SEBU8600-04 (en-us)

December 2020

Operation and
Maintenance
Manual
C7.1 Industrial Engine
770 1-UP (Engine)

PUBLICATIONS.CAT.COM
 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.
SEBU8600-04 3
Table of Contents

Table of Contents Cold Weather Operation ................................. 68

Foreword ........................................................... 4 Maintenance Section

Refill Capacities............................................... 72
Safety Section
Maintenance Recommendations .................... 77
Safety Messages............................................... 6
Maintenance Interval Schedule....................... 80
General Hazard Information.............................. 8

Burn Prevention............................................... 12 Warranty Section

Fire Prevention and Explosion Prevention...... 14 Warranty Information..................................... 126

Crushing Prevention and Cutting Prevention.. 16 Reference Information Section

Mounting and Dismounting ............................. 16 Engine Ratings .............................................. 127

High Pressure Fuel Lines ................................ 16 Customer Service.......................................... 128

Before Starting Engine .................................... 18 Reference Materials ...................................... 129

Engine Starting................................................ 18 Index Section

Engine Stopping .............................................. 18 Index.............................................................. 132

Electrical System............................................. 19

Engine Electronics........................................... 20

Product Information Section

Model Views .................................................... 22

Product Identification Information ................... 29

Operation Section

Lifting and Storage .......................................... 32

Gauges and Indicators .................................... 36

Features and Controls..................................... 38

Engine Diagnostics ......................................... 48

Engine Starting................................................ 59

Engine Operation ............................................ 62

Engine Stopping .............................................. 66

4 SEBU8600-04
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.
SEBU8600-04 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 SEBU8600-04
Safety Section
Safety Messages

Safety Section
i05034564

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

(1) Universal Warning

Do not operate or work on this equipment unless

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

Illustration 1 g01154807
Typical example

The Universal Warning label (1) is located in two

positions. The warning labels are located on the front
right side of the valve mechanism cover and on the
top of the NOx reduction system (NRS).
SEBU8600-04 7
Safety Section
Safety Messages

Illustration 2 g02305279

(1) Universal warning

(2) Ether

Do not use aerosol types of starting aids such as

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

Illustration 3 g01154809
Typical example

The ether warning label (2) is located on the top of

the NOx reduction system (NRS).
8 SEBU8600-04
Safety Section
General Hazard Information

Illustration 4 g02305282

(2) Ether (3) Hand (High Pressure)

(3) Hand (High Pressure) The warning label for the Hand (High Pressure) (3) is
located on a high-pressure fuel line.

i08314796

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel General Hazard Information
spray may cause a fire hazard. Failure to follow SMCS Code: 1000; 7405
these inspection, maintenance and service in-
structions may cause personal injury or death.

Illustration 6 g00104545

Illustration 5 g01154858 Attach a “Do Not Operate” warning tag or a similar

Typical example warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each
operator control station. When appropriate,
disconnect the starting controls.
SEBU8600-04 9
Safety Section
General Hazard Information

Do not allow unauthorized personnel on the engine, • Do not attempt any repairs or any adjustments to
or around the engine when the engine is being the engine while the engine is operating.
serviced.
• Do not attempt any repairs that are not
• Tampering with the engine installation or understood. Use the proper tools. Replace any
tampering with the OEM supplied wiring can be equipment that is damaged or repair the
dangerous. Personal injury, death and/or engine equipment.
damage could result.
• For initial start-up of a new engine or for starting
• Vent the engine exhaust to the outside when the an engine that has been serviced, make
engine is operated in an enclosed area. provisions to stop the engine if an overspeed
occurs. The stopping of the engine may be
• If the engine is not running, do not release the accomplished by shutting off the fuel supply and/
secondary brake or the parking brake systems or the air supply to the engine. Ensure that only
unless the vehicle is blocked or unless the vehicle the fuel supply line is shut off. Ensure that the fuel
is restrained. return line is open.
• Wear a hard hat, protective glasses, and other • Start the engine from the operators station (cab).
protective equipment, as required. Never short across the starting motor terminals or
the batteries. This action could bypass the engine
• When work is performed around an engine that is
neutral start system and/or the electrical system
operating, wear protective devices for ears to help
could be damaged.
prevent damage to hearing.
Engine exhaust contains products of combustion
• Do not wear loose clothing or jewelry that can which may be harmful to your health. Always start the
snag on controls or on other parts of the engine. engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
• Ensure that all protective guards and all covers engine exhaust to the outside.
are secured in place on the engine.
Cautiously remove the following parts. To help
• Never put maintenance fluids into glass prevent spraying or splashing of pressurized fluids,
containers. Glass containers can break. hold a rag over the part that is being removed.
• Use all cleaning solutions with care. • Filler caps
• Report all necessary repairs. • Grease fittings
Unless other instructions are provided, perform the • Pressure taps
maintenance under the following conditions:
• Breathers
• The engine is stopped. Ensure that the engine
cannot be started. • Drain plugs
• The protective locks or the controls are in the Use caution when cover plates are removed.
applied position. Gradually loosen, but do not remove the last two
bolts or nuts that are at opposite ends of the cover
• Engage the secondary brakes or parking brakes. plate or the device. Before removing the last two
bolts or nuts, pry the cover loose to relieve any spring
• Block the vehicle or restrain the vehicle before pressure or other pressure.
maintenance or repairs are performed.
• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads to help prevent sparks. If equipped,
allow the diesel exhaust fluid to be purged before
disconnecting the battery.
• If equipped, disconnect the connectors for the unit
injectors that are on the valve cover base. This
action will help prevent personal injury from the
high voltage to the unit injectors. Do not come in
contact with the unit injector terminals while the
engine is operating.
10 SEBU8600-04
Safety Section
General Hazard Information

The maximum air pressure for cleaning purposes

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

Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved
correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
Illustration 7 g00702020
components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
• Wear a hard hat, protective glasses, and other information for any procedures that are required to
protective equipment, as required. relieve the hydraulic pressure.
• When work is performed around an engine that is
operating, wear protective devices for ears to help
prevent damage to hearing.
• Do not wear loose clothing or jewelry that can
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. Illustration 8 g00687600

Unless other instructions are provided, perform Always use a board or cardboard when you check for
the maintenance under the following conditions: a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
• The engine is stopped. Ensure that the engine serious injury and possible death. A pin hole leak can
cannot be started. cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
• Disconnect the batteries when maintenance is from a doctor that is familiar with this type of injury.
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads to help prevent sparks. Containing Fluid Spillage
• Do not attempt any repairs that are not Care must be taken to ensure that fluids are
understood. Use the proper tools. Replace any contained during performance of inspection,
equipment that is damaged or repair the maintenance, testing, adjusting, and repair of the
product. Be prepared to collect the fluid with suitable
equipment.
containers before opening any compartment or
disassembling any component containing fluids.
Pressurized Air and Water
Refer to Special Publication, NENG2500, “Cat Dealer
Pressurized air and/or water can cause debris and/or Service Tool Catalog” for tools and supplies suitable
hot water to be blown out. This action could result in to collect and contain fluids on Cat products.
personal injury.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
SEBU8600-04 11
Safety Section
General Hazard Information

Dispose of all fluids according to local regulations

and mandates.
Avoid static electricity risk when fueling. Ultra-
Static Electricity Hazard when low sulfur diesel fuel (ULSD fuel) poses a greater
static ignition hazard than earlier diesel formula-
Fueling with Ultra-low Sulfur Diesel tions with a higher sulfur contents. Avoid death
Fuel or serious injury from fire or explosion. Consult
with your fuel or fuel system supplier to ensure
The removal of sulfur and other compounds in ultra- the delivery system is in compliance with fueling
low sulfur diesel fuel (ULSD fuel) decreases the standards for proper grounding and bonding
conductivity of ULSD and increases the ability of practices.
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
Inhalation
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.

Illustration 9 g00702022

Exhaust
Use caution. Exhaust fumes can be hazardous to
health. If you operate the equipment in an enclosed
area, adequate ventilation is necessary.

Hexavalent Chromium
Caterpillar equipment and replacement parts comply
with applicable regulations and requirements where
originally sold. Caterpillar recommends the use of
only genuine Caterpillar replacement parts.
Hexavalent chromium has occasionally been
detected on exhaust and heat shield systems on
Caterpillar engines. Although laboratory testing is the
only accurate way to know if hexavalent chromium is,
in fact, present, the presence of a yellow deposit in
areas of high heat (for example, exhaust system
components or exhaust insulation) may be an
indication of the presence of hexavalent chromium.
Use caution if you suspect the presence of
hexavalent chromium. Avoid skin contact when
handling items that you suspect may contain
hexavalent chromium, and avoid inhalation of any
dust in the suspect area. Inhalation of, or skin contact
with, hexavalent chromium dust may be hazardous to
your health.
12 SEBU8600-04
Safety Section
Burn Prevention

If such yellow deposits are found on the engine, • Use exhaust ventilation on permanent machining
engine component parts, or associated equipment or jobs.
packages, Caterpillar recommends following local
health and safety regulations and guidelines, utilizing • Wear an approved respirator if there is no other
good hygiene, and adhering to safe work practices way to control the dust.
when handling the equipment or parts. Caterpillar
also recommends the following: • Comply with applicable rules and regulations for
the work place. In the United States, use
• Wear appropriate Personal Protective Equipment Occupational Safety and Health Administration
(PPE) (OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Wash your hands and face with soap and water
prior to eating, drinking, or smoking, and also • Obey environmental regulations for the disposal of
during rest room breaks, to prevent ingestion of asbestos.
any yellow powder
• Stay away from areas that might have asbestos
• Never use compressed air for cleaning areas particles in the air.
suspected of containing hexavalent chromium

• Avoid brushing, grinding, or cutting materials Dispose of Waste Properly

suspected of containing hexavalent chromium

• Obey environmental regulations for the disposal of

all materials that may contain or have come into
contact with hexavalent chromium

• Stay away from areas that might have hexavalent

chromium particles in the air.

Asbestos Information
Cat equipment and replacement parts that are
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. Illustration 10 g00706404

Use caution. Avoid inhaling dust that might be Improperly disposing of waste can threaten the
generated when you handle components that contain environment. Potentially harmful fluids should be
asbestos fibers. Inhaling this dust can be hazardous disposed of according to local regulations.
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining Always use leakproof containers when you drain
material, clutch plates, and some gaskets. The fluids. Do not pour waste onto the ground, down a
asbestos that is used in these components is usually drain, or into any source of water.
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated. i05784129

If dust that may contain asbestos is present, there Burn Prevention

are several guidelines that should be followed:
SMCS Code: 1000; 7405
• Never use compressed air for cleaning.
Do not touch any part of an operating engine system.
• Avoid brushing materials that contain asbestos. The engine, the exhaust, and the engine
aftertreatment system can reach temperatures as
• Avoid grinding materials that contain asbestos. high as 650 °C (1202 °F) under normal operating
conditions. If the engine or the engine aftertreatment
• Use a wet method to clean up asbestos materials. system unexpectedly fails, the temperature of the gas
at the Diesel Particulate Filter (DPF) may increase to
• A vacuum cleaner that is equipped with a high 900°C (1652°F).
efficiency particulate air filter (HEPA) can also be
used.
SEBU8600-04 13
Safety Section
Burn Prevention

At idle engine speed and/or zero vehicle speed, an Induction System

operator can request a manual regeneration. Under
this condition, the exhaust gas temperature can
reach 650 °C (1202 °F). Otherwise automatic
regeneration can produce exhaust gas temperatures
as high as 450 °C (842 °F). Sulfuric Acid Burn Hazard may cause serious
personal injury or death.
Allow the engine system to cool before any
maintenance is performed. Relieve all pressure in the The exhaust gas cooler may contain a small
air system, in the hydraulic system, in the lubrication amount of sulfuric acid. The use of fuel with sul-
system, in the fuel system, or in the cooling system fur levels greater than 15 ppm may increase the
before any lines, fittings, or related items are amount of sulfuric acid formed. The sulfuric acid
disconnected. may spill from the cooler during service of the en-
gine. The sulfuric acid will burn the eyes, skin
and clothing on contact. Always wear the appro-
priate personal protective equipment (PPE) that
is noted on a material safety data sheet (MSDS)
Contact with high pressure fuel may cause fluid for sulfuric acid. Always follow the directions for
penetration and burn hazards. High pressure fuel first aid that are noted on a material safety data
spray may cause a fire hazard. Failure to follow sheet (MSDS) for sulfuric acid.
these inspection, maintenance and service in-
structions may cause personal injury or death.
Coolant
After the engine has stopped, wait for 10 minutes in
order to allow the fuel pressure to be purged from the When the engine is at operating temperature, the
high-pressure fuel lines before any service or repair engine coolant is hot. The coolant is also under
is performed on the engine fuel lines. The 10 minute pressure. The radiator and all lines to the heaters or
wait will also allow static charge to dissipate from the to the engine contain hot coolant. The aftertreatment
low-pressure fuel system. regeneration device (ARD) is connected to the
coolant system and will contain hot coolant.
Allow the pressure to be purged in the air system, in
the hydraulic system, in the lubrication system, or in Any contact with hot coolant or with steam can cause
the cooling system before any lines, fittings, or severe burns. Allow cooling system components to
related items are disconnected. cool before the cooling system is drained.
Check that the coolant level after the engine has
stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
14 SEBU8600-04
Safety Section
Fire Prevention and Explosion Prevention

Cooling system conditioner contains alkali. Alkali can If the application involves the presence of
cause personal injury. Do not allow alkali to contact combustible gases, consult your Cat dealer for
the skin, the eyes, or the mouth. additional information about suitable protection
devices.
Oils Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
Hot oil and hot lubricating components can cause materials to accumulate on the engine.
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact Store fuels and lubricants in properly marked
the skin. containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
Batteries containers. Do not smoke in areas that are used for
storing flammable materials.
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or Do not expose the engine to any flame.
the eyes. Always wear protective glasses for Exhaust shields (if equipped) protect hot exhaust
servicing batteries. Wash hands after touching the components from oil or fuel spray in a line, a tube, or
batteries and connectors. Use of gloves is a seal failure. Exhaust shields must be installed
recommended. correctly.
i05784184 Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
Fire Prevention and Explosion thoroughly with a nonflammable solvent prior to
Prevention welding or flame cutting.
SMCS Code: 1000; 7405 Wiring must be kept in good condition. All electrical
wires must be properly routed and securely attached.
Check all electrical wires daily. Repair any wires that
are loose or frayed before you operate the engine.
Clean all electrical connections and tighten all
electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.

Illustration 11 g00704000
Contact with high pressure fuel may cause fluid
All fuels, most lubricants, and some coolant mixtures penetration and burn hazards. High pressure fuel
are flammable.
spray may cause a fire hazard. Failure to follow
Flammable fluids that are leaking or spilled onto hot these inspection, maintenance and service in-
surfaces or onto electrical components can cause a structions may cause personal injury or death.
fire. Fire may cause personal injury and property
damage.
After the engine has stopped, you must wait for 10
A flash fire may result if the covers for the engine minutes in order to allow the fuel pressure to be
crankcase are removed within 15 minutes after an purged from the high-pressure fuel lines before any
emergency shutdown. service or repair is performed on the engine fuel
lines. The 10 minute wait will also allow static charge
Determine whether the engine will be operated in an to dissipate from the low-pressure fuel system.
environment that allows combustible gases to be
drawn into the air inlet system. These gases could Inspect all lines and hoses for wear or for
cause the engine to overspeed. Personal injury, deterioration. The hoses must be properly routed.
property damage, or engine damage could result. The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
SEBU8600-04 15
Safety Section
Fire Prevention and Explosion Prevention

Oil filters and fuel filters must be properly installed. Improper jumper cable connections can cause an
The filter housings must be tightened to the proper explosion that can result in injury. Refer to the
torque. Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This action may
cause an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.

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

Ether
Ether is flammable and poisonous.
Use ether in that are ventilated . Do not smoke while
Illustration 12 g00704059 you are replacing an ether cylinder or while you are
using an ether spray.
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not Do not store ether cylinders in living areas or in the
refuel an engine near open flames or sparks. Always engine compartment. Do not store ether cylinders in
stop the engine before refueling. 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 Caterpillar dealer for
repair or for replacement parts.
Check lines, tubes, and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
Illustration 13 g00704135 cardboard to check for leaks. Tighten all connections
to the recommended torque.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do Replace the parts if any of the following conditions
not smoke in battery charging areas. are present:
Never check the battery charge by placing a metal • High-pressure fuel line or lines are removed.
object across the terminal posts. Use a voltmeter or a
hydrometer. • End fittings are damaged or leaking.
16 SEBU8600-04
Safety Section
Crushing Prevention and Cutting Prevention

• Outer coverings are chafed or cut. Refer to the OEM for the location of foot and hand
holds for your specific application.
• Wires are exposed.
i07671624
• Outer coverings are ballooning.
• Flexible parts of the hoses are kinked. High Pressure Fuel Lines
SMCS Code: 1274
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields Contact with high pressure fuel may cause fluid
are installed correctly. During engine operation, penetration and burn hazards. High pressure fuel
correct installment will help to prevent vibration, spray may cause a fire hazard. Failure to follow
rubbing against other parts, and excessive heat. these inspection, maintenance and service in-
structions may cause personal injury or death.
Regeneration
The exhaust gas temperature during regeneration
will be elevated. Follow proper fire prevention
instructions and use the disable switch function when
appropriate.

i08162291

Crushing Prevention and

Cutting Prevention
SMCS Code: 1000; 7405
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses to
avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.

i05768982

Mounting and Dismounting

SMCS Code: 1000; 7405
Do not climb on the engine or the engine
aftertreatment system. The engine and
aftertreatment system have not been designed with
mounting or dismounting locations.
SEBU8600-04 17
Safety Section
High Pressure Fuel Lines

Illustration 14 g01877473

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

The high-pressure fuel lines are the fuel lines that are Do not loosen the high-pressure fuel lines to remove
between the high-pressure fuel pump and the high- air from the fuel system. This procedure is not
pressure fuel manifold and the fuel lines that are required.
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel Visually inspect the high-pressure fuel lines before
systems. the engine is started. This inspection should be
performed each day.
The differences are as follows:
If the engine is inspected whilst in operation, always
• The high-pressure fuel lines are constantly use the correct inspection procedure to avoid a fluid
charged with high pressure while the engine is in penetration hazard. Refer to Operation and
operation and up to 10 minutes after the engine Maintenance Manual, “General hazard Information”.
has stopped.
• Inspect the high-pressure fuel lines for damage,
• The internal pressures of the high-pressure fuel deformation, a nick, a cut, a crease, or a dent.
lines are higher than other types of fuel system.
• Do not operate the engine with a fuel leak. If there
• The high-pressure fuel lines are formed to shape is a leak, do not tighten the connection, to stop the
and then strengthened by a special process. leak. The connection must only be tightened to the
recommended torque. Refer to Disassembly and
Do not step on the high-pressure fuel lines. Do not Assembly, “Fuel injection lines - Remove and Fuel
deform the high-pressure fuel lines. Do not bend or injection lines - Install”.
strike the high-pressure fuel lines. Deformation or
damage of the high-pressure fuel lines may cause a • If the high-pressure fuel lines are torqued correctly
point of weakness and potential failure. and the high-pressure fuel lines are leaking, the
high-pressure fuel lines must be replaced.
Do not check the high-pressure fuel lines with the
engine or the starting motor in operation. After the • Ensure that all clips on the high-pressure fuel lines
engine has stopped, you must wait for 10 minutes to are in place. Do not operate the engine with clips
allow the fuel pressure to be purged from the high- that are damaged, missing, or loose.
pressure fuel lines before any service or repair is
performed on the engine fuel lines. The 10 minute • Do not attach any other item to the high-pressure
wait will also allow static charge to dissipate from the fuel lines.
low-pressure fuel system.
18 SEBU8600-04
Safety Section
Before Starting Engine

• Loosened high-pressure fuel lines must be i03635086

replaced. High-pressure fuel lines that have been
removed must be replaced. Refer to Disassembly Engine Starting
and assembly manual, “Fuel Injection Lines -
Install”. SMCS Code: 1000

i08258438

Before Starting Engine Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
SMCS Code: 1000 personal injury.
If a warning tag is attached to the engine start switch
NOTICE or to the controls DO NOT start the engine or move
For initial start-up of a new or rebuilt engine, and for the controls. Consult with the person that attached
start-up of an engine that has been serviced, make the warning tag before the engine is started.
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the All protective guards and all protective covers must
air and/or fuel supply to the engine. be installed if the engine must be started in order to
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.

Engine exhaust contains products of combustion Start the engine from the operator's compartment or
which may be harmful to your health. Always from the engine start switch.
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust Always start the engine according to the procedure
to the outside. that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Inspect the engine for potential hazards. Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Do not start the engine if there is a “DO NOT Knowing the procedure will also help to prevent
OPERATE” warning tag or similar warning tag personal injury.
attached to the start switch. Do not move any of the
controls if there is a “DO NOT OPERATE” warning To ensure that the jacket water heater (if equipped)
tag or similar warning tag attached to the controls. and/or the lube oil heater (if equipped) is working
correctly, check the water temperature gauge and/or
Before starting the engine, ensure that no one is on, the oil temperature gauge during the heater
underneath, or close to the engine. Ensure that the operation.
area is free of personnel.
Engine exhaust contains products of combustion
If equipped, ensure that the lighting system for the which can be harmful to your health. Always start the
engine is suitable for the conditions. Ensure that all engine and operate the engine in a well ventilated
lights work properly, if equipped. area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
All protective guards and all protective covers must
be installed if the engine must be started to perform These engines are equipped with a glow plug starting
service procedures. To help prevent an accident that aid in each individual cylinder that heats the intake air
is caused by parts in rotation, work around the parts in order to improve starting. Some Caterpillar engines
carefully. may have a cold starting system that is controlled by
the ECM that allows a controlled flow of ether into the
Do not bypass the automatic shutoff circuits. Do not engine. The ECM will disconnect the glow plugs
disable the automatic shutoff circuits. The circuits are before the ether is introduced. This system would be
provided to help prevent personal injury. The circuits installed at the factory.
are also provided to help prevent engine damage.
i03648639
See the Service Manual for repairs and for
adjustments.
Engine Stopping
SMCS Code: 1000
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to this Operation and Maintenance
Manual, “Engine Stopping” topic (Operation Section).
SEBU8600-04 19
Safety Section
Electrical System

Use the Emergency Stop Button (if equipped) ONLY Grounding Practices
in an emergency situation. DO NOT use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop the
engine if an overspeed condition occurs.

i04947824

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 “−” cable should be connected last from the
external power source to the primary position for
grounding.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical
connections before the engine is started. Repair all
frayed electrical wires before the engine is started.
See the Operation and Maintenance Manual for Illustration 15 g02145392
specific starting instructions.
Typical example
(1) Ground to the battery
(2) Primary position for grounding
(3) Ground to the starting motor
(4) Ground to the engine block
20 SEBU8600-04
Safety Section
Engine Electronics

The power supply connections and the ground

connections for the engine electronics should always
be from the isolator to the battery.

i03554965

Engine Electronics
SMCS Code: 1000; 1400; 1900

Tampering with the electronic system installation

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

Electrical Shock Hazard. The electronic unit injec-

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

This engine has a comprehensive, programmable

Illustration 16 g02145733 Engine Monitoring System. The Electronic Control
Typical example Module (ECM) has the ability to monitor the engine
(5) Ground to the battery operating conditions. If any of the engine parameters
(6) Ground to the engine block extend outside an allowable range, the ECM will
(7) Primary position for grounding initiate an immediate action.

Correct grounding for the engine electrical system is The following actions are available for engine
necessary for optimum engine performance and monitoring control:
reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable • Warning
electrical circuit paths.
• Derate
Uncontrolled electrical circuit paths can result in
damage to the crankshaft bearing journal surfaces • Shutdown
and to aluminum components. The following monitored engine operating conditions
Engines that are installed without engine-to-frame and components have the ability to limit engine
ground straps can be damaged by electrical speed and/or the engine power:
discharge.
• Engine Coolant Temperature
To ensure that the engine and the engine electrical
systems function correctly, an engine-to-frame • Engine Oil Pressure
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct • Engine Speed
engine ground to the frame.
• Intake Manifold Air Temperature
The connections for the grounds should be tight and
free of corrosion. The engine alternator must be • Engine Intake Throttle Valve Fault
grounded to the negative “-” battery terminal with a
• Wastegate Regulator
wire that is adequate to handle the full charging
current of the alternator. • Supply Voltage to Sensors

• Fuel Pressure in Manifold (Rail)

• NOx Reduction System
SEBU8600-04 21
Safety Section
Engine Electronics

• Engine Aftertreatment System

The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: Many of the engine control systems and
display modules that are available for Caterpillar
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting for
more information on the Engine Monitoring System.
22 SEBU8600-04
Product Information Section
Model Views

Product Information
Section

Model Views
i03913230

Model View Illustrations

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

Note: Only major components are identified on the

following illustrations.

Engine views

Illustration 17 g02150184
Typical example
(1) Rear lifting eye (2) NOx reduction system NRS
SEBU8600-04 23
Product Information Section
Model View Illustrations

(3) Front lifting eye (6) High-pressure turbocharger (9) Flywheel housing
(4) Alternator (7) Low-pressure turbocharger (10) Flywheel
(5) Refrigerant compressor (8) Engine oil drain (11) NRS cooler

Illustration 18 g02150185
Typical example
(12) Crankcase breather (16) Oil gauge (20) In-line fuel strainer
(13) Electronic control module (ECM) (17) Oil filler (21) Electric fuel priming pump
(14) Starting motor (18) Primary fuel filter
(15) Oil filter (19) Secondary fuel filter

The location of the in-line fuel strainer (20) and the

priming pump (21) will depend on the application.
24 SEBU8600-04
Product Information Section
Model View Illustrations

Illustration 19 g02150187
Typical example
(22) Outlet connection to the air to air (25) Housing for the water temperature (28) Vibration damper
charge cooler regulator (29) Belt tensioner
(23) Connection for the air inlet (26) Water pump (30) Belt
(24) Outlet connection for the coolant (27) Inlet connection for the Coolant

Engine Aftertreatment System

The following view shows typical features of the
engine aftertreatment system. Due to individual
applications, your system may appear different from
the illustrations.
SEBU8600-04 25
Product Information Section
Model View Illustrations

Illustration 20 g02162626
Typical example
(1) Diesel oxidation catalyst (DOC) (5) Securing clamp (8) Air inlet for aftertreatment regeneration
(2) Securing clamp (6) Torca clamp device (ARD)
(3) Torca clamp (7) Lifting eye (9) Connections for Coolant manifold
(4) Diesel particulate filter (DPF) (10) Lifting eye
26 SEBU8600-04
Product Information Section
Model View Illustrations

Illustration 21 g02162641

(11) Outlet to exhaust system (13) Lifting eye (15) Mounting cradle
(12) Aftertreatment regeneration device (14) Exhaust Inlet

Fuel Pump for Engine Aftertreatment

System
Note: The fuel for the engine aftertreatment system
is supplied by a designated fuel pump. The location
of this pump can change depending on the
application.
SEBU8600-04 27
Product Information Section
Engine Description

Illustration 23 g01127295
Cylinder and valve location
(A) Exhaust valves
(B) Inlet valves

Table 1

Illustration 22 g02163775 C7.1 Engine Specifications

Typical example Operating Range (rpm) 900 to 2800(1)
(16) Fuel inlet
(17) Electrical connector Number of Cylinders 6 In-Line
(18) Fuel supply line
(19) Return to tank Bore 105 mm (4.13 inch)
(20) Fuel inlet
(21) Fuel inlet Stroke 135 mm (5.31495 inch)

Power 225 kW (301.72 hp)

i03995531
Aspiration Turbocharged charge cooled
Engine Description Compression Ratio 16.5:1
SMCS Code: 1000 Displacement 7.01 L (428 in3)
The Caterpillar C7.1 Industrial Engine has the Firing Order 1-5-3-6-2-4
following characteristics.
Rotation (flywheel end) Counterclockwise
• In-line Six cylinder (1) The operating rpm is dependent on the engine rating, the appli-
cation, and the configuration of the throttle.
• Four stroke cycle

• Series turbocharged charge cooled Electronic Engine Features

Engine Specifications The engine operating conditions are monitored. The
Electronic Control Module (ECM) controls the
Note: The front end of the engine is opposite the response of the engine to these conditions and to the
flywheel end of the engine. The left and the right demands of the operator. These conditions and
sides of the engine are determined from the flywheel operator demands determine the precise control of
fuel injection by the ECM. The electronic engine
end. The number 1 cylinder is the front cylinder.
control system provides the following features:

• Engine monitoring
• Engine speed governing

• Control of the injection pressure

• Cold start strategy
• Automatic air/fuel ratio control
28 SEBU8600-04
Product Information Section
Engine Description

• Torque rise shaping Engine efficiency, efficiency of emission controls, and

engine performance depend on adherence to proper
• Injection timing control operation and maintenance recommendations.
Engine performance and efficiency also depend on
• System diagnostics the use of recommended fuels, lubrication oils, and
coolants. Refer to this Operation and Maintenance
• Aftertreatment regeneration control Manual, “Maintenance Interval Schedule” for more
information on maintenance items.
• NOx reduction system control
For more information on electronic engine features, Engine Service Life
refer to the Operation and Maintenance Manual,
“Features and Controls” topic (Operation Section). Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
Engine Diagnostics addition, use recommended fuels, coolants and
lubricants. Use the Operation and Maintenance
The engine has built-in diagnostics in order to ensure Manual as a guide for required engine maintenance.
that the engine systems are functioning correctly. The
operator will be alerted to the condition by a “Stop or Expected engine life is generally predicted by the
Warning” lamp. Under certain conditions, the engine average power that is demanded. The average
horsepower and the vehicle speed may be limited. power that is demanded is based on fuel
The electronic service tool may be used to display consumption of the engine over a period of time.
the diagnostic codes. Reduced hours of operation at full throttle and/or
operating at reduced throttle settings result in a lower
There are three types of diagnostic codes: active, average power demand. Reduced hours of operation
logged and event. will increase the length of operating time before an
engine overhaul is required. For more information,
Most of the diagnostic codes are logged and stored in refer to the Operation and Maintenance Manual,
the ECM. For additional information, refer to the “Overhaul Considerations” topic (Maintenance
Operation and Maintenance Manual, “Engine Section).
Diagnostics” topic (Operation Section).
The ECM provides an electronic governor that Aftermarket Products and
controls the injector output in order to maintain the Caterpillar Engines
desired engine rpm.
Caterpillar does not warrant the quality or
Engine Cooling and Lubrication performance of non-Caterpillar fluids and filters.

