from storage. valve rotators should turn slightly when the valves
The volatile vapors are removed by simply running close.
the engine to operating temperature. A mineral oil
base is left behind after the volatile vapors are NOTICE
removed. A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
i03964791 shorten valve life. If a damaged rotator is not re-
placed, valve face guttering could result and cause
Engine Valve Lash - Check pieces of the valve to fall into the cylinder. This can
cause piston and cylinder head damage.
SMCS Code: 1105-535
Note: Procedures for adjusting the valve lash can be If a valve fails to rotate, consult your Caterpillar
found in Systems Operation/Testing and Adjusting, dealer.
“Valve Lash Adjustment”. Consult your Cat dealer for
assistance. i02784507
Fan Drive Bearing - Lubricate

SMCS Code: 1359-086-BD
Ensure that the engine cannot be started while
this maintenance is being performed. To help pre- Some of the fan drives have grease fittings and some
vent possible injury, do not use the starting motor of the fan drives do not have grease fittings. If there is
to turn the flywheel. no grease fitting, periodic lubrication is not required.
The fan drive requires grease only if the fan drive is
Hot engine components can cause burns. Allow equipped with a zerk.
additional time for the engine to cool before
measuring/adjusting valve lash clearance.
SEBU7901-09 87
Maintenance Section
Fan Drive Bearing - Replace
i02075183
Fuel System - Prime

SMCS Code: 1250-548; 1258-548
The Secondary Fuel Filter Has

Been Replaced
Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
Illustration 42 g00746166 changing fuel filters or water separator elements.
Typical location of the grease fitting (if equipped) that Clean up fuel spills immediately.
is for the fan drive bearing
The pulley is shown with the belt guards that have
been removed. NOTICE
Use a suitable container to catch any fuel that might
Lubricate the grease fitting that is on the fan drive spill. Clean up any spilled fuel immediately.
bearing with High Speed Ball Bearing Grease or the
equivalent.
NOTICE
Inspect the fan drive pulley assembly for wear or for Do not allow dirt to enter the fuel system. Thoroughly
damage. If the shaft is loose, an inspection of the clean the area around a fuel system component that
internal components should be performed. Refer to will be disconnected. Fit a suitable cover over discon-
the Systems Operation Testing and Adjusting Manual nected fuel system component.
for additional information.
Note: Refer to Operation and Maintenance Manual,
i02053753
“Fuel System Secondary Filter - Replace” for
information on replacing the filter.
Fan Drive Bearing - Replace
SMCS Code: 1359-510-BD 1. Turn the ignition switch to the “OFF” position.
1. Remove Bearings. Refer to Disassembly and

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

“Closed (Prime)” position in order to prime the fuel
system.
88 SEBU7901-09
Maintenance Section
Fuel System - Prime
3. Open air purge screw (2) for the fuel filter by three
full turns. Do not remove the air purge screw.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Start the engine. The engine should start and the

engine should run smoothly.
Note: You may use the fuel priming pump for the fuel
filter (IF EQUIPPED) instead of starting the engine
and running the engine.
5. While the engine is running, observe air purge Illustration 44 g00975199
screw (2). When a small drop of fuel appears at (1) Fuel priming pump
(2) Air purge screw
the threads of the air purge screw, close and (3) Priming valve (If Equipped)
tighten air purge screw (2).
Note: There may be a noticeable change in the 3. Turn the priming valve (3) (If Equipped) to the
sound of the running engine when the air purge “Closed (Prime)” position in order to prime the fuel
screw is tightened. The change in the sound of the system.
engine is normal. 4. Open air purge screw (2) for the fuel filter by three
Note: Failure to tighten all fittings could result in full turns. Do not remove the air purge screw.
serious fuel leaks.
NOTICE
6. Clean any residual fuel from the engine Do not crank the engine continuously for more than
components. 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
7. After the engine has operated smoothly for 30
seconds, turn the priming valve (3) to the “Open 5. Crank the engine for 30 seconds. Use a suitable
(Run)” position. container to catch the fuel while you crank the
Note: Shortened injector life may occur if the priming engine. Allow the starter motor to cool for 2
valve (3) is left in the “Closed (Prime)” position. minutes.
Note: You may use the fuel priming pump (1) (IF
The Engine Has Been Run Out of EQUIPPED) for the fuel filter instead of cranking the
Fuel engine.
6. Crank the engine for 30 seconds. Allow the starter

NOTICE motor to cool for 2 minutes.
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately. 7. Repeat Step 6 until the engine starts and the
engine runs.
NOTICE Note: Failure to tighten all fittings could result in
Do not allow dirt to enter the fuel system. Thoroughly serious fuel leaks.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon- 8. After the engine has operated smoothly for 30
nected fuel system component.
seconds, turn the priming valve (3) to the “Open
(Run)” position.
1. Turn the ignition switch to the “OFF” position.
Note: Shortened injector life may occur if the priming
2. Fill the fuel tank(s) with clean diesel fuel. valve (3) is left in the “Closed (Prime)” position.
SEBU7901-09 89
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
9. Clean any residual fuel from the engine

NOTICE
components. Do not fill fuel filters with fuel before installing
them. The fuel will not be filtered and could be
i05354209 contaminated. Contaminated fuel will cause ac-
celerated wear to fuel system parts. The fuel sys-
tem should be primed prior to starting the engine.
Fuel System Primary Filter
(Water Separator) Element - 1. Close the main fuel supply valve.
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.
The primary filter/water separator also provides
filtration in order to help extend the life of the
secondary fuel filter. The element should be changed
regularly. If a vacuum gauge is installed, the primary
filter/water separator should be changed at
50 to 70 kPa (15 to 20 inches Hg).
Replace the Element Illustration 45 g01453091

(1) Element
(2) Bowl
(3) Drain
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent 2. Remove element (1) from the element mounting
possible injury, turn the start switch off when base while bowl (2) is attached.
changing fuel filters or water separator elements.
Clean up fuel spills immediately. 3. Dispose of the contents of the filter. Remove bowl
(2) from element (1). The bowl is reusable. Do not
discard the bowl. Dispose of the used element.
NOTICE 4. Remove the O-ring from the gland of the bowl.
tained during performance of inspection, mainte- Clean the following components:
Be prepared to collect the fluid with suitable contain- • Bowl
bling any component containing fluids. • O-ring
Refer to Special Publication, NENG2500, “Dealer • Mounting base

Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. Inspect the O-ring for damage and for
deterioration. Replace the O-ring, if necessary.
and mandates. 5. Lubricate the O-ring with clean diesel fuel.
6. Install bowl (2) on a new element. Tighten the bowl
NOTICE by hand. Do not use tools in order to tighten the
Do not allow dirt to enter the fuel system. Thoroughly bowl.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon- 7. Lubricate the top seal of element (1) with clean
nected fuel system component. diesel fuel. Install the new element on the
mounting base. Tighten the element by hand.
90 SEBU7901-09
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the
fuel system.
8. Open the main fuel supply valve.

