M0097687-03 (en-us)

April 2021

Operation and
Maintenance
Manual
C9.3B Industrial Engine and C9.3B
Power System Package
NGL 1-UP (C9.3B Industrial
Engine)
RBZ 1-UP (C9.3B Industrial
Engine)
PJJ 1-UP (C9.3B Power
System Package)

Language: Original Instructions

Scan to find and purchase genuine Cat® parts and related

service information.
 i07966018

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

NOTICE
When replacement parts are required for this product Caterpillar recommends using original Cater-
pillar® replacement parts.
Other parts may not meet certain original equipment specifications.
When replacement parts are installed, the machine owner/user should ensure that the machine re-
mains in compliance with all applicable requirements.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
M0097687-03 3
Table of Contents

Table of Contents Refill Capacities............................................... 47

Maintenance Recommendations .................... 56

Foreword ........................................................... 4
Maintenance Interval Schedule....................... 59
Safety Section

Safety Messages............................................... 6
Warranty Section

Warranty Information....................................... 93
Additional Messages ......................................... 9

General Hazard Information.............................. 9 Reference Information Section

Burn Prevention............................................... 13 Engine Ratings ................................................ 94

Fire Prevention and Explosion Prevention...... 14 Customer Service............................................ 95

Crushing Prevention and Cutting Prevention.. 16 Reference Materials ........................................ 96

Mounting and Dismounting ............................. 16 Index Section

Engine Starting................................................ 16 Index................................................................ 97

Engine Stopping .............................................. 17

Electrical System............................................. 17

Engine Electronics........................................... 18

Product Information Section

General Information ........................................ 19

Product Identification Information ................... 24

Operation Section

Lifting and Storage .......................................... 27

Features and Controls..................................... 31

Engine Diagnostics ......................................... 36

Engine Starting................................................ 37

Engine Operation ............................................ 41

Cold Weather Operation ................................. 43

Engine Stopping .............................................. 45

Maintenance Section
4 M0097687-03
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.
M0097687-03 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 M0097687-03
Safety Section
Safety Messages

Safety Section
i06983622

Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on
your engine. The exact location and a description of
the safety messages are reviewed in this section.
Become familiar with all safety messages.
Ensure that all the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and
soap to clean the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off the
engine.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part of
the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar
dealer can provide new safety messages.
M0097687-03 7
Safety Section
Safety Messages

Illustration 1 g02199153
View of the left side and view of the right side of a C9.3B Industrial Engine

Universal Warning (1)

Illustration 2 g01370904

One safety message is on the left side of the front

housing. One safety message is on the base for the
oil filter, on the right side of the engine.
8 M0097687-03
Safety Section
Safety Messages

Do not operate or work on this equipment unless Contact with high pressure fuel may cause fluid
you have read and understand the instructions penetration and burn hazards. High pressure fuel
and warnings in the Operation and Maintenance spray may cause a fire hazard. Failure to follow
Manual. Failure to follow the instructions or heed these inspection, maintenance and service in-
the warnings could result in injury or death. Con- structions may cause personal injury or death.
tact any Caterpillar dealer for replacement man-
uals. Proper care is your responsibility.
Sulfuric Acid Burn (3)
High Pressure (2)

Illustration 3 g01381180

One safety message for high pressure (2) is on the

bottom of the fuel pump. Two messages are on the
fuel rail.
Illustration 4 g01382725

The safety message for sulfuric acid burn (3) is on

top of the exhaust cooler.
M0097687-03 9
Safety Section
Additional Messages

This notice is located next to the battery disconnect

switch.
Sulfuric Acid Burn Hazard may cause serious
personal injury or death. NOTICE
Do not turn the battery disconnect switch off until the
The exhaust gas cooler may contain a small indicator lamp has turned off.
amount of sulfuric acid. The use of fuel with sul-
fur levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid i08340590
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- General Hazard Information
priate personal protective equipment (PPE) that SMCS Code: 1000; 4450; 7405
is noted on a material safety data sheet (MSDS)
for sulfuric acid. Always follow the directions for
first aid that are noted on a material safety data
sheet (MSDS) for sulfuric acid.

i07501764

Additional Messages
SMCS Code: 1000; 7405
There are several specific messages on this engine.
The exact location of the messages and the
description of the information are reviewed in this
section. Become familiar with all messages.
Make sure that all the messages are legible. Clean Illustration 6 g03838041
the messages or replace the messages if you cannot
read the words. Replace the illustrations if the Attach a “Do Not Operate” warning tag to the start
illustrations are not legible. When you clean the switch or controls before the engine is serviced or
messages, use a cloth, water, and soap. Do not use repaired. These warning tags (Special Instruction,
solvent, gasoline, or other harsh chemicals to clean SEHS7332) are available from your Cat dealer.
the messages. Solvents, gasoline, or harsh Attach the warning tags to the engine and to each
chemicals could loosen the adhesive that secures the operator control station. When appropriate,
messages. Loose adhesive will allow the messages disconnect the starting controls.
to fall.
Do not allow unauthorized personnel on the engine,
Replace any message that is damaged, or missing. If or around the engine when the engine is being
a message is attached to a part that is replaced, serviced.
install a message on the replacement part. Any Cat
dealer can provide new messages. Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps

• Grease fittings
• Pressure taps

• Breathers
• Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of the
Illustration 5 g03422039 cover plate or the device. Before removing the last
two bolts or nuts, pry the cover loose in order to
Purge notice message relieve any spring pressure or other pressure.
10 M0097687-03
Safety Section
General Hazard Information

• Start the engine with the operator controls. Never

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

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or
hot water to be blown out which could result in
personal injury.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip
guarding (if applicable) and personal protective
Illustration 7 g00702020
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
• Wear a hard hat, protective glasses, and other
protective equipment, as required. When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
• When work is performed around an engine that is shoes, and eye protection. Eye protection includes
operating, wear protective devices for ears in goggles or a protective face shield. Always wear eye
order to help prevent damage to hearing. protection for cleaning the cooling system.
• 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.

Unless other instructions are provided, perform
the maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot be started.

• The protective locks or the controls are in the

applied position.

• Disconnect the batteries when maintenance is

performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• When starting a new engine, make provisions to
stop the engine if an overspeed occurs. If an
engine has not been started since service has
been performed, make provisions to stop the
engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine.
• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.
M0097687-03 11
Safety Section
General Hazard Information

Avoid direct spraying of water on electrical Static Electricity Hazard when

connectors, connections, and components. When
using air for cleaning, allow the machine to cool to Fueling with Ultra-low Sulfur Diesel
reduce the possibility of fine debris igniting when Fuel
redeposited on hot surfaces.
The removal of sulfur and other compounds in ultra-
Fluid Penetration low sulfur diesel fuel (ULSD fuel) decreases the
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.

Illustration 8 g00687600
Avoid static electricity risk when fueling. Ultra-
Always use a board or cardboard when you check for low sulfur diesel fuel (ULSD fuel) poses a greater
a leak. Leaking fluid that is under pressure can static ignition hazard than earlier diesel formula-
penetrate body tissue. Fluid penetration can cause tions with a higher sulfur contents. Avoid death
serious injury and possible death. A pin hole leak can or serious injury from fire or explosion. Consult
cause severe injury. If fluid is injected into your skin, with your fuel or fuel system supplier to ensure
you must get treatment immediately. Seek treatment the delivery system is in compliance with fueling
from a doctor that is familiar with this type of injury. standards for proper grounding and bonding
practices.
Containing Fluid Spillage
NOTICE Lines, Tubes, and Hoses
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Do not bend or strike high-pressure lines. Do not
nance, testing, adjusting, and repair of the product. install lines, tubes, or hoses that are damaged.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Repair any fuel lines, oil lines, tubes, or hoses that
bling any component containing fluids. are loose or damaged. Leaks can cause fires.

Refer to Special Publication, NENG2500, “Cat Dealer Inspect all lines, tubes, and hoses carefully. Do not
Service Tool Catalog” or refer to Special Publication, use bare hands to check for leaks. Always use a
PECJ0003, “Cat Shop Supplies and Tools Catalog” board or cardboard for checking engine components
for tools and supplies suitable to collect and contain for leaks. Tighten all connections to the
fluids on Cat products. recommended torque.

Dispose of all fluids according to local regulations Check for the following conditions:
and mandates.
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut

• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering
12 M0097687-03
Safety Section
General Hazard Information

Ensure that all of the clamps, the guards, and the • Wear appropriate personal protective equipment
heat shields are installed correctly. Correct (PPE).
installation of these components will help to prevent
these effects: vibration, rubbing against other parts • Wash your hands and face with soap and water
and excessive heat during operation. prior to eating, drinking, or smoking, and also
during rest room breaks, to prevent ingestion of
Inhalation any yellow powder.

• Never use compressed air for cleaning areas

suspected of containing hexavalent chromium.

• Avoid brushing, grinding, or cutting materials

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
Illustration 9 g02159053 shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat
Exhaust replacement parts. Use the following guidelines when
you handle any replacement parts that contain
Use caution. Exhaust fumes can be hazardous to asbestos or when you handle asbestos debris.
your health. If you operate the equipment in an
enclosed area, adequate ventilation is necessary. Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
Hexavalent Chromium to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
Cat equipment and replacement parts comply with material, clutch plates, and some gaskets. The
applicable regulations and requirements where asbestos that is used in these components is bound
originally sold. Caterpillar recommends the use of in a resin or sealed in some way. Normal handling is
only genuine Cat replacement parts. not hazardous unless airborne dust that contains
asbestos is generated.
Hexavalent chromium has occasionally been
detected on exhaust and heat shield systems on Cat If dust that may contain asbestos is present, there
engines. Although lab testing is the only accurate are several guidelines that should be followed:
way to know if hexavalent chromium is, in fact,
present, the presence of a yellow deposit in areas of • Never use compressed air for cleaning.
high heat (for example, exhaust system components
or exhaust insulation) may be an indication of the • Avoid brushing materials that contain asbestos.
presence of hexavalent chromium.
• Avoid grinding materials that contain asbestos.
Use caution if you suspect the presence of
hexavalent chromium. Avoid skin contact when • Use a wet method in order to clean up asbestos
handling items that you suspect may contain materials.
hexavalent chromium, and avoid inhalation of any
dust in the suspect area. Inhalation of, or skin contact • A vacuum cleaner that is equipped with a high
with, hexavalent chromium dust may be hazardous to efficiency particulate air filter (HEPA) can also be
your health. used.
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:
M0097687-03 13
Safety Section
Burn Prevention

• Comply with applicable rules and regulations for Always use leakproof containers when you drain
the work place. In the United States, use fluids. Do not pour waste onto the ground, down a
Occupational Safety and Health Administration drain, or into any source of water.
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”. i08162288

• Obey environmental regulations for the disposal of

asbestos.
Burn Prevention
SMCS Code: 1000; 4450; 7405
• Stay away from areas that might have asbestos
particles in the air. Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
Softwrap air system, hydraulic system, lubrication system, fuel
system, and cooling system before any lines, fittings,
Keep the engine room ventilation operating at full or related items are disconnected.
capacity. Wear a particulate respirator that has been
approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate Coolant
protective clothing in order to minimize direct contact.
Use good hygiene practices and wash hands When the engine is at operating temperature, the
thoroughly after handling Softwrap material. Do not engine coolant is hot. The coolant is also under
smoke until washing hands thoroughly after handling pressure. The radiator and all lines to the heaters or
Softwrap material. Clean up debris with a vacuum or to the engine contain hot coolant.
by wet sweeping. Do not use pressurized air to clean Any contact with hot coolant or with steam can cause
up debris. severe burns. Allow cooling system components to
Reference: The applicable material safety data cool before the cooling system is drained.
sheets can be found at the following web site by Check that the coolant level after the engine has
searching using part number or the name: stopped and the engine has been allowed to cool.
https://catmsds.cat.com/MSDSSearch/servlet/ Ensure that the filler cap is cool before removing the
cat.cis.ecs. filler cap. The filler cap must be cool enough to touch
msdsSearch.controller. with a bare hand. Remove the filler cap slowly to
UserIdentificationDisplayServlet relieve pressure.

Dispose of Waste Properly

Illustration 10 g00706404

Improperly disposing of waste can threaten the

environment. Potentially harmful fluids should be
disposed of according to local regulations.
14 M0097687-03
Safety Section
Fire Prevention and Explosion Prevention

Cooling system conditioner contains alkali. Alkali can Determine whether the engine will be operated in an
cause personal injury. Do not allow alkali to contact environment that allows combustible gases to be
the skin, the eyes, or the mouth. drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
Oils property damage, or engine damage could result.
If the application involves the presence of
Hot oil and hot lubricating components can cause
combustible gases, consult your Cat dealer for
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact additional information about suitable protection
the skin. devices.
Remove all flammable materials such as fuel, oil, and
Batteries debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or All fluids that are captured in the fluid spill
the eyes. Always wear protective glasses for containment basin should be cleaned up
servicing batteries. Wash hands after touching the immediately. Failure to clean up spilled fluids can
batteries and connectors. Use of gloves is cause a fire. Fire may cause personal injury and
recommended. property damage.
Store fuels and lubricants in properly marked
i08302987 containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
Fire Prevention and Explosion containers. Do not smoke in areas that are used for
storing flammable materials.
Prevention
Do not expose the engine to any flame.
SMCS Code: 1000; 4450; 7405
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in a line, a tube, or
a seal failure. Exhaust shields must be installed
correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not use flame to cut lines or tanks that
contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Properly route
and attach all electrical wires. Check all electrical
wires daily. Repair any wires that are loose or frayed
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.

Illustration 11 g00704000
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
Use of personal protection equipment (PPE) may be smaller than the recommended gauge. Do not
needed. bypass any fuses and/or circuit breakers.

All fuels, most lubricants, and some coolant mixtures Arcing or sparking could cause a fire. Secure
are flammable. connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
Always perform a Walk-Around Inspection, which or sparking.
may help you identify a fire hazard. Do not operate a
product when a fire hazard exists. Contact your Cat Inspect all lines and hoses for wear or for
dealer for service. deterioration. Properly route all hoses. The lines and
hoses must have adequate support and secure
Flammable fluids that are leaking or spilled onto hot clamps. Tighten all connections to the recommended
surfaces or onto electrical components can cause a torque. Leaks can cause fires.
fire. Fire may cause personal injury and property
damage. Properly install all oil filters and fuel filters. The filter
housings must be tightened to the proper torque.
Flash fires may result if the covers for the engine
crankcase are removed within 15 minutes after an
emergency shutdown.
M0097687-03 15
Safety Section
Fire Prevention and Explosion Prevention

Illustration 12 g00704059 Illustration 13 g02298225

Use caution when you are refueling an engine. Do Gases from a battery can explode. Keep any open
not smoke while you are refueling an engine. Do not flames or sparks away from the top of a battery. Do
refuel an engine near open flames or sparks. Always not smoke in battery charging areas.
stop the engine before refueling.
Never check the battery charge by placing a metal
Avoid static electricity risk when fueling. Ultra Low object across the terminal posts. Use a voltmeter or a
Sulfur Diesel (ULSD) poses a greater static ignition hydrometer.
hazard than earlier diesel formulations with a higher
Sulfur content. Avoid death or serious injury from fire Improper jumper cable connections can cause an
or explosion. Consult with your fuel or fuel system explosion that can result in injury. Refer to the
supplier to ensure that the delivery system is in Operation Section of this manual for specific
compliance with fueling standards for proper instructions.
grounding and bonding practices.
Do not charge a frozen battery. Charging a frozen
battery may result in 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 ventilated areas. Do not smoke while
you are replacing an ether cylinder or while you are
using an ether spray.
16 M0097687-03
Safety Section
Crushing Prevention and Cutting Prevention

Do not store ether cylinders in living areas or in the Stay clear of all rotating parts and of all moving parts.
engine compartment. Do not store ether cylinders in Leave the guards in place until maintenance is
direct sunlight or in temperatures above 49 °C performed. After the maintenance is performed,
(120 °F). Keep ether cylinders away from open reinstall the guards.
flames or sparks.
Keep objects away from moving fan blades. The fan
Dispose of used ether cylinders properly. Do not blades will throw objects or cut objects.
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel. When objects are struck, wear protective glasses to
avoid injury to the eyes.
Do not spray ether into an engine if the engine is
equipped with a thermal starting aid for cold weather Chips or other debris may fly off objects when objects
starting. are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
Lines, Tubes, and Hoses
i08159517
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent Mounting and Dismounting
or damaged.
SMCS Code: 1000; 4450; 7405
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Cat dealer for repair or Inspect the steps, the handholds, and the work area
for replacement parts. before mounting the engine. Keep these items clean
and keep these items in good repair.
Check lines, tubes, and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or Mount the engine and dismount the engine only at
cardboard to check for leaks. Tighten all connections locations that have steps and/or handholds. Do not
to the recommended torque. climb on the engine, and do not jump off the engine.

Replace the parts if any of the following conditions Face the engine to mount the engine or dismount the
are present: engine. With your feet and hands, always maintain a
three-point contact with the steps and designated
• End fittings are damaged or leaking. handholds. Do not use any controls as handholds.

• Outer coverings are chafed or cut. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
• Wires are exposed. platform. Secure the climbing equipment so that the
equipment will not move.
• Outer coverings are ballooning.
Do not carry tools or supplies when you mount the
• Flexible parts of the hoses are kinked. engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
• Outer covers have embedded armoring.
i04021433
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
Engine Starting
are installed correctly to prevent vibration, rubbing SMCS Code: 1000
against other parts, and excessive heat.
If a warning tag is attached to the engine start switch
i08162291
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
Crushing Prevention and
Cutting Prevention All protective guards and all protective covers must
be installed if the engine must be started in order to
SMCS Code: 1000; 4450; 7405 perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
Support the component properly when work beneath around the parts carefully.
the component is performed.
Start the engine from the operator's compartment or
Unless other maintenance instructions are provided, from the engine start switch.
never attempt adjustments while the engine is
running.
M0097687-03 17
Safety Section
Engine Stopping

Always start the engine according to the procedure Grounding Practices

that is described in this Operation and Maintenance
Manual, “Engine Starting” topic (Operation Section).
Knowledge of the correct procedure will help to
prevent major damage to the engine components.
Knowledge of the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge and the
oil temperature gauge during the heater operation.
Engine exhaust contains products of combustion that
can be harmful to your health. Always start the
engine and operate the engine in a ventilated area. If
the engine is started in an enclosed area, vent the
engine exhaust to the outside.

i06299648

Engine Stopping
SMCS Code: 1000
Do not stop the engine immediately after the machine
has been operated under load. Stopping the engine
immediately can cause overheating and accelerated
wear of engine components.
After the machine is parked and the parking brake is
engaged, allow the engine to run at low idle for 5
minutes before shutdown. Running the engine allows Illustration 14 g00771448
hot areas of the engine to cool gradually.
Typical example
i02469632 Grounding Stud To Battery Ground

Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” jump start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. Refer to
the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.
18 M0097687-03
Safety Section
Engine Electronics

All grounds should be tight and free of corrosion. The

engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.

i04021529

Engine Electronics
SMCS Code: 1000; 1900

Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.
The Electronic Control Module (ECM) provides a
comprehensive, programmable engine monitoring
system for this engine. The ECM monitors specific
engine operating parameters in order to detect
abnormal conditions that may develop. The ECM will
generate an event code if a specific engine
parameter exceeds an acceptable range that is
defined by the engine monitoring system. The ECM
will react with an action that is dependent on the
severity of the condition. For information on event
codes, refer to this Operation and Maintenance
Illustration 15 g00771487 Manual, “Event Codes” topic (Operation Section) The
Typical example following actions may be initiated by the ECM. These
actions are dependent on the severity of the
Alternate Grounding Stud To Battery Ground condition:
Proper grounding for the engine electrical system is • Illumination of a warning lamp or warning alarm
necessary for optimum engine performance and
reliability. Improper grounding will result in • Engine derate
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths. • Engine protection shutdown
Uncontrolled electrical circuit paths can result in The Engine Monitoring package can vary for different
damage to main bearings, to crankshaft bearing engine models and different engine applications.
journal surfaces, and to aluminum components. However, the monitoring system and the engine
monitoring control will be similar for all engines.
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical Note: Many of the engine control systems and
discharge. display modules that are available for Caterpillar
Engines will work in unison with the Engine
To ensure that the engine and the engine electrical
Monitoring System. Together, the two controls will
systems function properly, an engine-to-frame
ground strap with a direct path to the battery must be provide the engine monitoring function for the specific
used. This path may be provided by way of a starting engine application. Refer to the Troubleshooting
motor ground, a starting motor ground to the frame, Manual for more information.
or a direct engine ground to the frame.
M0097687-03 19
Product Information Section
General Information

Product Information
Section

General Information
i07501731

Model View Illustrations

SMCS Code: 1000

Illustration 16 g06200473
View of the top of a typical C9.3B Engine
(1) Oil pan (3) Turbocharger
(2) Lifting eyes (4) Oil cap
20 M0097687-03
Product Information Section
Model View Illustrations

Illustration 17 g06204459
View of the left side of a typical 9.3B Engine
(5) Oil filler tube (7) Electronic Control module (ECM)
(6) Fuel Injection pump (8) Starting motor
M0097687-03 21
Product Information Section
Model View Illustrations

Illustration 18 g06204604
View of the left side of a typical 9.3B Engine
(9) Secondary fuel filters (12) Crankcase ventilation filter (if equipped) (15) Oil dipstick
(10) Primary fuel filter/ water separator (13) Crankcase breather
(11) Fuel pump switch assembly (14) Flywheel housing
22 M0097687-03
Product Information Section
Product Description

Illustration 19 g06204634
View of the front right side of a typical 9.3B Engine
(16) Oil filter (17) Alternator

i07501705

Product Description
SMCS Code: 1000; 4450; 4491
The Caterpillar C9.3B Industrial Engine has the
following characteristics:
• Four-stroke cycle

• High-pressure common rail fuel system

• Turbocharged

Engine Specifications
Illustration 20 g01387009
Note: The front end of the engine is opposite the Cylinder and valve location
flywheel end of the engine. The left and the right (A) Exhaust valve
sides of the engine are determined from the flywheel (B) Inlet valve
end. The number 1 cylinder is the front cylinder.
M0097687-03 23
Product Information Section
Product Description

Table 1
C-9.3B Engine Specifications The fuel pump pressurizes the fuel, and pumps the
Arrangement and Cylinders In-Line six cylinder
fuel to the common fuel rail. The common rail fuel
injectors inject the fuel into the cylinders at a precise
Bore 115.0 mm (4.53 inch) time. The fuel is injected into the cylinders with the
appropriate volume. Electronic sensors on the engine
Stroke 149.0 mm (5.87 inch) determine time and volume of fuel injection.
ATAAC(1)
Aspiration Engine Service Life
SCAC (2)

Displacement 9.3 L (568 in3) Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
Firing Order 1-5-3-6-2-4 operation and maintenance recommendations. In
addition, use recommended fuels, coolants, and
Rotation (flywheel end) Counterclockwise lubricants. Use the Operation and Maintenance
(1) Air-to-air aftercooled
Manual as a guide for required engine maintenance.
(2) Separate circuit after cooling
Expected engine life is predicted by the average
power that is demanded. The average power that is
Electronic Engine Features demanded is based on fuel consumption of the
engine over a time. Reduced hours of operation at
The Caterpillar C9.3B Engine is designed for full throttle and/or operating at reduced throttle
electronic controls. The integral on board computer settings result in a lower average power demand.
controls the operation of the engine. Current Reduced hours of operation will increase the length
operating conditions are monitored. The Electronic of operating time before an engine overhaul is
Control Module (ECM) controls the response of the required. For more information, refer to the Operation
engine to these conditions and to the demands of the and Maintenance Manual, “Overhaul Considerations”
operator. These conditions and operator demands topic (Maintenance Section).
determine the precise control of fuel injection by the
ECM. The electronic engine control system provides Aftermarket Products and
the following features:
Caterpillar Engines
• Engine speed governor

• Automatic air/fuel ratio control NOTICE

In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a
• Torque rise shaping four micron[c] absolute high efficiency fuel filter is re-
• Injection timing control quired for all Caterpillar common rail fuel systems.
Caterpillar High Efficiency Fuel Filters meet these re-
• System diagnostics quirements. Consult your Caterpillar dealer for the
proper part numbers.
Additional Features When auxiliary devices, accessories, or
consumables made by other manufacturers are used
The following features provide increased engine fuel on Caterpillar products, the Caterpillar warranty is not
economy and serviceability: affected simply because of such use.
• Cold starting capability However, failures that result from the installation
or use of devices, accessories, or consumables
• Tampering detection from other manufacturers are NOT Caterpillar
defects. Therefore, the defects are NOT covered
• Diagnostics under the Caterpillar warranty.

