SEBU7772-06-C9 OMM JSC1-Up MBD1-Up REH1-Up

SEBU7772-06 (en-us)
July 2017
Operation and
Maintenance
Manual
C9 Industrial Engines
JSC 1-UP (Engine)
REH 1-UP (Engine)
MBD 1-UP (Engine)
JLW 1-UP (Engine)
MNK 1-UP (Engine)
PAZ 1-UP (Package)
PDZ 1-UP (Package)
SAFETY.CAT.COM
i06558969
Important Safety Information

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

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

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7772-06 3
Table of Contents
Table of Contents Refill Capacities............................................... 55
Maintenance Recommendations .................... 64

Foreword ........................................................... 4
Maintenance Interval Schedule....................... 67
Safety Section
Safety Messages............................................... 5
Warranty Section
Warranty Information..................................... 107

General Hazard Information.............................. 7
Burn Prevention................................................11 Reference Information Section
Fire Prevention and Explosion Prevention.......11 Engine Ratings .............................................. 108
Crushing Prevention and Cutting Prevention.. 13 Customer Service.......................................... 109
Mounting and Dismounting ............................. 14 Reference Materials ....................................... 111
Before Starting Engine .................................... 14 Index Section
Engine Starting................................................ 14 Index...............................................................114
Engine Stopping .............................................. 15
Electrical System............................................. 15
Engine Electronics........................................... 16
Product Information Section
General Information ........................................ 17
Product Identification Information ................... 23
Operation Section
Lifting and Storage .......................................... 25
Features and Controls..................................... 28
Engine Diagnostics ......................................... 34
Engine Starting................................................ 44
Engine Operation ............................................ 49
Cold Weather Operation ................................. 51
Engine Stopping .............................................. 53
Maintenance Section
4 SEBU7772-06
Foreword
Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
This manual contains safety, operation instructions, wet or freezing cold operating conditions, more
lubrication and maintenance information. This frequent lubrication and maintenance than is
manual should be stored in or near the engine area in specified in the Maintenance Interval Schedule may
a literature holder or literature storage area. Read, be necessary.
study and keep it with the literature and engine
information. The maintenance schedule items are organized for a
preventive maintenance management program. If the
English is the primary language for all Cat preventive maintenance program is followed, a
publications. The English used facilitates translation periodic tune-up is not required. The implementation
and consistency in electronic media delivery. of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures.
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design Maintenance Intervals
may have caused changes to your engine which are
not included in this manual. Whenever a question Perform maintenance on items at multiples of the
arises regarding your engine, or this manual, please original requirement. Each level and/or individual
consult with your Cat dealer for the latest available items in each level should be shifted ahead or back
information. depending upon your specific maintenance practices,
operation and application. We recommend that the
maintenance schedules be reproduced and
Safety displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
This safety section lists basic safety precautions. In maintained as part of the engine's permanent record.
addition, this section identifies hazardous, warning
situations. Read and understand the basic See the section in the Operation and Maintenance
precautions listed in the safety section before Manual, “Maintenance Records” for information
operating or performing lubrication, maintenance and regarding documents that are generally accepted as
repair on this product. proof of maintenance or repair. Your authorized Cat
dealer can assist you in adjusting your maintenance
schedule to meet the needs of your operating
Operation environment.
Operating techniques outlined in this manual are
basic. They assist with developing the skills and Overhaul
techniques required to operate the engine more
efficiently and economically. Skill and techniques Major engine overhaul details are not covered in the
develop as the operator gains knowledge of the Operation and Maintenance Manual except for the
engine and its capabilities. interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
The operation section is a reference for operators. authorized Cat dealer. Your Cat dealer offers a
variety of options regarding overhaul programs. If you
Photographs and illustrations guide the operator experience a major engine failure, there are also
through procedures of inspecting, starting, operating numerous after failure overhaul options available
and stopping the engine. This section also includes a from your Cat dealer. Consult with your dealer for
discussion of electronic diagnostic information. information regarding these options.
Maintenance California Proposition 65 Warning

The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped Diesel engine exhaust and some of its constituents
by fuel consumption, service hours and/or calendar are known to the State of California to cause cancer,
time maintenance intervals. Items in the maintenance birth defects, and other reproductive harm.
schedule are referenced to detailed instructions that
follow. Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
Use fuel consumption or service hours to determine after handling.
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.
SEBU7772-06 5
Safety Section
Safety Messages
Safety Section
i02246834
Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages 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 safety
messages.
Ensure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
pictures are not visible. When the safety messages
are cleaned, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
the safety messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
safety messages. The safety messages that are
loosened could drop off of the engine.
Replace any damaged safety messages or missing
safety messages. If a safety message is attached to
a part of the engine that is replaced, install a new
safety message on the replacement part. Any
Caterpillar dealer can provide new safety messages.
Do not work on the engine and do not operate the
engine unless the instructions and the warnings in
the Operation and Maintenance Manual are
understood. Proper care is your responsibility. Failure
to follow the instructions or failure to heed the
warnings could result in injury or in death.
6 SEBU7772-06
Safety Section
Safety Messages
Illustration 1 g01104158
SEBU7772-06 7
Safety Section
General Hazard Information
The following section describes the safety messages

that are found on the engine.
(1) Universal Warning
The universal safety messages are located on each

side of the valve covers.
Do not operate or work on this equipment unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.
i06300340

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

switch or controls before the engine is serviced or
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each
operator control station. When appropriate,
disconnect the starting controls.
8 SEBU7772-06
Safety Section
Do not allow unauthorized personnel on the engine, • The engine is stopped. Ensure that the engine
or around the engine when the engine is being cannot be started.
serviced.
• The protective locks or the controls are in the
Cautiously remove the following parts. To help applied position.
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed. • Disconnect the batteries when maintenance is
performed or when the electrical system is
• Filler caps serviced. Disconnect the battery ground leads.
• Grease fittings Tape the leads in order to help prevent sparks.
• Pressure taps • When starting a new engine, make provisions to

stop the engine if an overspeed occurs. If an
• Breathers engine has not been started since service has
been performed, make provisions to stop the
• Drain plugs engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the
Use caution when cover plates are removed. fuel supply and/or the air supply to the engine.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of the • Do not attempt any repairs that are not
cover plate or the device. Before removing the last understood. Use the proper tools. Replace any
two bolts or nuts, pry the cover loose in order to equipment that is damaged or repair the
relieve any spring pressure or other pressure. equipment.
• Start the engine with the operator controls. Never
short across the starting motor terminals or the
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the
electrical system could be damaged.
Pressurized Air and Water

