Manual Motor Cat c9

SEBU7502-05
April 2002
Operation and
Maintenance
Manual
C-9 Engine
CLJ1-Up (Engine)
i01658146
Important Safety Information

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

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

product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
3
Table of Contents
Table of Contents
Cooling System Specifications ............................. 59

Refill Capacities .................................................... 71
Foreword ................................................................. 4
Safety Section
Safety Signs and Labels ......................................... 6
General Hazard Information ................................... 7
Maintenance Interval Schedule ............................ 72
Warranty Section
Warranty Information .......................................... 111
Reference Information Section
Burn Prevention .................................................... 10

Engine Ratings ................................................... 112
Fire Prevention and Explosion Prevention ............ 10
Customer Service ............................................... 114
Crushing Prevention and Cutting Prevention ........ 12
Reference Materials ............................................ 116
Mounting and Dismounting ................................... 13
Index Section
Before Starting Engine .......................................... 13
Index ................................................................... 120
Engine Starting ..................................................... 13
Engine Stopping ................................................... 14
Electrical System .................................................. 14
Engine Electronics ................................................ 15
Product Information Section

General Information .............................................. 17
Model Views ......................................................... 18
Product Identification Information ........................ 21
Operation Section
Engine Lifting and Storage ................................... 25
Gauges and Indicators .......................................... 26
Engine Features and Controls .............................. 30
Engine Diagnostics ............................................... 34
Engine Starting ..................................................... 39
Engine Operation .................................................. 45
Engine Stopping ................................................... 46
Cold Weather Operation ....................................... 48
Maintenance Section
Lubricant Specifications ........................................ 50
Fuel Specifications ................................................ 57
4
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.
English is the primary language for all Caterpillar
publications. The English used facilitates translation
and consistency in electronic media delivery.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Caterpillar dealer for the latest
available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance
and repair on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting,
operating and stopping the engine. This section
also includes a discussion of electronic diagnostic
information.
Maintenance
The maintenance section is a guide to engine
care. The illustrated, step-by-step instructions are
grouped by fuel consumption, service hours and/or
calendar time maintenance intervals. Items in the
maintenance schedule are referenced to detailed
instructions that follow.
Use fuel consumption or service hours to determine

intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals
if they provide more convenient schedules and
approximate the indicated service meter reading.
Recommended service should be performed
at the appropriate intervals as indicated in
the Maintenance Interval Schedule. The actual
operating environment of the engine also governs
the Maintenance Interval Schedule. Therefore,
under extremely severe, dusty, wet or freezing cold
operating conditions, more frequent lubrication and
maintenance than is specified in the Maintenance
Interval Schedule may be necessary.
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
engines permanent record.
See the section in the Operation and Maintenance
Manual, Maintenance Records for information
regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized
Caterpillar 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 Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
programs. If you experience a major engine failure,
there are also numerous after failure overhaul
options available from your Caterpillar dealer.
Consult with your dealer for information regarding
these options.
5
Foreword
California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
6
Safety Section
Safety Signs and Labels
Starting Aid
Safety Section
i01504798
Safety Signs and Labels

SMCS Code: 1000; 7405
There may be several specific warning signs on
an engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiar with all warning
signs.
Ensure that all of the warning signs are legible.
Clean the warning signs or replace the warning
signs if the words cannot be read or if the pictures
are not visible. When the warning signs are
cleaned, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
the warning signs. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures
the warning signs. The warning signs that are
loosened could drop off of the engine.
Illustration 1
g00780729
(1) Valve cover

(2) Hydraulic Pump
The warning label for the starting aid is located on

the flat portion of the valve cover.
Replace any damaged warning signs or missing

warning signs. If a warning sign is attached to a part
of the engine that is replaced, install a new warning
sign on the replacement part. Any Caterpillar dealer
can provide new warning signs.
Do not operate or work on this engine unless you

have read and understand the instructions and
warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.
The warning labels that may be found on the engine
are illustrated and described below.
g00283559
If the engine is equipped with an air inlet heater

for cold weather starting, the optional ether
injection system is the only starting system that is
recommended. Do not use starting aids that contain
aerosols. Using such types of starting aids could
result in an explosion and personal injury.
7
Safety Section
General Hazard Information
Engine Lifting
Clutch
Illustration 3
g00367054
The warning label for lifting the engine with a fuel

tank is located on the fuel tank (if equipped).
Illustration 2
g00107406
The warning label for the clutch is located on the

clutch housing (if equipped).
g00100728
g00107407
Rotating gears can cause entanglement of the

fingers. Rotating gears can cause entanglement of
the hands. Do not service this component without
first reading the operator manual.
Lift eyes or tank can fail when lifting tank containing fluids resulting in possible personal injury.
Drain tank of all fluids before lifting.
i01377208

SMCS Code: 1000; 7405
Illustration 4
g00104545
8
Safety Section
Attach a Do Not Operate warning tag or a similar

warning tag to the start switch or to the controls
before the engine is serviced or before the engine
is repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine
and to each operator control station. When it is
appropriate, disconnect the starting controls.
Do not wear loose clothing or jewelry that can
Do not allow unauthorized personnel on the engine,

or around the engine when the engine is being
serviced.
Use all cleaning solutions with care.
Engine exhaust contains products of combustion

which may be harmful to your health. Always
start the engine and operate the engine in a well
ventilated area. If the engine is in an enclosed area,
vent the engine exhaust to the outside.
Unless other instructions are provided, perform

the maintenance under the following conditions:
Cautiously remove the following parts. To help

prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
Disconnect the batteries when maintenance
Filler caps
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.
Report all necessary repairs.
The engine is stopped. Ensure that the engine

cannot be started.
is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
Do not attempt any repairs that are not
Grease fittings
understood. Use the proper tools. Replace

any equipment that is damaged or repair the
equipment.
Pressure taps
Breathers
Pressure Air and Water
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 cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order
to relieve any spring pressure or other pressure.
Pressurized air and/or water can cause debris

and/or hot water to be blown out. This could result
in personal injury.
When pressure air and/or pressure water is used
for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be
below 275 kPa (40 psi).
Illustration 5
g00702020
Wear a hard hat, protective glasses, and other

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

is operating, wear protective devices for ears in
order to help prevent damage to hearing.
9
Safety Section
Fluid Penetration
Illustration 6
Asbestos Information
g00687600
Always use a board or cardboard when you check

for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak
can cause severe injury. If fluid is injected into your
skin, you must get treatment immediately. Seek
treatment from a doctor that is familiar with this type
of injury.
Containing Fluid Spillage

Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Tools and
Shop Products Guide for the following items:
Tools that are suitable for collecting fluids and

equipment that is suitable for collecting fluids
Tools that are suitable for containing fluids and

equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.
Illustration 7
g00702022
Caterpillar equipment and replacement parts that

are shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine
Caterpillar replacement parts. Use the following
guidelines when you handle any replacement parts
that contain asbestos or when you handle asbestos
debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that
contain asbestos fibers. Inhaling this dust can
be hazardous to your health. The components
that may contain asbestos fibers are brake pads,
brake bands, lining material, clutch plates, and
some gaskets. The asbestos that is used in these
components is usually bound in a resin or sealed in
some way. Normal handling is not hazardous unless
airborne dust that contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
Never use compressed air for cleaning.

Avoid brushing materials that contain asbestos.
Avoid grinding materials that contain asbestos.
Use a wet method in order to clean up asbestos
materials.
A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be
used.
Use exhaust ventilation on permanent machining

jobs.
Wear an approved respirator if there is no other

way to control the dust.
10
Safety Section
Burn Prevention
Comply with applicable rules and regulations

for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in 29 CFR 1910.1001.
Obey environmental regulations for the disposal
Any contact with hot coolant or with steam

can cause severe burns. Allow cooling system
components to cool before the cooling system is
drained.
Check the coolant level after the engine has
stopped and the engine has been allowed to cool.
of asbestos.
Stay away from areas that might have asbestos

particles in the air.
Dispose of Waste Properly
Ensure that the filler cap is cool before removing

the filler cap. The filler cap must be cool enough
to touch with a bare hand. Remove the filler cap
slowly in order to relieve pressure.
Cooling system conditioner contains alkali. Alkali
can cause personal injury. Do not allow alkali to
contact the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
Illustration 8
g00706404
Improperly disposing of waste can threaten the

environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01480768
Burn Prevention
Electrolyte is an acid. Electrolyte can cause

personal injury. Do not allow electrolyte to contact
the skin or the eyes. Always wear protective glasses
for servicing batteries. Wash hands after touching
the batteries and connectors. Use of gloves is
recommended.
i01372254
Fire Prevention and Explosion

Prevention
SMCS Code: 1000; 7405
SMCS Code: 1000; 7405

Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Illustration 9
g00704000
All fuels, most lubricants, and some coolant mixtures

are flammable.
11
Safety Section
Fire Prevention and Explosion Prevention
Flammable fluids that are leaking or spilled onto hot

surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
an emergency shutdown.
Inspect all lines and hoses for wear or for

deterioration. The hoses must be properly routed.
The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
Oil filters and fuel filters must be properly installed.
The filter housings must be tightened to the proper
torque.
Determine whether the engine will be operated in

an environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of
combustible gases, consult your Caterpillar dealer
for additional information about suitable protection
devices.
Remove all flammable materials such as fuel, oil,
and debris from the engine. Do not allow any
flammable materials to accumulate on the engine.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
a tube, or a seal failure. Exhaust shields must be
installed correctly.
Illustration 10
g00704059
Use caution when you are refueling an engine. Do

not smoke while you are refueling an engine. Do
not refuel an engine near open flames or sparks.
Always stop the engine before refueling.
Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. All electrical
wires must be properly routed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate
the engine. Clean all electrical connections and
tighten all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that
are smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Illustration 11
g00704135
12
Safety Section
Crushing Prevention and Cutting Prevention
Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Check lines, tubes and hoses carefully. Do not

use your bare hand to check for leaks. Use a
board or cardboard to check for leaks. Tighten all
connections to the recommended torque.
Replace the parts if any of the following conditions
are present:
End fittings are damaged or leaking.

Outer coverings are chafed or cut.
Wires are exposed.
Do not charge a frozen battery. This may cause

an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery
box covers when the engine is operated.
Outer coverings are ballooning.

Flexible part of the hoses are kinked.
Outer covers have embedded armoring.
End fittings are displaced.
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
Make sure that all clamps, guards, and heat shields

are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
i01359666
Crushing Prevention and

Cutting Prevention
Ether is flammable and poisonous.

SMCS Code: 1000; 7405
Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while
you are using an ether spray.
Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders
in direct sunlight or in temperatures above 49 C
(120 F). Keep ether cylinders away from open
flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Do not spray ether into an engine if the engine
is equipped with a thermal starting aid for cold
weather starting.
Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Support the component properly when work

beneath the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The
fan blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when
objects are struck. Before objects are struck, ensure
that no one will be injured by flying debris.
13
Safety Section
Mounting and Dismounting
i01372247
i00910470
Mounting and Dismounting
Engine Starting
SMCS Code: 1000; 7405
SMCS Code: 1000
Inspect the steps, the handholds, and the work

area before mounting the engine. Keep these items
clean and keep these items in good repair.
If a warning tag is attached to the engine start

switch or to the controls, do not start the engine
or move the controls. Also, do not disengage
the parking brakes. Consult with the person that
attached the warning tag before the engine is
started.
Mount the engine and dismount the engine only at

locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use
any controls as handholds.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a
hand line to raise and lower tools or supplies.
i00911989
Before Starting Engine

SMCS Code: 1000
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. All protective
guards and all protective covers must be installed
if the engine must be started in order to perform
service procedures. To help prevent an accident
that is caused by parts in rotation, work around the
parts carefully.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits
are provided in order to help prevent personal
injury. The circuits are also provided in order to help
prevent engine damage.
On the initial start-up of a new engine or an engine
that has been serviced, prepare to stop the engine
if an overspeed condition occurs. This may be
accomplished by shutting off the fuel supply to
the engine and/or shutting off the air supply to the
engine.
See the Service Manual for repairs and for
adjustments.
All protective guards and all protective covers must

be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine from the operators station (cab).
Never short across the starting motor terminals or
the batteries. This could bypass the engine neutral
start system and/or the electrical system could be
damaged.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, Engine Starting topic (Operation Section).
Knowing the correct procedure will help to prevent
major damage to the engine components. Knowing
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.
that can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Ether
Ether is poisonous and flammable. Do not inhale
ether, and do not allow ether to contact the skin.
Personal injury could result. Do not smoke while
ether cylinders are changed. Use ether in well
ventilated areas.
Keep ether cylinders out of the reach of
unauthorized persons. Store ether cylinders in
authorized storage areas only. Do not store ether
cylinders in direct sunlight or at temperatures above
39 C (102 F). Discard the ether cylinders in a safe
place. Do not puncture the ether cylinders. Do not
burn the ether cylinders.
14
Safety Section
Engine Stopping
i01462046
Grounding Practices
Engine Stopping
SMCS Code: 1000
Stop the engine according to the procedure in
the Operation and Maintenance Manual, Engine
Stopping (Operation Section) in order to avoid
overheating of the engine and accelerated wear of
the engine components.
Use the Emergency Stop Button (if equipped)
ONLY in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled. This may be
accomplished by shutting off the fuel supply to
the engine and/or shutting off the air supply to the
engine.
To stop an electronically controlled engine, cut the
power to the engine.
i01489749
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. See
the Operation and Maintenance Manual for specific
starting instructions.
Illustration 12
Typical example
Grounding Stud To Battery Ground
g00774062
15
Safety Section
Engine Electronics
i01563743
Engine Electronics
SMCS Code: 1000; 1400; 1900
Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine damage.
This engine has a comprehensive, programmable
Engine Monitoring System. The Engine Control
Module (ECM) has the ability to monitor the
engine operating conditions. If any of the engine
parameters extend outside an allowable range, the
ECM will initiate an immediate action.
The following actions are available for engine
monitoring control: WARNING, DERATE, and
SHUTDOWN. These engine monitoring modes have
the ability to limit engine speed and/or the engine
power.
Illustration 13
g00774088
Typical example
Alternate Grounding Stud To Battery Ground
Proper grounding for the engine electrical system

is necessary for optimum engine performance
and reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Many of the parameters that are monitored by

the ECM can be programmed for the engine
monitoring functions. The following parameters can
be monitored as a part of the Engine Monitoring
System:
Operating Altitude
Engine Coolant Level
Engine Coolant Temperature
Uncontrolled electrical circuit paths can result in

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

ground straps can be damaged by electrical
discharge.
Fuel Temperature
To ensure that the engine and the engine electrical

systems function properly, an engine-to-frame
ground strap with a direct path to the battery must
be used. This path may be provided by way of a
starting motor ground, a starting motor ground to
the frame, or a direct engine ground to the frame.
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.
Engine Speed
Intake Manifold Air Temperature

System Voltage
The Engine Monitoring package can vary for
different engine models and different engine
applications. However, the monitoring system and
the engine monitoring control will be similar for all
engines.
16
Safety Section
Engine Electronics
Note: Many of the engine control systems and

display modules that are available for Caterpillar
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the
specific engine application. Refer to the Electronic
Troubleshooting Manual for more information on the
Engine Monitoring System.
17
General Information
Product Information
Section
General Information
i01456258
Welding on Engines with

Electronic Controls
SMCS Code: 1000
NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding
onto a chassis frame or rail. Consult the OEM of
the equipment or your Caterpillar dealer regarding
welding on a chassis frame or rail.
Proper welding procedures are necessary in order
to avoid damage to the engines ECM, sensors,
and associated components. When possible,
remove the component from the unit and then
weld the component. If removal of the component
is not possible, the following procedure must be
followed when you weld on a unit that is equipped
with a Caterpillar Electronic Engine. The following
procedure is considered to be the safest procedure
to weld on a component. This procedure should
provide a minimum risk of damage to electronic
components.
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other components.
Illustration 14
g00765012
Use the example above. The current flow from the welder to
the ground clamp of the welder will not cause damage to any
associated components.
(1) Engine
(2) Welding rod
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Maximum distance between the component that is being
welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
4. Connect the welding ground cable directly to

the part that will be welded. Place the ground
cable as close as possible to the weld in order to
reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
components, and ground straps.
Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the possibility of damage.
Note: If electrical/electronic components are used

as a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.
1. Stop the engine. Turn the switched power to the

OFF position.
5. Protect the wiring harness from welding debris

and spatter.
2. Disconnect the negative battery cable from

the battery. If a battery disconnect switch is
provided, open the switch.
6. Use standard welding practices to weld the

materials.
3. Disconnect the J1/P1 and J2/P2 connectors from

the ECM. Move the harness to a position that will
not allow the harness to accidentally move back
and make contact with any of the ECM pins.
18
Model Views
Model Views
i01474848
Model View Illustrations

SMCS Code: 1000
Illustration 16
g00774521
Left Side View

(11) Engine oil filler
(12) Electronic Control Module (ECM)
(13) Air compressor
(14) Oil drain plug
Illustration 15
Right Side View
(1) Valve mechanism cover
(2) Turbocharger
(3) Engine oil filler cap
(4) Water temperature regulator housing
(5) Exhaust manifold
(6) Water pump
(7) Flywheel housing
(8) Engine oil pan
(9) Engine oil filter
(10) Vibration damper and crankshaft pulley
g00770182
i01477858
Engine Description
SMCS Code: 1000
The Caterpillar C-9 Industrial Engine has the
following characteristics:
In-Line 6 cylinder
Four stroke cycle
Hydraulically Actuated Electronic Unit Injection
(HEUI)
Turbocharged
Air-to-air aftercooled
Engine Specifications
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.
19
Model Views
For more information on electronic engine features,

refer to the Operation and Maintenance Manual,
Engine Features and Controls topic (Operation
Section).
Additional Features
The following additional features provide increased
engine fuel economy and serviceability:
Cold starting capability

Tampering detection
g00609479
Illustration 17
Cylinder and valve location
Hydraulic Electronic Unit Injectors
(A) Exhaust valve

(B) Inlet valve
Hydraulically Actuated Electronic Unit Injectors

(HEUI) perform the following functions:
Table 1
C-9 Engine Specifications

Arrangement and
Cylinders
Diagnostics
In-Line 6 cylinder
Bore
112.0 mm (4.41 inch)
Stroke
Pump the fuel.

Meter the fuel.
149.0 mm (5.87 inch)
Aspiration
ATAAC(1)
8.8 L (537 in3)
Displacement
Firing Order
Rotation (flywheel end)
1-5-3-6-2-4
0.38 mm (0.015 inch)
Valve Lash (exhaust)
0.64 mm (0.025 inch)
Air-to-air aftercooled
Electronic Engine Features

The Caterpillar C-9 Engine is designed for electronic
controls. The integral on board computer controls
the operation of the engine. Current operating
conditions are monitored. The Electronic Control
Module (ECM) controls the response of the engine
to these conditions and to the demands of the
operator. These conditions and operator demands
determine the precise control of fuel injection by the
ECM. The electronic engine control system provides
the following features:
Engine speed governor

Automatic air/fuel ratio control
Torque rise shaping
Injection timing control
System diagnostics
The unit injectors are controlled by the ECM which

uses the camshaft position and the engine speed
signals from the engine speed/timing sensors and
the inlet air pressure sensors. The engines rated
rpm is identified on the Information Plate.
Counterclockwise
Valve Lash (inlet)
(1)
Time the fuel injection.
Engine Diagnostics
The engine has built-in diagnostics in order to
ensure that all of the components are functioning
properly. In the event of a deviation from the
programmed limits, the operator will be alerted
to the condition by a DIAGNOSTIC lamp that
is mounted on the dashboard. Under certain
conditions, the engine horsepower and the vehicle
speed may be limited. A Caterpillar electronic
service tool may be used to display the diagnostic
code.
There are three types of diagnostic codes: active,
logged, and event.
Most of the diagnostic codes are logged and stored
in the ECM. For additional information, refer to
the Operation and Maintenance Manual, Engine
Diagnostics topic (Operation Section).
The ECM provides an electronic governor that
controls the injector output in order to maintain the
desired engine rpm. The functionality of electronic
governor is similar to the Caterpillar mechanical
governor, but the electronic governor includes
additional features.
20
Model Views
Engine Cooling and Lubrication

The cooling system consists of the following
components:
Centrifugal pump that is driven by belts

Water temperature regulator which regulates the
engine coolant temperature
Oil cooler and radiator which incorporates a shunt
When auxiliary devices, accessories, or

consumables (filters, additives, catalysts, etc) which
are made by other manufacturers are used on
Caterpillar products, the Caterpillar warranty is not
affected simply because of such use.
However, failures that result from the installation
or use of other manufacturers devices,
accessories, or consumables are NOT Caterpillar
defects. Therefore, the defects are NOT covered
under the Caterpillar warranty.
system
The engine lubricating oil that is supplied is cooled.
The engine lubricating oil is also filtered. Bypass
valves provide unrestricted flow of lubrication oil
to the engine components during the following
conditions:
High oil viscosity

Plugged oil cooler or plugged oil filter elements
(paper cartridge)
Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants and
lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
Expected engine life is generally predicted
by the average power that is demanded. The
average power that is demanded is based on fuel
consumption of the engine over a period of time.
Reduced hours of operation at full throttle and/or
operating at reduced throttle settings result in a
lower average power demand. Reduced hours
of operation will increase the length of operating
time before an engine overhaul is required. For
more information, refer to the Operation and
Maintenance Manual, Overhaul Considerations
topic (Maintenance Section).
Aftermarket Products and

Caterpillar Engines
NOTICE
In order to maximize fuel system life and prevent
premature wear out from abrasive particles in the
fuel, a two micron absolute high efficiency fuel filter
is required for all Caterpillar Electronic Unit Injectors.
Caterpillar High Efficiency Fuel Filters meet these
requirements. Consult your Caterpillar dealer for the
proper part numbers.
Welding and Caterpillar Electronic

Engines
NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding
onto a chassis frame or rail. Consult the OEM of
the equipment or your Caterpillar dealer regarding
welding on a chassis frame or rail.
To help avoid damage to the electronic controls,
proper welding procedures are necessary. Before
welding on an engine that is equipped with an
electronic engine, observe the following precautions:
1. Turn off the engine. Place the key start switch in
the OFF position.
2. If the machine has a battery disconnect switch,
open the switch. Otherwise, disconnect the
negative - battery cable from the battery of the
vehicle.
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other components.
Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the possibility of damage.
3. Clamp the ground cable from the welder to the
component that will be welded. Place the clamp
as close as possible to the weld.
4. Protect wiring harnesses from welding debris
and spatter. Use proper welding procedures.
21
Product Identification Information
Product Identification
Information
i01484593
Information Plate
SMCS Code: 1000
i01028428
Engine Identification
SMCS Code: 1000
Caterpillar engines are identified with serial
numbers, with performance specification numbers,
and with arrangement numbers. In some of the
cases, modification numbers are used. These
numbers are shown on the Serial Number Plate
and the Information Plate that are mounted on the
engine.
Caterpillar dealers need these numbers in order to
determine the components that were included with
the engine. This permits accurate identification of
replacement part numbers.
i01461841
Serial Number Plate

SMCS Code: 1000
Illustration 19
g00764335
The Information Plate is on the valve cover. 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.
i00610276
Reference Numbers
SMCS Code: 1000
Illustration 18
g00764267
The Serial Number Plate is located on the right side

of the cylinder block near the rear of the engine.
The following information is stamped on the Serial
Number Plate: engine serial number, engine model,
and arrangement number.
Information for the following items may be needed

to order parts. Locate the information for your
engine. Record the information on the appropriate
space. Make a copy of this list for a record. Retain
the information for future reference.
Record for Reference

Engine Model _________
_____________________________________
Engine Serial No. _________
_________________________________
Engine Arrangement No. _________
_______________________
Modification No. _________
__________________________________
Engine Low Idle rpm _________
____________________________
Engine Full Load rpm _________
___________________________
Performance Specification No. _________
________________
Primary Fuel Filter No. _________
__________________________
Water Separator Element No. _________
_________________
22
Secondary Fuel Filter Element No. _________

___________
Lubrication Oil Filter Element No. _________
____________
Auxiliary Oil Filter Element No. _________
________________
Supplemental Coolant Additive Maintenance
__________________________
Element No. (Optional) _________
Total Lubrication System Capacity _________
___________
Total Cooling System Capacity _________
_______________
Air Cleaner Element No. _________
________________________
Fan Drive Belt No. _________
_______________________________
Alternator Belt No. _________
_______________________________
i01542360
Emissions Certification Film

SMCS Code: 1000; 7405
Note: This information is pertinent in the United
States and in Canada.
A typical example is shown.
23
g00776690
Illustration 20
i00811683
Customer Specified
Parameters
SMCS Code: 1000
Rating Selection (A-E) _________

_________________________
Air/Fuel Ratio
Level 1: Minimal Smoke ______________________________

Level 2: Optimum Performance _____________________
To record programmed specifications, use the

following blanks.
Level 3: Maximum Acceleration ____________________
Customer Passwords
PTO Governor Parameters
_________________________________
First Password _________
_
PTO Engine Speed Ramp Rate _________ rpm/sec
_____________________________
Second Password _________
Engine Parameters
_____________________
Power Rating (hp at rpm) _________
Top Engine Limit (TEL) at 100 percent load (If

Applicable) _________
______________________________________
24
_____________________________________
Torque Limit _________
_____________________
High Idle (If Applicable) _________
_________________________________________
Low Idle _________
___________________________
Intermediate Speed _________
Engine Monitoring Mode

_____________________________________________
OFF _________
Warning _________________________________________________
______________________________
Warning/Derate _________
Warning/Derate/Shutdown _________________________
Coolant Level Sensor Enable/Disable ___________
Fuel Pressure Sensor Enable/Disable ___________
Inlet Manifold Air Temperature Sensor
________________________________
Enable/Disable _________
Equipment ID
Maintenance Indicator
Manual-Hours
Auto-Hours
Manual-Fuel
Auto-Fuel
Auxiliary Pressure
High Warning Set Point _______________________________

Auxiliary Temperature
High Warning Set Point _______________________________
25
Operation Section
Engine Lifting and Storage
Operation Section
i00777190
Engine Storage
Engine Lifting and Storage

i01028344
Engine Lifting
SMCS Code: 1000; 1122
SMCS Code: 1000

If the engine will not be started for several weeks,
the lubricating oil will drain from the cylinder walls
and from the piston rings. Rust can form on the
cylinder liner surface. Rust on the cylinder liner
surface will cause increased engine wear and a
reduction in engine service life.
To help prevent excessive engine wear, use the
following guidelines:
Complete all of the lubrication recommendations
that are listed in this Operation and Maintenance

Manual, Maintenance Interval Schedule
(Maintenance Section).
If freezing temperatures are expected, check the

cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, General Coolant Information
Illustration 21
g00103219
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle
between the supporting members and the object becomes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should
be parallel to each other. The chains and cables
should be perpendicular to the top of the object
that is being lifted.
Some removals require lifting the fixtures in order to
obtain proper balance and safety.
To remove the engine ONLY, use the lifting eyes that
are on the engine.
Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting
eyes and/or the engine make the lifting eyes and
the lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Caterpillar dealer for information
regarding fixtures for proper engine lifting.
If an engine is out of operation and if use of the

engine is not planned, special precautions should
be made. If the engine will be stored for more than
one month, a complete protection procedure is
recommended.
For more detailed information on engine storage,
see Special Instruction, SEHS9031, Storage
Procedure For Caterpillar Products.
Your Caterpillar dealer can assist in preparing the
engine for extended storage periods.
26
Operation Section
Gauges and Indicators
3. Check the oil level. Maintain the oil level at the

proper amount.
i01465281

SMCS Code: 1900; 7450
Your engine may not have the same gauges or all of
the gauges that are described. For more information
about the gauge package, see the literature that
is provided by the OEM.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a period of time.
Noticeable changes in gauge readings indicate
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if the readings are within specifications.
Determine the cause of any significant change
in the readings. Then, correct any cause of any
significant change in the readings. Consult your
Caterpillar dealer for assistance.
Caterpillar requires one lamp in addition to
the gauge package that is normally provided.
The Diagnostic lamp is yellow or amber. The
Diagnostic lamp will communicate the status of
the engines electronic system. The optional red
Warning lamp is also available. This red Warning
lamp warns the operator of engine problems.
The following conditions are some examples of the
engine problems:
Low oil pressure
If the gauge continues to fluctuate, consult your