Common Rail Fuel Injection System

The common rail fuel injection system performs the
following functions:

• Pump the fuel.

• Meter the fuel.

• Time the fuel injection.

24 M0097687-03
Product Information Section
Product Identification Information

Product Identification
Information
i07501710

Plate Locations and Film

Locations
SMCS Code: 1000; 4450

Illustration 21 g06205197
View of the left side of a C9.3B Industrial Engine
The serial number plate is on the right side of the cylinder block. The engine control module will obstruct the view of
the serial number plate.
M0097687-03 25
Product Information Section
Reference Information

The following information is on the information plate:

engine serial number, engine model, engine
arrangement number, maximum altitude of the
engine that is necessary to achieve the rated power,
horsepower, high idle, full load rpm, fuel settings, and
other information

i04128675

Reference Information
SMCS Code: 1000; 4450
Information for the following items may be needed to
order parts. Locate the information for your engine.
Record the information on the appropriate space.
Illustration 22 g06199254 Make a copy of this list for a record. Retain the
Serial number plate information for future reference.

The following information is stamped on the serial Record for Reference

number plate: engine serial number, engine model,
and arrangement number. Table 2
System or Component Information

Chassis serial number

Engine model

Engine serial number

Engine arrangement
number
Modification number
Engine low idle rpm

Engine full load rpm

Performance specification
number
Engine horsepower

Primary fuel filter part

number
Water separator element
part number
Illustration 23 g02201394
Secondary fuel filter ele-
View of the top of a C9.3B Industrial Engine
ment part number
The engine information plate is located toward the
rear of the valve cover. The engine information plate Lubrication oil filter ele-
may be read from the right side of the engine. ment part number

Auxiliary oil filter element

part number

Supplemental coolant ad-

ditive maintenance ele-
ment part number (if
equipped)

Total lubrication system

capacity
Illustration 24 g01347963
Engine information plate
(continued)
26 M0097687-03
Product Information Section
Reference Information

(Table 2, contd)
Total cooling system
capacity

Engine air cleaner ele-

ment part number

Fan drive belt part

number
Alternator belt part
number
M0097687-03 27
Operation Section
Lifting and Storage

Operation Section 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,
Lifting and Storage ensure that proper lifting devices are provided.
Consult your Caterpillar dealer for information
regarding fixtures for proper engine lifting.
i07501715

Product Lifting Engine

SMCS Code: 7000; 7002 To lift engines, use the load rings provided on the
front and rear mounting brackets, with a certified
spreader bar.
Refer to the Special Publication, NENG2500, “Cat
Dealer Service Tool Catalog” for the latest in lifting
devise part numbers. Follow the safety instructions
for the selected tool to ensure a safe lift. For most
packages, the recommended spreader bar is 6V-
6146 set at 142 cm (56 inch) with the lift hook
locations set at about 3/4 of the way toward the front
stop (closest to the front engine lift eye).
Remove any ATAAC lines, air cleaners, or other
attachments that would otherwise interfere with the
lift chains or other lifting devises.
The engine package center of gravity will change
depending on the engine attachments. Adjust the
Illustration 25 g00103219
spreader bar and chains as necessary to maintain a
lift within 5 degrees of horizontal in all directions.
NOTICE
Always inspect lifting eyebolts and all other lifting Remove the front load ring before returning the
equipment for damage before performing any lifting. engine to service, to prevent the last load ring from
rubbing on the fan belt.
Never bend the eyebolts or the brackets. Never per-
form product lifting if components are damaged. Only Engine and Installed Radiator Only
load the eyebolts and the brackets under tension. Re-
member that the capacity of an eyebolt is less as the
The engine lifting eyes are rated to lift an engine with
angle between the supporting members and the ob-
attached radiator, assuming a less than 5 degree tilt
ject becomes less than 90 degrees.
angle can be maintained. Be sure to use an
When removing a component at an angle is neces- appropriate spreader set so that lifting chains are
sary, only use a link bracket that is properly rated for perpendicular to the engine.
the weight.
Radiator Only
Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the engine. All Detach the radiator, and mounting bracket at the
supporting members (chains and cables) should be engine front support. Add eyebolts or lifting brackets
parallel to each other. The chains and cables should to the threaded holes marked for lifting.
be perpendicular to the top of the object that is being
lifted.
i07501717
Some removals require lifting the fixtures to obtain
proper balance and safety. Product Storage
To remove the engine ONLY, use the lifting eyes that SMCS Code: 7002
are on the engine.
Storage (Less Than One Year)
If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls,
piston rings, main bearings, connecting rod bearings,
crankshaft, and gears.
28 M0097687-03
Operation Section
Product Storage

This lack of lubricant allows corrosion to begin to 9. Remove the fuel from the secondary fuel filter
appear on the metal. This condition is worse in areas housing. Alternately, empty and reinstall the spin-
of high humidity. on fuel filter element to remove any dirt and water.
When the engine is started again, metal to metal Drain any sleeve metering fuel pump.
contact will cause wear before the surfaces receive Clean the primary fuel filter. Fill with calibration
oil. To minimize this wear, use the starter to turn the
engine with the throttle in the FUEL OFF position. fluid or kerosene. Install the primary fuel filter and
When oil pressure is shown on the pressure gauge, operate the priming pump. This procedure will
start the engine. send clean oil to the secondary filter and the
1. Clean the engine of any dirt, rust, grease, and oil. engine.
Inspect the exterior. Paint areas that contain paint Open the fuel tank drain valve to drain any water
damage with a good quality paint. and dirt from the fuel tank. Apply a spray of
2. Remove dirt from the air cleaners. Check all seals, calibration fluid or kerosene at the rate of
gaskets, and the filter element for damage. 30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank
capacity to prevent rust in the fuel tank. Add
3. Apply lubricant to all points in this Operation and 0.15 mL per L (.02 oz per 1 gal US) of commercial
Maintenance Manual, “Maintenance Interval biocide such as Biobor JF to the fuel.
Schedule”.
Apply a small amount of oil to the threads on the
4. Drain the crankcase oil. Replace the crankcase oil fuel tank filler neck and install the cap. Seal all
and change the oil filters. For the proper openings to the tank to prevent evaporation of the
procedure, refer to this Operation and fuel and as a preservative.
Maintenance Manual.
10. Remove the fuel nozzles or spark plugs. Apply
5. If the engine is equipped with an air starting motor, 30 mL (1 oz) of the mixture of oils (50 percent VCI
fill the reservoir with the following mixture: 50 oil and 50 percent engine oil) into each cylinder.
percent volatile corrosion inhibitor oil
(<nomen>VCI oil</nomen>) and 50 percent Use a bar or a turning tool to turn over the engine
engine oil. slowly. This procedure puts the oil on the cylinder
walls. Install all fuel nozzles or spark plugs and
6. Add VCI oil to the crankcase oil. The volume of tighten to the correct torque.
VCI oil in the crankcase oil should be 3 to 4
percent. 11. Spray a thin amount of a mixture of 50 percent
VCI oil and 50 percent engine oil onto the following
Note: If the engine crankcase is full, drain enough components: flywheel, ring gear teeth, and starter
engine oil so the mixture can be added. pinion. Install the covers to prevent evaporation of
the vapors from the VCI oil.
7. Remove the air filter elements. Turn the engine at
cranking speed with the throttle control in FUEL 12. Apply a heavy amount of Cat Multipurpose
OFF position. Use a sprayer to add a mixture of 50 Grease (MPGM) to all outside parts that move,
percent VCI oil and 50 percent engine oil into the such as rod threads, ball joints, linkage.
air inlet or turbocharger inlet.
Note: Install all covers. Ensure that tape has been
Note: The mixture of VCI oil can be added to the inlet installed over all openings, air inlets, exhaust
by removing the plug for checking turbocharger boost openings, the flywheel housing, the crankcase
pressure. The minimum application rate for the VCI breathers, the dipstick tubes.
oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of
engine displacement. Ensure that all covers are airtight and
weatherproof. Use a waterproof weather resistant
8. Use a sprayer to apply a mixture of 50 percent VCI tape such as Kendall No. 231 or an equivalent. Do
oil and 50 percent crankcase oil into the exhaust not use duct tape. Duct tape will only seal for a
openings. The minimum application rate for the oil short time.
mixture is 5.5 mL per L (3 oz per 1000 cu in) of 13. Under most conditions, removing the batteries is
engine displacement. Seal the exhaust pipe and the best procedure. As an alternative, place the
seal any drain holes in the muffler. batteries in storage. As needed, periodically
charge the batteries while the batteries are in
storage.
M0097687-03 29
Operation Section
Product Storage

If the batteries are not removed, wash the tops of

the batteries until the tops are clean. Apply an
electrical charge to the batteries to obtain a
specific gravity of 1.225.
Disconnect the battery terminals. Place a plastic
cover over the batteries.
Note: For additional information, refer to Special
Instruction, SEHS7633, “Battery Test Procedure”.

14. Loosen all belts.

15. Place a waterproof cover over the engine. Ensure
that the engine cover is secure. The cover should
be loose enough to allow air to circulate around
the engine to prevent damage from condensation.
16. Attach a tag with the storage date to the engine.
17. Remove the waterproof cover at 2-month or 3-
month intervals to check the engine for corrosion.
If the engine has signs of corrosion, repeat the
Illustration 26 g06260878
protection procedure.
(1) Plugs for oil system
Coolant System
8. If an engine is stored for more than 1 year,
Completely fill the cooling system before storage. Caterpillar recommends pre-lubrication of the
engine to avoid dry starting. Use a suitable pump
Refer to this Operation and Maintenance Manual, to put engine oil into the engine oil system.
“Fluid Recommendations” for more information about
coolants. The pump will need to create a minimum pressure
within the engine of 0.25 bar (3.60 psi). This
Removal from Storage pressure is needed for 15 seconds to lubricate the
internal surfaces.
1. Remove all outside protective covers.
Remove one of the plugs (1) shown in illustration
2. Change the oil and filters. 26 to connect to the engine oil system. The
3. Check the condition of the fan and alternator belts. connection required is 9/16 in x 18 tpi. Ensure that
Replace the belts, if necessary. Refer to this the correct oil specifications used. Refer to this
Operation and Maintenance Manual, “Belts - Operation and Maintenance Manual, Fluid
Inspect/Adjust/Replace” for the correct procedure. Recommendations for more information. After the
engine internal surfaces have been lubricated,
4. Replace the fuel filter elements. remove connector, and install plug (1). Tighten
5. Remove the plastic covers from the air cleaner plug to a torque of 60 N·m (530 lb in). Caterpillar
elements. recommends performing the procedure in a
minimum ambient temperature of 0° C (32° F).
6. Use a bar or a turning tool to turn the engine in the
normal direction of rotation. The procedure 9. Check the condition of all rubber hoses. Replace
ensures that no hydraulic locks or resistance exist. any worn hoses. Replace any damaged hoses.

7. Before starting the engine, remove the valve cover 10. Before start-up, test the cooling system for a 3
or covers. Put a large amount of engine oil on the percent to a 6 percent concentration of coolant
camshaft, cam followers, and valve mechanism to conditioner. Add liquid coolant conditioner or a
prevent damage to the mechanism. coolant conditioner element, if equipped.
Test the coolant mixture for proper nitrite level. If
necessary, adjust the coolant mixture.
Prime the engine with clean diesel fuel before
starting.
30 M0097687-03
Operation Section
Product Storage

11. Ensure that the cooling system is clean. Ensure

that the system is full. Ensure that the system has
the correct amount of supplemental cooling
system conditioner.
12. On the first day of operation, check the entire
engine several times for leaks and correct
operation.
13. If the engine was removed from storage in which
temperatures of less than -12°C (10°F) were
encountered, refer to Service Manual, SEBU5898,
“Cold Weather Recommendations Operation and
Maintenance”.
M0097687-03 31
Operation Section
Features and Controls

Features and Controls The battery disconnect switch and the engine start
switch perform different functions. The entire
electrical system is disabled when you turn the
i07501791 battery disconnect switch to the OFF position. The
battery remains connected to the electrical system
Battery Disconnect Switch when you turn the engine start switch to the OFF
position.
(If Equipped)
Turn the battery disconnect switch to the OFF
SMCS Code: 1411
position and remove the key when you service the
electrical system or any other engine components.
Turn the battery disconnect switch to the OFF
position and remove the disconnect switch key after
you operate the engine. Turning the battery
disconnect switch to OFF will prevent the battery
from being discharged. The following problems can
cause battery discharge:
• short circuits

• current draw via some components

• vandalism

i07504953

Illustration 27 g03422039
Monitoring System
NOTICE SMCS Code: 1900; 7400; 7450; 7451
Do not turn the battery disconnect switch off until the
indicator lamp has turned off. The Monitoring System is designed to alert the
operator to an immediate problem with any of the
engine systems that are monitored. The Monitoring
System is also designed to alert the operator to an
NOTICE impending problem with any of the engine systems
Never move the battery disconnect switch to the OFF that are monitored.
position while the engine is operating. Serious dam-
age to the electrical system could result.

Battery Disconnect Switch – The battery

disconnect switch can be used to
disconnect the battery from the engines
electrical system. The key must be inserted into
the battery disconnect switch before the battery
disconnect switch can be turned.

ON – To activate the electrical system,

insert the disconnect switch key and
turn the battery disconnect switch
clockwise. The battery disconnect switch must
be turned to the ON position before you start the
engine.

OFF – To deactivate the electrical

system, turn the battery disconnect
switch counterclockwise to the OFF
position.
32 M0097687-03
Operation Section
Monitoring System

Indicators and Gauges NOTICE

To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
damage to the engine. The engine can be operated
at high idle without damage, but should never be al-
lowed to exceed high idle rpm.

Note: The high idle rpm and the full load rpm are
stamped on the Information Plate.
Coolant Temperature (4) – When the
coolant temperature is above the normal
operating value, the coolant
temperature gauge will be in the red zone. Refer
to the Messenger display for any additional
information that may be available.
Warning Lamp (5) – There is a general
fault in the engine. Refer to the
Messenger display for any additional
information that may be available.

Fuel Pressure (6) – This gauge indicates

Illustration 28 g01063079 fuel pressure to the fuel injection pump
Gauge cluster and indicators from the fuel filter. A decrease in fuel
pressure usually indicates a dirty fuel filter or a
Diagnostic Lamp (1) – The diagnostic plugged fuel filter. As the fuel filter becomes
lamp is used to indicate the existence of plugged, there will be a noticeable reduction in
a fault by flashing. the performance of the engine.

Engine Oil Pressure (2) – The oil System Voltage (7) – This gauge
pressure should be greatest after a cold indicates the voltage of the electrical
engine is started. The pressure will system.
decrease as the engine warms up. The pressure Circuit Breaker (8) – Reset the circuit breaker if a
will increase when the engine rpm is increased. circuit breaker trips. Press the button to reset the
The pressure will stabilize when the engine rpm circuit breaker. If the electrical system is working
is stable. properly, the button will remain pressed. If the button
does not remain pressed or if the circuit breaker trips
A lower oil pressure is normal at low idle. If the load is
soon after being reset, check the appropriate
stable and the gauge reading changes, perform the
electrical circuit. Repair the electrical circuit, if
following procedure: necessary.
1. Remove the load. Start Switch (9) – The start switch has three
2. Reduce engine speed to low idle. positions: OFF, RUN, and START. When the start
switch is turned clockwise to the RUN position, the
3. Check and maintain the oil level. lamps will flash for 5 seconds during the system test.
The lamps will then shut off. In the RUN position, the
Tachometer (3) – This gauge indicates ECM and electronic systems are powered up.
engine speed (rpm). When the throttle
control lever is moved to the full throttle
position without load, the engine is running at Idle Speed Switch (10) – When the
high idle. The engine is running at the full load switch is in the up position, the engine
rpm when the throttle control lever is at the full speed increases to HIGH IDLE. When
throttle position with maximum rated load. the switch is in the down position, the engine
speed decreases to LOW IDLE.
M0097687-03 33
Operation Section
Monitoring System

Maintenance Lamp (11) – The ECM scroll to the left through information that is shown on
records data that is related to equipment the display area.
maintenance. The ECM will activate the
maintenance indicator lamp when scheduled “ Scroll down/scroll right button”” (18) – This button
maintenance is due. The maintenance indicator is used to scroll down through information that is
lamp can be reset by actuating the maintenance shown on the display area. The button can also be
clear switch. The maintenance interval may be used to scroll to the right through information that is
based on operating hours or fuel consumption. shown on the display area.
The ECM provides information that pertains to
maintenance intervals and the last maintenance
that was performed. OK button (19) – This button may be used to confirm
the selections that were selected with the “scroll up/
Maintenance Clear Switch (12) – The scroll left” button, and with the “scroll down/scroll
right” button.
maintenance clear switch is required to
reset the maintenance lamp after
maintenance on the engine is performed. Performance Monitor Screen
Shutdown Switch (13) – Use the engine The following options are available through the
shutdown switch to stop the engine. performance monitor screen:
Push the shutdown switch to put the
switch in the OFF position. This will stop the Engine Speed – When you scroll to this option, the
engine. After the engine stops, turn the knob performance monitor screen will show the engine
clockwise. This will reset the engine shutdown RPM.
switch to the ON position.
Service Tool Connector (14) – For more information Engine Coolant Temperature – When you scroll to
regarding the use of Caterpillar Electronic Technician this option, the performance monitor screen will show
(ET) and the PC requirements for Cat ET, refer to the the engine coolant temperature in degrees fahrenheit
documentation that accompanies your Cat ET or in degrees celsius.
software.
Fuel Level – When you scroll to this option, the
performance monitor screen will show the amount of
Caterpillar Messenger Display fuel that remains in the fuel tank as a percentage of a
full tank.

Display Screen for Totals

The following information is available through the
display:
Service Hours – When you scroll to this option, the
display shows the total amount of service hours that
the engine has accumulated.

Total Time – When you scroll to this option, the

display shows the total hours for the engine ECM.

Total Fuel – When you scroll to this option, the

Illustration 29 g01063102 display shows the total amount of fuel that has been
consumed.
Digital display area (15) – The Messenger system
shows information on the digital display area.
Display Screen for Settings
Previous button (16) – Use the previous button to
return to information that was previously shown on The following options are available through the
the digital display area. payload display:
Language – Select this option to change the
“ Scroll up/scroll left button”” (17) – This button is language that is shown on the display.
used to scroll up through information that is shown on
the display area. The button can also be used to
34 M0097687-03
Operation Section
Monitoring System

Units – Select this option to choose the desired • Coolant Flow When you scroll to this option, the
system of measurement. The choices are metric or amount of coolant flow is displayed.
English.
• Boost Pressure When you scroll to this option,
the boost pressure is displayed.
Adjust Contrast – Select this option to adjust the
contrast of the display so that visibility will be • Atmospheric Pressure When you scroll to this
improved. option, the atmospheric pressure is displayed.

Adjust the Backlight – Select this option to adjust • Turbocharger Inlet Pressure When you scroll
the backlighting of the display so that visibility will be to this option, the turbocharger inlet pressure is
improved. displayed.
• Oil Pressure When you scroll to this option, the
Equipment ID – Select this option to view the absolute engine oil pressure is displayed.
product identification number.
• Oil Pressure When you scroll to this option, the
Product Identification – Select this option to view engine oil pressure gauge is displayed.
the product identification number.
• Fuel Temperature When you scroll to this
option, the fuel temperature is displayed.
Service Display SYSTEMS TESTS
The following options are password protection. You “ SYSTEM SELF TEST””
must enter a password to change the settings.
If you select this option, the monitoring system will
View – Select this option to view events that have initiate the self test. The self test is similar to the
been logged by the monitoring system. If you use an functional test that occurs when you turn the start
authorized password, you can clear individual switch from the OFF position to the ON position.
events.
INFORMATION on MONITORING and ENGINE
Clear All Diagnostics – If you use an authorized SYSTEMS
password, you can select this option to clear all
MONITORING SYSTEM
logged events.
• Software Part Number When you scroll to this
SYSTEM PARAMETERS option, the software part number is displayed.

MONITORING SYSTEM • ECM Part Number When you scroll to this

option, the ECM part number is displayed.
• Battery Voltage When you scroll to this option,
the battery voltage is displayed. • “ Software Release Date”” When you scroll to
this option, the release date of the software is
• Fuel Level When you scroll to this option, the displayed.
fuel level is displayed.
• “ Software Description”” When you scroll to this
• Status of the Alternator When you scroll to this option, the description of the software is displayed.
option, the status of the alternator is displayed.
ENGINE
• Engine Speed When you scroll to this option,
the engine RPM is displayed. • ECM Serial Number When you scroll to this
option, the ECM serial number is displayed.
• Desired Engine Speed When you scroll to this
option, the desired engine speed is displayed. • Software Part Number When you scroll to this
This parameter is used by the Automatic Retarder option, the software part number is displayed.
Control to prevent the engine from overspeeding.
• “ Software Release Date”” When you scroll to
If you have an approved password, you can
this option, the release date of the software is
change this parameter.
displayed.
• Throttle Position When you scroll to this option,
• “ Software Description”” When you scroll to this
the throttle position is displayed.
option, the description of the software is displayed.
• Coolant Temperature When you scroll to this
option, the coolant temperature is displayed.
M0097687-03 35
Operation Section
Monitoring System

• Engine Serial Number When you scroll to this

option, the engine serial number is displayed.

TATTLETALE

• “ Full Tattletale Readout”” When this option is

selected, all displays and gauges will display the
maximum values that have been reached during
operation.

• Engine Coolant Temperature When this option

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

• Tachometer When this option is selected, all

indicators will display the maximum values that
have been reached during operation. The
tachometer will also show the maximum value that
was reached during operation.
• Fuel Level When this option is selected, all
indicators will display the maximum values that
were reached during operation. The fuel level
gauge will also show the minimum value that was
reached during operation.