9. Start the engine and check for leaks. Run the
engine for 1 minute. Stop the engine and check for
leaks again.
Detecting leaks is difficult while the engine is
running. The primary filter/water separator is under
suction. A leak will allow air to enter the fuel. The Illustration 46 g01453091
air in the fuel can cause low power due to aeration
(1) Element
of the fuel. Ensure that the components are (2) Bowl
correctly installed to prevent air from entering the (3) Drain
fuel system.
Bowl (2) should be monitored daily for signs of water.
If water is present, drain the water from the bowl.
i02927285
1. Open drain (3). The drain is a self-ventilated drain.
Fuel System Primary Filter/ Catch the draining water in a suitable container.
Water Separator - Drain Dispose of the water properly.
SMCS Code: 1260-543; 1263-543 2. Close drain (3).
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
Fuel leaked or spilled onto hot surfaces or electri- ened securely to help prevent air from entering the
cal components can cause a fire. To help prevent fuel system.
possible injury, turn the start switch off when
Clean up fuel spills immediately. i03478081
NOTICE
Fuel System Secondary Filter -
Replace
nance, testing, adjusting, and repair of the product. SMCS Code: 1261-510-SE
Refer to Special Publication, NENG2500, “Dealer Fuel leaked or spilled onto hot surfaces or electri-
Service Tool Catalog” for tools and supplies suitable cal components can cause a fire. To help prevent
to collect and contain fluids on Cat products. possible injury, turn the start switch off when
Dispose of all fluids according to local regulations Clean up fuel spills immediately.
and mandates.
NOTICE
NOTICE Do not allow dirt to enter the fuel system. Thoroughly
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that
clean the area around a fuel system component that will be disconnected. Fit a suitable cover over any
will be disconnected. Fit a suitable cover over discon- disconnected fuel system components.
nected fuel system component.
SEBU7901-09 91
Maintenance Section
Fuel Tank Water and Sediment - Drain
6. Install the new fuel filter. Spin the fuel filter onto the
NOTICE
Care must be taken to ensure that fluids are con- fuel filter base until the gasket contacts the base.
tained during performance of inspection, mainte- Use the rotation index marks on the filters as a
nance, testing, adjusting, and repair of the product. guide for proper tightening. Tighten the filter
Be prepared to collect the fluid with suitable contain- according to the instructions that are on the fuel
ers before opening any compartment or disassem- filter. Do not overtighten the filter.
7. Open the fuel supply valve. The engine will need to
be purged of air. Refer to the Operation and
PECJ0003, “Cat Shop Supplies and Tools Catalog” Maintenance Manual, “Fuel System - Prime” topic
for tools and supplies suitable to collect and contain (Maintenance Section) for more information.
i06104305
and mandates.
Fuel Tank Water and Sediment
1. Stop the engine. Turn the ignition switch to the
- Drain
OFF position or disconnect the battery. Refer to SMCS Code: 1273-543-M&S
the Operation and Maintenance Manual, “Battery
or Battery Cable - Disconnect” topic (Maintenance NOTICE
Section) for more information. Shut off the fuel Care must be taken to ensure that fluids are con-
supply valve (if equipped). tained during performance of inspection, mainte-
2. It may be necessary to relieve residual fuel Be prepared to collect the fluid with suitable contain-
pressure from the fuel system before the fuel filter ers before opening any compartment or disassem-
is removed. Wait for one to five minutes until the
fuel pressure has lowered. Use a suitable Refer to Special Publication, NENG2500, “Cat Dealer
container in order to catch any fuel that may spill. Service Tool Catalog” or refer to Special Publication,
3. Remove the used fuel filter and discard the used for tools and supplies suitable to collect and contain
fuel filter. fluids on Cat products.
4. Clean the gasket sealing surface of the fuel filter Dispose of all fluids according to local regulations
base. Ensure that all of the old gasket is removed. and mandates.
5. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE Fuel Tank

Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be Fuel quality is critical to the performance and to the
contaminated. Contaminated fuel will cause acceler- service life of the engine. Water in the fuel can cause
ated wear to fuel system parts. excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
NOTICE fuel system and the fuel returns to the fuel tank. This
In order to meet expected fuel system component life, causes water to accumulate in fuel tanks. Draining
4 micron (c) absolute or less secondary fuel filtration the fuel tank regularly and obtaining fuel from reliable
is required for all Cat Diesel Engines that are sources can help to eliminate water in the fuel. The
equipped with unit injected fuel systems. All current fuel tank utilizes a fuel tank vent to prevent an air lock
Cat Diesel Engines are factory equipped with Cat Ad- or vacuum. Ensure that the vent is free of debris and
vanced Efficiency 4 micron(c) absolute fuel filters. not damaged.
Caterpillar does not warrant the quality or perform- Drain the Water and the Sediment
ance of non-Cat fluids and filters.
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Prepare to catch water and sediment in an
appropriate container. Connect a hose (if necessary)
to the valve prior to opening the valve.
92 SEBU7901-09
Maintenance Section
Grounding Stud - Inspect/Clean/Tighten
Open the drain valve on the bottom of the fuel tank in If a bulk storage tank has been refilled or moved
order to drain the water and the sediment. Close the recently, allow adequate time for the sediment to
drain valve. settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
Note: Failure to close the drain properly could result sediment. Filtering fuel that is pumped from the
in fuel leakage, which could have detrimental results storage tank helps to ensure the quality of the fuel.
to performance. When possible, water separators should be used.
Check the fuel daily. Drain the water and sediment
i04230950
from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow 5 to 10 minutes before Grounding Stud - Inspect/
performing this procedure.
Clean/Tighten
Fill the fuel tank after operating the engine in order to SMCS Code: 7423-079; 7423-040; 7423-070
drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
overflow.
The connection of battery cables to a battery and
Some fuel tanks use stand pipes that allow water and the disconnection of battery cables from a battery
sediment to settle below the end of the fuel stand may cause an explosion which may result in in-
pipe. Some fuel tanks use supply lines that take fuel jury or death. The connection and the disconnec-
directly from the bottom of the tank. If the engine is tion of other electrical equipment may also cause
equipped with this system, regular maintenance of an explosion which may result in injury or death.
the fuel system filter is important. The procedures for the connection and the dis-
connection of battery cables and other electrical
Fuel Storage Tanks equipment should only be performed in a nonex-
plosive atmosphere.
Drain the water and the sediment from the fuel
storage tank during the following conditions:
• Weekly
• Refill of the tank

This procedure will help prevent water or sediment
from being pumped from the storage tank into the
engine fuel tank. A four micron(c) absolute filter for
the breather vent on the fuel tank is also
recommended.
Electronics grounding stud (side view)
Inspect the OEM harness for good connections.