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

• Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
SEBU7772-06 9
Safety Section
Avoid direct spraying of water on electrical Static Electricity Hazard when

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

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

• Armoring that is embedded in the outer covering
10 SEBU7772-06
Safety Section
Ensure that all of the clamps, the guards, and the • A vacuum cleaner that is equipped with a high
heat shields are installed correctly. Correct efficiency particulate air filter (HEPA) can also be
installation of these components will help to prevent used.
these effects: vibration, rubbing against other parts
and excessive heat during operation. • Use exhaust ventilation on permanent machining
jobs.
Inhalation • Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos

particles in the air.
Softwrap
Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
Exhaust approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate
Use caution. Exhaust fumes can be hazardous to protective clothing in order to minimize direct contact.
your health. If you operate the equipment in an Use good hygiene practices and wash hands
enclosed area, adequate ventilation is necessary. thoroughly after handling Softwrap material. Do not
smoke until washing hands thoroughly after handling
Asbestos Information Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean
Cat equipment and replacement parts that are up debris.
shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.

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

• Use a wet method in order to clean up asbestos
materials.
SEBU7772-06 11
Safety Section
Burn Prevention
Reference: The applicable material safety data Ensure that the filler cap is cool before removing the
sheets can be found at the following web site by filler cap. The filler cap must be cool enough to touch
searching using part number or the name: with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
https://catmsds.cat.com/MSDSSearch/servlet/
cat.cis.ecs. Cooling system conditioner contains alkali. Alkali can
msdsSearch.controller. cause personal injury. Do not allow alkali to contact
UserIdentificationDisplayServlet the skin, the eyes, or the mouth.
Dispose of Waste Properly Oils

Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
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.
i05626649
Illustration 8 g00706404 Fire Prevention and Explosion

Improperly disposing of waste can threaten the Prevention
environment. Potentially harmful fluids should be
disposed of according to local regulations. SMCS Code: 1000; 4450; 7405
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
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
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.
Use of personal protection equipment (PPE) may be
Coolant needed.
When the engine is at operating temperature, the All fuels, most lubricants, and some coolant mixtures
engine coolant is hot. The coolant is also under are flammable.
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
Any contact with hot coolant or with steam can cause product when a fire hazard exists. Contact your Cat
severe burns. Allow cooling system components to dealer for service.
cool before the cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
12 SEBU7772-06
Safety Section
Fire Prevention and Explosion Prevention
Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause a deterioration. Properly route all hoses. The lines and
fire. Fire may cause personal injury and property hoses must have adequate support and secure
damage. clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an Properly install all oil filters and fuel filters. The filter
emergency shutdown. 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 Cat dealer for
additional information about suitable protection
devices.
Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
All fluids that are captured in the fluid spill
containment basin should be cleaned up
immediately. Failure to clean up spilled fluids can
cause a fire. Fire may cause personal injury and
property damage.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective Illustration 10 g00704059
containers. Do not smoke in areas that are used for
storing flammable materials. Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not
Do not expose the engine to any flame. refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in a line, a tube, or Avoid static electricity risk when fueling. Ultra Low
a seal failure. Exhaust shields must be installed Sulfur Diesel (ULSD) poses a greater static ignition
correctly. hazard than earlier diesel formulations with a higher
Sulfur content. Avoid death or serious injury from fire
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain or explosion. Consult with your fuel or fuel system
flammable fluid. Clean any such lines or tanks supplier to ensure that the delivery system is in
thoroughly with a nonflammable solvent prior to compliance with fueling standards for proper
welding or flame cutting. grounding and bonding practices.
Wiring must be kept in good condition. Properly route

and attach all electrical wires. Check all electrical
wires daily. Repair any wires that are loose or frayed
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
SEBU7772-06 13
Safety Section
Crushing Prevention and Cutting Prevention
Do not store ether cylinders in living areas or in the

engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49 °C
(120 °F). Keep ether cylinders away from open
flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Do not spray ether into an engine if the engine is
equipped with a thermal starting aid for cold weather
starting.
Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Cat dealer for repair or
for replacement parts.
Check lines, tubes, and hoses carefully. Do not use
Gases from a battery can explode. Keep any open your bare hand to check for leaks. Use a board or
flames or sparks away from the top of a battery. Do cardboard to check for leaks. Tighten all connections
not smoke in battery charging areas. to the recommended torque.
Never check the battery charge by placing a metal Replace the parts if any of the following conditions
object across the terminal posts. Use a voltmeter or a are present:
hydrometer.
• End fittings are damaged or leaking.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the • Outer coverings are chafed or cut.
Operation Section of this manual for specific
instructions. • Wires are exposed.
Do not charge a frozen battery. Charging a frozen • Outer coverings are ballooning.
battery may result in an explosion.
• Flexible parts of the hoses are kinked.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the • Outer covers have embedded armoring.
recommended cables, connections, and battery box
covers when the engine is operated. • End fittings are displaced.
Fire Extinguisher Make sure that all clamps, guards, and heat shields
are installed correctly in order to prevent vibration,
Make sure that a fire extinguisher is available. Be rubbing against other parts, and excessive heat.
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire i01359666
extinguisher regularly. Obey the recommendations
on the instruction plate. Crushing Prevention and
Ether Cutting Prevention
SMCS Code: 1000; 4450; 7405
Ether is flammable and poisonous.
Support the component properly when work beneath
Use ether in ventilated areas. Do not smoke while the component is performed.
you are replacing an ether cylinder or while you are
using an ether spray. Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
14 SEBU7772-06
Safety Section
Mounting and Dismounting
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, Engine exhaust contains products of combustion
reinstall the guards.
which may be harmful to your health. Always
Keep objects away from moving fan blades. The fan start and operate the engine in a well ventilated
blades will throw objects or cut objects. area and, if in an enclosed area, vent the exhaust
to the outside.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes. Inspect the engine for potential hazards.
Chips or other debris may fly off objects when objects Do not start the engine or move any of the controls if
are struck. Before objects are struck, ensure that no there is a “DO NOT OPERATE” warning tag or similar
one will be injured by flying debris. warning tag attached to the start switch or to the
controls.
i01372247 Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
Mounting and Dismounting area is free of personnel.
SMCS Code: 1000; 4450; 7405 If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
Inspect the steps, the handholds, and the work area lights work properly, if equipped.
before mounting the engine. Keep these items clean
and keep these items in good repair. All protective guards and all protective covers must
be installed if the engine must be started in order to
Mount the engine and dismount the engine only at perform service procedures. To help prevent an
locations that have steps and/or handholds. Do not accident that is caused by parts in rotation, work
climb on the engine, and do not jump off the engine. around the parts carefully.
Face the engine in order to mount the engine or Do not start an engine when the governor linkage is
dismount the engine. Maintain a three-point contact disconnected.
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any Do not bypass the automatic shutoff circuits. Do not
controls as handholds. disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
Do not stand on components which cannot support circuits are also provided in order to help prevent
your weight. Use an adequate ladder or use a work engine damage.
platform. Secure the climbing equipment so that the
equipment will not move. i04021433
Do not carry tools or supplies when you mount the