• Clear If you have an approved password, you

can clear the maximum values that have been
stored by the monitoring system.
36 M0097687-03
Operation Section
Engine Diagnostics

Engine Diagnostics i03840813

i01563934
Fault Logging
SMCS Code: 1000; 1900; 1901; 1902
Self-Diagnostics The system provides the capability of Fault Logging.
SMCS Code: 1000; 1900; 1901; 1902 When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will be
Caterpillar Electronic Engines have the capability to logged in the memory of the ECM. The codes that
perform a self-diagnostics test. When the system have been logged in the memory of the ECM can be
detects an active problem, the “DIAGNOSTIC” lamp retrieved with Caterpillar electronic service tools. The
is activated. Diagnostic codes will be stored in codes that have been logged can be cleared with
permanent memory in the Electronic Control Module Caterpillar electronic service tools. The codes that
(ECM). The diagnostic codes can be retrieved by have been logged in the memory of the ECM will be
using the following components: automatically cleared from the memory after 100
hours. The following faults cannot be cleared from
• Caterpillar electronic service tools the memory of the ECM without using a factory
password: overspeed, low engine oil pressure and
• “DIAGNOSTIC” lamp high engine coolant temperature.
Note: The “DIAGNOSTIC” lamp must be installed by
the OEM or by the customer.
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. If a code
is active, the “DIAGNOSTIC” lamp will flash the flash
code at five second intervals.
Logged codes represent the following items:

• Intermittent problems
• Recorded events

• Performance history
The problems may have been repaired since the
logging of the code. These codes do not indicate that
a repair is needed. The codes are guides or signals
when a situation exists. Codes may be helpful to
troubleshoot problems.
When the problems have been corrected, the
corresponding logged fault codes should be cleared.
M0097687-03 37
Operation Section
Engine Starting

Engine Starting • Ensure that the areas around the rotating parts are
clear.
i02354640 • All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair
Before Starting Engine any damaged guards. Replace damaged guards
and/or missing guards.
SMCS Code: 1000; 1400; 1450
• Disconnect any battery chargers that are not
Perform the required daily maintenance and other
protected against the high current drain that is
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can created when the electric starting motor (if
help prevent major repairs at a later date. equipped) is engaged. Check electrical cables and
check the battery for poor connections and for
• For the maximum service life of the engine, make corrosion.
a thorough inspection before starting the engine.
Look for the following items: oil leaks, coolant • Reset any of the shutoff components or alarm
leaks, loose bolts and trash buildup. Remove trash components.
buildup and arrange for repairs, as needed.
• Check the engine lubrication oil level. Maintain the
• Inspect the cooling system hoses for cracks and oil level between the “ADD” mark and the “FULL”
for loose clamps. mark on the oil level gauge.

• Inspect the alternator and accessory drive belts for • Check the coolant level. Maintain the coolant level
cracks, breaks, and other damage. within 13 mm (0.5 inch) of the bottom of the filler
pipe. If the engine is equipped with a sight glass,
• Inspect the wiring for loose connections and for maintain the coolant level in the sight glass.
worn wires or frayed wires.
• Observe the air cleaner service indicator. Service
• Check the fuel supply. Drain water from the water the air cleaner when the red target locks in the
separator (if equipped). Open the fuel supply visible position.
valve.
• Disengage any driven equipment. Remove any
electrical loads.
NOTICE
All valves in the fuel return line must be open before
i04132731
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage. Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
If the engine has not been run for several weeks, fuel
Startability will be improved at temperatures below
may have drained from the fuel system. Air may have
10°C (50°F) from the use of a cylinder block coolant
entered the filter housing. Also, when fuel filters have
heater or from other means that are used to heat the
been changed, some air space will be left in the crankcase oil. Some engine applications use a jacket
housing. In these instances, prime the fuel system. water heater to improve startability. Use of a jacket
Refer to the Operation and Maintenance Manual, water heater will help reduce white smoke and
“Fuel System - Prime” for more information on misfire during start-up in cold weather.
priming the fuel system.
Note: If the engine has not been run for several
weeks, fuel may have drained. Air may have moved
into the filter housing. Also, when fuel filters have
Engine exhaust contains products of combustion been changed, some air will be left in the filter
which may be harmful to your health. Always housing. Refer to the Operation and Maintenance
start and operate the engine in a well ventilated Manual, “Fuel System - Prime” (Maintenance
area and, if in an enclosed area, vent the exhaust Section) for more information on priming the fuel
to the outside. system.

• 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.
38 M0097687-03
Operation Section
Starting the Engine

Ether Injection System (If NOTICE

Equipped) Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
The ether injection system is controlled by the ECM.
The ECM monitors the coolant temperature, intake If the engine fails to start within 30 seconds, release
air temperature, ambient air temperature, and the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
barometric pressure to determine when ether
start the engine again.
injection is needed. At sea level, ether will be used if
any of the temperatures fails to exceed 0° C (32° F).
This temperature is subject to an increase as 3. Push the start button or turn the ignition switch to
barometric pressure increases. the START position to crank the engine.
Do not push down or hold the throttle down while
the engine is cranked. The system will
Personal injury or property damage can result automatically provide the correct amount of fuel
from alcohol or starting fluids. that is needed to start the engine.
Alcohol or starting fluids are highly flammable 4. If the engine fails to start within 30 seconds,
and toxic and if improperly stored could result in release the start button, or the ignition switch. Wait
injury or property damage. for 2 minutes to allow the starting motor to cool
before attempting to start the engine again.
Follow the procedure in this Operation and
Maintenance Manual, “Starting the Engine”. NOTICE
Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine rpm until the oil
i07504962
pressure gauge indicates normal. If oil pressure is
not indicated on the gauge within 15 seconds, DO
Starting the Engine NOT operate the engine. STOP the engine, investi-
SMCS Code: 1000; 1450 gate and correct the cause.

5. Allow the engine to idle for approximately 3

minutes. Idle the engine until the water
Engine exhaust contains products of combustion temperature gauge has begun to rise. Check all
which may be harmful to your health. Always gauges during the warmup period.
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust Note: Oil pressures and fuel pressures should be in
to the outside. the normal range on the instrument panel. Engines
that are equipped with “WARNING” lamps do not
have an operating range. The “WARNING and
Starting the Engine DIAGNOSTIC” lamp (if equipped) will flash while the
engine is cranking. The lamp should turn off after
Refer to the Owner's Manual of the OEM for your proper engine oil pressure or fuel pressure is
type of controls. Use the following procedure to start achieved. Do not apply a load to the engine or
the engine. increase engine rpm until the oil pressure gauge
indicates at least normal pressure. Inspect the engine
1. Place the transmission in NEUTRAL. Disengage
for leaks and/or unusual noises.
the flywheel clutch to allow the engine to start
faster, and to reduce the draining of the battery. If the engine is operated with a low load, the engine
will reach normal operating temperature sooner than
2. Turn the ignition switch to the ON position. idling the engine with no load. When the engine is
idled in cold weather, increase the engine rpm to
During the key on, the diagnostic lamp, and approximately 1000 to 1200 rpm to warm up the
warning lamp will be checked for proper bulb engine more quickly. Do not exceed the
operation. If any of the lamps do not illuminate, recommended rpm to increase the speed of the
replace the bulb. warmup. Limit unnecessary idle time to 10 minutes.

Starting Problems
An occasional starting problem may be caused by
one of the following items:
M0097687-03 39
Operation Section
Starting with Jump Start Cables

• Low battery charge 3. Start the engine. If the engine does not start,
consult the nearest Caterpillar dealer for
• Lack of fuel assistance.
• Problem with the wiring harness
i06983895
If the engine fuel system has been run dry, fill the fuel
tank and prime the fuel system. Refer to the Starting with Jump Start
Operation and Maintenance Manual, “Fuel System -
Prime” topic (Maintenance Section). Cables
If the other problems are suspected, perform the (Do Not Use This Procedure in
appropriate procedure to start the engine. Hazardous Locations that have
Problems with the Wiring Harness Explosive Atmospheres)
SMCS Code: 1000; 1401; 1402; 1900
If the installation is not equipped with a backup
battery system, starting the engine from an external
electrical source may be necessary.
First, determine the reason that starting the engine
from an external electrical source is necessary. Refer
to Troubleshooting, M0076536, “C9.3B Engines”.
Many batteries which are considered unusable are
still rechargeable. After jump starting, the alternator
may not be able to recharge batteries that are
severely discharged. The batteries must be charged
to the proper voltage with a battery charger. For
information on testing and charging, refer to the
Special Instruction, SEHS7633, “Battery Test
Procedure”.

NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
Illustration 30 g01248812
Do not reverse the battery cables. The alternator can
ECM Connector J2/P2 be damaged. Attach ground cable last and remove
Locate the ECM. Check the connector to ensure that first.
the connector is secure. Lightly pull each of the wires When using an external electrical source to start the
in the chassis harness. engine, turn the generator set control switch to the
1. Pull each wire with approximately 4.5 kg (10 lb) of “OFF” position. Turn all electrical accessories OFF
before attaching the jump start cables.
force. The wire should remain in the connector.
2. If a wire is loose, push the wire back into the Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
connector. Pull the wire again to ensure that the gine being started.
wire is secure.

1. Turn the start switch on the stalled engine to OFF.

Turn off all accessories.
2. Connect one positive end of the jump-start cable to
the positive cable terminal of the discharged
battery. Connect the other positive end of the
jump-start cable to the positive cable terminal of
the electrical source.
40 M0097687-03
Operation Section
After Starting Engine

3. Connect one negative end of the jump-start cable

to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump-start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.
4. Charge the batteries. The engine will not continue
to run after starting if the batteries have not been
charged.
5. Start the engine.
6. Immediately after the stalled engine is started,
disconnect the jump-start cables in reverse order.
Refer to the Electrical Schematic for your engine.
Consult your Caterpillar dealer for more information.

i07501724

After Starting Engine

SMCS Code: 1000

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

the warmup time is approximately 3 minutes. In
temperatures below 0°C (32°F), extra warmup time
may be required.
When the engine is idling during warmup, observe
the following conditions:
• Check for fluid or air leaks at idle rpm and at one-
half full rpm (no load on the engine) before
operating the engine under load. Operating the
engine at idle and at one-half full rpm with no load
is not possible in some applications.

• Operate the engine at low idle until all systems

achieve operating temperatures. Check all gauges
during the warmup period.

Note: Gauge readings should be observed and the

data should be recorded frequently while the engine
is operating. Comparing the data over time will help
to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.

Extended Idle at Cold Ambient

Temperature
The engine may automatically change speeds when
the engine is idling in cold ambient temperatures
(typically less than 0° C (32° F) for extended periods.
The purpose of the automatic speed change is to
keep the engine coolant warm. The engine speed
may rise to 1600 rpm for as long as 20 minutes.
M0097687-03 41
Operation Section
Engine Operation

Engine Operation Interrupted starts put excessive stress on the drive

train. Interrupted starts also waste fuel. To get the
driven equipment in motion, engage the clutch
i06545704
smoothly with no load on the equipment. This
method should produce a start that is smooth and
Engine Operation easy. The engine rpm should not increase and the
SMCS Code: 1000 clutch should not slip.
Proper operation and maintenance are key factors in 3. Ensure that the ranges of the gauges are normal
obtaining the maximum life and economy of the when the engine is operating at one-half of the
engine. If the directions in the Operation and rated rpm. Ensure that all gauges operate
Maintenance Manual are followed, costs can be properly.
minimized and engine service life can be maximized.
4. Increase the engine rpm to the rated rpm. Always
The time that is needed for the engine to reach
normal operating temperature can be less than the increase the engine rpm to the rated rpm before
time needed for a walk-around inspection of the the load is applied.
engine.
5. Apply the load. Begin operating the engine at low
After the engine is started and after the engine load. Check the gauges and equipment for proper
reaches normal operating temperature, the engine operation. After normal oil pressure is reached and
can be operated at the rated rpm. The engine will the temperature gauge begins to move, the engine
reach normal operating temperature faster when the may be operated at full load. Check the gauges
engine is at rated speed. The engine will reach
and equipment frequently when the engine is
normal operating temperature faster when the engine
is at low-power demand. This procedure is more operated under load.
effective than idling the engine at no load. The engine Extended operation at low idle or at reduced load
should reach operating temperature in a few minutes.
may cause increased oil consumption and carbon
Gauge readings should be observed and the data buildup in the cylinders. This carbon buildup
should be recorded frequently while the engine is results in a loss of power and/or poor
operating. Comparing the data over time will help to performance.
determine normal readings for each gauge.
Comparing data over time will also help detect i01136207
abnormal operating developments. Significant
changes in the readings should be investigated.
Fuel Conservation Practices
Engines rated for constant speed use are allowed to SMCS Code: 1000; 1250
complete a starting sequence, an operation at a
single constant speed, and a shutdown sequence. The efficiency of the engine can affect the fuel
Every time the engine is run, each of these economy. Caterpillar's design and technology in
operations should occur only once. The starting manufacturing provides maximum fuel efficiency in
sequence and shutdown sequence can include a all applications. Follow the recommended procedures
short period of operation at the low idle speed for in order to attain optimum performance for the life of
purposes of warming up and cooling down the engine the engine.
or driven equipment. The emissions type approval is
not valid for operation of a constant speed engine in • Avoid spilling fuel.
a manner different from that described above.
Fuel expands when the fuel is warmed up. The fuel
i04038637 may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
Engaging the Driven • Be aware of the properties of the different fuels.
Equipment Use only the recommended fuels.
SMCS Code: 1000 • Avoid unnecessary idling.
1. Operate the engine at one-half of the rated rpm, Shut off the engine rather than idle for long periods of
when possible. time.
2. Engage the driven equipment without a load on the • Observe the service indicator frequently. Keep the
equipment, when possible. air cleaner elements clean.
42 M0097687-03
Operation Section
Fuel Conservation Practices

• Ensure that the turbochargers are operating

correctly so that the proper air/fuel ratio is
maintained. Clean exhaust indicates proper
functioning.
• Maintain a good electrical system.
One faulty battery cell will overwork the alternator.
This will consume excess power and excess fuel.

• Ensure that the belts are properly adjusted. The

belts should be in good condition.

• Ensure that all of the connections of the hoses are

tight. The connections should not leak.
• Ensure that the driven equipment is in good
working order.
• Cold engines consume excess fuel. 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.
M0097687-03 43
Operation Section
Cold Weather Operation

Cold Weather Operation There are three major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
i03729720
• Lower cloud point
Radiator Restrictions • Lower pour point
SMCS Code: 1353; 1396
• Lower rating of kJ (BTU) per unit volume of fuel
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow When No. 1 diesel fuel is used, a decrease in power
restriction can cause the following conditions: and in fuel efficiency may be noticed.
• High exhaust temperatures The cloud point is the temperature when a cloud of
wax crystals begins to form in the fuel. These crystals
• Power loss can cause the fuel filters to plug. The pour point is the
temperature when diesel fuel will thicken. The diesel
• Excessive fan usage fuel becomes more resistant to flow through fuel
pumps and through fuel lines.
• Reduction in fuel economy
Be aware of these values when diesel fuel is
If an airflow restriction device must be used, the purchased. Anticipate the average ambient
device should have a permanent opening directly in temperature of the area. Engines that are fueled in
line with the fan hub. The device must have a one climate may not operate well if the engines are
minimum opening dimension of at least 770 cm2 moved to another climate. Problems can result due to
(120 in2). changes in temperature.
A centered opening that is directly in line with the fan Before troubleshooting for low power or for poor
hub is specified in order to prevent an interrupted performance in the winter, check the type of fuel that
airflow on the fan blades. Interrupted airflow on the is being used.
fan blades could cause a fan failure.
When No. 2 diesel fuel is used, the following
Caterpillar recommends a warning device for the inlet components provide a means of minimizing problems
manifold temperature and/or the installation of an in cold weather:
inlet air temperature gauge. The warning device for
the inlet manifold temperature should be set at 90° C • Starting aids
(194° F). The inlet manifold air temperature should
not exceed 75 °C (167 °F). Temperatures that • Engine oil pan heaters
exceed this limit can cause power loss and potential
engine damage. • Engine coolant heaters

i08230315 • Fuel heaters

Fuel and the Effect from Cold • Fuel line insulation

Weather For more information on cold-weather operation, see

Special Publication, SEBU5898, “Cold-Weather
SMCS Code: 1000; 1250; 1280 Recommendations”.
The following fuels are the grades that are available i03728501
for Cat engines:
• No. 1 Fuel Related Components in
• No. 2
Cold Weather
SMCS Code: 1000; 1250; 1280
• Blend of No. 1 and No. 2
No. 2 diesel fuel is the most commonly used fuel. Fuel Tanks
Either No. 1 diesel fuel or a blend of No. 1 and No. 2
is best suited for cold-weather operation. Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after operating the engine.
Quantities of No. 1 diesel fuel are limited. No. 1
diesel fuels are available during the months of the
winter in the colder climates. During cold-weather
operation, if No. 1 diesel fuel is not available, use No.
2 diesel fuel, if necessary.
44 M0097687-03
Operation Section
Fuel Related Components in Cold Weather

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.
Drain the water and sediment from any fuel storage
tank at the following intervals:

• Weekly
• Oil changes

• Refueling of the fuel tank

This will help prevent water and/or sediment from
being pumped from the fuel storage tank and into the
engine fuel tank.

Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in order for the fuel to be heated before
the fuel enters the primary fuel filter.
Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater
with a large heating surface. The fuel heater should
be practical in size. Small heaters can be too hot due
to the limited surface area.
Disconnect the fuel heater in warm weather.

Note: Fuel heaters that are controlled by the water

temperature regulator or self-regulating fuel heaters
should be used with this engine. Fuel heaters that are
not controlled by the water temperature regulator can
heat the fuel in excess of 65° C (149° F). A loss of
engine power can occur if the fuel supply
temperature exceeds 37° C (100° F).
Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
the fuel in warm weather operation.
For further information on fuel heaters, consult your
Caterpillar dealer.
M0097687-03 45
Operation Section
Engine Stopping

Engine Stopping i05812522

i07501737
Manual Stop Procedure
SMCS Code: 1000; 7418
Stopping the Engine
SMCS Code: 1000 NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
NOTICE celerated wear of the engine components.
Stopping the engine immediately after working under
load can result in overheating, and accelerated wear If the engine has been operating at high rpm and/or
of the engine components. high loads, run at low idle for at least three minutes to
reduce and stabilize internal engine temperature be-
Refer to the following stopping procedure to allow the fore stopping the engine.
engine to cool, and to prevent excessive tempera-
tures in the turbocharger center housing. Avoiding hot engine shutdowns will maximize turbo-
charger shaft and bearing life.
Positions of the engine key switch are indicated by a
film that surrounds the engine key switch.
Note: Individual applications have different control
systems. Ensure that the shutoff procedures are
understood. Use the following general guidelines in
order to stop the engine.

1. Remove the load from the engine so that the

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

i01465494

Illustration 31 g06340185
Type 1 engine key switch positions
After Stopping Engine
(1) OFF SMCS Code: 1000
(2) ON
(3) START Note: Before you check the engine oil, do not
operate the engine for at least 10 minutes in order to
1. Before shutting down, run the engine for 5 minutes allow the engine oil to return to the oil pan.
at low idle. Idling the engine allows hot areas of
the engine to cool gradually. • Check the crankcase oil level. Maintain the oil
level between the “ADD” mark and the “FULL”
2. Turn the engine key switch to OFF position (1) and mark on the oil level gauge.
remove the key.
• If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.
• Note the service hour meter reading. Perform the
maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
• Fill the fuel tank in order to help prevent
accumulation of moisture in the fuel. Do not overfill
the fuel tank.
46 M0097687-03
Operation Section
After Stopping Engine

NOTICE
Only use antifreeze/coolant mixtures recommended
in the Coolant Specifications that are in the Operation
and Maintenance Manual. Failure to do so can cause
engine damage.

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

• If freezing temperatures are expected, check the

coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.
M0097687-03 47
Maintenance Section
Refill Capacities

Maintenance Section 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 more oil. Refer to the OEM specifications for
Refill Capacities the capacity of the auxiliary oil filter.
Table 3
i07764666 C9.3B Industrial Engine
Approximate Refill Capacities
Refill Capacities Oil Sump(1) Liters Quarts
SMCS Code: 1000; 1348; 1395; 7560
Standard Oil Pan 32 L 33.8 qt
Refer to this Operation and Maintenance Manual,
Center Oil Pan 32 L 33.8 qt
“Fluid Recommendations” for information about the
fluids which are acceptable for this engine. (1) These values are approximate capacities for the crankcase oil
sump which include the standard oil filters that are installed at
Refer to Special Publication, SEBU6251, “Caterpillar the factory. Engines with auxiliary oil filters will require more oil.
Commercial Engine Fluids Recommendations” for Refer to the OEM specifications for the capacity of the auxiliary
additional information. oil filter.

Lubricant Refill Capacities Coolant Refill Capacities

To maintain the cooling system, the total cooling
system capacity must be known. The capacity of the
total cooling system will vary. The capacity will
depend on the size of the radiator (capacity). Table 4
should be completed by the customer for the
maintenance of the cooling system.
Table 4
Approximate Capacity of the Cooling System

Compartment or
Liters Quarts
System

Total Cooling Sys-

tem(1)
(1) The total cooling system capacity includes the following compo-
nents: the engine block, the radiator, and all coolant hoses and
lines.

i04327214

Fluid Recommendations
SMCS Code: 1280; 1348; 1395; 7560
Illustration 32 g02293575
Standard and deep oil pans Refer to this Operation and Maintenance Manual,
“Severe Service Application” for information about
operating an engine in a severe service application.
Note: The interval for changing the coolant varies
depending on the type of coolant being replaced.
Refer to this article, “Coolant Recommendations”, for
the intervals for changing the coolant.

Diesel Engine Oil

Illustration 33 g02289293
For more information, refer to Special Publication,
Center oil pan SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.
48 M0097687-03
Maintenance Section
Fluid Recommendations

Cat Diesel Engine Oil (Cat DEO) (Table 6, contd)

API CI-4 / CI-4 PLUS Oil Category per-
Cat oils have been developed and tested in order to formance requirements
provide the full performance and service life that has
been designed and built into Cat engines. Cat oils Cat ECF-2
Passing standard Cat C13 engine test
are currently used to fill Cat Diesel Engines at the per API requirements
factory. These oils are offered by Cat dealers for
Oils of sulfated ash > 1.50 percent are
continued use when the engine oil is changed.
not allowed
Consult your Cat dealer for more information on
these oils. API CH-4 Oil Category performance
requirements
Due to significant variations in the quality and in the
performance of commercially available oils, For oils that are between 1.30 percent
Caterpillar makes the following recommendations: Cat ECF-1-a
and 1.50 percent sulfated ash, passing
Table 5 one additional Cat 1P SCOTE test
(“ASTM D6681”) is required
Cat Lubricants Viscosity Grade
Oils of sulfated ash > 1.50 percent are
SAE 15W-40 not allowed
Cat DEO-ULS
Diesel Engine SAE 10W-30
Oil-Ultra Low In selecting oil for any engine application, both of the
Cat DEO-ULS SYN SAE 5W-40
Sulfur following must be satisfied: the oil viscosity and the
Cat Cold Weather category of oil performance or the specification for oil
SAE 0W-40 performance . Using only one of these parameters
DEO-ULS
will not sufficiently define oil for an engine
SAE 15W-40 application.
Diesel Engine Cat DEO
SAE 10W-30
Oil The proper SAE viscosity grade of oil is determined
Cat DEO SYN SAE 5W-40 by the following temperatures: minimum ambient
temperature during cold engine start-up and
maximum ambient temperature during engine
Note: Cat DEO and Cat DEO-ULS multigrade oils
operation.
are the preferred oils for use in this Cat Diesel
Engine. Refer to Table 7 (minimum temperature) in order to
determine the required oil viscosity for starting a cold
Commercial Oil engine.