The cooling system and lubrication system consists When auxiliary devices, accessories, or
of the following components: consumables (filters, additives, catalysts,) which are
made by other manufacturers are used on Caterpillar
• Gear-driven centrifugal water pump products, the Caterpillar warranty is not affected
simply because of such use.
• Water temperature regulator which regulates the
engine coolant temperature However, failures that result from the installation
or use of other manufacturers devices,
• Gear-driven rotor type oil pump accessories, or consumables are NOT Caterpillar
defects. Therefore, the defects are NOT covered
under the Caterpillar warranty.
• Oil cooler
The engine lubricating oil is supplied by a rotor type Aftertreatment System
oil pump. The engine lubricating oil is cooled and the
engine lubricating oil is filtered. The bypass valve can The aftertreatment system is approved for use by
provide unrestricted flow of lubrication oil to the Caterpillar. In order to be emission-compliant only the
engine if the oil filter element should become approved Caterpillar aftertreatment system must be
plugged. used on a Caterpillar engine.
SEBU8600-04 29
Product Information Section
Product Identification Information

Product Identification
Information
i03921393

Plate Locations and Film

Locations
(Engine Aftertreatment System)
SMCS Code: 1000

Illustration 24 g02151573
Typical example

The module arrangement exhaust plate is installed Record the information that is on the plate. This
on the mounting plate (1). The location of the information identifies the engine aftertreatment
arrangement plate mounting plate can alter system. This information will be required by your
depending on the application. Caterpillar dealer.

Illustration 25 g02109493
Module Arrangement Exhaust Plate
30 SEBU8600-04
Product Information Section
Plate Locations and Film Locations

i05034578

Plate Locations and Film

Locations
SMCS Code: 1000

Illustration 27 g01332986
Typical example

i03867276

Reference Numbers
SMCS Code: 1000
Information for the following items may be needed to
order parts. Locate the information for your engine.
Record the information in the appropriate space.
Make a copy of this list for a record. Keep the
information for future reference.
Illustration 26 g01877975
Location of the serial number plate Record for Reference
Engine Model
Serial Number Plate (1)
Engine Serial number
The engine serial number plate is located on the left
side of the cylinder block to the rear of the front Engine Low Idle rpm
engine mounting.
Engine Full Load rpm
Caterpillar dealers need all of these numbers in order
to determine the components that were included with Primary Fuel Filter
the engine.
Water Separator Element
Secondary Fuel Filter Element
Lubrication Oil Filter Element
Auxiliary Oil Filter Element
Total Lubrication System Capacity
Total Cooling System Capacity
Air Cleaner Element
Drive Belt

Engine Aftertreatment System

Part Number
SEBU8600-04 31
Product Information Section
Emissions Certification Film

Serial Number

i04945629

Emissions Certification Film

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

Illustration 28 g03130916
Typical example
32 SEBU8600-04
Operation Section
Lifting and Storage

Operation Section

Lifting and Storage

i07434234

Product Lifting
(Engine)
SMCS Code: 1000; 1404; 7002

Illustration 29 g00103219

NOTICE
Always inspect lifting eyebolts and all other lifting
equipment for damage before performing any lifting.
Never bend the eyebolts and the brackets. Never
perform product lifting if components are damaged.
Only load the eyebolts and the brackets under ten-
sion. Remember that the capacity of an eyebolt is
less as the angle between the supporting members
and the object becomes less than 90 degrees.
Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting the fixtures to obtain
proper balance and safety.
To remove the engine ONLY, use the lifting eyes that
are on the engine.
Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting
eyes and/or the engine make the lifting eyes and the
lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Caterpillar dealer for information
regarding fixtures for proper engine lifting.
SEBU8600-04 33
Operation Section
Product Lifting

i07434787

Product Lifting
SMCS Code: 1000; 1404; 7002

Illustration 30 g02354678
Typical example

NOTICE
Always inspect lifting eyebolts and all other lifting
equipment for damage before performing any lifting.
Never Bend the eyebolts and the brackets. Never
perform product lifting if the components are
damaged.

The lifting points (1) are for the application shown. A

suitable lift truck will be required to lift the application.
The lifting eyes on the application will have blanking
devices (2) installed.
34 SEBU8600-04
Operation Section
Product Lifting

Illustration 31 g02354717
(A) Typical engine lifting eye
(B) Typical CEM lifting eye

To lift the clean emission module, refer to this

Operation and Maintenance Manual, “Product Lifting
(Clean Emission Module)”. To lift the engine, refer to
this Operation and Maintenance Manual, “Product
Lifting (Engine)”.

i07435428

Product Lifting
(Clean Emission Module) Illustration 32 g02293733
Typical example
SMCS Code: 1000; 1404; 7002
To remove the Clean Emission Module (CEM), use
NOTICE lifting eyes (1). Lifting eyes are designed and
Always inspect lifting eyebolts and all other lifting installed for the specific CEM arrangement. Do not
equipment for damage before performing any lifting. use the lifting eyes for any other purpose than lifting
Never bend the eyebolts and the brackets. Never the CEM.
perform product lifting if components are damaged.
Only load the eyebolts and the brackets under ten- Alterations to the lifting eyes and/or the
sion. Remember that the capacity of an eyebolt is aftertreatment make the lifting eyes and the lifting
less as the angle between the supporting members fixtures obsolete. If alterations are made, ensure that
and the object becomes less than 90 degrees. proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
Use a hoist to remove heavy components. Use an for proper aftertreatment lifting.
adjustable lifting beam to lift the Clean Emission
Module. All supporting members (chains and cables) i08257552
should be parallel to each other. The chains and
cables should be perpendicular to the top of the
object that is being lifted.
Product Storage
SMCS Code: 1000; 1404; 7002
Some removals may require lifting the fixtures to
obtain proper balance and safety. If the engine will not be started for several weeks, the
lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface. Rust on the cylinder liner surface will
cause increased engine wear and a reduction in
engine service life.
To help prevent excessive engine wear, use the
following guidelines:
SEBU8600-04 35
Operation Section
Product Storage

• Complete all lubrication recommendations that are

listed in this Operation and Maintenance Manual,
“Maintenance Interval Schedule” (Maintenance
Section).
• If freezing temperatures are expected, check the
cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
(Maintenance Section).
If an engine is out of operation and if use of the
engine is not planned, special precautions should be
made. If the engine will be stored for more than 1
month, a complete protection procedure is
recommended.
For more detailed information on engine storage, see
Special Instruction, SEHS9031, “Storage Procedure
For Caterpillar Products”.
Your Cat dealer can help prepare the engine for
extended storage periods.
36 SEBU8600-04
Operation Section
Gauges and Indicators

Gauges and Indicators 3. Check and maintain the oil level.

Jacket Water Coolant Temperature –
i03932253 Typical temperature range is 82° to 94°C
(179.6° to 169.2°F). This temperature
Gauges and Indicators range will vary according to engine load and the
ambient temperature.
SMCS Code: 1900; 7450
A 100 kPa (14.5 psi) radiator cap must be installed
Your engine may not have the same gauges or all of on the cooling system. The maximum temperature for
the gauges that are described. For more information the cooling system is 108° C (226.4° F). This
about the gauge package, see the OEM information. temperature is measured at the outlet for the water
temperature regulator. The engine coolant
Gauges provide indications of engine performance. temperature is regulated by the engine sensors and
Ensure that the gauges are in good working order. the engine ECM. This programming cannot be
Determine the normal operating range by observing
altered. Derates can occur if the maximum engine
the gauges over a period. coolant temperature is exceeded.
Noticeable changes in gauge readings indicate
If the engine is operating above the normal range,
potential gauge or engine problems. Problems may
reduce the engine load. If high coolant temperatures
also be indicated by gauge readings that change
are a frequent event, perform the following
even if the readings are within specifications.
procedures:
Determine and correct the cause of any significant
change in the readings. Consult your Caterpillar 1. Reduce the load on the engine.
dealer for assistance.
2. Determine if the engine must be shut down
Some engine applications are equipped with immediately or if the engine can be cooled by
Indicator Lamps. Indicator lamps can be used as a
diagnostic aid. There are two lamps. One lamp has reducing the load.
an orange lens and the other lamp has a red lens. 3. Inspect the cooling system for leaks. If necessary,
These indicator lamps can be used in two ways: consult your Caterpillar dealer for assistance.

• The indicator lamps can be used to identify the Tachometer – This gauge indicates
current operational status of the engine. The engine speed (rpm). When the throttle
indicator lamps can also indicate that the engine control lever is moved to the full throttle
has a fault. This system is automatically operated position without load, the engine is running at
via the ignition switch. high idle. The engine is running at the full load
rpm when the throttle control lever is at the full
• The indicator lamps can be used to identify active throttle position with maximum rated load.
diagnostic codes. This system is activated by
pressing the Flash Code button. NOTICE
To help prevent engine damage, never exceed the
Refer to the Troubleshooting Guide, “Indicator high idle rpm. Overspeeding can result in serious
Lamps” for further information. damage to the engine. Operation at speeds exceed-
ing high idle rpm should be kept to a minimum.
NOTICE
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP Ammeter – This gauge indicates the
the engine. Engine damage can result. amount of charge or discharge in the
battery charging circuit. Operation of
the indicator should be to the “ +”” side of “ 0””
Engine Oil Pressure – The oil pressure (zero).
should be greatest after a cold engine is
started. The typical engine oil pressure Fuel Level – This gauge indicates the
with SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) fuel level in the fuel tank. The fuel level
at rated rpm. gauge operates when the “ START/STOP””
switch is in the “ on”” position.
A lower oil pressure is normal at low idle. If the load is
stable and the gauge reading changes, perform the Service Hour Meter – The gauge
following procedure: indicates total operating hours of the
1. Remove the load. engine.

2. Stop the engine.

SEBU8600-04 37
Operation Section
Gauges and Indicators

Indicator Lamps
• Shutdown lamp
• Warning lamp

• Wait to start lamp

• Low oil pressure lamp
For information, refer to this manual, “Monitoring
System (Table for the Indicator Lamps)” for the
sequence of operation of the shutdown lamp and the
warning lamp.
The function of the wait to start lamp is automatically
controlled at engine start-up.
The function of the low oil pressure lamp is controlled
by the engine ECM. If low oil pressure is detected,
the lamp will be illuminated. The reason for the
illumination of the low-pressure lamp should be
investigated immediately.
All lamps will illuminate for 2 seconds in order to
check that the lamps are functioning when the
keyswitch is turned to the ON position. If any of the
lamps stay illuminated, the reason for illumination
should be investigated immediately.

Aftertreatment Lamps
For information on the aftertreatment lamp, refer to
this Operation and Maintenance Manual, “Diesel
Particulate Filter Regeneration”.
38 SEBU8600-04
Operation Section
Features and Controls

Features and Controls

i03552521

Monitoring System
(Engine)
SMCS Code: 1900; 7400; 7402; 7450; 7451

Table 2
Shutdown
Warning Lamp Lamp Status Description of Lamp Status Engine Status
Lamp

Lamp check When the engine start switch is turned to the “ON” posi- The engine has not been
ON ON
tion both lamps will illuminate for 2 seconds only. started.

No faults There are no active diagnostic faults. The engine is running

OFF OFF
normally.

Active diagnos- An active diagnostic fault has been detected. The engine is running
ON OFF
tic fault normally.

Active diagnos- A serious active diagnostic fault has been detected and The engine is running but the
ON FLASHING
tic fault an engine derate has been invoked. engine has been derated.

Derate and One or more of the engine protection values has been The engine is running but the
FLASHING OFF
warning exceeded. engine has been derated.

Engine One or more of the engine protection values has been ex- The engine is shutdown or
FLASHING ON shutdown ceeded or a serious active diagnostic fault has been shutdown is imminent.
detected.

i03921355 • Intake manifold air pressure

Monitoring System • Oil pressure

(Engine) • Pressure in the fuel rail

SMCS Code: 1900; 7400; 7402; 7450; 7451 • Fuel filter differential pressure

• Fuel temperature
• Water in fuel
If the Shutdown mode has been selected and the
warning indicator activates, engine shutdown
• Engine speed/timing
may take as little as 20 seconds from the time the
warning indicator is activated. Depending on the • Atmospheric pressure (Barometric pressure)
application, special precautions should be taken
to avoid personal injury. The engine can be re- • The Inlet pressure of the NOx reduction system
started following shutdown for emergency ma-
neuvers, if necessary. • The differential pressure within the NOx reduction
system
NOTICE • Temperature of the NOx reduction system
The Engine Monitoring System is not a guarantee
against catastrophic failures. Programmed delays • The amount of soot in the Diesel particulate filter
and derate schedules are designed to minimize false
alarms and provide time for the operator to stop the
engine.
The following parameters are monitored:

• Coolant temperature
• Intake manifold air temperature
SEBU8600-04 39
Operation Section
Sensors and Electrical Components

Programmable Options and For more information or assistance for repairs,

consult your Caterpillar dealer.
Systems Operation
Instrument panels and Displays
In order to monitor the engine a wide verity of
If the Warning/Derate/Shutdown mode has been instrument panels are available. These instrument
selected and the warning indicator activates, panels can contain the aftertreatment lamps and the
bring the engine to a stop whenever possible. De- indicator lamps and the gauges for the application.
pending on the application, special precautions The regeneration switch can be incorporate within
should be taken to avoid personal injury. the panel.
The engine can be programmed to the following Also available are mini power displays and
modes: performance monitors. These displays and monitors
can show the operator the following engine
“ Warning”” information.

The “Warning” lamp and the warning signal (orange • The system configuration parameters
lamp) turn “ON” and the warning signal is activated
continuously in order to alert the operator that one or • The customer specified parameters
more of the engine parameters is not within normal
operating range. • Diagnostic codes

• Event codes
“ Warning/Derate””
• Coolant temperature
The “Diagnostic” lamp turns “ON” and the warning
signal (red lamp) is activated. After the warning, the • Oil temperature
engine power will be derated. The warning lamp will
begin to flash when the derating occurs. • Oil pressure

The engine will be derated if the engine exceeds • Intake temperature

preset operational limits. The engine derate is
achieved by restricting the amount of fuel that is • Intake pressure
available for each injection. The amount of this
reduction of fuel is dependent on the severity of the • Atmospheric pressure
fault that has caused the engine derate. This
reduction in fuel results in a predetermined reduction • Fuel temperature
in engine power.
i03915130
“ Warning/Derate/Shutdown””
Sensors and Electrical
The “Diagnostic” lamp turns “ON” and the warning
signal (red lamp) is activated. After the warning, the Components
engine power will be derated. The engine will
continue at the rpm of the set derate until a shutdown
(Engine)
of the engine occurs. The engine can be restarted SMCS Code: 1439; 1900; 7400
after a shutdown for use in an emergency.
A shutdown of the engine may occur in as little as 20 Sensor Locations
seconds. The engine can be restarted after a
shutdown for use in an emergency. However, the The Illustration within the section shows the typical
cause of the initial shutdown may still exist. The locations of the sensors for a C7.1 Industrial Engine.
engine may shut down again in as little as 20 Specific engines may appear different from the
seconds. illustration due to differences in applications.

If there is a signal for low oil pressure or for coolant

temperature, there will be a two second delay in
order to verify the condition.
For each of the programmed modes, refer to
Troubleshooting Guide, “Indicator Lamps” for more
information on Indicator Lamps.
40 SEBU8600-04
Operation Section
Engine

Illustration 33 g02150593

(1) Engine Intake Throttle Valve (6) Differential Pressure Sensor for the NOx (12) Primary Speed/Timing Sensor
(2) Wastegate Regulator Reduction System (NRS) (13) Starting Motor
(3) Control Valve for the NOx Reduction (7) Fuel Pressure Sensor (Fuel Rail (14) Oil Pressure Sensor
System (NRS) Pressure Sensor) (15) Oil level Switch ( if Equipped)
(4) Temperature Sensor for the NOx (8) Intake Manifold Air Temperature Sensor (16) Diagnostic Connector
Reduction System (9) Intake Manifold Pressure Sensor (17) Fuel Temperature Sensor
(5) Intake Pressure Sensor for the NOx (10) Electronic Control Module (ECM) (18) Solenoid for the High Pressure Fuel
Reduction System (NRS) (11) Atmospheric Pressure Sensor Pump
(Barometric Pressure Sensor) (19) Coolant Temperature Sensor
SEBU8600-04 41
Operation Section
Engine

Illustration 34 g02150594
The location of the fuel filters will depend on the application.
(20) Differential Pressure Switch for the (22) Secondary Speed/Timing Sensor (25) Refrigerant Compressor (if equipped)
Secondary Fuel Filter (23) Fuel Priming Pump
(21) Water in Fuel Switch (24) Alternator
42 SEBU8600-04
Operation Section
Engine

Illustration 35 g02151173

(1) Engine Intake Throttle Valve (5) Intake Pressure Sensor for the NRS (8) Intake Manifold Air Temperature Sensor
(2) Wastegate Regulator (6) Differential Pressure Sensor for the NRS (9) Intake Manifold Pressure Sensor
(3) Control Valve for the NRS (7) Fuel Pressure Sensor (Fuel Rail
(4) Temperature Sensor for the NRS Pressure Sensor)

Illustration 36 g02151174

(10) Electronic Control Module (ECM) (12) Primary Speed/Timing Sensor (15) Oil Level Switch (if Equipped)
(11) Atmospheric Pressure Sensor (13) Starting Motor
(Barometric Pressure Sensor) (14) Oil Pressure Sensor

The oil level switch (15) will only operate with the
application on level ground and the power in the ON
position. The engine must be at zero RPM. A coolant
level switch can be installed, this switch only
operates at key on, and the application must be on
level ground.
SEBU8600-04 43
Operation Section
Engine

Illustration 37 g02151327

(16) Diagnostic Connector (18) Solenoid for the High Pressure Fuel (19) Coolant Temperature Sensor
(17) Fuel Temperature Sensor Pump

Illustration 38 g02151177

(20) Differential Pressure Switch for the (21) Water in Fuel Switch (23) Fuel Priming Pump
Secondary Fuel Filter (22) Secondary Speed/Timing Sensor

Programmable Monitoring System • Coolant Temperature Sensor

(PMS) • Intake Manifold Air Temperature Sensor
The Programmable Monitoring System determines • Intake Manifold Pressure Sensor
the level of action that is taken by the Engine Control
Module (ECM) (10). In response to a condition that • Fuel Pressure Sensor
can damage the engine. These conditions are
identified by the ECM from the signals that are • Engine Oil Pressure Sensor
produced from the following sensors.
44 SEBU8600-04
Operation Section
Sensors and Electrical Components

• Primary Speed/Timing Sensor

• Secondary Speed/Timing Sensor

• Fuel Temperature Sensor

• Temperature Sensor for the NRS

• Intake Pressure Sensor for the NRS

• Differential Pressure Sensor for the NRS

i03928178

Sensors and Electrical

Components
(Aftertreatment)
SMCS Code: 1439; 1900; 7400
The following view shows typical features of the
engine aftertreatment system. Due to individual
applications, your system may appear different from
the illustrations.

• Glossary
• ARD Aftertreatment Regeneration Device

• DOC Diesel Oxidation Catalyst

SEBU8600-04 45
Operation Section
Aftertreatment

Illustration 39 g02313693
Typical example
(1) Soot sensor connection (7) Soot sensor connection (13) Fuel pressure sensor (pilot)
(2) Spark plug lead (8) DOC Temperature sensor (not shown) (14) Aftertreatment device ID
(3) ARD air pressure sensor (9) Harness connector (15) Coil for spark plug
(4) DOC pressure sensor (10) Main fuel valve (If equipped) (16) ARD air control valve
(5) Pressure differential sensor (11) Pilot fuel valve (17) Location of spark plug
(6) Relay (12) Fuel pressure sensor (if equipped) (18) ARD exhaust gas temperature sensor
46 SEBU8600-04
Operation Section
Engine Shutoffs and Engine Alarms

i03928179 Intake manifold pressure – The intake manifold

pressure sensor checks the rated pressure in the
Engine Shutoffs and Engine engine manifold.
Alarms Fuel rail pressure – The fuel rail pressure sensor
checks for high pressure or low pressure in the fuel
SMCS Code: 1900; 7400; 7418 rail.
Engine oil pressure – The engine oil pressure
Shutoffs sensor indicates when oil pressure drops below rated
system pressure, at a set engine speed.
The shutoffs are electrically operated or mechanically
operated. The electrically operated shutoffs are Engine overspeed – If, the engine rpm exceeds the
controlled by the ECM. overspeed setting the alarm will be activated.
Shutoffs are set at critical levels for the following Air filter restriction – The switch checks the air filter
items: when the engine is operating.

• Operating temperature User-defined switch – This switch can shut down

the engine remotely.
• Operating pressure Water in fuel switch – This switch checks for water
in the primary fuel filter when the engine is operating.
• Operating level
Fuel temperature – The fuel temperature sensor
• Operating rpm monitors the pressurized fuel in the high-pressure
fuel pump.
The particular shutoff may need to be reset before
the engine will start. Fuel differential pressure – This switch checks the
pressure across the fuel filter.
NOTICE
Always determine the cause of the engine shutdown.
Make necessary repairs before attempting to restart Note: The sensing element of the coolant
the engine. temperature switch must be submerged in coolant in
order to operate.

Be familiar with the following items: Engines may be equipped with alarms in order to
alert the operator when undesirable operating
• Types and locations of shutoff conditions occur.

• Conditions which cause each shutoff to function NOTICE

When an alarm is activated, corrective measures
• The resetting procedure that is required to restart must be taken before the situation becomes an emer-
the engine gency in order to avoid possible engine damage.

Alarms If corrective measures are not taken within a

reasonable time, engine damage could result. The
The alarms are electrically operated. The operations alarm will continue until the condition is corrected.
of the alarms are controlled by the ECM. The alarm may need to be reset.
The alarm is operated by a sensor or by a switch. Note: If installed, the coolant level switch and the oil
When the sensor or the switch is activated, a signal is level switch are indicators. Both switches operate
sent to the ECM. An event code is created by the when the application is on level ground and the
ECM. The ECM will send a signal in order to engine RPM at zero.
illuminate the lamp.
Your engine may be equipped with the following Testing
sensors or switches:
Turning the keyswitch to the ON position will check
Coolant temperature – The coolant temperature the indicator lights on the control panel. All the
sensor indicates high jacket water coolant indicator lights will be illuminated for 2 seconds after
temperature. the keyswitch is operated. Replace suspect bulbs
Intake manifold air temperature – The intake immediately.
manifold air temperature sensor indicates high intake
air temperature.
SEBU8600-04 47
Operation Section
Overspeed

Refer to Troubleshooting, KENR9106 for more

information.

i03554501

Overspeed
SMCS Code: 1900; 1907; 1912; 7427

• ECM Electronic Control Module

• RPM Revolutions Per Minute

An overspeed is detected by the speed/timing
sensors.
The default setting for an overspeed is 3000 rpm.
The ECM will cut the power to the electronic unit
injectors, until the rpm drops below 200 rpm of the
overspeed setting. A diagnostic fault code will be
logged into the ECM memory and a warning lamp will
indicate a diagnostic fault code.
An overspeed can be set from 2600 rpm to 3000 rpm.
This setting depends on the application.
48 SEBU8600-04
Operation Section
Engine Diagnostics

Engine Diagnostics The codes will be flashing in sequence. For example

if the flash code equals 133, the diagnostic lamp will
flash once, pause, flash three times, pause, and flash
i01796959 three times.

Self-Diagnostics After the complete code has flashed, a 3 second

pause will take place before the next code will begin
SMCS Code: 1000; 1900; 1901; 1902 to flash (if another code is present).