engine or when you dismount the engine. Use a hand Engine Starting
line to raise and lower tools or supplies. SMCS Code: 1000
i04257031 If a warning tag is attached to the engine start switch

or to the controls, DO NOT start the engine or move
Before Starting Engine the controls. Consult with the person that attached
the warning tag before the engine is started.
SMCS Code: 1000
All protective guards and all protective covers must
be installed if the engine must be started in order to
NOTICE perform service procedures. To help prevent an
For initial start-up of a new or rebuilt engine, and for accident that is caused by parts in rotation, work
start-up of an engine that has been serviced, make around the parts carefully.
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the Start the engine from the operator's compartment or
air and/or fuel supply to the engine. from the engine start switch.
Always start the engine according to the procedure
that is described in this Operation and Maintenance
Manual, “Engine Starting” topic (Operation Section).
Knowledge of the correct procedure will help to
prevent major damage to the engine components.
Knowledge of the procedure will also help to prevent
personal injury.
SEBU7772-06 15
Safety Section
Engine Stopping
To ensure that the jacket water heater (if equipped) Grounding Practices
and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge and the
oil temperature gauge during the heater operation.
Engine exhaust contains products of combustion that
can be harmful to your health. Always start the
engine and operate the engine in a ventilated area. If
the engine is started in an enclosed area, vent the
engine exhaust to the outside.
i01462046
Engine Stopping
SMCS Code: 1000
Stop the engine according to the procedure in the
Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
the engine components.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled. This may be
accomplished by shutting off the fuel supply to the
engine and/or shutting off the air supply to the Typical example
engine. Grounding Stud To Battery Ground
To stop an electronically controlled engine, cut the
power to the engine.
i02469632
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” jump start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. Refer to
the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.
16 SEBU7772-06
Safety Section
Engine Electronics
All grounds should be tight and free of corrosion. The

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

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

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

ground straps can be damaged by electrical
discharge. • Fuel Temperature
To ensure that the engine and the engine electrical • Intake Manifold Air Temperature
systems function properly, an engine-to-frame
ground strap with a direct path to the battery must be • System Voltage
used. This path may be provided by way of a starting
motor ground, a starting motor ground to the frame, The Engine Monitoring package can vary for different
or a direct engine ground to the frame. engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: Many of the engine control systems and
display modules that are available for Caterpillar
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting
Manual for more information.
SEBU7772-06 17
General Information
Product Information
Section
General Information
i02946601
Model View Illustrations

SMCS Code: 1000
Left Side View
(9) Fumes disposal tube
(10) Engine oil level gauge
(11) Fuel filter
(14) Water outlet
i03690940

SMCS Code: 1000
S/N: PAZ1–Up
S/N: PDZ1–Up
Right Side View
(1) Valve mechanism cover
(2) Turbocharger
(3) Engine oil filler cap
(4) Water temperature regulator housing
(5) Vibration damper and crankshaft pulley
(6) Engine oil drain plug
(7) Engine oil filter
(8) Flywheel housing
18 SEBU7772-06
Illustration 16 g01460598 Illustration 17 g01460603

Right Side View Left Side View
(1) Valve mechanism cover (9) Fumes disposal tube
(2) Turbocharger (10) Engine oil level gauge
(3) Engine oil filler cap (11) Fuel filter
(4) Water temperature regulator housing (14) Water outlet
(5) Vibration damper and crankshaft pulley
(6) Engine oil drain plug
(7) Engine oil filter
(8) Flywheel housing
SEBU7772-06 19
CX31-P600 Transmission
(1) Scheduled oil sampling port (S·O·S port) (6) PTO (13) SAE J1926 #4 Supply port for the
(2) Outlet pressure for the transmission oil (7) Location of the identification and serial auxiliary PTO control
filter plate (14) Output yoke
(3) Customer interface connector (8) Oil filler and dipstick (15) Transmission oil filter
(4) Lifting points (9) Four M16x2 threaded mounts
(5) SAE J615 mounting pads SAE #1 bolt (10) Rear magnetic drain plug
pattern with 6 M16 x 2 threaded holes. (11) Optional rear power take-off (RPTO)
SAE #2 width between mounting pads (12) Transmission output speed sensors
20 SEBU7772-06
Product Description
CX31-P600 Transmission
(5) SAE J615 mounting pads SAE #1 bolt (22) Engine output speed sensor (31) Coupler for transmission lubrication
pattern with 6 M16 x 2 threaded holes. (23) Torque converter output speed sensor pressure (cooler outlet)
SAE #2 width between mounting pads (24) Electronic Control Unit (ECU) (32) Coupler for torque converter outlet
(16) Crankshaft to flex plate connection (25) Filter bypass switch pressure
(17) Flex plate (26) Transmission oil temperature sensor (33) Coupler for transmission oil cooler
(18) Starter ring gear (pump outlet and filter inlet) (34) SAE J1926 #16 outlet to cooler port
(19) No. 1 SAE J617 flywheel housing (24 (27) Location of oil level sensor (35) Transmission oil temperature sensor
bolt) (28) Guard for the ECPC valves (36) Torque converter outlet relief valve
(20) PTO (29) ECPC valves (six) (37) Transmission main relief valve
(21) Transmission breather (30) SAE J1926 #16 inlet from cooler port (38) Drain plug
i04368417 Engine Specifications

Product Description Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
SMCS Code: 1000; 4450; 4491 sides of the engine are determined from the flywheel
The Cat C9 Industrial Engine has the following end. The number 1 cylinder is the front cylinder.
characteristics:
• In-Line 6-cylinder
• Four-stroke cycle
• Hydraulically Actuated Electronic Unit Injection

(HEUI)
• Turbocharged
• Air-to-air aftercooled (ATAAC)
SEBU7772-06 21
Product Description
Additional Features
The following additional features provide increased
engine fuel economy and serviceability:
• Cold starting capability
• Tampering detection
• Diagnostics
Hydraulic Electronic Unit Injectors