Caterpillar dealer.
The diagnostic lamp will turn on if the oil pressure
drops below 35 kPa (5 psi) at low idle rpm. The
diagnostic code will be logged in the Engine Control
Module (ECM).
Engine Oil Temperature This gauge
indicates the engine oil temperature. An
oil temperature that is higher than normal
indicates a heat problem in the lubrication system
and/or the cooling system. This problem can
damage the cylinder heads, the cylinder liners, the
pistons, and the crankshaft bearings.
Jacket Water Coolant Temperature
Typical temperature range is 88 to 102 C
(190 to 215 F). The maximum allowable
temperature with the pressurized cooling system is
105 C (220 F). Higher temperatures may occur
under certain conditions. The water temperature
reading may vary according to load. The reading
should never exceed the boiling point for the
pressurized system that is being used.
If the engine is operating above the normal range
or steam becomes apparent, perform the following
procedure:
1. Reduce the load and the engine rpm.
2. Inspect the cooling system for leaks.
3. Determine if the engine must be shut down
immediately or if the engine can be cooled by
reducing the load.
High coolant temperature

Low coolant level
High inlet air temperature
Engine Oil Pressure Typical oil pressure
for an engine at rated speed with
SAE 10W30 or with SAE 15W40 is
240 to 480 kPa (35 to 70 psi).
A lower oil pressure is normal at low idle. If the load
is stable and the gauge reading changes, perform
the following procedure:
1. Remove the load.
2. Reduce engine speed to low idle.
Pressurized System: Hot coolant can cause serious 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.
4. Check the coolant level.
Tachometer This gauge indicates engine
speed. When the throttle control lever is
moved to the full throttle position without
load, the engine is running at high idle. The engine
is running at the full load rpm when the throttle
control lever is at the full throttle position with
maximum rated load.
27
Operation Section
Note: The default high idle rpm and the full load
rpm are stamped on the Information Plate.
Ammeter This gauge indicates the
amount of charge or of discharge in the
battery charging circuit. Operation of the
indicator should be to the right side of 0(zero).
Service Hour Meter This gauge indicates
the total number of clock hours of engine
operation. Hours of operation are logged
in the ECM. A service tool is needed to retrieve the
hours from the ECM. A Service Hour Meter may be
installed on the engine.
Fuel Pressure This gauge indicates fuel
pressure to the electronic unit injectors
from the fuel filter. The indicator should
indicate the NORMAL range. A decrease in fuel
pressure usually indicates a plugged fuel filter.
Fuel Level This gauge indicates the
level of fuel in the fuel tank. The fuel level
gauge registers the fuel level only when
the ignition switch is in the ON position.
i01518477
Engine Monitoring System

(EMS)
SMCS Code: 7490
g00788015
Illustration 22
(1) Main unit
(2) Tachometer (unit)
(3) Quad gauge
28
Operation Section
The Caterpillar Engine Monitoring System (EMS) is

an option. The engine parameters are displayed in
both digital display and analog. The EMS display is
for electronically controlled engines.
Table 2
Abbreviation
Parameter
Engine Oil Pressure
GA-2
Coolant Temperature
GA-3
Battery Voltage
GA-4
Fuel Pressure
Boost
Boost Pressure
IAirT
Inlet Air Temperature

Fuel Temperature
Auxiliary Pressure
AccrT
Fuel
Fuel Rate
Hrs
Engine Hours
Load
EMS Main Unit
GA-1
AccrP
Refer to the EMS Operators Guide, LEXH7530 for

additional information. For information on installation
and troubleshooting, refer to Installation Guide,
SENR1025.
Engine Speed
FuelT
The EMS includes three individual gauge units. The

units can be installed in various combinations. The
main unit must be used if any of the units are used.
Spd
Percent of Engine Load

(speed and derate)
Note: For detailed information on the exact

parameters for your engine, refer to the Operation
and Maintenance Manual, Gauges and Indicators.
Quad Gauge Unit
Illustration 23
g00595165
(4) Engine oil pressure

(5) Engine coolant temperature
(6) Fuel pressure
(7) Inlet manifold temperature
(8) Fuel temperature
(9) Engine coolant level
(10) Battery voltage
(11) Active engine derate
(12) Auxiliary temperature
(13) Auxiliary pressure
The Engine Monitoring System provides warning

lamps. Refer to Illustration 23. The Engine
Monitoring System provides a LCD display for
engine parameters. When the scroll switch is
depressed, the parameters will scroll on the screen.
The EMS displays the real time value for the
parameter that is selected. The default is engine
speed.
The parameters are abbreviated on the LCD
display. Table 2 lists the parameters.
Illustration 24
g00595166
(14) Engine oil pressure

(15) Engine coolant temperature
(16) Battery voltage
(17) Fuel pressure
The quad gauge unit displays the following

information: engine oil pressure, engine coolant
temperature, battery voltage, and fuel pressure
29
Operation Section
Note: The gauge needles may not always return to

zero position when the engine is not running.
Tachometer Unit
Illustration 25
g00788023
(18) Tachometer
The tachometer displays the engine speed (rpm) on

an analog gauge.
Communication Data Link

The EMS provides two pins that are connected to
the data link. The data link is available to share data
with other modules. The ECM processes engine
parameters. The parameters will then be transmitted
to the EMS through the data link. The EMS receives
the information. The information is then displayed
on various gauges.
For additional information, refer to the
Troubleshooting Manual, Cat Data Link
Circuit-Test.
30
Operation Section
Engine Features and Controls
Engine Features and

Controls
i01503649
Sensors and Electrical

Components
SMCS Code: 1900; 7400
Sensor Locations
Illustration 26 shows the typical locations of the
sensors for a C-9 Industrial Engine. Specific engines
may appear different from the illustration due to
differences in applications.
g00779441
Illustration 26
(1) Coolant Temperature Sensor
(2) Injection Actuation Pressure Control
Valve(IAPCV)
(3) Inlet Air Heater Relay
(4) Turbocharger Outlet Pressure Sensor
(5) Inlet Air Temperature Sensor
(6) Timing Calibration Probe
(7) Engine Service Connector J63
(8) High Pressure Engine Oil Temperature

Sensor
(9) Primary Engine Speed/Timing Sensor
(10) Secondary Engine Speed/Timing
Sensor
(11) Injection Actuation Pressure Sensor
(12) Fuel Pressure Sensor
(13) High Pressure Engine Oil Temperature

Sensor
(14) Engine Oil Pressure Sensor
(15) ECM connector J2/P2
(16) ECM connector J1/P1
(17) Oil Grade Detection Plug
(18) Atmospheric Pressure Sensor
31
Operation Section
Failure of Sensors
All Sensors
A failure of any of the sensors may be caused by
one of the following malfunctions:
Sensor output is open.

Sensor output is shorted to - battery or +
battery.
Measured reading of the sensor is out of

specification.
Programmable Monitoring System

(PMS)
The Programmable Monitoring System determines
the level of action that is taken by the ECM in
response to a condition that can damage the
engine. These conditions are identified by the
ECM from the signals that are produced from the
following sensors.
Turbocharger Outlet Pressure

Sensor
Turbocharger outlet pressure sensor (4) provides
a signal which corresponds to turbocharger outlet
pressure to the ECM. The air/fuel ratio control utilizes
the actual engine speed and the turbocharger outlet
pressure in order to control the transient smoke
level. The ECM can control injection timing and the
amount of fuel that is injected. When the throttle is
increased and when the engine demands more fuel,
the fuel limit is controlled in order to reduce overall
smoke levels of the engine exhaust.
Failure of the Turbocharger Outlet

Pressure Sensor
The ECM will detect failure of the turbocharger outlet
pressure sensor. The operator will be warned of the
problem through the diagnostic lamp. The strategies
that are related to the boost will be disabled. Engine
power will be severely reduced in the event of a
failure of the turbocharger outlet pressure sensor. A
failure of the turbocharger outlet pressure sensor
will not cause a shutdown of the engine.
Inlet Air Temperature Sensor

Engine Coolant Temperature Sensor
Coolant Temperature Sensor
Fuel Pressure Sensor
Coolant temperature sensor (1) monitors engine

coolant temperature. The output of the ECM can
indicate a high coolant temperature through a relay
or a lamp. The coolant temperature sensor is used
by the ECM to determine initiation of the Cold Start
Condition.
Coolant Level Sensor
Table 4
Engine Oil Pressure Sensor

Engine Speed/Timing Sensors
Atmospheric Pressure Sensor

Atmospheric pressure sensor (18) measures
barometric pressure. A signal is sent to the
Electronic Control Module (ECM).
Table 3

Operating pressure
range
0 to 116 kPa (0 to 16.8 psi)

Activation temperature for the high
coolant temperature fault
103C (217F)
Activation temperature for the very

high coolant temperature fault
106C (229F)
Failure of the Coolant Temperature

Sensor
The ECM will detect a failure of the coolant
temperature sensor. The diagnostic lamp will
warn the operator about the status of the coolant
temperature sensor. A failure of the coolant
temperature sensor will not cause a shutdown of
the engine or any horsepower change.
32
Operation Section

Engine oil pressure sensor (14) is an absolute
pressure sensor that measures the engine oil
pressure in the main oil gallery. The engine oil
pressure sensor detects engine oil pressure for
diagnostic purposes. The engine oil pressure
sensor sends a signal to the ECM.
Table 5

Operating pressure
range
0 to 690 kPa (0 to 100 psi)
Low Oil Pressure Warning

The setpoint is dependent upon the engine speed.
The fault will be active and logged only if the engine
has been running for more than 15 seconds.
Very Low Oil Pressure Warning

The very low oil pressure setpoint is dependent
upon the engine speed. If the DERATE mode of the
engine monitoring system is selected, the ECM will
derate the engine power. The engine horsepower
will be limited.
Failure of the Engine Oil Pressure Sensor

The ECM will detect failure of the engine oil
pressure sensor. The diagnostic lamp warns the
user about the status of the engine oil pressure
sensor. The engine oil pressure related strategies
will be disabled in the event of a failure of the
engine oil pressure sensor. A failure of the engine
oil pressure sensor will not cause a shutdown of the
engine or any horsepower change.
Engine Oil Temperature Sensor

Engine oil temperature sensor (8) monitors the
temperature of the engine oil. The ECM uses the
information from the engine oil temperature sensor
in order to adjust the timing of the fuel injection and
the pressure of the fuel injection.
Table 6
Engine Oil Temperature Sensor

Operating temperature
range
40 to 120C (40 to 258F)
Crankshaft Position Sensor and

Camshaft Position Sensor
If the ECM does not receive a signal from crankshaft
position sensor (10), the DIAGNOSTIC lamp
will indicate a diagnostic fault code which will be
logged in the ECM memory.
If the ECM does not receive a signal from the
primary speed/timing sensor, the ECM will read the
signal from the secondary speed/timing sensor. The
ECM continually checks in order to determine if
there is a signal from both sensors. If either sensor
fails, the faulty sensor should be replaced.
Intermittent failure of the sensors will cause erratic
engine control.
Injection Actuation Pressure

Sensor
Injection actuation pressure sensor (2) provides
a signal of the injection actuation pressure to the
ECM. The ECM modifies the current to the injection
actuation pressure control valve (not shown) in
order to control the injection actuation pressure. The
desired actuation pressure is based on the following
engine parameters: quantity of fuel, injection timing,
engine speed, and engine operating mode.

Inlet air temperature sensor (5) measures the inlet
air temperature. A signal is sent to the Electronic
Control Module (ECM). The inlet air temperature
sensor is also used by the ECM to determine
initiation of the Cold Start Strategy.
Table 7

Operating temperature
range
40 to 120C (40 to 258F)
Throttle Position Sensor

The Throttle Position Sensor (TPS) sends a signal
to the ECM. The signal from the TPS is required in
order to govern engine speed. The throttle position
sensor signal is used by the ECM in order to
calculate the desired engine speed. The TPS is
calibrated during the initial installation of the engine.
Note: The throttle position sensor is not shown in
the illustration.
33
Operation Section
Failure of the Throttle Position Sensor

An intermittent failure in the TPS causes the engine
speed to vary erratically. The ECM will perform the
following process:
The ECM will detect the failure of the TPS.

The ECM will warn the operator of the failure
through the diagnostic lamp.
The ECM will set the desired engine speed to

low idle.
34
Operation Section
Engine Diagnostics
Engine Diagnostics
The DIAGNOSTIC lamp blinks on and off at five

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

lamp is checked for proper operation. If there
are any active codes except for Code 34, the
codes are displayed at this time.
Diagnostic Lamp
SMCS Code: 1000; 1900; 1901; 1902; 7451
The DIAGNOSTIC lamp is used to indicate the
existence of an active fault by flashing codes.
Note: The DIAGNOSTIC lamp will illuminate for

five seconds. The lamp will stay on if there is an
active diagnostic code.
When the ignition switch is first turned on, the

DIAGNOSTIC lamp will go through the following
procedure:
2. The Active Diagnostic codes will always be

flashed. There is no toggle switch that will shut
off the lamp.
The DIAGNOSTIC lamp will come on and
3. The DIAGNOSTIC lamp will flash in order

to indicate a two-digit code. The sequence
of flashes represents the system diagnostic
message. Each digit of the two-digit code is
determined by counting the number of flashes.
The lamp flashes at a rate of two times per
second. The lamp will pause for one second
between digits. The lamp will pause for two
seconds between codes.
the DIAGNOSTIC lamp will remain on for five

seconds. This checks the operation of the lamp.
The DIAGNOSTIC lamp will turn off.

The DIAGNOSTIC lamp will come on again and
the DIAGNOSTIC lamp will flash codes for any

active diagnostic codes. Not all diagnostic codes
have a unique flash code.
The DIAGNOSTIC lamp will turn off for five

seconds.
The DIAGNOSTIC lamp repeats all active

diagnostic codes.
A fault diagnostic code will remain active until the
problem is repaired. The electronic control module
will continue flashing the flash code at five second
intervals until the problem is repaired.
i01474158
Diagnostic Flash Code

Retrieval
SMCS Code: 1000; 1900; 1901; 1902
Diagnostic Lamp
Use the DIAGNOSTIC Lamp or Caterpillar ET in
order to determine the diagnostic flash code.
Use the following procedure to retrieve the
diagnostic codes if the engine is equipped with a
DIAGNOSTIC lamp:
1. Turn the ignition key to the ON position. The
engine does not need to be started in order to
view codes. The engine does not need to be
running while the ignition switch is in the ON
position.
Table 8 indicates the potential effect on the engine

performance with active flash codes. Table 8 also
forms a list of Electronic diagnostic codes and
descriptions.
35
Operation Section
Engine Diagnostics
Table 8
Diagnostic Flash Codes for C-9 Industrial Engine

Effect On Engine Performance
Engine
Misfire
Low
Power
Reduced
Engine
Speed
Suggested Action by the Operator
Engine
Shut
Down
Shut
down the
Engine(1)
Service(2)
Schedule
Service
for the
Engine.(3)
13
Fault for the Fuel Temperature

Sensor(4)
15
Open or Short Circuit of Injection

Actuation Pressure Sensor
17
High Injection Actuation Pressure
18
Open or Short for the Injection

Actuation Pressure Control Valve
21
Sensor Supply Voltage Above

Normal or Below Normal(4)
24
Oil Pressure Sensor Fault (4)
25
Inlet Manifold Air Pressure

Sensor Fault(5)
26

Fault(4)
27

Fault(4)
28
Check the Adjustments for the

Throttle Position Sensor.
34
Loss Of Engine RPM Signal
35
Event for Engine Overspeed
37
Fuel Pressure Sensor Fault(4)
38
Inlet Manifold Air Temperature

Sensor Fault(4)
39
Mechanical Failure of the

Injection Actuation Pressure
Sensor
42
Check the Calibration of the

Timing Sensor.
46
Low Oil Pressure Event
51
Intermittent Battery Power to the

ECM
52
Personality Module Fault
56
The following parameters must

be checked: Customer and
System
59
Incorrect Engine Software
61
Event for High Coolant

Temperature
62
Event for Low Coolant Level
63
Low Fuel Pressure Event
X
X
X
X
X
X
X
X
X
X
X
(continued)
36
Operation Section
Engine Diagnostics
(Table 8, contd)
Diagnostic Flash Codes for C-9 Industrial Engine

Effect On Engine Performance
Engine
Misfire
Low
Power
Reduced
Engine
Speed
Suggested Action by the Operator
Engine
Shut
Down
Shut
down the
Engine(1)
Service(2)
Schedule
Service
for the
Engine.(3)
64
Even for High Inlet Manifold Air

Temperature
65
Event for High Fuel Temperature
72
Fault of Cylinder 1 or Cylinder 2
73
74
(1)
(2)
(3)
(4)
(5)
Shut down the Engine: Operate the engine cautiously. Get immediate service. Severe engine damage may result.
The operator should go to the nearest location for service.
The operator should investigate the problem at a convenient time.
The Diagnostic Flash Codes reduce the effectiveness of the Engine Monitoring feature.
These Diagnostic Flash Codes may affect the system only under specific environmental conditions such as engine start-up at cold
temperatures, etc.
i01463504
Fault Logging
SMCS Code: 1000; 1900; 1901; 1902
The system provides the capability of Fault
Logging. When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will
be logged in the memory of the ECM. The codes
that have been logged in the memory of the ECM
can be retrieved with Caterpillar electronic service
tools. The codes that have been logged can be
cleared with Caterpillar electronic service tools.
The codes that have been logged in the memory
of the ECM will be automatically cleared from the
memory after 100 hours. The following faults can
not be cleared from the memory of the ECM without
using a factory password: overspeed, low engine
oil pressure, and high engine coolant temperature.
37
Operation Section
Engine Diagnostics
i01563981
i01456915
Engine Operation with Active

Diagnostic Codes
Engine Operation with

Intermittent Diagnostic Codes
SMCS Code: 1000; 1900; 1901; 1902
SMCS Code: 1000; 1900; 1901; 1902
If the diagnostic lamp starts to flash codes during

normal engine operation, the system has identified
a situation that is not within the specification. Use
Caterpillar electronic service tools to check the
active diagnostic codes.
If the diagnostic lamp starts to flash codes during

normal engine operation and the diagnostic lamp
shuts off, an intermittent fault may have occurred. If
a fault has occurred, the fault will be logged into the
memory of the Electronic Control Module (ECM).
Note: If the customer has selected DERATE and if

there is a low oil pressure condition, the Electronic
Control Module (ECM) will limit the engine power
until the problem is corrected. If the oil pressure
is within the normal range, the engine may be
operated at the rated speed and load. However,
maintenance should be performed as soon as
possible. Refer to Operation and Maintenance
Manual, Diagnostic Flash Code Retrieval for more
information on flash codes.
In most cases, it is not necessary to stop the

engine because of an intermittent code. However,
the operator should retrieve the logged fault codes
and the operator should reference the appropriate
information in order to identify the nature of the
event. The operator should log any observation that
could have caused the lamp to light.
Low power
Limits of the engine speed
The active diagnostic code should be investigated.

The cause of the problem should be corrected
as soon as possible. If the cause of the active
diagnostic code is repaired and there is only one
active diagnostic code, the diagnostic lamp will
turn off.
Operation of the engine and performance of the
engine can be limited as a result of the active
diagnostic code that is generated. Acceleration
rates may be significantly slower. Refer to the
Operation and Maintenance Manual for more
information on the relationship between these active
diagnostic codes and engine performance.
Excessive smoke, etc

This information can be useful to help troubleshoot
the situation. The information can also be used for
future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this
engine.
38
Operation Section
Engine Diagnostics
i00160113
Customer Specified
Parameters
SMCS Code: 1000; 1900; 1901; 1902
Customer specified parameters that will enhance
the fuel efficiency and the operators convenience
can be programmed into the Electronic Control
Module (ECM). Some parameters may affect engine
operation. This may lead to complaints from the
operator about power or about performance.
The following engine related parameters may be
programmed by the customer by using Caterpillar
electronic service tools in order to influence the
operation of the engine:
Customer Passwords
Power Rating (hp at rpm)
Rating Selection (A-E)
Air/Fuel Ratio
PTO Ramp Rate
Engine Parameters: Low Idle, High Idle, Top
Engine Limit, Torque Limit, and Intermediate
Speed
Engine Monitoring Mode

Equipment ID
Maintenance Indicator
Auxiliary Pressure
Parameter Lock Out
The customer specified parameters can be
changed as often as needed. Password protection
is provided so that the customer can change the
parameters. The customer can authorize someone
else to change the parameters. Ensure that a record
of the parameters is kept in the Operation and
Maintenance Manual. For detailed instructions on
programming the engine for optimum performance
and for optimum fuel economy, consult your
Caterpillar dealer.
39
Operation Section
Engine Starting
Engine Starting
i01486758
Before Starting Engine

SMCS Code: 1000; 1400; 1450

which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
Perform the required daily maintenance and

other periodic maintenance before the engine is
started. Inspect the engine compartment. This
inspection can help prevent major repairs at a
later date. Refer to the Operation and Maintenance
Manual, Maintenance Interval Schedule for more
information.
Do not start the engine or move any of the
For the maximum service life of the engine,
All of the guards must be put in place. Check for
make a thorough inspection before the engine

is started. Look for the following items: oil leaks,
coolant leaks, loose bolts, and trash buildup.
Remove trash buildup and arrange for repairs,
as needed.
Inspect the cooling system hoses for cracks and

for loose clamps.
Inspect the alternator and accessory drive belts

for cracks, breaks, and other damage.
Inspect the wiring for loose connections and for

worn wires or frayed wires.
Check the fuel supply. Drain water from the water

separator (if equipped). Open the fuel supply
valve.
NOTICE
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.
If the engine has not been started for several
weeks, fuel may have drained from the fuel system.
Air may have entered the filter housing. Also, when
fuel filters have been changed, some air pockets
will be trapped in the engine. In these instances,
prime the fuel system. Refer to the Operation and
Maintenance Manual, Fuel System - Prime for
more information on priming the fuel system.
controls if there is a DO NOT OPERATE warning

tag or similar warning tag attached to the start
switch or to the controls.
Ensure that the areas around the rotating parts

are clear.
damaged guards or for missing guards. Repair

any damaged guards. Replace damaged guards
and/or missing guards.
Disconnect any battery chargers that are not

protected against the high current drain that
is created when the electric starting motor (if
equipped) is engaged. Check electrical cables
and check the battery for poor connections and
for corrosion.
Reset all of the shutoffs or alarm components.

Check the engine lubrication oil level. Maintain
the oil level between the ADD mark and the
FULL mark on the oil level gauge.
Check the coolant level. Observe the coolant
level in the coolant recovery tank (if equipped).

Maintain the coolant level to the FULL mark on
the coolant recovery tank.
If the engine is not equipped with a coolant

recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe.
If the engine is equipped with a sight glass,
maintain the coolant level in the sight glass.
Observe the air cleaner service indicator (if

equipped). Service the air cleaner when the
yellow diaphragm enters the red zone, or when
the red piston locks in the visible position.
Ensure that any driven equipment has been

disengaged. Minimize electrical loads or remove
any electrical loads.
40
Operation Section
Engine Starting
i01512354
Starting the Engine

SMCS Code: 1000; 1450
All of the guards must be put in place. Check for

damaged guards or for missing guards. Repair
any damaged guards. Replace damaged guards
and/or missing guards.

which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
protected against the high current drain that

is created when the electric starting motor (if
equipped) is engaged. Check electrical cables
and check the battery for poor connections and
for corrosion.
Reset all of the shutoffs or alarm components.

Check the engine lubrication oil level. Maintain
Initial Inspection
Perform the required daily maintenance and other
periodic maintenance before you start the engine.
Inspect the engine compartment. This inspection
can help prevent major repairs at a later date.
Refer to the Operation and Maintenance Manual,
Walk-Around Inspection topic (Maintenance
Section) for more information.
For the maximum service life of the engine, make

a thorough inspection before you start the engine.
Look for the following items: oil leaks, coolant
leaks, loose bolts, and trash buildup. Remove
trash buildup and arrange for repairs, as needed.
Inspect the cooling system hoses for cracks and

for loose clamps.
Inspect the alternator and accessory drive belts
for cracks, breaks, and other damage.
Inspect the wiring for loose connections and for

worn wires or frayed wires.
Check the fuel supply. Drain water from the water

separator (if equipped). Open the fuel supply
valve.
NOTICE
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.
Do not start the engine or do not 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.
Ensure that the areas around the rotating parts

are clear.
the oil level between the ADD mark and the

FULL mark on the oil level gauge.
Check the coolant level. Observe the coolant

level in the coolant recovery tank (if equipped).
Maintain the coolant level to the FULL mark on
the coolant recovery tank.
If the engine is not equipped with a coolant
recovery tank maintain the coolant level within

13 mm (.5 inch) of the bottom of the filler pipe.
If the engine is equipped with a sight glass,
maintain the coolant level in the sight glass.
Observe the air cleaner service indicator (if
equipped). Service the air cleaner when the

yellow diaphragm enters the red zone, or when
the red piston locks in the visible position.
Ensure that any driven equipment has been

disengaged. Remove any electrical loads.
Cold Weather Starting

Starting the engine and operation in cold weather is
dependent on the type of fuel that is used, the oil
viscosity, and other optional starting aids. For more
information, refer to the Operation and Maintenance
Manual, Cold Weather Operation topic (Operation
Section).
Air Inlet Heater
DO NOT USE ETHER (starting fluids) unless

specifically instructed to do so. If the engine is
equipped with an Air Inlet Heater (electrically or
fuel ignited manifold heater), DO NOT use ether
(starting fluids) at any time. The use could result
in engine damage and/or personal injury.
Note: There will be an indicator lamp on the control
panel that is marked AIR INLET HEATER.
41
Operation Section
Engine Starting
For detailed information on the operation of the Air

Inlet Heater, refer to Troubleshooting Manual, Air
Inlet Heater Circuit - Test.
Refer to the Owners Manual of the OEM for your
type of controls. Use the following procedure to
start the engine.
1. Place the transmission in NEUTRAL. Disengage
the flywheel clutch in order to allow the engine
to start faster. This also reduces the draining of
the battery.
2. Turn the ignition switch to the ON position.
NOTICE
Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine rpm until the oil
pressure gauge indicates normal. If oil pressure is not
indicated on the gauge within 15 seconds, DO NOT
operate the engine. STOP the engine, investigate and
correct the cause.
5. Allow the engine to idle for approximately
three minutes. Idle the engine until the water
temperature gauge has begun to rise. Check all
gauges during the warm-up period.
The WARNING and DIAGNOSTIC lamp (if

equipped) will flash while the engine is cranking.
The lamp should turn off after proper engine
oil pressure is achieved. If the lamp fails to
flash, notify your authorized Caterpillar dealer.
If the lamp continues to flash, the Electronic
Control Module (ECM) has detected a problem
in the system. For more information, refer to the
Operation and Maintenance Manual, Diagnostic
Flash Code Retrival (Operation Section).
Note: Oil pressures and fuel pressures should be in

the normal range on the instrument panel. Engines
that are equipped with WARNING lamps do not
have an operating range. The WARNING and
DIAGNOSTIC lamp (if equipped) will flash while
the engine is cranking. The lamp should turn off
after proper engine oil pressure or fuel pressure
is achieved. Do not apply a load to the engine or
increase engine rpm until the oil pressure gauge
indicates at least normal pressure. Inspect the
engine for leaks and/or unusual noises.
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
After the engine has started, the air inlet heater may
continue to operate in a Continuous mode and/or
in an Intermittent mode. The air inlet heater will
turn OFF when the sum of the coolant temperature
and the air inlet temperature exceeds 35 C or 127