Inspect the condition of the OEM harness.
The electronics grounding stud must have a wire
ground to the battery. Tighten the electronics
grounding stud at every oil change. Ground wires
and straps should be combined at engine grounds.
All grounds should be tight and free of corrosion.
SEBU7901-09 93
Maintenance Section
Hoses and Clamps - Inspect/Replace
• Clean the electronics grounding stud and the • Hoses which exhibit signs of leakage which are
terminals for the electronics ground strap with a not the result of loose couplings or clamps
clean cloth.
Inspect all clamps for the following conditions.
• If the connections are corroded, clean the Replace any clamp which exhibits signs of any of the
connections with a solution of baking soda and following conditions.
water.
• Cracking
• Keep the electronics grounding stud and the strap
clean and coated with MPGM grease or petroleum • Looseness
jelly.
• Damage
i06825542 Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.
Hoses and Clamps - Inspect/ Each installation application can be different. The
Replace differences depend on the following factors:
SMCS Code: 7554-040; 7554-510 • Type of hose
Hoses and clamps must be inspected periodically • Type of fitting material
and replaced at the recommended interval to ensure
safe and continuous operation of the engine. Failure • Anticipated expansion and contraction of the hose
to replace a fuel hose at the recommended change
interval may result in a hazardous situation. Take • Anticipated expansion and contraction of the
proper safety precautions before inspecting or fittings
replacing hoses and clamps.
Due to extreme temperature changes, the hose will
Note: Always use a board or cardboard when the heat set. Heat setting causes hose clamps to loosen
engine components are checked for leaks. Leaking which can result in leaks. A constant torque hose
fluid that is under pressure can cause serious injury clamp will help to prevent loose hose clamps.
or possible death. Leaks that are the size of a pin
hole are included. Refer to Operation and Replace hoses that are cracked or soft. Replace
Maintenance Manual, “General Hazard Information” hoses that show signs of leakage. Replace hoses
for more information. that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace
Note: Ensure that the hose is compatible with the hose clamps which are loose.
application.
Replace the Hoses and the Clamps
Inspect Tubes, Hoses, Bellows, and
Clamps NOTICE
Inspect all tubes and hoses for leaks that are caused
by the following conditions. Replace any tube or hose nance, testing, adjusting, and repair of the product.
which exhibits any of the following conditions. Failure Be prepared to collect the fluid with suitable contain-
to replace a tube or hose which exhibits any of the
following conditions may result in a hazardous
situation. Refer to Special Publication, NENG2500, “Cat Dealer
• Hoses which are cracked PECJ0003, “Cat Shop Supplies and Tools Catalog”
• Hoses which are soft for tools and supplies suitable to collect and contain
• Outer covering that is chafed or cut Dispose of all fluids according to local regulations
and mandates.
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering
• Exhaust bellows for leaks or damage
94 SEBU7901-09
Maintenance Section
Hoses and Clamps - Inspect/Replace
Cooling System Fuel System
Pressurized System: Hot coolant can cause seri- Personal injury can result from removing hoses
ous burns. To open the cooling system filler cap, or fittings in a pressure system.
components are cool. Loosen the cooling system Failure to relieve pressure can cause personal
pressure cap slowly in order to relieve the injury.
pressure.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
Personal injury can result from removing hoses

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

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

NOTICE
5. Drain the coolant from the cooling system to a Do not allow dirt to enter the fuel system. Thoroughly
level that is below the hose that is being replaced. clean the area around a fuel system component that
Drain the coolant into a suitable clean container. will be disconnected. Fit a suitable cover over any
The coolant can be reused. disconnected fuel system components.
6. Remove the hose clamps.
Note: High-pressure fuel lines may be installed
7. Disconnect the old hose. between the high-pressure fuel pump and the fuel
8. Replace the old hose with a new hose. injectors. High-pressure fuel lines are constantly
charged with high pressure. Do not check the high-
9. Install hose clamps which have been inspected or pressure fuel lines with the engine or the starting
install new hose clamps. Refer to Specifications, motor in operation. Wait for 10 minutes after the
SENR3130, “Torque Specifications” “Hose engine stops before you perform any service or
Clamps” for information about selecting and repair on high-pressure fuel lines. Waiting for 10
installing the proper hose clamps. minutes will allow the pressure to be purged.
10. Refill the cooling system. 1. Drain the fuel from the fuel system to a level that is
below the hose that is being replaced.
11. Clean the coolant filler cap. Inspect the gaskets
on the filler cap. Inspect the gasket seat. Inspect 2. Remove the hose clamps.
the vacuum valve and seat for debris or damage.
3. Disconnect the old hose.
Replace the filler cap if the gaskets are damaged.
Install the filler cap. Note: When servicing fuel system, use cap/s or
12. Start the engine. Inspect the cooling system for cover/s as required to protect the system and
maintain fuel system cleanliness.
leaks.
4. Replace the old hose with a new hose.
SEBU7901-09 95
Maintenance Section
Jacket Water Heater - Check
5. Install hose clamps which have been inspected or 4. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications, install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications” “Hose SENR3130, “Torque Specifications” “Hose
Clamps” for information about selecting and Clamps” for information about selecting and
installing the proper hose clamps. installing the proper hose clamps.
6. Carefully inspect the engine for any spilled fuel. Note: The bellows and the V-clamps that are used on
Make sure that no fuel remains on or close to the the exhaust bellows should never be reused.
engine.
5. Start the engine. Inspect the air lines for leaks.
Note: Fuel must be added to the fuel system ahead
of the fuel filter. i08257569
7. Refill the fuel system. Refer to this Operation and

Maintenance Manual, “Fuel System - Prime” for
Jacket Water Heater - Check
information about priming the engine with fuel. SMCS Code: 1383-535
8. Start the engine. Inspect the fuel system for leaks. Jacket water heaters help to improve starting in
ambient temperatures that are below 21 °C (70 °F).
Lubrication System All installations that require automatic starting should
have jacket water heaters.
Check the operation of the jacket water heater.
Check the operation of the circulation pump, if
Hot oil and hot components can cause personal equipped. For an ambient temperature of 0 °C
injury. Do not allow hot oil or hot components to (32 °F), the heater should maintain the jacket water
contact the skin. coolant temperature at approximately 32 °C (90 °F).
i01848653
1. Drain the oil from the lubrication system to a level
that is below the hose that is being replaced. Overhaul Considerations
2. Remove the hose clamps. SMCS Code: 7595-043
S/N: HRA1–Up
S/N: GLS1–Up
5. Install hose clamps which have been inspected or
S/N: PDY1–Up
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications” “Hose S/N: PBZ1–Up
Clamps” for information about selecting and Reduced hours of operation at full load will result in a
installing the proper hose clamps. lower average power demand. A decreased average
6. Refill the lubrication system. Refer to this power demand should increase both the engine
service life and the overhaul interval.
Operation and Maintenance Manual, “Engine Oil
Level - Check” to ensure that the lubrication The need for an overhaul is generally indicated by
system is filled with the proper amount of engine increased fuel consumption and by reduced power.
oil.
The following factors are important when a decision
7. Start the engine. Inspect the lubrication system for is being made on the proper time for an engine
leaks. overhaul:
• The need for preventive maintenance
Air System
• The quality of the fuel that is being used
1. Remove the hose clamps.
• The operating conditions
• The results of the S·O·S analysis
96 SEBU7901-09
Maintenance Section
Overhaul Considerations
Oil Consumption as an Overhaul • Caterpillar Inc. remanufactured exchange

components
Indicator
Oil consumption, fuel consumption, and maintenance Overhaul Recommendation
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil To minimize downtime, a scheduled engine overhaul
consumption can also be used to estimate the by your Caterpillar dealer is recommended. This will
required capacity of a makeup oil tank that is suitable provide you with the best cost/value relationship.
for the maintenance intervals.
Note: Overhaul programs vary according to the
Oil consumption is in proportion to the percentage of engine application and according to the dealer that
the rated engine load. As the percentage of the performs the overhaul. Consult your Caterpillar
engine load is increased, the amount of oil that is dealer for specific information about the available
consumed per hour also increases.
overhaul programs and about overhaul services for
The oil consumption rate (brake specific oil extending the engine life.
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC) If an overhaul is performed without overhaul service
depends on the engine load. Consult your Caterpillar from your Caterpillar dealer, be aware of the following
dealer for assistance in determining the typical oil maintenance recommendations.
consumption rate for your engine.
Unit Fuel Injector
When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal Clean the fuel injector body and replace the O-rings.
wear, an engine overhaul should be scheduled. Replace the O-rings and the gasket on the injector
There may be a corresponding increase in blowby sleeve. Clean the area around the injector seating in
and a slight increase in fuel consumption. the injector sleeve. Refer to the Service Manual for
the complete procedure, or consult with your
Overhaul Options Caterpillar dealer for assistance.
Before Failure Overhaul Rebuild or Exchange