Hydraulically Actuated Electronic Unit Injectors
(HEUI) perform the following functions:
Illustration 20 g00609479 • Pump the fuel.
Cylinder and valve location
(A) Exhaust valve
• Meter the fuel.
(B) Inlet valve
• Time the fuel injection.
Table 1
The unit injectors are controlled by the ECM which
C9 Engine Specifications uses the camshaft position, the engine speed
signals, and the inlet air pressure sensors. The rated
Arrangement and Cylinders In-Line 6-cylinder
rpm is identified on the information plate.
Bore 112.0 mm (4.41 inch)
Engine Diagnostics
Stroke 149.0 mm (5.87 inch)
Aspiration ATAAC The engine has built-in diagnostics in order to ensure

that all of the components are functioning properly. In
Displacement 8.8 L (537 in3) the event of a deviation from the programmed limits,
the operator will be alerted to the condition by a
Firing Order 1-5-3-6-2-4 “DIAGNOSTIC” lamp. Under certain conditions, the
Rotation (flywheel end) Counterclockwise
engine horsepower and the vehicle speed may be
limited. A Cat electronic service tool may be used to
display the diagnostic code.
Electronic Engine Features There are three types of diagnostic codes: active,
logged and event.
The Cat C9 Engine is designed for electronic
controls. The integral on board computer controls the Most of the diagnostic codes are logged and stored in
operation of the engine. Current operating conditions the ECM. For additional information, refer to the
are monitored. The Electronic Control Module (ECM) Operation and Maintenance Manual, “Engine
controls the response of the engine to these Diagnostics” topic.
conditions and to the demands of the operator. These
conditions and operator demands determine the The ECM provides an electronic governor that
precise control of fuel injection by the ECM. The controls the injector output in order to maintain the
electronic engine control system provides the desired engine rpm. The functionality of electronic
following features: governor is similar to the Cat mechanical governor,
but the electronic governor includes additional
• Engine speed governor features.
• Automatic air/fuel ratio control Engine Cooling and Lubrication

• Torque rise shaping
The cooling system consists of the following
• Injection timing control components:
• System diagnostics • Centrifugal pump that is driven by belts
For more information on electronic engine features, • Water temperature regulator which regulates the
refer to the Operation and Maintenance Manual, engine coolant temperature
“Engine Diagnostics” topic.
• Oil cooler and radiator which incorporates a shunt
system
22 SEBU7772-06
Product Description
The engine lubricating oil that is supplied is cooled. However, failures that result from the installation
The engine lubricating oil is also filtered. Bypass or use of devices, accessories, or consumables
valves provide unrestricted flow of lubrication oil to from other manufacturers are NOT Caterpillar
the engine components during the following defects. Therefore, the defects are NOT covered
conditions: under the Caterpillar warranty.
• High oil viscosity Welding and Cat Electronic

• Plugged oil cooler or plugged oil filter elements Engines
(paper cartridge)
NOTICE
Engine Service Life Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
Engine efficiency and maximum utilization of engine a chassis frame or rail. Consult the OEM of the equip-
performance depend on the adherence to proper ment or your Cat dealer regarding welding on a chas-
operation and maintenance recommendations. In sis frame or rail.
addition, use recommended fuels, coolants, and
lubricants. Use the Operation and Maintenance To help avoid damage to the electronic controls,
Manual as a guide for required engine maintenance. proper welding procedures are necessary. Before
welding on an engine that is equipped with an
Expected engine life is generally predicted by the electronic engine, observe the following precautions:
average power that is demanded. The average
power that is demanded is based on fuel 1. Turn off the engine. Place the key start switch in
consumption of the engine over a time. Reduced the OFF position.
hours of operation at full throttle and/or operating at
reduced throttle settings result in a lower average 2. If the machine has a battery disconnect switch,
power demand. Reduced hours of operation will open the switch. Otherwise, disconnect the
increase the length of operating time before an negative “-” battery cable from the battery of the
engine overhaul is required. For more information, vehicle.
refer to the Operation and Maintenance Manual,
“Overhaul Considerations” topic. NOTICE
Do not ground the welder to electrical components
Aftermarket Products and Cat such as the ECM or sensors. Improper grounding
can cause damage to the drive train bearings, hy-
Engines draulic components, electrical components, and oth-
er components.
NOTICE Clamp the ground cable from the welder to the com-
Caterpillar requires the use of a 4 micron (c) secon- ponent that will be welded. Place the clamp as close
dary fuel filter for the following reasons: to maximize as possible to the weld. This will help reduce the pos-
fuel system life and to prevent premature wear out sibility of damage.
from abrasive particles in the fuel. Cat high efficiency
fuel filters meet these requirements. Consult your Cat
dealer for the proper part numbers. 3. Clamp the ground cable from the welder to the
component that will be welded. Place the clamp as
The use of auxiliary devices, accessories, or close as possible to the weld.
consumables (filters, additives, catalysts, etc.) which
are made by other manufacturers on Cat products do 4. Protect wiring harnesses from welding debris and
not automatically affect the Caterpillar warranty. spatter. Use proper welding procedures.
SEBU7772-06 23
Product Identification Information
Product Identification
Information
i02240570
Plate Locations and Film

Locations
SMCS Code: 1000; 4450
(1) Serial Number Plate
(2) Information Plate

24 SEBU7772-06
Emissions Certification Film
Caterpillar engines are identified by serial numbers Record for Reference

and by arrangement numbers. These numbers are
shown on the engine serial number plate and on the Table 2
engine information plate. Caterpillar dealers need System or Component Information
these numbers in order to determine the components
that were included with the engine. This permits Chassis serial number
accurate identification of replacement part numbers.
Engine model
Serial Number Plate (1) Engine serial number
Engine arrangement
The engine serial number plate is located on the number
upper right side of the engine block.
Modification number
Engine serial number
Engine low idle rpm
Engine model Engine full load rpm
Arrangement number Performance specification
number
Information Plate (2) Engine horsepower
The engine information plate is located on the valve Primary fuel filter part
cover base near the front of the left side of the number
engine. Water separator element
part number
Engine Serial Number
Secondary fuel filter ele-
Engine Arrangement Number ment part number
Engine Modification Number Lubrication oil filter ele-

ment part number
The engine identification plate also contains other
important information about the engine. Auxiliary oil filter element
part number
i04019095 Supplemental coolant ad-
ditive maintenance ele-
Emissions Certification Film ment part number (if
equipped)
SMCS Code: 1000; 7405
Total lubrication system
Note: This information is pertinent in the United capacity
States, in Canada and in Europe. Total cooling system
capacity
Consult your Cat dealer for an Emission Control
Warranty Statement. Engine air cleaner ele-
ment part number
This label is located on the engine.
Fan drive belt part
i04128675
number
Alternator belt part
Reference Information number
SMCS Code: 1000; 4450