F.
If the engine fails to start within 30 seconds, release

the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.
3. Push the start button or turn the ignition switch to
the START position in order to crank the engine.
Do not push down or hold the throttle down
while the engine is cranked. The system will
automatically provide the correct amount of fuel
that is needed to start the engine.
4. If the engine fails to start within 30 seconds,
release the start button, or the ignition switch.
Wait for two minutes in order to allow the starting
motor to cool before attempting to start the
engine again.
Note: The WARNING and DIAGNOSTIC lamps (if
equipped) may come on after the engine is started.
If this occurs, the ECM has detected a problem
with the system. For more information, refer to the
Operation and Maintenance Manual, Diagnostic
Flash Code Retrival (Operation Section) .
If the engine is operated with a low load, the engine

will reach normal operating temperature sooner than
idling the engine with no load. When the engine is
idled in cold weather, increase the engine rpm to
approximately 1000 to 1200 rpm. This will warm
up the engine more quickly. Do not exceed the
recommended rpm in order to increase the speed
of the warm-up. Limit unnecessary idle time to ten
minutes.
Ether Injection System
Personal injury or property damage can result

from alcohol or starting fluids.
Alcohol or starting fluids are highly flammable and
toxic and if improperly stored could result in injury
or property damage.
42
Operation Section
Engine Starting
DO NOT USE ETHER (starting fluids) unless

specifically instructed to do so. If the engine is
equipped with an Air Inlet Heater (electrically or
fuel ignited manifold heater), DO NOT use ether
(starting fluids) at any time. The use could result
in engine damage and/or personal injury.
NOTICE
The optional automatic ether injection system is the
only starting fluid system that is recommended. Excessive starting fluid can cause piston and ring damage. Use starting fluid for cold starting purposes only.
Startability will be improved at temperatures below
0 C (32 F) by the use of a continuous flow injection
system and/or a jacket water heater. This will help
alleviate white smoke and misfire during start-up
in cold weather. Consult your Caterpillar dealer
for other means of improving startability in cold
temperatures.
The Continuous Flow Ether is an optional ether
starting aid that is available for use with the engine.
The system injects ether into the air inlet manifold
after the air inlet heater. Extensive damage to the
engine could occur if ether is directed at the air
inlet heater during activation.
Continuous Flow Ether Control has two modes, the
Manual Mode and the Automatic Mode.
Manual Mode:
When the ether switch is placed in the automatic

mode, the ether injection system operates
automatically, when the engine is cranking. The
automatic mode is enabled if the engine has been
idling for less than 10 seconds, if the engine speed
is less than 200 rpm above low idle, if the ambient
air temperature is below 0 C (32 F), and if the
coolant temperature is below 0 (32 F).
Additional injections may be necessary in order
to start the engine. Additional injections may be
necessary in order to achieve the low idle speed.
For additional information on the Ether Injection
System refer to Troubleshooting Manual, Air Inlet
Heater Circuit - Test.
Starting Problems
An occasional starting problem may be caused by
one of the following items:
Low battery charge

Lack of fuel
Problem with the wiring harness
If the engine fuel system has been run dry, fill the
fuel tank and prime the fuel system. Refer to the
Operation and Maintenance Manual, Fuel System Prime topic (Maintenance Section).
If the other problems are suspected, perform the
appropriate procedure in order to start the engine.
Problems with the Wiring Harness
In the manual mode, as the ether switch is

depressed there is a predetermined amount of
ether that is injected. The manual mode is disabled,
if the engine speed is more than 200 rpm above the
low idle, if the ambient air temperature is above 0
C (32 F), or if the coolant temperature is above
0 C 32 F.
If the engine is equipped with the ether injection
system, perform the following procedure for the
manual mode:
1. Crank the engine.
2. Depress the ether switch.
3. Hold the ether switch for three seconds.
4. Release the ether switch.
Automatic Mode:
Illustration 27
(1) ECM Connector J2/P2
(2) ECM Connector J1/P1
g00772964
43
Operation Section
Engine Starting
Locate the ECM. Two harness connectors are

attached to the ECM. One connector is ECM
J2/P2 (1) and the other connector is ECM J1/P1.
Check the connectors in order to ensure that the
connectors are secure. Lightly pull each of the wires
in the chassis harness.
1. Pull each wire with approximately 4.5 kg (10 lb)
of force. The wire should remain in the connector.
2. If a wire is loose, push the wire back into the
connector. Pull the wire again in order to ensure
that the wire is secure.
3. Start the engine. If the engine does not start,
consult the nearest Caterpillar dealer for
assistance.
i01037941
Starting with Jump Start

Cables
SMCS Code: 1000; 1401; 1402; 1900
Improper jump start cable connections can cause

an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
If the installation is not equipped with a backup
battery system, it may be necessary to start the
engine from an external electrical source.
First, determine the reason that it is necessary to
start with power from an external source. Refer to
Special Instruction, SEHS7768, Use of the 6V-2150
Starting/Charging Analyzer.
Many batteries which are considered unusable are
still rechargeable. After jump starting, the alternator
may not be able to fully recharge batteries that
are severely discharged. The batteries must be
charged to the proper voltage with a battery
charger. 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.
Do not reverse the battery cables. The alternator can
be damaged. Attach ground cable last and remove
first.
When using an external electrical source to start the
engine, turn the engine control switch to the OFF position. Turn all electrical accessories OFF before attaching the jump start cables.
Ensure that the main power switch is in the OFF position before attaching the jump start cables to the engine being started.
1. Turn the start switch on the stalled engine to the
OFF position. Turn off all accessories.
2. Connect one positive end of the jump start cable
to the positive cable terminal of the discharged
battery. Connect the other positive end of the
jump start cable to the positive cable terminal
of the electrical source.
3. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.
4. 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.
44
Operation Section
Engine Starting
i01646248
After Starting Engine

SMCS Code: 1000
Note: In temperatures from 0 to 60C (32 to 140F),
the warm-up time is approximately three minutes. In
temperatures below 0C (32F), additional warm-up
time may be required.
Note: Ensure that the self test for the monitoring
system (if equipped) is completed before operating
the engine under load.
When the engine idles during warm-up, observe
the following conditions:
Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is
not possible in some applications.
Operate the engine at low idle until all systems

achieve operating temperatures. Check all
gauges during the warm-up period.
Note: Gauge readings should be observed and the
data should be recorded frequently while the engine
is operating. Comparing the data over time will
help to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
45
Operation Section
Engine Operation
Engine Operation
i01646335
i00718869
Engine Operation
SMCS Code: 1000
Proper operation and maintenance are key factors
in obtaining the maximum life and economy of
the engine. If the directions in the Operation and
Maintenance Manual are followed, costs can
be minimized and engine service life can be
maximized.
The time that is needed for the engine to reach
normal operating temperature can be less than the
time needed for a walk-around inspection of the
engine.
After the engine is started and after the engine
reaches normal operating temperature, the engine
can be operated at the rated rpm. The engine will
reach normal operating temperature faster when
the engine is at rated speed. The engine will reach
normal operating temperature faster when the
engine is at low power demand. This procedure is
more effective than idling the engine at no load.
The engine should reach operating temperature in
a few minutes.
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.
Engaging the Driven

Equipment
SMCS Code: 1000
1. Operate the engine at one-half of the rated rpm,
when possible.
2. Engage the driven equipment without a load on
the equipment, when possible.
Interrupted starts put excessive stress on the
drive train. Interrupted starts also waste fuel. To
get the driven equipment in motion, engage the
clutch smoothly with no load on the equipment.
This method should produce a start that is
smooth and easy. The engine rpm should not
increase and the clutch should not slip.
3. Ensure that the ranges of the gauges are normal
when the engine is operating at one-half of
the rated rpm. Ensure that all gauges operate
properly.
4. Increase the engine rpm to the rated rpm. Always
increase the engine rpm to the rated rpm before
the load is applied.
5. Apply the load. Begin operating the engine at
low load. Check the gauges and equipment for
proper operation. After normal oil pressure is
reached and the temperature gauge begins to
move, the engine may be operated at full load.
Check the gauges and equipment frequently
when the engine is operated under load.
Extended operation at low idle or at reduced
load may cause increased oil consumption and
carbon buildup in the cylinders. This carbon
buildup results in a loss of power and/or poor
performance.
46
Operation Section
Engine Stopping
Engine Stopping
i01057253
Emergency Stopping
i01428739
Stopping the Engine

SMCS Code: 1000; 7000
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and accelerated wear of the engine components.
If the engine has been operating at high rpm and/or
high loads, run at low idle for at least three minutes
to reduce and stabilize internal engine temperature
before stopping the engine.
SMCS Code: 1000; 7418

NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.
Ensure that any components for the external system
that support the engine operation are secured after
the engine is stopped.
Emergency Stop Button
Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life.
Prior to stopping an engine that is being operated
at low loads, operate the engine at low idle for 30
seconds before stopping. If the engine has been
operating at highway speeds and/or at high loads,
operate the engine at low idle for at least three
minutes. This procedure will cause the internal
engine temperature to be reduced and stabilized.
Ensure that the engine stopping procedure is
understood. Stop the engine according to the
shutoff system on the engine or refer to the
instructions that are provided by the OEM.
To stop the engine, turn the ignition key switch to

the OFF position.
Illustration 28
g00104303
Typical emergency stop button
The emergency stop button is in the OUT position

for normal engine operation. Push the emergency
stop button. The engine will not start when the
button is locked. Turn the button clockwise in order
to reset.
47
Operation Section
Engine Stopping
i01646416
i01465494
Manual Stop Procedure
After Stopping Engine
SMCS Code: 1000
SMCS Code: 1000
Note: Individual applications will have different

control systems. Ensure that the shutoff procedures
are understood. Use the following general
guidelines in order to stop the engine.
Note: Before you check the engine oil, do not

operate the engine for at least 10 minutes in order
to allow the engine oil to return to the oil pan.
1. Remove the load, when possible. Reduce the

engine speed (rpm) to low idle.
2. Increase the engine speed (rpm) to no more
than one-half of the rated rpm. Perform this
procedure for three to five minutes in order to
cool the engine. Reduce the engine speed (rpm)
to low idle.
3. After the cool down period, turn the key switch
to the OFF position.
Check the crankcase oil level. Maintain the oil
level between the ADD mark and the FULL

mark on the oil level gauge.
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.
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.
48
Operation Section
Cold Weather Operation

i01457051
Radiator Restrictions
SMCS Code: 1353; 1396
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow
restriction can cause the following conditions:
Quantities of No. 1 diesel fuel are limited. No.

1 diesel fuels are usually available during the
months of the winter in the colder climates. During
cold weather operation, if No. 1 diesel fuel is not
available, use No. 2 diesel fuel, if necessary.
There are three major differences between No. 1
and No. 2 diesel fuel. No. 1 diesel fuel has the
following properties:
Lower cloud point

Lower pour point
High exhaust temperatures
Lower rating of kJ (BTU) per unit volume of fuel
Power loss
When No. 1 diesel fuel is used, a decrease in

power and in fuel efficiency may be noticed. Other
operating effects should not be experienced.
Excessive fan usage

Reduction in fuel economy
If an airflow restriction device must be used, the
device should have a permanent opening directly
in line with the fan hub. The device must have a
minimum opening dimension of at least 770 cm2
(120 in2).
A centered opening that is directly in line with
the fan hub is specified in order to prevent an
interrupted airflow on the fan blades. Interrupted
airflow on the fan blades could cause a fan failure.
Caterpillar recommends a warning device for the
inlet manifold temperature and/or the installation of
an inlet air temperature gauge. The warning device
for the inlet manifold temperature should be set at
75 C (167 F). The inlet manifold air temperature
should not exceed 75 C (167 F). Temperatures
that exceed this limit can cause power loss and
potential engine damage.
i01190421
The cloud point is the temperature when a cloud

of wax crystals begins to form in the fuel. These
crystals can cause the fuel filters to plug. The
pour point is the temperature when diesel fuel will
thicken. The diesel fuel becomes more resistant to
flow through fuel pumps and through fuel lines.
Be aware of these values when diesel fuel is
purchased. Anticipate the average ambient
temperature within the area that the engine will be
operated. Engines that are fueled in one climate
may not operate well if the engines are moved
to another climate. Problems can result due to
changes in temperature.
Before troubleshooting for low power or for poor
performance in the winter, check the type of fuel
that is being used.
When No. 2 diesel fuel is used the following
components provide a means of minimizing
problems in cold weather:
Fuel and the Effect from Cold

Weather
Starting aids
SMCS Code: 1000; 1250
Engine coolant heaters
The following fuels are the grades that are available

for Caterpillar engines:
Fuel heaters
No. 1
No. 2
Blend of No. 1 and No. 2
No. 2 diesel fuel is the most commonly used fuel.
Either No. 1 diesel fuel or a blend of No. 1 and No.
2 is best suited for cold weather operation.
Engine oil pan heaters
Fuel line insulation

For more information on cold weather operation, see
Operation and Maintenance Manual, SEBU5898,
Cold Weather Recommendations.
49
Operation Section
Fuel Tanks
These engines are equipped with a primary

filter/water separator. The primary filter/water
separator must use a 10 micron filter to a 15 micron
filter. The filters are becoming more critical as fuel
injection pressures increase to 209 MPa (30000 psi)
and higher psi. For more information on priming the
fuel system, see the Operation and Maintenance
Manual, Fuel System - Prime topic (Maintenance
Section).
Condensation can form in partially filled fuel tanks.

Top off the fuel tanks after operating the engine.
Fuel Heaters
i01505157
Fuel Related Components in

Cold Weather
SMCS Code: 1000; 1250
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.
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.
Drain the water and sediment from any fuel storage

tank at the following intervals:
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.
Weekly
Disconnect the fuel heater in warm weather.
Oil changes
Note: Fuel heaters that are controlled by the water

temperature regulator or self-regulating fuel heaters
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).
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.
Refueling of the fuel tank

This will help prevent water and/or sediment from
being pumped from the fuel storage tank and into
the engine fuel tank.
Fuel Filters
NOTICE
Do not fill the fuel filters with fuel before installing them.
The fuel would not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear
to fuel system parts.
NOTICE
In order to maximize fuel system life and prevent premature wear out from abrasive particles in the fuel,
a two micron absolute high efficiency fuel filter is required for all Caterpillar Hydraulic Electronic Unit Injectors. Caterpillar High Efficiency Fuel Filters meet
these requirements. Consult your Caterpillar dealer for
the proper part numbers.
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.
50
Maintenance Section
Lubricant Specifications
Maintenance Section
Table 9
API Classifications
Current
Obsolete
CF-4, CG-4, CH-4
CE
CF
CC, CD
CF-2(1)
CD-2(1)
i01111306
Lubricant Information
(1)
SMCS Code: 1000; 1300; 7581
General Information
Because of government regulations regarding
the certification of engine exhaust emissions, the
lubricant recommendations must be followed.
Engine Manufacturers Association

(EMA) Oils
The Engine Manufacturers Association
Recommended Guideline on Diesel Engine Oil is
recognized by Caterpillar. For detailed information
about this guideline, see the latest edition of EMA
publication, EMA LRG-1.
API Oils
The Engine Oil Licensing and Certification System
by the American Petroleum Institute (API) is
recognized by Caterpillar. For detailed information
about this system, see the latest edition of the API
publication No. 1509. Engine oils that bear the API
symbol are authorized by API.
CD-2 and API CF-2 are classifications for two-cycle diesel

engines. Caterpillar does not sell engines that utilize CD-2 and
API CF-2 oils.
Note: API CF is not the same classification as

API CF-4. API CF oils are only recommended
for Caterpillar 3600 Series Diesel Engines and
Caterpillar engines with precombustion chamber
(PC) fuel systems.
Grease
The classifications of grease are based on the
ASTM D217 worked penetration characteristics.
These characteristics for grease are given a defined
consistency number.
Terminology
Certain abbreviations follow the nomenclature of
SAE J754. Some classifications follow SAE J183
abbreviations, and some classifications follow the
EMA Recommended Guideline on Diesel Engine
Oil. In addition to Caterpillar definitions, there
are other definitions that will be of assistance in
purchasing lubricants. Recommended oil viscosities
can be found in this publication, Engine Oil topic
i01539915
Engine Oil
SMCS Code: 1300; 1348; 7581
Caterpillar Diesel Engine Oil
Illustration 29
g00546535
Typical API symbol
Diesel engine oils CC, CD, CD-2, and CE have

not been API authorized classifications since 1
January 1996. Table 9 summarizes the status of the
classifications.
Caterpillar Oils have been developed and tested in

order to provide the full performance and service
life that has been designed and built into Caterpillar
Engines. Caterpillar Oils are currently used to fill
diesel engines at the factory. These oils are offered
by Caterpillar dealers for continued use when the
engine oil is changed. Consult your Caterpillar
dealer for more information on these oils.
Due to significant variations in the quality and in
the performance of commercially available oils,
Caterpillar makes the following recommendations:
Caterpillar Diesel Engine Oil (10W30)
51
Maintenance Section
Caterpillar Diesel Engine Oil (15W40)

Caterpillar multigrade Diesel Engine Oil is
formulated with the correct amounts of detergents,
dispersants, and alkalinity in order to provide
superior performance in Caterpillar Diesel Engines.
Caterpillar multigrade Diesel Engine Oil is available
in two viscosity grades (10W30 and 15W40). For
direct injection engines, see Table 10 in order
to choose the correct viscosity grade for the
ambient temperature. Multigrade oils provide the
correct viscosity for a broad range of operating
temperatures.
Multigrade oils are effective in maintaining low oil
consumption and low levels of piston deposits.
Caterpillar multigrade Diesel Engine Oil can be
used in other diesel engines and in gasoline
engines. See the engine manufacturers guide for
the recommended specifications. Compare the
specifications to the specifications of Caterpillar
multigrade Diesel Engine Oil. The current industry
standards for Caterpillar Diesel Engine Oil are listed
on the product label and on the data sheets for the
product.
Consult your Caterpillar dealer for part numbers
and for available sizes of containers.
Commercial Oils
The performance of commercial diesel engine
oils is based on American Petroleum Institute
(API) classifications. These API classifications are
developed in order to provide commercial lubricants
for a broad range of diesel engines that operate at
various conditions.
If Caterpillar multigrade Diesel Engine Oil is not
used, only use commercial oils that meet the
following classifications:
EMA LRG-1 multigrade oil (preferred oil)

API CH-4 multigrade oil (preferred oil)
API CG-4 multigrade oil (preferred oil)
API CF-4 multigrade oil (acceptable oil)
In order to make the proper choice of a commercial
oil, refer to the following explanations:
EMA LRG-1 The Engine Manufacturers

Association (EMA) has developed lubricant
recommendations as an alternative to the API oil
classification system. LRG-1 is a Recommended
Guideline that defines a level of oil performance
for these types of diesel engines: high speed, four
stroke cycle, heavy-duty, and light duty. LRG-1
oils may be used in Caterpillar engines when the
following oils are recommended: API CH-4, API
CG-4, and API CF-4. LRG-1 oils are intended to
provide superior performance in comparison to API
CG-4 and API CF-4.
LRG-1 oils will meet the needs of high performance
Caterpillar diesel engines that are operating in
many applications. The tests and the test limits that
are used to define LRG-1 are similar to the new
API CH-4 classification. Therefore, these oils will
also meet the requirements of the low emissions
diesel engines. LRG-1 oils are designed to control
the harmful effects of soot with improved wear
resistance and improved resistance to plugging of
the oil filter. These oils will also provide superior
piston deposit control for engines with either
two-piece steel pistons or aluminum pistons.
All LRG-1 oils must complete a full test program
with the base stock and with the viscosity grade of
the finished commercial oil. The use of API Base
Oil Interchange Guidelines are not appropriate for
LRG-1 oils. This feature reduces the variation in
performance that can occur when base stocks are
changed in commercial oil formulations.
LRG-1 oils are recommended for use in extended
oil change interval programs that optimize oil life.
These oil change interval programs are based
on oil analysis. LRG-1 oils are recommended
for conditions that demand a premium oil. Your
Caterpillar dealer has the specific guidelines for
optimizing oil change intervals.
API CH-4 API CH-4 oils were developed in
order to meet the requirements of the new high
performance diesel engines. Also, the oil was
designed to meet the requirements of the low
emissions diesel engines. API CH-4 oils are also
acceptable for use in older diesel engines and in
diesel engines that use high sulfur diesel fuel. API
CH-4 oils may be used in Caterpillar engines that
use API CG-4 and API CF-4 oils. API CH-4 oils will
generally exceed the performance of API CG-4 oils
in the following criteria: deposits on pistons, control
of oil consumption, wear of piston rings, valve train
wear, viscosity control, and corrosion.
52
Maintenance Section
Three new engine tests were developed for the

API CH-4 oil. The first test specifically evaluates
deposits on pistons for engines with the two-piece
steel piston. This test (piston deposit) also measures
the control of oil consumption. A second test is
conducted with moderate oil soot. The second
test measures the following criteria: wear of piston
rings, wear of cylinder liners, and resistance to
corrosion. A third new test measures the following
characteristics with high levels of soot in the oil:
wear of the valve train, resistance of the oil in
plugging the oil filter, and control of sludge.
Some commercial oils that meet the API

classifications may require reduced oil change
intervals. To determine the oil change interval,
closely monitor the condition of the oil and perform a
wear metal analysis. Caterpillars SOS oil analysis
program is the preferred method.
In addition to the new tests, API CH-4 oils have

tougher limits for viscosity control in applications
that generate high soot. The oils also have improved
oxidation resistance. API CH-4 oils must pass an
additional test (piston deposit) for engines that use
aluminum pistons (single piece). Oil performance is
also established for engines that operate in areas
with high sulfur diesel fuel.
Total Base Number (TBN) and Fuel

Sulfur Levels for Direct Injection
(DI) Diesel Engines
All of these improvements allow the API CH-4 oil

to achieve optimum oil change intervals. API CH-4
oils are recommended for use in extended oil
change intervals. API CH-4 oils are recommended
for conditions that demand a premium oil. Your
Caterpillar dealer has specific guidelines for
optimizing oil change intervals.
NOTICE
Failure to follow these oil recommendations can cause
shortened engine service life due to deposits and/or
excessive wear.
The Total Base Number (TBN) for an oil depends on

the fuel sulfur level. For direct injection engines that
use distillate fuel, the minimum TBN of the new oil
must be 10 times the fuel sulfur level. The TBN is
defined by ASTM D2896. The minimum TBN of
the oil is 5 regardless of fuel sulfur level. Illustration
30 demonstrates the TBN.
API CG-4 API CG-4 oils were developed primarily

for diesel engines that use a 0.05 percent level of
fuel sulfur. However, API CG-4 oils can be used
with higher sulfur fuels. The TBN of the new oil
determines the maximum fuel sulfur level for API
CG-4 and API CF-4 oils. See Illustration 30.
API CG-4 oils are the first oils that are required to
pass industry standard tests for foam control and
viscosity shear loss. API CG-4 oils must also pass
tests that were developed for corrosion, wear and
oxidation.
API CF-4 These oils service a wide variety of
modern diesel engines. API CF-4 oils provide more
stable oil control and reduced piston deposits in
comparison to API CF and the obsolete CE and CD
classifications of oil. API CF-4 oils provide improved
soot dispersancy in comparison to API CF and
obsolete CD oils. The API CF-4 classification was
developed with a 0.40 percent sulfur diesel fuel.
This represents the type of diesel fuels that are
commonly available worldwide.
Note: Do not use single grade API CF oils or
multigrade API CF oils in Caterpillar Direct Injection
(DI) Commercial Diesel Engines.
Illustration 30
g00799818
(Y) TBN by ASTM D2896

(X) Percentage of fuel sulfur by weight
(1) TBN of new oil
(2) Change the oil when the TBN deteriorates to 50 percent of
the original TBN.
Use the following guidelines for fuel sulfur levels

that exceed 1.5 percent:
Choose an oil with the highest TBN that meets

one of these classifications: EMA LRG-1, API
CH-4, API CG-4, and API CF-4.
Reduce the oil change interval. Base the oil

change interval on the oil analysis. Ensure that
the oil analysis includes the condition of the oil
and a wear metal analysis.
53
Maintenance Section
Excessive piston deposits can be produced by an

oil with a high TBN. These deposits can lead to a
loss of control of the oil consumption and to the
polishing of the cylinder bore.
Synthetic Base Stock Oils
NOTICE
Operating Direct Injection (DI) diesel engines with fuel
sulfur levels over 1.0 percent may require shortened
oil change intervals in order to help maintain adequate
wear protection.
Synthetic base oils are acceptable for use

in Caterpillar engines if these oils meet the
performance requirements that are specified for the
engine compartment.
Lubricant Viscosity Recommendations

for Direct Injection (DI) Diesel Engines
The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during
cold engine start-up, and the maximum ambient
temperature during engine operation.
Refer to Table 10 (minimum temperature) in order
to determine the required oil viscosity for starting
a cold engine.
Refer to Table 10 (maximum temperature) in order
to select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
Generally, use the highest oil viscosity that
is available to meet the requirement for the
temperature at start-up.
i01111406
SMCS Code: 1300; 1348; 7581
Synthetic base oils generally perform better than

conventional oils in the following two areas:
Synthetic base oils have improved flow at low

temperatures especially in arctic conditions.
Synthetic base oils have improved oxidation

stability especially at high operating temperatures.
Some synthetic base oils have performance
characteristics that enhance the service life of the
oil. However, Caterpillar does not recommend the
automatic extension of oil change intervals for
any type of oil. Oil change intervals for Caterpillar
engines can only be adjusted after an oil analysis
program that contains the following tests: oil
condition and wear metal analysis (Caterpillars
SOS oil analysis), trend analysis, fuel consumption,
and oil consumption.
i01111412
Table 10
Re-refined Base Stock Oils
Engine Oil Viscosity

Caterpillar DEO
Multigrade
EMA LRG-1
API CH-4
API CG-4 and
API CF-4
Viscosity Grade
Ambient Temperature
Minimum
Maximum
SAE 0W20
40 C (40 F)
10 C (50 F)
SAE 0W30
40 C (40 F)
30 C (86 F)
SAE 0W40
40 C (40 F)
40 C (104 F)
SAE 5W30
30 C (22 F)
30 C (86 F)
SAE 5W40
30 C (22 F)
40 C (104 F)
SAE 10W30
20 C (4 F)
40 C (104 F)
SAE 15W40
15 C (5 F)
50 C (122 F)
SMCS Code: 1300; 7581

Re-refined base stock oils are acceptable for
use in Caterpillar engines if these oils meet the
performance requirements that are specified by
Caterpillar. Re-refined base stock oils can be used
exclusively in finished oil or in a combination with
new base stock oils. The US military specifications
and the specifications of other heavy equipment
manufacturers also allow the use of re-refined base
stock oils that meet the same criteria.
The process that is used to make re-refined base
stock oil should adequately remove all wear metals
that are in the used oil and all additives that are
in the used oil. The process that is used to make
re-refined base stock oil generally involves the
processes of vacuum distillation and hydrotreating
the used oil. Filtering is inadequate for the
production of high quality re-refined base stock oils
from used oil.
54
Maintenance Section
i01113213
i01123104
Cold Weather Lubricants
Aftermarket Oil Additives
SMCS Code: 1300; 1348; 7581
SMCS Code: 1300; 1348; 7581
When an engine is started and an engine is

operated in ambient temperatures below 20 C
(4 F), use multigrade oils that are capable of
flowing in low temperatures.
Caterpillar does not recommend the use of

aftermarket additives in oil. It is not necessary to
use aftermarket additives in order to achieve the
engines maximum service life or rated performance.
Fully formulated, finished oils consist of base oils
and of commercial additive packages. These
additive packages are blended into the base oils
at precise percentages in order to help provide
finished oils with performance characteristics that
meet industry standards.
These oils have lubricant viscosity grades of SAE

0W or SAE 5W.
When an engine is started and operated in ambient
temperatures below 30 C (22 F), use a synthetic
base stock multigrade oil with a 0W viscosity grade
or with a 5W viscosity grade. Use an oil with a pour
point that is lower than 50 C (58 F).
The number of acceptable lubricants is limited in
cold weather conditions. Caterpillar recommends
the following lubricants for use in cold weather
conditions:
First Choice use an oil with an EMA LRG-1
Recommended Guideline or use a CH-4 oil that is
API licensed with an SAE 0W20, SAE 0W30, SAE
0W40, SAE 5W30, or SAE 5W40 lubricant viscosity
grade. A CG-4 oil that is API licensed with an SAE
0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE
5W40 lubricant viscosity grade may also be used.
A CF-4 oil that is API licensed with an SAE 0W20,
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40
lubricant viscosity grade may also be used.
There are no industry standard tests that evaluate

the performance or the compatibility of aftermarket
additives in finished oil. Aftermarket additives may
not be compatible with the finished oils additive
package, which could lower the performance of the
finished oil. The aftermarket additive could fail to
mix with the finished oil. This could produce sludge
in the crankcase. Caterpillar discourages the use of
aftermarket additives in finished oils.
To achieve the best performance from a Caterpillar
engine, conform to the following guidelines:
Select the proper Caterpillar oil or a commercial

oil that meets the EMA Recommended Guideline
on Diesel Engine Oil or the recommended API
classification.
See the appropriate Lubricant Viscosities table