A planned overhaul before failure may be the best Cylinder Head Assembly, Connecting Rods,
value for the following reasons: Pistons, Cylinder Liners, Turbocharger, Cylinder
Packs, Oil Pump, and Fuel Transfer Pump
• Costly unplanned downtime can be avoided.
These components should be inspected according to
• Many original parts can be reused according to the the instructions that are found in various Caterpillar
standards for reusable parts. reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
• The engine service life can be extended without needed for inspecting the engine parts.
the risk of a major catastrophe due to engine
failure. If the parts comply with the established inspection
specifications that are expressed in the reusable
• The best cost/value relationship per hour of parts guideline, the parts should be reused.
extended life can be attained.
Parts that are not within the established inspection
After Failure Overhaul specifications should be dealt with in one of the
following manners:
If a major engine failure occurs and the engine must
be removed, many options are available. An overhaul • Salvaging
should be performed if the engine block or the
crankshaft needs to be repaired. • Repairing
If the engine block is repairable and/or the crankshaft • Replacing
is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine Parts that do not comply with the established
with a similar exchange core. inspection specifications can result in the following
problems:
This lower cost can be attributed to three aspects:
• Unscheduled downtime
• Specially designed Caterpillar engine features
• Costly repairs
• Caterpillar dealer exchange components
• Damage to other engine parts
SEBU7901-09 97
Maintenance Section
• Reduced engine efficiency • Camshaft followers

• Increased fuel consumption Caterpillar Inc. recommends replacing the crankshaft
vibration damper.
Reduced engine efficiency and increased fuel
consumption translates into higher operating costs. Oil Cooler Core and Aftercooler Core
Therefore, Caterpillar Inc. recommends repairing out-
of-spec parts or replacing out-of-spec parts. During an overhaul, the removal of the oil cooler core
and the aftercooler core is recommended. The oil
cooler core and the aftercooler core should be
Inspection and/or Replacement cleaned and pressure tested.
Piston Rings, Crankshaft Bearings, Valve NOTICE
Rotators, and Crankshaft Seals Do not use caustic cleaners to clean the core.
The following components may not last until the Caustic cleaners can attack the internal metals of the
second overhaul. core and cause leakage.
• Thrust bearings
Obtain Coolant Analysis
• Main bearings
The concentration of supplemental coolant additive
• Rod bearings
(SCA) should be checked regularly with test kits or
• Valve rotators with S·O·S Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine is
• Crankshaft seals overhauled.
Caterpillar Inc. recommends the installation of new A coolant analysis can be conducted in order to verify
parts at each overhaul period. the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
Inspect these parts while the engine is disassembled by consulting your local water utility company or an
for an overhaul. agricultural agent. Private laboratories are also
available for water analysis.
Inspect the crankshaft for any of the following
conditions: Caterpillar Inc. recommends an S·O·S Coolant
Analysis (Level 2).
• Deflection
S·O·S Coolant Analysis (Level 2)
• Damage to the journals
An S·O·S Coolant Analysis (Level 2) is a
• Bearing material that has seized to the journals comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
Check the journal taper and the profile of the system. An S·O·S Coolant Analysis (Level 2)
crankshaft journals. Check these components by provides the following information:
interpreting the wear patterns on the following
components: • Complete S·O·S Coolant Analysis (Level 2)
• Rod bearing • Visual inspection of properties
• Main bearings • Identification of metal corrosion
Note: If the crankshaft is removed for any reason, • Identification of contaminants
use the magnetic particle inspection process to check
for cracks in the crankshaft. • Identification of built up impurities (corrosion and
scale)
Inspect the camshaft for damage to the journals and
to the lobes. S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
Note: If the camshaft is removed for any reason, use recommendations.
the magnetic particle inspection process to check for
cracks in the camshaft.
Inspect the following components for signs of wear or
for signs of scuffing:
• Camshaft bearings
98 SEBU7901-09
Maintenance Section
For more information about coolant analysis, consult Overhaul Options

your Caterpillar dealer.
Before Failure Overhaul
i08291873
A planned overhaul before failure may be the best
value for the following reasons:
SMCS Code: 7595-043 • Costly unplanned downtime can be avoided.
S/N: RRA1–Up • Many original parts can be reused according to the

standards for reusable parts.
S/N: LGK1–Up
• The engine service life can be extended without
S/N: PDN1–Up the risk of a major catastrophe due to engine
S/N: PBY1–Up failure.
Reduced hours of operation at full load will result in a • The best cost/value relationship per hour of
lower average power demand. A decreased average extended life can be attained.
power demand should increase both the engine
service life and the overhaul interval. After Failure Overhaul
The need for an overhaul is generally indicated by If a major engine failure occurs and the engine must
increased fuel consumption and by reduced power. be removed, many options are available. An overhaul
should be performed if the engine block or the
The following factors are important when a decision crankshaft needs to be repaired.
is being made on the proper time for an engine
overhaul: If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
• The need for preventive maintenance percent and 50 percent of the cost of a new engine
with a similar exchange core.
• The quality of the fuel that is being used
This lower cost can be attributed to three aspects:
• The operating conditions
• Specially designed Caterpillar engine features
• The results of the S·O·S analysis
• Caterpillar dealer exchange components
Oil Consumption as an Overhaul • Caterpillar Inc. remanufactured exchange
Indicator components
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total Overhaul Recommendation
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the To minimize downtime, a scheduled engine overhaul
required capacity of a makeup oil tank that is suitable by your Caterpillar dealer is recommended. This will
for the maintenance intervals. provide you with the best cost/value relationship.
Oil consumption is in proportion to the percentage of Note: Overhaul programs vary according to the
the rated engine load. As the percentage of the engine application and according to the dealer that
engine load is increased, the amount of oil that is performs the overhaul. Consult your Caterpillar
consumed per hour also increases. dealer for specific information about the available
overhaul programs and about overhaul services for
The oil consumption rate (brake specific oil extending the engine life.
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC) If an overhaul is performed without overhaul service
depends on the engine load. Consult your Caterpillar from your Caterpillar dealer, be aware of the following
dealer for assistance in determining the typical oil maintenance recommendations.
consumption rate for your engine.
When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
SEBU7901-09 99
Maintenance Section
Unit Fuel Injector • Rod bearings
Clean the fuel injector body and replace the O-rings. • Valve rotators
Replace the O-rings and the gasket on the injector
sleeve. Clean the area around the injector seating in • Crankshaft seals
the injector sleeve. Refer to the Service Manual for
Caterpillar Inc. recommends the installation of new
the complete procedure, or consult with your parts at each overhaul period.
Caterpillar dealer for assistance.
Inspect these parts while the engine is disassembled
Rebuild or Exchange for an overhaul.
Cylinder Head Assembly, Connecting Rods, Inspect the crankshaft for any of the following
Pistons, Cylinder Liners, Turbocharger, Cylinder conditions:
Packs, Oil Pump, and Fuel Transfer Pump
• Deflection
These components should be inspected according to • Damage to the journals
the instructions that are found in various Caterpillar
reusability publications. The Special Publication, • Bearing material that has seized to the journals
SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts. Check the journal taper and the profile of the
crankshaft journals. Check these components by
If the parts comply with the established inspection interpreting the wear patterns on the following
specifications that are expressed in the reusable components:
parts guideline, the parts should be reused.
• Rod bearing
Parts that are not within the established inspection
specifications should be dealt with in one of the • Main bearings
following manners:
Note: If the crankshaft is removed for any reason,
• Salvaging use the magnetic particle inspection process to check
• Repairing for cracks in the crankshaft.
Inspect the camshaft for damage to the journals and
• Replacing to the lobes.
Parts that do not comply with the established Note: If the camshaft is removed for any reason, use
inspection specifications can result in the following the magnetic particle inspection process to check for
problems:
cracks in the camshaft.
• Unscheduled downtime Inspect the following components for signs of wear or
for signs of scuffing:
• Costly repairs
• Camshaft bearings
• Damage to other engine parts
• Camshaft followers
• Reduced engine efficiency
Caterpillar Inc. recommends replacing the crankshaft
• Increased fuel consumption vibration damper.
Reduced engine efficiency and increased fuel Oil Cooler Core and Aftercooler Core
consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing out- During an overhaul, the removal of the oil cooler core
of-spec parts or replacing out-of-spec parts. and the aftercooler core is recommended. The oil
cooler core and the aftercooler core should be
Inspection and/or Replacement cleaned and pressure tested.
Piston Rings, Crankshaft Bearings, Valve NOTICE