Information for the following items may be needed to
order parts. Locate the information for your engine.
Record the information on the appropriate space.
Make a copy of this list for a record. Retain the
information for future reference.
SEBU7772-06 25
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage

i04369138
Product Lifting
SMCS Code: 7000; 7002
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Re-
member that the capacity of an eyebolt is less as the
angle between the supporting members and the ob-
ject 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
Lifting eye on a typical C9 Industrial Engine obtain proper balance and safety.
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 Cat dealer for information regarding
fixtures for proper engine lifting.
i05260537
Product Storage
SMCS Code: 7002
Storage (Less Than One Year)

If an engine is not used, oil can run off the following
parts that normally receive lubrication: cylinder walls,
piston rings, main bearings, connecting rod bearings,
crankshaft and gears.
This lack of lubricant allows corrosion to begin to
appear on the metal. This condition is worse in areas
of high humidity.
26 SEBU7772-06
Operation Section
Product Storage
When the engine is started again, metal to metal Clean the primary fuel filter. Fill with calibration
contact will cause wear before the surfaces receive fluid or kerosene. Install the primary fuel filter and
oil. To minimize this wear, use the starter to turn the operate the priming pump. This procedure will
engine with the throttle in the FUEL OFF position. send clean oil to the secondary filter and the
When oil pressure is shown on the pressure gauge, engine.
start the engine.
Open the fuel tank drain valve in order to drain any
1. Clean the engine of any dirt, rust, grease, and oil. water and dirt from the fuel tank. Apply a spray of
Inspect the exterior. Paint areas that contain paint calibration fluid or kerosene at the rate of
damage with a good quality paint. 30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank
capacity in order to prevent rust in the fuel tank.
2. Remove dirt from the air cleaners. Check all seals, Add 0.15 mL per L (.02 oz per 1 gal US) of
gaskets, and the filter element for damage. commercial biocide such as Biobor JF to the fuel.
3. Apply lubricant to all points in this Operation and Apply a small amount of oil to the threads on the
Maintenance Manual, “Maintenance Interval fuel tank filler neck and install the cap. Seal all
Schedule”. openings to the tank in order to prevent
evaporation of the fuel and as a preservative.
4. Drain the crankcase oil. Replace the crankcase oil
and change the oil filters. For the proper 10. Remove the fuel nozzles or spark plugs. Apply
procedure, refer to this Operation and 30 mL (1 oz) of the mixture of oils (50 percent VCI
Maintenance Manual. oil and 50 percent engine oil) into each cylinder.
5. If the engine is equipped with an air starting motor, Use a bar or a turning tool in order to turn over the
fill the reservoir with the following mixture: 50 engine slowly. This procedure puts the oil on the
cylinder walls. Install all fuel nozzles or spark plugs
percent volatile corrosion inhibitor oil and tighten to the correct torque.
(<nomen>VCI oil</nomen>) and 50 percent
engine oil. 11. Spray a thin amount of a mixture of 50 percent
VCI oil and 50 percent engine oil onto the following
6. Add VCI oil to the crankcase oil. The volume of components: flywheel, ring gear teeth and starter
VCI oil in the crankcase oil should be 3 to 4 pinion. Install the covers in order to prevent
percent. evaporation of the vapors from the VCI oil.
Note: If the engine crankcase is full, drain enough 12. Apply a heavy amount of Cat Multipurpose
engine oil so the mixture can be added. Grease (MPGM) to all outside parts that move,
such as rod threads, ball joints, linkage.
7. Remove the air filter elements. Turn the engine at
cranking speed with the throttle control in FUEL Note: Install all covers. Ensure that tape has been
OFF position. Use a sprayer to add a mixture of 50 installed over all openings, air inlets, exhaust
percent VCI oil and 50 percent engine oil into the openings, the flywheel housing, the crankcase
air inlet or turbocharger inlet. breathers, the dipstick tubes.
Note: The mixture of VCI oil can be added to the inlet Ensure that all covers are airtight and
by removing the plug for checking turbocharger boost weatherproof. Use a waterproof weather resistant
pressure. The minimum application rate for the VCI tape such as Kendall No. 231 or an equivalent. Do
oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of not use duct tape. Duct tape will only seal for a
engine displacement. short time.
13. Under most conditions, removing the batteries is
8. Use a sprayer to apply a mixture of 50 percent VCI the best procedure. As an alternative, place the
oil and 50 percent crankcase oil into the exhaust batteries in storage. As needed, periodically
openings. The minimum application rate for the oil charge the batteries while the batteries are in
mixture is 5.5 mL per L (3 oz per 1000 cu in) of storage.
engine displacement. Seal the exhaust pipe and
seal any drain holes in the muffler. If the batteries are not removed, wash the tops of
the batteries until the tops are clean. Apply an
9. Remove the fuel from the secondary fuel filter electrical charge to the batteries in order to obtain
housing. Alternately, empty and reinstall the spin- a specific gravity of 1.225.
on fuel filter element in order to remove any dirt
and water. Drain any sleeve metering fuel pump. Disconnect the battery terminals. Place a plastic
cover over the batteries.
Note: For additional information, refer to Special