Note: Non-Cat commercial oils are second choice Refer to Table 7 (maximum temperature) in order to
oils for your engine. select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
NOTICE Note: Generally, use the highest oil viscosity that is
Caterpillar does not warrant the quality or perform- available to meet the requirement for the temperature
ance of non-Cat fluids. at start-up.
The three current Caterpillar ECF specifications are: Table 7
Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each
higher Cat ECF specification provides increased Lubricant Viscosities for Ambient Temperatures
performance over lower Cat ECF specifications. for Cat Diesel Engines

A commercial oil must meet the following standards Oil Type and Per- °C °F
Viscosity
to be considered an equivalent of a Cat Diesel formance
Grade Min Max Min Max
Requirements
Engine Oil:
Table 6 Cat ECF-1-a
Cat ECF-2 SAE 0W-30 −40 30 −40 86
Cat Engine Crankcase Fluids (ECF) Definitions
Cat ECF-3
Cat Performance Cat Cold Weather
Cat ECF Specifications Requirements
Requirement DEO-ULS
Cat ECF-1-a SAE 0W-40 −40 40 −40 104
API CJ-4 Oil Category performance
Cat ECF-3 Cat ECF-2
requirements
Cat ECF-3

(continued)
(continued)
M0097687-03 49
Maintenance Section
Fluid Recommendations

(Table 7, contd) (Table 8, contd)

(1) When using fuel with 0.10% sulfur (1000 ppm) or higher, refer
Lubricant Viscosities for Ambient Temperatures
to this Operation and Maintenance Manual, “Severe Service
for Cat Diesel Engines Application” for more information.
(2) For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
Cat DEO-ULS
refer to TBN and engine oil guidelines given in this section.
Cat ECF-1-a (3) Cat DEO-ULS may be used if an oil analysis program is fol-
SAE 5W-30 −30 30 −22 86
Cat ECF-2 lowed. Base the oil change interval on the analysis.
Cat ECF-3
Cat DEO-ULS SYN S·O·S Services Oil Analysis
Cat DEO
Cat ECF-1-a SAE 5W-40 −30 50 −22 122 Caterpillar has developed a maintenance tool that
Cat ECF-2 evaluates oil degradation. the maintenance
Cat ECF-3 management also detects the early signs of wear on
Cat ECF-1-a internal components. The Caterpillar tool for oil
SAE 10W- analysis is called S·O·S oil analysis and the tool is
Cat ECF-2 −18 40 0 104
30 part of the S·O·S Services program. S·O·S oil
Cat ECF-3
analysis divides oil analysis into four categories:
SAE 10W-
−18 50 0 122
Cat DEO-ULS 40 • Component wear rate
Cat DEO SAE 15W-
−9.5 50 15 122 • Oil condition
40

• Oil contamination
Note: A cold soaked start occurs when the engine
has not been operated recently, allowing the oil to • Identification of oil
become more viscous due to cooler ambient
These four types of analysis are used to monitor the
temperatures. Supplemental heat is recommended
condition of your equipment. The four types of
for cold soaked starts below the minimum ambient analysis will also help you identify potential problems.
temperature. Supplemental heat may be necessary A properly administered S·O·S oil analysis program
for cold soaked starts that are above the minimum will reduce repair costs and the program will lessen
temperature depending on factors such as parasitic the impact of downtime.
load.
The S·O·S Oil Analysis program uses a wide range
Total Base Number (TBN) and Fuel Sulfur of tests to determine the condition of the oil and the
crankcase. Guidelines that are based on experience
Levels and a correlation to failures have been established
for these tests. Exceeding one or more of these
The use of Cat S·O·S Services oil analysis is guidelines could indicate serious fluid degradation or
recommended strongly for determining oil life. a pending component failure. A trained person at
your Cat dealership should make the final analysis.
The minimum required Total Base Number (TBN) for
oil depends on the fuel sulfur level. The TBN for new
oil is typically determined by the “ASTM D2896” NOTICE
procedure. For direct injection engines that use Always use a designated pump for oil sampling, and
distillate fuel, the following guidelines apply: use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
Table 8 ples may contaminate the samples that are being
TBN recommendations for applications in Cat engines drawn. This contaminate may cause a false analysis
(1) and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
TBN of Com-
Fuel Sulfur Level per-
Cat Engine Oils mercial Engine
cent (ppm)
Oils
≤0.05 percent (≤500 Cat DEO-ULS
Min 7
ppm) Cat DEO

0. 1- 0.05 percent Cat DEO-ULS

Min 7
(1000-500 ppm) Cat DEO

Above 0.1 percent

Cat DEO(3) Min 10
(above 1000 ppm)(2)

(continued)
50 M0097687-03
Maintenance Section
Fluid Recommendations

Refer to Special Publication, SEBU6251, “Cat Note: The permissible fuels are some crude oils,
Commercial Diesel Engine Fluids some blends of crude oil with distillate fuel, some
Recommendations” in order to obtain additional biodiesel, and some marine diesel fuel. These fuels
information about S·O·S Services oil analysis. You are not suitable for use in all engine applications.
can also contact your local Cat dealer. The acceptability of these fuels for use is determined
on a case by case basis. A complete fuel analysis is
Fuel required. Consult your Cat dealer for further
information.
Note: Caterpillar strongly recommends the filtration
of fuel through a fuel filter with a rating of four
NOTICE
microns(c) absolute or less. This filtration should be The footnotes are a key part of the “Caterpillar Speci-
located on the device that dispenses the fuel to the fication for Distillate Diesel Fuel for Off-Highway Die-
fuel tank for the engine. This filtration should also be sel Engines” Table. Read ALL of the footnotes.
located on the device that dispenses fuel from the
bulk storage tank. Series filtration is recommended. Table 9
Caterpillar Specification for Distillate Fuel for Nonroad
NOTICE Diesel Engines
In order to meet expected fuel system component life,
4 micron (c) absolute or less secondary fuel filtration ASTM
is required for all Cat Diesel Engines that are Specifications Requirements Test ISO Test
equipped with unit injected fuel systems. All current
Aromatics 35% maximum “D1319” “ISO 3837”
Cat Diesel Engines are factory equipped with Cat Ad-
vanced Efficiency 4 micron(c) absolute fuel filters. 0.01% maximum
Ash “D482” “ISO 6245”
(weight)
Caterpillar does not warrant the quality or perform-
ance of non-Cat fluids and filters. Carbon Residue 0.35% maximum
“D524” “ISO 4262”
on 10% Bottoms (weight)
Diesel engines can burn a wide variety of fuels.
These fuels are divided into two general groups. The 40 minimum (DI
engines) “D613”
two groups are called the preferred fuels and the Cetane Number (1) or “ISO 5165”
permissible fuels. 35 minimum (PC “D6890”
engines)
Note: The permissible fuels are some crude oils,
some blends of crude oil with distillate fuel, some The cloud point
biodiesel, and some marine diesel fuel. These fuels must not exceed
are not suitable for use in all engine applications. The Cloud Point the lowest ex- “D2500” “ISO 3015”
acceptability of these fuels for use is determined on pected ambient
temperature.
an individual basis. A complete fuel analysis is
required. Copper Strip
No. 3 maximum “D130” “ISO 2160”
Corrosion
For more information, refer to Special Publication,
SEBU6251, “Cat Commercial Diesel Engine Fluids 10% at 282 °C
Recommendations” or consult your Cat dealer for (540 °F)
further information. maximum
Distillation “D86” “ISO 3405”
90% at 360 °C
Diesel Distillate Fuel (680 °F)
maximum
Diesel engines may burn a wide variety of fuels. legal limit
Flash Point “D93” “ISO 2719”
These fuels are divided into two general groups. The
two groups are called the preferred fuels and the Minimum of 80%
permissible fuels. reflectance after
No equiva-
Thermal Stability aging for 180 mi- “D6468”
The preferred fuels provide maximum engine lent test
nutes at 150 °C
service life and performance. The preferred fuels (302 °F)
are distillate fuels. These fuels are commonly called
diesel fuel, furnace oil, gas oil, or kerosene. These 30 minimum No equiva-
API Gravity (2) “D287”
fuels must meet the “Cat Specification for Distillate 45 maximum lent test
Diesel Fuel for Off-Highway Diesel Engines” found in
this Special Publication, “Distillate Diesel Fuel”
article.
(continued)
M0097687-03 51
Maintenance Section
Fluid Recommendations

(Table 9, contd) Biodiesel

Caterpillar Specification for Distillate Fuel for Nonroad
A biodiesel blend of up to 20 percent may be used in
Diesel Engines
the engine when the fuel blend meets the
ASTM recommendations in table 10 and meets the
Specifications Requirements Test ISO Test recommendations in Special Publication, SEBU6251,
“Biodiesel”.
6 °C (10 °F) mini-
Pour Point mum below ambi- “D97” “ISO 3016” Note: A complete Cat S·O·S Services oil analysis
ent temperature program is recommended strongly when using
biodiesel blends above 5 percent.
“D5453” ISO 20846
Sulfur (3)(4)(5) or or Table 10
“D2622” ISO 20884
Biodiesel Blends for Cat Commercial Diesel Engines
1.4 cSt minimum
and 20.0 cSt max- Distillate diesel fuel
Biodiesel blend stock Final blend
imum as delivered used for blend
to the fuel injec-
Caterpillar distillate
Kinematic tion pumps Caterpillar biodiesel B20: “ASTM
- - diesel fuel specifica-
Viscosity specification, “ASTM D7467” and “API”
1.4 cSt minimum tion, “ASTM D975” or
D6751” or “EN14214” gravity 30-45
and 4.5 cSt maxi- “EN590”
mum as delivered
to the rotary fuel
injection pumps Fuel Additives
“D1796” Cat Diesel Fuel Conditioner
Water and
0.05% maximum or “ISO 3734”
Sediment
“D2709” Cat Diesel Fuel Conditioner is a proprietary
No equiva- formulation that has been extensively tested for use
Water 0.05% maximum “D6304” with distillate diesel fuels for use in Cat Diesel
lent test
Engines. Cat Diesel Fuel Conditioner is a high
Sediment
0.05% maximum
“D473” “ISO 3735”
performance diesel fuel conditioner for use with lower
(weight) quality fuels that do not meet the minimum
requirements of any of the following:
Gums and Resins 10 mg per 100 mL
(6) “D381” “ISO 6246”
maximum • “Caterpillar Specification for Distillate Diesel Fuel”
0.52 mm
(0.0205 inch) No equiva- • National Conference on Weights and Measures
Lubricity “D6079” (NCWM) Premium Diesel definition (refer to the
maximum at 60 °C lent test
(140 °F) 2004 or newer National Institute of Standards &
(1) Alternatively, to ensure a minimum cetane number of 35 (PC
Technology (NIST) Handbook).
engines), and 40 (DI engines), distillate diesel fuel should have
a minimum cetane index of 37.5 (PC engines), and 44.2 (DI en- • EN590 (non-arctic)
gines) when the “ASTM D4737-96a” test method is used. A fuel
with a higher cetane number may be required for operation at a • ASTM D975
higher altitude or in cold weather.
(2) Via standards tables, the equivalent kg/m3 (kilograms per cubic Cat Diesel Fuel Conditioner is the only fuel
meter) using the “ASTM D287” test method temperature of conditioner/additive available to the end user that is
15.56° C (60° F) for the minimum API gravity of 30 is 875.7 kg/ tested and approved by Caterpillar for use in Cat
m3, and for the maximum API gravity of 45 is 801.3 kg/m3. Diesel Engines.
(3) ULSD 0.0015% (<15 ppm S) is required by law for Tier 4 en-
gines and engines with aftertreatment devices. Refer to Special Publication, SEBU6251, “Cat
(4) Certain Cat fuel systems and engine components can operate
on fuel with a maximum sulfur content of 3%. Contact your Cat
Commercial Diesel Engine Fluids
dealer for guidance about appropriate maintenance intervals Recommendations” for information about the use of
and fluids for engines operating on fuel with sulfur levels be- Cat Diesel Fuel Conditioner.
tween 0.1% and 3%.
(5) An engine which operates on fuel with 0.1% (1000 ppm) of sul- Cat Diesel Fuel System Cleaner
fur or more is operating in a severe service application. Refer to
this Operation and Maintenance Manual, “Severe Service Ap- Note: Cat Diesel Fuel System Cleaner is the only fuel
plication” for information about operating an engine in a severe
service application. system cleaner available to the end user that is
(6) Follow the test conditions and procedures for gasoline (motor). tested and approved by Caterpillar for use in Cat
Diesel Engines.
52 M0097687-03
Maintenance Section
Fluid Recommendations

Cat Diesel Fuel System Cleaner is a proven high

performance detergent product designed specifically
for cleaning deposits that form in the fuel system. The cooling system operates under pressure
Deposits in the fuel system reduce system which is controlled by the radiator pressure cap.
performance and can increase fuel consumption. Cat Removing the cap while the system is hot may al-
Diesel Fuel System Cleaner addresses the deposits low the escape of hot coolant and steam, causing
formed due to the use of degraded diesel fuel, poor serious burns.
quality diesel fuel, and diesel fuel containing high
quantities of high molecular weight compounds. Cat Before you remove the radiator cap, allow the
Diesel Fuel System Cleaner addresses deposits system to cool. Use a thick cloth and turn the ra-
formed due to the use of biodiesel, biodiesel blends, diator cap slowly to the first stop to allow pres-
and biodiesel that does not meet the appropriate sure to escape before fully removing the cap.
quality specifications. Continued use of Cat Diesel
Fuel System Cleaner is proven to inhibit the growth of Avoid contact with coolant.
new deposits.
Caterpillar strongly recommends that Cat Diesel
Fuel System Cleaner be used with biodiesel and NOTICE
Never add coolant to an overheated engine. Engine
biodiesel blends. Cat Diesel Fuel System Cleaner is damage could result. Allow the engine to cool first.
suitable for use with biodiesel/biodiesel blends that
meet Caterpillar biodiesel recommendations and
requirements. Not all fuel cleaners are suitable for
use with biodiesel/biodiesel blends. Read and follow NOTICE
all applicable label usage instructions. Also, refer to If the engine is to be stored in, or shipped to an area
Special Publication, SEBU6251, “Cat Commercial with below freezing temperatures, the cooling system
Diesel Engine Fluids Recommendations” “Distillate must be either protected to the lowest outside tem-
Diesel Fuel”, article and also refer to the “Biodiesel” perature or drained completely in order to prevent
article, which includes Caterpillar biodiesel damage caused by freezing coolant.
recommendations and requirements.
Never operate an engine without water temperature
Aftermarket Fuel Additives regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
There are many different types of fuel additives that proper operating temperature. Cooling system
are available to use. Caterpillar does not generally problems can develop without water temperature
recommend the use of fuel additives. regulators. Removing the regulators allows some
coolant to bypass the radiator, potentially causing
In special circumstances, Caterpillar recognizes the overheating.
need for fuel additives. Use fuel additives with
caution. The additive may not be compatible with the
fuel. Some additives may precipitate. This action Coolant Recommendations
causes deposits in the fuel system. The deposits may
cause seizure. Some additives may plug fuel filters. Note: A Cat Diesel Engine equipped with air-to-air
Some additives may be corrosive, and some aftercooling (ATAAC) requires a minimum of 30
additives may be harmful to the elastomers in the fuel percent glycol to help prevent water pump cavitation.
system. Some additives may damage emission
control systems. Some additives may raise fuel sulfur
levels above the maximum levels that are allowed by
the following agencies: EPA and other regulatory
agencies. Contact your fuel supplier for those
circumstances when fuel additives are required. Your
fuel supplier can make recommendations for
additives to use and for the proper level of treatment.
Note: For best results, your fuel supplier should treat
the fuel when additives are needed.

Cooling System
Note: Refer to Special Publication , SEBU6251, “Cat
Commercial Diesel Engine Fluids
Recommendations” for complete information about
the proper fluids for use in the cooling system.
M0097687-03 53
Maintenance Section
Fluid Recommendations

Table 11
Coolant Recommendations for use in Cat Diesel Engines
Service Hours
Recommendations Product (1)(2)(3)
Required Maintenance

Add Cat ELC Extender at

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

SCA (Supplemental cool-

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

“ASTM D4985” and(1)

Min requirements for Com- Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US
3000 hours or 1 SCA at initial fill and SCA
mercial coolants requiring gal) and maximum of 2400 ppm (140 grains/US gal)
year at maintenance intervals
SCA precharge Silicon concentration: minimum of 100 ppm and maximum of 275
ppm
(1) New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets
Reagent 4 “ASTM D1193” requirements.
(2) Maintain the in-service coolant at the given limits.
(3) When referring to the service hours, use the interval that occurs first. These coolant change intervals are only achievable with annual S·O·S
Services Level 2 coolant sampling analysis.

Table 12
Special Requirements
Cat C7-C32 Marine Engines with heat exchangers
Minimum of 30% glycol is required. 50% Glycol is recommended.
Cat diesel engines equipped with air-to-air aftercooling (ATAAC) Water alone or water with SCA or with ELI is NOT allowed.
54 M0097687-03
Maintenance Section
Fluid Recommendations

The following properties of the coolant are tested:

NOTICE
Use Only Approved SCAs and Extenders
• Glycol concentration for freeze protection and boil
Conventional coolants require the maintenance addi- protection
tion of SCA throughout the expected life of the cool-
ants. Do NOT use an SCA with a coolant unless • Ability to protect from erosion and corrosion
approved specifically by the coolant supplier. The
coolant manufacturer is responsible for ensuring • pH
compatibility and acceptable performance.
• Conductivity
To help ensure expected performance, EC-1 coolants
require the one time maintenance addition of an ex- • Visual analysis
tender at coolant service mid-life. Do not use an ex-
tender with a coolant unless the extender has been • Odor analysis
approved specifically for use by the coolant manufac-
turer. The coolant manufacturer is responsible for en- The results are reported, and appropriate
suring compatibility and acceptable performance. recommendations are made.

Failure to follow these recommendations can result in S·O·S Services Coolant Analysis (Level 2)
shortened cooling system component life.
A coolant analysis (Level 2) is a comprehensive
Cat ELC can be recycled into conventional coolants. chemical evaluation of the coolant. This analysis is
also a check of the overall condition of the cooling
For more information, refer to Special Publication, system.
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”. The S·O·S coolant analysis (Level 2) has the
following features:
S·O·S Services Coolant Analysis
• Full coolant analysis (Level 1)
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and • Identification of metal corrosion and of
corrosion. The analysis also tests the ability of the contaminants
coolant to protect the engine from boiling and
freezing. S·O·S coolant analysis can be done at your • Identification of buildup of the impurities that
Cat dealer. Cat S·O·S coolant analysis is the best cause corrosion
way to monitor the condition of your coolant and your
cooling system. S·O·S coolant analysis is a program • Identification of buildup of the impurities that
that is based on periodic samples. cause scaling
Table 13 • Determination of the possibility of electrolysis
within the cooling system of the engine
Recommended Interval
The results are reported, and appropriate
Type of Level 1 Level 2 recommendations are made.
Coolant
For more information on S·O·S coolant analysis,
Cat DEAC consult your Cat dealer.
Conventional Heavy- Every 250 hours Yearly(1)
Duty Coolants
Greases
Cat ELC
Cat ELI
Optional Yearly(1)
If it is necessary to choose a single grease, always
Commercial EC-1 choose a grease that meets or exceeds the
Coolants requirements of the most demanding application.
(1) The Level 2 Coolant Analysis should be performed sooner if a Remember that the products which barely meet the
problem is suspected or identified. minimum performance requirements can be
expected to barely produce the minimum lives of your
Note: Check the SCA (Supplemental Coolant parts. False economy is being used if a grease is
Additive) of the conventional coolant at every oil purchased with the lowest cost as the only
consideration. Instead, use the grease that yields the
change or at every 250 hours. Perform this check at
lowest total operating cost. The cost should be based
the interval that occurs first. on an analysis that includes the costs of parts, labor,
downtime, and the cost of the amount of grease that
S·O·S Services Coolant Analysis (Level 1)
is required.
A coolant analysis (Level 1) is a test of the properties
of the coolant.
M0097687-03 55
Maintenance Section
Fluid Recommendations

For more information, refer to Special Publication,

SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.
56 M0097687-03
Maintenance Section
Maintenance Recommendations

Maintenance Do not loosen the high-pressure fuel lines to remove

air pressure from the fuel system.
Recommendations
Engine Oil
i08186078
To relieve pressure from the lubricating system, turn
System Pressure Release off the engine.
SMCS Code: 1250; 1300; 1350; 5050 i07504983

Coolant System Welding on Engines with

Electronic Controls
SMCS Code: 1000
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra- NOTICE
diator is cool. Then loosen cap slowly to relieve Because the strength of the frame may decrease,
the pressure. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Cat dealer regarding welding on a chas-
off the engine. Allow the cooling system pressure cap sis frame or rail.
to cool. Remove the cooling system pressure cap
slowly to relieve pressure. Proper welding procedures are necessary to avoid
damage to the engine Electronic Control Module
Fuel System (ECM), sensors, and associated components. When
possible, remove the component from the unit and
then weld the component. If removal of the
To relieve the pressure from the fuel system, turn off
component is not possible, the following procedure
the engine.
must be followed when you weld on a unit that is
equipped with a Caterpillar Electronic Engine. The
High-Pressure Fuel Lines (If Equipped) following procedure is considered to be the safest
procedure to weld on a component. This procedure
should provide a minimum risk of damage to
electronic components.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel NOTICE
spray may cause a fire hazard. Failure to follow Do not ground the welder to electrical components
these inspection, maintenance and service in- such as the ECM or sensors. Improper grounding
structions may cause personal injury or death. can cause damage to the drive train, the bearings,
hydraulic components, electrical components, and
The high-pressure fuel lines are between the high- other components.
pressure fuel pump and the high-pressure fuel Do not ground the welder across the centerline of the
manifold. The high-pressure fuel lines are also package. Improper grounding could cause damage
between the fuel manifold and cylinder head. These to the bearings, the crankshaft, the rotor shaft, and
fuel lines are different from fuel lines on other fuel other components.
systems.
The following are the differences: Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
• The high-pressure fuel lines are constantly as possible to the weld. This will help reduce the pos-
charged with high pressure. sibility of damage.

• The internal pressures of the high-pressure fuel

lines are higher than other types of fuel system. Note: Perform the welding in areas that are free from
explosive hazards.
Before any service or repair is performed on the
engine fuel lines, perform the following tasks: 1. Stop the engine. Turn the switched power to the
OFF position.
1. Stop the engine.
2. Disconnect the negative battery cable from the
2. Wait for 10 minutes. battery. If a battery disconnect switch is provided,
open the switch.
M0097687-03 57
Maintenance Section
Severe Service Application

3. Disconnect the J1/P1 and J2/P2 connectors from Note: If electrical/electronic components are used as
the ECM and. Disconnect the wiring from the a ground for the welder, or electrical/electronic
CEM. Move the harnesses to a position that will components are located between the welder ground
not allow the harnesses to contact with any of the and the weld, current flow from the welder could
ECM, CEM, or pins accidentally. severely damage the component.