Rotators, and Crankshaft Seals Do not use caustic cleaners to clean the core.
Caustic cleaners can attack the internal metals of the
The following components may not last until the core and cause leakage.
second overhaul.
• Thrust bearings
• Main bearings
100 SEBU7901-09
Maintenance Section
Power Take-Off Clutch - Check
Obtain Coolant Analysis

The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits or
with S·O·S Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine is
overhauled.
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
by consulting your local water utility company or an
agricultural agent. Private laboratories are also
available for water analysis.
Caterpillar Inc. recommends an S·O·S Coolant
Analysis (Level 2). Illustration 48 g00781502
(1) Instruction plate
S·O·S Coolant Analysis (Level 2) (2) Serial number plate
An S·O·S Coolant Analysis (Level 2) is a Check the clutch adjustment regularly after “wear in”.
comprehensive coolant analysis which completely Heavy-duty applications which have engagements
analyzes the coolant and the effects on the cooling that are frequent and relatively long periods of clutch
system. An S·O·S Coolant Analysis (Level 2) slippage require more frequent adjustment than light-
provides the following information: duty applications. The operating torque should be
measured in order to determine if a clutch adjustment
• Complete S·O·S Coolant Analysis (Level 2) is required.
• 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 in-
the results of both the analysis and the maintenance jury may result.
recommendations.
If the clutch is damaged to the point of burst fail-
For more information about coolant analysis, consult 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.
i03901481
Power Take-Off Clutch - Check i08254039
SMCS Code: 3055-535 Radiator - Clean

SMCS Code: 1353-070
NOTICE
New power take-offs should have the clutch adjust- Note: Adjust the frequency of cleaning according to
ment checked before being placed into service. The the effects of the operating environment.
clutch adjustment should be checked again after the
first ten hours of operation. New clutch plates have a Inspect the radiator for these items: damaged fins,
“wear in” period, and the clutch may require several corrosion, dirt, grease, insects, leaves, oil, and other
adjustments until the new plates are “worn in”. debris. Clean the radiator, if necessary.
SEBU7901-09 101
Maintenance Section
Starting Motor - Inspect
i05965726
Personal injury can result from air pressure. Turbocharger - Inspect

Personal injury can result without following prop- SMCS Code: 1052-040
er procedure. When using pressure air, wear a Periodic inspection and cleaning are recommended
protective face shield and protective clothing. for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through
The maximum air pressure for cleaning purposes
the air inlet system. Therefore, by-products from oil
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded. and from combustion can collect in the turbocharger
compressor housing. Over time, this buildup can
contribute to loss of engine power, increased black
Pressurized air is the preferred method for removing smoke and overall loss of engine efficiency.
loose debris. Direct the air in the opposite direction of
the air flow. Hold the nozzle approximately 6 mm If the turbocharger fails during engine operation,
(0.25 inch) away from the fins. Slowly move the air damage to the turbocharger compressor wheel and/
nozzle in a direction that is parallel with the tubes. or to the engine may occur. Damage to the
This movement will remove debris that is between turbocharger compressor wheel can cause additional
the tubes. damage to the pistons, the valves, and the cylinder
head.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes NOTICE
must be less than 275 kPa (40 psi). Use pressurized Turbocharger bearing failures can cause large quan-
water to soften mud. Clean the core from both sides. tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
Use a degreaser and steam for removal of oil and damage.
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the Minor leakage of a turbocharger housing under ex-
core with clean water. tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not
After cleaning, start the engine and bring the engine occurred.
to high idle. This procedure will help in the removal of
debris and drying of the core. Stop the engine. Use a When a turbocharger bearing failure is accompanied
light bulb behind the core to inspect the core for by a significant engine performance loss (exhaust
cleanliness. Repeat the cleaning, if necessary. smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
Inspect the fins for damage. Bent fins may be opened replaced.
with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary. An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
i00651416 turbocharger can also reduce the chance for potential
damage to other engine parts.
Starting Motor - Inspect Note: Turbocharger components require precision
SMCS Code: 1451-040; 1453-040 clearances. The turbocharger cartridge must be
balanced due to high rpm. Severe Service
Caterpillar Inc. recommends a scheduled inspection Applications can accelerate component wear. Severe
of the starting motor. If the starting motor fails, the Service Applications require more frequent
engine may not start in an emergency situation. inspections of the cartridge.
Check the starting motor for proper operation. Check
the electrical connections and clean the electrical
connections. Refer to the Service Manual for more
information on the checking procedure and for
specifications or consult your Caterpillar dealer for
assistance.
102 SEBU7901-09
Maintenance Section
Walk-Around Inspection
Removal and Installation For maximum engine service life, make a thorough
inspection of the engine compartment before starting
For options regarding the removal, installation, repair, the engine. Look for items such as oil leaks or
and replacement, consult your Cat dealer. Refer to coolant leaks, loose bolts, worn belts, loose
the Service Manual for this engine for the procedure connections and trash buildup. Make repairs, as
and specifications. needed:
• The guards must be in the proper place. Repair
Cleaning and Inspecting damaged guards or replace missing guards.
1. Remove the exhaust outlet piping and remove the • Wipe all caps and plugs before the engine is
air inlet piping from the turbocharger. Visually serviced in order to reduce the chance of system
inspect the piping for the presence of oil. Clean the contamination.
interior of the pipes in order to prevent dirt from
entering during reassembly. NOTICE
For any type of leak (coolant, lube, or fuel) clean up
2. Turn the compressor wheel and the turbine wheel the fluid. If leaking is observed, find the source and
by hand. The assembly should turn freely. Inspect correct the leak. If leaking is suspected, check the flu-
the compressor wheel and the turbine wheel for id levels more often than recommended until the leak
contact with the turbocharger housing. There is found or fixed, or until the suspicion of a leak is
should not be any visible signs of contact between proved to be unwarranted.
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
NOTICE
contact between the rotating turbine wheel or the Accumulated grease and/or oil on an engine or deck
compressor wheel and the turbocharger housing, is a fire hazard. Remove this debris with steam clean-
the turbocharger must be reconditioned. ing or high pressure water.
3. Check the compressor wheel for cleanliness. If