Instruction, SEHS7633, “Battery Test Procedure”.
SEBU7772-06 27
Operation Section
Product Storage
14. Loosen all belts. 10. Before start-up, test the cooling system for a 3
percent to a 6 percent concentration of coolant
15. Place a waterproof cover over the engine. Ensure
conditioner. Add liquid coolant conditioner or a
that the engine cover is secure. The cover should
coolant conditioner element, if equipped.
be loose enough to allow air to circulate around
the engine in order to prevent damage from Test the coolant mixture for proper nitrite level. If
condensation. necessary, adjust the coolant mixture.
16. Attach a tag with the storage date to the engine. Prime the engine with clean diesel fuel before
starting.
17. Remove the waterproof cover at 2 month or 3
month intervals in order to check the engine for 11. Ensure that the cooling system is clean. Ensure
corrosion. If the engine has signs of corrosion, that the system is full. Ensure that the system has
repeat the protection procedure. the correct amount of supplemental cooling
system conditioner.
Coolant System
12. On the first day of operation, check the entire
Completely fill the cooling system before storage. engine several times for leaks and correct
operation.
Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for more information about 13. If the engine was removed from storage in which
coolants. temperatures of less than -12°C (10°F) were
encountered, refer to Service Manual, SEBU5898,
Removal from Storage “Cold Weather Recommendations Operation and
Maintenance”.
1. Remove all outside protective covers.
2. Change the oil and filters.
3. Check the condition of the fan and alternator belts.
Replace the belts, if necessary. Refer to this
Operation and Maintenance Manual, “Belts -
Inspect/Adjust/Replace” for the correct procedure.
4. Replace the fuel filter elements.
5. Remove the plastic covers from the air cleaner
elements.
6. Use a bar or a turning tool in order to turn the
engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
resistance exist.
7. Before starting the engine, remove the valve cover
or covers. Put a large amount of engine oil on the
camshaft, cam followers, and valve mechanism in
order to prevent damage to the mechanism.
8. Pressure-lubricate the engine before starting the
engine. Pressure lubricating the engine ensures
immediate lubrication and prevents damage to the
engine during the first few minutes of engine
operation. If the engine is not equipped with a
prelube pump, contact your Cat dealer for
information about lubrication of the engine before
starting the engine.
9. Check the condition of all rubber hoses. Replace
any worn hoses. Replace any damaged hoses.
28 SEBU7772-06
Operation Section
Features and Controls
Features and Controls The diagnostic lamp will turn on if the oil pressure
drops below 35 kPa (5 psi) at low idle rpm. The
diagnostic code will be logged in the Engine Control
i01465281 Module (ECM).
Gauges and Indicators Engine Oil Temperature – This gauge
indicates the engine oil temperature. An
SMCS Code: 7450
oil temperature that is higher than
Your engine may not have the same gauges or all of normal indicates a heat problem in the lubrication
the gauges that are described. For more information system and/or the cooling system. This problem
about the gauge package, see the literature that is can damage the cylinder heads, the cylinder
provided by the OEM. liners, the pistons, and the crankshaft bearings.
Gauges provide indications of engine performance. Jacket Water Coolant Temperature –

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

Pressurized System: Hot coolant can cause seri-
• High coolant temperature ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
• Low coolant level components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
• High inlet air temperature pressure.
Engine Oil Pressure – Typical oil 4. Check the coolant level.
pressure for an engine at rated speed
with SAE 10W30 or with SAE 15W40 is Tachometer – This gauge indicates
240 to 480 kPa (35 to 70 psi). engine speed. When the throttle control
lever is moved to the full throttle
A lower oil pressure is normal at low idle. If the load is
stable and the gauge reading changes, perform the position without load, the engine is running at
following procedure: high idle. The engine is running at the full load
rpm when the throttle control lever is at the full
1. Remove the load. throttle position with maximum rated load.
2. Reduce engine speed to low idle. Note: The default high idle rpm and the full load rpm
are stamped on the Information Plate.
3. Check the oil level. Maintain the oil level at the
proper amount. Ammeter – This gauge indicates the
amount of charge or of discharge in the
If the gauge continues to fluctuate, consult your
Caterpillar dealer. battery charging circuit. Operation of
the indicator should be to the right side of “ 0””
(zero).
SEBU7772-06 29
Operation Section
Monitoring System
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.
i04364224
Monitoring System
(If Equipped)
SMCS Code: 1900; 7400; 7450; 7451
Indicators and Gauges Illustration 25 g02517116
The instrument panel may look like the instrument

panel in illustration 25 or the instrument panel in
illustration 26 . The instrument panel may not include
all of the instruments that are shown in the
illustrations.
Warning Lamp (1) – There is a general

fault in the engine. Refer to the
Messenger display for any additional
information that may be available.
30 SEBU7772-06
Operation Section
If Equipped
Circuit Breaker (2) – Reset the circuit Fuel Pressure (10) – This gauge
breaker if a circuit breaker trips. Press indicates fuel pressure to the fuel
the button in order to reset the circuit injection pump from the fuel filter. A
breaker. If the electrical system is working decrease in fuel pressure usually indicates a dirty
properly, the button will remain pressed. If the fuel filter or a plugged fuel filter. As the fuel filter
button does not remain pressed or if the circuit becomes plugged, there will be a noticeable
breaker trips soon after being reset, check the reduction in the engine performance.
appropriate electrical circuit. Repair the electrical
circuit, if necessary. Ammeter (11) – This gauge indicates the
amount of electrical charge or of
Diagnostic Lamp (3) – The diagnostic discharge in the battery charging circuit.
lamp is used to indicate the existence of Operation of the indicator should be to the right
a fault by flashing a fault code. For a side of “ 0”” (zero).
more detailed discussion of the diagnostic lamp,
see this Operation and Maintenance Manual, Engine Oil Pressure (12) – The oil
“Diagnostic Lamp” topic. pressure should be greatest after a cold
engine is started. The pressure will
Start Switch (4) – The start switch has decrease as the engine warms up. The pressure
three positions: OFF, RUN and START. will increase when the engine rpm is increased.
When the start switch is turned The pressure will stabilize when the engine rpm
clockwise to the RUN position, the lamps will is stable.
flash for 5 seconds during the system test. The
lamps will then shut off. In the RUN position, the A lower oil pressure is normal at low idle. If the load is
ECM and electronic systems are powered up. stable and the gauge reading changes, perform the
following procedure:
Idle Speed Switch (5) – When the switch 1. Remove the load.
is in the up position, the engine speed
increases to HIGH IDLE. When the 2. Reduce engine speed to low idle.
switch is in the down position, the engine speed
decreases to LOW IDLE. 3. Check and maintain the oil level.
Service Meter (6) – This display NOTICE

indicates the total operating hours of the To help prevent engine damage, never exceed the
engine. Use the display in order to high idle rpm. An overspeed can result in serious
determine the service hour maintenance damage to the engine. The engine can be operated
at high idle without damage, but the engine should
intervals. Hours of operation are logged in the never be allowed to exceed the high idle rpm.
ECM. A service tool is needed to retrieve the
hours from the ECM.
Note: The high idle rpm and the full load rpm are
Shutdown Switch (7) – Use the engine stamped on the Information Plate.
shutdown switch in order to stop the
engine. Push the shutdown switch in Jacket Water Coolant Temperature (13) –
order to put the switch in the OFF position. This Typical temperature range is 87 to 98°C
action will stop the engine. After the engine (189 to 208°F). Higher temperatures may
stops, turn the knob clockwise. This action will occur under certain conditions. The water
reset the engine shutdown switch to the ON temperature reading may vary according to load.
position. The reading should never exceed the boiling
point for the pressurized system that is being
Tachometer (8) – This gauge indicates used.
engine speed (rpm). When the throttle
control lever is moved to the full throttle Engine Oil Temperature (14) – This
position without load, the engine is running at gauge indicates the engine oil
high idle. The engine is running at the full load temperature. Maximum oil temperature
rpm when the throttle control lever is at the full at rated speed with a full load is 115 °C (239 °F).
throttle position with maximum rated load.
Coolant Temperature (15) – When the
Voltmeter (9) – This gauge indicates the coolant temperature is above the normal
voltage of the electrical system. The operating value, the coolant
needle in the red range indicates low temperature gauge will be in the red zone. Refer
voltage or high voltage. to the Messenger panel for any additional
information that may be available.
SEBU7772-06 31
Operation Section
If Equipped
Service Tool Connector (16) – For more information