Caterpillar Electronic Engines have the capability to Note: For more information refer to
perform a self-diagnostics test. When the system Troubleshootingmanual.
detects an active problem, a diagnostic lamp is
activated. Diagnostic codes will be stored in
permanent memory in the Electronic Control Module
(ECM). The diagnostic codes can be retrieved by
using Caterpillar electronic service tools.
Some installations have electronic displays that
provide direct readouts of the engine diagnostic
codes. Refer to the manual that is provided by the
OEM for more information on retrieving engine
diagnostic codes.
Active codes represent problems that currently exist.
These problems should be investigated first.
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.

i03554520

Diagnostic Lamp
SMCS Code: 1000; 1900; 1901; 1902; 7451
A diagnostic lamp is used to indicate the existence of
an active fault. A fault diagnostic code will remain
active until the problem is repaired. The diagnostic
code may be retrieved by using the electronic service
tool.

i04036139

Diagnostic Flash Code

Retrieval
SMCS Code: 1000; 1900; 1901; 1902
In order to read the diagnostic flash codes through
the diagnostic lamp, cycle the key switch from off to
on twice within 3 seconds.
SEBU8600-04 49
Operation Section
Diagnostic Flash Code Retrieval

Table 3

CDL Code Description J1939 Code Flash Code

N/A No Diagnostic Code Detected N/A 551

1-2 Cylinder #1 Injector data incorrect 651-2

1-5 Cylinder #1 Injector current below normal 651-5 111

1-6 Cylinder #1 Injector current above normal 651-6

2-2 Cylinder #2 Injector data incorrect 652-2

2-5 Cylinder #2 Injector current below normal 652-5 112

2-6 Cylinder #2 Injector current above normal 652-6

3-2 Cylinder #3 Injector data incorrect 653-2

3-5 Cylinder #3 Injector current below normal 653-5 113

3-6 Cylinder #3 Injector current above normal 653-6

4-2 Cylinder #4 Injector data incorrect 654-2

4-5 Cylinder #4 Injector current below normal 654-5 114

4-6 Cylinder #4 Injector current above normal 654-6

5-2 Cylinder #5 Injector data incorrect 655-2

5-5 Cylinder #5 Injector current below normal 655-5 115

5-6 Cylinder #5 Injector current above normal 655-6

6-2 Cylinder #6 Injector data incorrect 656-2

6-5 Cylinder #6 Injector current below normal 656-5 116

6-6 Cylinder #6 Injector current above normal 656-6

18-5 Fuel Control Valve current below normal 1076-5 -

18-6 Fuel Control Valve current above normal 1076-6 -

41-3 8 Volt DC Supply voltage above normal 678-3

517
41-4 8 Volt DC Supply voltage below normal 678-4

91-2 Throttle Position Sensor erratic, intermittent, or incorrect 91-2

91-3 Throttle Position Sensor voltage above normal 91-3

154
91-4 Throttle Position Sensor voltage below normal 91-4

91-8 Throttle Position Sensor abnormal frequency, pulse width, or period 91-08

100-3 Engine Oil Pressure Sensor voltage above normal 100-3

100-4 Engine Oil Pressure Sensor voltage below normal 100-4 157

100-21 Engine Oil Pressure Sensor data drifted low 100-21

110-3 Engine Coolant Temperature Sensor voltage above normal 110-3

168
110-4 Engine Coolant Temperature Sensor voltage below normal 110-4

168-2 Electrical System Voltage erratic, intermittent, or incorrect 168-2

168-3 Electrical System Voltage voltage above normal 168-3 511

168-4 Electrical System Voltage voltage Below normal 168-4

(continued)
50 SEBU8600-04
Operation Section
Diagnostic Flash Code Retrieval

(Table 3, contd)
CDL Code Description J1939 Code Flash Code
172-3 Intake Manifold Air Temperature Sensor voltage above normal 105-3
133
172-4 Intake Manifold Air Temperature Sensor voltage below normal 105-4

174-3 Fuel Temperature Sensor voltage above normal 174-3

165
174-4 Fuel Temperature Sensor voltage below normal 174-4

190-8 Engine Speed Sensor abnormal frequency, pulse width, or period 190-8 141

247-9 SAE J1939 Data Link abnormal update rate - 514

253-2 Personality Module erratic, intermittent, or incorrect 631-2 415

261-11 Engine Timing Offset fault 637-11 143

262-3 5 Volt Sensor DC Power Supply voltage above normal 3509-3

516
262-4 5 Volt Sensor DC Power Supply voltage below normal 3509-4

268-2 Programmed Parameter Fault erratic, intermittent, or incorrect 630-2 527

274-3 Atmospheric Pressure Sensor voltage above normal 108-3

274-4 Atmospheric Pressure Sensor voltage below normal 108-4

152
274-13 Atmospheric Pressure Sensor calibration required 108-13

274-21 Atmospheric Pressure Sensor data drifted low 108-21

342-8 Secondary Engine Speed Sensor abnormal frequency, pulse width, or period 723-8 142

526-5 Turbo Wastegate Drive current below normal 1188-5

177
526-6 Turbo Wastegate Drive current above normal 1188-6

535-3 Exhaust Temperature Sensor voltage above normal 3241-3

185
535-4 Exhaust Temperature Sensor voltage below normal 3241-4

774-2 Secondary Throttle Position Sensor erratic, intermittent, or incorrect 29-2

774-3 Secondary Throttle Position Sensor voltage above normal 29-3

155
774-4 Secondary Throttle Position Sensor voltage below normal 29-4

774-8 Secondary Throttle Position Sensor abnormal frequency, pulse width, or period 29-8

993-2 DPF Active Regeneration Inhibited Due to Inhibit Switch 3703-31 -

1262-2 Engine Throttle Actuator 1 Control Command not responding properly 3464-7 -

1634-2 Idle Validation Switch #1 erratic, intermittent or incorrect 558-2 245

1635-2 Idle Validation Switch #2 erratic, intermittent or incorrect 2970-2

246
1639-9 Machine Security System Module abnormal update rate 1196-9

1743-2 Engine Operation Mode Selector Switch erratic, intermittent, or incorrect 2882-2 144

1785-3 Intake Manifold Pressure Sensor voltage above normal 3563-3

1785-4 Intake Manifold Pressure Sensor voltage below normal 3563-4

197
1785-13 Intake Manifold Pressure Sensor calibration required 3563-13

1785-21 Intake Manifold Pressure Sensor data drifted low 3563-21

1797-3 Fuel Rail Pressure Sensor voltage above normal 157-3 159

(continued)
SEBU8600-04 51
Operation Section
Diagnostic Flash Code Retrieval

(Table 3, contd)
CDL Code Description J1939 Code Flash Code
1797-4 Fuel Rail Pressure Sensor voltage below normal 157-4

1797-7 Fuel Rail Pressure Sensor not responding properly 157-7

1834-2 Ignition Key Switch loss of signal 158-2 429

2131-3 5 Volt Sensor DC Power Supply #2 voltage above normal 3510-3

528
2131-4 5 Volt Sensor DC Power Supply #2 voltage below normal 3510-4

2246-6 Glow Plug Start Aid Relay current above normal 676-6 199

2417-5 Ether Injection Control Solenoid current below normal 626-5 233
2417-6 Ether Injection Control Solenoid current above normal 626-6 233

2452-3 DPF #1 Intake Temperature Sensor voltage above normal 3242-3 224

2452-4 DPF #1 Intake Temperature Sensor voltage below normal 3242-4 224

2458-3 DPF #1 Differential Pressure Sensor : voltage above normal 3251-3 222

2458-4 DPF #1 Differential Pressure Sensor : voltage below normal 3251-4 222

2460-3 ARD Fuel Pressure #1 Sensor voltage above normal 3480-3 219

2460-4 ARD Fuel Pressure #1 Sensor voltage below normal 3480-4 219

2461-5 ARD Fuel Pressure #1 Control current below normal 3479-5

216
2461-6 ARD Fuel Pressure #1 Control current above normal 3479-6

2465-5 Aftertreatment #1 Ignition Transformer Primary current below normal 3484-5

243
2465-6 Aftertreatment #1 Ignition Transformer Primary current above normal 3484-6

2489-5 ARD Air Pressure Control Actuator current below normal 3487-5
211
2489-6 ARD Air Pressure Control Actuator current above normal 3487-6

2490-3 ARD Air Pressure Control Actuator Position Sensor voltage above normal 3488-3
212
2490-4 ARD Air Pressure Control Actuator Position Sensor voltage below normal 3488-4

2498-3 ARD Supply Air Pressure Sensor voltage above normal 3837-3 -

2498-4 ARD Supply Air Pressure Sensor voltage below normal 3837-4 -

2498-13 ARD Supply Air Pressure Sensor calibration required 3837-13 -

2498-21 ARD Supply Air Pressure Sensor data drifted low 3837-21 -

2526-3 Air Inlet Temperature Sensor voltage above normal 172-3 232

2526-4 Air Inlet Temperature Sensor voltage below normal 172-4 232

3180-5 Aftertreatment #1 Ignition Transformer Secondary current below normal 4265-5

244
3180-6 Aftertreatment #1 Ignition Transformer Secondary current above normal 4265-6

3182-5 Aftertreatment #1 Fuel Injector #1 Heater current below normal 5425-5

215
3182-6 Aftertreatment #1 Fuel Injector #1 Heater current above normal 5425-6

3385-3 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage above normal 3358-3

3385-4 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage below normal 3358-4 231

3385-13 Engine Exhaust Gas Recirculation Intake Pressure Sensor calibration required 3358-13

(continued)
52 SEBU8600-04
Operation Section
Diagnostic Flash Code Retrieval

(Table 3, contd)
CDL Code Description J1939 Code Flash Code
3385-21 Engine Exhaust Gas Recirculation Intake Pressure Sensor data drifted low 3358-21

3386-3 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage above normal 412-3
227
3386-4 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage below normal 412-4

3397-2 DPF #1 Soot Loading Sensor : Erratic, Intermittent, or Incorrect 4783-2

3397-3 DPF #1 Soot Loading Sensor : Voltage Above Normal 4783-3

3397-4 DPF #1 Soot Loading Sensor : Voltage Below Normal 4783-4

3397-9 DPF #1 Soot Loading Sensor abnormal update rate 4783-9

226
3397-12 DPF #1 Soot Loading Sensor failure 4783-12

3397-13 DPF #1 Soot Loading Sensor calibration required 4783-13

3397-19 DPF #1 Soot Loading Sensor data error 4783-19

3397-21 DPF #1 Soot Loading Sensor data drifted low 4783-21

3405-5 Engine Exhaust Gas Recirculation Valve Control current below normal 2791-5
228
3405-6 Engine Exhaust Gas Recirculation Valve Control current above normal 2791-6

3407-3 Engine Exhaust Gas Recirculation Valve Position Sensor voltage above normal 27-3
229
3407-4 Engine Exhaust Gas Recirculation Valve Position Sensor voltage below normal 27-4

3427-5 Aftertreatment Fuel Pump Relay current below normal 5423-5 218

3427-6 Aftertreatment Fuel Pump Relay current above normal 5423-6 218

3464-3 DPF #1 Intake Pressure Sensor voltage above normal 3609-3

3464-4 DPF #1 Intake Pressure Sensor voltage below normal 3609-4

223
3464-13 DPF #1 Intake Pressure Sensor calibration required 3609-13

3464-21 DPF #1 Intake Pressure Sensor data drifted low 3609-21

3468-2 Aftertreatment #1 Identification Number Module erratic, intermittent, or incorrect 5576-2 -

3468-8 Aftertreatment #1 Identification Number Module abnormal frequency, pulse width, or period 5576-8 -

3468-14 Aftertreatment #1 Identification Number Module special instruction 5576-14 -

3511-3 Engine Exhaust Gas Recirculation Outlet Pressure Sensor voltage above normal 5019-3

3511-4 Engine Exhaust Gas Recirculation Outlet Pressure Sensor voltage below normal 5019-4
247
3511-13 Engine Exhaust Gas Recirculation Outlet Pressure Sensor calibration required 5019-13

3511-21 Engine Exhaust Gas Recirculation Outlet Pressure Sensor data drifted low 5019-21

3514-5 Engine Throttle Actuator Control Command current below normal 3464-5 -

3514-6 Engine Throttle Actuator Control Command current above normal 3464-6 -

3515-3 Engine Throttle Valve Position Sensor voltage above normal 51-3
252
3515-4 Engine Throttle Valve Position Sensor voltage below normal 51-4

Event Codes

E172-1 High Air Filter Restriction - Warning 107-15 151

E232-1 High Fuel/Water Separator Water Level - Warning 97-17 -

(continued)
SEBU8600-04 53
Operation Section
Diagnostic Flash Code Retrieval

(Table 3, contd)
CDL Code Description J1939 Code Flash Code
E360-1 Low Engine Oil Pressure - Warning 100-17
157
E360-3 Low Engine Oil Pressure - Shutdown 100-01

E361-1 High Engine Coolant Temperature - Warning 110-15

E361-2 High Engine Coolant Temperature - Derate 110-16 168

E361-3 High Engine Coolant Temperature - Shutdown 110-0

E362-1 Engine Overspeed - Warning 190-15 141

E363-1 High Fuel Supply Temperature - Warning 174-15

165
E363-2 High Fuel Supply Temperature - Derate 174-16

E396-2 High Fuel Rail Pressure - Warning 157-16

E398-2 Low Fuel Rail Pressure - Warning 157-18 159

E499-3 Fuel Rail #1 Pressure Leak - Shutdown 1239-0

E539-1 High Intake Manifold Air Temperature - Warning 105-15

133
E539-2 High Intake Manifold Air Temperature - Derate 105-16

E593-2 Aftertreatment Insufficient Temperature to Complete Regeneration - Derate 3711-31 214

E991-3 DPF Active Regeneration Inhibited Due to Permanent System Lockout - Shutdown 3715-31 -

E992-3 DPF Active Regeneration Inhibited Due to Temporary System Lockout - Shutdown 3714-31 -

E995-2 High DPF #1 Soot Loading - Derate 3719-16

226
E995-3 High DPF #1 Soot Loading - Shutdown 3719-0

E997-1 High DPF #1 Ash Loading - Warning 3720-15 -

E997-2 High DPF #1 Ash Loading - Derate 3720-16 -

E1008-2 High DPF #1 Intake Temperature - Derate 3242-16 224

E1014-2 Low DPF #1 Intake Temperature - Derate 3242-18 224

E1022-1 Low ARD Fuel Pressure #1 - Warning 3480-17

219
E1022-2 Low ARD Fuel Pressure #1 - Derate 3480-18

E1025-2 Aftertreatment #1 Loss of Ignition - Derate 3473-31 244

E1026-2 Aftertreatment #1 Loss of Combustion - Derate 3474-31 -

E1041-2 ARD Air Pressure Control Actuator Not Responding To Command - Derate 3487-7 211

E1044-2 High Intake Manifold Pressure - Derate 102-16

197
E1045-2 Low Intake Manifold Pressure - Derate 102-18

E1050-1 High Aftertreatment #1 Fuel Pressure #1 - Warning 3480-15

219
E1050-2 High Aftertreatment #1 Fuel Pressure #1 - Derate 3480-16

E1070-1 Aftertreatment Fuel Injector #1 not responding - Warning 3556-7 -

E1092-1 High Engine Exhaust Gas Recirculation Temperature - Warning 412-15 227

E1092-2 High Engine Exhaust Gas Recirculation Temperature - Derate 412-16 227

E1121-2 Engine Exhaust Gas Recirculation Valve Control Not Responding to Command - Derate 2791-7 228

(continued)
54 SEBU8600-04
Operation Section
Fault Logging

(Table 3, contd)
CDL Code Description J1939 Code Flash Code
E1154-2 Low DPF #1 Intake Pressure - Warning 3609-18
223
E1156-1 High DPF #1 Intake Pressure - Warning 3609-15

E1170-2 Low Aftertreatment #1 Secondary Air Pressure - Derate 3837-18 -

E1264-3 High Pressure Common Rail Fuel Pressure Relief Valve Active - Shutdown 5571-0 159

E1305-1 Initial Assembly Aftertreatment #1 Regeneration Required - Warning 3483-11 -

E1319-2 Engine Exhaust Gas Recirculation Mass Flow Rate Not Responding - Derate 2659-7 -

E2143-3 Low Engine Coolant Level - Shutdown 111-01 169

i03554529 Operation of the engine and performance of the

engine can be limited as a result of the active
Fault Logging diagnostic code that is generated. Acceleration rates
may be significantly slower. Refer to the
SMCS Code: 1000; 1900; 1901; 1902 Troubleshooting Guide for more information on the
relationship between these active diagnostic codes
The system provides the capability of Fault Logging. and engine performance.
When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will be
i01797063
logged in the memory of the ECM. The codes that
have been logged in the memory of the ECM can be
retrieved with electronic service tools. The codes that Engine Operation with
have been logged can be cleared with electronic
service tools. The codes that have been logged in the Intermittent Diagnostic Codes
memory of the ECM will be automatically cleared SMCS Code: 1000; 1900; 1901; 1902
from the memory after 100 hours. The following faults
can not be cleared from the memory of the ECM If a diagnostic lamp illuminates during normal engine
without using a factory password: overspeed, low operation and the diagnostic lamp shuts off, an
engine oil pressure and high engine coolant intermittent fault may have occurred. If a fault has
temperature. occurred, the fault will be logged into the memory of
the Electronic Control Module (ECM).
i03554534
In most cases, it is not necessary to stop the engine
because of an intermittent code. However, the
Engine Operation with Active operator should retrieve the logged fault codes and
Diagnostic Codes the operator should reference the appropriate
information in order to identify the nature of the event.
SMCS Code: 1000; 1900; 1901; 1902 The operator should log any observation that could
have caused the lamp to light.
If a diagnostic lamp illuminates during normal engine
operation, the system has identified a situation that is • Low power
not within the specification. Use electronic service
tools to check the active diagnostic codes. • Limits of the engine speed
Note: If the customer has selected “DERATE” and if • Excessive smoke, etc
there is a low oil pressure condition, the Electronic
Control Module (ECM) will limit the engine power This information can be useful to help troubleshoot
until the problem is corrected. If the oil pressure is the situation. The information can also be used for
future reference. For more information on diagnostic
within the normal range, the engine may be operated codes, refer to the Troubleshooting Guide for this
at the rated speed and load. However, maintenance engine.
should be performed as soon as possible.
The active diagnostic code should be investigated.
The cause of the problem should be corrected as
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.
SEBU8600-04 55
Operation Section
Configuration Parameters

i03905586

Configuration Parameters
SMCS Code: 1000; 1900; 1901; 1902
The engine electronic control module (ECM) has two
types of configuration parameters. The system
configuration parameters and the customer specified
parameters.
The electronic service tool is required in order to alter
the configuration parameters.

System Configuration Parameters

System configuration parameters affect the
emissions of the engine or the power of the engine.
System configuration parameters are programmed at
the factory. Normally, system configuration
parameters would never require changing through
the life of the engine. System configuration
parameters must be reprogrammed if an ECM is
replaced. System configuration parameters do not
require reprogrammed if the ECM software is
changed. Factory passwords are required to change
these parameters.
Table 4
System Configuration Parameters

Configuration Parameters Record

Engine Serial Number

Delayed Engine Shutdown

Factory Installed Aftertreatment #1 Identification Number

DPF #1 Soot Loading Sensing System Configuration Code

Limp Home Engine Speed Ramp Rate

System Operating Voltage Configuration

Rating Number

CAN Communication Protocol Write Security

Customer Specified Parameters

Customer specified parameters allow the engine to
be configured to the exact needs of the application.
The electronic service tool is required in order to alter
the customer configuration parameters.
Customer parameters may be changed repeatedly as
operational requirements change.
Table 5
Customer Specified Parameters

Specified Parameters Record

(continued)
56 SEBU8600-04
Operation Section
Configuration Parameters

(Table 5, contd)
Throttle Type Channel 1

Throttle Type Channel 2

Continuous Position Throttle Configuration 1

Continuous Position Throttle Configuration 2

Multi Position Throttle Switch Configuration

Throttle Arbitration
Equipment ID

Low Idle Speed

Ether Solenoid Configuration

Engine Idle Shutdown Minimum Ambient Air Temperature

Engine Idle Shutdown Maximum Ambient Air Temperature

Engine Idle Shutdown Enable Status

Engine Idle Shutdown Delay Time

Engine Idle Shutdown Ambient Temperature Override Enable Status

Delayed Engine Shutdown Maximum Time

High Soot Load Aftertreatment Protection Enable Status

Key off regen enable status

Key Off Aftertreatment Regeneration Maximum Time

Multiple Engines on J1939

Air Shutoff
ARD Auto Regeneration Enable Status

Throttle Lock Feature Installation Status

PTO Mode
Throttle Lock Engine Set Speed #1

Throttle Lock Engine Set Speed #2

Throttle Lock Increment Speed Ramp Rate

Throttle Lock Decrement Speed Ramp Rate

Throttle Lock Engine Set Speed Increment

Throttle Lock Engine Set Speed Decrement

Monitoring Mode Shutdowns

Monitoring Mode Derates

Limp Home Desired Engine Speed

Engine Acceleration Rate

Engine Speed Decelerating Ramp Rate

Intermediate Engine Speed

Fan

(continued)
SEBU8600-04 57
Operation Section
Configuration Parameters

(Table 5, contd)
Engine Fan Control

Engine Fan Type Configuration

Engine Cooling Fan Pulley Ratio

Engine Cooling Fan Temperature Error Increasing Hysteresis

Engine Cooling Fan Temperature Error Decreasing Hysteresis

Engine Cooling Fan Current Ramp Rate

Engine Cooling Fan Speed

Top Engine Fan Speed

Minimum Desired Engine Cooling Fan Speed

Engine Cooling Fan Solenoid Minimum Current

Engine Cooling Fan Solenoid Maximum Current

Engine cooling Fan solenoid Dither Frequency

Engine Cooling Fan Solenoid Dither Amplitude

Fan Temperatures

Engine Fan Control Charge Air Cooler Outlet Temperature Input Enable

Engine Cooling Fan Maximum Air Flow Charge Air Cooler Outlet Temperature

Engine Cooling Fan Minimum Air Flow Charge Air Cooler Outlet Temperature

Engine Cooling Fan Control Coolant Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Coolant Temperature

Engine Cooling Fan Minimum Air Flow Coolant Temperature

Engine Cooling Fan Control Transmission Oil Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Transmission Oil Temperature

Engine Cooling Fan Minimum Air Flow Transmission Oil Temperature

Engine Cooling Fan Control Hydraulic Oil Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Hydraulic Oil Temperature

Engine Cooling Fan Minimum Air Flow Hydraulic Oil Temperature

Engine Cooling Fan Control Auxiliary #1 Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Auxiliary #1 Temperature

Engine Cooling Fan Minimum Air Flow Auxiliary #1 Temperature

Engine Cooling Fan Control Auxiliary #2 Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Auxiliary #2 Temperature

Engine Cooling Fan Minimum Air Flow Auxiliary #2 Temperature

Reversing Fan

Engine Fan Reversing Feature

Engine Fan Reverse Operation Early Termination Enable Status

Engine Fan Manual Purge

(continued)
58 SEBU8600-04
Operation Section
Configuration Parameters

(Table 5, contd)
Engine Fan Suspend Purge

Engine Fan Purge Cycle Interval

Engine Fan Purge Cycle Duration

Other Parameters
Maintenance Indicator Mode
Maintenance Level 1 Cycle Interval Hours

Coolant Level Sensor

Air Filter Restriction Switch Installation Status
Air Filter Restriction Switch Configuration

Fuel/Water Separator Switch Installation Status

User Defined Switch Installation Status

Auxiliary Temperature Sensor Installation Status

Auxiliary Pressure Sensor Installation Status

Engine Overspeed Setpoint

Fuel Filter Differential Pressure Switch Config

Diesel Particulate Filter Regeneration Force/ Inhibit Switch Installation

Diesel Particulate Filter Regeneration Inhibit Indicator Installation

Diesel Particulate Filter Soot Loading Indicator Installation

High Exhaust System Temperature Indicator Installation

Auxiliary Temp #2

Remote Torque Speed Control Enable Status

Number of Engine Operating Mode Switches

Engine Operating Mode Configuration

SEBU8600-04 59
Operation Section
Engine Starting

Engine Starting i02322203

i03648917
Starting the Engine
SMCS Code: 1000; 1450
Before Starting Engine Note: Do not adjust the engine speed control during
SMCS Code: 1000; 1400; 1450 start-up. The electronic control module (ECM) will
control the engine speed during start-up.
Perform the required daily maintenance and other
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can Starting the Engine
help prevent major repairs at a later date. Refer to
the Operation and Maintenance Manual, 1. Disengage any equipment that is driven by the
“Maintenance Interval Schedule” for more engine.
information.
2. Turn the keyswitch to the RUN position. Leave the
• Ensure that the engine has an adequate fuel keyswitch in the RUN position until the warning
supply. light for the glow plugs is extinguished.
• Open the fuel supply valve (if equipped). 3. When the warning light for the glow plugs is
extinguished turn the keyswitch to the START
NOTICE position in order to engage the electric starting
All valves in the fuel return line must be open and fuel motor and crank the engine.
supply lines must be open. Damage to the fuel sys-
tem can occure if fuel lines are closed with the engine Note: The operating period of the warning light for
in operation. the glow plugs will change due to the temperature of
the engine.
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air may NOTICE
have entered the filter housing. Also, when fuel filters Do not engage the starting motor when flywheel is
have been changed, some air pockets will be trapped turning. Do not start the engine under load.
in the engine. In these instances, prime the fuel
system. Refer to the Operation and Maintenance If the engine fails to start within 30 seconds, release
Manual, “Fuel System - Prime” for more information the starter switch or button and wait two minutes to
on priming the fuel system. Also, check that the fuel allow the starting motor to cool before attempting to
specification is correct and that the fuel condition is start the engine again.
correct. Refer to the Operation and Maintenance
Manual, “Fuel Recommendations”. 4. Allow the keyswitch to return to the RUN position
after the engine starts.
5. Repeat step 2 through step 4 if the engine fails to
Engine exhaust contains products of combustion start.
which may be harmful to your health. Always
start and operate the engine in a well ventilated i05354321
area and, if in an enclosed area, vent the exhaust
to the outside.
Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
• 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
to the controls.
Do not use aerosol types of starting aids such as
• Reset all of the shutoffs or alarm components. ether. Such use could result in an explosion and
personal injury.
• Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove Startability will be improved at temperatures below
−18 °C (0 °F) from the use of a jacket water heater or
any electrical loads.
extra battery capacity.
60 SEBU8600-04
Operation Section
Starting with Jump Start Cables

The following items provide a means of minimizing 7. Operate the engine at low load until all systems
starting problems and fuel problems in cold weather: reach operating temperature. Check the gauges
Engine oil pan heaters, jacket water heaters, fuel during the warm-up period.
heaters and fuel line insulation. For more information,
refer to Commercial Diesel Engine Fluids Following a cold start white smoke can be seen from
Recommendations , SEBU6251. the tailpipe. This smoke is normal and caused by
Use the procedure that follows for cold weather condensation leaving the exhaust system after
starting. warming up. The white smoke should clear following
working of the engine.
Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will i06893937
control the engine speed during start-up.
Starting with Jump Start
1. Disengage any driven equipment.
Cables
2. Turn the keyswitch to the RUN position. Leave the
keyswitch in the RUN position until the warning (Do Not Use This Procedure in
light for the glow plugs is extinguished. Hazardous Locations that have
NOTICE Explosive Atmospheres)
Do not engage the starting motor when flywheel is SMCS Code: 1000; 1401; 1402; 1900
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to The connection of battery cables to a battery and
start the engine again. the disconnection of battery cables from a battery
may cause an explosion which may result in in-
jury or death. The connection and the disconnec-
3. When the warning light for the glow plugs is
tion of other electrical equipment may also cause
extinguished cycle the keyswitch. Turn the an explosion which may result in injury or death.
keyswitch to the OFF position and then to the The procedures for the connection and the dis-
START position in order to engage the electric connection of battery cables and other electrical
starting motor and crank the engine. equipment should only be performed in a nonex-
plosive atmosphere.
Note: The operating period of the warning light for
the glow plugs will change due to the temperature of
the engine.

4. Allow the keyswitch to return to the RUN position Improper jump start cable connections can cause
after the engine starts. an explosion resulting in personal injury.
5. Repeat step 2 through step 4 if the engine fails to Prevent sparks near the batteries. Sparks could
start. cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
Note: After starting, the engine may be held at low
speed for a duration between 1 and 25 seconds to If the installation is not equipped with a backup
allow engine systems to stabilize. The duration will battery system, then start the engine from an external
depend on ambient temperature, time since last run electrical source.
and other factors. The glow plug warning lamp will For information on troubleshooting the charging
flash in order to indicate that the engine is been held system, refer to Special Instruction, REHS0354,
at low speed. “Charging System Troubleshooting”.
6. The engine should not be “raced” in order to speed Many batteries which are considered unusable are
up the warm-up process. Allow the engine to idle still rechargeable. After jump starting, the alternator
for 3 to 5 minutes, or allow the engine to idle until may not be able to fully recharge batteries that are
the water temperature indicator begins to rise. severely discharged. The batteries must be charged
When idling after the engine has started in cold to the proper voltage with a battery charger. For
information on testing and charging, refer to the
weather, increase the engine rpm from 1000 to Special Instruction, SEHS7633, “Battery Test
1200 rpm. This procedure will warm up the engine Procedure”.
more quickly.
SEBU8600-04 61
Operation Section
After Starting Engine

i02330138
NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for After Starting Engine
jump starting. The use of higher voltage will damage SMCS Code: 1000
the electrical system.
Do not reverse the battery cables. The alternator can Note: In ambient temperatures from 0 to 60°C
be damaged. Attach ground cable last and remove (32 to 140°F), the warm-up time is approximately
first. three minutes. In temperatures below 0°C (32°F),
additional warm-up time may be required.
When using an external electrical source to start the
engine, turn the generator set control switch to the When the engine idles during warm-up, observe the
“OFF” position. Turn all electrical accessories OFF following conditions:
before attaching the jump start cables.
Do not check the high pressure fuel lines with the
Ensure that the main power switch is in the OFF posi- engine or the starting motor in operation. If you
tion before attaching the jump start cables to the en- inspect the engine in operation, always use the
gine being started. proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
1. Turn the start switch on the stalled engine to the
OFF position. Turn off all the engines accessories. • Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
2. Connect one positive end of the jump-start cable to before operating the engine under load. This is not
the positive cable terminal of the discharged possible in some applications.
battery. Connect the other positive end of the
jump-start cable to the positive cable terminal of • Allow the engine to idle for three to five minutes, or
the electrical source. allow the engine to idle until the water temperature
indicator begins to rise. Check all gauges during
3. Connect one negative end of the jump-start cable the warm-up period.
to the negative cable terminal of the electrical
source. Connect the other negative end of the Note: Gauge readings should be observed and the
jump-start cable to the engine block or to the data should be recorded frequently while the engine
is operating. Comparing the data over time will help
chassis ground. This procedure helps to prevent
to determine normal readings for each gauge.
potential sparks from igniting the combustible Comparing data over time will also help detect
gases that are produced by some batteries. abnormal operating developments. Significant
changes in the readings should be investigated.
Note: The engine ECM must be powered before the
starting motor is operated or damage can occur.