only the blade side of the wheel is dirty, dirt and/or • Ensure that the cooling lines are properly clamped
moisture is passing through the air filtering and that the cooling lines are tight. Check for
system. If oil is found only on the back side of the leaks. Check the condition of all pipes.
wheel, there is a possibility of a failed turbocharger • Inspect the water pumps for coolant leaks.
oil seal.
Note: The water pump seal is lubricated by coolant in
The presence of oil may be the result of extended
the cooling system. It is normal for a small amount of
engine operation at low idle. The presence of oil leakage to occur as the engine cools down and the
may also be the result of a restriction of the line for parts contract.
the inlet air (plugged air filters), which causes the
turbocharger to slobber. Excessive coolant leakage may indicate the need to
replace the water pump seal. For the removal of
4. Inspect the bore of the turbine housing for water pumps and the installation of water pumps and/
corrosion. or seals, refer to the Service Manual for the engine or
consult your Caterpillar dealer.
5. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush. • Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
6. Fasten the air inlet piping and the exhaust outlet pan, the oil filters and the valve cover.
piping to the turbocharger housing.
• Inspect the fuel system for leaks. Look for loose
i01185304 fuel line clamps or for loose fuel line tie-wraps.
Walk-Around Inspection • Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure
SMCS Code: 1000-040 that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
Inspect the Engine for Leaks and • Inspect the alternator belt and the accessory drive
for Loose Connections belts for cracks, breaks or other damage.
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
SEBU7901-09 103
Maintenance Section
Water Pump - Inspect
Belts for multiple groove pulleys must be replaced as Inspect the water pump for wear, cracks, pin holes,
matched sets. If only one belt is replaced, the belt will and proper operation. Refer to the Parts Manual for
carry more load than the belts that are not replaced. the correct part numbers for your engine or consult
The older belts are stretched. The additional load on your Cat dealer if repair is needed or replacement is
the new belt could cause the belt to break. needed.
• Drain the water and the sediment from fuel tanks
on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for

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

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

gauges that are cracked. Replace any gauge that
can not be calibrated.
i08273264
Water Pump - Inspect

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

• A piston seizure
• Other potential damage to the engine

A failed water pump might cause severe engine
overheating problems. Overheating could result in
cracks in the cylinder head, a piston seizure, or other
potential damage to the engine.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all
water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
Disassemble and Water Pump - Assemble” for the
disassembly and assembly procedure. If necessary
to remove the water pump, refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
Remove and Water Pump - Install”.
104 SEBU7901-09
Warranty Section
Warranty Information
Warranty Section 3. New non-road diesel engines installed in

construction machines conforming to the South
Korean regulations for construction machines
Warranty Information manufactured after January 1, 2015, and operated
and serviced in South Korea, including all parts of
their emission control systems (“emission related
i06112217 components”), are:
Emissions Warranty a. Designed, built, and equipped so as to conform,
at the time of sale, with applicable emission
Information standards prescribed in the Enforcement Rule
SMCS Code: 1000 of the Clean Air Conservation Act promulgated
by South Korea MOE.
The certifying engine manufacturer warrants to the
ultimate purchaser and each subsequent purchaser b. Free from defects in materials and
that: workmanship in emission-related components
1. New non-road diesel engines and stationary diesel that can cause the engine to fail to conform to
engines less than 10 liters per cylinder (including applicable emission standards for the warranty
Tier 1 and Tier 2 marine engines < 37 kW, but period.
excluding locomotive and other marine engines) A detailed explanation of the Emission Control
operated and serviced in the United States and Warranty that is applicable to new non-road and
Canada, including all parts of their emission stationary diesel engines, including the components
control systems (“emission related components”), covered and the warranty period, is found in a
are: supplemental Special Publication. Consult your
authorized Cat dealer to determine if your engine is
a. Designed, built, and equipped so as to conform, subject to an Emission Control Warranty and to
at the time of sale, with applicable emission obtain a copy of the applicable Special Publication.
standards prescribed by the United States
Environmental Protection Agency (EPA) by way
of regulation.
b. Free from defects in materials and
workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.
2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to conform,
at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
(ARB).
b. Free from defects in materials and
workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the engine manufacturer's
application for certification for the warranty
period.
SEBU7901-09 105
Reference Information Section
Engine Ratings
Reference Information Table 20

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

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

Operating engines above the rating definitions can
Subtract the power that is required to drive auxiliary result in shorter service life before overhaul.
components from the gross output. This will produce
the net power that is available for the external load
(flywheel).
i03880100
Engine Rating Definitions

SMCS Code: 1000
In selecting a rating for a specific application, the
most important consideration is the time that is spent
at full throttle. These rating definitions identify the
percent of time at full throttle. The definitions also
identify the corresponding times below rated rpm.
“Configuration Parameters” for information about the
rating for this engine.
Note: The examples of the applications are only for
reference. For an exact determination of the
appropriate rating, follow the OEM specifications or
consult your Caterpillar dealer.
106 SEBU7901-09
Customer Service
Customer Service Europe, Africa, and Middle East

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

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

Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801
SEBU7901-09 107
Ordering Replacement Parts
Australia and New Zealand

Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
i08292376
Ordering Replacement Parts

SMCS Code: 4450; 7567
When replacement parts are required for this

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

dealers throughout the world. Cat dealer parts
inventories are up to date. The parts stocks include
all the parts that are normally needed to protect your
Cat engine investment.
When you order parts, specify the following
information:
• Part number
• Part name
• Quantity
If there is a question concerning the part number,
provide your dealer with a complete description of the
needed item.
When a Cat engine requires maintenance and/or
repair, provide the dealer with all the information that
is stamped on the Information Plate. This information
is described in this Operation and Maintenance
Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This information will help the
dealer in troubleshooting the problem and solving the
problem faster.
108 SEBU7901-09
Reference Materials
Reference Materials
i08160279
Maintenance Records
SMCS Code: 1000; 4450
Caterpillar recommends the retention of accurate
maintenance records. Accurate maintenance records
can be used for the following purposes:
• Determine operating costs.
• Establish maintenance schedules for other

engines that are operated in the same
environment.
• Show compliance with the required maintenance