regarding the use of Cat Electronic Technician (ET)
and the requirements for Cat ET, refer to the OK button (23) – The “OK” button may be used to
documentation that accompanies your Cat ET confirm the selections that were made with the “scroll
software. up/left” and the “scroll down/right” buttons.
Maintenance Clear Switch (17) – The Performance Monitor Panel

maintenance clear switch is required to
reset the maintenance lamp after
maintenance on the engine is performed.
Maintenance Lamp (18) – The ECM

records data that is related to equipment
maintenance. The ECM will activate the
maintenance indicator lamp when scheduled
maintenance is due. The maintenance indicator
lamp can be reset by actuating the maintenance
clear switch. The maintenance interval may be
based on operating hours or fuel consumption.
The ECM provides information that pertains to
maintenance intervals and the last maintenance
that was performed.
Cat Messenger Display Illustration 28 g01054560

Typical performance monitor panel
The following options are available through the

performance monitor panel:
Engine Speed – When you scroll to this option, the
display will show the engine RPM.
Engine Coolant Temperature – When you scroll to

this option, the display will show the engine coolant
temperature in degrees fahrenheit or in degrees
celsius.
Fuel Level – When you scroll to this option, the

display will show the amount of fuel in the tank as a
percentage of a full tank.
Digital display area (19) – The Messenger system

shows information on the digital display area.
Previous button (20) – Use the previous button to

return to information that was previously shown on
the digital display area.
“ Scroll up/left button”” (21) – This button is used to

scroll up through information that is shown on the
display area. The button can also be used to scroll to
the left through information that is shown on the
display area.
“ Scroll down/right button”” (22) – This button is

used to scroll down through information that is shown
on the display area. The button can also be used to
scroll to the right through information that is shown on
the display area.
32 SEBU7772-06
Operation Section
If Equipped
Totals Display MONITORING SYSTEM

Language – Select this option in order to change the
language that is shown on the display.
Units – Select this option in order to choose the

desired system of measurement. The choices are
metric or English.
Adjust Contrast – Select this option in order to

adjust the contrast of the display.
“ Adjust Backlight”” – Select this option in order to

adjust the backlighting of the display.
ENGINE
Typical totals display “ Equipment Identification”” – Select this option in
order to view the identification number of the
The following information is available through the equipment.
display:
CUMULATIVE TOTALS Product Identification – Select this option in order

to view the identification number of the product.
Service Hours – When you scroll to this option, the
display shows the total amount of service hours that
the engine has accumulated. Performance Monitor Panel for Service
Total Time – When you scroll to this option, the

display shows the total hours for the engine ECM.
Total Fuel – When you scroll to this option, the

display shows the total amount of fuel that has been
consumed.
Performance Monitor Panel for Settings
Typical service display
DIAGNOSTICS and EVENTS

The following options are password protection. Enter
a password in order to change the settings.
View – Select this option in order to view events that
have been logged by the monitoring system. If you
use an authorized password, you can clear individual
events.
Typical performance monitor panel for settings
Clear All Diagnostics – If you use an authorized
The following options are available through the password, you can select this option in order to clear
payload display: all logged events.
SEBU7772-06 33
Operation Section
If Equipped
SYSTEM PARAMETERS • Software Part Number When you scroll to this

option, the software part number is displayed.
MONITORING SYSTEM
• ECM Part Number When you scroll to this
• Battery Voltage When you scroll to this option, option, the ECM part number is displayed.
the battery voltage is displayed.
• “ Software Release Date”” When you scroll to
• Fuel Level When you scroll to this option, the this option, the date of the software release is
fuel level is displayed. displayed.
• “ Alternator Status”” When you scroll to this • “ Software Description”” When you scroll to this
option, the status of the alternator is displayed. option, the description of the software is displayed.
• Engine Speed When you scroll to this option, ENGINE
the engine RPM is displayed.
• “ ECM Serial Number”” When you scroll to this
• Desired Engine Speed When you scroll to this option, the ECM serial number is displayed.
option, the desired engine speed is displayed.
This parameter is used by the Automatic Retarder • “ Software Part Number”” When you scroll to
Control to prevent the engine from overspeeding. this option, the software part number is displayed.
If you have an approved password, you can
change this parameter. • “ Software Release Date”” When you scroll to
this option, the release date of the software is
• Throttle Position When you scroll to this option, displayed.
the throttle position is displayed.
• “ Software Description”” When you scroll to this
• Coolant Temperature When you scroll to this option, the description of the software is displayed.
option, the coolant temperature is displayed.
• Engine Serial Number When you scroll to this
• Coolant Flow When you scroll to this option, the option, the engine serial number is displayed.
amount of coolant flow is displayed.
TATTLETALE
• Boost Pressure When you scroll to this option,
the boost pressure is displayed. • “ Full Tattletale Readout”” When you select this
option, the indicators, and the gauges display the
• Atmospheric Pressure When you scroll to this maximum values that were reached during
option, the atmospheric pressure is displayed. operation.
• Turbocharger Inlet Pressure When you scroll • Engine Coolant Temperature When you select
to this option, the turbocharger inlet pressure is this option, the indicators display the maximum
displayed. values that were reached during operation. The
engine coolant temperature gauge will also show
• Oil Pressure When you scroll to this option, the the maximum value that was reached during
absolute engine oil pressure is displayed. operation.
• Oil Pressure When you scroll to this option, the • Tachometer When you select this option, the
engine oil pressure gauge is displayed. indicators will display the maximum values that
were reached during operation. The tachometer
• Fuel Temperature When you scroll to this
will also show the maximum value that was
option, the fuel temperature is displayed.
reached during operation.
SYSTEMS TESTS
• Fuel Level When you select this option, the
indicators display the maximum values that were
• “ System Self Test”” When you select this
reached during operation. The fuel level gauge will
option, the monitoring system will initiate the self
also show the minimum value that was reached
test. The self test is similar to the functional test
during operation.
that occurs when you turn the start switch from the
OFF position to the ON position. • Clear If you have an approved password, you
can clear the maximum values that have been
INFORMATION ABOUT SYSTEMS
stored by the monitoring system.
MONITORING SYSTEM
34 SEBU7772-06
Operation Section
Engine Diagnostics
Engine Diagnostics • The “DIAGNOSTIC” lamp will come on and the