4. Start the engine in the normal operating

procedure. Refer to this Operation and
Maintenance Manual, “Starting the Engine”.
5. Immediately after the engine is started, disconnect
the jump-start cables in reverse order.
After jump starting, the alternator may not be ableto
fully recharge batteries that are severely discharged.
The batteries must be replaced or charged to the
proper voltage with a battery charger after the engine
is stopped. Many batteries which are considered
unusable are still rechargeable. Refer to Operation
and Maintenance Manual, “Battery - Replace” and
Testing and Adjusting Manual, “Battery - Test”.
Refer to the Electrical Schematic for your engine.
Consult your Caterpillar dealer for more information.
62 SEBU8600-04
Operation Section
Engine Operation

Engine Operation raise the temperature of the exhaust gas. When the
regeneration process is complete, the ARD turns off.

i04156659
The operator will receive information on the status of
the ARD from dash lamps and the driver will be able
Engine Operation to request a regeneration by using a switch. Refer to
SMCS Code: 1000 this Operation and Maintenance Manual, “Monitoring
System” for more information.
Proper operation and maintenance are key factors in
obtaining the maximum life and economy of the Engine Operation and Active
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be Regeneration
minimized and engine service life can be maximized.
Your ARD may perform an active regeneration while
The time that is needed for the engine to reach your engine is at idle. During this active regeneration
normal operating temperature can be less than the of the DPF, the engine may operate at idle for periods
time taken for a walk-around inspection of the longer than 5 minutes.
engine.
The engine can be operated at the rated rpm after i04945862
the engine is started and after the engine reaches
operating temperature. The engine will reach normal Diesel Particulate Filter
operating temperature sooner during a low engine
speed (rpm) and during a low-power demand. This Regeneration
procedure is more effective than idling the engine at SMCS Code: 108F
no load. The engine should reach operating
temperature in a few minutes.
Regeneration
Avoid excess idling. Excessive idling causes carbon
buildup, engine slobber and soot loading of the Regeneration is the removal of soot from the Diesel
Diesel Particulate Filter (DPF). This is harmful to the Particulate Filter (DPF). The Caterpillar Regeneration
engine. System (CRS) is used to regenerate the DPF. The
DPF traps both soot and ash. The ash is removed
Gauge readings should be observed and the data through a cleaning process. Refer to Operation and
should be recorded frequently while the engine is Maintenance Manual, “Diesel Particulate Filter -
operating. Comparing the data over time will help to Clean/Replace” for more information on the service
determine normal readings for each gauge. of the DPF.
Comparing data over time will also help detect
abnormal operating developments. Significant Regeneration Indicators
changes in the readings should be investigated.
Regeneration Active – This indicator will
Reduction of Particulate Emissions illuminate in order to show that the CRS
is active. This indicator shows that
The Diesel Particulate Filter (DPF) and the elevated emission temperatures are possible.
Aftertreatment Regeneration Device (ARD) work
This indicator will turn off when regeneration is
together in order to reduce particulate emissions. The
DPF collects the soot and any ash that is produced complete.
by the combustion in the engine. During
DPF – This indicator will illuminate in
regeneration, the soot is converted into a gas which
is released into the atmosphere. The Ash remains in order to show that a regeneration is
the DPF until the ash is cleaned out of the DPF. needed. This indicator will illuminate
when the soot level reaches 90%.
The temperature of the DPF must be above a
particular value in order for regeneration to occur. Regeneration Disabled – This indicator
The exhaust gas provides heat for the regeneration will illuminate in order to show that a
process. There are two types of regeneration: regeneration has been disabled.
Passive Regeneration – Is a chemical reaction
within the system and the engine provides sufficient Regeneration Switch
exhaust gas temperature for regeneration.
Force Regeneration – Press in the top of
Active Regeneration – The engines duty cycle does the switch for 2 seconds in order to
not provide sufficient exhaust temperature for begin regeneration.
passive regeneration. The ARD operates in order to
SEBU8600-04 63
Operation Section
Diesel Particulate Filter Regeneration

Disable Regeneration – Press in the Note: Automatic adjustments of engine speed may
bottom of the switch for 2 seconds in be noticed during automatic regenerations. If a
order to disable regeneration. regeneration is taking place and the engine is taken
to low idle, the engine speed may remain elevated in
Note: The MIDDLE position of the regeneration order to maintain the regeneration.
switch is the default position for automatic
regeneration. Note: If an automatic regeneration is started while
the engine is at low idle and the application is taken
Note: You may return to normal operation at any back to work, this may stop the regeneration. The
point during a regeneration. engine ECM will continue to monitor inputs to
determine the best time to restart the regeneration.
Note: To re-enable automatic regeneration, cycle the
engine start switch key or press and hold down the Manual: A manual regeneration is initiated by
force regeneration switch for 2 seconds. If the soot pressing the force regeneration switch. A manual
level is above 15%, regeneration will begin if the regeneration is allowed when the soot level is equal
application is at low idle and the engine interlocks are to or greater than 15%. The application must be
enabled. stationary, the engine interlocks must be applied, and
the engine must be at low idle in order to perform a
Note: If the engine start switch key is cycled while manual regeneration.
the regeneration system is disabled through the
disable regeneration switch, press and hold the Disabled: When the regeneration system is in
disable regeneration switch for 2 seconds to reinitiate disabled mode, automatic regenerations will not be
the disable regeneration. performed.

Soot Level Monitoring Regeneration System Warning

Indicators

Illustration 40 g02228033
Illustration 41 g02117258
The soot level monitor indicates the level of soot that
has accumulated within the DPF. The five marks on Indicator will illuminate when DPF soot load is
the monitor represent a percentage of soot within the greater than 90%
DPF. The first mark indicates 0% soot level. The
second mark indicates 25% soot level. The middle Regeneration should be performed as soon as
mark indicates 50% soot level. The fourth mark possible. The operation of the application may
indicates 75% soot level. The last mark indicates not allow an automatic regeneration to take
100% soot level. The soot level monitor can be used
to optimize DPF regenerations based upon the work place. A manual regeneration should be
cycle of your application. If application conditions do performed as soon as possible.
not allow for an automatic regeneration, a manual
regeneration should be performed before the soot Indicator will turn off once DPF regeneration has
level gauge indicates 100%. started.
Note: In some situations, the DPF indicator may stay
Modes of Regeneration illuminated when the soot load is below 90%. The
illuminated DPF indicator indicates that a complete
Automatic: The engine ECM uses multiple inputs regeneration has not been performed. A complete
from the engine and the application to determine the regeneration is when the soot level is reduced to 0%.
best time to perform an automatic regeneration. If the DPF indicator stays illuminated, perform a
Automatic regenerations can take place throughout regeneration without interruption until the soot level is
the operating cycle of the engine. The regeneration reduced to 0%. A complete regeneration will reset
active indicator will be illuminated when a the DPF indicator.
regeneration is being performed. Interruptions of the
regeneration are acceptable. If a regeneration is in
progress and needs to be stopped for any reason, it
is permissible to press the disable regeneration
switch or turn off the engine.
64 SEBU8600-04
Operation Section
Engaging the Driven Equipment

Finally, if the engine is still allowed to run through

multiple forced engine shutdowns, all types of
regenerations are locked out. The DPF must be
replaced. Consult your local Caterpillar dealer if the
DPF needs to be replaced.

i01646335

Illustration 42 g02117259 Engaging the Driven

If the amount of soot collected in the DPF has
Equipment
reached a level that a regeneration is required, the SMCS Code: 1000
DPF indicator and an action lamp will illuminate. Stop
the application and apply the engine interlocks. With 1. Operate the engine at one-half of the rated rpm,
the engine at low idle, initiate a manual regeneration.
when possible.
Engine power will be slightly derated if the application
continues to operate. 2. Engage the driven equipment without a load on the
equipment, when possible.
Interrupted starts put excessive stress on the drive
train. Interrupted starts also waste fuel. To get the
driven equipment in motion, engage the clutch
smoothly with no load on the equipment. This
method should produce a start that is smooth and
easy. The engine rpm should not increase and the
Illustration 43 g02117261 clutch should not slip.
After a certain period, if no action is taken to 3. Ensure that the ranges of the gauges are normal
regenerate an action alarm will activate. After 5 when the engine is operating at one-half of the
minutes with the action alarm active, the engine will rated rpm. Ensure that all gauges operate
automatically be taken to low idle. properly.
A manual regeneration is required at this time. A 4. Increase the engine rpm to the rated rpm. Always
complete regeneration will unlock the forced low idle increase the engine rpm to the rated rpm before
speed. Cycling the engine start switch key will unlock
the forced low idle speed. the load is applied.
5. Apply the load. Begin operating the engine at low
Once the engine has been in the forced low idle
strategy for approximately 10 minutes, regeneration load. Check the gauges and equipment for proper
will be locked out. At this time, a regeneration can operation. After normal oil pressure is reached and
only be done through the electronic service tool, by the temperature gauge begins to move, the engine
an authorized Caterpillar dealer. may be operated at full load. Check the gauges
and equipment frequently when the engine is
After a certain amount of time, engine will
automatically shut down. Engine can be restarted but operated under load.
will only run for 30 seconds before shutting down Extended operation at low idle or at reduced load
again.
may cause increased oil consumption and carbon
buildup in the cylinders. This carbon buildup
results in a loss of power and/or poor
performance.
SEBU8600-04 65
Operation Section
Fuel Conservation Practices

i04018250

Fuel Conservation Practices

SMCS Code: 1000; 1250
The efficiency of the engine can affect the fuel
economy. Caterpillar's design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
in order to attain optimum performance for the life of
the engine.
• Avoid spilling fuel.
Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
• Be aware of the properties of the different fuels.
Use only the recommended fuels. Refer to the
Operations and Maintenance Manual, “Fuel
Recommendations”for further information.
• Avoid unnecessary idling.
Shut off the engine rather than idle for long periods of
time.

• Observe the service indicator frequently. Keep the

air cleaner elements clean.

• Ensure that the turbocharger is operating

correctly. For more information refer to this
Operation and Maintenance Manual,
“Turbocharger - Inspect”.
• Maintain a good electrical system.
One faulty battery cell will overwork the alternator.
This fault will consume excess power and excess
fuel.
• The belt should be in good condition. Refer to the
Systems Operation, Testing and Adjusting, “V -
Belt Test” for further information.
• Ensure that all of the connections of the hoses are
tight. The connections should not leak.
• Ensure that the driven equipment is in good
working order.

• Cold engines consume excess fuel. Utilize heat

from the jacket water system and the exhaust
system, when possible. Keep cooling system
components clean and keep cooling system
components in good repair. Never operate the
engine without water temperature regulators. All of
these items will help maintain operating
temperatures.
66 SEBU8600-04
Operation Section
Engine Stopping

Engine Stopping Emergency Stop Button

i06832774

Stopping the Engine

SMCS Code: 1000; 7000

NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and ac-
celerated wear of the engine components.
Avoid accelerating the engine prior to shutting it
down.
Avoiding hot engine shutdowns will maximize turbo-
charger shaft and bearing life. Illustration 44 g00104303
Typical emergency stop button
Note: Individual applications will have different The emergency stop button is in the OUT position for
control systems. Ensure that the shutoff procedures normal engine operation. Push the emergency stop
are understood. Use the following general guidelines button. The engine will not start when the button is
to stop the engine. locked. Turn the button clockwise in order to reset.
1. Remove the load from the engine. Reduce the Refer to Operation and Maintenance Manual,
engine speed (rpm) to low idle. Allow the engine to “Features and Controls” for the location and the
operation of the emergency stop button.
idle for 5 minutes to cool the engine.
2. Stop the engine after the cool down period i05784249
according to the shutoff system on the engine.
Turn the ignition key switch to the OFF position. If After Stopping Engine
necessary, refer to the instructions that are SMCS Code: 1000
provided by the OEM.
Note: Before you check the engine oil, do not
NOTICE operate the engine for at least 10 minutes. This
Before any service or repairs are performed, ensure period will allow the engine oil to return to the oil pan.
that the power supply to the engine is disconnected.

i03554860
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
Emergency Stopping spray may cause a fire hazard. Failure to follow
SMCS Code: 1000; 7418 these inspection, maintenance and service in-
structions may cause personal injury or death.
NOTICE
Emergency shutoff controls are for EMERGENCY • After the engine has stopped, you must wait for 10
use ONLY. DO NOT use emergency shutoff devices minutes in order to allow the fuel pressure to be
or controls for normal stopping procedure. purged from the high-pressure fuel lines before
Ensure that any components for the external system any service or repair is performed on the engine
that support the engine operation are secured after fuel lines. The 10 minute wait will also allow static
the engine is stopped. charge to dissipate from the low-pressure fuel
system. If necessary, perform minor adjustments.
Repair any leaks from the low-pressure fuel
system and from the cooling, lubrication, or air
systems. Replace any high-pressure fuel line that
has leaked. Refer to Disassembly and assembly
Manual, “Fuel Injection Lines - Install”.
SEBU8600-04 67
Operation Section
After Stopping Engine

• Check the crankcase oil level. Maintain the oil

level between the “MIN” mark and the “MAX” mark
on the engine oil level gauge.

• If the engine is equipped with a service hour

meter, note the reading. Perform the maintenance
that is in the Operation and Maintenance Manual,
“Maintenance Interval Schedule”.
• Fill the fuel tank, in order to help prevent
accumulation of moisture in the fuel. Do not overfill
the fuel tank.

NOTICE
Only use antifreeze/coolant mixtures recommended
in this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” topic or in this
Operation and Maintenance Manual, “Fluid Recom-
mendations” topic. Failure to do so can cause engine
damage.

Pressurized System: Hot coolant can cause seri-

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

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

• Check the coolant for correct antifreeze protection
and the correct corrosion protection. Add the
correct coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.
68 SEBU8600-04
Operation Section
Cold Weather Operation

Cold Weather Operation • The cooling system and the lubrication system for
the engine do not lose heat immediately upon
shutdown. This means that an engine can be shut
i05774855 down for a period and the engine can still start
readily.
Cold Weather Operation
• Install the correct specification and grade of
SMCS Code: 1000; 1250 engine lubricant before the beginning of cold
Caterpillar Diesel Engines can operate effectively in weather.
cold weather. During cold weather, the starting and
the operation of the diesel engine is dependent on • Check all rubber parts (hoses, fan drive belts)
the following items: weekly.

• The type of fuel that is used • Check all electrical wiring and connections for any
fraying or damaged insulation.
• The viscosity of the engine oil
• Keep all batteries fully charged and warm.
• The operation of the glow plugs
• Fill the fuel tank at the end of each shift.
• Optional Cold starting aid
• Drain the water from the fuel system. Refer to this
• Battery condition Operation and Maintenance Manual, “Fuel System
Primary Filter/Water Separator - Drain”.
• Ambient air temperature
• Check the air cleaners and the air intake daily.
Refer to Special Publication, SEBU5898, “Cold Check the air intake more often when you operate
Weather Recommendations for Caterpillar in snow.
Machines”.
• Ensure that the glow plugs are in working order.
This section will cover the following information: Refer to Troubleshooting , “Glow Plug Starting Aid
• Potential problems that are caused by cold- - Test”.
weather operation
• Suggest steps which can be taken in order to
minimize starting problems and operating Personal injury or property damage can result
problems when the ambient air temperature is from alcohol or starting fluids.
between “0° to −40 °C (32° to -40 °F)”.
Alcohol or starting fluids are highly flammable
The operation and maintenance of an engine in and toxic and if improperly stored could result in
freezing temperatures is complex . This complexity is injury or property damage.
because of the following conditions:
• Weather conditions
• Engine applications Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
Recommendations from your Cat dealer are based personal injury.
on past proven practices. The information that is
contained in this section provides guidelines for cold-
weather operation.
• For jump starting with cables in cold weather, refer
to the Operation and Maintenance Manual,
Hints for Cold Weather Operation “Starting with Jump Start Cables.” for instructions.
• After starting the engine, the engine speed will be
governed for up to a maximum of 25 seconds.
Viscosity of the Engine Lubrication
After this period, the engine should be operated at Oil
low loads until a minimum operating temperature
of 80° C (176° F) is achieved Correct engine oil viscosity is essential. Oil viscosity
affects the amount of torque that is needed to crank
• Achieving operating temperature will help prevent the engine. Refer to this Operation and Maintenance
the intake valves and exhaust valves from Manual, “Fluid Recommendations” for the
sticking. recommended viscosity of oil.
SEBU8600-04 69
Operation Section
Cold Weather Operation

At temperatures below −10° C (14° F) damage to When the engine is operated below normal operating
engine components can occur if the engine is temperatures, fuel and oil are not burned completely
allowed to operate at high load and speed in the combustion chamber. This fuel and oil causes
immediately after starting. soft carbon deposits to form on the valve stems.
Generally, the deposits do not cause problems and
the deposits are burned off during operation at
Recommendations for the Coolant normal engine operating temperatures.
Provide cooling system protection for the lowest When the engine is started and the engine is stopped
expected outside temperature. Refer to this many times without being operated in order to warm
Operation and Maintenance Manual, “Fluid up completely, the carbon deposits become thicker.
Recommendations” for the recommended coolant This carbon can cause the following problems:
mixture.
In cold weather, check the coolant often for the • Free operation of the valves is prevented.
correct glycol concentration in order to ensure
adequate freeze protection. • Valves become stuck.
• Pushrods may become bent.
Engine Block Heaters
• Other damage to valve train components can
Engine block heaters (if equipped) heat the engine result.
jacket water that surrounds the combustion
chambers. This heat provides the following functions: For these reasons, when the engine is started, the
engine must be operated until the coolant
• Startability is improved. temperature is 80° C (176° F) minimum. Carbon
deposits on the valve stems will be kept at a
• Warm up time is reduced. minimum. The free operation of the valves and the
valve components will be maintained.
An electric block heater can be activated once the
engine is stopped. A block heater can be 110V dc or The engine must be warmed thoroughly in order to
240V dc. The output can be 750/1000W. Consult keep other engine parts in better condition. Also, the
your Cat dealer for more information. service life of the engine will be generally extended.
Lubrication will be improved. There will be less acid
Idling the Engine and less sludge in the oil. This improvement will
provide longer service life for the engine bearings,
After starting the engine, the engine speed will be the piston rings, and other parts. However, limit
governed for a maximum period of 25 seconds. unnecessary idle time to 10 minutes in order to
When idling after the engine is started in cold reduce wear and unnecessary fuel consumption.
weather, increase the engine rpm from 1000 to 1200
rpm. This increase in RPM will warm up the engine The Water Temperature Regulator and
more quickly. Maintaining an elevated low idle speed Insulated Heater Lines
for extended periods will be easier with the
installation of a hand throttle. The engine should not The engine is equipped with a water temperature
be “raced” in order to speed up the warm-up process. regulator. When the engine coolant is below the
correct operating temperature, jacket water circulates
While the engine is idling, the application of a light through the engine cylinder block and into the engine
load (parasitic load) will assist in achieving the cylinder head. The coolant then returns to the
minimum operating temperature. The minimum cylinder block via an internal passage that bypasses
operating temperature is 80° C (176° F). the valve of the coolant temperature regulator. This
coolant return circuit ensures that coolant flows
Recommendations for Coolant around the engine under cold operating conditions.
The water temperature regulator begins to open
Warm Up when the engine jacket water has reached the
correct minimum operating temperature. As the
Warm up an engine that has cooled below normal jacket water coolant temperature rises above the
operating temperatures due to inactivity. This minimum operating temperature the water
procedure should be performed before the engine is temperature regulator opens further allowing more
returned to full operation. During operation in very coolant through the radiator to dissipate excess heat.
cold temperature conditions, damage to engine valve
mechanisms can result from engine operation for The progressive opening of the water temperature
short intervals. This damage can happen if the regulator operates the progressive closing of the
engine is started and the engine is stopped many bypass passage between the cylinder block and
times without being operated in order to warm up head. This process ensures maximum coolant flow to
completely. the radiator in order to achieve maximum heat
dissipation.
70 SEBU8600-04
Operation Section
Radiator Restrictions

Note: Do not restrict the air flow. Restriction to the air Reducing air flow over components will also affect
flow can damage the fuel system. Caterpillar strongly under hood temperatures. Reducing air flow can
discourages the use of all air flow restriction devices increase surface temperatures during an
such as radiator shutters. Restriction of the air flow aftertreatment regeneration and could affect
can result in the following: high exhaust component reliability.
temperatures, power loss, excessive fan usage and
Reducing air flow can increase surface temperatures
reduction in fuel economy.
during an aftertreatment regeneration and could
A cab heater is beneficial in very cold weather. The affect component reliability.
feed from the engine and the return lines from the
If an airflow restriction device must be used, the
cab should be insulated in order to reduce heat loss device should have a permanent opening directly in
to the outside air.
line with the fan hub. The device must have a
minimum opening dimension of at least 770 cm2
Insulating the Air Inlet and Engine (120 in2).
Compartment
A centered opening that is directly in line with the fan
When temperatures below −18 °C (−0 °F) will be hub is specified in order to prevent an interrupted
frequently encountered, an air cleaner inlet that is airflow on the fan blades. Interrupted airflow on the
located in the engine compartment may be specified. fan blades could cause a fan failure.
An air cleaner that is located in the engine
compartment may also minimize the entry of snow i08230315
into the air cleaner. Also, heat that is rejected by the
engine helps to warm the intake air. Fuel and the Effect from Cold
Additional heat can be retained around the engine by Weather
insulating the engine compartment. SMCS Code: 1000; 1250
Recommendation for Crankcase The following fuels are the grades that are available
Breather Protection for Cat engines:

Crankcase ventilation gases contain a large quantity • No. 1

of water vapor. This water vapor can freeze in cold
ambient conditions and can plug or damage the • No. 2
crankcase ventilation system. If the engine is
operated in temperatures below −25° C (−13° F), • Blend of No. 1 and No. 2
measures must be taken to prevent freezing and No. 2 diesel fuel is the most commonly used fuel.
plugging of the breather system. Insulated hoses and Either No. 1 diesel fuel or a blend of No. 1 and No. 2
a heated canister assembly should be installed. is best suited for cold-weather operation.
Consult with your Cat dealer for the recommended Quantities of No. 1 diesel fuel are limited. No. 1
breather components for operation from diesel fuels are available during the months of the
−25° to -40°C (−13° to -40.°F). winter in the colder climates. During cold-weather
operation, if No. 1 diesel fuel is not available, use No.
i05966861 2 diesel fuel, if necessary.
There are three major differences between No. 1 and
Radiator Restrictions No. 2 diesel fuel. No. 1 diesel fuel has the following
SMCS Code: 1353; 1396 properties:

Caterpillar discourages the use of airflow restriction • Lower cloud point

devices that are mounted in front of radiators. Airflow
restriction can cause the following conditions: • Lower pour point

• High exhaust temperatures • Lower rating of kJ (BTU) per unit volume of fuel

• Power loss When No. 1 diesel fuel is used, a decrease in power

and in fuel efficiency may be noticed.
• Excessive fan usage
The cloud point is the temperature when a cloud of
• Reduction in fuel economy wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is the
temperature when diesel fuel will thicken. The diesel
fuel becomes more resistant to flow through fuel
pumps and through fuel lines.
SEBU8600-04 71
Operation Section
Fuel Related Components in Cold Weather

Be aware of these values when diesel fuel is Drain the water and sediment from any fuel storage
purchased. Anticipate the average ambient tank at the following intervals: weekly, service
temperature of the area. Engines that are fueled in intervals and refueling of the fuel tank. This
one climate may not operate well if the engines are procedure will help prevent water and/or sediment
moved to another climate. Problems can result due to from being pumped from the fuel storage tank and
changes in temperature. into the engine fuel tank.
Before troubleshooting for low power or for poor
performance in the winter, check the type of fuel that Fuel Filters
is being used.
After you change the fuel filter, always prime the fuel
When No. 2 diesel fuel is used, the following system in order to remove air bubbles from the fuel
components provide a means of minimizing problems system. Refer to the Operation and Maintenance
in cold weather: Manual in the Maintenance Section for more
information on priming the fuel system.
• Starting aids
The micron rating and the location of a primary fuel
• Engine oil pan heaters filter is important in cold-weather operation. The In-
line filter, primary fuel filter, and the fuel supply line
• Engine coolant heaters are the most common components that are affected
by cold fuel.
• Fuel heaters
NOTICE
• Fuel line insulation In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a
For more information on cold-weather operation, see four micron[c] absolute high efficiency fuel filter is re-
Special Publication, SEBU5898, “Cold-Weather quired for all Caterpillar Electronic Unit Injectors. Cat-
Recommendations”. erpillar High Efficiency Fuel Filters meet these
requirements. Consult your Cat dealer for the proper
i05354369 part numbers.

Fuel Related Components in

Cold Weather Fuel Heaters
SMCS Code: 1000; 1250 Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in the fuel system before the electric fuel
Fuel Tanks pump.
Condensation can form in partially filled fuel tanks. For further information on fuel heaters, consult your
Top off the fuel tanks after you operate the engine. Cat dealer.
Fuel tanks should contain some provision for draining
water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.
Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.
72 SEBU8600-04
Maintenance Section
Refill Capacities

Maintenance Section Consult your Caterpillar dealer for part numbers and
for available sizes of containers.

Note: Cat DEO-ULS in SAE 15W-40 passes the

Refill Capacities following proprietary tests: sticking of the piston ring,
oil control tests, wear tests and soot tests.
Proprietary tests help ensure that Caterpillar
i04251329
multigrade oil provides superior performance in
Caterpillar Diesel Engines. In addition, Cat DEO-ULS
Refill Capacities and Multigrade oil exceeds many of the performance
Recommendations requirements of other manufacturers of diesel
engines. Therefore, this oil is an excellent choice for
SMCS Code: 1348; 1395; 7560 many mixed fleets. True high performance oil is
produced with a combination of the following
Engine Oil factors: industry standard tests, proprietary
tests, field tests and prior experience with similar
formulations. The design and the development of
NOTICE Caterpillar lubricants that are both high
These recommendations are subject to change with-
out notice. Contact your local Caterpillar dealer for performance and high quality are based on these
the most up-to-date fluids recommendations. factors.

Commercial Oils
• EMA Engine Manufacturers Association
Note: Non-Caterpillar commercial oils are second
• API American Petroleum Institute choice oils.
• SAE Society Of Automotive Engineers Inc.
NOTICE
• DEO-ULS Diesel Engine Oil-Ultra Low Caterpillar require the use of the following specifica-
Sulfur tion of engine oil. Failure to use the appropriate spec-
ification of engine oil will reduce the life of your
engine. Failure to use the correct specification of en-
Cat DEO-ULS gine will also reduce the life and the effectiveness of
Cat DEO-ULS is developed and tested in order to your aftertreatment system.
provide superior protection and life for your
Caterpillar engines. Table 6
API Classifications for the Industrial Engine
• Better Detergents
Oil Specification
• Advanced Additive Package
ECF-3
• Enhanced Dispersants CJ-4
AECA E9
• Improved Protection from Thermal breakdown and
Oxidation Breakdown
NOTICE
Due to significant variations in the quality and in the Failure to follow these oil recommendations can
performance of commercially available oils, cause shortened engine service life due to deposits
Caterpillar makes the following recommendations: and/or excessive wear.

• Cat DEO-ULS (SAE 10W-30)

Note: Refer to Special Publication, SEBU6251,
• Cat DEO-ULS (SAE 15W-40) “Caterpillar Commercial Diesel Engine Fluids
Recommendations” for additional information that
Cat DEO-ULS Multigrade oil is available in various relates to lubrication for your engine.
viscosity grades that include SAE 10W-30 and SAE
15W-40. To choose the correct viscosity grade for the
ambient temperature, see illustration 45 . Multigrade
Lubricant Viscosity Recommendations
oils provide the correct viscosity for a broad range of
operating temperatures. Multigrade oils are also The proper SAE viscosity grade of oil is determined
effective in maintaining low oil consumption and low by the minimum ambient temperature during cold
levels of piston deposits. engine start-up, and the maximum ambient
temperature during engine operation.
SEBU8600-04 73
Maintenance Section
Refill Capacities and Recommendations

Refer to illustration 45 (minimum temperature) in The wear analysis monitors metal particles, some oil
order to determine the required oil viscosity for additives, and some contaminants.
starting a cold engine.
Oil condition uses infrared (IR) analysis to evaluate
Refer to illustration 45 (maximum temperature) in the chemistry of the oil. Infrared analysis is also used
order to select the oil viscosity for engine operation at to detect certain types of contamination.
the highest ambient temperature that is anticipated.
Additional tests are used to measure contamination
Note: Generally, use the highest oil viscosity that is levels from water, fuel, or coolant. Oil viscosity and
available to meet the requirement for the temperature corrosion protection can be evaluated, as needed.
at start-up. Refer to Special Publication, SEBU6251, “Caterpillar
If ambient temperature conditions at engine start-up Commercial Diesel Engine Fluids
require the use of multigrade SAE 0W oil, SAE 0W- Recommendations” or contact your local Caterpillar
40 viscosity grade is preferred over SAE 0W-20 or dealer for additional information concerning the
SAE 0W-30. S·O·S Oil Analysis program.