Second Choice use an oil that contains the CH-4,
CG-4, or CF-4 additive package although the oil
has not been tested for the requirements of the
API license. The oil must have an SAE 0W20,
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40
lubricant viscosity grade.
NOTICE
Shortened engine service life could result if second
choice oils are used.
in order to find the correct oil viscosity grade for

your engine.
At the specified interval, service the engine
compartment. Use new oil and install a new oil

filter.
Perform maintenance at the intervals that are

specified in the Operation and Maintenance
Manual, Maintenance Interval Schedule.
i01585773
Lubricating Grease
SMCS Code: 7581
Caterpillar provides greases in order to cover a
variety of applications and extreme temperature
conditions. Consult your Caterpillar dealer for part
numbers and for available sizes of containers.
55
Maintenance Section
Note: Some greases may not be used with other

greases. When a commercial grease is used,
ensure that the grease is compatible with the
grease that is currently used in the system. If the
commercial grease is not compatible, the system
must be purged. If any questions arise concerning
the compatibility of a grease, consult the supplier.
Multipurpose Greases
Multipurpose Lithium Complex Grease
(MPGL)
Multipurpose Lithium Complex Grease (MPGL)
is a general purpose lithium complex grease for
medium-duty applications. This product has good
characteristics at high temperatures such as a
dropping point of 260 C (500 F). MPGL contains
unleaded extreme pressure additives, antiwear
inhibitors, and corrosion inhibitors that provide extra
protection in the following applications:
Construction
Agricultural
Automotive
MPGL meets the requirements for extended service
intervals of automotive chassis points. MPGL also
meets the requirements for extended service
intervals of wheel bearings with disc brakes in
automobiles, in vans and in light trucks. This
product meets the NLGI certification of GC-LB.
MPGL is also available in a NLGI No. 2 grade.
Normal operating temperatures for this product are
28 to 149 C (18 to 300 F). This product is also
available as a white lithium complex grease.
Multipurpose Lithium Complex Grease

with Molybdenum (MPGM)
Multipurpose Lithium Complex Grease with
Molybdenum (MPGM) is a general purpose
lithium complex grease that is used for light-duty
applications and for medium-duty applications. The
MPGM is available in the following grades: NLGI
No. 2 grade and NLGI No. 0 grade. The MPGM is
strengthened with a molybdenum disulfide and a
polymer for extra lubrication and protection. MPGM
contains unleaded additives. MPGM also contains
antiwear inhibitors, rust inhibitors, and corrosion
inhibitors that are for protection and lubrication in
many environments. The MPGM is formulated with a
base fluid that has high viscosity.
The MPGM has the following features:
Increased protection against water washout
Increased retention
Resistance to heavy loads
This product is recommended for heavily loaded pin
joints and for journal bearings. This product meets
the certification of GC-LB. Normal operating
temperatures for this product are 28 to 149 C
(18 to 300 F) for the NLGI No. 0 grade. Normal
operating temperatures for this product are
18 to 149 C (0 to 300 F) for the NLGI No. 2 grade.
Note: If MPGM is not available, use a multipurpose
type grease which contains three to five percent
molybdenum.
Special Purpose Grease (SPG)

Bearing Lubricant (SPG)
Bearing Lubricant (SPG) is available in a NLGI
No. 2 grade with a polyurea thickener. This
grease is recommended for high temperature
antifriction bearings in the following applications:
electric starting motors, alternators, fan drives,
and generators. The Bearing Lubricant (SPG) has
an effective operating range of 29 to 177 C
(20 to 350 F).
Water and Temperature Resistant Grease

(WTR)
The Water and Temperature Resistant Grease is
designed for use whenever the following conditions
are a concern: water washout, severe corrosion,
and high operating temperatures. The Water and
Temperature Resistant Grease provides extreme
pressure protection, antiwear protection, rust
protection and corrosion protection. The Water and
Temperature Resistant Grease is an environmentally
friendly grease which does not contain the following
materials: antimony, sulfur, barium, zinc, lead, and
phosphorous materials. The Water and Temperature
Resistant Grease has excellent shear stability. Water
and Temperature Resistant Grease can also resist
breakdown in the presence of water. The Water
and Temperature Resistant Grease works well in
the following applications:
Construction
Agricultural
Automotive
Industrial
Marine
56
Maintenance Section
This product meets the NLGI certification of

GC-LB. Normal operating temperatures for this
product are 40 to 204C (40 to 400F).
Caterpillar Premium Grease (CPG)

Desert Gold (CPG)
Desert Gold is a heavy-duty, premium synthetic
grease that is developed for the most extreme
operating environments. This grease is formulated
with the following characteristics: high viscosity
synthetic base fluid, polymers, molybdenum
disulfide, high viscosity index, and high dropping
point.
Desert Gold will protect equipment against
heavy shock loads. Desert Gold protects against
corrosion in extreme heat, in moist conditions, or
in dusty conditions. This product has excellent
characteristics of adhesion and of stability.
Desert Gold provides longer protection than other
greases. Desert Gold is an environmentally friendly
grease which does not contain the following
materials: antimony, sulfur, barium, zinc, lead,
and phosphorous materials. Normal operating
temperatures are 6 to 230 C (21 to 450 F). Desert
Gold can operate at higher temperatures for short
time periods. Desert Gold has additional extreme
pressure protection for highly loaded pin joints.
i01540432
SOS Oil Analysis

SMCS Code: 1348; 7542; 7581
Caterpillar recommends the use of the SOS
oil analysis program in order to monitor the
condition and the maintenance requirements of
the equipment. The SOS oil analysis program will
complement the preventive maintenance program.
The SOS oil analysis is a diagnostic tool that is
used to determine oil performance and component
wear rates. Contamination can be identified and
measured through the use of the SOS oil analysis.
The SOS oil analysis includes the following tests:
The Wear Rate Analysis monitors the wear of the

engines metals. The amount of wear metal and
type of wear metal that is in the oil is analyzed.
The increase in the rate of engine wear metal in
the oil is as important as the quantity of engine
wear metal in the oil. For this reason, regular
sampling at specified intervals is necessary
in order to establish wear rates. Intermittent
sampling does not allow wear rate trend lines
to be established. Engine wear metals in the oil
sample are compared to established Caterpillar
norms in order to determine acceptability.
Tests are conducted in order to detect

Arctic Platinum (CPG)
Arctic Platinum is a super-premium extreme
pressure lubricating grease that is developed for
lubrication in temperatures that are below zero to
moderate operating temperatures. Arctic Platinum
is available in grades 000, 00, 0, 1, and 2. These
grades ensure pumpability in central lube systems in
a variety of ambient temperatures from 60 to 18 C
(76 to 65 F). Arctic Platinum has a high dropping
point. Arctic Platinum contains a five percent
concentrate of molybdenum disulfide for protection
against extra heavy loads. Arctic Platinum provides
excellent corrosion protection and rust protection.
Arctic Platinum is an environmentally friendly grease
which does not contain the following materials:
antimony, sulfur, barium, zinc, and phosphorous.
Arctic Platinum is designed for long life lubrication
of the following components: horizontal pivot
bearings, lower link bearings, steering cylinders,
kingbolt bearings, upper hitch link bearings, and
ejector carrier roller bearings. This grease is extra
tacky for retention on excavator carbody bearings.
Arctic Platinum has additional extreme pressure
protection for highly loaded pin joints.
contamination of the oil by water, glycol or fuel.
The Oil Condition Analysis determines the loss

of the oils lubricating properties. An infrared
analysis is used to compare the properties of
new oil to the properties of the used oil sample.
This analysis allows technicians to determine
the amount of deterioration of the oil during use.
This analysis also allows technicians to verify
the performance of the oil according to the
specification during the entire oil change interval.
The test results of the oil samples will then be used
as a basis for determining the oil change interval
for the engine. The results of the SOS oil analysis
may allow the engine to operate longer between oil
changes without the risk of engine damage.
Table 11
SOS Oil Analysis Interval

Compartment
Interval
Engine crankcase
Every 250 Service Hours
Engine crankcase
Every 500 Service Hours
Consult your Caterpillar dealer for complete

information and assistance about the SOS oil
analysis program.
57
Maintenance Section
Fuel Specifications
Fuel Specifications
(Table 12, contd)
Caterpillar Specifications for Distillate Diesel Fuel

i01196007
Specifications
Fuel Recommendations
Requirements
10% at 282 C (540 F)
maximum
SMCS Code: 1250; 1280
Distillation
Diesel engines have the ability to burn a wide

variety of fuels. These fuels are divided into two
general groups. The two groups are called the
preferred fuels and the permissible fuels.
Flash Point
The preferred fuels provide maximum engine

service life and performance. The preferred fuels
are distillate fuels. These fuels are commonly called
diesel fuel, furnace fuel, gas oil, or kerosene.
ASTM
Test
D86
90% at 360 C (680 F)

maximum
legal limit
D93
30 minimum
D287
API Gravity
45 maximum
Pour Point
6 C (10 F) minimum

below ambient
temperature
D97
Diesel fuels that meet the specifications in Table 12

will help to provide maximum engine service life
and performance. In North America, diesel fuel that
is identified as No. 1-D or No. 2-D in ASTM D975
generally meet the specifications. Table 12 is for
diesel fuels that are distilled from crude oil. Diesel
fuels from other sources could exhibit detrimental
properties that are not defined or controlled by this
specification.
3% maximum
D3605
or
D1552
1.4 cSt minimum and 20.0

cSt maximum at 40 C
(104 F)
D445
Water and
Sediment
0.1% maximum
D1796
Water
0.1% maximum
D1744
Sediment
0.05% maximum (weight)
D473
Gums and
Resins (3)
10 mg per 100 mL
maximum
D381
3100 g minimum
The permissible fuels are crude oils or blended

fuels. Use of these fuels can result in higher
maintenance costs and in reduced engine service
life.
D6078
0.45 mm (0.018 inch)

maximum at 60 C
(140 F)
D6079
Sulfur
(1)
Kinematic
Viscosity (2)
Table 12
Caterpillar Specifications for Distillate Diesel Fuel

Specifications
Requirements
Lubricity
ASTM
Test
Aromatics
35% maximum
D1319
Ash

D524
40 minimum (DI engines)
D613
0.38 mm (0.015 inch)

maximum at 25 C (77 F)
D482
Carbon
Residue on
10% Bottoms
Cetane Number
(1)
(2)
35 minimum (PC engines)
Cloud Point
Copper Strip
Corrosion
The cloud point must

not exceed the lowest
expected ambient
temperature.
No. 3 maximum
(3)
D130
(continued)
(4)
(4)
Caterpillar fuel systems and engine components can

operate on high sulfur fuels. Fuel sulfur levels affect exhaust
emissions. High sulfur fuels also increase the potential for
corrosion of internal components. Fuel sulfur levels above 1.0
percent may significantly shorten the oil change interval. For
additional information, see this publication, Engine Oil topic
The values of the fuel viscosity are the values as the fuel
is delivered to the fuel injection pumps. If a fuel with a low
viscosity is used, cooling of the fuel may be required to maintain
a 1.4 cSt viscosity at the fuel injection pump. Fuels with a high
viscosity might require fuel heaters in order to bring down the
viscosity to a 20 cSt viscosity. For additional information, see
Special Publication, SEBD0717, Diesel Fuel and Your Engine.
Follow the test conditions and procedures for gasoline (motor).
The lubricity of a fuel is a concern with low sulfur fuel. To
determine the lubricity of the fuel, use either the ASTM D6078
Scuffing Load Wear Test (SBOCLE) or the ASTM D6079 High
Frequency Reciprocating Rig (HFRR) test. If the lubricity of a
fuel does not meet the minimum requirements, consult your
fuel supplier. Do not treat the fuel without consulting the fuel
supplier. Some additives are not compatible. These additives
can cause problems in the fuel system.
58
Maintenance Section
Fuel Specifications
NOTICE
Operating with fuels that do not meet Caterpillars recommendations can cause the following effects: starting difficulty, poor combustion, deposits in the fuel injectors, reduced service life of the fuel system, deposits in the combustion chamber, and reduced service life of the engine.
In the USA, 0.05 percent diesel fuels have been
used in all on-highway truck engines since 1
January 1994. This low sulfur diesel fuel was
mandated as a means of directly reducing
particulate emissions from diesel truck engines.
This low sulfur fuel will also be used in Caterpillar
commercial diesel engines when low emissions are
required or when the fuel supply sources provide
this type of fuel. Caterpillar has not seen any
detrimental effects with 0.05 percent sulfur fuel in
Caterpillar diesel engines.
NOTICE
Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel
must NOT be used in Caterpillar diesel engines (except in 3600 Series HFO engines). Severe component
wear and component failures will result if HFO type fuels are used in engines that are configured to use distillate fuel.
In extreme cold ambient conditions, you may
use the distillate fuels that are specified in Table
13. However, the fuel that is selected must meet
the requirements that are specified in Table 12.
These fuels are intended to be used in operating
temperatures that are down to 54 C (65 F).
Table 13
Distillate Fuels
(1)
Specification
MIL-T-5624R
JP-5
ASTM D1655
Jet-A-1
MIL-T-83133D
(1)
Grade
JP-8
The fuels that are listed in this Table may not meet the
requirements that are specified in the Caterpillar Specifications
for Distillate Diesel Fuel Table. Consult the supplier for the
recommended additives in order to maintain the proper fuel
lubricity.
These fuels are lighter than the No. 2 grades of fuel.

The cetane number of the fuels in Table 13 must be
at least 40. If the viscosity is below 1.4 cSt at 38 C
(100 F), use the fuel only in temperatures below
0 C (32 F). Do not use any fuels with a viscosity
of less than 1.2 cSt at 38 C (100 F). Fuel cooling
may be required in order to maintain the minimum
viscosity of 1.4 cSt at the fuel injection pump.
There are many other diesel fuel specifications that

are published by governments and by technological
societies. Usually, those specifications do not
review all the requirements that are addressed
in this specification. To ensure optimum engine
performance, a complete fuel analysis should be
obtained before engine operation. The fuel analysis
should include all of the properties that are listed
in Table 12.
59
Maintenance Section
Cooling System Specifications
Cooling System
Specifications
Many engine failures are related to the cooling

system. The following problems are related to
cooling system failures: overheating, leakage of the
water pump, plugged radiators or heat exchangers,
and pitting of the cylinder liners.
i01646523
General Coolant Information

SMCS Code: 1350; 1395
NOTICE
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first.
NOTICE
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temperature or drained completely to prevent damage.
NOTICE
Frequently check the specific gravity of the coolant for
proper freeze protection or for anti-boil protection.
Clean the cooling system for the following reasons:
Contamination of the cooling system

Overheating of the engine
Foaming of the coolant
Note: Air pockets can form in the cooling system if
the cooling system is filled at a rate that is greater
than 20 L (5 US gal) per minute.
After you drain the cooling system and after you
refill the cooling system, operate the engine.
Operate the engine without the filler cap until the
coolant reaches normal operating temperature and
the coolant level stabilizes. Ensure that the coolant
is maintained to the proper level.
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system problems can develop without water temperature regulators.
Refer to Special Instruction, SEBD0518, Know
Your Cooling System and Special Instruction,
SEBD0970, Coolant and Your Engine for more
detailed information.
These failures can be avoided with proper cooling

system maintenance. Cooling system maintenance
is as important as maintenance of the fuel system
and the lubrication system. Quality of the coolant
is as important as the quality of the fuel and the
lubricating oil.
Coolant is normally composed of three elements:
water, additives, and glycol.
Water
NOTICE
All Caterpillar diesel engines equipped with air-to-air
aftercooling (ATAAC) require a minimum of 30 percent
glycol to prevent water pump cavitation.
NOTICE
Never use water alone without Supplemental Coolant
Additives (SCA) or without inhibited coolant. Water
alone is corrosive at engine operating temperatures.
Water alone does not provide adequate protection
against boiling or freezing.
Water is used in the cooling system in order to
transfer heat.
Distilled water or deionized water is
recommended for use in engine cooling systems.
DO NOT use the following types of water in cooling
systems: hard water, softened water that has been
conditioned with salt, and sea water.
If distilled water or deionized water is not available,
use water with the properties that are listed in Table
14.
60
Maintenance Section
Formation of gel compounds
Table 14
Caterpillar Minimum Acceptable Water Requirements
Reduction of heat transfer
Property
Maximum Limit
ASTM Test
Chloride (Cl)
40 mg/L
(2.4 grains/US gal)
D512,
D4327
Sulfate (SO4)
100 mg/L
(5.9 grains/US gal)
D516
Total Hardness
170 mg/L
(10 grains/US gal)
D1126
Glycol
Total Solids
340 mg/L
(20 grain/US gal)
D1888
Glycol in the coolant helps to provide protection

against the following conditions:
Acidity
pH of 5.5 to 9.0
D1293
Boiling
For a water analysis, consult one of the following

sources:
Caterpillar dealer
Local water utility company
Agricultural agent
Independent laboratory
Additives
Additives help to protect the metal surfaces of
the cooling system. A lack of coolant additives
or insufficient amounts of additives enable the
following conditions to occur:
Leakage of the water pump seal

Plugging of radiators, coolers, and small
passages
Freezing
For optimum performance, Caterpillar recommends
a 1:1 mixture of a water/glycol solution.
Note: Use a mixture that will provide protection
against the lowest ambient temperature.
Note: 100 percent pure glycol will freeze at a
temperature of 23 C (9 F).
Most conventional heavy-duty coolant/antifreezes
use ethylene glycol. Propylene glycol may also be
used. In a 1:1 mixture with water, ethylene and
propylene glycol provide similar protection against
freezing and boiling. See Tables 15 and 16.
Table 15
Ethylene Glycol
Corrosion
Rust
Concentration
Freeze
Protection
Boil
Protection
50 Percent
36 C (33 F)
106 C (223 F)
60 Percent
Formation of mineral deposits
51 C (60 F)
111 C (232 F)
Scale
Pitting and erosion from cavitation of the cylinder
liner

Many additives are depleted during engine
operation. These additives must be replaced
periodically. This can be done by adding
Supplemental Coolant Additives (SCA) to Diesel
Engine Antifreeze/Coolant (DEAC) or by adding
ELC Extender to Extended Life Coolant (ELC).
Additives must be added at the proper
concentration. Overconcentration of additives can
cause the inhibitors to drop out-of-solution. The
deposits can enable the following problems to
occur:
NOTICE
Do not use propylene glycol in concentrations that exceed 50 percent glycol because of propylene glycols
reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against
boiling or freezing.
61
Maintenance Section
Table 16
Propylene Glycol
Concentration
Freeze
Protection
Boil
Protection
50 Percent
29 C (20 F)
NOTICE
106 C (223 F)

Table 17
To check the concentration of glycol, use the

1U-7298 Coolant/Battery Tester (Degree Celsius)
or use the 1U-7297 Coolant/Battery Tester (Degree
Fahrenheit). The testers give readings that are
immediate and accurate. The testers can be used
with ethylene or propylene glycol.
Coolant Service Life
Coolant Recommendations
SMCS Code: 1350; 1395
The following two coolants are used in Caterpillar
diesel engines:
Preferred Caterpillar Extended Life Coolant (ELC)
or a commercial extended life coolant that meets
the Caterpillar EC-1 specification
Acceptable A Caterpillar Diesel Engine
Antifreeze/Coolant (DEAC) or a commercial
heavy-duty coolant/antifreeze that meets ASTM
D4985 or ASTM D5345 specifications
Service Life
Caterpillar ELC
6000 Service Hours or

Six Years
Caterpillar DEAC
i01096597
Coolant Type

Three Years
Commercial Heavy-Duty
Coolant/Antifreeze that
meets ASTM D5345

Two Years
Coolant/Antifreeze that
meets ASTM D4985

One Year
Caterpillar SCA and

Water

Two Years
Commercial SCA and

Water

One Year
i01200209
SOS Coolant Analysis

SMCS Code: 1352; 1395; 7542
NOTICE
Do not use a commercial coolant/antifreeze that only
meets the ASTM D3306 or D4656 specification. This
type of coolant/antifreeze is made for light duty automotive applications.
Caterpillar recommends a 1:1 mixture of water
and glycol. This mixture of water and glycol will
provide optimum heavy-duty performance as a
coolant/antifreeze.
Note: Caterpillar DEAC DOES NOT require a
treatment with an SCA at the initial fill. Commercial
heavy-duty coolant/antifreeze that meets ASTM
D4985 or ASTM D5345 specifications MAY
require a treatment with an SCA at the initial fill.
Read the label or the instructions that are provided
by the OEM of the product.
In stationary engine applications and marine engine
applications that do not require anti-boil protection
or freeze protection, a mixture of SCA and water is
acceptable. Caterpillar recommends a six percent
to eight percent concentration of SCA in those
cooling systems. Distilled water or deionized water
is preferred. Water which has the recommended
properties may be used.
Testing the engine coolant is important to ensure

that the engine is protected from internal cavitation
and from corrosion. The analysis also tests the
ability of the coolant to protect the engine from
boiling and from freezing. The SOS Coolant
Analysis can be done at your Caterpillar dealer.
Caterpillar SOS Coolant Analysis is the best
way to monitor the condition of your coolant and
your cooling system. SOS Coolant Analysis is a
program that is based on periodic samples.
NOTICE
Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant
samples.
A small residue of either type sample may remain in
the pump and may cause a false positive analysis for
the sample being taken.
Always use a designated pump for oil sampling and a
designated pump for coolant sampling.
Failure to do so may cause a false analysis which
could lead to customer and dealer concerns.
62
Maintenance Section
New Systems, Refilled Systems,

and Converted Systems
Perform a coolant analysis (Level 2) at 500 service
hours for new systems, for refilled systems, or for
converted systems that use ELC or use DEAC. This
500 hour check will also check for any residual
cleaner that may have contaminated the system.
Recommended Interval for SOS

Coolant Sample
Perform a coolant analysis (Level 1) at every 500
service hour interval. Perform a coolant analysis
(Level 2) annually.
Note: Check the standard coolants Supplemental
Coolant Additive at every oil change.
Identification of buildup of the impurities that

cause corrosion
Identification of buildup of the impurities that

cause scaling
Determination of possible electrolysis within the

engines cooling system
The results are reported, and appropriate
recommendations are made.
For more information on SOS Coolant Analysis,
consult your Caterpillar dealer.
i01096605
Extended Life Coolant (ELC)

SMCS Code: 1350; 1395
SOS Coolant Analysis (Level 1)

A coolant analysis (Level 1) is a test of the
properties of the coolant.
The following properties of the coolant are tested:
Glycol Concentration for freeze protection

Ability to protect from erosion and corrosion
pH
Conductivity
Water hardness
Visual analysis
Odor analysis
The results are reported, and appropriate
recommendations are made.

Level 2 coolant analysis is a comprehensive
chemical evaluation of the coolant. This analysis is
also a check of the overall condition of the inside of
the cooling system.
The SOS Coolant Analysis has the following five
features:
Full analysis of Level 1
Caterpillar provides Extended Life Coolant (ELC) for

use in the following applications:
Heavy-duty spark ignited gas engines

Heavy-duty diesel engines
Automotive applications
The anti-corrosion package for Caterpillar ELC is
different from the anti-corrosion package for other
coolants. Caterpillar ELC is an ethylene glycol
base coolant. However, Caterpillar ELC contains
organic corrosion inhibitors and antifoam agents
with low amounts of nitrite. Caterpillar ELC has
been formulated with the correct amount of these
additives in order to provide superior corrosion
protection for all metals in engine cooling systems.
ELC extends the service life of the coolant to 6000
service hours or six years. ELC does not require
a frequent addition of a Supplemental Coolant
Additive (SCA). An Extender is the only additional
maintenance that is needed at 3000 service hours
or one half of the ELC service life.
ELC is available in a 1:1 premixed cooling solution
with distilled water. The Premixed ELC provides
freeze protection to 36 C (33 F). The Premixed
ELC is recommended for the initial fill of the cooling
system. The Premixed ELC is also recommended
for topping off the cooling system.
ELC Concentrate is also available. ELC Concentrate
can be used to lower the freezing point to 51 C
(60 F) for arctic conditions.
Identification of the source of metal corrosion and

of contaminants
Containers of several sizes are available. Consult

your Caterpillar dealer for the part numbers.
63
Maintenance Section
Note: Caterpillar developed the EC-1 specification.

The EC-1 specification is an industry standard. The
EC-1 specification defines all of the performance
requirements that are needed for an engine coolant
to be sold as an extended life coolant for Caterpillar
engines. ELC can be used in most OEM engines of
the following types: diesel, gasoline, and natural
gas. ELC meets the performance requirements of
ASTM D4985 and ASTM D5345 for heavy-duty
low silicate antifreeze/coolants. ELC also meets the
performance requirements of ASTM D3306 and
ASTM D4656 for automotive applications.
Caterpillar ELC Extender

Caterpillar ELC Extender is added to the cooling
system halfway through the ELC service life. Treat
the cooling system with ELC Extender at 3000 hours
or one half of the coolant service life. Use Table 18
in order to determine the proper amount of ELC
Extender that is required.
Table 18
Caterpillar ELC Extender Additions by

Cooling System Capacity
i01111712
Extended Life Coolant (ELC)

Cooling System Maintenance
Proper additions to the Extended
Life Coolant
NOTICE
Use only Caterpillar products or commercial products
that have passed Caterpillars EC-1 specification for
pre-mixed or concentrated coolants.
Use only Caterpillar Extender with Extended Life
Coolant.
Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. Failure to
follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed.
In order to maintain the correct balance between
the antifreeze and the additives, you must maintain
the recommended concentration of Extended Life
Coolant (ELC). Lowering the proportion of antifreeze
lowers the proportion of additive. This will lower
the ability of the coolant to protect the system from
pitting, from cavitation, from erosion, and from
deposits.
NOTICE
Do not use a conventional coolant to top-off a cooling
system that is filled with Extended Life Coolant (ELC).
Do not use standard supplemental coolant additive
(SCA). Only use ELC Extender in cooling systems that
are filled with ELC.
Addition of ELC
Extender
22 to 30 L (6 to 8 US gal)
0.57 L (20 fl oz)
31 to 38 L (9 to 10 US gal)
0.71 L (24 fl oz)
39 to 49 L (11 to 13 US gal)
0.95 L (32 fl oz)
50 to 64 L (14 to 17 US gal)
1.18 L (40 fl oz)
65 to 83 L (18 to 22 US gal)
SMCS Code: 1350; 1352; 1395
Cooling System Capacity
1.60 L (54 fl oz)
84 to 114 L (23 to 30 US gal)
2.15 L (72 fl oz)
115 to 163 L (31 to 43 US gal)
3.00 L (100 fl oz)
164 to 242 L (44 to 64 US gal)
4.40 L (148 fl oz)
For cooling system capacities that exceed the

capacities that are specified in Table 18, use the
equation that is in Table 19 in order to determine
the proper amount of ELC Extender that is required.
Table 19
Equation For Adding ELC Extender To ELC

V 0.02 = X
V is the total volume of the cooling system.
X is the amount of ELC Extender that is required.
Table 20 is an example for using the equation that

is in Table 19.
Table 20
Example Of The Equation For Adding ELC

Extender To ELC
Total Volume
of the Cooling
System (V)
Multiplication
Factor
Amount of ELC
Extender that is
Required (X)
946 L
(250 US gal)
0.02
19 L
(5 US gal)
64
Maintenance Section
NOTICE
When using Caterpillar ELC, do not use standard
SCAs or SCA filters. To avoid SCA contamination of
an ELC system, remove the SCA filter base and plug
off or by-pass the coolant lines.
ELC Cooling System Cleaning
NOTICE
Do not leave an empty SCA filter on an ELC system.
The filter housing may corrode and leak causing an
engine failure.
Remove the SCA filter base and plug off or by-pass
the coolant lines.
Note: If the cooling system is already using ELC,

cleaning agents are not required to be used at
the specified coolant change interval. Cleaning
agents are only required if the system has been
contaminated by the addition of some other type of
coolant or by cooling system damage.
3. Remove the empty SCA filter and remove the

filter base. Plug the coolant lines or bypass the
coolant lines.
Clean water is the only cleaning agent that is

required when ELC is drained from the cooling
system.
5. Use Caterpillar cleaner to clean the system.