5. Protect the wiring harness from welding debris and

spatter.
6. Use standard welding practices to weld the
materials.

i04889860

Severe Service Application

SMCS Code: 1000
An engine which operates outside of normal
conditions is operating in a severe service
application.
An engine that operates in a severe service
application may need more frequent maintenance
intervals in order to maximize the following
conditions:
• Reliability
• Service life
The number of individual applications cause the
impossibility of identifying all of the factors which may
contribute to severe service operation. Consult your
Cat dealer for the unique maintenance that may be
necessary for your engine.
Illustration 34 g01075639 An application is a severe service application if any of
Use the example above. The current flow from the the following conditions apply:
welder to the ground clamp of the welder will not
damage any associated components. Severe Environmental Factors
(1) Engine
(2) Welding electrode • Frequent operation in dirty air
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables • Frequent operation at an altitude which is above
(6) Battery 1525 m (5000 ft)
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being • Frequent operation in ambient temperatures which
welded and any electrical/electronic component are above 32° C (90° F)
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
• Frequent operation in ambient temperatures which
are below 0° C (32° F)
4. Connect the welding ground cable directly to the
part that will be welded. Place the ground cable as Severe Operating Conditions
close as possible to the weld to reduce the
• Frequent operation with inlet air which has a
possibility of welding current damage to bearings,
corrosive content
hydraulic components, electrical components, and
ground straps. • Operation with inlet air which has a combustible
content
• Operation which is outside of the intended
application
58 M0097687-03
Maintenance Section
Severe Service Application

• Operation with a plugged fuel filter

• Extended operation at low idle (more than 20% of
hours)
• Frequent cold starts at temperatures below 0° C
(32° F)

• Frequent dry starts (starting after more than 72

hours of shutdown)

• Frequent hot shutdowns (shutting down the

engine without the minimum of 2 minutes to 5
minutes of cool down time)

• Operation above the engine rated speed

• Operation below the peak torque speed

• Operating with fuel which does not meet the

standards for distillate diesel fuel as stated in
Special Publication, SEBU6251, “Cat Commercial
Diesel Engine Fluids Recommendations”
“Distillate Diesel Fuel”
• Operating with a blend of distillate fuel which
contains more than 20 percent biodiesel

Improper Maintenance Procedures

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

• Using fluids which are not recommended in

Special Publication, SEBU6251, “Cat Commercial
Diesel Engine Fluids Recommendations”

• Extending maintenance intervals for changing the

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

• Extending maintenance intervals for changing air

filters, oil filters, and fuel filters

• Failure to use a water separator

• Using filters which are not recommended by
Special Publication, PEWJ0074, “2008 Cat Filter
and Fluid Application Guide”
M0097687-03 59
Maintenance Section
Maintenance Interval Schedule

i08454670 “ Walk-Around Inspection“ . . . . . . . . . . . . . . . . . . . . 92

Maintenance Interval Schedule Every 250 Service Hours

SMCS Code: 1000; 4450; 7500
“ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . . 76
Ensure that all safety information, warnings, and
instructions are read and understood before any “ Grounding Stud - Inspect/Clean/Tighten“. . . . . . . 85
operation or any maintenance procedures are
performed. The user is responsible for the Initial 500 Service Hours
performance of maintenance, including all
adjustments, the use of proper lubricants, fluids, and “ Engine Valve Lash - Check“ . . . . . . . . . . . . . . . . . 80
filters. The user is also responsible for the
replacement of components due to normal wear and
aging. Failure to adhere to proper maintenance Every 500 Service Hours
intervals and procedures may result in diminished
performance of the product and/or accelerated wear “ Air Shutoff - Test“ . . . . . . . . . . . . . . . . . . . . . . . . . . 61
of components. Use fuel consumption, service hours, “ Battery Electrolyte Level - Check“ . . . . . . . . . . . . 63
or calendar time, WHICH EVER OCCURS FIRST, to
determine the maintenance intervals. Products that “ Belts - Inspect/Adjust/Replace“. . . . . . . . . . . . . . . 64
operate in severe operating conditions may require
more frequent maintenance. Before each “ Coolant Sample (Level 1) - Obtain“ . . . . . . . . . . . 70
consecutive interval is performed, all maintenance
from the previous interval must be performed. “ Cooling System Supplemental Coolant Additive
(SCA) - Test/Add“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
When Required
“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . . 77
“ Battery - Recycle“ . . . . . . . . . . . . . . . . . . . . . . . . . 62
“ Fuel System Primary Filter (Water Separator)
“ Battery - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 62 Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 80

“ Battery or Battery Cable - Disconnect“ . . . . . . . . . 63 “ Fuel System Secondary Filter - Replace“. . . . . . . 82

“ Engine - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 “ Hoses and Clamps - Inspect/Replace“. . . . . . . . . 85

“ Engine Air Cleaner Element (Dual Element) - Every 2000 Service Hours
Inspect/Clean/Replace“ . . . . . . . . . . . . . . . . . . . . . . 73
“ Fumes Disposal Filter Element (Emission Related
“ Engine Storage Procedure - Check“. . . . . . . . . . . 79 Component) - Replace“ . . . . . . . . . . . . . . . . . . . . . . 84
“ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . . 80
Every 2000 Service Hours or 1 Year
“ Fuel Tank Water and Sediment - Drain“ . . . . . . . . 83
“ Radiator - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . 91 “ Coolant Sample (Level 2) - Obtain“ . . . . . . . . . . . 71

Daily Every 2500 Service Hours

“ Air Tank Moisture and Sediment - Drain“ . . . . . . . 62 “ Compression Brake - Inspect/Adjust/Replace“ . . 65

“ Coolant Level - Check“ . . . . . . . . . . . . . . . . . . . . . 69 “ Engine Valve Lash - Check“ . . . . . . . . . . . . . . . . . 80

“ Driven Equipment - Check“ . . . . . . . . . . . . . . . . . . 73 Every 3000 Service Hours or 3

“ Engine Air Cleaner Service Indicator - Inspect“ . . 75 Years
“ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . . 75 “ Coolant (DEAC) - Change“ . . . . . . . . . . . . . . . . . . 65
“ Fuel System Primary Filter/Water Separator - “ Coolant Temperature Regulator - Replace“ . . . . . 71
Drain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
“ Power Take-Off Clutch - Check“ . . . . . . . . . . . . . . 90 Every 4000 Service Hours
“ Air Compressor - Check“. . . . . . . . . . . . . . . . . . . . 61
60 M0097687-03
Maintenance Section
Maintenance Interval Schedule

“ Engine Mounts - Inspect“ . . . . . . . . . . . . . . . . . . . 75

Every 4000 Service Hours or 2

Years
“ Starting Motor - Inspect“ . . . . . . . . . . . . . . . . . . . . 91

Every 6000 Service Hours or 3

Years
“ Coolant Extender (ELC) - Add“ . . . . . . . . . . . . . . . 69

Every 12 000 Service Hours or 6

Years
“ Coolant (ELC) - Change“. . . . . . . . . . . . . . . . . . . . 67

Every 340 500 L (90 000 US gal) of

Fuel
“ Overhaul Considerations“ . . . . . . . . . . . . . . . . . . . 87
M0097687-03 61
Maintenance Section
Air Compressor - Check

i08397638 Refer to the Service Manual or refer to the OEM

specifications in order to find information concerning
Air Compressor - Check the air compressor. Consult your Caterpillar dealer
for assistance.
(If equipped)
i08397620
SMCS Code: 1803-535
Air Shutoff - Test
(If Equipped)
Do not disconnect the air line from the air com-
pressor governor without purging the air brake SMCS Code: 1078-081
and the auxiliary air systems. Failure to purge the
air brake and the auxiliary air systems before re- To ensure that the air shutoff valve always shuts
moving the air compressor and/or the air lines down when the engine ingests gaseous fumes,
could cause personal injury. perform the test below at each oil change. A test
failure can indicate wear in the block off plate to valve
body interface and/or the bearing system.
1. Place engine at low idle speed. Ensure all
accessories that are normally used for the
application are in use, like a fan, or power takeoffs.
2. Actuate the air shutoff manually. On electrical
operator air shutoffs, utilize an applicable power
supply or jumper cables from the battery to
energize the air shut-off solenoid. Ensure that the
solenoid receives only a momentary signal to
prevent overheating. On hydraulic operator air
shutoffs, found on some hazardous location units,
actuate by pulling the emergency stop handle.
3. Ensure that air shutoff was actuated and that the
Illustration 35 g01212654
engine comes to a complete stop.
Typical example
(1) Pressure relief valve Note: As every application has different parasitic
loads and inertia, the duration for the problem to
occur cannot be specified. However, if the engine
stumbles or attempts to continue running, these
symptoms may be an indication that worn
If the air compressor pressure relief valve that is components may need replacement.
mounted in the air compressor cylinder head is
bypassing compressed air, there is a malfunction If additional help is needed, contact the Dealer
in the air system, possibly ice blockage. Under Solution Network.
these conditions, your engine may have insuffi-
cient air for normal brake operation. NOTICE
Actuating the air shutoff valve may result in oil leak-
Do not operate the engine until the reason for the age past the shaft seal in some cases. Repeated ac-
air bypass is identified and corrected. Failure to tuation of the air shutoff valve during loaded
heed this warning could lead to property damage,
operation of the engine can result in mechanical
personal injury, or death to the operator or
damage to the turbocharger and reduce turbocharger
bystanders.
life.
The function of the pressure relief valve is to bypass
air when there is a malfunction in the system for the
air compressor.
The pressure relief valve for the air compressor
releases air at 1723 kPa (250 psi). If the pressure
relief valve for the air compressor exhausts, all
personnel should be at a safe distance away from the
air compressor. All personnel should also stay clear
of the air compressor when the engine is operating
and the air compressor is exposed.
62 M0097687-03
Maintenance Section
Air Tank Moisture and Sediment - Drain

i08397622 i08397624

Air Tank Moisture and Battery - Replace

Sediment - Drain SMCS Code: 1401-510
(If Equipped)
SMCS Code: 1466-543-M&S
Batteries give off combustible gases which can
Moisture and sediment in the air starting system can explode. A spark can cause the combustible
cause the following conditions: gases to ignite. This can result in severe personal
injury or death.
• Freezing
Ensure proper ventilation for batteries that are in
• Corrosion of internal parts an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
• Malfunction of the air starting system near batteries. Do not smoke when batteries are
serviced.

When opening the drain valve, wear protective

gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could The battery cables or the batteries should not be
cause debris to be blown and result in personal removed with the battery cover in place. The bat-
injury. tery cover should be removed before any servic-
ing is attempted.
1. Open the drain valve that is on the bottom of the Removing the battery cables or the batteries with
air tank. Allow the moisture and sediment to drain. the cover in place may cause a battery explosion
resulting in personal injury.
2. Close the drain valve.
3. Check the air supply pressure. The air starting Note: Always recycle a battery. Never discard a
motor requires a minimum of 620 kPa (90 psi) of battery. Return used batteries to an appropriate
air pressure to operate properly. The maximum air recycling facility.
pressure must not exceed 1550 kPa (225 psi).
The normal air pressure will be 758 to 965 kPa 1. Turn the key start switch to the OFF position.
(110 to 140 psi). Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the
i08397621
charger.
Battery - Recycle 3. Turn battery isolator switch to OFF position.
SMCS Code: 1401-510; 1401-535; 1401-561; 1401- 4. The NEGATIVE “-” cable connects the NEGATIVE
005; 1401 “-” battery terminal to the ground plane.
Always recycle a battery. Never discard a battery. Disconnect the cable from the NEGATIVE “-”
Return used batteries to one of the following battery terminal.
locations: 5. The POSITIVE “+” cable connects the POSITIVE
• A battery supplier “+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+”
• An authorized battery collection facility battery terminal.
• A recycling facility Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
recycling facility.

6. Remove the used battery.

7. Install the new battery.

Note: Before the cables are connected, ensure that

the key start switch is OFF.
M0097687-03 63
Maintenance Section
Battery Electrolyte Level - Check

8. Connect the cable from the starting motor to the Use the 1U-9921 Battery Service Tool to clean
POSITIVE “+” battery terminal. the battery terminals. Use a wire brush to clean
the cable clamps. Clean the items until the
9. Connect the cable from the ground plane to the
surfaces are bright or shiny. DO NOT remove
NEGATIVE “-” battery terminal.
material excessively. Excessive removal of
material can cause the clamps to fit improperly.
i08397645
Coat the clamps and the terminals with the Loctite
®
product listed below, petroleum jelly or MPGM.
Battery Electrolyte Level -
Check • For Americas North - Loctite LB8632
SMCS Code: 1401-535-FLV • For Europe and Africa, Middle East, CIS
(AMEC) - Loctite LB8104
When the engine has not run for long or short periods
of time, the batteries may not fully recharge. Ensure a • For Asia Pacific - Loctite LB8801
full charge to help prevent the battery from freezing.
In warmer climates, check the electrolyte level more • For Americas South - Loctite LB Superlube
frequently.
For ordering the products listed above, go to the
Ensure that the electrolyte level is 13 mm (0.5 inch) following address.
above the top of the separators.
http://www.loctite.com/en/meta/meta-nav/
location-selector.html

i08397658
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a
face shield and protective clothing when working Battery or Battery Cable -
on or near batteries.
Disconnect
SMCS Code: 1401; 1402-029
1. Remove the filler caps. Maintain the electrolyte
level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled
water. If distilled water is not available, use clean The connection of battery cables to a battery and
water that is low in minerals. Do not use artificially the disconnection of battery cables from a battery
softened water. may cause an explosion which may result in in-
jury or death. The connection and the disconnec-
2. Check the condition of the electrolyte with the tion of other electrical equipment may also cause
245-5829 Coolant Battery Tester Refractometer. an explosion which may result in injury or death.
The procedures for the connection and the dis-
3. Keep the batteries clean. connection of battery cables and other electrical
equipment should only be performed in a nonex-
Clean the battery case with one of the following plosive atmosphere.
cleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and

1 L (1 qt) of clean water
The battery cables or the batteries should not be
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L removed with the battery cover in place. The bat-
(1 qt) of clean water tery cover should be removed before any servic-
ing is attempted.
Thoroughly rinse the battery case with clean
water. Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.

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

ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
64 M0097687-03
Maintenance Section
Belts - Inspect/Adjust/Replace

2. Disconnect the negative battery terminal at the To check the belt tension, apply 110 N (25 lb ft) of
battery that goes to the start switch. Ensure that force midway between the pulleys. A correctly
the cable cannot contact the terminal. When four adjusted belt will deflect 9 mm (0.35 inch) to 15 mm
12 volt batteries are involved, the negative side of (0.59 inch).
two batteries must be disconnected.
Alternator Belt
3. Tape the leads in order to help prevent accidental
starting.
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.

i08397630

Belts - Inspect/Adjust/Replace
SMCS Code: 1357-040; 1357-025; 1357-510

Inspection
Belt tension should be checked initially between
the first 20 to 40 hours of engine operation.
Illustration 37 g01154344
Typical alternator mounting
(1) Adjusting nuts
(2) Mounting bolt
(3) Mounting bolts

1. Slightly loosen mounting bolt (2) and mounting bolt

(3). Slightly loosen adjusting nut (1).
2. Move the pulley to adjust the belt tension.
3. Tighten the following: adjusting nuts (1), mounting
bolt, (2) and mounting bolt (3). Refer to the
Specifications, SENR3130 for the proper torques.
4. Install the belt guard. Refer to the Specifications,
Illustration 36 g06114636
SENR3130 for the proper torques.
Inspect the condition of the serpentine belt. Over time
the belt ribs will lose material (C). The space between
the ribs will increase (D). The loss of material will
cause the pulley sheave to contact the belt valley.
This will lead to belt slippage and accelerated wear
(E). Replace the belt if the belt is worn or frayed.
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only one
belt of a matched set will cause the new belt to carry
more load because the older belt is stretched. The
additional load on the new belt could cause the new
belt to break.
If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
If the belts are too tight, unnecessary stresses are
placed on the pulley bearings and on the belts. This
may shorten the service life of the components.
Inspect the condition and adjustment of the alternator
belts and accessory drive belts (if equipped).
M0097687-03 65
Maintenance Section
Compression Brake - Inspect/Adjust/Replace

If new belts are installed, check the belt tension again Tension the belt.
after 30 minutes of engine operation at the rated rpm.
Tighten the four mounting bolts (5). Refer to
Specification, SENR3130, “Torque Specifications” for
Drive Belt for the Air Compressor the correct torque.
(If Equipped)
i08397619

Compression Brake - Inspect/

Adjust/Replace
SMCS Code: 1129-040; 1129-025; 1129-510
Contact your Cat dealer for the proper procedure.

i08397649

Coolant (DEAC) - Change

SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
system before the recommended maintenance
Illustration 38 g01389673
interval if the following conditions exist:
(4) Drive belt for the air compressor
(5) Mounting bolts • The engine overheats frequently.
Loosen the four mounting bolts from the bracket that • Foaming is observed.
holds the air compressor.
• 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.

Note: Inspect the water pump and the water

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

Drain
Illustration 39 g01389675
Side view of the air compressor and pulley
Pressurized System: Hot coolant can cause seri-
(6) Bolt
(7) Adjusting bolt
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
Loosen bolt 6. Loosen bolt 7. Slide the air components are cool. Loosen the cooling system
compressor closer to the pulley. Remove the old belt. pressure cap slowly in order to relieve the
Install a new belt. pressure.

Slide the air compressor into position. Tighten bolt 7.

Refer to Specification, SENR3130, “Torque
Specifications” for the correct torque.
66 M0097687-03
Maintenance Section
Coolant (DEAC) - Change

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

NOTICE
Loosen the cooling system filler cap slowly in Improper or incomplete rinsing of the cooling system
order to relieve any pressure. Remove the cooling can result in damage to copper and other metal
system filler cap. components.
2. Open the cooling system drain valve (if equipped). To avoid damage to the cooling system, make sure to
If the cooling system is not equipped with a drain completely flush the cooling system with clear water.
valve, remove one of the drain plugs. Continue to flush the system until all signs of the
cleaning agent are gone.
Note: If equipped, be sure to drain the heater and
any related supply and return lines.
5. Stop the engine and allow the engine to cool.
Allow the coolant to drain. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
NOTICE system filler cap. Open the drain valve (if
Dispose of used engine coolant properly or recycle. equipped) or remove the cooling system drain
Various methods have been proposed to reclaim plugs. Allow the water to drain. Flush the cooling
used coolant for reuse in engine cooling systems. system with clean water. If equipped, be sure to
The full distillation procedure is the only method ac-
ceptable by Caterpillar to reclaim the used coolant. flush the heater and any related supply and return
lines. Close the drain valve (if equipped). Clean
the drain plugs. Install the drain plugs. Refer to the
For information regarding the disposal and the Specifications Manual, SENR3130, “Torque
recycling of used coolant, consult your Caterpillar Specifications” for more information on the proper
dealer or consult Caterpillar Dealer Service Tool
Group: torques.

Outside Illinois 1-800-542-TOOL Cooling Systems with Heavy

Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL
Deposits or Plugging
Note: For the following procedure to be effective,
Flush there must be some active flow through the cooling
system components.
1. Flush the cooling system with clean water in order
to remove any debris. 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 the Note: If equipped, be sure to flush the heater and
Specifications Manual, SENR3130, “Torque any related supply and return lines.
Specifications” for more information on the proper
torques. 2. Close the drain valve (if equipped). Clean the drain
plugs. Install the drain plugs. Refer to the
NOTICE Specifications Manual, SENR3130, “Torque
Fill the cooling system no faster than 19 L (5 US gal) Specifications” for more information on the proper
per minute to avoid air locks. torques.

3. Fill the cooling system with a mixture of clean NOTICE

Fill the cooling system no faster than 19 L (5 US gal)
water and Caterpillar Fast Acting Cooling System per minute to avoid air locks.
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap. 3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
4. Start and run the engine at low idle for a minimum Cleaner. Add 0.5 L (1 pint) of cleaner per
of 30 minutes. The coolant temperature should be 3.8 to 7.6 L (1 to 2 US gal) of the cooling system
at least 82 °C (180 °F). capacity. Install the cooling system filler cap.
4. Start and run the engine at low idle for a minimum
of 90 minutes. The coolant temperature should be
at least 82 °C (180 °F).
M0097687-03 67
Maintenance Section
Coolant (ELC) - Change

4. Clean the cooling system filler cap. Inspect the

NOTICE
Improper or incomplete rinsing of the cooling system gasket that is on the cooling system filler cap. If
can result in damage to copper and other metal the gasket that is on the cooling system filler cap is
components. damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water. gasket that is on the cooling system filler cap is not
Continue to flush the system until all signs of the damaged, perform a pressure test. A 9S-8140
cleaning agent are gone. Pressurizing Pump is used to perform the
pressure test. The correct pressure for the cooling
system filler cap is stamped on the face of the
5. Stop the engine and allow the engine to cool.
cooling system filler cap. If the cooling system filler
Loosen the cooling system filler cap slowly in
cap does not retain the correct pressure, install a
order to relieve any pressure. Remove the cooling
new cooling system filler cap.
system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain 5. Start the engine. Inspect the cooling system for
plugs. Allow the water to drain. Flush the cooling leaks and for proper operating temperature.
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain i08397627
plugs. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more Coolant (ELC) - Change
information on the proper torques. SMCS Code: 1350-070; 1395-044

Fill Clean the cooling system and flush the cooling

system before the recommended maintenance
interval if the following conditions exist:
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) • The engine overheats frequently.
per minute to avoid air locks.
• Foaming is observed.
1. Fill the cooling system with an antifreeze/coolant • The oil has entered the cooling system and the
solution. Refer to the Operation and Maintenance coolant is contaminated.
Manual, “Refill Capacitites and
Recommendations” topic (Maintenance Section) • The fuel has entered the cooling system and the
for more information on cooling system coolant is contaminated.
specifications. Do not install the cooling system Note: When the cooling system is cleaned, only
filler cap. clean water is needed when the ELC is drained and
2. Start and run the engine at low idle. Increase the replaced.
engine rpm to 1500 rpm. Run the engine at high Note: Inspect the water pump and the water
idle for one minute in order to purge the air from temperature regulator after the cooling system has
the cavities of the engine block. Stop the engine. been drained. This is a good opportunity to replace
3. Check the coolant level. Maintain the coolant level the water pump, the water temperature regulator and
the hoses, if necessary.
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight Drain
glass (if equipped).