Lubrication System
The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will
require additional oil. Refer to the OEM specifications
in order to find the capacity of the auxiliary oil filter.
Table 7
Engine
Refill Capacities

Compartment or Minimum Maximum

System

Crankcase Oil Sump 13.5 L (14.3 qt) 16.5 L (17.4 qt)

(1)

(1) These values are the approximate capacities for the crankcase
oil sump (aluminum) which includes the standard factory in-
stalled oil filters. Engines with auxiliary oil filters will require ad-
ditional oil. Refer to the OEM specifications for the capacity of
the auxiliary oil filter. The design of the oil pan can change the
oil capacity of the oil pan.
Illustration 45 g01918619
Supplemental heat is recommended for cold soaked Lubricating Grease
starts below the minimum ambient temperature.
Supplemental heat may be required for cold soaked Caterpillar provides a range of moderate greases to
starts that are above the minimum temperature that extremely high performance greases in order to
is stated, depending on the parasitic load and other service the entire line of Caterpillar products that
factors. Cold soaked starts occur when the engine operate throughout the wide variety of climates. You
has not been operated for a period of time. This will will always be able to find a grease that will meet your
allow the oil to become more viscous due to cooler machines requirements for a certain application.
ambient temperatures. Caterpillar grease products often exceed Caterpillar
specifications.
S·O·S Oil Analysis
Before selecting a grease products for any
Caterpillar has developed a tool for maintenance application, the performance requirements must be
management that evaluates oil degradation and the determined. Consult the grease recommendations
tool also detects the early signs of wear on internal that are made by the OEM for the equipment when
components. The Caterpillar tool for oil analysis is the equipment is operated in the expected
called S·O·S Oil Analysis and the tool is part of the conditions. Then, consult with your Caterpillar dealer
S·O·S Services program. S·O·S Oil Analysis divides for a list of greases and the following related
oil analysis into three categories: characteristics.

• Wear Analysis • Performance specifications

• Oil condition • Available sizes of containers

• Additional tests • Part numbers

74 SEBU8600-04
Maintenance Section
Refill Capacities and Recommendations

Always choose a grease that meets the Fuel tank inlet labels are installed in order to ensure
recommendations that are specified by the that the correct fuels are used. Illustration 46 is an
equipment manufacturer for the application, or example of one of the labels designs that will be
choose a grease that exceeds the recommendations installed.
that are specified by the equipment manufacturer for
the application.
If it is necessary to choose a single grease for use on
all of the equipment at one site, always choose a
grease that meets the requirements of the most
demanding application. A product that barely meets
the minimum performance requirements will shorten
the life of the part. Use the grease that yields the
least total operating cost. Base this cost on an
analysis that includes the costs of the parts, the
labor, the downtime, and the cost of the grease that is
used.
Some greases are not chemically compatible.
Consult your supplier in order to determine if two or
more greases are compatible. Illustration 46 g02157153
Typical example
Purge the grease from a joint at the following times:

• Switching from one grease to another grease Fuel Additives

• Switching from one supplier to another supplier Many types of fuel additives are available. Caterpillar
does not generally recommend the use of fuel
Note: All Caterpillar brand name greases are additives.
compatible with each other.
In special circumstances, Caterpillar recognizes the
Note: Refer to Special Publication, SEBU6251, need for fuel additives. Fuel additives need to be
“Caterpillar Commercial Diesel Engine Fluids used with caution. The additive may not be
Recommendations” for additional information that compatible with the fuel. Some additives may
precipitate. This action causes deposits in the fuel
relates to lubrication for your engine.
system. The deposits may cause seizure. Some
additives may be corrosive and some additives may
Fuel be harmful to the elastomers in the fuel system.
Refer to Special Publication, SEBU6251, “Caterpillar Some additives may damage emission control
Commercial Diesel Engine Fluids systems. Some additives may cause the amount of
Recommendations” for the Caterpillar Specification sulfur in the fuel to be greater than 15 ppm.
for distillate fuel and for additional information that
relates to fuel for your engine. Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier
Ultra low Sulfur Diesel (ULSD) can recommend the best additives for your
application and for the proper level of treatment.
Your Caterpillar Diesel Engine must use ultra low
sulfur diesel fuel. This fuel complies with the Note: For the best results, your fuel supplier should
emissions regulations that are prescribed by the treat the fuel when additives are necessary.
Environmental Protection Agency of the United
States.
Coolant
Engines that are manufactured by Caterpillar are
certified with the fuel that is prescribed by the United The following two coolants are used in Caterpillar
States Environmental Protection Agency. Engines diesel engines:
that are manufactured by Caterpillar are certified with
the fuel that is prescribed by the European Preferred – Cat ELC (Extended Life Coolant) or a
Certification. Caterpillar does not certify diesel commercial extended life coolant that meets the
engines on any other fuel. Caterpillar EC-1 specification

Note: The owner and the operator of the engine has Acceptable – A Cat DEAC (Diesel Engine
the responsibility of using the fuel that is prescribed Antifreeze/Coolant) or a commercial heavy-duty
by the United States Environmental Protection antifreeze that meets “ASTM D6210” specifications
Agency and other appropriate regulatory agencies.
SEBU8600-04 75
Maintenance Section
Refill Capacities and Recommendations

Note: Refer to Special Publication, SEBU6251,

NOTICE
The Caterpillar industrial engine must be oper- “Caterpillar Commercial Diesel Engine Fluids
ated with a 1:1 mixture of water and glycol. This Recommendations” for additional information that
concentration allows the NOx reduction system relates to coolant for your engine.
to operate correctly at high ambient
temperatures. S·O·S Coolant Analysis
Table 9
NOTICE
Do not use a commercial coolant/antifreeze that only Recommended Interval
meets the ASTM “D3306” or equivalent specification.
This type of coolant/antifreeze is made for light duty Type of
Level 1 Level 2
automotive applications. Coolant
Use only the coolant/antifreeze that is recommended. DEAC Every 250 Hours (1) Yearly(1)

ELC Optional (1) Yearly

Caterpillar recommends a 1:1 mixture of water and (1) The Level 2 Coolant Analysis should be performed sooner if a
glycol. This mixture of water and glycol will provide problem is identified by a Level 1 Coolant Analysis.
optimum heavy-duty performance as an antifreeze.
S·O·S Coolant Analysis (Level 1)
Note: Cat DEAC does not require a treatment with an
SCA at the initial fill. Commercial heavy-duty A coolant analysis (Level 1) is a test of the properties
antifreeze that meets “ASTM D6210” specifications of the coolant.
MAY require a treatment with an SCA at the initial fill.
Read the label or the instructions that are provided by The following properties of the coolant are tested:
the OEM of the product. • Glycol concentration for freeze protection and boil
In stationary engine applications that do not require protection
anti-boil protection or freeze protection, a mixture of
SCA and water is acceptable. Caterpillar • Ability to protect from erosion and corrosion
recommends a 6 percent to 8 percent concentration
of SCA in those cooling systems. Distilled water or • pH
deionized water is preferred. Water which has the
• Conductivity
recommended properties may be used.
Table 8 • Visual analysis
Coolant Service Life
• Odor analysis
Coolant Type Service Life (1)
The results are reported, and appropriate
12000 Service Hours or Six recommendations are made.
Cat ELC
Years(2)
Refer to the Maintenance Interval Schedule in this
Commercial coolant that Operation and Maintenance Manual in order to find
6000 Service Hours or Six Years
meets the Caterpillar EC-1 (3) the maintenance interval for collecting the coolant
Specification samples.
3000 Service Hours or Three
Cat DEAC S·O·S Coolant Analysis (Level 2)
Years
Commercial Heavy-Duty Cool- A coolant analysis (Level 2) is a comprehensive
ant/Antifreeze that meets 3000 Service Hours or Two Years chemical evaluation of the coolant. This analysis is
“ASTM D6210” also a check of the overall condition of the inside of
(1)
the cooling system.
Use the interval that occurs first. The cooling system must also
be flushed out at this time.
(2) Cat ELC Extender must be added at 6000 service hours or one
The S·O·S Coolant Analysis has the following
half of the service life of the Cat ELC. Refer to your machine features:
Operation and Maintenance Manual for exceptions.
(3) An extender must be added at 3000 service hours or one half • Full coolant analysis (Level 1)
of the service life of the coolant.
• Identification of the source of metal corrosion and
of contaminants

• Water hardness
76 SEBU8600-04
Maintenance Section
Refill Capacities and Recommendations

• Identification of buildup of the impurities that

cause corrosion

• Identification of buildup of the impurities that

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

Refill Capacity
Table 10
Engine
Refill Capacities

Compartment or System Liters

15 L
Engine Only
(3.96 US gal)

External System Per OEM(1)

(1) The External System includes a radiator or an expansion tank
with the following components: heat exchanger and piping. Re-
fer to the OEM specifications. Enter the value for the capacity
of the External System in this row.
SEBU8600-04 77
Maintenance Section
Maintenance Recommendations

Maintenance • The high-pressure fuel lines are constantly

charged with high pressure.
Recommendations • The internal pressures of the high-pressure fuel
lines are higher than other types of fuel system.
i07819420
Before any service or repair is performed on the
System Pressure Release engine fuel lines, perform the following tasks:
SMCS Code: 1250; 1300; 1350; 5050 1. Stop the engine.
2. Wait for 10 minutes.
Coolant System
Do not loosen the high-pressure fuel lines to remove
air from the fuel system.

Pressurized system: Hot coolant can cause seri- Engine Oil

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve To relieve pressure from the lubricating system, turn
the pressure. off the engine.

i05611259

Welding on Engines with

When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid person- Electronic Controls
al injury, always remain clear of the the engine SMCS Code: 1000
when the engine is in the AUTOMATIC mode.

The engine can have the ability to auto start. Ensure NOTICE
that the power supply is isolated before any service Because the strength of the frame may decrease,
or repair is performed. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your 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 in order to
avoid damage to the engines ECM, sensors, and
associated components. When possible, remove the
Fuel System component from the unit and then weld the
component. If removal of the component is not
To relieve the pressure from the fuel system, turn off possible, the following procedure must be followed
the engine. when you weld on a unit equipped with an Electronic
Engine. The following procedure is considered to be
High-Pressure Fuel Lines the safest procedure to weld on a component. This
procedure should provide a minimum risk of damage
to electronic components.

NOTICE
Contact with high pressure fuel may cause fluid Do not ground the welder to electrical components
penetration and burn hazards. High pressure fuel such as the ECM or sensors. Improper grounding
spray may cause a fire hazard. Failure to follow can cause damage to the drive train bearings, hy-
these inspection, maintenance and service in- draulic components, electrical components, and oth-
structions may cause personal injury or death. er components.
The high-pressure fuel lines are the fuel lines that are Clamp the ground cable from the welder to the com-
between the high-pressure fuel pump and the high- ponent that will be welded. Place the clamp as close
pressure fuel manifold and the fuel lines that are as possible to the weld. This will help reduce the pos-
between the fuel manifold and the fuel injectors. sibility of damage.
The high-pressure fuel lines are different from fuel
lines on other fuel systems, the differences are as Note: Perform the welding in areas that are free from
follows: explosive hazards.
78 SEBU8600-04
Maintenance Section
Welding on Engines with Electronic Controls

1. Stop the engine. Turn the switched power to the

OFF position.
2. Ensure that the fuel supply to the engine is turned
off.
3. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
open the switch.
4. Disconnect all electronic components from the
wiring harnesses. Include the following
components:

• Electronic components for the driven

equipment

• ECM

• Sensors

• Electronically controlled valves

• Relays

• Electric fuel pump

• Aftertreatment ID module

• Diesel exhaust fluid pump controller

Illustration 47 g01075639
Use the example above. The current flow from the
NOTICE welder to the ground clamp of the welder will not
Do not use electrical components (ECM or ECM sen- damage any associated components.
sors) or electronic component grounding points for
(1) Engine
grounding the welder. (2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being
welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder

5. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to the
following components. Bearings, hydraulic
components, electrical components, and ground
straps.

Note: If electrical/electronic components are used as

a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.

6. Protect the wiring harness from welding debris and

spatter.
SEBU8600-04 79
Maintenance Section
Welding on Engines with Electronic Controls

7. Use standard welding practices to weld the

materials.
80 SEBU8600-04
Maintenance Section
Maintenance Interval Schedule

i08315712 “ Fuel Filter (In-Line) - Replace“ . . . . . . . . . . . . . . 109

Maintenance Interval Schedule Every 500 Service Hours or 1 Year

SMCS Code: 1000; 7500
“ Battery Electrolyte Level - Check“ . . . . . . . . . . . . 84
When Required “ Cooling System Supplemental Coolant Additive
(SCA) - Test/Add“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
“ Battery - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 83
“ Crankshaft Vibration Damper - Inspect“ . . . . . . . . 94
“ Battery or Battery Cable - Disconnect“ . . . . . . . . . 84
“ Engine Air Cleaner Element (Dual Element) - Clean/
“ Engine - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

“ Engine Air Cleaner Element (Dual Element) - Clean/ “ Engine Air Cleaner Element (Single Element) -
Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Inspect/Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

“ Engine Air Cleaner Element (Single Element) - “ Engine Air Cleaner Element (Single Element) -
Inspect/Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

“ Engine Air Cleaner Element (Single Element) - “ Engine Oil and Filter - Change“. . . . . . . . . . . . . . 105
Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
“ Fuel System Primary Filter (Water Separator)
“ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . 110 Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . .111

“ Severe Service Application - Check“ . . . . . . . . . 120 “ Fuel System Secondary Filter - Replace“. . . . . . 113
“ Radiator - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . 119
Daily
“ Cooling System Coolant Level - Check“. . . . . . . . 91 Every 1000 Service Hours
“ Driven Equipment - Check“ . . . . . . . . . . . . . . . . . . 95 “ Alternator - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . 83

“ Engine Air Cleaner Service Indicator - Inspect“ . . 99 “ Belt Tensioner - Inspect“ . . . . . . . . . . . . . . . . . . . . 85

“ Engine Air Precleaner - Check/Clean“ . . . . . . . . 100 “ Water Pump - Inspect“. . . . . . . . . . . . . . . . . . . . . 124

“ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . 104 Every 1500 Service Hours

“ Fuel System Primary Filter/Water Separator -
Drain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 “ Engine Crankcase Breather Element -
Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
“ Walk-Around Inspection“ . . . . . . . . . . . . . . . . . . . 123
Every 2000 Service Hours
Every Week
“ Aftercooler Core - Inspect“ . . . . . . . . . . . . . . . . . . 82
“ Hoses and Clamps - Inspect/Replace“. . . . . . . . 116
“ Engine Mounts - Inspect“ . . . . . . . . . . . . . . . . . . 104
Every 50 Service Hours or Weekly “ Starting Motor - Inspect“ . . . . . . . . . . . . . . . . . . . 121
“ Fuel Tank Water and Sediment - Drain“ . . . . . . . 115 “ Turbocharger - Inspect“ . . . . . . . . . . . . . . . . . . . . 121

Every 250 Service Hours Every Year

“ Cooling System Coolant Sample (Level 1) - “ Cooling System Coolant Sample (Level 2) -
Obtain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Obtain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
“ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . 105
Every 3000 Service Hours
Every 500 Service Hours “ Alternator and Fan Belts - Replace“ . . . . . . . . . . . 83
“ Belt - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
“ Fan Clearance - Check“ . . . . . . . . . . . . . . . . . . . 108
SEBU8600-04 81
Maintenance Section
Maintenance Interval Schedule

“ Radiator Pressure Cap - Clean/Replace“. . . . . . 120

Every 3000 Service Hours or 2

Years
“ Cooling System Coolant (DEAC) - Change“ . . . . 85

Every 4000 Service Hours

“ Aftercooler Core - Clean/Test“ . . . . . . . . . . . . . . . 82

Every 4500 Service Hours

“ ARD Spark Plug - Clean/Inspect/Replace“ . . . . . 82

Every 5000 Service Hours

“ Diesel Particulate Filter - Clean“ . . . . . . . . . . . . . . 94

Every 6000 Service Hours or 3

Years
“ Cooling System Coolant Extender (ELC) -
Add“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Every 12 000 Service Hours or 6

Years
“ Cooling System Coolant (ELC) - Change“ . . . . . . 88

Overhaul
“ Overhaul Considerations“ . . . . . . . . . . . . . . . . . . 117

Commissioning
“ Fan Clearance - Check“ . . . . . . . . . . . . . . . . . . . 108
82 SEBU8600-04
Maintenance Section
ARD Spark Plug - Clean/Inspect/Replace

i03907823

ARD Spark Plug - Clean/

Inspect/Replace
SMCS Code: 1555-070; 1555-040; 1555-510

• ARD Aftertreatment Regeneration Device

NOTICE
If the engine is running, or the keyswitch is in the ON
position the ARD spark plug will continue to fire. Turn
the keyswitch to the OFF position before servicing
the ARD spark plug.

Illustration 49 g02148769

3. Use 305-2389 Plug Bore Brush in order to clean

the ground electrode (3).
4. Install the new spark plug by hand. Tighten the
spark plug to a torque of 47 N·m (34 lb ft).
5. Connect the wiring harness (2).

i01807350

Aftercooler Core - Clean/Test

(Air-To-Air Aftercooler)
SMCS Code: 1064-070; 1064-081
Illustration 48 g01947378
The air-to-air aftercooler is OEM installed in many
1. Ensure that the power is in the “OFF” position and applications. Please refer to the OEM specifications
the engine has stopped. Remove any dirt or debris for information that is related to the aftercooler.
from the area around the spark plug. Remove wire
i04380914
harness (2) from spark plug (1).
2. Use a 342-9516 Socket in order to remove the Aftercooler Core - Inspect
spark plug. Loosen the spark plug and use the
SMCS Code: 1064-040
socket to remove the spark plug by hand in order
to detect problems with the threads. Discard the Note: Adjust the frequency of cleaning according to
spark plug. the effects of the operating environment.
Inspect the aftercooler for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the aftercooler, if necessary.
For air-to-air aftercoolers, use the same methods that
are used for cleaning radiators.
SEBU8600-04 83
Maintenance Section
Alternator - Inspect

Check the alternator and the battery charger for

proper operation. If the batteries are properly
Personal injury can result from air pressure. charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
Personal injury can result without following prop- batteries should be kept warm because temperature
er procedure. When using pressure air, wear a affects the cranking power of the battery. If the
protective face shield and protective clothing. battery is too cold, the battery will not crank the
engine.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes. When the engine is not run for long periods of time or
if the engine is run for short periods, the batteries
may not fully charge. A battery with a low charge will
Pressurized air is the preferred method for removing freeze more easily than a battery with a full charge.
loose debris. Direct the air in the opposite direction of
the fans air flow. Hold the nozzle approximately 6 mm i02320208
(.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes. Alternator and Fan Belts -
The pressurized air will remove debris that is
between the tubes. Replace
Pressurized water may also be used for cleaning. SMCS Code: 1357-510
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized Refer to Disassembly and Assembly Manual , “
water in order to soften mud. Clean the core from Alternator Belt - Remove and Install”.
both sides.
i03559623
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the Battery - Replace
core with clean water. SMCS Code: 1401-510
After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine. Use
a light bulb behind the core in order to inspect the Batteries give off combustible gases which can
core for cleanliness. Repeat the cleaning, if explode. A spark can cause the combustible
necessary. gases to ignite. This can result in severe personal
injury or death.
Inspect the fins for damage. Bent fins may be opened
with a “comb”. Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
Note: If parts of the aftercooler system are repaired der to help prevent electrical arcs and/or sparks
or replaced, a leak test is highly recommended. For near batteries. Do not smoke when batteries are
more information, refer to OEM specification for the serviced.
aftercooler.
Inspect these items for good condition: welds,
mounting brackets, air lines, connections, clamps
and seals. Make repairs, if necessary.
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
i03641972 tery cover should be removed before any servic-
ing is attempted.
Alternator - Inspect
Removing the battery cables or the batteries with
SMCS Code: 1405-040 the cover in place may cause a battery explosion
resulting in personal injury.
Caterpillar recommends a scheduled inspection of
the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the 1. Switch the engine to the OFF position. Remove all
ammeter (if equipped) during engine operation in electrical loads.
order to ensure proper battery performance and/or
proper performance of the electrical system. Make 2. Turn off any battery chargers. Disconnect any
repairs, as required. battery chargers.
3. Ensure that the battery disconnect switch is in the
OFF position.
84 SEBU8600-04
Maintenance Section
Battery Electrolyte Level - Check

4. Disconnect the NEGATIVE “-” cable from the • Use a solution of 0.1 kg (0.2 lb) baking soda
NEGATIVE “-” battery terminal. and 1 L (1 qt) of clean water.
5. Disconnect the POSITIVE “+” cable from the • Use a solution of ammonium hydroxide.
POSITIVE “+” battery terminal.
Thoroughly rinse the battery case with clean
Note: Always recycle a battery. Never discard a water.
battery. Dispose of used batteries to an appropriate
recycling facility. Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
6. Remove the used battery. until the surfaces are bright or shiny. DO NOT
7. Install the new battery. remove material excessively. Excessive removal
of material can cause the clamps to not fit
Note: Before the cables are connected, ensure that properly. Coat the clamps and the terminals with
the battery disconnect switch is in the OFF position. 5N-5561 Silicone Lubricant, petroleum jelly or
MPGM.
8. Connect the POSITIVE “+” cable to the POSITIVE
“+” battery terminal. i07819485
9. Connect the NEGATIVE “-” cable to the
NEGATIVE “-” battery terminal. Battery or Battery Cable -
10. Turn the battery disconnect switch to the ON Disconnect
position. SMCS Code: 1402-029

i02724529

Battery Electrolyte Level - The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
Check tery cover should be removed before any servic-
SMCS Code: 1401-535 ing is attempted.

When the engine is not run for long periods of time or Removing the battery cables or the batteries with
when the engine is run for short periods, the batteries the cover in place may cause a battery explosion
may not fully recharge. Ensure a full charge in order resulting in personal injury.
to help prevent the battery from freezing. If batteries
are properly charged, ammeter reading should be
very near zero,when the engine is in operation. 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.
2. Disconnect the negative battery terminal. Ensure
All lead-acid batteries contain sulfuric acid which that the cable cannot contact the terminal. When
can burn the skin and clothing. Always wear a
four 12 volt batteries are involved, two negative
face shield and protective clothing when working
on or near batteries. connection must be disconnected.
3. Remove the positive connection.
1. Remove the filler caps. Maintain the electrolyte 4. Clean all disconnected connection and battery
level to the “FULL” mark on the battery. terminals.
If the addition of water is necessary, use distilled 5. Use a fine grade of sandpaper to clean the
water. If distilled water is not available use clean terminals and the cable clamps. Clean the items
water that is low in minerals. Do not use artificially until the surfaces are bright or shiny. DO NOT
softened water. remove material excessively. Excessive removal
2. Check the condition of the electrolyte with the of material can cause the clamps to not fit
245-5829 Coolant Battery Tester Refractometer. correctly. Coat the clamps and the terminals with a
suitable silicone lubricant or petroleum jelly.
3. Keep the batteries clean.
6. Tape the cable connections to help prevent
Clean the battery case with one of the following accidental starting.
cleaning solutions:
7. Proceed with necessary system repairs.
SEBU8600-04 85
Maintenance Section
Belt - Inspect

8. To connect the battery, connect the positive i03557440

connection before the negative connection.
Belt Tensioner - Inspect
i03973719
SMCS Code: 1358-040
Belt - Inspect
SMCS Code: 1357; 1357-040; 1397; 1397-040

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

Illustration 51 g01880953
Typical example

Remove the belt. Refer to Disassembly and

Assembly, “Alternator Belt - Remove and Install”.
Ensure that the belt tensioner is securely installed.
Visually inspect the belt tensioner (1) for damage.
Illustration 50 g01906354
Check that the pulley on the tensioner rotates freely
and that the bearing is not loose. Some engines have
Typical example a idler pulley (2). Ensure that the idler pulley is
securely installed. Visually inspect the idler pulley for
To maximize the engine performance, inspect the damage. Ensure that the idler pulley can rotate freely
belt (1) for wear and for cracking. Replace the belt if and that the bearing is not loose. If necessary,
the belt is worn or damaged. replace damaged components.
• Inspect the belt for cracks, splits, glazing, grease, Install the belt. Refer to Disassembly and Assembly,
displacement of the cord and evidence of fluid “Alternator Belt - Remove and Install”.
contamination.
i04155953
The belt must be replaced if the following conditions
are present.
Cooling System Coolant
• The belt has a crack in more than one rib.
(DEAC) - Change
• More than one section of the belt is displaced in SMCS Code: 1350-070; 1395-044
one rib of a maximum length of 50.8 mm (2 inch).
Clean the cooling system and flush the cooling
To replace the belt, refer to Disassembly and system before the recommended maintenance
Assembly, “Alternator Belt - Remove and Install”. If interval if the following conditions exist:
necessary, replace the belt tensioner. Refer to
Disassembly and Assembly, “Alternator Belt - • The engine overheats frequently.
Remove and Install” for the correct procedure.
• Foaming is observed.
86 SEBU8600-04
Maintenance Section
Cooling System Coolant (DEAC) - Change

• The oil has entered the cooling system and the

coolant is contaminated.

• The fuel has entered the cooling system and the

coolant is contaminated.

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

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

Note: Inspect the water pump and the water

Illustration 52 g02350782
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace Typical example
the water pump, the water temperature regulator, and
the hoses, if necessary.

Drain

Pressurized System: Hot coolant can cause seri-

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

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

Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
Containing Fluid Spillage.
Illustration 53 g02350785
Typical example

2. Open the drain cock or remove the drain plug (1)

on the engine. Also remove the drain plug (2).
Open the drain cock or remove the drain plug on
the radiator.
Allow the coolant to drain into a suitable container.
3. Properly dispose of the drained material. Obey
local regulations for the disposal of the material.
SEBU8600-04 87
Maintenance Section
Cooling System Coolant (DEAC) - Change

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

NOTICE
Dispose of used engine coolant properly or recycle. Loosen the cooling system filler cap slowly in
Various methods have been proposed to reclaim order to relieve any pressure. Remove the cooling
used coolant for reuse in engine cooling systems. system filler cap. Open the drain valve (if
The full distillation procedure is the only method ac- equipped) or remove the cooling system drain
ceptable by Caterpillar to reclaim the used coolant. plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
Flush plugs. Refer to Torque Specifications, SENR3130
for more information on the correct torques.
1. Flush the cooling system with clean water in order
to remove any debris.
Cooling Systems with Heavy
2. Close the drain valve (if equipped). Clean the drain Deposits or Plugging
plugs. Install the drain plugs. Refer to Torque
Specifications, SENR3130 for more information on Note: For the following procedure to be effective,
the correct torques. there must be some active flow through the cooling
system components.
NOTICE
Do not fill the cooling system faster than 5 L 1. Flush the cooling system with clean water in order
(1.3 US gal) per minute to avoid air locks. to remove any debris.
Cooling system air locks may result in engine 2. Close the drain valve (if equipped). Clean the drain
damage. plugs. Install the drain plugs. Refer to Torque
Specifications, SENR3130 for more information on
3. Fill the cooling system with a mixture of clean the correct torques.
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L NOTICE
Do not fill the cooling system faster than 5 L
(4 US gal) of the cooling system capacity. Install (1.3 US gal) per minute to avoid air locks.
the cooling system filler cap.
Cooling system air locks may result in engine
4. Start and run the engine at low idle for a minimum damage.
of 30 minutes. The coolant temperature should be
at least 82 °C (180 °F).
3. Fill the cooling system with a mixture of clean
NOTICE water and Caterpillar Fast Acting Cooling System
Improper or incomplete rinsing of the cooling system Cleaner. Add 0.5 L (1 pint) of cleaner per
can result in damage to copper and other metal 3.8 to 7.6 L (1 to 2 US gal) of the cooling system
components. capacity. Install the cooling system filler cap.
To avoid damage to the cooling system, make sure to 4. Start and run the engine at low idle for a minimum
completely flush the cooling system with clear water. of 90 minutes. The coolant temperature should be
Continue to flush the system until all signs of the
cleaning agent are gone. at least 82 °C (180 °F).

NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal
components.
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water.
Continue to flush the system until all signs of the
cleaning agent are gone.
88 SEBU8600-04
Maintenance Section
Cooling System Coolant (ELC) - Change

5. Stop the engine and allow the engine to cool. 5. Start the engine. Inspect the cooling system for
Loosen the cooling system filler cap slowly in leaks and for the correct operating temperature.
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if i04155958
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling Cooling System Coolant (ELC)
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
- Change
plugs. Refer to Torque Specifications, SENR3130 SMCS Code: 1350-070; 1395-044
for more information on the correct torques. Clean the cooling system and flush the cooling
system before the recommended maintenance
Fill interval if the following conditions exist:

• The engine overheats frequently.