Follow the instruction on the label.
ELC can be recycled. The drained coolant mixture

can be distilled in order to remove the ethylene
glycol and the water. The ethylene glycol and the
water can be reused. Consult your Caterpillar dealer
for more information.
After the cooling system is drained and after the
cooling system is refilled, operate the engine while
the cooling system filler cap is removed. Operate
the engine until the coolant level reaches the normal
operating temperature and until the coolant level
stabilizes. As needed, add the coolant mixture in
order to fill the system to the proper level.
Changing to Caterpillar ELC

To change from heavy-duty coolant/antifreeze to the
Caterpillar ELC, perform the following steps:
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
1. Drain the coolant into a suitable container.
2. Dispose of the coolant according to local
regulations.
4. Flush the system with clean water in order to

remove any debris.
6. Drain the cleaner into a suitable container. Flush

the cooling system with clean water.
7. Fill the cooling system with clean water and
operate the engine until the engine is warmed to
49 to 66C (120 to 150F).
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal components.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear water. Continue to flush the system until all signs of the
cleaning agent are gone.
8. Drain the cooling system into a suitable container
and flush the cooling system with clean water.
Note: The cooling system cleaner must be
thoroughly flushed from the cooling system. Cooling
system cleaner that is left in the system will
contaminate the coolant. The cleaner may also
corrode the cooling system.
9. Repeat Steps 7 and 8 until the system is
completely clean.
10. Fill the cooling system with the Caterpillar
premixed ELC.
11. Attach the Special Publication, PEEP5027,
Label to the cooling system filler for the engine
in order to indicate the use of Caterpillar ELC.
65
Maintenance Section
ELC Cooling System

Contamination
NOTICE
Mixing ELC with other products reduces the effectiveness of the ELC and shortens the ELC service life.
Use only Caterpillar products or commercial products
that have passed the Caterpillar EC-1 specification for
premixed or concentrate coolants. Use only Caterpillar
ELC Extender with Caterpillar ELC. Failure to follow
these recommendations can result in shortened cooling system component life.
ELC cooling systems can withstand contamination
to a maximum of ten percent of conventional
heavy-duty coolant/antifreeze or SCA. If the
contamination exceeds ten percent of the total
system capacity, perform ONE of the following
procedures:
Drain the cooling system into a suitable container.
Dispose of the coolant according to local

regulations. Flush the system with clean water. Fill
the system with the Caterpillar ELC.
Drain a portion of the cooling system into a

suitable container according to local regulations.
Then, fill the cooling system with premixed ELC.
This should lower the contamination to less than
10 percent.
Maintain the system as a conventional Diesel

Engine Antifreeze/Coolant (DEAC). Treat the
system with an SCA. Change the coolant at the
interval that is recommended for the conventional
Diesel Engine Antifreeze/Coolant (DEAC).
i01111753
Diesel Engine Antifreeze/

Coolant (DEAC)
SMCS Code: 1350; 1395
Caterpillar recommends using Caterpillar
Diesel Engine Antifreeze/Coolant (DEAC) for
cooling systems that require a heavy-duty
coolant/antifreeze. Caterpillar DEAC is an alkaline
single-phase ethylene glycol type antifreeze that
contains corrosion inhibitors and antifoam agents.
Caterpillar DEAC is formulated with the correct
amount of Caterpillar Supplemental Coolant Additive
(SCA). Do no use SCA at the initial fill when DEAC
is used.
If concentrated DEAC is used, Caterpillar
recommends mixing the concentrate with distilled
water or with deionized water. If distilled water is
not available or deionized water is not available,
use water which has the required properties. For
the water properties, see this publication, General
Coolant Information topic (Maintenance Section).
i01069295
Supplemental Coolant Additive

(SCA)
SMCS Code: 1350; 1352; 1395
Commercial ELC
The use of SCA helps to prevent the following

conditions from occurring:
If Caterpillar ELC is not used, then select a

commercial ELC that meets the Caterpillar
specification of EC-1 and either the ASTM D5345
specification or the ASTM D4985 specification. Do
not use an extended life coolant that does not meet
the EC-1 specification. Follow the maintenance
guide for the coolant from the supplier of the
commercial ELC. Follow the Caterpillar guidelines
for the quality of water and the specified coolant
change interval.
Corrosion
Cavitation erosion of the cylinder liners
Caterpillar Diesel Engine Antifreeze/Coolant (DEAC)
is formulated with the correct level of Caterpillar
SCA. When the cooling system is initially filled with
DEAC, adding more SCA is not necessary until the
concentration of SCA has been depleted. To ensure
that the correct amount of SCA is in the cooling
system, the concentration of SCA must be tested
on a scheduled basis. Refer to the specific engines
Operation and Maintenance Manual, Maintenance
Interval Schedule.
66
Maintenance Section
Containers of SCA are available in several sizes.

Consult your Caterpillar dealer for the part numbers.
i01164588
Coolant/Antifreeze and SCA
SMCS Code: 1350; 1395
If Caterpillar DEAC is not used, select a
coolant/antifreeze with low silicate content for
heavy-duty applications that meets ASTM D5345
or ASTM D4985 specifications.
Note: When you are not using Caterpillar DEAC the
cooling system must be drained one time during
every year. The cooling system must be flushed at
this time as well.
NOTICE
Never use water alone without Supplemental Coolant
Additives (SCA) or without inhibited coolant. Water
alone is corrosive at engine operating temperatures.
Water alone does not provide adequate protection
against boiling or freezing.
Note: Premix the coolant solution in order to provide
protection to the lowest ambient temperature that
is expected.
Note: Pure undiluted antifreeze freezes at 23 C
(9 F).
In engine cooling systems that use water alone,
Caterpillar recommends the use of SCA. SCA helps
to prevent the following conditions from occurring:
Corrosion
When a heavy-duty coolant/antifreeze is used,
treat the cooling system with three to six
percent Caterpillar SCA by volume. For more
information, see this publication, Conventional
Coolant/Antifreeze Cooling System Maintenance
topic (Maintenance Section).

Cavitation erosion of the cylinder liner
If Caterpillar SCA is not used, select a commercial

SCA. The commercial SCA must provide a minimum
of 1200 mg/L or 1200 ppm (70 grains/US gal) of
nitrites in the final coolant mixture.
If Caterpillar SCA is not used, select a commercial

SCA. The commercial SCA must provide a minimum
of 2400 mg/L or 2400 ppm (140 grains/US gal) of
nitrites in the final coolant mixture.
Coolant/antifreeze that meets ASTM D5345 or

ASTM D4985 specifications MAY require treatment
with SCA at the initial fill. These coolants WILL
require treatment with SCA on a maintenance basis.
The quality of the water is a very important factor

in this type of cooling system. Distilled water
or deionized water is recommended for use in
cooling systems. If distilled water or deionized
water is not available, use water that meets the
minimum requirements that are listed in the table for
recommended water properties in this publication,
General Coolant Information topic (Maintenance
Section).
When concentrated coolant/antifreeze is mixed,

Caterpillar recommends mixing the concentrate with
distilled water or with deionized water. If distilled
water or deionized water is not available, water
which has the required properties may be used. For
the water properties, see this publication, General
Coolant Information topic (Maintenance Section).
i01318169
Water/Supplemental Coolant
Additive (SCA)
SMCS Code: 1350; 1352; 1395
NOTICE
A cooling system that uses a mixture of SCA

and water only needs more SCA than a cooling
system that uses a mixture of glycol and water. The
SCA concentration in a cooling system that uses
SCA and water should be six to eight percent by
volume. Refer to Table 21 for the amount of SCA
that is required for various capacities of the cooling
system.
67
Maintenance Section
Table 21
Caterpillar SCA Requirements for SCA and

Water Cooling Systems
Cooling System
Capacity
Caterpillar SCA
at Initial Fill
Caterpillar SCA
at 250 Hours
22 to 30 L
(6 to 8 US gal)
1.75 L (64 fl oz)
0.44 L (15 fl oz)
31 to 38 L
(9 to 10 US gal)
2.30 L (80 fl oz)
0.57 L (20 fl oz)
39 to 49 L
(11 to 13 US gal)
3.00 L (100 fl oz)
0.75 L (25 fl oz)
50 to 64 L
(14 to 17 US gal)
3.90 L (128 fl oz)

5.00 L (168 fl oz)
1.25 L (42 fl oz)
84 to 110 L
(23 to 29 US gal)
6.60 L (224 fl oz)
1.65 L (56 fl oz)
111 to 145 L
(30 to 38 US gal)
8.75 L (296 fl oz)
2.19 L (74 fl oz)
146 to 190 L
(39 to 50 US gal)
11.50 L
(392 fl oz)
2.88 L (98 fl oz)
191 to 250 L
(51 to 66 US gal)
15.00 L
(512 fl oz)
3.75 L (128 fl oz)
Adding the SCA to Water at the Initial Fill
0.95 L (32 fl oz)
65 to 83 L
(18 to 22 US gal)
Cooling Systems with Larger

Capacities
Use the equation that is in Table 23 to determine

the amount of Caterpillar SCA that is required at
the initial fill. This equation is for a mixture of only
SCA and water.
Table 23
Equation For Adding The SCA To Water

At The Initial Fill
V 0.07 = X
X is the amount of SCA that is required.

is in Table 23.
Table 24
Refer to Table 22 for part numbers and for quantities

of SCA.
Example Of The Equation For Adding The SCA

To Water At The Initial Fill
Total Volume
of the Cooling
System (V)
Multiplication
Factor
Amount of SCA
that is Required
(X)
946 L
(250 US gal)
0.07
66 L
(18 US gal)
Table 22
Caterpillar Liquid SCA

Part Number
Quantity
6V-3542
0.24 L (8 oz)
111-2372
0.36 L (12 oz)
8T-1589
0.47 L (16 oz)
3P-2044
0.94 L (32 oz)
8C-3680
19 L (5 US gal)
5P-2907
208 L (55 US gal)
Maintain the SCA in the same way as you would

maintain a cooling system that uses heavy-duty
coolant/antifreeze. Adjust the maintenance for the
amount of SCA additions. See Table 21 for the
amount of SCA that is required.
Adding the SCA to Water for Maintenance

For the recommended service interval, refer to the
Interval Schedule for your engine.
Use the 8T-5296 Coolant Conditioner Test Kit to
test the concentration of SCA. Make the following
modifications to Steps 3 and 5 of the 8T-5296
Coolant Conditioner Test Kit instructions:
STEP 3 Add tap water to the vial up to the 20
ml mark.
STEP 5 When the defined procedure is used,
a concentration of six to eight percent will yield
between 20 drops and 27 drops. If the number of
drops is below 20 drops, the concentration of SCA
is low. If the number of drops is above 27 drops, the
concentration of SCA is high. Make the appropriate
adjustments to the concentration of SCA.
Test the concentration of SCA or submit a
coolant sample to your Caterpillar dealer. See
this publication, SOS Coolant Analysis topic
68
Maintenance Section
Additions of SCA are based on the results of the

test or based on the results of the coolant analysis.
The size of the cooling system determines the
amount of SCA that is required.
the amount of Caterpillar SCA that is required for
maintenance, if necessary:
Table 25
SCA To Water Addition Equation For Maintenance

V 0.023 = X

is in Table 23.
Table 26
SCA To Water Addition Equation Example

For Maintenance
Total Volume
of the Cooling
System (V)
Multiplication
Factor
Amount of SCA
that is Required
(X)
946 L
(250 US gal)
0.023
22 L
(6 US gal)
Note: Specific engine applications may require

maintenance practices to be periodically evaluated
in order to properly maintain the engines cooling
system.
Table 22 lists part numbers and quantities of SCA
that is available from your Caterpillar dealer.
i01570193
Conventional Coolant/
Antifreeze Cooling System
Maintenance
SMCS Code: 1350; 1352; 1395
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system problems can develop without water temperature regulators.
Check the coolant/antifreeze (glycol concentration)

in order to ensure adequate protection against
boiling or freezing. Caterpillar recommends the
use of a refractometer for checking the glycol
concentration. Use the 1U-7298 Coolant/Battery
Tester (Degree Celsius) or use the 1U-7297
Coolant/Battery Tester (Degree Fahrenheit). The
testers give readings that are immediate and
accurate. The testers can be used with ethylene
or with propylene glycol.
Caterpillar engine cooling systems should be
tested at 250 hour intervals for the concentration of
Supplemental Coolant Additive (SCA). SCA test kits
are available from your Caterpillar dealer. Test the
concentration of SCA or submit a coolant sample to
your Caterpillar dealer at 250 hour intervals. Refer
to SOS Coolant Analysis for more information on
this topic.
An SCA that is liquid or a maintenance element for
an SCA (if equipped) may be needed at 250 hour
intervals.
Table 27 lists the amount of Caterpillar SCA
that is needed at the initial fill in order to treat
coolant/antifreeze. These amounts of SCA are for
systems that use heavy-duty coolant/antifreeze.
Table 27 also lists additions of SCA for liquid
and for maintenance elements at 250 hours. The
additions are required for Caterpillar DEAC and for
commercial coolant/antifreezes.
69
Maintenance Section
Table 27
Caterpillar SCA Requirements for Heavy-Duty Coolant/Antifreeze

Spin-on
Element at 250
Service Hour
Maintenance
(If Equipped)(3)
Cooling System
Capacity
22 to 30 L
(6 to 8 US gal)
111-2370 (1)
1.18 L (40 fl oz)
0.36 L (12 fl oz)
111-2369 (1)
1.42 L (48 fl oz)
0.36 L (12 fl oz)
111-2369 (1)
50 to 64 L
(14 to 17 US gal)
1.90 L (64 fl oz)
0.47 L (16 fl oz)
9N-3368 (1)
65 to 83 L
(18 to 22 US gal)
2.37 L (80 fl oz)
0.60 L (20 fl oz)
111-2371 (1)
84 to 114 L
(23 to 30 US gal)
3.32 L (112 fl oz)
0.95 L (32 fl oz)
9N-3718 (1)
115 to 163 L
(31 to 43 US gal)
4.75 L (160 fl oz)
1.18 L (40 fl oz)
111-2371 (2)
164 to 242 L
(44 to 64 US gal)
(3)
0.24 L (8 fl oz)
39 to 49 L
(11 to 13 US gal)
(2)
0.95 L (32 fl oz)
31 to 38 L
(9 to 10 US gal)
(1)
Initial Fill(1)
250 Service
Hour
Maintenance(2)
7.60 L (256 fl oz)
1.90 L (64 fl oz)
9N-3718 (2)
When the coolant system is first filled, the SCA is not required to be used with
Caterpillar DEAC.
Do not exceed the six percent maximum concentration. Check the concentration
of SCA with a SCA test kit.
Do not use the maintenance element for the SCA and the liquid for the SCA at the
same time.

system.
Refer to Table 28 for part numbers and for quantities
of SCA.
Table 28
Caterpillar Liquid SCA

Part Number
Quantity
6V-3542
0.24 L (8 oz)
111-2372
0.36 L (12 oz)
8T-1589
0.47 L (16 oz)
3P-2044
0.94 L (32 oz)
8C-3680
19 L (5 US gal)
5P-2907
208 L (55 US gal)
Cooling Systems with Larger

Capacities
Adding the SCA to Conventional
Coolant/Antifreeze at the Initial Fill
Note: Caterpillar DEAC DOES NOT require an
addition of SCA when the cooling system is initially
filled.
Commercial heavy-duty coolant/antifreeze
that meets ASTM D4985 or ASTM D5345
specifications MAY require an addition of SCA at
the initial fill. Read the label or the instructions that
are provided by the OEM of the product.
the amount of Caterpillar SCA that is required when
the cooling system is initially filled with the following
fluids:
ASTM D4985
ASTM D5345
70
Maintenance Section
Table 29
Table 32
Equation For Adding The SCA To Conventional

Coolant/Antifreeze At The Initial Fill
V 0.045 = X
Example Of The Equation For Adding The SCA To

Conventional Coolant/Antifreeze For Maintenance

is in Table 29.
Table 30
Example Of The Equation For Adding The SCA To

Conventional Coolant/Antifreeze At The Initial Fill
Total Volume
of the Cooling
System (V)
Multiplication
Factor
Amount of SCA
that is Required
(X)
946 L
(250 US gal)
0.045
43 L
(11 US gal)
Adding the SCA to Conventional

Coolant/Antifreeze For Maintenance
Heavy duty coolant/antifreeze of all types REQUIRE
periodic additions of an SCA.
Test the coolant/antifreeze periodically for the
concentration of SCA. For the interval, see the
Interval Schedule (Maintenance Section). SCA
test kits are available from your Caterpillar
dealer. Test the concentration of SCA or submit
a coolant sample to your Caterpillar dealer. See
this publication, SOS Coolant Analysis topic
The size of the cooling system determines the
amount of SCA that is needed.
the amount of Caterpillar SCA that is required, if
necessary:
Table 31
Equation For Adding The SCA To Conventional

Coolant/Antifreeze For Maintenance
V 0.014 = X

is in Table 31.
Multiplication
Factor
Amount of SCA
that is Required
(X)
946 L
(250 US gal)
Total Volume
of the Cooling
System (V)
0.014
9 L
(4 US gal)

system.
Table 28 lists part numbers and quantities of SCA
that is available from your Caterpillar dealer.
Cleaning the System of Heavy-Duty

Coolant/Antifreeze
Caterpillar cooling system cleaners are designed
to clean the cooling system of harmful scale and
corrosion. Caterpillar cooling system cleaners
dissolve mineral scale, corrosion products, light oil
contamination and sludge.
Clean the cooling system after used coolant is

drained or before the cooling system is filled with
new coolant.
Clean the cooling system whenever the coolant is
contaminated or whenever the coolant is foaming.
For the recommended service interval, refer
to the Operation and Maintenance Manual,

Maintenance Interval Schedule for your engine.
71
Maintenance Section
Refill Capacities
Refill Capacities
i01539748
Refill Capacities
SMCS Code: 1348; 1395; 7560
Lubrication System
The refill capacities for the engine crankcase
reflect the approximate capacity of the crankcase
or sump plus standard oil filters. Auxiliary oil filter
systems will require additional oil. Refer to the
OEM specifications for the capacity of the auxiliary
oil filter. Refer to the Operation and Maintenance
Manual, Lubricant Specifications (Maintenance
Section) for more information.
Table 33
C-9 Industrial Engine

Approximate Refill Capacities
Refill Capacity for
Changing the Oil
and the Filter
Liters
Oil
(1)
Quarts
31
Sump(1)
33
These values should be inserted by the customer as

approximate capacities for the crankcase oil sump which
include the standard oil filters that are installed at the factory.
Engines with auxiliary oil filters will require additional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil
filter.
Cooling System
To maintain the cooling system, the Total Cooling
System capacity must be known. The capacity of
the Total Cooling System will vary. The capacity
will depend on the size of the radiator (capacity)
that is provided by the vehicle manufacturer. Table
34 should be completed by the customer for the
maintenance of the cooling system. Refer to the
Operation and Maintenance Manual, Cooling
System Specifications (Maintenance Section) for
more information.
Table 34
C-9 Industrial Engine

Approximate Refill Capacities
Compartment or System
Total Cooling System
Liters
Quarts
72
Maintenance Section
Maintenance Interval Schedule
i01660955
Initial 500 Service Hours
Engine Valve Lash - Inspect/Adjust ...................... 97
SMCS Code: 1000; 7500
Every 6000 Service Hours or 6 Years
Operating conditions and oil API Classifications

will determine the amount of service hours for the
PM Level 1 Maintenance Interval Schedule. Refer
to Operation and Maintenance Manual, Engine Oil
and Filter - Change for your specific oil change
interval.
Cooling System Coolant (ELC) - Change ............. 82
Note: Ensure that the Safety Information, warnings,

and instructions are read and understood
before operation or maintenance procedures are
performed.
Note: Use fuel consumption, service hours, or
calendar time, whichever occurs first in order to
determine the maintenance intervals. Engines that
operate in severe operating conditions may require
more frequent maintenance.
Before each consecutive interval is performed, all
of the maintenance requirements from the previous
interval must also be performed.
When Required
Battery - Replace .................................................. 76
Battery or Battery Cable - Disconnect .................. 77
Engine Air Cleaner Element (Dual Element) Clean/Replace .................................................... 88
Engine Storage Procedure - Check ...................... 97
Ether Starting Aid Cylinder - Replace ................... 98
Fuel System - Prime ............................................. 98
Severe Service Application - Check .................... 107
Daily
Air Tank Moisture and Sediment - Drain ............... 76
Cooling System Coolant Level - Check ................ 84
Driven Equipment - Check .................................... 87
Engine Air Cleaner Service Indicator - Inspect ..... 90
Engine Oil Level - Check ...................................... 92
Fuel System Primary Filter/Water Separator Drain ................................................................... 99
Power Take-Off Clutch - Check/Adjust/
Lubricate ........................................................... 106
Walk-Around Inspection ...................................... 109
Initial 20 to 40 Service Hours

Belt - Inspect ......................................................... 78
Every Week
Battery Charger - Check ....................................... 78
Jacket Water Heater - Check .............................. 103
PM Level 1 - Every 10 400 L (2750 US gal) of

Fuel or 250 Service Hours or 6 Months
Air Compressor Filter - Clean/Replace ................. 75
Battery Electrolyte Level - Check .......................... 77
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 85
Engine Oil Sample - Obtain .................................. 92
Engine Oil and Filter - Change ............................. 93
Fan Drive Bearing - Lubricate ............................... 98
Fuel System Primary Filter/Water Separator Element
- Replace ........................................................... 100
Fuel System Secondary Filter - Replace ............ 101
Fuel Tank Water and Sediment - Drain ............... 102
Hoses and Clamps - Inspect/Replace ................ 102
Radiator - Clean .................................................. 107
PM Level 1 - Every 20 800 L (5500 US gal) of

Fuel or 500 Service Hours or 6 Months
Air Compressor Filter - Clean/Replace ................. 75
(SCA) - Test/Add ................................................. 85
Engine Oil Sample - Obtain .................................. 92
Engine Oil and Filter - Change ............................. 93
Fan Drive Bearing - Lubricate ............................... 98
- Replace ........................................................... 100
Fuel System Secondary Filter - Replace ............ 101
Fuel Tank Water and Sediment - Drain ............... 102
Hoses and Clamps - Inspect/Replace ................ 102
Radiator - Clean .................................................. 107
PM Level 2 - Every 83 250 L (22 000 US gal)

of Fuel or 2000 Service Hours or 1 Year
Aftercooler Core - Inspect .....................................
Alternator - Inspect ...............................................
Engine Crankcase Breather - Clean .....................
Engine Valve Lash - Inspect/Adjust ......................
Engine Valve Rotators - Inspect ............................
74
76
91
97
97
PM Level 3 - Every 166 500 L (44 000 US gal)

of Fuel or 4000 Service Hours or 2 Years
Aftercooler Core - Clean/Test ...............................
Air Compressor - Inspect ......................................
Belt Tensioner - Inspect ........................................
Cooling System Coolant (DEAC) - Change ..........
Cooling System Coolant Extender (ELC) - Add ....
Cooling System Water Temperature Regulator Replace ...............................................................
Crankshaft Vibration Damper - Inspect .................
74
75
80
80
84
86
86
73
Maintenance Section
Engine - Clean ...................................................... 87

Engine Mounts - Inspect ....................................... 91
Every 340 000 L (90 000 US gal) of Fuel or

10 000 Service Hours
Cylinder Head Grounding Stud - Inspect/Clean/
Tighten ................................................................ 87
Overhaul Considerations .................................... 103
Every 208 000 L (55 000 US gal) of Fuel or

5000 Service Hours
Starting Motor - Inspect ...................................... 108
Turbocharger - Inspect ........................................ 108
Water Pump - Inspect ......................................... 110
74
Maintenance Section
Aftercooler Core - Clean/Test
i01546702
Aftercooler Core - Clean/Test

SMCS Code: 1064-070; 1064-081
1. Remove the core. Refer to the Service Manual
for the procedure.
2. Turn the aftercooler core upside-down in order
to remove debris.
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
cleaner.
7. Inspect the core in order to ensure cleanliness.

Pressure test the core. Many shops that service
radiators are equipped to perform pressure tests.
If necessary, repair the core.
8. Install the core. Refer to the Service Manual for
the procedure.
For more information on cleaning the core, consult
your Caterpillar dealer.
i01468985
Aftercooler Core - Inspect

SMCS Code: 1064-040
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 35 lists Hydrosolv liquid
cleaners that are available from your Caterpillar
dealer.
Inspect the aftercooler for these items: damaged

fins, corrosion, dirt, grease, insects, leaves, oil, and
other debris. Clean the aftercooler, if necessary.
For air-to-air aftercoolers, use the same methods
that are used for cleaning radiators.
Table 35
Hydrosolv Liquid Cleaners(1)

Part
Number
Description
1U-5490
Hydrosolv 4165
19 L (5 US gallon)
174-6854
Hydrosolv 100
19 L (5 US gallon)
(1)
Size
Use a two to five percent concentration of the cleaner

at temperatures up to 93C (200F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more
information.
4. Steam clean the core in order to remove any

residue. Flush the fins of the aftercooler core.
Remove any other trapped debris.
5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
6. Dry the core with compressed air. Direct the air
in the reverse direction of the normal flow.

Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
of the fans air flow. Hold the nozzle approximately
6 mm (.25 inch) away from the fins. Slowly move
the air nozzle in a direction that is parallel with the
tubes. This will remove debris that is between the
tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
75
Maintenance Section
Air Compressor - Inspect
After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
Inspect the fins for damage. Bent fins may be
opened with a comb.
Note: If parts of the aftercooler system are repaired
or replaced, a leak test is highly recommended.
The FT1984 Aftercooler Testing Group is used
to perform leak tests on the aftercooler. Refer to
the Systems Operation/Testing and Adjusting,
Aftercooler - Test and the Special Instruction,
SEHS8622 for the proper testing procedure.
Inspect these items for good condition: welds,
mounting brackets, air lines, connections, clamps,
and seals. Make repairs, if necessary.
For more detailed information on cleaning and
inspection, see Special Publication, SEBD0518,
Know Your Cooling System.
i01183385
Air Compressor - Inspect
If the air compressor pressure relief valve that is

mounted in the air compressor cylinder head is
bypassing compressed air, there is a malfunction
in the air system, possibly ice blockage. Under
these conditions, your engine may have insufficient air for normal brake operation.
Do not operate the engine until the reason for the
air bypass is identified and corrected. Failure to
heed this warning could lead to property damage,
personal injury, or death to the operator or bystanders.
The function of the air compressor pressure relief
valve is to bypass air when there is a malfunction in
the air compressor system.
The air compressor pressure relief valve releases
air at 1723 kPa (250 psi). It is very important that
all personnel stand clear of the air compressor
pressure relief valve when compressed air is
released. All personnel should also stay clear of the
air compressor when the engine is operating and
the air compressor is exposed.
Refer to the Service Manual or refer to the OEM
specifications in order to find information concerning
the air compressor. Consult your Caterpillar dealer
for assistance.
SMCS Code: 1803-040
i01544231
Do not disconnect the air line from the air compressor governor without purging the air brake
and the auxiliary air systems. Failure to purge the
air brake and the auxiliary air systems before removing the air compressor and/or the air lines
could cause personal injury.
Air Compressor Filter Clean/Replace

(If Equipped)
SMCS Code: 1803-070-FQ; 1803-510-FQ
One of the single most important aspects of
preventive maintenance for the air compressor is
the induction of clean air. The type of maintenance
that is required for the air compressor and the
maintenance interval depends on the type of air
induction system that is used. Operating conditions
(dust, dirt and debris) may require more frequent
service.
Illustration 31
(1) Air compressor pressure relief valve
g00633741
Refer to the Service Manual for the type of

air compressor that is installed on the engine.
Follow the maintenance recommendations that are
provided by the OEM of the air compressor. Some
engines use boost air pressure so the engine air
cleaner will require servicing.
76
Maintenance Section
Air Tank Moisture and Sediment - Drain
i00847451
Air Tank Moisture and

Sediment - Drain
(If Equipped)
SMCS Code: 1466-543-M&S
Moisture and sediment in the air starting system
can cause the following conditions:
Freezing
Check the alternator and the battery charger for

proper operation. If the batteries are properly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time
or if the engine is run for short periods, the batteries
may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
Corrosion of internal parts
i01492550
Battery - Replace
Malfunction of the air starting system
SMCS Code: 1401-510

When opening the drain valve, wear protective
gloves, a protective face shield, protective clothing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal
injury.
1. Open the drain valve that is on the bottom of
the air tank. Allow the moisture and sediment
to drain.
2. Close the drain valve.
3. Check the air supply pressure. The air starting
motor requires a minimum of 620 kPa (90 psi) of
air pressure to operate properly. The maximum
air pressure must not exceed 1550 kPa (225 psi).
The normal air pressure will be 758 to 965 kPa
(110 to 140 psi).
i00072207
Alternator - Inspect
Batteries give off combustible gases which can

explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
The battery cables or the batteries should not be

removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
SMCS Code: 1405-040

Caterpillar recommends a scheduled inspection
of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect
the ammeter (if equipped) during engine operation
in order to ensure proper battery performance
and/or proper performance of the electrical system.
Make repairs, as required. Refer to the Service
Manual.
1. Turn the key start switch to the OFF position.

Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the
charger.
3. The NEGATIVE - cable connects the NEGATIVE
- battery terminal to the ground plane.
Disconnect the cable from the NEGATIVE -
battery terminal.
4. The POSITIVE + cable connects the POSITIVE
+ battery terminal to the starting motor.
Disconnect the cable from the POSITIVE +
battery terminal.
77
Maintenance Section
Battery Electrolyte Level - Check
Note: Always recycle a battery. Never discard a

battery. Return used batteries to an appropriate
recycling facility.
A mixture of 0.1 L (0.11 qt) of ammonia and

1 L (1 qt) of clean water
Thoroughly rinse the battery case with clean
water.
5. Remove the used battery.

6. Install the new battery.
Note: Before the cables are connected, ensure that
the key start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE + battery terminal.
Use a fine grade of sandpaper to clean the

terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit
properly. Coat the clamps and the terminals with
5N-5561 Silicone Lubricant, petroleum jelly or
MPGM grease.
8. Connect the cable from the ground plane to the

NEGATIVE - battery terminal.
i01492654
i01639002
Battery Electrolyte Level Check
Battery or Battery Cable Disconnect

SMCS Code: 1402-029
SMCS Code: 1401-535

When the engine is not run for long periods of
time or when the engine is run for short periods,
the batteries may not fully recharge. Ensure a full
charge in order to help prevent the battery from
freezing. If batteries are properly charged, ammeter
reading should be very near zero.
The battery cables or the batteries should not be

removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.
All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
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.
1. Remove the filler caps. Maintain the electrolyte

level to the FULL mark on the battery.
2. Disconnect the negative battery terminal at the

battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side
of two batteries must be disconnected.
If the addition of water is necessary, use distilled

water. If distilled water is not available use
clean water that is low in minerals. Do not use
artificially softened water.
2. Check the condition of the electrolyte with the
1U-7298 Coolant/Battery Tester (C) or the
1U-7297 Coolant/Battery Tester (F).
3. Keep the batteries clean.
Clean the battery case with one of the following
cleaning solutions:
A mixture of 0.1 kg (0.2 lb) of baking soda and

1 L (1 qt) of clean water
Removing the battery cables or the batteries with

the cover in place may cause a battery explosion
resulting in personal injury.
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.
78
Maintenance Section
Battery Charger - Check
i01039758
Battery Charger - Check

SMCS Code: 1401-535
Checking Before Start-Up

Check the battery charger for proper operation. If
the batteries are properly charged, the needle of
the ammeter will register near 0 (zero).
The battery charger must not produce excessive
current during start-up. Alternatively, the charger
must be automatically disconnected for start-up.
If the engine has an alternator, the charger must
be automatically disconnected during start-up and
during engine operation.
Charging the Battery
The battery emits smoke or a dense vapor (gas).

Perform one of the following procedures if the
battery shows symptoms of overcharging:
Reduce the rate of charging by a significant
amount. Complete the charging at the reduced

rate.
Turn OFF the charger.

Table 36 describes the effects of overcharging on
different types of batteries.
Table 36
Effects of Overcharging Batteries

Type of Battery
Effect
Caterpillar General Service

Batteries
Caterpillar Premium High
Output Batteries
All of the battery cells have

a low level of electrolyte.
Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result.
When the plates of the

battery are inspected
through the filler holes, the
plates may appear to be
warped. This is caused by
an excessive temperature.
The battery may not pass
a load test.
Perform the following procedure to charge the

battery:
1. Ensure that the charger is turned OFF.
Caterpillar Maintenance
Free Batteries
The battery may not pass

a load test.
2. Adjust the voltage of the charger in order to

match the voltage of the battery.
3. Connect the POSITIVE + lead of the charger
to the POSITIVE + battery terminal. Connect
the NEGATIVE - lead of the charger to the
NEGATIVE - battery terminal.
4. Turn ON the battery charger.
Checking After Stopping

Ensure that the battery charger is connected
properly. Observe the meter of the charger. Record
the amperage.
Overcharging of Batteries
Overcharging reduces the service life of batteries.
Use a battery charger that will not overcharge the
battery. DO NOT charge the battery if the meter of
the battery charger is in the RED zone.
Overcharging is indicated by the following
symptoms:
The battery is very warm to the touch.

A strong odor of acid is present.
The battery may not accept

a charging current.
i01539754
Belt - Inspect
SMCS Code: 1357-040; 1357; 1397-040; 1397
Inspection
Belt tension should be checked initially between
the first 20 to 40 hours of engine operation.
After the initial check, the belt tension should be
checked at every oil change.
79
Maintenance Section
Belt - Inspect
To maximize the engine performance, inspect the

belts for wear and for cracking. Replace belts that
are worn or damaged.
Adjustment
Alternator Belt
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.
Remove the belt guard, if equipped. Inspect the
condition and adjustment of the alternator belts and
accessory drive belts (if equipped).
To check the belt tension, apply 110 N (25 lb ft)
of force midway between the pulleys. A correctly
adjusted belt will deflect 9 mm (0.35 inch) to 15 mm
(0.59 inch).
If the belt does not require replacement or
adjustment, install the belt guard. If the belt requires
adjustment or replacement, perform the following
procedure to adjust the belt tension.
Illustration 32
(1)
(2)
(3)
(4)
g00768640
Nut
Adjusting Nut
Bolt
Nut
1. Slightly loosen mounting bolt (3) and nut (4).

2. Loosen nut (1).
3. Tighten adjusting bolt (2) and mounting bolts
(3) and (4). Tighten bolt (1). Refer to the
Operation and Maintenance Manual, Torque
Specifications topic (Maintenance Section).
If new belts are installed, check the belt tension
again after 30 minutes of engine operation at the
rated rpm.
80
Maintenance Section
Belt Tensioner - Inspect
Water Pump Belt
i01555583
Belt Tensioner - Inspect

(If Equipped)
SMCS Code: 1358-040
Illustration 33
g00426869
Typical example
Exploded view of the drive assembly for a water pump belt
(1) Mounting bolt
(2) Square hole
(3) Adjusting bolt
Illustration 34
g00426964
Belt tensioner
1. Slightly loosen mounting bolt (1) and adjusting

bolt (3).
2. Adjust the belt tension with a square drive in
square hole (2).
3. Tighten adjusting bolt (3) and mounting bolt (1).
Torque Specifications topic (Maintenance
Section).
4. Install the belt guard, if equipped.
If new belts are installed, check the belt tension after
30 minutes of engine operation at the rated rpm.
Inspect the belt tensioner for unusual noise,

excessive looseness and/or shaking of the bearings.
If the belt tensioner should require disassembly,
refer to the Service Manual for the procedure.
i01206425
Cooling System Coolant

(DEAC) - Change
SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
The engine overheats frequently.

Foaming is observed.
The oil has entered the cooling system and the
coolant is contaminated.
The fuel has entered the cooling system and the

NOTICE
Use of commercially available cooling system cleaners may cause damage to cooling system components. Use only cooling system cleaners that are approved for Caterpillar engines.
81
Maintenance Section
Cooling System Coolant (DEAC) - Change
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.
3. Fill the cooling system with a mixture of clean

water and Caterpillar Fast Acting Cooling System
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.
Drain
4. Start and run the engine at low idle for a

minimum of 30 minutes. The coolant temperature
should be at least 82 C (180 F).
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap.
2. Open the cooling system drain valve (if
equipped). If the cooling system is not equipped
with a drain valve, remove one of the drain plugs.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology
Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
1. Flush the cooling system with clean water in
order to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the
Specifications topic (Maintenance Section) for
more information on the proper torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
NOTICE
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system
drain plugs. Allow the water to drain. Flush the
cooling system with clean water. Close the drain
valve (if equipped). Clean the drain plugs. Install
the drain plugs. Refer to the Operation and
Maintenance Manual, Torque Specifications
topic (Maintenance Section) for more information
on the proper torques.
Cooling Systems with Heavy

Deposits or Plugging
Note: For the following procedure to be effective,
there must be some active flow through the cooling
system components.
NOTICE
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the cooling system filler cap.
82
Maintenance Section
Cooling System Coolant (ELC) - Change
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).
NOTICE
Fill
NOTICE
4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, perform a pressure test. A
9S-8140 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 cooling system filler cap. If the cooling
system filler cap does not retain the correct
pressure, install a new cooling system filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i01206445
Cooling System Coolant (ELC)

- Change
SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
The engine overheats frequently.

Foaming is observed.
The oil has entered the cooling system and the
1. Fill the cooling system with coolant/antifreeze.

Refer to the Operation and Maintenance
Manual, Cooling System Specifications topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant
level 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 glass (if equipped).
The fuel has entered the cooling system and the

Note: When the cooling system is cleaned, only

clean water is needed when the ELC is drained
and replaced.
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
83
Maintenance Section
Cooling System Coolant (ELC) - Change

2. Open the cooling system drain valve (if
equipped). If the cooling system is not equipped
with a drain valve, remove the cooling system
drain plugs.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Service Technology
Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
NOTICE
3. Fill the cooling system with clean water. Install
the cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 C (120 to 150 F).

Fill
NOTICE
1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to the Operation and Maintenance
Manual, Cooling System Specifications topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
2. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant
level 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 glass (if equipped).
gasket that is on the cooling system filler cap. If
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
is not damaged, use a 9S-8140 Pressurizing
Pump in order to pressure test the cooling
system filler cap. 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.
leaks and for proper operating temperature.
84
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i00259474
Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352-045; 1395-081
Caterpillar Extended Life Coolant (ELC) does not
require the frequent Supplemental Coolant Additive
(SCA) additions associated with the present
conventional coolants. The Extender only needs to
be added once.
Check the cooling system only when the engine is
stopped and cool.
Illustration 35
g00285520
1. Loosen the cooling system filler cap slowly in

order to relieve pressure. Remove the cooling
system filler cap.
Cooling system filler cap
2. It may be necessary to drain enough coolant

from the cooling system in order to add the
Extender.
3. Add Extender according to the requirements for

your engines cooling system capacity. Refer to
the Operation and Maintenance Manual, Refill
Capacities in the Maintenance Section for the
capacity of the cooling system for your engine.
Cooling System Specifications information for
the Caterpillar ELC Extender additions.
cooling system filler cap gaskets. Replace the
cooling system filler cap if the cooling system
filler cap gaskets are damaged. Install the
1. Remove the cooling system filler cap slowly in

order to relieve pressure.
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
i01197583
Cooling System Coolant Level

- Check
SMCS Code: 1395-082
Check the coolant level when the engine is stopped
and cool.
Illustration 36
g00103639
Typical filler cap gaskets
3. Clean the cooling system filler cap and check the

condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets
are damaged. Reinstall the cooling system filler
cap.
4. Inspect the cooling system for leaks.
85
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
i01463635
Cooling System Supplemental

Coolant Additive (SCA) Test/Add
SMCS Code: 1352-045; 1395-081
Level 1
Level 1 is a basic analysis of the coolant. The
following items are tested:
Glycol Concentration
Concentration of SCA
pH
Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact with
the skin and the eyes. Do not drink cooling system
coolant additive.
Note: Test the concentration of the Supplemental
Coolant Additive (SCA) or test the SCA concentration
as part of an SOS Coolant Analysis.
Test for SCA Concentration

Coolant/Antifreeze and SCA
NOTICE
Do not exceed the recommended six percent supplemental coolant additive concentration.
Use the 8T-5296 Coolant Conditioner Test Kit or
use the 4C-9301 Coolant Conditioner Test Kit in
order to check the concentration of the SCA. Refer
to the Operation and Maintenance Manual for more
information.
Water and SCA

NOTICE
Do not exceed the recommended eight percent supplemental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Refer to the Operation
and Maintenance Manual, Water/Supplemental
Coolant Additive (SCA) topic (Maintenance
Section). Refer to the Operation and Maintenance
Manual, Conventional Coolant/Antifreeze Cooling
System Maintenance topic (Maintenance Section).
SOS Coolant Analysis

SOS coolant samples can be analyzed at your
Caterpillar dealer. SOS Coolant Analysis is a
program that is based on periodic samples.
Conductivity
The results are reported, and recommendations
are made according to the results. Consult your
Caterpillar dealer for information on the benefits of
managing your equipment with an SOS Coolant
Analysis.
Level 2
This level coolant analysis is recommended
when the engine is overhauled. Refer to the
Operations and Maintenance Manual, Overhaul
Considerations for further information.
Add the SCA, If Necessary

NOTICE
Do not exceed the recommended amount of supplemental coolant additive concentration. Excessive
supplemental coolant additive concentration can form
deposits on the higher temperature surfaces of the
cooling system, reducing the engines heat transfer
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high temperature components. Excessive supplemental coolant
additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated water
pump seal wear. Never use both liquid supplemental
coolant additive and the spin-on element (if equipped)
at the same time. The use of those additives together
could result in supplemental coolant additive concentration exceeding the recommended maximum.
1. Slowly loosen the cooling system filler cap in
order to relieve the pressure. Remove the cooling
system filler cap.
86
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Note: Always discard drained fluids according to

local regulations.
2. If necessary, drain some coolant from the cooling
system into a suitable container in order to allow
space for the extra SCA.
3. Add the proper amount of SCA. Refer to the
Operation and Maintenance Manual for more
information on SCA requirements.
gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.
i00912898
Cooling System Water

Temperature Regulator Replace
SMCS Code: 1355-510
Replace the water temperature regulator before
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime.
A water temperature regulator that fails in a
partially 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.
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water
temperature regulator installed.
If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature regulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or
cylinder head surface.
Refer to the Service Manual for the replacement
procedure of the water temperature regulator, or
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system
to a level that is below the water temperature
regulator housing.
i00072369
Crankshaft Vibration Damper

- Inspect
SMCS Code: 1205-040
Damage to the crankshaft vibration damper or
failure of the crankshaft vibration damper can
increase torsional vibrations. This can result in
damage to the crankshaft and to other engine
components. A deteriorating damper can cause
excessive gear train noise at variable points in the
speed range.
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the
engine.
Removal and Installation

Refer to the Service Manual for the damper
removal procedure and for the damper installation
procedure.
87
Maintenance Section
Cylinder Head Grounding Stud - Inspect/Clean/Tighten
Visconic Damper
i00174798
The visconic damper has a weight that is located

inside a fluid filled case. The weight moves in the
case in order to limit torsional vibration. Inspect
the damper for evidence of dents, cracks or leaks
of the fluid.
Replace the damper if the damper is dented,
cracked or leaking. Refer to the Service Manual
or consult your Caterpillar dealer for damper
replacement.
i01473487
Cylinder Head Grounding Stud

- Inspect/Clean/Tighten
SMCS Code: 7423-040; 7423-070; 7423-079
Driven Equipment - Check

SMCS Code: 3279-535
Refer to the OEM specifications for more information
on the following maintenance recommendations for
the driven equipment:
Inspection
Adjustment
Lubrication
Other maintenance recommendations
Perform any maintenance for the driven equipment
which is recommended by the OEM.
i01646701
Engine - Clean
SMCS Code: 1000-070
Personal injury or death can result from high voltage.

Moisture can create paths of electrical conductivity.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls DO
NOT OPERATE.
Illustration 37
g00768411
Typical example
Inspect the OEM harness for good connections and

condition.
The electrical grounding stud must have a wire
ground to the battery. Tighten the electrical
grounding stud at every oil change. Ground wires
and straps should be combined at engine grounds.
All grounds should be tight and free of corrosion.
If the connections are corroded, clean the
connections with a solution of baking soda and

water.
Keep the electrical grounding stud and the

strap clean and coated with MPGM grease or
petroleum jelly.
NOTICE
Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the
following benefits:
Easy detection of fluid leaks

Maximum heat transfer characteristics
Ease of maintenance
88
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Note: Caution must be used in order to prevent

electrical components from being damaged by
excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
starter, and the ECM.
i01553486
Engine Air Cleaner Element

(Dual Element) - Clean/Replace
SMCS Code: 1054-037; 1054-510
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Replace the dirty paper air cleaner elements with

clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked
for tears and/or holes in the filter material. Inspect
the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner
elements for replacement purposes.
Dual Element Air Cleaners

The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner
element. The primary air cleaner element can be
used up to six times if the element is properly
cleaned and inspected. The primary air cleaner
element should be replaced at least one time
per year. This replacement should be performed
regardless of the number of cleanings.
The secondary air cleaner element is not serviceable
or washable. The secondary air cleaner element
should be removed and discarded for every three
cleanings of the primary air cleaner element. When
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require
more frequent replacement.
Servicing the Air Cleaner Elements

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

and debris, as needed.
Operating conditions (dust, dirt and debris) may

require more frequent service of the air cleaner
element.
The air cleaner element may be cleaned up to

six times if the element is properly cleaned and
inspected.
The air cleaner element should be replaced
at least one time per year. This replacement

should be performed regardless of the number
of cleanings.
Illustration 38
(1)
(2)
(3)
(4)
g00736431
Cover
Primary air cleaner element
Secondary air cleaner element
Turbocharger air inlet
1. Remove the cover. Remove the primary air

cleaner element.
2. The secondary air cleaner element should be
removed and discarded for every three cleanings
of the primary air cleaner element.
Note: Refer to Cleaning the Primary Air Cleaner
Elements.
3. Cover the turbocharger air inlet with tape in
order to keep dirt out.
4. Clean the inside of the air cleaner cover and
body with a clean, dry cloth.
89
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
5. Remove the tape for the turbocharger air inlet.

Install the secondary air cleaner element. Install
a primary air cleaner element that is new or
cleaned.
Visually inspect the primary air cleaner elements

before cleaning. Inspect the air cleaner elements
for damage to the seal, the gaskets, and the outer
cover. Discard any damaged air cleaner elements.
6. Install the air cleaner cover.
There are two common methods that are used to

clean primary air cleaner elements:
7. Reset the air cleaner service indicator.
Pressurized air
Cleaning the Primary Air Cleaner

Elements
NOTICE
Caterpillar recommends certified air filter cleaning
services that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with
a maximum pressure of 207 kPa (30 psi).
Observe the following guidelines if you attempt to

clean the filter element:
Do not tap or strike the filter element in order to remove
dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
The primary air cleaner element can be used up
to six times if the element is properly cleaned and
inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
The primary air cleaner element should be replaced
at least one time per year. This replacement
should be performed regardless of the number of
cleanings.
Use clean primary air cleaner elements while dirty
elements are being cleaned.
NOTICE
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine
damage could result.
Illustration 39
g00281692
Note: When the primary air cleaner elements are

cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
of air directly at the primary air cleaner element. Dirt
could be forced further into the pleats.
Note: Refer to Inspecting the Primary Air Cleaner
Elements.
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
primary air cleaner elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended
prior to vacuum cleaning. Vacuum cleaning will not
remove deposits of carbon and oil.
Note: Refer to Inspecting the Primary Air Cleaner
Elements.
90
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Inspecting the Primary Air Cleaner

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

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage,
wrap the primary air cleaner elements in Volatile
Corrosion Inhibited (VCI) paper.
Place the primary air cleaner element into a box
for storage. For identification, mark the outside of
the box and mark the primary air cleaner element.
Include the following information:
Date of cleaning
Number of cleanings
Store the box in a dry location.
Illustration 40
g00281693
i01175055
Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a
similar facility. Place the blue light in the primary
air cleaner element. Rotate the primary air cleaner
element. Inspect the primary air cleaner element for
tears and/or holes. Inspect the primary air cleaner
element for light that may show through the filter
material. If it is necessary in order to confirm the
result, compare the primary air cleaner element
to a new primary air cleaner element that has the
same part number.
Do not use a primary air cleaner element that has
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
pleats, gaskets or seals. Discard damaged primary
air cleaner elements.
Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes
inspection will not be used, the primary air cleaner
element can be stored for future use.
Engine Air Cleaner Service

Indicator - Inspect
SMCS Code: 7452-040
Some engines may be equipped with a different
service indicator.
Some engines are equipped with a differential
gauge for inlet air pressure. The differential gauge
for inlet air pressure displays the difference in the
pressure that is measured before the air cleaner
element and the pressure that is measured after
the air cleaner element. As the air cleaner element
becomes dirty, the pressure differential rises. If your
engine is equipped with a different type of service
indicator, follow the OEM recommendations in order
to service the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner element or in a remote location.
Illustration 42
Illustration 41
g00281694
Typical service indicator
g00103777
91
Maintenance Section
Engine Crankcase Breather - Clean
Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner
element should be replaced when one of the
following conditions occur:
The yellow diaphragm enters the red zone.

The red piston locks in the visible position.
Test the Service Indicator

Service indicators are important instruments.
Check for ease of resetting. The service indicator

should reset in less than three pushes.
Check the movement of the yellow core when the
engine is accelerated to the engine rated speed.

The yellow core should latch approximately at the
greatest vacuum that is attained.
If the service indicator does not reset easily, or if the

yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the
new service indicator will not reset, the hole for the
service indicator may be plugged.
The service indicator may need to be replaced
frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled,
and whenever major engine components are
replaced.
Note: When a new service indicator is installed,
excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque
of 2 Nm (18 lb in).
i01473536
Engine Crankcase Breather Clean

SMCS Code: 1317-070
Illustration 43
(1)
(2)
(3)
(4)
g00768439
Breather assembly
Bolt
Hose clamp
Hose
1. Loosen hose clamp (3) and remove hose (4)

from breather assembly (1).
2. Remove bolt (2) and the washer. Remove the
breather assembly (1) and the seal.
3. Wash the breather element in solvent that is
clean and nonflammable. Allow the breather
element to dry before installation.
4. Install a breather element that is clean and dry.
Install breather assembly (1) and the seal.
5. Install bolt (2) and the washer. Refer to the
Operation and Maintenance Manual for the
proper torque.
6. Install hose (4) on breather assembly (1). Tighten
hose clamp (3). Refer to the Operation and
Maintenance Manual, Torque Specifications for
the proper torques.
NOTICE
Perform this maintenance with the engine stopped.
i00687861
Engine Mounts - Inspect

NOTICE
If the crankcase breather is not maintained on a
regular basis, it can become plugged. A plugged
breather will cause excessive crankcase pressure
that may cause crankshaft seal leakage.
SMCS Code: 1152-040

Inspect the engine mounts for deterioration and for
proper bolt torque. Engine vibration can be caused
by the following conditions:
Improper mounting of the engine
92
Maintenance Section
Engine Oil Level - Check
Deterioration of the engine mounts
i01534451
Any engine mount that shows deterioration should

be replaced. Refer to the Service Manual for the
recommended torques. Refer to your Caterpillar
dealer for more information.
i00623423
Engine Oil Level - Check

SMCS Code: 1348-535-FLV
Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1348-554-SM;
7542-554-OC, SM
In addition to a good preventive maintenance
program, Caterpillar recommends using SOS oil
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine.
Obtain the Sample and the Analysis

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.

contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
Illustration 44
g00110310
(Y) ADD mark. (X) FULL mark.
Engine model
Service hours on the engine
NOTICE
Perform this maintenance with the engine stopped.
The number of hours that have accumulated
1. Maintain the oil level between ADD mark (Y)

and FULL mark (X) on oil level gauge (1). Do
not fill the crankcase above FULL mark (X).
The amount of oil that has been added since the
NOTICE
Operating your engine when the oil level is above the
FULL mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oils lubricating characteristics and could result in the loss of power.
2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap.
since the last oil change

last oil change
To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
93
Maintenance Section
Engine Oil and Filter - Change
NOTICE
Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant
samples.
A small residue of either type sample may remain in
the pump and may cause a false positive analysis for
the sample being taken.
Always use a designated pump for oil sampling and a
designated pump for coolant sampling.
Failure to do so may cause a false analysis which
could lead to customer and dealer concerns.
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, PEHP6001,
How To Take A Good Oil Sample. Consult your
Caterpillar dealer for complete information and
assistance in establishing an SOS program for
your engine.
i01730738

SMCS Code: 1318-510; 1348-044
Selection of Oil Change Interval

NOTICE
This engine meets EPA Tier 2, Euro Stage II, or MOC
Step 2 emission regulations. A 500 hour engine oil
change interval is available, provided that operating
conditions and recommended multigrade oil types are
met. When these requirements are not met, shorten
the oil change interval to 250 hours, or use an SOS
oil sampling and analysis program to determine an
acceptable oil change interval.
If you select an interval for oil and filter change that is
too long, you may damage the engine.

contact the skin.
Caterpillar oil filters are recommended for oil
changes. Recommended multigrade oil types are
listed in Table 37. Do not use single grade oils.
Illustration 45
g00783061
API Trademark
Commercial oils that are licensed by the American Petroleum
Institute (API) bear this trademark. Commercial oils that do
not bear this trademark are not licensed and these oils are
not recommended. Oils that are not listed in Table 37 are not
recommended.
Abnormally harsh operating cycles or harsh

environments can shorten the service life of
the engine oil. Arctic temperatures, corrosive
environments, or extremely dusty conditions may
require a reduction in engine oil change intervals
from the recommendations in Table 37. Poor
maintenance of air filters or of fuel filters requires
reduced oil change intervals. See your Caterpillar
dealer for more information if this product will
experience abnormally harsh operating cycles or
harsh environments.
94
Maintenance Section
Program A
Table 37
Oil Change Interval for C-9 Industrial Engine
(1)
Verification for an Oil Change Interval of 500 Hours
Operating Conditions
Severe
Normal(2)
Multigrade
Oil Type
High
Load
Factor
above
43 L
(11 US
gal per
hour of
fuel)
Fuel
Sulfur
from
0.3% to
0.5%
Altitude
above
1830 m
(6000 ft)
(4)
If a sample does not pass the oil analysis, take one

of these actions:
(3)
Cat DEO
Preferred
500 hr
API CH-4
11.0
minimum
TBN(4)
Preferred
500 hr
API CH-4
TBN(4)
below 11.0
500 hr
API CG-4
500 hr
250 hr(5)
250 hr(5)
250 hr(6)
API CF-4
250 hr(5)
250 hr(6)
250 hr(6)
250 hr(6)
(1)
(2)
(3)
(4)
(5)
(6)
500 hr
This program consists of three oil change intervals

of 500 hours. Oil sampling and analysis is done
at 250 hours and 500 hours for each of the three
intervals for a total of six oil samples. The analysis
includes oil viscosity and infrared (IR) analysis of
the oil. If all of the results are satisfactory, the 500
hour oil change interval is acceptable for the engine
in that application. Repeat Program A if you change
the application of the engine.
500 hr
250 hr(6)
Shorten the oil change interval to 250 hours.

Proceed to Program B.
500 hr
500 hr
250 hr(6)
Change to a preferred oil type in Table 37.