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.
68 M0097687-03
Maintenance Section
Coolant (ELC) - Change

1. Stop the engine and allow the engine to cool. 5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling order to relieve any pressure. Remove the cooling
system filler cap. system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
2. Open the cooling system drain valve (if equipped).
plugs. Allow the water to drain. Flush the cooling
If the cooling system is not equipped with a drain
system with clean water. Close the drain valve (if
valve, remove the cooling system drain plugs.
equipped). Clean the drain plugs. Install the drain
Allow the coolant to drain. plugs. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more
NOTICE information on the proper torques.
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim
used coolant for reuse in engine cooling systems. Fill
The full distillation procedure is the only method ac-
ceptable by Caterpillar to reclaim the used coolant. NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tool 1. Fill the cooling system with Extended Life Coolant
Group: (ELC). Refer to the Operation and Maintenance
Outside Illinois 1-800-542-TOOL Manual, “Refill Capacities and Recommendations”
Inside Illinois 1-800-541-TOOL topic (Maintenance Section) for more information
Canada 1-800-523-TOOL on cooling system specifications. Do not install the
cooling system filler cap.
Flush 2. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
1. Flush the cooling system with clean water in order idle for one minute in order to purge the air from
to remove any debris. the cavities of the engine block. Stop the engine.
2. Close the drain valve (if equipped). Clean the drain 3. Check the coolant level. Maintain the coolant level
plugs. Install the drain plugs. Refer to the within 13 mm (0.5 inch) below the bottom of the
Specifications Manual, SENR3130, “Torque pipe for filling. Maintain the coolant level within
Specifications” for more information on the proper 13 mm (0.5 inch) to the proper level on the sight
torques. glass (if equipped).
NOTICE 4. Clean the cooling system filler cap. Inspect the
Fill the cooling system no faster than 19 L (5 US gal) gasket that is on the cooling system filler cap. If
per minute to avoid air locks. the gasket that is on the cooling system filler cap is
damaged, discard the old cooling system filler cap
3. Fill the cooling system with clean water. Install the and install a new cooling system filler cap. If the
cooling system filler cap. gasket that is on the cooling system filler cap is not
damaged, use a 9S-8140 Pressurizing Pump in
4. Start and run the engine at low idle until the order to pressure test the cooling system filler cap.
temperature reaches 49 to 66 °C (120 to 150 °F). The correct pressure for the cooling system filler
cap is stamped on the face of the cooling system
filler cap. If the cooling system filler cap does not
retain the correct pressure, install a new cooling
system filler cap.
M0097687-03 69
Maintenance Section
Coolant Extender (ELC) - Add

5. Start the engine. Inspect the cooling system for

NOTICE
leaks and for proper operating temperature. Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
i08397632 nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Coolant Extender (ELC) - Add ers before opening any compartment or disassem-
bling any component containing fluids.
SMCS Code: 1352-544-NL
Refer to Special Publication, NENG2500, “Cat Dealer
Cat ELC (Extended Life Coolant) does not require Service Tool Catalog” or refer to Special Publication,
the frequent additions of any supplemental cooling PECJ0003, “Cat Shop Supplies and Tools Catalog”
additives which are associated with the present for tools and supplies suitable to collect and contain
conventional coolants. The Cat ELC Extender will fluids on Cat products.
only be added one time.
Dispose of all fluids according to local regulations
NOTICE and mandates.
Use only Cat Extended Life Coolant (ELC) Extender
with Cat ELC.
1. Loosen the cooling system filler cap slowly in order
Do NOT use conventional supplemental coolant addi- to relieve pressure. Remove the cooling system
tive (SCA) with Cat ELC. Mixing Cat ELC with con- filler cap.
ventional coolants and/or conventional SCA reduces
the Cat ELC service life. 2. If necessary, drain enough coolant from the
cooling system in order to add the Cat ELC
Check the cooling system only when the engine is Extender.
stopped and cool. 3. Add Cat ELC Extender according to the
requirements for the cooling system capacity.
Refer to this Operation and Maintenance Manual,
“Refill Capacities” or to this Operation and
Personal injury can result from hot coolant, Maintenance Manual, “Fluid Recommendations”
steam and alkali.
for more information.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to 4. Clean the cooling system filler cap. Inspect the
heaters or the engine contain hot coolant or gaskets on the cooling system filler cap. Replace
steam. Any contact can cause severe burns. the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
i08397612
cooling system pressure cap is cool enough to
touch with your bare hand.
Coolant Level - Check
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing SMCS Code: 1395-082
burns.
Check the coolant level when the engine is stopped
Cooling System Coolant Additive contains alkali. and cool.
Avoid contact with skin and eyes.
70 M0097687-03
Maintenance Section
Coolant Sample (Level 1) - Obtain

i08397647

Coolant Sample (Level 1) -

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

Note: Obtaining a Coolant Sample (Level 1) is

optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems
filled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended
interval as stated in the maintenance interval
schedule.
Illustration 40 g00285520 Note: Obtain a Coolant Sample (Level 1) if the
Cooling system filler cap cooling system is filled with any other coolant
instead of Cat ELC including the following
coolants:
• Commercial long life coolants that meet the
Pressurized System: Hot coolant can cause seri- Caterpillar Engine Coolant Specification -1
ous burns. To open the cooling system filler cap, (Caterpillar EC-1)
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system • Cat DEAC (Diesel Engine Antifreeze/Coolant)
pressure cap slowly in order to relieve the
pressure. • Commercial heavy-duty coolant/antifreeze
Table 14
1. Remove the cooling system filler cap slowly in
Recommended Interval
order to relieve pressure.
Type of Coolant Level 1 Level 2
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is Cat DEAC
Every 500 service 2000 Hours or Every
equipped with a sight glass, maintain the coolant Conventional heavy year(1)
hours
level to the proper level in the sight glass. duty-coolant

Cat ELC or conven- 2000 Hours or Every

Optional
tional EC-1 coolant year(1)
(1) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.

Illustration 41 g00103639 Note: Level 1 results may indicate a need for

Typical filler cap gaskets Level 2 Analysis.
Obtain the sample of the coolant as close as possible
3. Clean the cooling system filler cap and check the to the recommended sampling interval. In order to
condition of the filler cap gaskets. Replace the receive the full effect of S·O·S analysis, establish a
cooling system filler cap if the filler cap gaskets are consistent trend of data. In order to establish a
damaged. Reinstall the cooling system filler cap. pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for
4. Inspect the cooling system for leaks. collecting samples can be obtained from your
Caterpillar dealer.
M0097687-03 71
Maintenance Section
Coolant Sample (Level 2) - Obtain

Use the following guidelines for proper sampling of

the coolant: NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
• Complete the information on the label for the nance, testing, adjusting, and repair of the product.
sampling bottle before you begin to take the Be prepared to collect the fluid with suitable contain-
samples. ers before opening any compartment or disassem-
bling any component containing fluids.
• Keep the unused sampling bottles stored in plastic
bags. Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
• Obtain coolant samples directly from the coolant PECJ0003, “Cat Shop Supplies and Tools Catalog”
sample port. You should not obtain the samples for tools and supplies suitable to collect and contain
from any other location. fluids on Cat products.
• Keep the lids on empty sampling bottles until you Dispose of all fluids according to local regulations
are ready to collect the sample. and mandates.

• Place the sample in the mailing tube immediately Refer to Operation and Maintenance Manual,
after obtaining the sample in order to avoid “Cooling System Coolant Sample (Level 1) - Obtain”
contamination. for the guidelines for a proper sampling of the
coolant.
• Never collect samples from expansion bottles.
Submit the sample for Level 2 analysis.
• Never collect samples from the drain for a system.
For additional information about coolant analysis, see
Submit the sample for Level 1 analysis. Special Publication, SEBU7003, “Cat 3600 Series
and C280 Series Diesel Engine Fluids
For additional information about coolant analysis, see Recommendations” or consult your Cat dealer.
this Operation and Maintenance Manual, “Fluid
Recommendations” or consult your Caterpillar dealer. i08397639

i08397652 Coolant Temperature

Coolant Sample (Level 2) - Regulator - Replace
SMCS Code: 1355-510
Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 Replace the water temperature regulator before the
water temperature regulator fails. Replacing the
water temperature regulator is a recommended
NOTICE preventive maintenance practice. Replacing the
Always use a designated pump for oil sampling, and water temperature regulator reduces the chances for
use a separate designated pump for coolant sam- unscheduled downtime. Refer to this Operation and
pling. Using the same pump for both types of sam- Maintenance Manual, “Maintenance Interval
ples may contaminate the samples that are being Schedule” for the proper maintenance interval.
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con- A water temperature regulator that fails in a partially
cerns by both dealers and customers. opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or piston seizure problems.
A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear of
the cylinder liner.
72 M0097687-03
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

NOTICE NOTICE
Failure to replace your water temperature regulator Excessive supplemental coolant additive concentra-
on a regularly scheduled basis could cause severe tion can form deposits on the higher temperature sur-
engine damage. faces of the cooling system, reducing the engine's
heat transfer characteristics. Reduced heat transfer
Cat engines incorporate a shunt bypass design cool- could cause cracking of the cylinder head and other
ing system and require operating the engine with a high temperature components.
water temperature regulator installed.
Excessive supplemental coolant additive concentra-
If the water temperature regulator is installed incor- tion could also result in blockage of the heat ex-
rectly, the engine may overheat, causing cylinder changer, overheating, and/or accelerated wear of the
head damage. Ensure that the new water tempera- water pump seal.
ture regulator is installed in the original position. En-
sure that the water temperature regulator vent hole is Do not exceed the recommended amount of supple-
open. mental coolant additive concentration.
Do not use liquid gasket material on the gasket or cyl- This maintenance procedure is required for
inder head surface. conventional coolants such as DEAC.Do not
perform this maintenance for cooling systems
that are filled with Cat Extended Life Coolant (Cat
Refer to two articles in the Disassembly and ELC) or Cat Extended Life Inhibitor (Cat ELI).
Assembly Manual, “Water Temperature Regulators -
Remove and Water Temperature Regulators - Install” Note: Caterpillar recommends an S·O·S coolant
for the replacement procedure of the water analysis (Level 1).
temperature regulator, or consult your Caterpillar
dealer.
NOTICE
Note: If the water temperature regulators are Do NOT mix brands or types of SCA. Do NOT mix
replaced, drain the coolant from the cooling system SCAs and extenders.
to a level that is below the water temperature Failure to follow the recommendations can result in
regulator housing. shortened cooling system component life.

i08397656
NOTICE
Cooling System Supplemental Use Only Approved SCAs. Conventional coolants
require the maintenance addition of SCA throughout
Coolant Additive (SCA) - Test/ their expected life. Do NOT use an SCA with a cool-
ant unless specifically approved by the coolant sup-
Add plier for use with their coolant. It is the responsibility
SMCS Code: 1352-045; 1395-081 of the coolant manufacturer to ensure compatibility
and acceptable performance.
Failure to follow the recommendations can result in
shortened cooling system component life.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact
with the skin and eyes. Do not drink cooling sys- NOTICE
tem coolant additive. 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” and to Special Publication,
GECJ0003, “Cat Shop Supplies and Tools” for tools
and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to applicable regula-
tions and mandates.
M0097687-03 73
Maintenance Section
Driven Equipment - Check

Note: Caterpillar recommends that an S·O·S Coolant i08397657

Analysis (Level 1) is performed to check the
concentration of SCA. Engine - Clean
SMCS Code: 1000-070
Maintain the Proper Concentration
of SCA in the Coolant
Personal injury or death can result from high
voltage.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, Moisture can create paths of electrical
stop the engine and wait until the cooling system conductivity.
components are cool. Loosen the cooling system Make sure that the electrical system is OFF. Lock
pressure cap slowly in order to relieve the out the starting controls and tag the controls “ DO
pressure.
NOT OPERATE”” .
1. Remove the cooling system filler cap slowly.
2. Test the concentration of the SCA with a NOTICE
286-2578 Nitrite Test Strip or review the results Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and
of the S·O·S Coolant Analysis (Level 1). fluid spills whenever a significant quantity accumu-
3. If necessary, drain some coolant to allow space for lates on the engine.
the addition of the SCA. Periodic cleaning of the engine is recommended.
4. Add the amount of SCA required to maintain a Steam cleaning the engine will remove accumulated
concentration of 3 percent to 6 percent SCA in the oil and grease. A clean engine provides the following
benefits:
coolant.
5. Clean the cooling system filler cap. Install the • Easy detection of fluid leaks
cooling system filler cap. • Maximum heat transfer characteristics
For further information, refer to Special Publication, • Ease of maintenance
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”. Note: Caution must be used to prevent electrical
For information on Cat coolant conditioner for components from being damaged by excessive water
aluminum components, refer to Special Instruction, when you clean the engine. Avoid electrical
REHS7296, “Instructions for Use of Cat Coolant components such as the alternator, the starter, and
Conditioner for Aluminum Components”. the ECM.

i08397642 i08397640

Driven Equipment - Check Engine Air Cleaner Element

SMCS Code: 3279-535 (Dual Element) - Inspect/Clean/
Refer to the OEM specifications for more information Replace
on the following maintenance recommendations for
SMCS Code: 1051; 1054-510; 1054-040; 1054-070
the driven equipment:
• Inspection NOTICE
Never run the engine without an air cleaner element
• Adjustment installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements
• Lubrication with damaged pleats, gaskets or seals. Dirt entering
the engine causes premature wear and damage to
• Other maintenance recommendations engine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.
Perform any maintenance for the driven equipment
which is recommended by the OEM.
74 M0097687-03
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace

NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

Note: The air filter system may not have been
provided by Caterpillar. The procedure that follows is
for a typical air filter system. Refer to the OEM
information for the correct procedure.
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. Refer to the OEM information for the
correct air cleaner elements for your application.

• Check the precleaner (if equipped) and the dust

bowl daily for accumulation of dirt and debris.
Remove any dirt and debris, as needed.

• Operating in dirty conditions may require more

frequent service of the air cleaner element.

• The air cleaner element should be replaced at

least one time per year.
Replace the dirty air cleaner elements with clean air
cleaner elements. Before installation, the new air Illustration 42 g06217098
cleaner elements should be thoroughly checked for Typical example
tears and/or holes in the filter material. Inspect the
gasket or the seal of the air cleaner element for 1. Ensure that the outer body of the air cleaner to be
damage. Maintain a supply of suitable air cleaner
elements for replacement purposes. serviced is clean and free from dirt.
2. Inspect the top cover (1) and if necessary remove
Dual Element Air Cleaners top cover to clean cover. Ensure that dirt cannot
enter the air cleaner system with top cover
The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner removed. If necessary, clean top cover and install.
element. 3. Remove end cover (4) from air cleaner body (2). If
Do not replace the air cleaner filter elements in a dirty necessary, clean end cover and ensure that the
environment, as dirt can enter the air system when valve (5) is clean and free from dirt. Check the
the elements are removed. valve (5) for wear or damage, replace if necessary.
4. Remove primary air filter element (3) and remove
the secondary air filter element (Not Shown).
Discard all old air filter elements.
5. Install new secondary air filter element (Not
Shown) and install new primary air filter element
(3).
M0097687-03 75
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

6. Install end cover (4) to air cleaner body (2) and • Check for ease of resetting. The service indicator
secure end cover. If necessary, reset the air should reset in less than three pushes.
service indicator, refer to this Operation and
Maintenance Manual, Engine Air Cleaner Service • Check the movement of the service indicator core
when the engine is run at full load speed. The core
Indicator - Inspect for more information.
should latch approximately at the greatest vacuum
that is attained.
i08397637
If the service indicator does not reset easily, or if the
Engine Air Cleaner Service core does not latch at the greatest vacuum, the
service indicator should be replaced. If the new
Indicator - Inspect service indicator will not reset, the hole for the service
indicator may be plugged.
(If Equipped)
If necessary, replace the service indicator more
SMCS Code: 7452-040 frequently in environments that are severely dusty.
Some engines may be equipped with a different Replace the service indicator annually regardless of
service indicator. the operating conditions. Replace the service
indicator when the engine is overhauled, and
Some engines are equipped with a differential gauge whenever major engine components are replaced.
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure Note: When a new service indicator is installed,
that is measured before and after the air cleaner excessive force may crack the top of the service
element. As the air cleaner element becomes dirty, indicator. Tighten the service indicator to a torque of
the pressure differential rises. If your engine is 2 N·m (18 lb in).
equipped with a different type of service indicator,
follow the OEM recommendations in order to service i08397617
the air cleaner service indicator.
The service indicator may be mounted on the clean Engine Mounts - Inspect
side of the air cleaner housing or in a remote
location. SMCS Code: 1152; 1152-040
Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused
by the following conditions:
• Improper mounting of the engine

• Deterioration of the engine mounts

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

i08397629
Illustration 43 g00103777
Typical service indicator
Engine Oil Level - Check
Observe the service indicator. The air cleaner SMCS Code: 1348-535-FLV
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. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
• The red piston locks in the visible position. contact the skin.

Test the Service Indicator

Service indicators are important instruments.
76 M0097687-03
Maintenance Section
Engine Oil Sample - Obtain

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

For information about choosing the correct oil for
the engine, refer to one of the following articles:
Operation and Maintenance Manual, “Refill
Capacities and Recommendations” or Operation
and Maintenance Manual, “Fluid
Recommendations”. Do not fill the crankcase
above “FULL” mark (X) on the oil level gauge.
Illustration 44 g00110310
Clean the oil filler cap. Install the oil filler cap.
(Y) “ADD” mark
(X) “FULL” mark 3. Record the amount of oil that is added. For the
next oil sample and analysis, include the total
NOTICE amount of oil that has been added since the
Perform this maintenance with the engine stopped. previous sample. This information will help to
provide the most accurate oil analysis.

NOTICE i08397634
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. Engine Oil Sample - Obtain
Be prepared to collect the fluid with suitable contain- SMCS Code: 1348-554-SM
ers before opening any compartment or disassem-
bling any component containing fluids. In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
Refer to Special Publication, NENG2500, “Cat Dealer analysis at regularly scheduled intervals. S·O·S oil
Service Tool Catalog” or refer to Special Publication, analysis provides infrared analysis, which is required
PECJ0003, “Cat Shop Supplies and Tools Catalog” for determining nitration and oxidation levels.
for tools and supplies suitable to collect and contain
fluids on Cat products.
Obtain the Sample and the
Dispose of all fluids according to local regulations Analysis
and mandates.

1. Maintain the oil level between “ADD” mark (Y) and

“FULL” mark (X) on the oil level gauge. Do not fill Hot oil and hot components can cause personal
the crankcase above “FULL” mark (X). injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
Engine damage can occur if the crankcase is filled Before you take the oil sample, complete the Label,
above the “FULL” mark on the oil level gauge PEEP5031 for identification of the sample. To help
(dipstick). obtain the most accurate analysis, provide the
following information:
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel- • Engine model
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re- • Service hours on the engine
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the • The number of hours that have accumulated since
crankcase breathers and excessive oil consumption. the last oil change
Excessive oil consumption will cause deposits to form • The amount of oil that has been added since the
on the pistons and in the combustion chamber. De- last oil change
posits in the combustion chamber lead to the follow-
ing problems: guttering of the valves, packing of To ensure that the sample is representative of the oil
carbon under the piston rings and wear of the cylin- in the crankcase, obtain a warm, mixed oil sample.
der liner.
To avoid contamination of the oil samples, the tools
If the oil level is above the “FULL” mark on the oil lev- and the supplies that are used for obtaining oil
el gauge, drain some of the oil immediately. samples must be clean.
M0097687-03 77
Maintenance Section
Engine Oil and Filter - Change

Caterpillar recommends using the sampling valve to Use the chart below to determine the oil drain for
obtain oil samples. The quality and the consistency of your engine, based on the oil type, oil filter, and oil
the samples are better when the sampling valve is sampling. Oil drains of up to 1000 hours require the
used. The location of the sampling valve allows oil use of : Caterpillar branded oil (CK-4), Caterpillar oil
that is flowing under pressure to be obtained during filters, an oil pan capable of extended oil drains, and
normal engine operation. Caterpillar S·O·S Services oil analysis. If oil, filter,
pan, or Caterpillar S·O·S services are not available,
The 169-8373 Fluid Sampling Bottle is then must use the standard 500-hour oil drain
recommended for use with the sampling valve. The interval. Some severe duty machines may not be
fluid sampling bottle includes the parts that are able to extend oil drains, due to the listed severe duty
needed for obtaining oil samples. Instructions are factors. Use S·O·S Services oil analysis to determine
also provided. the optimum oil change when operating in severe
conditions. If S·O·S Services oil analysis is not being
NOTICE used, the oil change interval should be reduced to
Always use a designated pump for oil sampling, and 250 hrs.
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam- Severe Duty Factors
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis • Dusty Environments
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers. • High Altitude
• Extended Idling
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion into
the sump.
For instructions, see Special Publication, PEGJ0047,
“How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.

i07815025

Engine Oil and Filter - Change

SMCS Code: 1318-510

Hot oil and hot components can cause personal

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

Selection of Oil Change Interval

Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for further information
about oils that may be used in Caterpillar engines.
78 M0097687-03
Maintenance Section
Engine Oil and Filter - Change

Table 15
Expected Ambient Temperatures Oil Sam- Oil Sam-
Maximum pling
Engine Oil Viscosity Air and pling In-
Oil Drain - Min ° Max °C Min °C Max °C Laborato-
Grade Oil Filters terval -
Hours C ry Hours
Cat DEO-ULS SOS
1000+ 5W-40 -30 50 -22 122 Cat 250
SYN Services
Cat DEO-ULS SOS
1000 10W-30 -18 40 0 104 Cat 250
Services
Cat DEO-ULS SOS
1000 15W-40 -10 50 14 122 Cat 250
Services
Cat DEO-Cold SOS
1000 0W-40 -40 40 -40 104 Cat 250
weather Services
Commercial
500 15W-40 -10 50 14 122 Cat or Commercial 250
CK-4

Table 16 (Table 17, contd)

(1) Refer to Special Publication, PEHJ0192, “Optimizing Oil
Oil Pan Volume Ca- Oil Pan Volume Ca- Change Intervals” for further information.
pable of Standard pable of 1000
Engine
500 Hours Oil Hours Extended Oil
Drains (Liters) Drains (Liters) Drain the Engine Oil
C9.3B 32 32
After the engine has been run at the normal
C13 30, 32 Any Pan >37 operating temperature, stop the engine. Attach a “DO
NOT OPERATE” or a similar warning tag to the
C13B 34, 36 Any Pan >37 ignition keyswitch before the engine is serviced.
C15 34, 36, 60 Any Pan >62
NOTICE
C18 34, 36, 60 Any Pan >62 Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
Table 17
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Standard Oil Change Interval (1) ers before opening any compartment or disassem-
bling any component containing fluids.
Multigrade Oil Type Operating Conditions
Refer to Special Publication, NENG2500, “Cat Dealer
Normal Severe Service
Service Tool Catalog” or refer to Special Publication,
Application
PECJ0003, “Cat Shop Supplies and Tools Catalog”
Cat DEO-ULS 500 hr 250 hr for tools and supplies suitable to collect and contain
Preferred fluids on Cat products.
Oil meeting the require- 500 hr 250 hr Dispose of all fluids according to local regulations
ments of the Cat ECF-3 and mandates.
Specification, or the API CJ-
4, or API CK-4 classification
8 minimum TBN 1. Remove the oil drain plug to allow the oil to drain.
Preferred
Oil meeting the require- 500 hr 250 hr
ments of the ACEA C9/E6
Specification
TBN below 10.4

(continued)
M0097687-03 79
Maintenance Section
Engine Storage Procedure - Check

2. After the oil has drained, the oil drain plug should 4. Install the oil filter. Tighten the oil filter until the oil
be cleaned and installed. filter gasket contacts the base. Tighten the oil filter
by hand according to the instructions that are
Replace the Oil Filter shown on the oil filter. Do not overtighten the oil
filter.
NOTICE
Caterpillar oil filters are built to Caterpillar specifica- Fill the Engine Crankcase
tions. Use of an oil filter not recommended by Cater-
pillar could result in severe engine damage to the 1. Remove the oil filler cap. Fill the crankcase with
engine bearings, crankshaft, etc., as a result of the the proper amount of oil. Refer to the Operation
larger waste particles from unfiltered oil entering the and Maintenance Manual, “Refill Capacities and
engine lubricating system. Only use oil filters recom-
mended by Caterpillar. Recommendations” topic (Maintenance Section)
for more information.