NOTICE
Do not fill the cooling system faster than 5 L • Foaming is observed.
(1.3 US gal) per minute to avoid air locks.
• The oil has entered the cooling system and the
Cooling system air locks may result in engine coolant is contaminated.
damage.
• The fuel has entered the cooling system and the
1. Fill the cooling system with the coolant/antifreeze. coolant is contaminated.
Refer to this Operation and Maintenance Manual, Note: When the cooling system is cleaned, only
“Refill Capacities and Recommendations” topic clean water is needed when the ELC is drained and
(Maintenance Section) for more information on replaced.
cooling system specifications. Do not install the
cooling system filler cap. Note: Inspect the water pump and the water
temperature regulator after the cooling system has
2. Start and run the engine at low idle. Increase the been drained. Replace the water pump, the water
engine rpm to high idle. Operate the engine in temperature regulator, and the hoses, if necessary.
order to open the engine thermostat. This will
allow any air in the system to be purged. Decrease NOTICE
the engine speed to low idle. Stop the engine. Service or repair of the engine cooling system must
be performed on level ground. The engine must be
3. Maintain the coolant level at the maximum mark level in order to check the coolant level. The engine
that is correct for your application. must be level in order to avoid the risk of introducing
an air lock into the coolant system.
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap is
damaged, discard the old cooling system filler cap
Drain
and install a new cooling system filler cap. If the
gasket that is on the cooling system filler cap is not
damaged, perform a pressure test. A 9S-8140 Pressurized System: Hot coolant can cause seri-
Pressurizing Pump is used to perform the ous burns. To open the cooling system filler cap,
pressure test. The correct pressure for the cooling stop the engine and wait until the cooling system
system filler cap is stamped on the face of the components are cool. Loosen the cooling system
cooling system filler cap. If the cooling system filler pressure cap slowly in order to relieve the
pressure.
cap does not retain the correct pressure, install a
new cooling system filler cap.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
SEBU8600-04 89
Maintenance Section
Cooling System Coolant (ELC) - Change

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

For information regarding the disposal and the

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

Flush
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the drain
plugs. Install the drain plugs. Refer to Torque
Specifications, SENR3130 for more information on
the correct torques.
Illustration 54 g02350782
NOTICE
Typical example Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine
damage.

3. Fill the cooling system with clean water. Install the

cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
plugs. Refer to Torque Specifications, SENR3130
for more information on the correct torques.

Illustration 55 g02350785 Fill

Typical example
NOTICE
2. Open the drain cock or remove the drain plug (1) Do not fill the cooling system faster than 5 L
on the engine. Also remove the drain plug (2). (1.3 US gal) per minute to avoid air locks.
Open the drain cock or remove the drain plug on
the radiator. Cooling system air locks may result in engine
damage.
Allow the coolant to drain.
90 SEBU8600-04
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

1. Fill the cooling system with Extended Life Coolant

(ELC). Refer to this Operation and Maintenance
Manual, “Refill Capacities and Recommendations” Personal injury can result from hot coolant,
topic (Maintenance Section) for more information steam and alkali.
on cooling system specifications. Do not install the
At operating temperature, engine coolant is hot
cooling system filler cap. and under pressure. The radiator and all lines to
2. Start and run the engine at low idle. Increase the heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
engine rpm to high idle. Operate the engine in
order to open the engine thermostat. An open Remove cooling system pressure cap slowly to
thermostat will allow any air in the system to be relieve pressure only when engine is stopped and
purged. Decrease the engine speed to low idle. cooling system pressure cap is cool enough to
Stop the engine. touch with your bare hand.

3. Maintain the coolant level at the maximum mark Do not attempt to tighten hose connections when
that is correct for your application. the coolant is hot, the hose can come off causing
burns.
4. Clean the cooling system filler cap. Inspect the
Cooling System Coolant Additive contains alkali.
gasket that is on the cooling system filler cap. If Avoid contact with skin and eyes.
the gasket that is on the cooling system filler cap is
damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the NOTICE
gasket that is on the cooling system filler cap is not Care must be taken to ensure that fluids are con-
damaged, use a 9S-8140 Pressurizing Pump in tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
order to pressure test the cooling system filler cap.
Be prepared to collect the fluid with suitable contain-
The correct pressure for the cooling system filler ers before opening any compartment or disassem-
cap is stamped on the face of the cooling system bling any component containing fluids.
filler cap. If the cooling system filler cap does not
retain the correct pressure, install a new cooling Refer to Cat Hand Tools and Shop Supplies for suit-
system filler cap. able contains use on Cat products.

5. Start the engine. Inspect the cooling system for Dispose of all fluids according to local regulations
leaks and for proper operating temperature. and mandates.

i04403146
NOTICE
When any servicing or repair of the engine cooling
Cooling System Coolant system is performed, the procedure must be per-
formed with the engine on level ground. This proce-
Extender (ELC) - Add dure will allow you to check accurately the coolant
SMCS Code: 1352-045; 1395-081 level. This procedure will also help in avoiding the risk
of introducing an air lock into the coolant system.
Cat ELC (Extended Life Coolant) does not require
the frequent additions of any supplemental cooling
additives which are associated with the present 1. Loosen the cooling system filler cap slowly in order
conventional coolants. The Cat ELC Extender only to relieve pressure. Remove the cooling system
needs adding once. filler cap.

NOTICE 2. If necessary, drain enough coolant from the

Use only Cat Extended Life Coolant (ELC) Extender cooling system in order to add the Cat ELC
with Cat ELC. Extender.
Do NOT use conventional supplemental coolant addi- 3. Add Cat ELC Extender according to the
tive (SCA) with Cat ELC. Mixing Cat ELC with con- requirements for your engines cooling system
ventional coolants and/or conventional SCA reduces capacity. Refer to the Operation and Maintenance
the Cat ELC service life.
Manual, “Refill Capacities and Recommendations”
article for more information.
Check the cooling system only when the engine is
stopped and cool.
SEBU8600-04 91
Maintenance Section
Cooling System Coolant Level - Check

4. Clean the cooling system filler cap. Inspect the

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

i04403158

Cooling System Coolant Level

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

Illustration 57 g02590196
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.
Illustration 56 g00285520
4. Inspect the cooling system for leaks.
Cooling system filler cap
i04035949

Cooling System Coolant

Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, Sample (Level 1) - Obtain
stop the engine and wait until the cooling system SMCS Code: 1350-008; 1395-008; 1395-554; 7542
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure. Note: Obtaining a Coolant Sample (Level 1) is
optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems
NOTICE filled with Cat ELC should have a Coolant Sample
When any servicing or repair of the engine cooling (Level 2) that is obtained at the recommended
system is performed, the procedure must be per- interval as stated in the maintenance interval
formed with the engine on level ground. This proce- schedule.
dure will allow you to check accurately the coolant
level. This procedure will also help in avoiding the risk Note: Obtain a Coolant Sample (Level 1) if the
of introducing an air lock into the coolant system. cooling system is filled with any other coolant
instead of Cat ELC including the following
coolants:
1. Remove the cooling system filler cap slowly in
order to relieve pressure. • Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
2. Maintain the coolant level at the maximum mark (Caterpillar EC-1)
that is correct for your application. If the engine is
equipped with a sight glass, maintain the coolant • Cat DEAC (Diesel Engine Antifreeze/Coolant)
level to the correct level in the sight glass.
• Commercial heavy-duty coolant/antifreeze
92 SEBU8600-04
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

Table 11
Recommended Interval • Never collect samples from the drain for a system.
Type of Coolant Level 1 Level 2
Submit the sample for Level 1 analysis.
Cat DEAC
For additional information about coolant analysis, see
Conventional heavy this Operation and Maintenance Manual, “Refill
duty-coolant Capacities and Recommendations” or consult your
Every 250 service Caterpillar dealer.
Commercial coolant Every year(1)
hours
that meets the re-
quirements of the i08258445
Caterpillar EC-1
standard Cooling System Coolant
Cat ELC or conven-
tional EC-1 coolant
Optional Every year(1) Sample (Level 2) - Obtain
(1) The Level 2 Coolant Analysis should be performed sooner if a SMCS Code: 1350-008; 1395-554; 1395-008; 7542
problem is suspected or identified.
NOTICE
NOTICE Always use a designated pump for oil sampling, and
Always use a designated pump for oil sampling, and use a separate designated pump for coolant sam-
use a separate designated pump for coolant sam- pling. Using the same pump for both types of sam-
pling. Using the same pump for both types of sam- ples may contaminate the samples that are being
ples may contaminate the samples that are being drawn. This contaminate may cause a false analysis
drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to con-
and an incorrect interpretation that could lead to con- cerns by both dealers and customers.
cerns by both dealers and customers.

NOTICE
Note: Level 1 results may indicate a need for Care must be taken to ensure that fluids are con-
Level 2 Analysis. tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Obtain the sample of the coolant as close as possible Be prepared to collect the fluid with suitable contain-
to the recommended sampling interval. In order to ers before opening any compartment or disassem-
receive the full effect of S·O·S analysis, establish a bling any component containing fluids.
consistent trend of data. In order to establish a
pertinent history of data, perform consistent Refer to Special Publication, NENG2500, “Cat Dealer
samplings that are evenly spaced. Supplies for Service Tool Catalog” or refer to Special Publication,
collecting samples can be obtained from your PECJ0003, “Cat Shop Supplies and Tools Catalog”
Caterpillar dealer. for tools and supplies suitable to collect and contain
fluids on Cat products.
Use the following guidelines for proper sampling of
the coolant: Dispose of all fluids according to local regulations
and mandates.
• Complete the information on the label for the
sampling bottle before you begin to take the Refer to Operation and Maintenance Manual,
samples. “Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.
• Keep the unused sampling bottles stored in plastic
bags. Submit the sample for Level 2 analysis.

• Obtain coolant samples directly from the coolant For additional information about coolant analysis, see
Special Publication, SEBU6251, “Caterpillar
sample port. You should not obtain the samples Commercial Diesel Engines Fluids
from any other location. Recommendations” or consult your Cat dealer.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample.
• Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
contamination.

• Never collect samples from expansion bottles.

SEBU8600-04 93
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i03644817 • pH

Cooling System Supplemental • Conductivity

Coolant Additive (SCA) - Test/ The results are reported, and recommendations are
made according to the results. Consult your
Add Caterpillar dealer for information on the benefits of
SMCS Code: 1352-045; 1395-081 managing your equipment with an S·O·S Coolant
Analysis.

Level 2
Cooling system coolant additive contains alkali. This level coolant analysis is recommended when the
To help prevent personal injury, avoid contact engine is overhauled. Refer to this Operations and
with the skin and the eyes. Do not drink cooling Maintenance Manual, “Overhaul Considerations” for
system coolant additive. further information.

Note: Test the concentration of the Supplemental

Add the SCA, If Necessary
Coolant Additive (SCA) or test the SCA concentration
as part of an S·O·S Coolant Analysis. NOTICE
Do not exceed the recommended amount of supple-
mental coolant additive concentration. Excessive
Test for SCA Concentration supplemental coolant additive concentration can form
deposits on the higher temperature surfaces of the
Coolant and SCA cooling system, reducing the engine's heat transfer
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high tempera-
NOTICE ture components. Excessive supplemental coolant
Do not exceed the recommended six percent supple- additive concentration could also result in radiator
mental coolant additive concentration. tube blockage, overheating, and/or accelerated water
pump seal wear. Never use both liquid supplemental
Use the 8T-5296 Coolant Conditioner Test Kit or coolant additive and the spin-on element (if
use the 4C-9301 Coolant Conditioner Test Kit in equipped) at the same time. The use of those addi-
order to check the concentration of the SCA. Refer to tives together could result in supplemental coolant
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” for more additive concentration exceeding the recommended
information. maximum.

Water and SCA

NOTICE Pressurized System: Hot coolant can cause seri-

Do not exceed the recommended eight percent sup- ous burns. To open the cooling system filler cap,
plemental coolant additive concentration. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
Test the concentration of the SCA with the 8T-5296 pressure cap slowly in order to relieve the
Coolant Conditioner Test Kit. Refer to the Special pressure.
Publication, SEBU6251, “Caterpillar Commercial
Diesel Engine Fluids Recommendations” for more
information.
NOTICE
When any servicing or repair of the engine cooling
S·O·S Coolant Analysis system is performed the procedure must be per-
formed with the engine on level ground. This will al-
S·O·S coolant samples can be analyzed at your low you to accurately check the coolant level. This
Caterpillar dealer. S·O·S Coolant Analysis is a will also help in avoiding the risk of introducing an air
program that is based on periodic samples. lock into the coolant system.

Level 1 1. Slowly loosen the cooling system filler cap in order

Level 1 is a basic analysis of the coolant. The to relieve the pressure. Remove the cooling
following items are tested: system filler cap.

• Glycol Concentration Note: Always discard drained fluids according to

local regulations.
• Concentration of SCA
94 SEBU8600-04
Maintenance Section
Crankshaft Vibration Damper - Inspect

2. If necessary, drain some coolant from the cooling For information on removal of the crankshaft damper,
system into a suitable container in order to allow refer to Disassembly and Assembly, “Vibration
space for the extra SCA. Damper and Pulley - Remove and Install”.

3. Add the proper amount of SCA. Refer to the i04083930

Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engines Fluids Diesel Particulate Filter - Clean
Recommendations” for more information on SCA
SMCS Code: 108F-070
requirements.
4. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling Wear goggles, gloves, protective clothing, and a
system filler cap with a new cooling system filler National Institute for Occupational Safety and
cap. Install the cooling system filler cap. Health (NIOSH) approved P95 or N95 half-face
respirator when handling a used Diesel Particu-
late Filter or Catalytic Converter Muffler. Failure
i03634651 to do so could result in personal injury.

Crankshaft Vibration Damper -

Inspect
SMCS Code: 1205-040 The muffler, catalytic converter/muffler, and die-
sel particulate filter will become extremely hot
Viscous Damper during engine operation. A hot muffler, catalytic
converter/muffler and diesel particulate filter can
The viscous damper has a inertia weight that is cause serious burns. Allow adequate cooling
located inside a fluid filled case. The inertia weight time before working on or near the muffler, cata-
moves in the case in order to limit torsional vibration. lytic converter/muffler and diesel particulate
filter.
Visually inspect the crankshaft damper. Ensure that
the cooling fins (1) on the crankshaft damper are
clean and free from dirt.

Illustration 59 g01949226
Typical example
Illustration 58 g01950241
Typical example • DPF Diesel Particulate Filter

Inspect the damper and replace the damper for any

of the following reasons:
• The damper is dented, cracked, or leaking.
SEBU8600-04 95
Maintenance Section
Driven Equipment - Check

Note: Caterpillar recommends the use of the

NOTICE
Caterpillar ash service tool. Caterpillar does not Accumulated grease and oil on an engine is a fire
endorse the use of non-Caterpillar ash service tools. hazard. Keep the engine clean. Remove debris and
Improper cleaning or repair of the DPF can damage fluid spills whenever a significant quantity accumu-
the DPF and the engine aftertreatment system. lates on the engine.
Contact your Caterpillar dealer for more information.
Periodic cleaning of the engine is recommended.
Before the DPF can be removed for cleaning, you Steam cleaning the engine will remove accumulated
must perform a service regeneration in order to oil and grease. A clean engine provides the following
remove the soot from the DPF. The DPF will need to benefits:
cool before removal. New torca clamps (1) must be
installed on the DPF. • Easy detection of fluid leaks
For information on removal of the DPF, refer to • Maximum heat transfer characteristics
Disassembly and Assembly, “DPF - Remove”. Also,
refer to System Operation Testing and Adjusting,
• Ease of maintenance
“Diesel Particulate Filter- Clean”.
Only ultra low sufur diesel fuel can be used in an Note: Caution must be used in order to prevent
application that has an engine aftertreatment system. electrical components from being damaged by
The use of other fuel will damage your engine excessive water when the engine is cleaned.
system. Pressure washers and steam cleaners should not be
directed at any electrical connectors or the junction of
Caterpillar recommend the use of Cat DEO-ULS cables into the rear of the connectors. Avoid
engine oil. electrical components such as the alternator, the
starter, and the ECM. Protect the fuel injection pump
i00174798 from fluids in order to wash the engine.

Driven Equipment - Check Aftertreatment System

SMCS Code: 3279-535
During the engine cleaning process, ensure that
Refer to the OEM specifications for more information water or cleaning fluids cannot enter the
on the following maintenance recommendations for aftertreatment system. If cleaning fluids enters the
the driven equipment: aftertreatment system, damage could occur.

• Inspection i04404720

• Adjustment
Engine Air Cleaner Element
• Lubrication (Dual Element) - Clean/Replace
• Other maintenance recommendations SMCS Code: 1054-510; 1054-037
Perform any maintenance for the driven equipment
which is recommended by the OEM. NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
i04947820
cleaner element. Do not use air cleaner elements
with damaged pleats, gaskets or seals. Dirt entering
Engine - Clean the engine causes premature wear and damage to
engine components. Air cleaner elements help to pre-
SMCS Code: 1000-070 vent airborne debris from entering the air inlet.

NOTICE
Personal injury or death can result from high Never service the air cleaner element with the engine
voltage. running since this will allow dirt to enter the engine.
Moisture can create paths of electrical
conductivity.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “ DO
NOT OPERATE”” .
96 SEBU8600-04
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

Servicing the Air Cleaner Elements

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

• Check the precleaner (if equipped) daily for

accumulation of dirt and debris. Remove any dirt
and debris, as needed.
• Operating conditions (dust, dirt, and debris) may
require more frequent service of the air cleaner
Illustration 60 g00736431
element.
(1) Cover
• The air cleaner element may be cleaned up to six (2) Primary air cleaner element
(3) Secondary air cleaner element
times if the element is properly cleaned and (4) Turbocharger air inlet
inspected.
• The air cleaner element should be replaced at 1. Remove the cover. Remove the primary air cleaner
least one time per year. This replacement should element.
be performed regardless of the number of 2. The secondary air cleaner element should be
cleanings.
removed and discarded for every three cleanings
Replace the dirty paper air cleaner elements with of the primary air cleaner element.
clean air cleaner elements. Before installation, the air
cleaner elements should be thoroughly checked for Note: Refer to “Cleaning the Primary Air Cleaner
tears and/or holes in the filter material. Inspect the Elements”.
gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner 3. Cover the turbocharger air inlet with tape in order
elements for replacement purposes. to keep out dirt.

Dual Element Air Cleaners 4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner 5. Remove the tape for the turbocharger air inlet.
element. The primary air cleaner element can be Install the secondary air cleaner element. Install a
used up to six times if the element is properly primary air cleaner element that is new or cleaned.
cleaned and inspected. The primary air cleaner
element should be replaced at least one time per 6. Install the air cleaner cover.
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.
SEBU8600-04 97
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

7. Reset the air cleaner service indicator. Pressurized Air

Pressurized air can be used to clean primary air
Cleaning the Primary Air Cleaner cleaner elements that have not been cleaned more
Elements than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
NOTICE
Caterpillar recommends certified air filter cleaning
services that are available at Cat dealers. The Cat
cleaning process uses proven procedures to assure
consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to re-
move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter Illustration 61 g00281692
element. Take extreme care in order to avoid damage
to the pleats. Note: When the primary air cleaner elements are
cleaned, always begin with the clean side (inside) in
Do not use air filters with damaged pleats, gaskets,
or seals. Dirt entering the engine will cause damage order to force dirt particles toward the dirty side
to engine components. (outside).

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

NOTICE Vacuum cleaning is a good method for cleaning

Do not clean the air cleaner elements by bumping or primary air cleaner elements which require daily
tapping. This could damage the seals. Do not use el- cleaning because of a dry, dusty environment.
ements with damaged pleats, gaskets or seals. Dam- Cleaning with pressurized air is recommended prior
aged elements will allow dirt to pass through. Engine to vacuum cleaning. Vacuum cleaning will not
damage could result. remove deposits of carbon and oil.
Note: Refer to “Inspecting the Primary Air Cleaner
Visually inspect the primary air cleaner elements Elements”.
before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
There are two common methods that are used to
clean primary air cleaner elements:

• Pressurized air
• Vacuum cleaning
98 SEBU8600-04
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Replace

Inspecting the Primary Air Cleaner

Elements

Illustration 62 g00281693

Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a similar Illustration 63 g02595738
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element. Typical example
Inspect the primary air cleaner element for tears and/
or holes. Inspect the primary air cleaner element for Do not use paint, a waterproof cover, or plastic as a
light that may show through the filter material. If it is protective covering for storage. An airflow restriction
necessary in order to confirm the result, compare the may result. To protect against dirt and damage, wrap
primary air cleaner element to a new primary air the primary air cleaner elements in Volatile Corrosion
cleaner element that has the same part number. Inhibited (VCI) paper.

Do not use a primary air cleaner element that has Place the primary air cleaner element into a box for
any tears and/or holes in the filter material. Do not storage. For identification, mark the outside of the
use a primary air cleaner element with damaged box and mark the primary air cleaner element.
pleats, gaskets, or seals. Discard damaged primary Include the following information:
air cleaner elements.
• Date of cleaning
Storing Primary Air Cleaner Elements • Number of cleanings
If a primary air cleaner element that passes Store the box in a dry location.
inspection will not be used, the primary air cleaner
element can be stored for future use.
i01432811

Engine Air Cleaner Element

(Single Element) - Inspect/
Replace
SMCS Code: 1054-510; 1054-040
Perform the Operation and Maintenance Manual,
“Engine Air Cleaner Service Indicator-Inspect”
procedure and perform the Operation and
Maintenance Manual, “Engine Air Precleaner Check/
Clean” procedure (if equipped) before performing the
following procedure.
SEBU8600-04 99
Maintenance Section
Engine Air Cleaner Element (Single Element) - Replace

i02242500
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air Engine Air Cleaner Element
cleaner element. Do not use air cleaner elements (Single Element) - Replace
with damaged pleats, gaskets or seals. Dirt entering
the engine causes premature wear and damage to SMCS Code: 1051; 1054-510
engine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

Illustration 65 g00109823
(1) Air cleaner element. (2) Clamp.
Illustration 64 g00310664
(1) Air cleaner cover 1. Loosen clamp (2) which fastens air cleaner
(2) Air filter element element (1) to the air inlet. Remove the dirty air
(3) Air inlet cleaner element and clamp.
1. Remove air cleaner cover (1) and remove air filter 2. Install clamp (2) on new air cleaner element (1).
element (2). 3. Install new air cleaner element (1) to the air inlet
2. Cover air inlet (3) with tape or a clean cloth so that and tighten clamp (2). Refer to Torque
debris cannot enter the air inlet. Specifications, SENR3130 for the correct torque.
3. Clean the inside of air cleaner cover (1). Clean the i02335405
body that holds the air cleaner element.
4. Inspect the replacement element for the following Engine Air Cleaner Service
items:damage, dirt and debris. Indicator - Inspect
5. Remove the seal from the opening of the air inlet. SMCS Code: 7452-040
6. Install a clean, undamaged air filter element (2). Some engines may be equipped with a different
service indicator.
7. Install air cleaner cover (1).
Some engines are equipped with a differential gauge
8. Reset the air cleaner service indicator.
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
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 air
cleaner element or in a remote location.
100 SEBU8600-04
Maintenance Section
Engine Air Precleaner - Check/Clean

The service indicator may need to be replaced

frequently in environments that are severely dusty.

i07819526

Engine Air Precleaner - Check/

Clean
SMCS Code: 1055-535; 1055-070

Illustration 66 g00103777
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.

Illustration 67 g01453058

Test the Service Indicator Typical engine air precleaner

(1) Wing nut
Service indicators are important instruments. (2) Cover
(3) Body
• Check for ease of resetting. The service indicator
should reset in less than three pushes. Remove wing nut (1) and cover (2). Check for an
accumulation of dirt and debris in body (3). Clean the
• Check the movement of the yellow core when the body, if necessary.
engine is accelerated to the engine rated speed.
The yellow core should latch at the greatest After cleaning the precleaner, install cover (2) and
vacuum that is attained. wing nut (1).

If the service indicator does not reset easily, or if the Note: When the engine is operated in dusty
yellow core does not latch at the greatest vacuum, conditions, more frequent cleaning is required.
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service Do not tap or strike the air cleaner element.
indicator may be restricted.
i04946934

Engine Crankcase Breather

Element - Replace
SMCS Code: 1317-510-FQ

Hot oil and hot components can cause personal

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

NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
SEBU8600-04 101
Maintenance Section
Engine Crankcase Breather Element - Replace

NOTICE
Top Service
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
The crankcase breather is a very important
component in order to keep your engine emissions
compliant.
• The filter element within the crankcase breather
must be serviced at the prescribed service
interval.
• The correct filter element must be installed before
the engine is operated.
• The installation of the filter element is very
important.
• The quality of the filter element that is installed is
very important. Illustration 68 g03132641
Typical example
For information on aftermarket products, refer to
Operation and Maintenance Manual, “Engine
Description”. Within that section, refer to the title 1. Ensure that dirt cannot enter the breather
“Aftermarket Products and Caterpillar engines”. assembly. Ensure that the outside body of the
breather assembly is clean and free from damage.
The breather element can be serviced from the top Place a container under the breather assembly.
position or the breather element can be serviced from
the bottom position. 2. Rotate the top cap (1) counterclockwise into the
unlocked position. Remove the top cap from the
body of the breather (3) and remove the filter
element (2).
102 SEBU8600-04
Maintenance Section
Engine Crankcase Breather Element - Replace

4. Install a new filter element into the breather body

(3). Ensure the correct position of the element,
refer to illustration 70 . Align position (A) on the top
cap to position (B) on the filter element.

Illustration 69 g03132656
Typical example

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

Note: The cut away from section (5) in the top cap Illustration 71 g02346577
allows access to the seal. Typical example

5. Install the top cap (1). Rotate the top cap by hand
clockwise until the top cap locks into the locked
position (C) on the breather body.
6. Remove the container.

Bottom Service
Ensure that dirt cannot enter the breather assembly.

Illustration 70 g03132658
(A) Alignment position
(B) Alignment position
SEBU8600-04 103
Maintenance Section
Engine Crankcase Breather Element - Replace

Illustration 72 g03132659
Typical example
(X) Alignment mark
(Y) Alignment mark

1. Ensure that the outside body of the breather

assembly is clean and free from damage. Place a Illustration 73 g03132661
container under the breather. Typical example
2. Remove the tube connection (1). Ensure that dirt (A) Alignment postion
(B) Alignment postion
cannot enter the tube connection. Note the
position of the alignment marks (X and Y). Rotate
3. Remove the filter element (4). Remove the seal
the bottom cap (2) counterclockwise in order to
(5).
release the cap and the filter element (4) from the
breather body (3). Note: The bottom cap has a section that allows
access in order to remove the seal.

4. Install a new seal (5). Install a new filter element

into the bottom cap (2).
5. Align position (A) on the top cap to position (B) on
the filter element. Refer to illustration 73 .
6. Install the assembly of the filter element and the
bottom cap (2). Rotate the bottom cap by hand
clockwise until the bottom cap locks into the
locked position on the breather body. Ensure that
the alignment marks (X and Y) are correctly
aligned. Refer to illustration 72 .
104 SEBU8600-04
Maintenance Section
Engine Mounts - Inspect

7. Install tube connection (1). Ensure that the i04947803

retaining clips on the tube connection are correctly
engaged. Remove the container. Engine Oil Level - Check
SMCS Code: 1348-535-FLV
Check the System

Hot oil and hot components can cause personal

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

Illustration 75 g02173847

Illustration 74 g02346500 “L” Low

Typical example “H” High

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

NOTICE
the outlet (2) is clean and free from any obstructions. Perform this maintenance with the engine stopped.
Ice can cause obstructions in adverse weather
conditions.
Note: Ensure that the engine is either level or that
i02456872
the engine is in the normal operating position in order
to obtain a true level indication.
Engine Mounts - Inspect
Note: After the engine has been switched OFF, wait
SMCS Code: 1152-040
for 10 minutes in order to allow the engine oil to drain
Inspect the engine mounts for deterioration and for to the oil pan before checking the oil level.
proper bolt torque. Engine vibration can be caused
by the following conditions: 1. Maintain the oil level between the mark (L) and the
mark (H) on the engine oil dipstick. Do not fill the
• Improper mounting of the engine crankcase above the “H” .
• Deterioration of the engine mounts
NOTICE
Operating your engine when the oil level is above the
Any engine mount that shows deterioration should be
“FULL” mark could cause your crankshaft to dip into
replaced. Refer to Special Publication, SENR3130,
the oil. The air bubbles created from the crankshaft
“Torque Specifications” for the recommended dipping into the oil reduces the oil's lubricating char-
torques. Refer to the OEM recommendations for acteristics and could result in the loss of power.
more information.