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

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
• Dealer work orders and itemized bills
• Owner repair costs
• Owner receipts
• Maintenance log
SEBU7901-09 109
Maintenance Log
i08254037
Maintenance Log
SMCS Code: 1000; 4450
Table 21
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity Of
Service Item Date Authorization
Hours Fuel
110 SEBU7901-09
Reference Material
i08292374
Reference Material
SMCS Code: 1000; 4450
Additional literature regarding your product may be
purchased from your local Cat dealer or by visiting
publications.cat.com. Use the product name, sales
model, and serial number to obtain the correct
information for your product.
publications.cat.com
SEBU7901-09 111
Index Section
Index
A Crankshaft Vibration Damper - Inspect........... 76
Visconic Damper.......................................... 76
After Starting Engine ....................................... 43
Crushing Prevention and Cutting Prevention.. 13
After Stopping Engine ..................................... 48
Customer Assistance .................................... 106
Aftercooler Core - Clean/Test (Air-To-Air
Outside of the USA and of Canada ........... 106
Aftercooler) .................................................... 66
USA and Canada....................................... 106
Air Shutoff - Test .............................................. 66
Customer Service.......................................... 106
Alternator - Inspect .......................................... 67
D
B
Diagnostic Flash Code Retrieval..................... 31
Battery - Replace............................................. 67
Diagnostic Lamp.............................................. 31
Battery Electrolyte Level - Check .................... 67
Driven Equipment - Check .............................. 76
Battery or Battery Cable - Disconnect............. 68
Check the Alignment ................................... 76
Before Starting Engine .............................. 14, 41
Inspect the Drive Coupling .......................... 76
Belts - Inspect/Adjust/Replace ........................ 68
Inspect the Rear Gear Train ........................ 76
Adjustment of the Fan Drive Belt................. 69
Alternator Belt Adjustment........................... 69
Inspection .................................................... 68 E
Replacement................................................ 69 Electrical System............................................. 15
Burn Prevention................................................11 Grounding Practices .................................... 15
Batteries........................................................11 Electronic Unit Injector - Check/Replace ........ 77
Coolant .........................................................11 Emergency Stopping....................................... 48
Oils................................................................11 Emergency Stop Button (If Equipped)......... 48
Emissions Certification Film ............................ 21
C Emissions Warranty Information ................... 104
Engaging the Driven Equipment ..................... 44
Cold Weather Operation ................................. 46
Industrial Engines ........................................ 44
Cold Weather Starting ..................................... 41
Engine - Clean................................................. 77
Configuration Parameters ............................... 35
Engine Air Cleaner Element (Dual Element)
Parameter Descriptions ............................... 35
- Inspect/Clean/Replace ................................ 77
System Configuration Parameters .............. 38
Cleaning the Primary Air Cleaner
Coolant - Change ............................................ 69
Elements .................................................... 79
Drain the Cooling System............................ 69
Servicing the Air Cleaner Elements............. 78
Fill the Cooling System ................................ 71
Engine Air Cleaner Service Indicator -
Flush ............................................................ 70
Inspect (If Equipped) ..................................... 80
Coolant Extender (ELC) - Add ........................ 71
Test the Service Indicator ............................ 81
Coolant Level - Check ..................................... 72
Engine Crankcase Breather - Clean ............... 81
Coolant Sample (Level 1) - Obtain.................. 73
Engine Diagnostics ......................................... 31
Sampling Conditions.................................... 73
Engine Electronics........................................... 16
Timing of the Sampling ................................ 73
Engine Mounts - Inspect.................................. 82
Coolant Sample (Level 2) - Obtain.................. 73
Engine Oil and Filter - Change ........................ 83
Obtaining the Sample .................................. 74
Drain the Engine Oil..................................... 84
Coolant Temperature Regulator - Replace ..... 74
Fill the Engine Crankcase............................ 84
Cooling System Supplemental Coolant
Interval for Engine Oil and Engine Oil Filter
Additive (SCA) - Test/Add (Systems
Change ...................................................... 83
Which are Filled with Conventional
Replace the Oil Filter ................................... 84
Coolant) ......................................................... 75
Engine Oil Level - Check................................. 82
Maintain the Proper Concentration of SCA in
Engine Oil Sample - Obtain............................. 82
the Coolant................................................. 75
112 SEBU7901-09
Index Section
Obtain the Sample and the Analysis ........... 83 The Engine Has Been Run Out of Fuel ....... 88
Engine Operation ............................................ 44 The Secondary Fuel Filter Has Been
Minimum Engine Run Time ......................... 44 Replaced.................................................... 87
Engine Operation with Active Diagnostic Fuel System Primary Filter (Water
Codes ............................................................ 34 Separator) Element - Replace....................... 89
Engine Operation with Intermittent Replace the Element ................................... 89
Diagnostic Codes .......................................... 35 Fuel System Primary Filter/Water
Engine Protective Devices - Check................. 85 Separator - Drain ........................................... 90
Calibration Check ........................................ 85 Fuel System Secondary Filter - Replace ........ 90
Visual Inspection.......................................... 85 Fuel Tank Water and Sediment - Drain ........... 91
Engine Rating Conditions.............................. 105 Drain the Water and the Sediment .............. 91
Engine Rating Definitions.............................. 105 Fuel Storage Tanks...................................... 92
Engine Ratings .............................................. 105 Fuel Tank ..................................................... 91
Engine Speed/Timing Sensor - Clean/
Inspect ........................................................... 85 G
Engine Starting.......................................... 14, 41
Engine Stopping ........................................ 15, 48 Gauges and Indicators .................................... 26
Engine Storage Procedure - Check ................ 85 General Hazard Information.............................. 7
Engine Valve Lash - Check ............................. 86 Containing Fluid Spillage............................... 9
Engine Valve Rotators - Inspect ...................... 86 Dispose of Waste Properly ...........................11
Fluid Penetration ........................................... 9
Inhalation ..................................................... 10
F
Lines, Tubes, and Hoses ............................... 9
Fan Drive Bearing - Lubricate ......................... 86 Pressurized Air and Water............................. 8
Fan Drive Bearing - Replace ........................... 87 Softwrap....................................................... 10
Fault Logging................................................... 34 Static Electricity Hazard when Fueling with
Features and Controls..................................... 26 Ultra-low Sulfur Diesel Fuel ......................... 9
Fire Prevention and Explosion Prevention.......11 General Information ........................................ 17
Ether ............................................................ 13 Grounding Stud - Inspect/Clean/Tighten......... 92
Fire Extinguisher.......................................... 13
Lines, Tubes, and Hoses ............................. 13 H
Fluid Recommendations ................................. 50
Cooling System............................................ 55 Hoses and Clamps - Inspect/Replace............. 93
Diesel Engine Oil ......................................... 51 Inspect Tubes, Hoses, Bellows, and
Fuel .............................................................. 53 Clamps....................................................... 93
Greases ....................................................... 57 Replace the Hoses and the Clamps ............ 93
Foreword ........................................................... 4
California Proposition 65 Warning ................. 4 I
Literature Information .................................... 4
Important Safety Information............................. 2
Maintenance .................................................. 4
Maintenance Intervals ................................... 5
Operation ....................................................... 4 J
Overhaul ........................................................ 5 Jacket Water Heater - Check .......................... 95
Safety............................................................. 4
Fuel and the Effect from Cold Weather ........... 46
L
Fuel Conservation Practices ........................... 44
Fuel Related Components in Cold Weather ... 46 Lifting and Storage .......................................... 23
Fuel Filters ................................................... 47
Fuel Heaters ................................................ 47 M
Fuel Tanks ................................................... 46
Fuel System - Prime ........................................ 87 Maintenance Interval Schedule................. 62, 64
SEBU7901-09 113
Index Section
Maintenance Interval Schedule (Engines Which Overhaul Recommendation................... 96, 98