NOTICE
If equipped with an auxiliary oil filter or system, extra
oil must be added when filling the crankcase. Follow
the OEM or filter manufacturer's recommendations. If
the extra oil is not added, the engine may starve for
oil.

NOTICE
To help prevent crankshaft or bearing damage, crank
engine to fill all filters before starting. Do not crank
engine for more than 30 seconds.

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

for 2 minutes. Perform this procedure to ensure
Illustration 45 g00103713 that the lubrication system has oil and that the oil
Typical filter mounting base and filter gasket filters are filled. Inspect the oil filter for oil leaks.

1. Remove the oil filter with a 185-3630 Strap 3. Stop the engine and allow the oil to drain back to
Wrench. the sump for a minimum of 10 minutes.

2. Clean the sealing surface of the filter mounting 4. Remove the oil level gauge to check the oil level.
base. Ensure that all the old oil filter gasket is Maintain the oil level between the “ADD” and
removed. “FULL” marks on the “ENGINE STOPPED” side of
the oil level gauge.
3. Apply clean engine oil to the new oil filter gasket.
i08397654
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
Engine Storage Procedure -
nated. Contaminated oil can cause accelerated wear
to engine components or engine damage.
Check
SMCS Code: 1000-535
Caterpillar recommends storage procedures and
start-up procedures for all engines that are stored for
more than 1 month. These procedures provide
maximum protection to internal engine components.
Refer to Special Instruction, SEHS9031, “Storage
Procedure For Caterpillar Products” for information
on these procedures.
An extension of the oil change interval to 12 months
is permitted if you follow the required procedures for
storage and start-up. This extension is permitted if
the following intervals in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule” have not been reached:
80 M0097687-03
Maintenance Section
Engine Valve Lash - Check

• Operating hours 4. When the water separator is full of fuel, attempt to

start the engine. If the engine starts and the
• Fuel consumption engine runs rough or the engine misfires, operate
at low idle until the engine is running smoothly. If
i07504990
the engine cannot be started, or if the engine
continues to misfire or smoke, repeat Step 1.
Engine Valve Lash - Check
SMCS Code: 1105-535 Manual Switch Priming (if
Note: Procedures for adjusting the valve lash can be equipped)
found in Systems Operation/Testing and Adjusting,
“Valve Lash Adjustment”. Consult your Cat dealer for The manual switch is located on the primary filter
assistance. base/electric priming pump assembly.
1. Hold the manual switch in the up position until fuel
has filled the water separator.
Ensure that the engine cannot be started while 2. Continue to hold the switch for 30 seconds after
this maintenance is being performed. To help pre- the water separator is full.
vent possible injury, do not use the starting motor
to turn the flywheel. 3. Attempt to start the engine. If engine starts and
runs rough or misfires, operate at low idle until the
Hot engine components can cause burns. Allow engine is running smoothly. If the engine cannot
additional time for the engine to cool before be started, continue to prime the fuel system for 30
measuring/adjusting valve lash clearance. more seconds.
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is i08397614
recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear and Fuel System Primary Filter
seating of the valve train components. This
maintenance is recommended as part of a lubrication (Water Separator) Element -
and preventive maintenance schedule to help
provide maximum engine life.
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
i08397615

Fuel System - Prime

Personal injury or death may result from failure
SMCS Code: 1250-548; 1258-548 to adhere to the following procedures.

NOTICE Fuel leaked or spilled onto hot surfaces or electri-

Do not allow dirt to enter the fuel system. Thoroughly cal components can cause a fire.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any Clean up all leaked or spilled fuel. Do not smoke
disconnected fuel system components. while working on the fuel system.
Turn the disconnect switch OFF or disconnect
the battery when changing fuel filters.
Key-on Priming (if equipped)
1. Turn the engine start switch to the ON position. NOTICE
Leave the engine start switch in the ON position Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be
for 2 minutes. contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
2. Verify that the water separator is full of fuel.
3. If the water separator is not full of fuel, turn the
engine start switch OFF and then turn the engine
start switch ON. Turning the switch OFF, then ON
will cycle the fuel priming pump again.
M0097687-03 81
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

8. Remove the filter and discard the filter. Clean the

NOTICE
Care must be taken to ensure that fluids are con- bottom of the filter mounting base. Make sure that
tained during performance of inspection, mainte- all of the old filter seal is removed from the bottom
nance, testing, adjusting and repair of the product. groove of the opening in the base.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- 9. Clean the water separator bowl and clean the
bling any component containing fluids. groove for the seal. Inspect the seal. If the seal is
worn or damaged, replace the seal.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” guide for tools and sup- 10. Lubricate the seal with clean diesel fuel or
plies suitable to collect and contain fluids on Caterpil- lubricate the seal with clean motor oil. Place the
lar products. seal in the groove on the water separator bowl.
Dispose of all fluids according to local regulations 11. Install the water separator bowl onto the new fuel
and mandates. filter by hand. Tighten the bowl assembly to 15
15 N·m (11 lb ft).
1. Turn the start switch to the OFF position or
12. Apply clean diesel fuel to the seal of the new
disconnect the battery (starting motor) when
filter.
maintenance is performed on a fuel filter.
13. Install the new filter onto the base. Tighten the
2. Shut off the fuel supply.
filter by hand until the seal contacts the filter base.
Additionally tighten the filter by 1/3 to 1/2 rotation.
14. Open the fuel shutoff valve.
15. Reconnect the battery, if necessary.
16. Purge the air from the fuel system. See this
Operation and Maintenance Manual, “Fuel System
- Prime” for further instructions.
17. Stop the engine and check for leaks.
Note: The secondary fuel filter should also be
replaced at this time. See this Operation and
Maintenance Manual, “Fuel System Secondary Filter
- Replace” for further information.
Illustration 46 g00104012
i08397648
(1) filter body
(2) bowl
(3) drain valve Fuel System Primary Filter/
Note: Refer to this Operation and Maintenance
Water Separator - Drain
Manual, “General Hazard Information” that pertains SMCS Code: 1260-543; 1263-543
to containing fluid spillage.

3. Turn drain valve (3) counterclockwise in order to

open. The drain valve is located on the bottom of Fuel leaked or spilled onto hot surfaces or electri-
the water separator. cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
4. Drain the water and sediment into a suitable changing fuel filters or water separator elements.
container. Dispose of the drained fluids and used Clean up fuel spills immediately.
filters according to local regulations.
5. Close the drain valve.
6. Hold the bottom of the filter while you loosen the
bowl. Remove the bowl.
7. Turn the filter counterclockwise in order to loosen
the filter. If the filter will not turn, use a strap
wrench to loosen the filter.
82 M0097687-03
Maintenance Section
Fuel System Secondary Filter - Replace

i08397618

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.
Illustration 47 g01453091
Typical primary fuel filter/water separator
(1) Primary fuel filter element
(2) Collection bowl for the water separator
(3) Drain for the water separator

The bowl should be monitored daily for signs of

water. If water is present, drain the water from the
bowl.

NOTICE
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. Illustration 48 g02145531
(1) Fuel supply connections
Refer to Special Publication, NENG2500, “Cat Dealer (2) Fuel filters
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain NOTICE
fluids on Cat products. Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
Dispose of all fluids according to local regulations will be disconnected. Fit a suitable cover over any
and mandates. disconnected fuel system components.

1. Open the drain. The drain is a self-ventilated drain.

NOTICE
Catch the draining water in a suitable container. Use a suitable container to catch any fuel that might
Dispose of the water properly. spill. Clean up any spilled fuel immediately.
2. Close the drain.
1. It may be necessary to relieve residual fuel
NOTICE pressure from the fuel system before removing the
The water separator is under suction during normal fuel filter.
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the Loosen one of the fuel supply connections (1) in
fuel system. order to purge any residual pressure.

NOTICE
Do not loosen fuel lines or fittings at the fuel manifold
or ECM. The engine components may be damaged.

2. Remove the used fuel filter.

3. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.
M0097687-03 83
Maintenance Section
Fuel Tank Water and Sediment - Drain

4. Apply clean diesel fuel to the new fuel filter gasket. Prepare to catch water and sediment in an
appropriate container. Connect a hose (if necessary)
NOTICE to the valve prior to opening the valve.
Do not fill the secondary and tertiary fuel filters with
fuel before installing. The fuel would not be filtered Open the drain valve on the bottom of the fuel tank to
and could be contaminated. Contaminated fuel will drain the water and the sediment. Close the drain
cause accelerated wear to fuel system parts. valve.
Note: Failure to close the drain properly could result
5. Install the new fuel filter. Spin the fuel filter onto the in fuel leakage, which could have detrimental results
fuel filter base until the gasket contacts the base. to performance.
Use the rotation index marks on the filters as a
Check the fuel daily. Drain the water and sediment
guide for proper tightening. Tighten the filter for an from the fuel tank after operating the engine. Drain
additional 3/4 turn by hand. Do not overtighten the the water and sediment from the fuel tank after the
filter. fuel tank has been filled. Allow 5 to 10 minutes before
performing this procedure.
i08397650
Fill the fuel tank after operating the engine to drive
out moist air. This procedure will help prevent
Fuel Tank Water and Sediment condensation. Do not fill the tank to the top. The fuel
- Drain expands as the fuel gets warm. The tank may
overflow.
SMCS Code: 1273-543-M&S
Some fuel tanks use stand pipes that allow water and
sediment to settle below the end of the fuel stand
NOTICE pipe. Some fuel tanks use supply lines that take fuel
Care must be taken to ensure that fluids are con- directly from the bottom of the tank. If the engine is
tained during performance of inspection, mainte- equipped with this system, regular maintenance of
nance, testing, adjusting, and repair of the product. the fuel system filter is important.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids. Fuel Storage Tanks
Refer to Special Publication, NENG2500, “Cat Dealer Drain the water and the sediment from the fuel
Service Tool Catalog” or refer to Special Publication, storage tank during the following conditions:
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain • Weekly
fluids on Cat products.
• Refill of the tank
Dispose of all fluids according to local regulations
and mandates. This procedure will help prevent water or sediment
from being pumped from the storage tank into the
engine fuel tank. A four micron(c) absolute filter for
the breather vent on the fuel tank is also
Fuel Tank recommended.

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. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel. The
fuel tank utilizes a fuel tank vent to prevent an air lock
or vacuum. Ensure that the vent is free of debris and
not damaged.

Drain the Water and the Sediment

Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
84 M0097687-03
Maintenance Section
Fumes Disposal Filter Element (Emission Related Component) - Replace

If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.

i08397631

Fumes Disposal Filter Element

(Emission Related
Component) - Replace
SMCS Code: 1074-510
The filter for the open crankcase ventilation system
(OCV) may be located toward the front or toward the
rear of the left side of the engine. A filter that has
been used may contain a small amount of engine oil.

NOTICE Illustration 49 g02021434

Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- (1) Cap
nance, testing, adjusting and repair of the machine. (2) Housing for the filter element
(3) Filter element
Be prepared to collect the fluid with suitable contain- (4) Cup
ers before opening any compartment or disassem-
bling any component containing fluids. Remove either the cap or the cup from the housing
for the OCV filter. Remove the OCV filter. The filter
Refer to Special Publication, NENG2500, “Caterpillar may not be used again. Dispose of the filter. Place a
Tools and Shop Products Guide”, for tools and sup- new OCV filter inside the filter housing. If the cap was
plies suitable to collect and contain fluids in Caterpil- removed, replace the cap. If the cup was removed,
lar machines. replace the cup. Tighten hand tight.
Dispose of all fluids according to local regulations
Note: Caterpillar will not be held liable for an engine
and mandates.
that does not comply with EPA emissions standards
due to modification of the OCV filter or due to the use
of a filter that is not approved by Caterpillar.
NOTICE
Failure to perform this maintenance procedure at less
than 1500 service hours will not void the emissions-
related warranty.
M0097687-03 85
Maintenance Section
Grounding Stud - Inspect/Clean/Tighten

i08397616 Note: Always use a board or cardboard when the

engine components are checked for leaks. Leaking
Grounding Stud - Inspect/ fluid that is under pressure can cause serious injury
or possible death. Leaks that are the size of a pin
Clean/Tighten hole are included. Refer to Operation and
SMCS Code: 7423-079; 7423-040; 7423-070 Maintenance Manual, “General Hazard Information”
for more information.
Note: Ensure that the hose is compatible with the
application.

Inspect Tubes, Hoses, Bellows, and

Clamps
Inspect all tubes and hoses for leaks that are caused
by the following conditions. Replace any tube or hose
which exhibits any of the following conditions. Failure
to replace a tube or hose which exhibits any of the
following conditions may result in a hazardous
situation.

• Hoses which are cracked

Illustration 50 g01376112
The grounding stud is located on the upper left corner • Hoses which are soft
of the engine control module.
• Outer covering that is chafed or cut
Inspect the OEM harness for good connections. • Exposed wire that is used for reinforcement
Inspect the condition of the OEM harness.
• Outer covering that is ballooning locally
The grounding stud must have a wire ground to the
battery. Tighten the grounding stud at every oil • Flexible part of the hose that is kinked or crushed
change. Ground wires and straps should be
combined at engine grounds. All grounds should be • Armoring that is embedded in the outer covering
tight and free of corrosion.
• Exhaust bellows for leaks or damage
• Clean the grounding stud and the terminals for the
ground strap with a clean cloth. • Hoses which exhibit signs of leakage which are
not the result of loose couplings or clamps
• If the connections are corroded, clean the
connections with a solution of baking soda and Inspect all clamps for the following conditions.
water. Replace any clamp which exhibits signs of any of the
following conditions.
• Keep the grounding stud and the strap clean and
coated with MPGM grease or petroleum jelly. • Cracking

i08397613 • Looseness

• Damage
Hoses and Clamps - Inspect/
Replace Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.
SMCS Code: 7554-510; 7554-040
Each installation application can be different. The
Hoses and clamps must be inspected periodically differences depend on the following factors:
and replaced at the recommended interval to ensure
safe and continuous operation of the engine. Failure • Type of hose
to replace a fuel hose at the recommended change
interval may result in a hazardous situation. Take • Type of fitting material
proper safety precautions before inspecting or
replacing hoses and clamps. • Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of the

fittings
86 M0097687-03
Maintenance Section
Hoses and Clamps - Inspect/Replace

Due to extreme temperature changes, the hose will 5. Drain the coolant from the cooling system to a
heat set. Heat setting causes hose clamps to loosen level that is below the hose that is being replaced.
which can result in leaks. A constant torque hose Drain the coolant into a suitable clean container.
clamp will help to prevent loose hose clamps.
The coolant can be reused.
Replace hoses that are cracked or soft. Replace 6. Remove the hose clamps.
hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps 7. Disconnect the old hose.
that are cracked or damaged. Tighten or replace
hose clamps which are loose. 8. Replace the old hose with a new hose.
9. Install hose clamps which have been inspected or
Replace the Hoses and the Clamps install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications” “Hose
NOTICE Clamps” for information about selecting and
Care must be taken to ensure that fluids are con- installing the proper hose clamps.
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. 10. Refill the cooling system.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- 11. Clean the coolant filler cap. Inspect the gaskets
bling any component containing fluids. on the filler cap. Inspect the gasket seat. Inspect
the vacuum valve and seat for debris or damage.
Refer to Special Publication, NENG2500, “Cat Dealer
Replace the filler cap if the gaskets are damaged.
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” Install the filler cap.
for tools and supplies suitable to collect and contain 12. Start the engine. Inspect the cooling system for
fluids on Cat products.
leaks.
Dispose of all fluids according to local regulations
and mandates. Fuel System

Cooling System
Personal injury can result from removing hoses
or fittings in a pressure system.
Failure to relieve pressure can cause personal
Pressurized System: Hot coolant can cause seri-
injury.
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system Do not disconnect or remove hoses or fittings un-
components are cool. Loosen the cooling system til all pressure in the system has been relieved.
pressure cap slowly in order to relieve the
pressure.

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
Personal injury can result from removing hoses
spray may cause a fire hazard. Failure to follow
or fittings in a pressure system.
these inspection, maintenance and service in-
Failure to relieve pressure can cause personal structions may cause personal injury or death.
injury.
Do not disconnect or remove hoses or fittings un- NOTICE
til all pressure in the system has been relieved. Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
1. Stop the engine. hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the
2. Allow the engine to cool. recommended torque.
3. Before servicing a coolant hose, slowly loosen the
filler cap for the cooling system to relieve any
pressure.
4. Remove the filler cap for the cooling system.
M0097687-03 87
Maintenance Section
Overhaul Considerations

3. Disconnect the old hose.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly 4. Replace the old hose with a new hose.
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any 5. Install hose clamps which have been inspected or
disconnected fuel system components. install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications” “Hose
Clamps” for information about selecting and
Note: High-pressure fuel lines may be installed
between the high-pressure fuel pump and the fuel installing the proper hose clamps.
injectors. High-pressure fuel lines are constantly 6. Refill the lubrication system. Refer to this
charged with high pressure. Do not check the high- Operation and Maintenance Manual, “Engine Oil
pressure fuel lines with the engine or the starting Level - Check” to ensure that the lubrication
motor in operation. Wait for 10 minutes after the
system is filled with the proper amount of engine
engine stops before you perform any service or
repair on high-pressure fuel lines. Waiting for 10 oil.
minutes will allow the pressure to be purged. 7. Start the engine. Inspect the lubrication system for
leaks.
1. Drain the fuel from the fuel system to a level that is
below the hose that is being replaced. Air System
2. Remove the hose clamps.
1. Remove the hose clamps.
3. Disconnect the old hose.
2. Disconnect the old hose.
Note: When servicing fuel system, use cap/s or
cover/s as required to protect the system and 3. Replace the old hose with a new hose.
maintain fuel system cleanliness. 4. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
4. Replace the old hose with a new hose.
SENR3130, “Torque Specifications” “Hose
5. Install hose clamps which have been inspected or Clamps” for information about selecting and
install new hose clamps. Refer to Specifications, installing the proper hose clamps.
SENR3130, “Torque Specifications” “Hose
Clamps” for information about selecting and Note: The bellows and the V-clamps that are used on
installing the proper hose clamps. the exhaust bellows should never be reused.

6. Carefully inspect the engine for any spilled fuel. 5. Start the engine. Inspect the air lines for leaks.
Make sure that no fuel remains on or close to the
engine. i08397625

Note: Fuel must be added to the fuel system ahead Overhaul Considerations
of the fuel filter.
SMCS Code: 7595-043
7. Refill the fuel system. Refer to this Operation and
Reduced hours of operation at full load will result in a
Maintenance Manual, “Fuel System - Prime” for lower average power demand and reduced fuel
information about priming the engine with fuel. consumption. A decreased average power demand
8. Start the engine. Inspect the fuel system for leaks. should increase both the engine service life and the
overhaul interval.
Lubrication System The need for an overhaul is indicated by increased
fuel consumption, increased oil consumption,
excessive engine blowby, and reduced power. Arctic
temperatures, extreme high temperatures, corrosive
environments, or extreme dusty conditions contribute
Hot oil and hot components can cause personal to premature wear and the need for an overhaul.
injury. Do not allow hot oil or hot components to
contact the skin. The following factors are important when a decision
is being made on the proper time for an engine
overhaul:
1. Drain the oil from the lubrication system to a level
that is below the hose that is being replaced. • The need for preventive maintenance
2. Remove the hose clamps. • The quality of the fuel that is being used
88 M0097687-03
Maintenance Section
Overhaul Considerations

• The operating conditions If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
• The results of the S·O·S analysis percent and 50 percent of the cost of a new engine
with a similar exchange core.
Note: The aftertreatment system can be expected to
function properly for the useful life of the engine This lower cost can be attributed to three aspects:
(emissions durability period), as defined by
regulation, subject to prescribed maintenance • Specially designed Cat engine features
requirements being followed.
• Cat dealer exchange components
Oil Consumption as an Overhaul • Caterpillar remanufactured exchange components
Indicator
Overhaul Recommendation
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total To minimize downtime, Caterpillar recommends a
operating cost for your Cat engine. Oil consumption scheduled engine overhaul by your Cat dealer before
can also be used to estimate the required capacity of the engine fails. A scheduled engine overhaul will
a makeup oil tank that is suitable for the maintenance provide you with the best cost/value relationship.
intervals.
Note: Overhaul programs vary according to the
Oil consumption is in proportion to the percentage of engine application and according to the dealer that
the rated engine load. As the percentage of the performs the overhaul. Consult your Cat dealer for
engine load is increased, the amount of oil that is
specific information about the available overhaul
consumed per hour also increases.
programs and about overhaul services for extending
The oil consumption rate (brake-specific oil the engine life.
consumption) is measured in grams per kW/h (lb per
bhp). The brake-specific oil consumption (BSOC) If an overhaul is performed without overhaul service
depends on the engine load. Consult your Cat dealer from your Cat dealer, be aware of the following
for assistance in determining the typical oil maintenance recommendations.
consumption rate for your engine.
Rebuild or Exchange
When the oil consumption of an engine has risen to
three times the original oil consumption rate due to Cylinder Head Assembly, Cylinder Packs, Oil
normal wear, an engine overhaul should be Pump, and Fuel Transfer Pump
scheduled. There may be a corresponding increase
in blowby and a slight increase in fuel consumption. These components should be inspected according to
the instructions that are found in various Cat
Overhaul Options reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
Before Failure Overhaul needed for inspecting the engine parts.

A planned overhaul before failure may be the best If the parts comply with the established inspection
value for the following reasons: specifications that are expressed in the reusable
parts guideline, the parts should be reused.
• Costly unplanned downtime can be avoided.
Parts that are not within the established inspection
• Many original parts can be reused according to the specifications should be dealt with in one of the
standards for reusable parts. following manners:

• The service life of the engine can be extended • Salvaging

without the risk of a major catastrophe due to • Repairing
engine failure.
• Replacing
• The best cost/value relationship per hour of
extended life can be attained. Using out-of-spec parts can result in the following
problems:
After Failure Overhaul
• Unscheduled downtime
If a major engine failure occurs and the engine must
be removed, many options are available. An overhaul • Costly repairs
should be performed if the engine block or the
crankshaft needs to be repaired. • Damage to other engine parts
M0097687-03 89
Maintenance Section
Overhaul Considerations

• Reduced engine efficiency Oil Cooler Core

• Increased fuel consumption During an overhaul, Caterpillar recommends the
removal of the oil cooler core. Clean the oil cooler
Reduced engine efficiency and increased fuel core. Then, pressure test the oil cooler core.
consumption translates into higher operating costs.
Therefore, Caterpillar recommends repairing out-of- NOTICE
spec parts or replacing out-of-spec parts. Do not use caustic cleaners to clean the core.