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

Clean the oil filler cap. Install the oil filler cap.
If an increase in the oil level is noticed, refer to
Troubleshooting, “Oil Contains Fuel”.
SEBU8600-04 105
Maintenance Section
Engine Oil Sample - Obtain

i08234825
NOTICE
Always use a designated pump for oil sampling, and
Engine Oil Sample - Obtain use a separate designated pump for coolant sam-
SMCS Code: 1000-008; 1348-554-SM; 7542-554- pling. Using the same pump for both types of sam-
OC; 7542-554-SM ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
In addition to a good preventive maintenance and an incorrect interpretation that could lead to con-
program, Caterpillar recommends using S·O·S oil cerns by both dealers and customers.
analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required If the engine is not equipped with a sampling valve,
for determining nitration and oxidation levels. use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
Obtain the Sample and the tubing must be attached to the pump for insertion into
the sump.
Analysis
For instructions, see Special Publication, PEGJ0047,
“How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
Hot oil and hot components can cause personal engine.
injury. Do not allow hot oil or hot components to
contact the skin.
i08308045
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. To help Engine Oil and Filter - Change
obtain the most accurate analysis, provide the
following information: SMCS Code: 1318-510; 1348-044

• Engine model
• Service hours on the engine
Hot oil and hot components can cause personal
• The number of hours that have accumulated since injury. Do not allow hot oil or hot components to
contact the skin.
the last oil change
• The amount of oil that has been added since the
last oil change NOTICE
Care must be taken to ensure that fluids are con-
To ensure that the sample is representative of the oil tained during performance of inspection, mainte-
in the crankcase, obtain a warm, mixed oil sample. nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
To avoid contamination of the oil samples, the tools ers before opening any compartment or disassem-
and the supplies that are used for obtaining oil bling any component containing fluids.
samples must be clean.
Dispose of all fluids according to local regulations
Caterpillar recommends using the sampling valve to and mandates.
obtain oil samples. The quality and the consistency of
the samples are better when the sampling valve is
used. The location of the sampling valve allows oil NOTICE
that is flowing under pressure to be obtained during Keep all parts clean from contaminants.
normal engine operation.
Contaminants may cause rapid wear and shortened
The 169-8373 Fluid Sampling Bottle is component life.
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are Do not drain the engine lubricating oil when the
needed for obtaining oil samples. Instructions are engine is cold. As the engine lubricating oil cools,
also provided. suspended waste particles settle on the bottom of the
oil pan. The waste particles are not removed with
draining cold oil. Drain the oil pan with the engine
stopped. Drain the oil pan with the oil warm. This
draining method allows the waste particles that are
suspended in the oil to be drained properly.
106 SEBU8600-04
Maintenance Section
Engine Oil and Filter - Change

Failure to follow this recommended procedure will

cause the waste particles to be recirculated through
the engine lubrication system with the new oil.

Oil and Filter Change Intervals

The standard engine oil and filter change period is
500 hours. There are several other factors that can
alter the standard engine oil and filter change of 500
hours.

• If the engine is using engine oil analysis to

determine oil and filter change period.

• The engine is working in a severe service

environment/Load Factor
• Infrequent operation of the engine
Refer to this Operation and Maintenance Manual,
Severe Service Application for more information on
reducing the engine oil and filter change period. For
severe service applications the recommended oil and
Illustration 76 g01880893
filter change period is 250 hours.
Typical example
If the engine is operated in severe service conditions,
Caterpillar recommends the use of engine oil • If the engine is equipped with a drain valve, turn
sampling. Refer to this Operation and Maintenance the drain valve knob counterclockwise to drain the
Manual, Engine Oil sample - Obtain for more oil. After the oil has drained, turn the drain valve
information. knob clockwise to close the drain valve.
If the engine is operated infrequently less than 500
• If the engine is not equipped with a drain valve,
hours in a 12-month period, then the engine oil and
filter change should be conducted yearly. remove oil drain plug (1) to allow the oil to drain. If
the engine is equipped with a shallow oil pan,
remove the bottom oil drain plugs from both ends
Drain the Engine Lubricating Oil of the oil pan.
Note: Ensure that the vessel that will be used is large After the oil has drained, the oil drain plugs should be
enough to collect the waste oil. cleaned and installed. If necessary, replace the O
ring seal. Tighten the drain plug to 34 N·m (25 lb ft).
After the engine has been run at the normal
operating temperature, stop the engine. Use one of
the following methods to drain the engine oil pan: Replace the Oil Filter
NOTICE
Caterpillar oil filters are manufactured to Caterpillar
specifications. Use of an oil filter that is not recom-
mended by Caterpillar could result in severe damage
to the engine bearings, crankshaft. and so forth. As a
result of the larger waste particles from unfiltered oil
entering the engine lubricating system. Only use oil
filters recommended by Caterpillar.

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

Wrench.

Note: The following actions can be carried out as

part of the preventive maintenance program.
SEBU8600-04 107
Maintenance Section
Engine Oil and Filter - Change

Illustration 77 g01999595 Illustration 78 g02351361

Element with debris Typical example

2. Cut the oil filter open with a 175-7546 Oil Filter 3. Clean the sealing surface of the oil filter base (2).
Cutter. Break apart the pleats and inspect the oil
4. Apply clean engine oil to the O ring seal (3) for the
filter for metal debris. An excessive amount of
new oil filter.
metal debris in the oil filter may indicate early wear
or a pending failure.
NOTICE
Use a magnet to differentiate between the ferrous Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
metals and the nonferrous metals that are found in nated. Contaminated oil can cause accelerated wear
the oil filter element. Ferrous metals may indicate to engine components or engine damage.
wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the 5. Install the engine oil filter. Spin on the oil filter until
aluminum parts, brass parts, or bronze parts of the the O ring seal contacts the oil filter base. Rotate
engine. Parts that may be affected include the the oil filter ¾ of a full turn by hand.
following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads. Fill the Oil Pan
During to normal wear small amounts of debris
1. Remove the oil filler cap. Refer to this Operation
may be found in the oil filter. Consult your Cat ®
and Maintenance Manual, “Fluid
dealer to arrange for a further analysis if an
Recommendations” for more information on
excessive amount of debris is found in the oil filter.
suitable oils. Fill the oil pan with the correct
amount of new engine lubricating oil. Refer to this
Operation and Maintenance Manual, “Refill
Capacities” for more information on refill
capacities.

NOTICE
If equipped with an auxiliary oil filter system or a re-
mote filter system, follow the OEM or the filter manu-
factures recommendations. Under-filling or over filling
the crankcase with oil can cause engine damage.
108 SEBU8600-04
Maintenance Section
Fan Clearance - Check

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

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

Illustration 79 g02173847
“L” Low
“H” High

4. Remove the engine oil level gauge to check the oil

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

i03926370

Fan Clearance - Check

SMCS Code: 1356; 1359; 1360
There are different types of cooling systems. Refer to
the OEM for information on clearance for the fan.
Ensure that the engine is stopped. Ensure that the
battery disconnect switch is in the OFF position.
Ensure that the cooling system is full. The clearance
between the cover (1) and the fan (2) will require
checking. The gap (A) between the edge of the cover
and the tip of the fan blade must be checked in four
equally spaced positions.
SEBU8600-04 109
Maintenance Section
Fuel Filter (In-Line) - Replace

Illustration 80 g01348394

Adjustment of the cover will change the clearance Note: Refer to Systems Operation, Testing, and
(gap) between the edge of the cover and the tip of Adjusting, “Cleanliness of Fuel System
the fan blade. Ensure that the cover is centralized to Components” for detailed information on the
the fan. standards of cleanliness that must be observed
The clearance (A) must be 11 ± 2 mm during ALL work on the fuel system.
(0.43307 ± 0.07874 inch).
NOTICE
i04945626 Ensure that the engine is stopped before any servic-
ing or repair is performed.
Fuel Filter (In-Line) - Replace The location of the in-line fuel filter will depend on the
SMCS Code: 1261-510; 1261 application that the engine has been installed.

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
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
110 SEBU8600-04
Maintenance Section
Fuel System - Prime

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

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

from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:

• The fuel tank is empty or the fuel tank has been

partially drained.

• The low-pressure fuel lines are disconnected.

• A leak exists in the low-pressure fuel system.

• The fuel filter has been replaced.

Use the following procedures in order to remove air
from the fuel system:

Illustration 81 g03130884
1. Ensure that the fuel system is in working order.
Check that the fuel supply valve (if equipped) is in
Typical example
the “ON” position.
1. Turn the fuel supply valve (if equipped) to the OFF 2. Turn the keyswitch to the “RUN” position.
position. Remove any brackets that hold the in-line
fuel filter (1) in place, refer to OEM information. 3. The keyswitch will allow the electric priming pump
to operate. Operate the electric priming pump. The
2. Release the hose clips (3) and remove the hose ECM will stop the pump after 2 minutes.
lines from the in-line fuel filter. Remove the in-line
filter. 4. Turn the keyswitch to the “OFF” position. The fuel
system should now be primed and the engine
3. Install a new in-line filter and secure, refer to OEM should be able to start.
information. Ensure that the arrow mark (2) is
aligned to the direction of fuel flow from the tank to 5. Operate the engine starter and crank the engine.
the fuel pump. After the engine has started, operate the engine at
low idle for a minimum of 5 minutes. Ensure that
4. Install the fuel hose lines and install the hose clips the fuel system is free from leaks.
(3). Turn the fuel supply valve (if equipped) to the
ON position. Note: Operating the engine for this period will help
ensure that the fuel system is free of air. DO NOT
5. The in-line fuel filter must be changed with the loosen the high-pressure fuel lines in order to
primary filter and the secondary fuel filter. purge air from the fuel system. This procedure is
not required.
i05774864
After the engine has stopped, you must wait for 10
minutes in order to allow the fuel pressure to be
Fuel System - Prime purged from the high-pressure fuel lines before any
SMCS Code: 1258-548 service or repair is performed on the engine fuel
lines. The 10 minute wait will also allow static charge
Note: Refer to Systems Operation, Testing, and to dissipate from the low-pressure fuel system. If
Adjusting, “Cleanliness of Fuel System necessary, perform minor adjustments. Repair any
Components” for detailed information on the leaks from the low-pressure fuel system and from the
standards of cleanliness that must be observed cooling, lubrication, or air systems. Replace any high-
during ALL work on the fuel system. pressure fuel line that has leaked. Refer to
Disassembly and Assembly Manual, “Fuel Injection
Ensure that all adjustments and repairs are Lines - Install”.
performed by authorized personnel that have had the If you inspect the engine in operation, always use the
correct training. proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
SEBU8600-04 111
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

If the engine will not start, refer to Troubleshooting,

“Engine Cranks but will not Start”.

i04946947

Fuel System Primary Filter

(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ

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
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

Note: Refer to Systems Operation, Testing, and

Adjusting, “Cleanliness of Fuel System Illustration 82 g03132696
Components” for detailed information on the Typical example
standards of cleanliness that must be observed
during ALL work on the fuel system. 3. Install a suitable tube onto drain (3). Open the
drain valve (2). Rotate the drain valve
NOTICE counterclockwise. Two full turns are required.
Ensure that the engine is stopped before any servic-
ing or repair is performed. 4. Loosen the vent screw (1).
5. Allow the fuel to drain into the container. Remove
the tube from the drain valve.
Remove the Element
6. Tighten the vent screw (1) securely . Remove the
1. Turn the fuel supply valve (if equipped) to the OFF wiring harness from connection (4).
position before performing this maintenance.
7. Rotate filter bowl (6) counterclockwise and remove
2. Place a suitable container under the water the filter bowl from assembly. Refer to your
separator in order to catch any fuel that might spill. caterpillar dealer for the correct tool.
Clean up any spilled fuel. Clean the outside body
of the filter assembly.
112 SEBU8600-04
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

8. Rotate the filter element (5) counterclockwise and

remove the filter element . Clean the filter bowl.

Install the New Filter Element

Illustration 83 g02148402
Typical example

Illustration 84 g03132717
Typical example

1. Locate the thread in the new filter element (8) onto

the threads (9). Spin on the filter element and
tighten the drain valve (2) securely.
2. Lubricate the O ring seal (7) with clean engine oil.
Do NOT fill the bowl with fuel before the assembly
is installed.
3. Do not use a tool in order to install the filter
assembly. Tighten the filter bowl (6) by hand.
Install the filter bowl (6). Turn the filter bowl
clockwise until the filter bowl locks into position
against the stops.
4. Remove the container and dispose of the fuel in a
safe place.
SEBU8600-04 113
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

5. The secondary filter element must be replaced at

the same time as the primary filter element. Refer
to the Operation and Maintenance Manual, “Fuel
System Secondary Filter - Replace”.

i04947017

Fuel System Primary Filter/

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

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
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE Illustration 85 g02148370

Ensure that the engine is stopped before any servic- Typical example
ing or repair is performed.
3. Install a suitable tube onto drain (3). Open the
drain valve (2). Rotate the drain valve
NOTICE
The water separator can be under suction during nor- counterclockwise. Two full turns are required.
mal engine operation. Ensure that the drain valve is Loosen vent screw (1).
tightened securely to help prevent air from entering
the fuel system. 4. Allow the fluid to drain into the container.
5. Tighten the drain valve clockwise by hand
1. Place a suitable container under the water pressure only. Remove the tube and remove the
separator in order to catch any fluid that might container.
spill. Clean up any spilled fluid. 6. Tighten the vent screw securely.
2. Ensure that the outer body of the filter assembly is
i04947024
clean and free from dirt.
Fuel System Secondary Filter -
Replace
SMCS Code: 1261-510-SE

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
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
114 SEBU8600-04
Maintenance Section
Fuel System Secondary Filter - Replace

Refer to Systems Operation, Testing, and

Adjusting, “Cleanliness of Fuel System
Components” for detailed information on the
standards of cleanliness that must be observed
during ALL work on the fuel system.

Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFF
position before performing this maintenance.
2. Place a suitable container under the fuel filter in
order to catch any fuel that might spill. Clean up
any spilled fuel. Clean the outside body of the filter
assembly.

Illustration 87 g02546456
Typical example

7. Rotate the filter element (5) counterclockwise and

remove the filter element. Clean the filter bowl.

Install the Element

Illustration 86 g03132762
Typical example

3. Install a suitable tube onto drain (4). Open the

drain valve (3). Rotate the drain valve
counterclockwise. Two full turns are required.
Loosen vent screw (1).
4. Allow the fuel to drain into the container and
remove the tube.
5. Tighten the vent screw (1) securely.
6. Remove the filter bowl (2). Rotate the filter
assembly counterclockwise in order to remove the
assembly. Refer to your caterpillar dealer for the Illustration 88 g03132767
correct tool number. Typical example

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

threads (8). Spin on the element and tighten the
drain valve (3) by hand.
SEBU8600-04 115
Maintenance Section
Fuel Tank Water and Sediment - Drain

2. Lubricate the O ring seal (6) with clean engine oil. Condensation occurs during the heating and cooling
Do NOT fill the filter bowl (2) with fuel before the of fuel. The condensation occurs as the fuel passes
filter assembly is installed. through the fuel system and the fuel returns to the
fuel tank. This causes water to accumulate in fuel
3. Do not use a tool in order to install the filter tanks. Draining the fuel tank regularly and obtaining
assembly. Tighten the assembly by hand. Install fuel from reliable sources can help to eliminate water
in the fuel.
the filter bowl (2). Turn the filter bowl clockwise
until the filter bowl locks into position against the
stops. Drain the Water and the Sediment
4. Turn the fuel supply valve to the ON position. Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
5. The primary fuel filter and the secondary fuel filter fuel tanks.
must be replaced at the same time. Refer to the
Open the drain valve on the bottom of the fuel tank in
Operation and Maintenance Manual , “Fuel order to drain the water and the sediment. Close the
System Primary Filter (Water Separator) Element - drain valve.
Replace”. Also, the in-line fuel must be replaced
when the primary and secondary filters are Check the fuel daily. Allow five minutes after the fuel
tank has been filled before draining water and
replaced. Refer to Operation and Maintenance sediment from the fuel tank.
Manual , “Fuel Filter (In-Line) - Replace”
Fill the fuel tank after operating the engine in order to
6. Prime the fuel system. Refer to the Operation and drive out moist air. This will help prevent
Maintenance Manual, “Fuel System - Prime” for condensation. Do not fill the tank to the top. The fuel
more information. expands as the fuel gets warm. The tank may
overflow.
i02348492
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
Fuel Tank Water and Sediment supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If the
- Drain engine is equipped with this system, regular
SMCS Code: 1273-543-M&S maintenance of the fuel system filter is important.

NOTICE Fuel Storage Tanks

Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Drain the water and the sediment from the fuel
nance, testing, adjusting and repair of the product. storage tank at the following intervals:
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- • Weekly
bling any component containing fluids.
• Service intervals
Dispose of all fluids according to local regulations
and mandates. • Refill of the tank
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
Fuel Tank tank.
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system.
Water can be introduced into the fuel tank when the
fuel tank is being filled.
116 SEBU8600-04
Maintenance Section
Hoses and Clamps - Inspect/Replace

If a bulk storage tank has been refilled or moved Due to extreme temperature changes, the hose will
recently, allow adequate time for the sediment to harden. Hardening of the hoses will cause hose
settle before filling the engine fuel tank. Internal clamps to loosen. This can result in leaks. A constant
baffles in the bulk storage tank will also help trap torque hose clamp will help to prevent loose hose
sediment. Filtering fuel that is pumped from the clamps.
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. Each installation application can be different. The
differences depend on the following factors:
i07819616
• Type of hose
Hoses and Clamps - Inspect/ • Type of fitting material
Replace • Anticipated expansion and contraction of the hose
SMCS Code: 7554-040; 7554-510
• Anticipated expansion and contraction of the
fittings

Contact with high pressure fuel may cause fluid Replace the Hoses and the Clamps
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow Refer to the OEM information for further information
these inspection, maintenance and service in- on removing and replacing fuel hoses (if equipped).
structions may cause personal injury or death. The following text describes a typical method of
If you inspect the engine in operation, always use the replacing coolant hoses. Refer to the OEM
proper inspection procedure to avoid a fluid information for further information on the coolant
system and the hoses for the coolant system.
penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”
and Operation and Maintenance Manual, “High
Pressure Fuel Lines” for the correct procedures.
Pressurized System: Hot coolant can cause seri-
Inspect all hoses for leaks that are caused by the ous burns. To open the cooling system filler cap,
following conditions: stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
• Cracking pressure cap slowly in order to relieve the
pressure.
• Softness

• Loose clamps 1. Stop the engine. Allow the engine to cool.

Replace hoses that are cracked or soft. Tighten any 2. Loosen the cooling system filler cap slowly to
loose clamps. relieve any pressure. Remove the cooling system
filler cap.
Check for the following conditions:
Note: Drain the coolant into a suitable, clean
• End fittings that are damaged or leaking
container. The coolant can be reused.
• Outer covering that is chafed or cut
3. Drain the coolant from the cooling system to a
• Exposed wire that is used for reinforcement level that is below the hose that is being replaced.

• Outer covering that is ballooning locally 4. Remove the hose clamps.

5. Disconnect the old hose.
• Flexible part of the hose that is kinked or crushed
6. Replace the old hose with a new hose.
• Armoring that is embedded in the outer covering
7. Install the hose clamps with a torque wrench.
A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant Note: For the correct coolant, see this Operation and
torque hose clamp is the same size as the standard Maintenance Manual, “Fluid Recommendations”.
clamp.
8. Refill the cooling system. Refer to the OEM
information for further information on refilling the
cooling system.
SEBU8600-04 117
Maintenance Section
Overhaul Considerations

9. Clean the cooling system filler cap. Inspect the Overhaul Options
cooling system filler cap's seals. Replace the
cooling system filler cap if the seals are damaged. Before Failure Overhaul
Install the cooling system filler cap.
A planned overhaul before failure may be the best
10. Start the engine. Inspect the cooling system for value for the following reasons:
leaks.
• Costly unplanned downtime can be avoided.
i04224312 • Many original parts can be reused according to the
standards for reusable parts.
Overhaul Considerations
• The engines service life can be extended without
SMCS Code: 7595-043
the risk of a major catastrophe due to engine
Reduced hours of operation at full load will result in a failure.
lower average power demand. A decreased average
power demand should increase both the engine • The best cost/value relationship per hour of
service life and the overhaul interval. extended life can be attained.

The need for an overhaul is indicated by increased After Failure Overhaul

fuel consumption, increased oil consumption,
excessive engine blowby, and reduced power. Arctic If a major engine failure occurs and the engine must
temperatures, extreme high temperatures, corrosive be removed, many options are available. An overhaul
environments, or extreme dusty conditions contribute should be performed if the engine block or the
to premature wear and the need for an overhaul. crankshaft needs to be repaired.

The following factors are important when a decision If the engine block is repairable and/or the crankshaft
is being made on the proper time for an engine is repairable, the overhaul cost will be less than the
overhaul: cost of a new engine with a similar exchange core.

• The need for preventive maintenance This lower cost can be attributed to three aspects:

• The quality of the fuel that is being used • Specially designed Caterpillar engine features

• The operating conditions • Caterpillar dealer exchange components

• The results of the S·O·S analysis • Caterpillar Inc. remanufactured exchange

components
Oil Consumption as an Overhaul
Indicator Overhaul Recommendation
To minimize downtime, Caterpillar Inc. recommends
Oil consumption, fuel consumption, and maintenance a scheduled engine overhaul by your Caterpillar
information can be used to estimate the total dealer before the engine fails. This process will
operating cost for your Caterpillar engine. Oil
provide you with the best cost/value relationship.
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable Note: Overhaul programs vary according to the
for the maintenance intervals.
engine application and according to the dealer that
Oil consumption is in proportion to the percentage of performs the overhaul. Consult your Caterpillar
the rated engine load. As the percentage of the dealer for specific information about the available
engine load is increased, the amount of oil that is overhaul programs and about overhaul services for
consumed per hour also increases. extending the engine life.
The oil consumption rate (brake-specific oil Aftertreatment
consumption) is measured in grams per kW/h (lb per
bhp). The brake-specific oil consumption (BSOC) The aftertreatment system can be expected to
depends on the engine load. Consult your Caterpillar function properly for the useful life of the engine
dealer for assistance in determining the typical oil (emissions durability period), as defined by
consumption rate for your engine. regulation, subject to prescribed maintenance
requirements being followed.
When an engines 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.
118 SEBU8600-04
Maintenance Section
Overhaul Considerations

Rebuild or Exchange Caterpillar Inc. recommends the installation of new

parts at each overhaul period.
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the following Inspect these parts while the engine is disassembled
maintenance recommendations. for an overhaul.

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

Crankshaft Bearings Crankshaft Seals and

Note: Use this cleaning procedure to clean the oil
Pistons
cooler core.
The following components may not last until the
second overhaul. 1. Remove the oil cooler core.
2. Remove any debris from the oil cooler core. To
• Thrust bearings
remove debris from the oil cooler core, turn the oil
• Main bearings cooler core onto one end.

• Rod bearings 3. Flush the oil cooler core internally with cleaner in
order to loosen foreign substances. This flushing
• Crankshaft seals will also help to remove oil from the oil cooler core.
• Piston assembly
SEBU8600-04 119
Maintenance Section
Radiator - Clean

Note: Caterpillar Inc. recommends the use of For example, considerable deposits are found in the
Hydrosolv Liquid Cleaners. Table 12 lists the water jacket areas on the external cooling system,
Hydrosolv Liquid Cleaners that are available from but the concentrations of coolant additives were
your Caterpillar dealer. carefully maintained. The coolant probably contained
minerals that were deposited on the engine over
Table 12 time.
Hydrosolv Liquid Cleaners A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the
Part Number Description Size
cooling system. A full water analysis can be obtained
1U-8812 4 L (1 US gallon) by consulting your local water utility company or an
agricultural agent. Private laboratories are also
1U-5490 Hydrosolv4165 19 L (5 US gallon) available for water analysis.
8T-7570 208 L (55 US gallon) Caterpillar Inc. recommends an S·O·S Coolant
1U-8804 4 L (1 US gallon)
Analysis (Level 2).

1U-5492 Hydrosolv100 19 L (5 US gallon) S·O·S Coolant Analysis (Level 2)

8T-5571 208 L (55 US gallon) An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
4. Use steam to clean the oil cooler core. The steam system. An S·O·S Coolant Analysis (Level 2)
will remove any remaining residue from the provides the following information:
cleaner. Flush the fins of the oil cooler core.
Remove any other trapped debris. • Complete S·O·S Coolant Analysis (Level 1)

5. Wash the oil cooler core with hot, soapy water. • Visual inspection of properties
Rinse the oil cooler core thoroughly with clean
water. • Identification of metal corrosion
• Identification of contaminants
• Identification of built up impurities (corrosion and
Personal injury can result from air pressure. scale)
Personal injury can result without following prop- S·O·S Coolant Analysis (Level 2) provides a report of
er procedure. When using pressure air, wear a the results of both the analysis and the maintenance
protective face shield and protective clothing. recommendations.
Maximum air pressure at the nozzle must be less For more information about coolant analysis, see
than 205 kPa (30 psi) for cleaning purposes. your Caterpillar dealer.

6. Dry the oil cooler core with compressed air. Direct i04248509
the air in the reverse direction of the normal flow.
7. Inspect the components in order to ensure
Radiator - Clean
cleanliness. The oil cooler core should be SMCS Code: 1353-070
pressure tested. Repair the oil cooler core, if
necessary. Install the oil cooler core. Note: Some applications will require a fuel cooler to
be installed. The fuel cooler is a type of radiator that
For more information about cleaning the cores, uses air to cool the fuel and the fuel cooler will
consult your Caterpillar dealer. require cleaning.

Obtain Coolant Analysis Note: Adjust the frequency of cleaning according to

the effects of the operating environment.
The concentration of supplemental coolant additive
Inspect the radiator for these items: damaged fins,
(SCA) should be checked regularly with test kits or
corrosion, dirt, grease, insects, leaves, oil and other
with S·O·S Coolant Analysis (Level 1). Further
debris. Clean the radiator, if necessary.
coolant analysis is recommended when the engine is
overhauled.
120 SEBU8600-04
Maintenance Section
Radiator Pressure Cap - Clean/Replace

NOTICE
When any servicing or repair of the engine cooling
Personal injury can result from air pressure. system is performed the procedure must be per-
formed with the engine on level ground. This will al-
Personal injury can result without following prop- low you to accurately check the coolant level. This
er procedure. When using pressure air, wear a will also help in avoiding the risk of introducing an air
protective face shield and protective clothing. lock into the coolant system.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air 1. Stop the engine and allow the engine to cool.
nozzle is deadheaded. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the radiator
Pressurized air is the preferred method for removing pressure cap.
loose debris. Direct the air in the opposite direction of 2. Check coolant level. Refer to Operation and
the air flow. Hold the nozzle approximately 6 mm
(0.25 inch) away from the fins. Slowly move the air Maintenance Manual, “Cooling System Coolant
nozzle in a direction that is parallel with the tubes. Level - Check”.
This movement will remove debris that is between
the tubes. 3. Install new radiator pressure cap.

Pressurized water may also be used for cleaning. i00151038

The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized Severe Service Application -
water in order to soften mud. Clean the core from
both sides. Check
Use a degreaser and steam for removal of oil and SMCS Code: 1000-535
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the Severe service is an application of an engine that
core with clean water. exceeds current published standards for that engine.
Caterpillar maintains standards for the following
After cleaning, start the engine and accelerate the engine parameters:
engine to high idle rpm. This procedure will help in
the removal of debris and drying of the core. Stop the • Performance (power range, speed range and fuel
engine. Use a light bulb behind the core in order to consumption)
inspect the core for cleanliness. Repeat the cleaning,
if necessary. • Fuel quality
Inspect the fins for damage. Bent fins may be opened • Altitude range
with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections, • Maintenance intervals
clamps and seals. Make repairs, if necessary.
• Oil selection and maintenance
i03639888
• Coolant selection and maintenance
Radiator Pressure Cap - Clean/ • Environmental qualities
Replace • Installation
SMCS Code: 1353-Z2
Refer to the standards for the engine or consult with
your Caterpillar dealer in order to determine if the
engine is operating within the defined parameters.
Pressurized System: Hot coolant can cause seri- Severe service operation can accelerate component
ous burns. To open the cooling system filler cap, wear. Engines that operate under severe conditions
stop the engine and wait until the cooling system may need more frequent maintenance intervals in
components are cool. Loosen the cooling system order to ensure maximum reliability and retention of
pressure cap slowly in order to relieve the full service life.
pressure.
Due to individual applications, it is not possible to
identify all of the factors which can contribute to
severe service operation. Consult your Caterpillar
dealer for the unique maintenance that is necessary
for the engine.
SEBU8600-04 121
Maintenance Section
Starting Motor - Inspect

The operating environment, improper operating Check the starting motor for correct operation. Check
procedures and improper maintenance procedures the electrical connections and clean the electrical
can be factors which contribute to severe service connections. Refer to the Systems Operation, Testing
conditions. and Adjusting Manual, “Electric Starting System -
Test” for more information on the checking procedure
Environmental Factors and for specifications or consult your Caterpillar
dealer for assistance.
Ambient temperatures – The engine may be
exposed to extended operation in extremely cold i04103131
environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
Turbocharger - Inspect
cold temperatures. Extremely hot inlet air reduces (High Pressure and Low
engine performance.
Pressure Turbochargers)
Air Quality – The engine may be exposed to
extended operation in an environment that is dirty or SMCS Code: 1052-040; 1052
dusty, unless the equipment is cleaned regularly.
Mud, dirt and dust can encase components.
Maintenance can be very difficult. The buildup can
contain corrosive chemicals.
Buildup – Compounds, elements, corrosive
chemicals and salt can damage some components.
Altitude – Problems can arise when the engine is
operated at altitudes that are higher than the
intended settings for that application. Necessary
adjustments should be made.