Have Deep Oil Pans)
Daily ............................................................. 62 P
Every 2000 Service Hours or 1 Year ........... 63
Every 250 Service Hours ............................. 62 Plate Locations and Film Locations ................ 21
Every 3000 Service Hours or 3 Years ......... 63 Information Plate (2) .................................... 21
Every 416 400 L (110 000 US gal) of Fuel... 63 Serial Number Plate (1) ............................... 21
Every 492 100 L (130 000 US gal) of Fuel .. 63 Power Take-Off Clutch - Check..................... 100
Every 500 Service Hours ............................. 62 Product Description......................................... 18
Every Week ................................................. 62 Aftermarket Products and Cat Engines ...... 19
Every Year ................................................... 63 Welding and Cat Electronic Engines .......... 19
Initial 500 Hours (for New Systems, Refilled Product Identification Information ................... 21
Systems, and Converted Systems) ........... 62 Product Information Section............................ 17
Initial 500 Service Hours (or at first oil Product Lifting ................................................. 23
change) ...................................................... 62 Product Storage .............................................. 23
Overhaul ...................................................... 63 Removal from Storage................................. 24
When Required............................................ 62 Storage (Less Than One Year).................... 23
Have Shallow Oil Pans) R
Daily ............................................................. 64
Radiator - Clean ............................................ 100
Every 2000 Service Hours or 1 Year ........... 65
Radiator Restrictions....................................... 46
Every 250 Service Hours ............................. 64
Reference Information..................................... 21
Every 3000 Service Hours or 3 Years ......... 65
Record for Reference .................................. 22
Every 416 400 L (110 000 US gal) of Fuel... 65
Reference Information Section ..................... 105
Every 492 100 L (130 000 US gal) of Fuel .. 65
Reference Material .........................................110
Every 500 Service Hours ............................. 64
Reference Materials ...................................... 108
Every Week ................................................. 64
Refill Capacities............................................... 50
Every Year ................................................... 65
Coolant ........................................................ 50
Initial 250 Service Hours (or at first oil
Engine Oil .................................................... 50
change) ...................................................... 64
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems) ........... 64 S
Overhaul ...................................................... 65 Safety Messages............................................... 6
When Required............................................ 64 Universal Warning (1) .................................... 7
Maintenance Log........................................... 109 Safety Section ................................................... 6
Maintenance Recommendations .................... 59 Self-Diagnostics .............................................. 31
Maintenance Records ................................... 108 Severe Service Application ............................. 60
Maintenance Section....................................... 50 Improper Maintenance Procedures
Manual Stop Procedure .................................. 48 (Maintenance Procedures Which May
Model View Illustrations .................................. 17 Contribute to a Severe Service
Monitoring System........................................... 27 Application) ................................................ 61
Caterpillar Messenger Display ................... 28 Severe Environmental Factors .................... 60
Indicators and Gauges ................................ 27 Severe Operating Conditions ...................... 61
Mounting and Dismounting ............................. 14 Starting Motor - Inspect ................................. 101
Starting the Engine.......................................... 42
O Starting a Cold Engine................................. 42
Starting a Warm Engine............................... 42
Operation Section............................................ 23
Starting with Jump Start Cables...................... 42
Ordering Replacement Parts......................... 107
System Pressure Release............................... 59
Overhaul Considerations........................... 95, 98
Coolant System ........................................... 59
Oil Consumption as an Overhaul
Engine Oil .................................................... 59
Indicator ............................................... 96, 98
114 SEBU7901-09
Index Section
Fuel System................................................. 59
T
Table of Contents .............................................. 3
Turbocharger - Inspect .................................. 101
Cleaning and Inspecting ............................ 102
Removal and Installation ........................... 102
W
Walk-Around Inspection ................................ 102
Inspect the Engine for Leaks and for Loose
Connections ............................................. 102
Warranty Information..................................... 104
Warranty Section........................................... 104
Water Pump - Inspect.................................... 103
Welding on Engines with Electronic
Controls ......................................................... 59
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:
SEBU7901 CAT, CATERPILLAR, LET’S DO THE WORK, their respective
©2020 Caterpillar logos, “Caterpillar Corporate Yellow”, the “Power Edge” and Cat
All Rights Reserved “Modern Hex” trade dress as well as corporate and product identity
used herein, are trademarks of Caterpillar and may not be used
without permission.
116 November 2020

CAT C13 Engine Manual SEBU7901-09

Uploaded by

Document Informationclick to expand document information

Document Informationclick to expand document information

Copyright:

Available Formats

CAT C13 Engine Manual SEBU7901-09

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CAT C13 Engine Manual SEBU7901-09

Uploaded by

Copyright:

Available Formats

SEBU7901-09 (en-us)

Scan to find and purchase genuine Cat® parts and related

Important Safety Information

The meaning of this safety alert symbol is as follows:

Table of Contents Refill Capacities............................................... 50

Maintenance Recommendations .................... 59

Burn Prevention................................................11 Warranty Section

Fire Prevention and Explosion Prevention.......11 Warranty Information..................................... 104

Crushing Prevention and Cutting Prevention.. 13 Reference Information Section

Mounting and Dismounting ............................. 14 Engine Ratings .............................................. 105

Before Starting Engine .................................... 14 Customer Service.......................................... 106

Engine Starting................................................ 14 Reference Materials ...................................... 108

Engine Stopping .............................................. 15 Index Section

Electrical System............................................. 15 Index............................................................... 111

Product Information Section

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

Product Identification Information ................... 21

Lifting and Storage .......................................... 23

Features and Controls..................................... 26

Engine Diagnostics ......................................... 31

Engine Operation ............................................ 44

Cold Weather Operation ................................. 46

Engine Stopping .............................................. 48

Foreword Some photographs or illustrations in this manual

WARNING – This product can Safety

The maintenance schedule items are organized for a

There may be several specific safety messages on

General Hazard Information

Attach a “Do Not Operate” warning tag to the start

• Start the engine with the operator controls. Never

Pressurized Air and Water

• Use all cleaning solutions with care.

• The engine is stopped. Ensure that the engine

Avoid direct spraying of water on electrical Static Electricity Hazard when

• Wire that is exposed in reinforced hose

• Flexible part of the hose that is kinked or crushed

• Stay away from areas that might have asbestos

• Never use compressed air for cleaning.

• Avoid grinding materials that contain asbestos.

i08159513 Fire Prevention and Explosion

Use of personal protection equipment (PPE) may be

Do not store ether cylinders in living areas or in the

Lines, Tubes, and Hoses

• Remove the load in increments.

• Allow the engine to run for five minutes to cool.

All grounds should be tight and free of corrosion. The

Tampering with the electronic system installation

Uncontrolled electrical circuit paths can result in • Engine Coolant Temperature

Engines that are installed without engine-to-frame • Engine Speed

Model View Illustrations

3. Clamp the ground cable from the welder to the

Product Identification Engine Modification Number

Information The engine identification plate also contains other

Plate Locations and Film Emissions Certification Film

Caterpillar engines are identified by serial numbers

The engine information plate is located on the intake

Record for Reference

Chassis serial number