Program B
500 hr
250 hr(5)
250 hr(6)
Optimizing Oil Change Intervals
The standard oil change interval in this engine is 500 hours, if

the operating conditions and recommended oil types that are
listed in this table are met. The traditional oil change interval for
engines is 250 hours. Improvements in the engine allow this
engine oil change interval. This new standard interval is not
permitted for other engines. Refer to the applicable Operation
and Maintenance Manuals for the other engines.
Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments.
High load factors can shorten the service life of your engine oil.
Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average
fuel consumption of your engine exceed 43 L (11 US gal) per
hour, follow the High Load Factor recommendations in Table
37. To determine average fuel consumption for your engine,
measure average fuel consumption for a period of 50 to 100
hours. If the application of the engine is changed, the average
fuel consumption may change.
For sulfur content above 0.5%, refer to Operation and
Maintenance Manual, Total Base Number (TBN) and Fuel
Sulfur Levels for Direct Injection (DI) Diesel Engines in the
Lubricant section of this manual. Also, you may refer to this
topic in Manual, SEBU6251.
In order to verify an oil change interval of 500 hours, refer to
Program A below.
Use Program B below to determine an appropriate interval.
Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additional
information on these programs.
Begin with a 250 hour oil change interval. The

oil change intervals are adjusted by increments.
Each interval is adjusted an additional 50 hours.
Periodic oil sampling and analysis is done during
each interval. The analysis includes oil viscosity and
infrared (IR) analysis of the oil. Repeat Program B if
you change the application of the engine.
If an oil sample does not pass the analysis, shorten
the oil change interval, or change to a preferred
multigrade oil type in the listing above.
References
Reference: Form, PEDP7035, Optimizing Oil
Change Intervals
Reference: Form, PEDP7036, SOS Fluid Analysis
Reference: Form, PEDP7076, Understanding the
SOS Oil Analysis Tests
Oil Grade Plug

The Oil Grade Plugs are used on the C-9 Industrial
engine to enhance start-up in cold weather
conditions. When changing oil grades, the operator
must ensure that the corresponding plug is inserted
into the wiring harness. The oil grade plugs can be
recognized by either the identification tags or by the
color of the wires. For the location of the oil grade
plug, refer to Operation and Maintenance Manual ,
Sensor and Electrical Components.
95
Maintenance Section
The following plugs are used to inform the ECM

when a particular grade of oil is being used.
10W30 and 15W40 oil grade plugs are shipped

with the engine. The 0W20 oil grade plug can be
ordered from the parts manual. Order the 214-7170
Repair Kit. The 0W20 oil grade plug can be made
from a 175-3700 Connector Repair Kit. Refer to
the Electrical Schematic or refer to Table 38 for the
proper pin locations.
Table 38
OIL GRADE PLUGS (214-7170)
Plug
Wire Color
Pin Connections
10W30
Green
B-C
15W40
Red
A-C
5
Illustration 46
Oil
Grade
0W20
Black
A-B-C
g00852969
Oil grade plugs being shipped with the engine.
Drain the Engine Oil
(1) Identification tag for 10W30 oil grade plug

(2) Identification tag for 15W40 oil grade plug
After the engine has been run at the normal

operating temperature, stop the engine. Attach a
DO NOT OPERATE or a similar warning tag to the
ignition keyswitch before the engine is serviced.
Catch the oil in a suitable container. Recycle the
used oil, or dispose of the used oil properly.
1. Remove the oil drain plug in order to allow the
oil to drain.
2. After the oil has drained, the oil drain plug should
be cleaned and installed.
Replace the Oil Filter
Illustration 47
214-7170 Repair Kit
(3) 10W30 oil grade plug (Green wire)
(4) 15W40 oil grade plug (Red wire)
(5) 0W20 oil grade plug (Black wire)
g00852892
NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
1. Remove the oil filter with a 185-3630 Strap
Wrench.
96
Maintenance Section
4. Apply clean engine oil to the new oil filter gasket.

NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminated. Contaminated oil can cause accelerated wear to
engine components.
5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that
are shown on the oil filter. Do not overtighten the
oil filter.
Illustration 48
g00588944
Fill the Engine Crankcase
Element with debris
2. Cut the oil filter open with a 175-7546 Oil Filter

Cutter . Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early
wear or a pending failure.
Use a magnet to differentiate between the
ferrous metals and the nonferrous metals that
are found in the oil filter element. Ferrous metals
may indicate wear on the steel and cast iron
parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
1. Remove the oil filler cap. Refer to the

Operation and Maintenance Manual, Lubricant
more information. Fill the crankcase with the
proper amount of oil. Refer to the Operation and
Maintenance Manual, Refill Capacities 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 manufacturers 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 two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
3. Stop the engine and allow the oil to drain back
to the sump for a minimum of ten minutes.
4. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the ADD
and FULL marks on the ENGINE STOPPED
side of the oil level gauge.
Illustration 49
g00103713
Typical filter mounting base and filter gasket
3. Clean the sealing surface of the filter mounting

base. Ensure that all of the old oil filter gasket
is removed.
97
Maintenance Section
Engine Storage Procedure - Check
i01430860
Engine Storage Procedure Check

SMCS Code: 1000-535
Caterpillar requires all engines that are stored for
more than 3 months to follow storage procedures
and start-up procedures. 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:
Operating hours
Ensure that the engine can not be started while

this maintenance is being performed. To help prevent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before measuring/adjusting valve lash clearance.
Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance
is performed.
Refer to the Service Manual for more information.
i01597115
Engine Valve Rotators - Inspect

SMCS Code: 1109-040
Fuel consumption
i00869628
Engine Valve Lash Inspect/Adjust
When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn, to help prevent being burned by
hot oil or spray.
SMCS Code: 1102-025

The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change.
The adjustment is necessary due to the initial wear
of the valve train components and to the seating of
the valve train components.
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage
and/or shortened engine component life.
Engine valve rotators rotate the valves when the

engine runs. This helps to prevent deposits from
building up on the valves and the valve seats.
Perform the following steps after the engine valve
lash is set, but before the valve covers are installed:
1. Start the engine according to Operation
and Maintenance Manual, Engine Starting
(Operation Section) for the procedure.
2. Operate the engine at low idle.
3. Observe the top surface of each valve rotator.
The valve rotators should turn slightly when the
valves close.
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
If a valve fails to rotate, consult your Caterpillar
dealer.
98
Maintenance Section
Ether Starting Aid Cylinder - Replace
i00805059
Ether Starting Aid Cylinder Replace

(If Equipped)
SMCS Code: 1456-510-CD
Lubricate the grease fitting that is on the fan drive

bearing with Bearing Lubricant or the equivalent.
Inspect the fan drive pulley assembly for wear or for
damage. If the shaft is loose, an inspection of the
internal components should be performed. Refer to
the Service Manual for additional information.
i01091827
Fuel System - Prime

SMCS Code: 1258-548
Fuel leaked or spilled onto hot surfaces or electrical 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 50
g00104888
Typical example
1. Loosen the ether cylinder clamp. Unscrew and

remove the empty ether cylinder.
2. Remove the used gasket. Install the new gasket
that is provided with each new ether cylinder.
3. Install the new ether cylinder. Hand tighten the
ether cylinder. Tighten the ether cylinder clamp
securely.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any disconnected fuel system components.
Prime the fuel system in order to fill the fuel filter.
Prime the fuel system in order to purge trapped
air. The fuel system should be primed under the
following conditions:
Running out of fuel

i01423301
Fan Drive Bearing - Lubricate
Storage
Replacement of the fuel filter
SMCS Code: 1359-086-BD
Engines that are Equipped with a

Fuel Priming Pump
NOTICE
Do not loosen the fuel lines at the fuel manifold. The
fittings may be damaged and/or a loss of priming pressure may occur when the fuel lines are loosened.
1. Open the fuel priming pump and operate the
fuel priming pump until a strong pressure is felt.
This procedure will require considerable strokes.
Lock the fuel priming pump.
Illustration 51
g00746166
Typical location of the grease fitting that is for the fan drive bearing
The pulley is shown with the belt guards removed
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
99
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
2. Promptly start the engine. If the engine runs

rough, continue to operate the engine at low idle.
Do not raise the engine rpm above an idle, until
the engine operates smoothly.
3. If the engine does not start, open the fuel priming
pump and repeat Steps 1 and 2 in order to start
the engine.
Engines that are Not Equipped with

a Fuel Priming Pump
If the engine is not equipped with a fuel priming
pump, you can use the following procedures to
prime the fuel system. These procedures will allow
only filtered fuel to enter the fuel system.
Fuel Filter Bases that are Not Equipped

with a Plug
NOTICE
1. Operate the starting motor. This will fill the fuel
filter and the fuel lines with fuel.
2. Once the engine starts, operate the engine at
low idle. Do not raise the engine speed above
an idle, until the engine operates smoothly.
i00259781
Fuel Filter Bases that are Equipped with

a Plug
Fuel System Primary

Filter/Water Separator - Drain
NOTICE
SMCS Code: 1260-543; 1263-543
Illustration 52
g00430478
(1) Plug
(2) Fuel filter
1. Remove plug (1) in order to fill fuel filter (2).

Ensure that air is able to vent from the fitting of
the plug while the fuel filter is being filled. Clean
up any spilled fuel immediately. Clean plug (1).
Install plug (1).
NOTICE
2. Start the engine and operate the engine at low
idle. Do not raise the engine speed above an
idle, until the engine operates smoothly.
Illustration 53
g00104007
(1) Element. (2) Bowl. (3) Drain.
Bowl (2) should be monitored daily for signs of

water. If water is present, drain the water from the
bowl.
1. Open drain (3). The drain is a self-ventilated
drain. Catch the draining water in a suitable
container. Dispose of the water properly.
2. Close drain (3).
100
Maintenance Section
Fuel System Primary Filter/Water Separator Element - Replace
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel
system.
i01488870
Fuel System Primary

Filter/Water Separator Element
- Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause a electronic unit injector
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.
The primary filter/water separator also provides
filtration in order to help extend the life of the
secondary fuel filter. The element should be
changed regularly. If a vacuum gauge is installed,
the primary filter/water separator should be changed
at 50 to 70 kPa (15 to 20 inches hg).
Replace the Element
Illustration 54
g00104012
(1) Element. (2) Bowl. (3) Drain.
2. Remove element (1) from the element mounting

base while bowl (2) is attached.
NOTICE
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
3. Dispose of the fuel in the fuel filter element.
Remove bowl (2) from element (1). The bowl is
reusable. Do not discard the bowl. Dispose of
the used element.
4. Remove the O-ring from the gland of the bowl.
Clean the following components:
Bowl
Note: A 10 to 15 micron absolute high efficiency
fuel filter is required for Caterpillar Electronic Unit
Injectors. Caterpillar High Efficiency Fuel Filters
meet these requirements. Consult your Caterpillar
dealer for the proper part number.
1. Close the main fuel supply valve.
O-ring
Mounting base
Inspect the O-ring for damage and for
deterioration. Replace the O-ring, if necessary.
5. Lubricate the O-ring with clean diesel fuel.
6. Install bowl (2) on a new element. Tighten the
bowl by hand. Do not use tools in order to tighten
the bowl.
101
Maintenance Section
Fuel System Secondary Filter - Replace
NOTICE
The primary filter/water separator may be prefilled with
fuel to avoid rough running/stalling of the engine due
to air. Do not fill the secondary filter with fuel before
installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
7. Lubricate the top seal of element (1) with clean
diesel fuel. The element may be filled with fuel at
this time. Install the new element on the mounting
base. Tighten the element by hand.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tightened securely to help prevent air from entering the fuel system.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
1. Stop the engine. Turn the ignition switch to the
OFF position or disconnect the battery. Refer
to the Operation and Maintenance Manual,
Battery or Battery Cable - Disconnect topic
(Maintenance Section) for more information. Shut
off the fuel supply valve (if equipped).
2. Remove the used fuel filter and discard the used
fuel filter.
3. Clean the gasket sealing surface of the fuel
filter base. Ensure that all of the old gasket is
removed.
4. Apply clean diesel fuel to the new fuel filter
gasket.
8. Open the main fuel supply valve.

9. Start the engine and check for leaks. Run the
engine for one minute. Stop the engine and
check for leaks again.
Detection of leaks is difficult while the engine
is running. The primary filter/water separator is
under suction. A leak will allow air to enter the
fuel. The air in the fuel can cause low power
due to aeration of the fuel. If air enters the fuel,
check the components for overtightening or
under tightening.
i01503750
Fuel System Secondary Filter Replace

SMCS Code: 1261-510-SE
NOTICE
NOTICE
Do not fill the secondary fuel filter with fuel before installing. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
NOTICE
In order to maximize fuel system life and prevent premature wear out from abrasive particles in the fuel,
a two micron absolute high efficiency fuel filter is required for all Caterpillar Hydraulic Electronic Unit Injectors. Caterpillar High Efficiency Fuel Filters meet
these requirements. Consult your Caterpillar dealer for
the proper part numbers.
5. Install the new fuel filter. Spin the fuel filter onto
the fuel filter base until the gasket contacts the
base. Use the rotation index marks on the filters
as a guide for proper tightening. Tighten the
filter for an additional one turn (360 degrees) by
hand. Do not overtighten the filter.
6. Open the fuel supply valve. Prime the fuel system.
Fuel System - Prime topic (Maintenance
Section) for more information. Start the engine
and inspect the fuel system for leaks.
NOTICE
102
Maintenance Section
Fuel Tank Water and Sediment - Drain
Note: There should be enough residual fuel in the

cylinder head in order to start the engine. If the
engine stops after starting, do not crank the engine
for more than 30 seconds. Then allow the starting
motor to cool for two minutes. Repeat this procedure
until the engine starts and the engine operates.
i00073301
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
Fuel Tank
Fuel quality is critical to the performance and to
the service life of the engine. Water in the fuel can
cause excessive fuel system wear. 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.
Fuel Storage Tanks

Drain the water and the sediment from the fuel
storage tank during the following conditions:
Weekly
Oil change
Refill of the tank
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank.
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.
i00907072
Hoses and Clamps Inspect/Replace
Drain the Water and the Sediment
SMCS Code: 7554-040; 7554-510
Fuel tanks should contain some provision for

draining water and draining sediment from the
bottom of the fuel tanks.
Inspect all hoses for leaks that are caused by the

Open the drain valve on the bottom of the fuel tank

in order to drain the water and the sediment. Close
the drain valve.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
Fill the fuel tank after operating the engine in
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
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.
Cracking
Softness
Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
NOTICE
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the recommended torque.
Check for the following conditions:
End fittings that are damaged or leaking

Outer covering that is chafed or cut
Exposed wire that is used for reinforcement
Outer covering that is ballooning locally
103
Maintenance Section
Jacket Water Heater - Check
Flexible part of the hose that is kinked or crushed
7. Install the hose clamps with a torque wrench.
Armoring that is embedded in the outer covering
Note: For the proper coolant to use, see this

Operation and Maintenance Manual, Coolant
Recommendations (Maintenance Section).
A constant torque hose clamp can be used in

place of any standard hose clamp. Ensure that the
constant torque hose clamp is the same size as
the standard clamp.
Due to extreme temperature changes, the hose
will heat set. Heat setting causes hose clamps to
loosen. This can result in leaks. A constant torque
hose clamp will help to prevent loose hose clamps.
Each installation application can be different. The
differences depend on the following factors:
Type of hose
Type of fitting material
Anticipated expansion and contraction of the
hose
Anticipated expansion and contraction of the

fittings
Replace the Hoses and the Clamps
1. Stop the engine. Allow the engine to cool.
2. Loosen the cooling system filler cap slowly
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
3. Drain the coolant from the cooling system to
a level that is below the hose that is being
replaced.
8. Refill the cooling system.

cooling system filler caps gaskets. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
leaks.
i01042517
Jacket Water Heater - Check

SMCS Code: 1383-535
Jacket water heaters help to improve startability in
ambient temperatures that are below 21 C (70 F).
All installations that require automatic starting
should have jacket water heaters.
Check the operation of the jacket water heater. For
an ambient temperature of 0 C (32 F), the heater
should maintain the jacket water temperature at
approximately 32 C (90 F).
i01452713
Overhaul Considerations
SMCS Code: 7595-043
Reduced hours of operation at full load will result
in a lower average power demand. A decreased
average power demand should increase both the
engine service life and the overhaul interval.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
The following factors are important when a decision
is being made on the proper time for an engine
overhaul:
The need for preventive maintenance
4. Remove the hose clamps.
The quality of the fuel that is being used
5. Disconnect the old hose.
The operating conditions
6. Replace the old hose with a new hose.
The results of the SOS analysis
Note: For torques on hose clamps, see this

Specifications (Maintenance Section).
104
Maintenance Section
Oil Consumption as an Overhaul

Indicator
Oil consumption, fuel consumption, and
maintenance information can be used to estimate
the total operating cost for your Caterpillar engine.
Oil consumption can also be used to estimate
the required capacity of a makeup oil tank that is
suitable for the maintenance intervals.
Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
consumed per hour also increases.
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h
(lb per bhp). The brake specific oil consumption
(BSOC) depends on the engine load. Consult your
Caterpillar dealer for assistance in determining the
typical oil consumption rate for your engine.
When an engines oil consumption has risen to
three times the original oil consumption rate due
to normal wear, an engine overhaul should be
scheduled. There may be a corresponding increase
in blowby and a slight increase in fuel consumption.
Overhaul Options
Before Failure Overhaul
A planned overhaul before failure may be the best
value for the following reasons:
Costly unplanned downtime can be avoided.

Many original parts can be reused according to
the standards for reusable parts.
The engines service life can be extended without

the risk of a major catastrophe due to engine
failure.
The best cost/value relationship per hour of

extended life can be attained.
Specially designed Caterpillar engine features

Caterpillar dealer exchange components
Caterpillar Inc. remanufactured exchange
components
Overhaul Recommendation
To minimize downtime, Caterpillar Inc. recommends
a scheduled engine overhaul by your Caterpillar
dealer before the engine fails. This will provide you
with the best cost/value relationship.
Note: Overhaul programs vary according to the
engine application and according to the dealer
that performs the overhaul. Consult your Caterpillar
dealer for specific information about the available
overhaul programs and about overhaul services for
extending the engine life.
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the
following maintenance recommendations.
Rebuild or Exchange
Cylinder Head Assembly, Cylinder Packs, Oil
Pump, and Fuel Transfer Pump
These components should be inspected according
to the instructions that are found in various
Caterpillar reusability publications. The Special
Publication, SEBF8029 lists the reusability
publications that are needed for inspecting the
engine parts.
If the parts comply with the established inspection
specifications that are expressed in the reusable
parts guideline, the parts should be reused.
Parts that are not within the established inspection
specifications should be dealt with in one of the
following manners:
Salvaging
After Failure Overhaul
Repairing
If a major engine failure occurs and the engine

must be removed, many options are available. An
overhaul should be performed if the engine block
or the crankshaft needs to be repaired.
Replacing
If the engine block is repairable and/or the

crankshaft is repairable, the overhaul cost should
be between 40 percent and 50 percent of the cost
of a new engine with a similar exchange core.
Using out-of-spec parts can result in the following

problems:
Unscheduled downtime
Costly repairs
Damage to other engine parts
This lower cost can be attributed to three aspects:
Reduced engine efficiency
105
Maintenance Section
Increased fuel consumption
Camshaft followers
Reduced engine efficiency and increased fuel

consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts.
Caterpillar Inc. recommends replacing the

crankshaft vibration damper.
Inspection and/or Replacement
During an overhaul, Caterpillar Inc. recommends

the removal of the oil cooler core. Clean the oil
cooler core. Then, pressure test the oil cooler core.
Crankshaft Bearings, Valve Rotators, and

Crankshaft Seals
The following components may not last until the
second overhaul.
Thrust bearings
Main bearings
Oil Cooler Core
NOTICE
Do not use caustic cleaners to clean the core.
Caustic cleaners can attack the internal metals of the
core and cause leakage.
Rod bearings
Note: Use this cleaning procedure to clean the oil

cooler core.
Valve rotators
1. Remove the oil cooler core.
Crankshaft seals
2. Remove any debris from the oil cooler core. To

remove debris from the oil cooler core, turn the
oil cooler core onto one end.
Caterpillar Inc. recommends the installation of new

parts at each overhaul period.
Inspect these parts while the engine is disassembled
for an overhaul.
Inspect the crankshaft for any of the following
conditions:
Deflection
Damage to the journals
3. Flush the oil cooler core internally with cleaner in

order to loosen foreign substances. This will also
help to remove oil from the oil cooler core.
Note: Caterpillar Inc. recommends the use of
Hydrosolv Liquid Cleaners. Table 39 lists the
Hydrosolv Liquid Cleaners that are available from
Table 39
HydrosolvLiquid Cleaners
Bearing material that has seized to the journals

Check the journal taper and the profile of the
crankshaft journals. Check these components by
interpreting the wear patterns on the following
components:
Part
Number
Description
1U-8812
1U-5490
Size
4 L (1 US gallon)
Hydrosolv4165
19 L (5 US gallon)
8T-7570
208 L (55 US gallon)
Rod bearing
1U-8804
4 L (1 US gallon)
Main bearings
1U-5492
Inspect the camshaft for damage to the journals

and to the lobes.
Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check
for cracks in the camshaft.
Inspect the following components for signs of wear
or for signs of scuffing:
Camshaft bearings
8T-5571
Hydrosolv100
19 L (5 US gallon)
208 L (55 US gallon)
4. Use steam to clean the oil cooler core. This

removes any remaining residue from the cleaner.
Flush the fins of the oil cooler core. Remove any
other trapped debris.
5. Wash the oil cooler core with hot, soapy water.
Rinse the oil cooler core thoroughly with clean
water.
106
Maintenance Section
Power Take-Off Clutch - Check/Adjust/Lubricate
Identification of metal corrosion

6. Dry the oil cooler core with compressed air.
Direct the air in the reverse direction of the
normal flow.
7. Inspect the components in order to ensure
cleanliness. The oil cooler core should be
pressure tested. Repair the oil cooler core, if
necessary. Install the oil cooler core.
Identification of contaminants
Identification of built up impurities (corrosion and
scale)
SOS Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
recommendations.
For more information about coolant analysis, see
i01506009
Power Take-Off Clutch Check/Adjust/Lubricate

SMCS Code: 3055-036; 3055-086
For more information about cleaning the cores,

Obtain Coolant Analysis

The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits
or with SOS Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine
is overhauled.
NOTICE
New power take-offs should have the clutch adjustment checked before being placed into service. The
clutch adjustment should be checked again after the
first ten hours of operation. New clutch plates have a
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 Inc. recommends an SOS Coolant
Analysis (Level 2).
An SOS Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An SOS Coolant Analysis (Level 2)
provides the following information:
Complete SOS Coolant Analysis (Level 1)

Visual inspection of properties
Illustration 55
g00781502
(1) Instruction plate

(2) Serial number plate
Check the clutch adjustment regularly after

wear in. Heavy-duty applications which have
engagements that are frequent and relatively long
periods of clutch slippage require more frequent
adjustment than light-duty applications. The
operating torque should be measured in order to
determine if a clutch adjustment is required.
Refer to the OEM information and instruction plate
(1) for instructions on lubrication, adjustment, and
other recommendations for service. Perform the
maintenance that is specified on the instruction
plate.
107
Maintenance Section
Radiator - Clean
Do not operate the engine with the Instruction

Plate cover removed from the clutch. Personal
injury may result.
If the clutch is damaged to the point of burst failure, expelled pieces can cause personal injury to
anyone in the immediate area. Proper safeguards
must be followed to help prevent accidents.
i01604510
Radiator - Clean
After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
Inspect the fins for damage. Bent fins may be
opened with a comb. Inspect these items for
good condition: welds, mounting brackets, air lines,
connections, clamps, and seals. Make repairs, if
necessary.
For more detailed information on cleaning and
inspection, refer to Special Publication, SEBD0518,
Know Your Cooling System.
SMCS Code: 1353-070

Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and
other debris. Clean the radiator, if necessary.

i00151038
Severe Service Application Check

SMCS Code: 1000-535
Severe service is an application of an engine
that exceeds current published standards for that
engine. Caterpillar maintains standards for the
following engine parameters:
Performance (power range, speed range, and

fuel consumption)
Fuel quality
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
of the fans air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move
the air nozzle in a direction that is parallel with the
tubes. This will remove debris that is between the
tubes.
Altitude range
Maintenance intervals
Oil selection and maintenance
Coolant selection and maintenance
Environmental qualities
Installation
Pressurized water may also be used for cleaning.

The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Refer to the standards for the engine or consult with

your Caterpillar dealer in order to determine if the
engine is operating within the defined parameters.
Use a degreaser and steam for removal of oil and

grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
Severe service operation can accelerate component

wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention
of full service life.
Due to individual applications, it is not possible to
identify all of the factors which can contribute to
severe service operation. Consult your Caterpillar
dealer for the unique maintenance that is necessary
for the engine.
108
Maintenance Section
Starting Motor - Inspect
The operating environment, improper operating

procedures and improper maintenance procedures
can be factors which contribute to severe service
conditions.
Environmental Factors
Ambient temperatures The engine may be
exposed to extended operation in extremely
cold environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
cold temperatures. Extremely hot inlet air reduces
engine performance.
Air Quality The engine may be exposed to
extended operation in an environment that is dirty
or dusty, unless the equipment is cleaned regularly.
Mud, dirt and dust can encase components.
Maintenance can be very difficult. The buildup can
contain corrosive chemicals.
Buildup Compounds, elements, corrosive
chemicals and salt can damage some components.
Altitude Problems can arise when the engine
is operated at altitudes that are higher than the
intended settings for that application. Necessary
adjustments should be made.
Improper Operating Procedures

Extended operation at low idle
Frequent hot shutdowns
Check the starting motor for proper operation.

Check the electrical connections and clean the
electrical connections. Refer to the Service Manual
for more information on the checking procedure and
for specifications or consult your Caterpillar dealer
for assistance.
i01539769
Turbocharger - Inspect
SMCS Code: 1052-040
Periodic inspection and cleaning is recommended
for the turbocharger compressor housing (inlet
side). Any fumes from the crankcase are filtered
through the air inlet system. Therefore, by-products
from oil and from combustion can collect in the
turbocharger compressor housing. Over time, this
buildup can contribute to loss of engine power,
increased black smoke and overall loss of engine
efficiency.
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to
the turbocharger compressor wheel can cause
additional damage to the pistons, the valves, and
the cylinder head.
NOTICE
Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
Minor leakage of a turbocharger housing under extended low idle operation should not cause problems
as long as a turbocharger bearing failure has not occurred.
Operating at excessive loads

Operating at excessive speeds
Operating outside the intended application
Improper Maintenance Procedures

Extending the maintenance intervals
When a turbocharger bearing failure is accompanied

by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
Failure to use recommended fuel, lubricants and

coolant/antifreeze
i00651416
Starting Motor - Inspect

SMCS Code: 1451-040; 1453-040
Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
An inspection of the turbocharger can minimize

unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for
potential damage to other engine parts.
Note: Turbocharger components require precision
clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
Severe Service Applications require more frequent
inspections of the cartridge.
109
Maintenance Section
Walk-Around Inspection
Removal and Installation

For options regarding the removal, installation,
repair and replacement, consult your Caterpillar
dealer. Refer to the Service Manual for this engine
for the procedure and specifications.
Cleaning and Inspecting

1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt
from entering during reassembly.
2. Turn the compressor wheel and the turbine
wheel by hand. The assembly should turn freely.
Inspect the compressor wheel and the turbine
wheel for contact with the turbocharger housing.
There should not be any visible signs of contact
between the turbine wheel or compressor
wheel and the turbocharger housing. If there is
any indication of contact between the rotating
turbine wheel or the compressor wheel and the
turbocharger housing, the turbocharger must be
reconditioned.
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty,
dirt and/or moisture is passing through the air
filtering system. If oil is found only on the back
side of the wheel, there is a possibility of a failed
turbocharger oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
for the inlet air (plugged air filters), which causes
the turbocharger to slobber.
4. Use a dial indicator to check the end clearance
on the shaft. If the measured end play is greater
than the Service Manual specifications, the
turbocharger should be repaired or replaced.
An end play measurement that is less than the
minimum Service Manual specifications could
indicate carbon buildup on the turbine wheel.
The turbocharger should be disassembled for
cleaning and for inspection if the measured end
play is less than the minimum Service Manual
specifications.
5. Inspect the bore of the turbine housing for
corrosion.
6. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.
7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
i01185304
Walk-Around Inspection
SMCS Code: 1000-040
Inspect the Engine for Leaks and

for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be
avoided.
For maximum engine service life, make a thorough
inspection of the engine compartment before
starting the engine. Look for items such as oil leaks
or coolant leaks, loose bolts, worn belts, loose
connections and trash buildup. Make repairs, as
needed:
The guards must be in the proper place. Repair

damaged guards or replace missing guards.
Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system
contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
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.

Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
the parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer.
110
Maintenance Section
Water Pump - Inspect
Inspect the lubrication system for leaks at the

front crankshaft seal, the rear crankshaft seal, the
oil pan, the oil filters and the valve cover.
Inspect the fuel system for leaks. Look for loose

fuel line clamps or for loose fuel line tie-wraps.
Other potential damage to the engine

Visually inspect the water pump for leaks. If any
leaking is observed, replace the water pump
seal or the water pump assembly. Refer to the
Service Manual for the disassembly and assembly
procedure.
Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
Inspect the alternator belt and the accessory

drive belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced
as matched sets. If only one belt is replaced, the
belt will carry more load than the belts that are
not replaced. The older belts are stretched. The
additional load on the new belt could cause the
belt to break.
Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.
Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed

wires.
Inspect the ground strap for a good connection

and for good condition.
Inspect the ECM to the cylinder head ground

strap for a good connection and for good
condition.

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

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

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

A piston seizure
Note: Refer to the Service Manual or consult your

Caterpillar dealer if any repair is needed or any
replacement is needed.
111
Warranty Section
Warranty Information
Warranty Section
Warranty Information
i01087950
Emissions Warranty
Information
SMCS Code: 1000
This engine may be certified to comply with
exhaust emission standards and gaseous emission
standards that are prescribed by law at the time
of manufacture, and this engine may be covered
by an Emissions Warranty. A detailed explanation
of the Emissions Warranty that is applicable to
emissions certified engines is found in Supplement,
SEBU6981, Federal Emissions Control Warranty
Information. Consult your authorized Caterpillar
dealer to determine if your engine is emissions
certified and if your engine is subject to an
Emissions Warranty.
112
Engine Ratings
Reference Information
Section
i00819749
Engine Rating Definitions

SMCS Code: 1000
Engine Ratings
i00727327
Engine Rating Conditions

SMCS Code: 1000
All engine ratings are in compliance with the
following standard ambient air conditions of SAE
J1349:
99 kPa (29.3 inches of Hg)

30 percent relative humidity
A temperature of 25 C (77 F)
Ratings relate to the standard conditions of
ISO8665, of ISO3046/1, of DIN6271, and of
BS5514.
The engine ratings are based on the following fuel
specifications:
fuel
Low heat value (LHV)of the of 42 780 kJ/kg
(18,390 Btu/lb) at 29 C (84 F)
Gravity (API) of 35 degrees at 15 C (60 F)

Specific gravity of .849 at 15 C (60 F)
Density of 850 kg/m3 (7.085 lb/US gal)
The engine ratings are gross output ratings.
Gross Output Ratings The total output capability
of the engine that is equipped with standard
accessories.
Standard accessories include the following
components:
Oil pumps
Fuel pumps
Water pumps
Subtract the power that is required to drive auxiliary
components from the gross output. This will produce
the net power that is available for the external load
(flywheel).
It is important to know the use of the engine so

that the rating will match the operating profile. The
proper rating selection is also important so that the
customers perception of price and value is realized.
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.
Note: The examples of the applications are only
for reference. For an exact determination of the
appropriate rating, follow the OEM specifications or
A Rating This rating is used for heavy-duty
applications that are operated at rated load and at
rated rpm up to 100 percent. This rating is used
for engines that operate without interruption of load
cycling. Typical applications include the following
examples: pipeline pumping and ventilation.
B Rating This rating is used when power and/or
rpm are cyclic. The engine should be run at full load.
The engine should not exceed 80 percent of the
duty cycle. Typical applications include the following
examples: irrigation, operation where normal pump
demand is 85 percent of the engine rating, oil
pumping/drilling, field mechanical pumping/drilling,
and stationary/plant air compressors.
C Rating This rating is used when power and/or
rpm are cyclic. The horsepower and the rpm of the
engine can be utilized continuously for one hour.
This is followed by one hour of operation at the A
rating or below the A rating. The engine should
be run at full load. The engine should not exceed
50 percent of the duty cycle. Typical applications
include the following examples: agricultural tractors,
harvesters and combines, off-highway trucks, fire
pumps, blast hole drills, rock curshers, wood
chippers with high torque rise, and oil field hoisting.
D Rating This rating is used when rated power
is required for periodic overloads. The maximum
horsepower and the rpm of the engine can be
utilized continuously for a maximum of 30 minutes.
This is followed by one hour of operation at the C
rating. The engine should be run at full load. The
engine should not exceed 10 percent of the duty
cycle. Typical applications include the following
examples: offshore cranes, runway snow blowers,
water well drills, portable air compressors, and fire
pump certification power.
113
Engine Ratings
E Rating This rating is used when rated power

is required for a short time for initial starting or
for sudden overload. The rating is also used for
emergency service when standard power is not
available. The horsepower and the rpm of the
engine can be utilized continuously for a maximum
of 15 minutes. This is followed by one hour of
operation at the C rating or by the duration of the
emergency. The engine should be run at full load.
The engine should not exceed 5 percent of the duty
cycle. Typical applications include the following
examples: standby centrifugal water pumps, oil
field well servicing, crash trucks, portable air
compressors, and gas turbine starting motors.
NOTICE
Operating engines above the rating definitions can result in shorter service life before overhaul.
114
Customer Service
Customer Service
i01706971
Customer Assistance
SMCS Code: 1000
USA and Canada

When a problem arises concerning the operation of
an engine or concerning the service of an engine,
the problem will normally be managed by the dealer
in your area.
Your satisfaction is a primary concern to Caterpillar
and to Caterpillar dealers. If you have a problem
that has not been handled to your complete
satisfaction, follow these steps:
1. Discuss your problem with a manager from the
dealership.
2. If your problem cannot be resolved at the dealer
level without additional assistance, use the
phone number that is listed below to talk with a
Field Service Coordinator:
1-800-447-4986
The normal hours are from 8:00 to 4:30 Monday
through Friday Central Standard Time.
3. If your needs have not been met still, submit the
matter in writing to the following address:
Caterpillar Inc.
Manager, Customer Service, Engine Division
Mossville Bldg AC
P.O. Box 610
Mossville, Illinois 61552-0610
Please keep in mind: probably, your problem will
ultimately be solved at the dealership, using the
dealerships facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a
problem is experienced.
Outside of the USA and of Canada

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

Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801
Europe, Africa, and Middle East
Caterpillar Overseas S.A.
76 Route de Frontenex
P.O. Box 6000
CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
Fax: 22-849-4544
Far East
Caterpillar Asia Pte. Ltd.
7 Tractor Road
Jurong, Singapore 627968
Republic of Singapore
Phone: 65-662-8333
Fax: 65-662-8302
China
Caterpillar China Ltd.
37/F., The Lee Gardens
33 Hysan Avenue
Causeway Bay
G.P.O. Box 3069
Hong Kong
Phone: 852-2848-0333
Fax: 852-2848-0440
Japan
Shin Caterpillar Mitsubishi Ltd.
SBS Tower
10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
Japan
Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Japan
Caterpillar Power Systems, Inc.
8F, AIG Aoyama Bldg.
2-11-16, Minami-Aoyama
Minato-ku, Tokyo 107-0062
Phone: 81-3-5786-3803
Fax: 81-3-5786-3809
Australia and New Zealand
Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
115
Customer Service
i01028392
Ordering Replacement Parts

SMCS Code: 7567
When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent specifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available
from Caterpillar dealers throughout the world.
Caterpillar dealers parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following
information:
Part number
Part name
Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and
the nature of the problem. Inform the dealer about
when the problem occurs. This will help the dealer
in troubleshooting the problem and solving the
problem faster.
116
Reference Materials
Reference Materials
Special Publication, PEHP0002, Data Sheet

- Multipurpose Lithium Complex Grease with
Molybdenum (MPGM)
i01498520
Reference Material
Special Publication, PEHP0017, Data Sheet -
SMCS Code: 1000
Special Publication, NEHP5621, How To Select
The following literature can be obtained through any

Caterpillar dealer.
Coolants
Special Publication, SEBD0970, Coolant and
Your Engine
Special Purpose Grease (SPG) Bearing Lubricant

The Right Grease For Any Job
Special Publication, PEHP6001, How To Take A

Good Oil Sample
Special Publication, SEBD0640, Oil and Your

Engine
Special Publications, PEDP7036, SOS Fluids

Special Publication, PEHP4036, Data Sheet-
Analysis Cornerstone
Extended Life Coolant
Special Publication, SEBD0518, Know Your

Cooling System
Special Publication, PEEP5027, Label - ELC

Radiator Label
Special Publication, PEHP7057, SOS Coolant

Analysis
Fuels
Miscellaneous
Service Manual, SENR9595, C-9 Industrial
Engine Service Manual
Special Publication, SEBU6251, Caterpillar

Commercial Diesel Engine Fluids
Recommendations For Lubricants, Diesel
Fuel, and Coolants
Special Publication, PECP6026, One Safe

Source
Special Publication, SENR9620, Improving Fuel

System Durability
Special Instruction, SMHS7001, Assembly of Fan

Drive Pulley Assemblies
Special Publication, SEBD0717, Diesel Fuels and

Your Engine
Special Instruction, SEHS7633, Battery Test

Procedure
Lubricants
Special Publication, PEDP7035, Optimizing Oil
Change Intervals
Special Publication, PEHP8038, Data Sheet -
Caterpillar Diesel Engine Oils (DEO) (CH-4, CG-4,

CF-4) (North America and Australia)
Special Publication, PEHP7041, Product Data

Sheet for Caterpillar Diesel Engine Oils (DEO)
CG-4 engine oils (International markets)
Special Publication, PEWP3014, Cat Fluids

Selector Dial (International)
Special Publication, PEWP9733, Cat Fluids

Selector Dial (North America)
Special Publication, NEDG6022, Data Sheet Multipurpose Lithium Complex Grease (MPG)
Special Publication, SEBF8062, Guideline for

Reusable Parts - Procedure to Inspect and Clean
Air Filters
Special Publication, SEBF8029, Index to

Guidelines for Reusable Parts and Salvage
Operations
Special Publication, PEDP0026, Power Analysis

Report
Special Publication, NEHS0526, Service

Technology Application Guide
Special Instruction, SEHS9031, Storage

Procedure for Caterpillar Products
Specifications, SENR3130, Torque Specifications

Module
Special Instruction, SEHS7768, Use of 6V-2150

Starting/Charging Analyzer
117
Reference Materials
Special Instruction, SEHS8742, Using the

8T-8697 Electronic Control Analyzer Programmer
(ECAP)
Special Instruction, SEHS8622, Using the FT1984 Air-To-Air Aftercooler Leak Test Group
Special Instruction, SEHS7332, Warning Tag Danger Do Not Operate
International Organization for Standardization

(ISO)
1, rue de Varemb
Case postale 56
CH-1211 Genve 20
Switzerland
Telephone: +41 22 749 01 11
Facsimile: +41 22 733 34 30
E-mail: [email protected]
Web site: http://www.iso.ch
Special Instruction, REHS0871, Electronic

Installation Guide.
i01109461
Additional Reference Material

SMCS Code: 1000
The EMA Lubricating Oils Data Book can
be obtained from the following locations: local
technological society, local library, and local college.
If necessary, consult EMA at the following address:
Engine Manufacturers Associaton
401 N. Michigan Ave.
Chicago, IL, USA 60611
Telephone: (312) 644-6610 ext. 3626
The Society of Automotive Engineers (SAE)
Specifications can be found in your SAE handbook.
This publication can also be obtained from the
following locations: local technological society, local
library, and local college. If necessary, consult SAE
at the following address:
SAE International
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841
The American Petroleum Institute Publication No.
1509 can be obtained from the following locations:
local technological society, local library, and local
college. If necessary, consult API at the following
address:
American Petroleum Institute
1220 L St. N.W.
Washington, DC, USA 20005
Telephone: (202) 682-8000
The International Organization for Standardization
(ISO) offers information and customer service
regarding international standards and standardizing
activities. ISO can also supply information on the
following subjects that are not controlled by ISO:
national standards, regional standards, regulations,
certification, and related activities. Consult the
member of ISO in your country.
European classifications are established by the

Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).
CIMAC Central Secretariat
Lyoner Strasse 18
60528 Frankfurt
Germany
Telephone: +49 69 6603 1567
Facsimile: +49 69 6603 1566
i00912149
Maintenance Records
SMCS Code: 1000
Caterpillar Inc. recommends the retention
of accurate maintenance records. Accurate
maintenance records can be used for the following
purposes:
Determine operating costs.

Establish maintenance schedules for other
engines that are operated in the same
environment.
Show compliance with the required maintenance

practices and maintenance intervals.
Maintenance records can be used for a variety of

other business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is well managed.
Accurate maintenance records can help your
Caterpillar dealer to fine tune the recommended
maintenance intervals in order to meet the specific
operating situation. This should result in a lower
engine operating cost.
Records should be kept for the following items:
118
Reference Materials
Fuel Consumption A record of fuel consumption

is essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines
overhaul intervals.
Service Hours A record of service hours is
essential to determine when the speed sensitive
components should be inspected or repaired.
Documents These items should be easy to obtain,
and these items should be kept in the engine
history file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number, and engine serial number. The
following types of documents should be kept as
proof of maintenance or repair for warranty:
Keep the following types of documents as proof of
maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
Dealer work orders and itemized bills

Owners repair costs
Owners receipts
Maintenance log
119
Reference Materials
i01176304
Maintenance Log
SMCS Code: 1000
Table 40
Engine Model
Customer Identifier
Serial Number
Arrangement Number
Service
Hours
Quantity
Of Fuel
Service Item
Date
Authorization
120
Index Section
Index
A
Additional Reference Material ............................. 117
After Starting Engine ............................................. 44
After Stopping Engine............................................ 47
Aftercooler Core - Clean/Test ................................ 74
Aftercooler Core - Inspect...................................... 74
Aftermarket Oil Additives ....................................... 54
Air Compressor - Inspect....................................... 75
Air Compressor Filter - Clean/Replace (If
Equipped) ............................................................ 75
Air Tank Moisture and Sediment - Drain (If
Equipped) ............................................................ 76
Alternator - Inspect ................................................ 76
B
Battery - Replace................................................... 76
Battery Charger - Check........................................ 78
Checking After Stopping .................................... 78
Checking Before Start-Up .................................. 78
Battery or Battery Cable - Disconnect ................... 77
Before Starting Engine .................................... 13, 39
Belt - Inspect.......................................................... 78
Adjustment ......................................................... 79
Inspection........................................................... 78
Belt Tensioner - Inspect (If Equipped) ................... 80
Burn Prevention..................................................... 10
Batteries............................................................. 10
Coolant............................................................... 10
Oils..................................................................... 10
C
Cold Weather Lubricants .......................................
Cold Weather Operation........................................
Commercial Heavy-Duty Coolant/Antifreeze and
SCA .....................................................................
Conventional Coolant/Antifreeze Cooling System
Maintenance ........................................................
Cleaning the System of Heavy-Duty
Coolant/Antifreeze ...........................................
Cooling Systems with Larger Capacities ...........
Coolant Recommendations ...................................
Cooling System Coolant (DEAC) - Change ...........
Cooling Systems with Heavy Deposits or
Plugging ...........................................................
Drain ..................................................................
Fill ......................................................................
Flush ..................................................................
Cooling System Coolant (ELC) - Change..............
Drain ..................................................................
Fill ......................................................................
Flush ..................................................................
Cooling System Coolant Extender (ELC) - Add.....
54
48
66
68
70
69
61
80
81
81
82
81
82
82
83
83
84
Cooling System Coolant Level - Check ................. 84

Cooling System Specifications .............................. 59
(SCA) - Test/Add.................................................. 85
Add the SCA, If Necessary ................................ 85
SOS Coolant Analysis...................................... 85
Test for SCA Concentration ............................... 85
Cooling System Water Temperature Regulator Replace................................................................ 86
Crankshaft Vibration Damper - Inspect ................. 86
Removal and Installation.................................... 86
Visconic Damper................................................ 87
Crushing Prevention and Cutting Prevention......... 12
Customer Assistance........................................... 114
Outside of the USA and of Canada.................. 114
USA and Canada ............................................. 114
Customer Service ................................................ 114
Customer Specified Parameters...................... 23, 38
Cylinder Head Grounding Stud - Inspect/Clean/
Tighten................................................................. 87
D
Diagnostic Flash Code Retrieval ...........................
Diagnostic Lamp..............................................
Diagnostic Lamp....................................................
Diesel Engine Antifreeze/Coolant (DEAC) ............
Driven Equipment - Check.....................................
34
34
34
65
87
E
Electrical System................................................... 14
Grounding Practices .......................................... 14
Emergency Stopping ............................................. 46
Emergency Stop Button ..................................... 46
Emissions Certification Film .................................. 22
Emissions Warranty Information.......................... 111
Engaging the Driven Equipment............................ 45
Engine - Clean....................................................... 87
Engine Air Cleaner Element (Dual Element) Clean/Replace ..................................................... 88
Cleaning the Primary Air Cleaner Elements ...... 89
Servicing the Air Cleaner Elements ................... 88
Engine Air Cleaner Service Indicator - Inspect...... 90
Test the Service Indicator .................................. 91
Engine Crankcase Breather - Clean...................... 91
Engine Description ................................................ 18
Aftermarket Products and Caterpillar Engines... 20
Electronic Engine Features ................................ 19
Engine Cooling and Lubrication......................... 20
Engine Service Life ............................................ 20
Engine Specifications......................................... 18
Welding and Caterpillar Electronic Engines....... 20
Engine Diagnostics................................................ 34
Engine Electronics................................................. 15
Engine Features and Controls............................... 30
121
Index Section
Engine Identification .............................................. 21

Engine Lifting......................................................... 25
Engine Lifting and Storage .................................... 25
Engine Monitoring System (EMS) ......................... 27
Communication Data Link.................................. 29
EMS Main Unit ................................................... 28
Quad Gauge Unit ............................................... 28
Tachometer Unit................................................. 29
Engine Mounts - Inspect........................................ 91
Engine Oil .............................................................. 50
Caterpillar Diesel Engine Oil .............................. 50
Commercial Oils................................................. 51
Total Base Number (TBN) and Fuel Sulfur Levels
for Direct Injection (DI) Diesel Engines ............ 52
Engine Oil and Filter - Change .............................. 93
Drain the Engine Oil........................................... 95
Fill the Engine Crankcase .................................. 96
Oil Grade Plug ................................................... 94
Replace the Oil Filter ......................................... 95
Selection of Oil Change Interval ........................ 93
Engine Oil Level - Check ....................................... 92
Engine Oil Sample - Obtain ................................... 92
Obtain the Sample and the Analysis.................. 92
Engine Operation................................................... 45
Engine Operation with Active Diagnostic Codes ... 37
Engine Operation with Intermittent Diagnostic
Codes .................................................................. 37
Engine Rating Conditions .................................... 112
Engine Rating Definitions .................................... 112
Engine Ratings .................................................... 112
Engine Starting................................................ 13, 39
Ether .................................................................. 13
Engine Stopping .............................................. 14, 46
Engine Storage...................................................... 25
Engine Storage Procedure - Check....................... 97
Engine Valve Lash - Inspect/Adjust ....................... 97
Engine Valve Rotators - Inspect ............................ 97
Ether Starting Aid Cylinder - Replace (If
Equipped) ............................................................ 98
Extended Life Coolant (ELC)................................. 62
Extended Life Coolant (ELC) Cooling System
Maintenance ........................................................ 63
Caterpillar ELC Extender .................................. 63
Changing to Caterpillar ELC .............................. 64
Commercial ELC................................................ 65
ELC Cooling System Cleaning........................... 64
ELC Cooling System Contamination.................. 65
Proper additions to the Extended Life Coolant .. 63
Foreword.................................................................. 5
California Proposition 65 Warning ....................... 5
Literature Information........................................... 4
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 4
Safety ................................................................... 4
Fuel and the Effect from Cold Weather ................. 48
Fuel Recommendations......................................... 57
Fuel Related Components in Cold Weather .......... 49
Fuel Filters ......................................................... 49
Fuel Heaters ...................................................... 49
Fuel Tanks.......................................................... 49
Fuel Specifications ................................................ 57
Fuel System - Prime.............................................. 98
Engines that are Equipped with a Fuel Priming
Pump................................................................ 98
Engines that are Not Equipped with a Fuel Priming
Pump................................................................ 99
Fuel System Primary Filter/Water Separator Drain .................................................................... 99
- Replace ........................................................... 100
Replace the Element........................................ 100
Fuel System Secondary Filter - Replace............. 101
Fuel Tank Water and Sediment - Drain................ 102
Drain the Water and the Sediment................... 102
Fuel Storage Tanks .......................................... 102
Fuel Tank ......................................................... 102
G
Gauges and Indicators .......................................... 26
General Coolant Information ................................. 59
Additives ............................................................ 60
Glycol ................................................................. 60
Water ................................................................. 59
General Hazard Information .................................... 7
Asbestos Information ........................................... 9
Containing Fluid Spillage ..................................... 9
Dispose of Waste Properly ................................ 10
Fluid Penetration .................................................. 9
Pressure Air and Water........................................ 8
General Information............................................... 17
H
F
Fan Drive Bearing - Lubricate................................
Fault Logging.........................................................
Fire Prevention and Explosion Prevention.............
Ether ..................................................................
Fire Extinguisher ................................................
Lines, Tubes and Hoses.....................................
Hoses and Clamps - Inspect/Replace ................. 102

Replace the Hoses and the Clamps ................ 103
98
36
10
12
12
12
I
Important Safety Information ................................... 2
Information Plate ................................................... 21
122
Index Section
J
Jacket Water Heater - Check............................... 103
Refill Capacities..................................................... 71
Cooling System.................................................. 71
Lubrication System ............................................ 71
Lubricant Information.............................................
API Oils ..............................................................
Engine Manufacturers Association (EMA) Oils ..
General Information ...........................................
Lubricant Specifications ........................................
Lubricating Grease ................................................
Caterpillar Premium Grease (CPG) ...................
Multipurpose Greases........................................
Special Purpose Grease (SPG).........................
50
50
50
50
50
54
56
55
55
M
Maintenance Interval Schedule ............................. 72
Maintenance Log ................................................. 119
Maintenance Records.......................................... 117
Maintenance Section ............................................. 50
Manual Stop Procedure......................................... 47
Model View Illustrations......................................... 18
Model Views .......................................................... 18
Mounting and Dismounting.................................... 13
O
Operation Section.................................................. 25
Ordering Replacement Parts............................... 115
Overhaul Considerations ..................................... 103
Oil Consumption as an Overhaul Indicator ...... 104
Overhaul Recommendation ............................. 104
P
Power Take-Off Clutch - Check/Adjust/Lubricate.. 106
Product Identification Information .......................... 21
Product Information Section .................................. 17
R
Radiator - Clean .................................................. 107
Radiator Restrictions ............................................. 48
Re-refined Base Stock Oils ................................... 53
Reference Information Section ............................ 112
Reference Material .............................................. 116
Coolants........................................................... 116
Fuels ................................................................ 116
Lubricants ........................................................ 116
Miscellaneous .................................................. 116
Reference Materials ............................................ 116
Reference Numbers .............................................. 21
Record for Reference......................................... 21
SOS Coolant Analysis ......................................... 61

New Systems, Refilled Systems, and Converted
Systems ........................................................... 62
Recommended Interval for SOS Coolant
Sample ............................................................. 62
SOS Coolant Analysis (Level 1)....................... 62
SOS Coolant Analysis (Level 2)....................... 62
SOS Oil Analysis ................................................. 56
Safety Section ......................................................... 6
Safety Signs and Labels.......................................... 6
Sensors and Electrical Components ..................... 30
Atmospheric Pressure Sensor ........................... 31
Coolant Temperature Sensor ............................. 31
Crankshaft Position Sensor and Camshaft Position
Sensor.............................................................. 32
Engine Oil Pressure Sensor............................... 32
Engine Oil Temperature Sensor......................... 32
Failure of Sensors .............................................. 31
Injection Actuation Pressure Sensor.................. 32
Inlet Air Temperature Sensor ............................. 32
Programmable Monitoring System (PMS) ......... 31
Sensor Locations ............................................... 30
Throttle Position Sensor..................................... 32
Turbocharger Outlet Pressure Sensor ............... 31
Serial Number Plate .............................................. 21
Severe Service Application - Check .................... 107
Environmental Factors ..................................... 108
Improper Maintenance Procedures.................. 108
Improper Operating Procedures ...................... 108
Starting Motor - Inspect ....................................... 108
Starting the Engine................................................ 40
Air Inlet Heater ................................................... 40
Cold Weather Starting ....................................... 40
Ether Injection System ....................................... 41
Initial Inspection ................................................. 40
Problems with the Wiring Harness..................... 42
Starting Problems .............................................. 42
Starting with Jump Start Cables ............................ 43
Stopping the Engine .............................................. 46
Supplemental Coolant Additive (SCA)................... 65
Synthetic Base Stock Oils ..................................... 53
T
Table of Contents..................................................... 3
Turbocharger - Inspect......................................... 108
Cleaning and Inspecting .................................. 109
Removal and Installation.................................. 109
123
Index Section
W
Walk-Around Inspection ...................................... 109
Inspect the Engine for Leaks and for Loose
Connections ................................................... 109
Warranty Information ........................................... 111
Warranty Section ................................................. 111
Water Pump - Inspect .......................................... 110
Water/Supplemental Coolant Additive (SCA) ........ 66
Cooling Systems with Larger Capacities ........... 67
Welding on Engines with Electronic Controls ........ 17
124
Index Section
Product and Dealer Information

Note: For product identification plate locations, see the section Product Identification Information in the
Operation and Maintenance Manual.
Delivery Date:
Product Information
Model:
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
Sales:
Parts:
Service:
Phone Number
Hours
2002 Caterpillar
All Rights Reserved
Printed in U.S.A.

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SEBU7502-05

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Cooling System Specifications ............................. 59

Maintenance Interval Schedule ............................ 72

Reference Information Section

Burn Prevention .................................................... 10

Product Information Section

Use fuel consumption or service hours to determine

California Proposition 65 Warning

Safety Signs and Labels

(1) Valve cover

The warning label for the starting aid is located on

Replace any damaged warning signs or missing

Do not operate or work on this engine unless you

If the engine is equipped with an air inlet heater

The warning label for lifting the engine with a fuel

The warning label for the clutch is located on the

Rotating gears can cause entanglement of the

General Hazard Information

Attach a Do Not Operate warning tag or a similar

Do not wear loose clothing or jewelry that can

Do not allow unauthorized personnel on the engine,

Use all cleaning solutions with care.

Engine exhaust contains products of combustion

Unless other instructions are provided, perform

Cautiously remove the following parts. To help

Disconnect the batteries when maintenance

snag on controls or on other parts of the engine.

Ensure that all protective guards and all covers

Never put maintenance fluids into glass

Report all necessary repairs.

The engine is stopped. Ensure that the engine

Do not attempt any repairs that are not

understood. Use the proper tools. Replace

Pressure Air and Water

Pressurized air and/or water can cause debris

Wear a hard hat, protective glasses, and other

When work is performed around an engine that

Always use a board or cardboard when you check

Containing Fluid Spillage

Tools that are suitable for collecting fluids and

Tools that are suitable for containing fluids and

Obey all local regulations for the disposal of liquids.

Caterpillar equipment and replacement parts that

Never use compressed air for cleaning.

A vacuum cleaner that is equipped with a high

Use exhaust ventilation on permanent machining

Wear an approved respirator if there is no other

Comply with applicable rules and regulations

Obey environmental regulations for the disposal

Any contact with hot coolant or with steam

Stay away from areas that might have asbestos

Dispose of Waste Properly

Ensure that the filler cap is cool before removing

Improperly disposing of waste can threaten the

Electrolyte is an acid. Electrolyte can cause

Fire Prevention and Explosion

SMCS Code: 1000; 7405