Inspection and/or Replacement Caustic cleaners can attack the internal metals of the
core and cause leakage.
Crankshaft Bearings, Valve Rotators, and
Crankshaft Seals Note: Use this cleaning procedure to clean the oil
cooler core.
The following components may not last until the
second overhaul. 1. Remove the oil cooler core.
• Thrust bearings 2. Remove any debris from the oil cooler core. To
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
• Crankshaft seals order to loosen foreign substances. Flushing the
oil cooler will also help to remove oil from the oil
Caterpillar recommends the installation of new parts cooler core.
at each overhaul period.
Note: Caterpillar recommends the use of Hydrosolv
Inspect these parts while the engine is disassembled Liquid Cleaners. Table 18 lists the Hydrosolv Liquid
for an overhaul.
Cleaners that are available from your Cat dealer.
Inspect the crankshaft for any of the following
Table 18
conditions:
HydrosolvLiquid Cleaners
• Deflection
Part Number Description Size
• Damage to the journals Hydrosolv4165 19 L (5 US gallon)
1U-5490
• Bearing material that has seized to the journals 174-6854 Hydrosolv100 19 L (5 US gallon)

Check the journal taper and the profile of the

crankshaft journals. Check these components by 4. Use steam to clean the oil cooler core. Steam-
interpreting the wear patterns on the following cleaning the oil cooler core removes any
components:
remaining residue from the cleaner. Flush the fins
• Rod bearing of the oil cooler core. Remove any other trapped
debris.
• Main bearings
5. Wash the oil cooler core with hot, soapy water.
Inspect the camshaft for damage to the journals and Rinse the oil cooler core thoroughly with clean
to the lobes. water.
Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check for
cracks in the camshaft.
Personal injury can result from air pressure.
Inspect the following components for signs of wear or
for signs of scuffing: Personal injury can result without following prop-
er procedure. When using pressure air, wear a
• Camshaft bearings protective face shield and protective clothing.

• Camshaft followers Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.
Caterpillar recommends replacing the crankshaft
vibration damper. 6. Dry the oil cooler core with compressed air. Direct
the air in the reverse direction of the normal flow.
90 M0097687-03
Maintenance Section
Power Take-Off Clutch - Check

7. Inspect the components in order to ensure For more information about coolant analysis, see
cleanliness. The oil cooler core should be your Cat dealer.
pressure tested. Repair the oil cooler core, if
necessary. Install the oil cooler core. i08397655

For more information about cleaning the cores, Power Take-Off Clutch - Check
consult your Cat dealer.
SMCS Code: 3055-535
Obtain Coolant Analysis
NOTICE
The concentration of supplemental coolant additive New power take-offs should have the clutch adjust-
(SCA) should be checked regularly with test kits or ment checked before being placed into service. The
with S·O·S Coolant Analysis (Level 1). Further clutch adjustment should be checked again after the
coolant analysis is recommended when the engine is first ten hours of operation. New clutch plates have a
overhauled. “wear in” period, and the clutch may require several
adjustments until the new plates are “worn in”.
For example, considerable deposits are found in the
water jacket areas on the external cooling system,
but the concentrations of coolant additives were
carefully maintained. The coolant water probably
contained minerals that were deposited on the
engine over time.
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
by consulting your local water utility company or an
agricultural agent. Private laboratories are also
available for water analysis.
Caterpillar recommends an S·O·S Coolant Analysis
(Level 2).

S·O·S Coolant Analysis (Level 2)

Illustration 51 g00781502
An S·O·S Coolant Analysis (Level 2) is a
(1) Instruction plate
comprehensive coolant analysis which completely (2) Serial number plate
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level 2) Check the clutch adjustment regularly after “wear in”.
provides the following information: Heavy-duty applications which have engagements
that are frequent and relatively long periods of clutch
• Complete S·O·S Coolant Analysis (Level 1) slippage require more frequent adjustment than light-
duty applications. The operating torque should be
• Visual inspection of properties
measured in order to determine if a clutch adjustment
• Identification of metal corrosion is required.
Refer to the OEM information and instruction plate
• Identification of contaminants
(1) for instructions on lubrication, adjustment, and
• Identification of built up impurities (corrosion and other recommendations for service. Perform the
maintenance that is specified on the instruction plate.
scale)
S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
recommendations. Do not operate the engine with the Instruction
Plate cover removed from the clutch. Personal in-
jury may result.
If the clutch is damaged to the point of burst fail-
ure, expelled pieces can cause personal injury to
anyone in the immediate area. Proper safeguards
must be followed to help prevent accidents.
M0097687-03 91
Maintenance Section
Radiator - Clean

i08397626 i08397644

Radiator - Clean Starting Motor - Inspect

SMCS Code: 1353-070 (If Equipped)
Note: Adjust the frequency of cleaning according to SMCS Code: 1451-040; 1453-040
the effects of the operating environment.
Note: The OEM may be responsible for the starting
Inspect the radiator for these items: damaged fins, motor for this engine application. Air starting motors
corrosion, dirt, grease, insects, leaves, oil and other are recommended if an explosive atmosphere may
debris. Clean the radiator, if necessary. be present. If the starting motor is supplied by an
OEM, refer to the Service Manual for the starter in
order to locate additional information on the checking
procedure and for specifications.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a The connection of battery cables to a battery and
protective face shield and protective clothing. the disconnection of battery cables from a battery
may cause an explosion which may result in in-
Maximum air pressure at the nozzle must be less jury or death. The connection and the disconnec-
than 205 kPa (30 psi) for cleaning purposes. tion of other electrical equipment may also cause
an explosion which may result in injury or death.
Pressurized air is the preferred method for removing The procedures for the connection and the dis-
loose debris. Direct the air in the opposite direction of connection of battery cables and other electrical
the fan's air flow. Hold the nozzle approximately equipment should only be performed in a nonex-
6 mm (0.25 inch) away from the fins. Slowly move plosive atmosphere.
the air nozzle in a direction that is parallel with the
tubes. This will remove debris that is between the If the starting motor fails, the engine may not start in
tubes. an emergency situation. A scheduled inspection of
the starting motor is recommended.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes The starting motor pinion and the flywheel ring gear
must be less than 275 kPa (40 psi). Use pressurized must be in good condition in order for the engine to
water in order to soften mud. Clean the core from start properly. The engine will not start if the starting
both sides. motor pinion does not engage the flywheel ring gear.
The teeth of the starting motor pinion and the
Use a degreaser and steam for removal of oil and flywheel ring gear can be damaged because of
grease. Clean both sides of the core. Wash the core irregular engagement.
with detergent and hot water. Thoroughly rinse the
core with clean water. Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
After cleaning, start the engine. This will help in the teeth of the starting motor pinion and the flywheel
removal of debris and drying of the core. Stop the ring gear. Look for patterns of wear on the teeth.
engine. Use a light bulb behind the core in order to Look for teeth that are broken or chipped. If damaged
inspect the core for cleanliness. Repeat the cleaning, teeth are found, the starting motor pinion and the
if necessary. flywheel ring gear must be replaced.
Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition: Electric Starting Motor
welds, mounting brackets, air lines, connections,
clamps and seals. Make repairs, if necessary. Note: Problems with the electric starting motor can
be caused by the following conditions: malfunction of
For more detailed information on cleaning and the solenoid and malfunction of the electric starting
inspection, refer to Special Publication, SEBD0518, system.
“Know Your Cooling System”.
Inspect the electrical system for the following
conditions:
• Loose connections

• Corrosion
• Wires that are worn or frayed
92 M0097687-03
Maintenance Section
Walk-Around Inspection

• Cleanliness Note: The water pump seal is lubricated by coolant in

the cooling system. It is normal for a small amount of
Make repairs, if necessary. leakage to occur as the engine cools down and the
parts contract.
Removal and Installation of the
Excessive coolant leakage may indicate the need to
Starting Motor replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/
Refer to the Service Manual, “Disassembly and or seals, refer to the Service Manual for the engine or
Assembly” module for information on removing the consult your Caterpillar dealer.
starting motor and installing the starting motor.
• Inspect the lubrication system for leaks at the front
Consult your Caterpillar dealer for assistance. crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
i08397633
• Inspect the fuel system for leaks. Look for loose
Walk-Around Inspection fuel line clamps or for loose fuel line tie-wraps.
SMCS Code: 1000-040 • Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure
Inspect the Engine for Leaks and that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
for Loose Connections
• Inspect the alternator belt and the accessory drive
A walk-around inspection should only take a few belts for cracks, breaks or other damage.
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided. Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
For maximum engine service life, make a thorough carry more load than the belts that are not replaced.
inspection of the engine compartment before starting The older belts are stretched. The additional load on
the engine. Look for items such as oil leaks or the new belt could cause the belt to break.
coolant leaks, loose bolts, worn belts, loose
connections and trash buildup. Make repairs, as • Drain the water and the sediment from fuel tanks
needed: on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• The guards must be in the proper place. Repair
damaged guards or replace missing guards. • Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
• Wipe all caps and plugs before the engine is
wires.
serviced in order to reduce the chance of system
contamination. • Inspect the ground strap for a good connection
and for good condition.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up • Inspect the ECM to the cylinder head ground strap
the fluid. If leaking is observed, find the source and for a good connection and for good condition.
correct the leak. If leaking is suspected, check the flu-
id levels more often than recommended until the leak • Disconnect any battery chargers that are not
is found or fixed, or until the suspicion of a leak is protected against the current drain of the starting
proved to be unwarranted. motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.
NOTICE
Accumulated grease and/or oil on an engine or deck • Check the condition of the gauges. Replace any
is a fire hazard. Remove this debris with steam clean- gauges that are cracked. Replace any gauge that
ing or high pressure water. can not be calibrated.

• Ensure that the cooling lines are properly clamped

and that the cooling lines are tight. Check for
leaks. Check the condition of all pipes.
• Inspect the water pumps for coolant leaks.
M0097687-03 93
Warranty Section
Warranty Information

Warranty Section that can cause the engine to fail to conform to

applicable emission standards for the warranty
period.
Warranty Information 2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
i02797420 1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
Warranty Information engines) operated and serviced in the state of
California, including all parts of their emission
SMCS Code: 1000
control systems (“emission related components”),
Engines are covered by a standard one year are:
warranty. The coverage of individual warranties may
be different due to the engine application and the a. Designed, built, and equipped so as to conform,
geographic location. at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
The warranty is shipped with other loose parts, or (ARB).
with the Parts Manual, when the engine is shipped.
b. Free from defects in materials and
Engine Protection Plans workmanship which cause the failure of an
emission-related component to be identical in
Extended Warranties and Service all material respects to the component as
described in the engine manufacturer's
Contracts application for certification for the warranty
A wide variety of protection plans are available for period.
Caterpillar Engines. Consult your Caterpillar dealer
3. New non-road diesel engines installed in
for detailed information on the specific programs and
coverages that are available. construction machines conforming to the South
Korean regulations for construction machines
Consult your Caterpillar dealer for information on a manufactured after January 1, 2015, and operated
plan that is tailored in order to fit your requirements. and serviced in South Korea, including all parts of
their emission control systems (“emission related
i08375716 components”), are:

Emissions Warranty a. Designed, built, and equipped so as to conform,

at the time of sale, with applicable emission
Information standards prescribed in the Enforcement Rule
SMCS Code: 1000 of the Clean Air Conservation Act promulgated
by South Korea MOE.
The certifying engine manufacturer warrants to the
ultimate purchaser and each subsequent purchaser b. Free from defects in materials and
that: workmanship in emission-related components
1. New non-road diesel engines and stationary diesel that can cause the engine to fail to conform to
engines less than 10 liters per cylinder (including applicable emission standards for the warranty
Tier 1 and Tier 2 marine engines < 37 kW, but period.
excluding locomotive and other marine engines) The aftertreatment system can be expected to
operated and serviced in the United States and function properly for the lifetime of the engine
Canada, including all parts of their emission (emissions durability period) subject to prescribed
control systems (“emission related components”), maintenance and operating environment
are: requirements being followed.

a. Designed, built, and equipped so as to conform, A detailed explanation of the Emission Control
at the time of sale, with applicable emission Warranty that is applicable to new non-road and
stationary diesel engines, including the components
standards prescribed by the United States
covered and the warranty period, is found in a
Environmental Protection Agency (EPA) by way supplemental Special Publication. Consult your
of regulation. authorized Cat dealer to determine if your engine is
subject to an Emission Control Warranty and to
b. Free from defects in materials and obtain a copy of the applicable Special Publication.
workmanship in emission-related components
94 M0097687-03
Reference Information Section
Engine Ratings

Reference Information Table 19

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

Engine Rating Conditions Irrigation pumps

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

• Water pumps NOTICE

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

i03880100

Engine Rating Definitions

SMCS Code: 1000
In selecting a rating for a specific application, the
most important consideration is the time that is spent
at full throttle. These rating definitions identify the
percent of time at full throttle. The definitions also
identify the corresponding times below rated rpm.
Refer to this Operation and Maintenance Manual,
“Configuration Parameters” for information about the
rating for this engine.
Note: The examples of the applications are only for
reference. For an exact determination of the
appropriate rating, follow the OEM specifications or
consult your Caterpillar dealer.
M0097687-03 95
Reference Information Section
Customer Service

Customer Service
i08292376

Ordering Replacement Parts

SMCS Code: 4450; 7567

When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent speci-
fications including, but not limited to, physical di-
mensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
Quality Cat replacement parts are available from Cat
dealers throughout the world. Cat dealer parts
inventories are up to date. The parts stocks include
all the parts that are normally needed to protect your
Cat engine investment.
When you order parts, specify the following
information:

• Part number
• Part name

• Quantity
If there is a question concerning the part number,
provide your dealer with a complete description of the
needed item.
When a Cat engine requires maintenance and/or
repair, provide the dealer with all the information that
is stamped on the Information Plate. This information
is described in this Operation and Maintenance
Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This information will help the
dealer in troubleshooting the problem and solving the
problem faster.
96 M0097687-03
Reference Information Section
Reference Materials

Reference Materials i08292374

i08160279
Reference Material
SMCS Code: 1000; 4450
Maintenance Records Additional literature regarding your product may be
SMCS Code: 1000; 4450 purchased from your local Cat dealer or by visiting
publications.cat.com. Use the product name, sales
Caterpillar recommends the retention of accurate model, and serial number to obtain the correct
maintenance records. Accurate maintenance records information for your product.
can be used for the following purposes:
publications.cat.com
• Determine operating costs.

• Establish maintenance schedules for other

engines that are operated in the same
environment.

• Show compliance with the required maintenance

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

Keep the following types of documents as proof of

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

• Owner receipts
• Maintenance log
M0097687-03 97
Index Section

Index
A Coolant Sample (Level 2) - Obtain.................. 71
Coolant Temperature Regulator - Replace ..... 71
Additional Messages ......................................... 9
Cooling System Supplemental Coolant
After Starting Engine ....................................... 40
Additive (SCA) - Test/Add.............................. 72
Extended Idle at Cold Ambient
Maintain the Proper Concentration of SCA in
Temperature............................................... 40
the Coolant................................................. 73
After Stopping Engine ..................................... 45
Crushing Prevention and Cutting Prevention.. 16
Air Compressor - Check (If equipped)............. 61
Customer Service............................................ 95
Air Shutoff - Test (If Equipped) ........................ 61
Air Tank Moisture and Sediment - Drain (If
Equipped) ...................................................... 62 D
Driven Equipment - Check .............................. 73
B
Battery - Recycle ............................................. 62 E
Battery - Replace............................................. 62 Electrical System............................................. 17
Battery Disconnect Switch (If Equipped)......... 31 Grounding Practices .................................... 17
Battery Electrolyte Level - Check .................... 63 Emissions Warranty Information ..................... 93
Battery or Battery Cable - Disconnect............. 63 Engaging the Driven Equipment ..................... 41
Before Starting Engine .................................... 37 Engine - Clean................................................. 73
Belts - Inspect/Adjust/Replace ........................ 64 Engine Air Cleaner Element (Dual Element)
Alternator Belt .............................................. 64 - Inspect/Clean/Replace ................................ 73
Drive Belt for the Air Compressor (If Servicing the Air Cleaner Elements............. 74
Equipped)................................................... 65 Engine Air Cleaner Service Indicator -
Inspection .................................................... 64 Inspect (If Equipped) ..................................... 75
Burn Prevention............................................... 13 Test the Service Indicator ............................ 75
Batteries....................................................... 14 Engine Diagnostics ......................................... 36
Coolant ........................................................ 13 Engine Electronics........................................... 18
Oils............................................................... 14 Engine Mounts - Inspect.................................. 75
Engine Oil and Filter - Change ........................ 77
C Drain the Engine Oil..................................... 78
Fill the Engine Crankcase............................ 79
Cold Weather Operation ................................. 43
Replace the Oil Filter ................................... 79
Cold Weather Starting ..................................... 37
Selection of Oil Change Interval .................. 77
Ether Injection System (If Equipped)........... 38
Engine Oil Level - Check................................. 75
Compression Brake - Inspect/Adjust/
Engine Oil Sample - Obtain............................. 76
Replace ......................................................... 65
Obtain the Sample and the Analysis ........... 76
Coolant (DEAC) - Change............................... 65
Engine Operation ............................................ 41
Cooling Systems with Heavy Deposits or
Engine Rating Conditions................................ 94
Plugging ..................................................... 66
Engine Rating Definitions................................ 94
Drain ............................................................ 65
Engine Ratings ................................................ 94
Fill ................................................................ 67
Engine Starting.......................................... 16, 37
Flush ............................................................ 66
Engine Stopping ........................................ 17, 45
Coolant (ELC) - Change.................................. 67
Engine Storage Procedure - Check ................ 79
Drain ............................................................ 67
Engine Valve Lash - Check ............................. 80
Fill ................................................................ 68
Flush ............................................................ 68
Coolant Extender (ELC) - Add ........................ 69 F
Coolant Level - Check ..................................... 69 Fault Logging................................................... 36
Coolant Sample (Level 1) - Obtain.................. 70 Features and Controls..................................... 31
98 M0097687-03
Index Section

Fire Prevention and Explosion Prevention...... 14 H

Ether ............................................................ 15
Hoses and Clamps - Inspect/Replace............. 85
Fire Extinguisher.......................................... 15
Inspect Tubes, Hoses, Bellows, and
Lines, Tubes, and Hoses ............................. 16
Clamps....................................................... 85
Fluid Recommendations ................................. 47
Replace the Hoses and the Clamps ............ 86
Cooling System............................................ 52
Diesel Engine Oil ......................................... 47
Fuel .............................................................. 50 I
Greases ....................................................... 54 Important Safety Information............................. 2
Foreword ........................................................... 4
California Proposition 65 Warning ................. 4
L
Literature Information .................................... 4
Maintenance .................................................. 4 Lifting and Storage .......................................... 27
Maintenance Intervals ................................... 5
Operation ....................................................... 4 M
Overhaul ........................................................ 5
Safety............................................................. 4 Maintenance Interval Schedule....................... 59
Fuel and the Effect from Cold Weather ........... 43 Daily ............................................................. 59
Fuel Conservation Practices ........................... 41 Every 12 000 Service Hours or 6 Years....... 60
Fuel Related Components in Cold Weather ... 43 Every 2000 Service Hours........................... 59
Fuel Heaters ................................................ 44 Every 2000 Service Hours or 1 Year ........... 59
Fuel Tanks ................................................... 43 Every 250 Service Hours ............................. 59
Fuel System - Prime ........................................ 80 Every 2500 Service Hours........................... 59
Key-on Priming (if equipped) ....................... 80 Every 3000 Service Hours or 3 Years ......... 59
Manual Switch Priming (if equipped)........... 80 Every 340 500 L (90 000 US gal) of Fuel .... 60
Fuel System Primary Filter (Water Every 4000 Service Hours........................... 59
Separator) Element - Replace....................... 80 Every 4000 Service Hours or 2 Years ......... 60
Fuel System Primary Filter/Water Every 500 Service Hours ............................. 59
Separator - Drain ........................................... 81 Every 6000 Service Hours or 3 Years ......... 60
Fuel System Secondary Filter - Replace ........ 82 Initial 500 Service Hours.............................. 59
Fuel Tank Water and Sediment - Drain ........... 83 When Required............................................ 59
Drain the Water and the Sediment .............. 83 Maintenance Recommendations .................... 56
Fuel Storage Tanks...................................... 83 Maintenance Records ..................................... 96
Fuel Tank ..................................................... 83 Maintenance Section....................................... 47
Fumes Disposal Filter Element (Emission Manual Stop Procedure .................................. 45
Related Component) - Replace..................... 84 Model View Illustrations .................................. 19
Monitoring System........................................... 31
Caterpillar Messenger Display ................... 33
G Indicators and Gauges ................................ 32
General Hazard Information.............................. 9 Mounting and Dismounting ............................. 16
Containing Fluid Spillage..............................11
Dispose of Waste Properly .......................... 13 O
Fluid Penetration ..........................................11
Inhalation ..................................................... 12 Operation Section............................................ 27
Lines, Tubes, and Hoses ..............................11 Ordering Replacement Parts........................... 95
Pressurized Air and Water........................... 10 Overhaul Considerations................................. 87
Softwrap....................................................... 13 Oil Consumption as an Overhaul Indicator.. 88
Static Electricity Hazard when Fueling with Overhaul Recommendation......................... 88
Ultra-low Sulfur Diesel Fuel ........................11
General Information ........................................ 19 P
Grounding Stud - Inspect/Clean/Tighten......... 85 Plate Locations and Film Locations ................ 24
M0097687-03 99
Index Section

Power Take-Off Clutch - Check....................... 90 Starting the Engine ...................................... 38

Product Description ......................................... 22 Starting with Jump Start Cables (Do Not
Aftermarket Products and Caterpillar Use This Procedure in Hazardous
Engines ...................................................... 23 Locations that have Explosive
Electronic Engine Features ......................... 23 Atmospheres) ................................................ 39
Engine Service Life...................................... 23 Stopping the Engine ........................................ 45
Engine Specifications .................................. 22 System Pressure Release............................... 56
Product Identification Information ................... 24 Coolant System ........................................... 56
Product Information Section............................ 19 Engine Oil .................................................... 56
Product Lifting ................................................. 27 Fuel System................................................. 56
Engine.......................................................... 27
Engine and Installed Radiator Only............. 27 T
Radiator Only............................................... 27
Product Storage .............................................. 27 Table of Contents .............................................. 3
Removal from Storage................................. 29
Storage (Less Than One Year).................... 27 W
Walk-Around Inspection .................................. 92
R Inspect the Engine for Leaks and for Loose
Radiator - Clean .............................................. 91 Connections ............................................... 92
Radiator Restrictions....................................... 43 Warranty Information....................................... 93
Reference Information..................................... 25 Engine Protection Plans .............................. 93
Record for Reference .................................. 25 Warranty Section ............................................. 93
Reference Information Section ....................... 94 Welding on Engines with Electronic
Reference Material .......................................... 96 Controls ......................................................... 56
Reference Materials ........................................ 96
Refill Capacities............................................... 47
Coolant Refill Capacities ............................. 47
Lubricant Refill Capacities ........................... 47

S
Safety Messages............................................... 6
High Pressure (2)........................................... 8
Sulfuric Acid Burn (3)..................................... 8
Universal Warning (1) .................................... 7
Safety Section ................................................... 6
Self-Diagnostics .............................................. 36
Severe Service Application ............................. 57
Improper Maintenance Procedures
(Maintenance Procedures Which May
Contribute to a Severe Service
Application) ................................................ 58
Severe Environmental Factors .................... 57
Severe Operating Conditions ...................... 57
Starting Motor - Inspect (If Equipped) ............. 91
Electric Starting Motor ................................. 91
Removal and Installation of the Starting
Motor .......................................................... 92
Starting the Engine.......................................... 38
Problems with the Wiring Harness .............. 39
Starting Problems ........................................ 38
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
M0097687 CAT, CATERPILLAR, LET’S DO THE WORK, their respective
©2021 Caterpillar logos, “Caterpillar Corporate Yellow”, the “Power Edge” and Cat
All Rights Reserved “Modern Hex” trade dress as well as corporate and product identity
used herein, are trademarks of Caterpillar and may not be used
without permission.

102 April 2021