Improper Operating Procedures

• Extended operation at low idle
• Frequent hot shutdowns

• Operating at excessive loads

• Operating at excessive speeds

• Operating outside the intended application Illustration 89 g02307134

Typical example
Improper Maintenance Procedures
• Extending the maintenance intervals
• Failure to use recommended fuel, lubricants and Hot engine components can cause injury from
coolant/antifreeze burns. Before performing maintenance on the en-
gine, allow the engine and the components to
cool.
i02348493
The engine is equipped with a high-pressure
Starting Motor - Inspect turbocharger (1) and a low-pressure turbocharger
(4). A regular visual inspection of both turbochargers
SMCS Code: 1451-040; 1453-040 is recommended. If the turbocharger fails during
engine operation, damage to the turbocharger
Caterpillar recommends a scheduled inspection of
the starting motor. If the starting motor fails, the compressor wheel and/or to the engine may occur.
engine may not start in an emergency situation. Damage to the turbocharger compressor wheel can
cause additional damage to the pistons, the valves,
and the cylinder head.
122 SEBU8600-04
Maintenance Section
High Pressure and Low Pressure Turbochargers

The presence of oil may be the result of extended

NOTICE
Turbocharger bearing failures can cause large quan- engine operation at low idle. The presence of oil
tities of oil to enter the air intake and exhaust sys- may also be the result of a restriction of the line for
tems. Loss of engine lubricant can result in serious the intake air (clogged air filters), which causes the
engine damage. turbocharger to slobber.
Minor leakage of oil into a turbocharger under ex- 7. If engine oil is found in the system, the cause can
tended low idle operation should not cause problems be the engine operating condition.
as long as a turbocharger bearing failure has not
occured. a. Ensure that the air duct (2) is clean and free
from dirt. Install air duct (2). Install bolt (3).
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust Ensure that the air intake is not clogged.
smoke or engine rpm up at no load), do not continue b. Operate the engine for 15 minutes at a
engine operation until the turbocharger is renewed. moderate high load condition.
c. Allow the engine to cool. Remove air duct and
A visual inspection of the turbochargers can minimize
unscheduled downtime. A visual inspection of the check for the presence of engine oil. If the
turbochargers can also reduce the chance for deposits of wet engine oil have been removed,
potential damage to other engine parts. Do not the air duct can be installed and the engine can
inspect the engine with the engine in operation. operate normally. For more information, refer to
Systems Operation, Testing and Adjusting,
Removal and Installation “Turbocharger - Inspect”.

Refer to the Disassembly and Assembly Manual, 8. Inspect the bore of the housing of the turbine outlet
“Turbocharger - Remove and Turbocharger Install” for corrosion.
for further information.

Inspecting
NOTICE
The compressor housing for the turbocharger must
not be removed from the turbocharger for inspection
or removed for the cleaning of the compressor.

1. Ensure that the turbocharger is clean and free from

dirt before removing components for inspection.
2. Remove the pipe from the high-pressure
turbocharger exhaust outlet and remove the air
intake pipe to the turbocharger. Visually inspect
the piping for the presence of oil. Clean the interior
of the pipes in order to prevent dirt from entering
during reassembly.
3. Remove bolt (3).
4. Remove air duct (2) and check for the presence of
engine oil.
5. Check for any loose bolts or any missing bolts.
Check for damage to the oil supply line and the oil
drain line. Check for cracks in the housing of the
turbocharger. Ensure that the compressor wheel
can rotate freely.
6. Check for the presence of oil. If oil is leaking from
the back side of the compressor wheel, there is a
possibility of a failed turbocharger oil seal.
SEBU8600-04 123
Maintenance Section
Walk-Around Inspection

9. Fasten the air intake pipe and the exhaust outlet • Wipe all caps and plugs before the engine is
pipe to the turbocharger housing. Ensure that all serviced in order to reduce the chance of system
clamps are installed correctly and that all clamps contamination.
are tightened securely.
NOTICE
i05784262 For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and
correct the leak. If leaking is suspected, check the flu-
Walk-Around Inspection id levels more often than recommended until the leak
SMCS Code: 1000-040 is found or fixed, or until the suspicion of a leak is
proved to be unwarranted.
Inspect the Tube of the Crankcase
Breather NOTICE
Accumulated grease and/or oil on an engine is a fire
hazard. Remove the accumulated grease and oil. Re-
fer to this Operation and Maintenance Manual, “En-
gine - Clean” for more information.

• Ensure that the cooling system hoses are correctly

clamped and that the cooling system hoses are
tight. Check for leaks. Check the condition of all
pipes.
• Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by the

coolant in the cooling system. It is normal for a small
amount of leakage to occur, as the engine cools
down and the parts contract.
Excessive coolant leakage may indicate the need to
replace the water pump. Remove the water pump.
Refer to Disassembly and Assembly , “Water Pump -
Remove and Install”. For more information, consult
your Cat dealer.

Illustration 90 g02351425
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
Typical example
pan, the oil filters, and the rocker cover.
Inspect the breather tube (1) for damage. Ensure that • Inspect the piping for the air intake system and the
the outlet (2) is clean and free from any obstructions. elbows for cracks and for loose clamps. Ensure
Ice can cause obstructions in adverse weather
conditions. that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses.
Inspect the Engine for Leaks and • Ensure that the areas around the rotating parts are
for Loose Connections clear.

A walk-around inspection should only take a few • Inspect the alternator belts and any accessory
minutes. When the time is taken to perform these drive belts for cracks, breaks, or other damage.
checks, costly repairs and accidents can be avoided.
• Inspect the wiring harness for damage.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or
coolant leaks, loose bolts, worn belts, loose
connections, and trash buildup. Make repairs, as
needed:

• The guards must be in the correct place. Repair

damaged guards or replace missing guards.
124 SEBU8600-04
Maintenance Section
Water Pump - Inspect

Belts for multiple groove pulleys must be replaced as • Check the condition of the gauges. Replace any
matched sets. If only one belt is replaced, the belt will gauges that are cracked. Replace any gauge that
carry more load than the belts that are not replaced. cannot be calibrated.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
i03570653

High Pressure Fuel Lines Water Pump - Inspect

SMCS Code: 1361; 1361-040
A failed water pump may cause severe engine
Contact with high pressure fuel may cause fluid overheating problems that could result in the
penetration and burn hazards. High pressure fuel following conditions:
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in- • Cracks in the cylinder head
structions may cause personal injury or death.
• A piston seizure
After the engine has stopped, you must wait for 10
minutes in order to allow the fuel pressure to be • Other potential damage to the engine
purged from the high-pressure fuel lines before any
service or repair is performed on the engine fuel
lines. The 10 minute wait will also allow static charge
to dissipate from the low-pressure fuel system. If
necessary, perform minor adjustments. Repair any
leaks from the low-pressure fuel system and from the
cooling, lubrication, or air systems. Replace any high-
pressure fuel line that has leaked. Refer to
Disassembly and Assembly Manual, “Fuel Injection
Lines - Install”.
If you inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
Visually inspect the high-pressure fuel lines for
damage or signs of fuel leakage. Replace any
damaged high-pressure fuel lines or high-pressure
fuel lines that have leaked.
Ensure that all clips on the high-pressure fuel lines
are in place and that the clips are not loose.

• Inspect the rest of the fuel system for leaks. Look

for loose fuel line clamps.

• Drain the water and the sediment from the fuel

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

• Inspect the wiring and the wiring harnesses for Illustration 91 g01904773
loose connections and for worn wires or frayed
(A) Weep hole
wires. Check for any loose tie-wraps or missing (B) Vent hole
tie-wraps.
• Inspect the ground strap for a good connection Note: The water pump seals are lubricated by the
and for good condition. coolant in the cooling system. It is normal for a small
amount of leakage to occur. Refer to illustration 91
• Disconnect any battery chargers that are not for the position of the weep hole and the vent hole.
protected against the current drain of the starting
Visually inspect the water pump for leaks.
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.
SEBU8600-04 125
Maintenance Section
Water Pump - Inspect

Note: If engine coolant enters the engine lubricating

system the lubricating oil and the engine oil filter must
be replaced. This will remove any contamination that
is caused by the coolant and this will prevent any
irregular oil samples.
The water pump is not a serviceable item. In order to
install a new water pump, refer to the Disassembly
and Assembly Manual, “Water Pump - Remove and
Install”.
126 SEBU8600-04
Warranty Section
Warranty Information

Warranty Section The aftertreatment system can be expected to

function properly for the lifetime of the engine
(emissions durability period) subject to prescribed
maintenance requirements being followed.
Warranty Information
A detailed explanation of the Emission Control
Warranty that is applicable to new non-road and
i05549472 stationary diesel engines, including the components
covered and the warranty period, is found in a
Emissions Warranty supplemental Special Publication. Consult your
authorized Cat dealer to determine if your engine is
Information subject to an Emission Control Warranty and to
SMCS Code: 1000 obtain a copy of the applicable Special Publication.

The certifying engine manufacturer warrants to the

ultimate purchaser and each subsequent purchaser
that:
1. New non-road diesel engines and stationary diesel
engines less than 10 liters per cylinder (including
Tier 1 and Tier 2 marine engines < 37 kW, but
excluding locomotive and other marine engines)
operated and serviced in the United States and
Canada, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to conform,
at the time of sale, with applicable emission
standards prescribed by the United States
Environmental Protection Agency (EPA) by way
of regulation.
b. Free from defects in materials and
workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.
2. New non-road diesel engines (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.
SEBU8600-04 127
Reference Information Section
Engine Ratings

Reference Information The engine ratings are gross output ratings.

Section Gross Output Ratings – The total output capability

of the engine that is equipped with standard
accessories.

Engine Ratings Standard accessories include the following

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

NOTICE
Operating engines above the rating definitions can
result in shorter service life before overhaul.

i04650089

Engine Rating Definitions

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

• 100 kPa (29.3 Inches Hg)

• 30 percent relative humidity

• A temperature of 25 °C (77 °F)

The engine ratings are based on the following fuel
specifications:
• The Low Heat Value (LHV) of the fuel at 29 °C
(84.2 °F) at 42780 kJ/kg (18390 Btu/lb)
• Specific gravity of .833 - 837 at 15 °C (60 °F)
128 SEBU8600-04
Reference Information Section
Customer Service

Customer Service Australia and New Zealand

Caterpillar of Australia Ltd.
1 Caterpillar Drive
i07191578
Private Mail Bag 4
Tullamarine, Victoria 3043
Customer Assistance Australia
SMCS Code: 1000 Phone: 03-9953-9333
Fax: 03-9335-3366
USA and Canada i03655027

When a problem arises concerning the operation or

the service of an engine, the problem will normally be Ordering Replacement Parts
managed by the dealer in your area.
SMCS Code: 7567
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 When replacement parts are required for this
dealer level, consult the appropriate Caterpillar office. product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent speci-
Latin America, Mexico, Carribean fications including, but not limited to, physical di-
Caterpillar Americas Co. mensions, type, strength and material.
701 Waterford Way, Suite 200 Failure to heed this warning can lead to prema-
Miami, FL 33126-4670 ture failures, product damage, personal injury or
USA death.
Phone: 305-476-6800
Fax: 305-476-6801 Quality Caterpillar replacement parts are available
from Caterpillar dealers throughout the world.
Europe, Africa, and Middle East Caterpillar dealers' parts inventories are up-to-date.
Caterpillar Overseas S.A. The parts stocks include all of the parts that are
76 Route de Frontenex normally needed to protect your Caterpillar engine
P.O. Box 6000 investment.
CH-1211 Geneva 6
Switzerland When you order parts, please specify the following
Phone: 22-849-4444 information:
Fax: 22-849-4544 • When a Caterpillar engine requires maintenance
Far East and/or repair, provide the dealer with all the
Caterpillar Asia Pte. Ltd. information that is stamped on the Information
7 Tractor Road Plate. Refer to this Operation and Maintenance
Jurong, Singapore 627968 Manual, “Plate Locations and Film Locations”.
Republic of Singapore • Part number
Phone: 65-662-8333
Fax: 65-662-8302 • Part name
China • Quantity
Caterpillar China Ltd.
37/F., The Lee Gardens If there is a question concerning the part number,
33 Hysan Avenue please provide your dealer with a complete
Causeway Bay description of the needed item.
G.P.O. Box 3069
Hong Kong Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
Phone: 852-2848-0333
nature of the problem. Inform the dealer about when
Fax: 852-2848-0440 the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
SEBU8600-04 129
Reference Information Section
Reference Materials

Reference Materials • Troubleshooting, KENR9106, “ C7.1 Industrial

Engines”
i03975270 • Systems Operation, Testing, and Adjusting,
KENR9104, “ C7.1 Industrial Engines”
Reference Material
• Specifications, KENR9103, “ C7.1 Industrial
SMCS Code: 1000 Engines.”
The following literature can be obtained through any
Caterpillar dealer. • Disassembly and Assembly, KENR9105, “ C7.1
Industrial Engines”
Lubricants • Specifications, SENR3130, “Torque
Specifications”
• Special Publication, PEHP8038, “Data Sheet -
Caterpillar Diesel Engine Oils (DEO) (CH-4) • Special Publication, PECP9067, “One Safe
(North America)” Source” English language for use in NACD

• Special Publication, PEHP9536, “Data Sheet - • Special Publication, LEDM5615, “Caterpillar

Caterpillar Diesel Engine Oil (DEO) (CF-4) Marine Parts and Service Locations Directory”
(International only)”
• Special Publication, SEBF8029, “Index to
• Special Publication, NEDG6022, “Cat Lubricating Guidelines for Reusable Parts and Salvage
Grease” Operations”

• Special Publication, PEHP0002, “Data Sheet - • Special Publication, SEBF8062, “Procedure to

Molybdenum (MPGM) Grease” Inspect and Clean Air Filters”

• Special Publication, NEHP6015, “Data Sheet - • Special Instruction, SEHS9031, “Storage

Caterpillar Special Purpose Grease (SPG)” Procedure for Caterpillar Products”

• Operation and Maintenance Manual, SEBU5898, • Special Publication, NEHS0526, “Service

“Cold Weather Recommendations” Technician Application Guide”

• Operation and Maintenance Manual, SEBU6251, • Special Publication, SEBU6251, “Caterpillar

“Caterpillar Commercial Diesel Engine Fluids Commercial Diesel Engine Fluids
Recommendations” Recommendations”

• Special Publication, PEHP6001, “How To Take A • Special Instruction, SEHS7633, “Battery Test
Good Oil Sample” Procedure”

Coolants
• Special Publication, PEHP4036, “Data Sheet -
Extended Life Coolant”
• Special Publication, PEHP7057, “Data Sheet -
S·O·S Coolant Analysis”

• Special Publication, SEBD0518, “Know Your

Cooling System”

• Label, PEEP5027, “Extended Life Coolant/

Antifreeze”

Miscellaneous
• Service Manual, REG1139F, “Service Manual
Contents Microfiche”

• Service Manual, UERN0603, “ C7.1 Industrial

Engines”
130 SEBU8600-04
Reference Information Section
Additional Reference Material

• Label, SEHS7332, “Danger Do Not Operate” European classifications are established by the
Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Emissions Warranty Engines).
This engine may be Certified and this engine may be CIMAC Central Secretariat
covered by an Emissions Warranty. A detailed Lyoner Strasse 18
explanation of the Emissions Warranty that is 60528 Frankfurt
applicable to Certified engines is found in Germany
Supplement, SMBU6981, “Emissions Control
Telephone +49 69 6603 1567
Warranty Information”. The engine is Certified if the
engine has a special label that verifies the Facsimile +49 69 6603 1566
certification. A Caterpillar dealer can also inform you
if the engine is certified.

i08254313

Additional Reference Material

SMCS Code: 1000
The “Society of Automotive Engineers (SAE)
Specifications” can be found in your SAE handbook.
This publication can also be obtained from the
following locations: local technological society, local
library, and local college. If necessary, consult SAE at
the following address:
SAE International
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
Telephone (724) 776-4841
The “American Petroleum Institute Publication No.
1509” can be obtained from the following locations:
local technological society, local library, and local
college. If necessary, consult API at the following
address:
American Petroleum Institute
1220 L St. N.W.
Washington, DC, USA 20005
Telephone (202) 682-8000
The International Organization for Standardization
(ISO) offers information and customer service
regarding international standards and standardizing
activities. ISO can also supply information on the
following subjects that are not controlled by ISO:
national standards, regional standards, regulations,
certification, and related activities. Consult the
member of ISO in your country.

International Organization for Standardization

(ISO)
1, rue de Varembé
Case postale 56
CH-1211 Genève 20
Switzerland
Telephone +41 22 749 01 11
Facsimile +41 22 733 34 30
E-mail [email protected]
Web site http://www.iso.ch
SEBU8600-04 131
Reference Information Section
Maintenance Log

i08254037

Maintenance Log
SMCS Code: 1000

Table 13
Engine Model Customer Identifier

Serial Number Arrangement Number

Service Quantity Of
Service Item Date Authorization
Hours Fuel
132 SEBU8600-04
Index Section

Index
A Cooling System Coolant Level - Check........... 91
Cooling System Coolant Sample (Level 1) -
Additional Reference Material ....................... 130
Obtain ............................................................ 91
After Starting Engine ....................................... 61
Cooling System Coolant Sample (Level 2) -
After Stopping Engine ..................................... 66
Obtain ............................................................ 92
Aftercooler Core - Clean/Test (Air-To-Air
Cooling System Supplemental Coolant
Aftercooler) .................................................... 82
Additive (SCA) - Test/Add.............................. 93
Aftercooler Core - Inspect ............................... 82
Add the SCA, If Necessary .......................... 93
Alternator - Inspect .......................................... 83
S·O·S Coolant Analysis............................... 93
Alternator and Fan Belts - Replace ................. 83
Test for SCA Concentration ......................... 93
ARD Spark Plug - Clean/Inspect/Replace ...... 82
Crankshaft Vibration Damper - Inspect........... 94
Viscous Damper .......................................... 94
B Crushing Prevention and Cutting Prevention.. 16
Battery - Replace............................................. 83 Customer Assistance .................................... 128
Battery Electrolyte Level - Check .................... 84 Outside of the USA and of Canada ........... 128
Battery or Battery Cable - Disconnect............. 84 USA and Canada....................................... 128
Before Starting Engine .............................. 18, 59 Customer Service.......................................... 128
Belt - Inspect.................................................... 85
Belt Tensioner - Inspect................................... 85 D
Burn Prevention............................................... 12
Diagnostic Flash Code Retrieval..................... 48
Batteries....................................................... 14
Diagnostic Lamp.............................................. 48
Coolant ........................................................ 13
Diesel Particulate Filter - Clean....................... 94
Induction System ......................................... 13
Diesel Particulate Filter Regeneration ............ 62
Oils............................................................... 14
Modes of Regeneration ............................... 63
Regeneration ............................................... 62
C Regeneration Indicators .............................. 62
Cold Weather Operation ................................. 68 Regeneration Switch ................................... 62
Hints for Cold Weather Operation ............... 68 Regeneration System Warning Indicators... 63
Idling the Engine .......................................... 69 Soot Level Monitoring.................................. 63
Recommendations for Coolant Warm Up.... 69 Driven Equipment - Check .............................. 95
Recommendations for the Coolant.............. 69
Viscosity of the Engine Lubrication Oil ........ 68 E
Cold Weather Starting ..................................... 59
Electrical System............................................. 19
Configuration Parameters ............................... 55
Grounding Practices .................................... 19
Customer Specified Parameters ................. 55
Emergency Stopping....................................... 66
System Configuration Parameters .............. 55
Emergency Stop Button............................... 66
Cooling System Coolant (DEAC) - Change .... 85
Emissions Certification Film ............................ 31
Cooling Systems with Heavy Deposits or
Emissions Warranty Information ................... 126
Plugging ..................................................... 87
Engaging the Driven Equipment ..................... 64
Drain ............................................................ 86
Engine - Clean................................................. 95
Fill ................................................................ 88
Aftertreatment System................................. 95
Flush ............................................................ 87
Engine Air Cleaner Element (Dual Element)
Cooling System Coolant (ELC) - Change ....... 88
- Clean/Replace............................................. 95
Drain ............................................................ 88
Cleaning the Primary Air Cleaner
Fill ................................................................ 89
Elements .................................................... 97
Flush ............................................................ 89
Servicing the Air Cleaner Elements............. 96
Cooling System Coolant Extender (ELC) -
Add ................................................................ 90
SEBU8600-04 133
Index Section

Engine Air Cleaner Element (Single F

Element) - Inspect/Replace ........................... 98
Fan Clearance - Check ................................. 108
Engine Air Cleaner Element (Single
Fault Logging................................................... 54
Element) - Replace........................................ 99
Features and Controls..................................... 38
Engine Air Cleaner Service Indicator -
Fire Prevention and Explosion Prevention...... 14
Inspect ........................................................... 99
Ether ............................................................ 15
Test the Service Indicator .......................... 100
Fire Extinguisher.......................................... 15
Engine Air Precleaner - Check/Clean ........... 100
Lines, Tubes, and Hoses ............................. 15
Engine Crankcase Breather Element -
Regeneration ............................................... 16
Replace ....................................................... 100
Foreword ........................................................... 4
Bottom Service .......................................... 102
California Proposition 65 Warning ................. 4
Check the System...................................... 104
Literature Information .................................... 4
Top Service ................................................ 101
Maintenance .................................................. 4
Engine Description .......................................... 27
Maintenance Intervals ................................... 5
Aftermarket Products and Caterpillar
Operation ....................................................... 4
Engines ...................................................... 28
Overhaul ........................................................ 5
Aftertreatment System................................. 28
Safety............................................................. 4
Electronic Engine Features ......................... 27
Fuel and the Effect from Cold Weather ........... 70
Engine Cooling and Lubrication .................. 28
Fuel Conservation Practices ........................... 65
Engine Diagnostics...................................... 28
Fuel Filter (In-Line) - Replace ....................... 109
Engine Service Life...................................... 28
Fuel Related Components in Cold Weather ... 71
Engine Specifications .................................. 27
Fuel Filters ................................................... 71
Engine Diagnostics ......................................... 48
Fuel Heaters ................................................ 71
Engine Electronics........................................... 20
Fuel Tanks ................................................... 71
Engine Mounts - Inspect................................ 104
Fuel System - Prime.......................................110
Engine Oil and Filter - Change ...................... 105
Fuel System Primary Filter (Water
Drain the Engine Lubricating Oil................ 106
Separator) Element - Replace...................... 111
Fill the Oil Pan............................................ 107
Install the New Filter Element.....................112
Oil and Filter Change Intervals .................. 106
Remove the Element .................................. 111
Replace the Oil Filter ................................. 106
Fuel System Primary Filter/Water
Engine Oil Level - Check............................... 104
Separator - Drain ..........................................113
Engine Oil Sample - Obtain........................... 105
Fuel System Secondary Filter - Replace .......113
Obtain the Sample and the Analysis ......... 105
Install the Element ......................................114
Engine Operation ............................................ 62
Remove the Element ..................................114
Engine Operation and Active
Fuel Tank Water and Sediment - Drain ..........115
Regeneration ............................................. 62
Drain the Water and the Sediment .............115
Reduction of Particulate Emissions............. 62
Fuel Storage Tanks.....................................115
Engine Operation with Active Diagnostic
Fuel Tank ....................................................115
Codes ............................................................ 54
Engine Operation with Intermittent
Diagnostic Codes .......................................... 54 G
Engine Rating Conditions.............................. 127 Gauges and Indicators .................................... 36
Engine Rating Definitions.............................. 127 Aftertreatment Lamps .................................. 37
Engine Ratings .............................................. 127 Indicator Lamps ........................................... 37
Engine Shutoffs and Engine Alarms ............... 46 General Hazard Information.............................. 8
Alarms.......................................................... 46 Containing Fluid Spillage............................. 10
Shutoffs........................................................ 46 Dispose of Waste Properly .......................... 12
Testing ......................................................... 46 Fluid Penetration ......................................... 10
Engine Starting.......................................... 18, 59 Inhalation ......................................................11
Engine Stopping ........................................ 18, 66 Pressurized Air and Water........................... 10
134 SEBU8600-04
Index Section

Static Electricity Hazard when Fueling with O

Ultra-low Sulfur Diesel Fuel ........................11
Operation Section............................................ 32
Ordering Replacement Parts......................... 128
H Overhaul Considerations................................117
High Pressure Fuel Lines ................................ 16 Oil Consumption as an Overhaul
Hoses and Clamps - Inspect/Replace............116 Indicator ....................................................117
Replace the Hoses and the Clamps ...........116 Overhaul Recommendation........................117
Overspeed....................................................... 47
I
P
Important Safety Information............................. 2
Plate Locations and Film Locations ................ 30
Serial Number Plate (1) ............................... 30
L
Plate Locations and Film Locations (Engine
Lifting and Storage .......................................... 32 Aftertreatment System) ................................. 29
Product Identification Information ................... 29
M Product Information Section............................ 22
Product Lifting ................................................. 33
Maintenance Interval Schedule....................... 80 Product Lifting (Clean Emission Module)........ 34
Commissioning ............................................ 81 Product Lifting (Engine)................................... 32
Daily ............................................................. 80 Product Storage .............................................. 34
Every 1000 Service Hours........................... 80
Every 12 000 Service Hours or 6 Years....... 81
R
Every 1500 Service Hours........................... 80
Every 2000 Service Hours........................... 80 Radiator - Clean .............................................119
Every 250 Service Hours ............................. 80 Radiator Pressure Cap - Clean/Replace....... 120
Every 3000 Service Hours........................... 80 Radiator Restrictions....................................... 70
Every 3000 Service Hours or 2 Years ......... 81 Reference Information Section ..................... 127
Every 4000 Service Hours........................... 81 Reference Material ........................................ 129
Every 4500 Service Hours........................... 81 Coolants..................................................... 129
Every 50 Service Hours or Weekly.............. 80 Emissions Warranty................................... 130
Every 500 Service Hours ............................. 80 Lubricants .................................................. 129
Every 500 Service Hours or 1 Year ............. 80 Miscellaneous ............................................ 129
Every 5000 Service Hours........................... 81 Reference Materials ...................................... 129
Every 6000 Service Hours or 3 Years ......... 81 Reference Numbers ........................................ 30
Every Week ................................................. 80 Record for Reference .................................. 30
Every Year ................................................... 80 Refill Capacities............................................... 72
Overhaul ...................................................... 81 Refill Capacities and Recommendations ........ 72
When Required............................................ 80 Coolant ........................................................ 74
Maintenance Log........................................... 131 Engine Oil .................................................... 72
Maintenance Recommendations .................... 77 Fuel .............................................................. 74
Maintenance Section....................................... 72 Lubricating Grease ...................................... 73
Model View Illustrations .................................. 22 S·O·S Coolant Analysis............................... 75
Engine Aftertreatment System .................... 24
Engine views................................................ 22 S
Model Views .................................................... 22
Monitoring System (Engine)............................ 38 Safety Messages............................................... 6
Instrument panels and Displays .................. 39 (1) Universal Warning .................................... 6
Programmable Options and Systems (2) Ether ......................................................... 7
Operation ................................................... 39 (3) Hand (High Pressure) .............................. 8
Mounting and Dismounting ............................. 16 Safety Section ................................................... 6
Self-Diagnostics .............................................. 48
SEBU8600-04 135
Index Section

Sensors and Electrical Components

(Aftertreatment) ............................................. 44
Sensors and Electrical Components
(Engine) ......................................................... 39
Programmable Monitoring System (PMS)... 43
Sensor Locations ......................................... 39
Severe Service Application - Check.............. 120
Environmental Factors............................... 121
Improper Maintenance Procedures........... 121
Improper Operating Procedures................ 121
Starting Motor - Inspect ................................. 121
Starting the Engine.......................................... 59
Starting the Engine ...................................... 59
Starting with Jump Start Cables (Do Not
Use This Procedure in Hazardous
Locations that have Explosive
Atmospheres) ................................................ 60
Stopping the Engine ........................................ 66
System Pressure Release............................... 77
Coolant System ........................................... 77
Engine Oil .................................................... 77
Fuel System................................................. 77

T
Table of Contents .............................................. 3
Turbocharger - Inspect (High Pressure and
Low Pressure Turbochargers)..................... 121
Inspecting .................................................. 122
Removal and Installation ........................... 122

W
Walk-Around Inspection ................................ 123
High Pressure Fuel Lines .......................... 124
Inspect the Engine for Leaks and for Loose
Connections ............................................. 123
Inspect the Tube of the Crankcase
Breather ................................................... 123
Warranty Information..................................... 126
Warranty Section........................................... 126
Water Pump - Inspect.................................... 124
Welding on Engines with Electronic
Controls ......................................................... 77
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:
SEBU8600 CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate
©2020 Caterpillar Yellow”, the “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product
All Rights Reserved identity used herein, are trademarks of Caterpillar and may not be used without permission.

138 December 2020