“DIAGNOSTIC” lamp will remain on for five
seconds. This checks the operation of the lamp.
i01563934
• The “DIAGNOSTIC” lamp will turn off.
Self-Diagnostics
• The “DIAGNOSTIC” lamp will come on again and
SMCS Code: 1000; 1900; 1901; 1902 the “DIAGNOSTIC” lamp will flash codes for any
active diagnostic codes. Not all diagnostic codes
Caterpillar Electronic Engines have the capability to
have a unique flash code.
perform a self-diagnostics test. When the system
detects an active problem, the “DIAGNOSTIC” lamp • The “DIAGNOSTIC” lamp will turn off for five
is activated. Diagnostic codes will be stored in
seconds.
permanent memory in the Electronic Control Module
(ECM). The diagnostic codes can be retrieved by • The “DIAGNOSTIC” lamp repeats all active
using the following components:
diagnostic codes.
• Caterpillar electronic service tools A fault diagnostic code will remain active until the
problem is repaired. The electronic control module
• “DIAGNOSTIC” lamp
will continue flashing the flash code at five second
Note: The “DIAGNOSTIC” lamp must be installed by intervals until the problem is repaired.
the OEM or by the customer.
i02890874
Some installations have electronic displays that
provide direct readouts of the engine diagnostic Diagnostic Flash Code
codes. Refer to the manual that is provided by the
OEM for more information on retrieving engine Retrieval
diagnostic codes. SMCS Code: 1000; 1900; 1901; 1902
Active codes represent problems that currently exist.
These problems should be investigated first. If a code “ Diagnostic”” Lamp
is active, the “DIAGNOSTIC” lamp will flash the flash
code at five second intervals. Use the “DIAGNOSTIC” Lamp or Caterpillar
Electronic Technician (ET) in order to determine the
Logged codes represent the following items:
diagnostic flash code.
• Intermittent problems Use the following procedure to retrieve the diagnostic
codes if the engine is equipped with a
• Recorded events
“DIAGNOSTIC” lamp:
• Performance history 1. Turn on the ignition system. The engine does not
The problems may have been repaired since the need to be started in order to view codes. The
logging of the code. These codes do not indicate that engine does not need to be running while the
a repair is needed. The codes are guides or signals ignition switch is in the ON position.
when a situation exists. Codes may be helpful to
troubleshoot problems. The “DIAGNOSTIC” lamp blinks on and off at five
second intervals.
When the problems have been corrected, the
corresponding logged fault codes should be cleared. • When the ignition key is in the ON position, the
lamp is checked for proper operation. If there
i01463253 are any active codes except for Code 34, the
codes are displayed at this time.
Diagnostic Lamp
Note: The “DIAGNOSTIC” lamp will illuminate for five
SMCS Code: 1000; 1900; 1901; 1902; 7451 seconds. The lamp will stay on if there is an active
diagnostic code.
The “DIAGNOSTIC” lamp is used to indicate the
existence of an active fault by flashing codes.
2. The Active Diagnostic codes will always be
When the ignition switch is first turned on, the flashed. There is no toggle switch that will shut off
“DIAGNOSTIC” lamp will go through the following the lamp.
procedure:
SEBU7772-06 35
Operation Section
Diagnostic Flash Code Retrieval
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.
Table 3 indicates the potential effect on the engine
performance with active flash codes. Table 3 also
forms a list of Electronic diagnostic codes and
descriptions.
Table 3
Diagnostic Flash Codes for C9 Engine
Effect On Engine Performance Suggested Action by the Operator
Schedule
Diagnostic Flash Code Reduced Engine Shut down
Engine Service
Low Power Engine Shut the Engine Service(2)
for the En-
Misfire Speed (1)
Down gine.(3)
Open or Short Circuit of Injection Ac-
15 X X
tuation Pressure Sensor
17 High Injection Actuation Pressure X X
Open or Short for the Injection Actua-

18 X X
tion Pressure Control Valve
Sensor Supply Voltage Above Normal
21 X X
or Below Normal (4)
24 Oil Pressure Sensor Fault (4) X
Inlet Manifold Air Pressure Sensor

25 X
Fault(5)
26 Atmospheric Pressure Sensor Fault(4) X X
27 Coolant Temperature Sensor Fault(4) X X X
Check the Adjustments for the Throttle

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

38 X X X
Fault(4)
Mechanical Failure of the Injection Ac-

39 X X
tuation Pressure Sensor
Check the Calibration of the Timing
42 X X X X X
Sensor.
46 Low Oil Pressure Event X X X
51 Intermittent Battery Power to the ECM X X X X X
52 Personality Module Fault X X X X X
(continued)
36 SEBU7772-06
Operation Section
Fault Logging
(Table 3, contd)
Diagnostic Flash Codes for C9 Engine
Effect On Engine Performance Suggested Action by the Operator
Schedule
Diagnostic Flash Code Reduced Engine Shut down
Engine Service
Low Power Engine Shut the Engine Service(2)
for the En-
Misfire Speed (1)
Down gine.(3)
The following parameters must be
56 X X X
checked: Customer and System
59 Incorrect Engine Software X X X X
61 Event for High Coolant Temperature X X X X
62 Event for Low Coolant Level X X X X

63 Low Fuel Pressure Event X X X X
Even for High Inlet Manifold Air
64 X X X
Temperature
72 Fault of Cylinder 1 or Cylinder 2 X X X

(1) Shut down the Engine: Operate the engine cautiously. Get immediate service. Severe engine damage may result.
(2) The operator should go to the nearest location for service.
(3) The operator should investigate the problem at a convenient time.
(4) The Diagnostic Flash Codes reduce the effectiveness of the Engine Monitoring feature.
(5) These Diagnostic Flash Codes may affect the system only under specific environmental conditions such as engine start-up at cold tempera-
tures, etc.
i03840813 i02784364
Fault Logging Engine Operation with Active

SMCS Code: 1000; 1900; 1901; 1902 Diagnostic Codes
The system provides the capability of Fault Logging. SMCS Code: 1000; 1900; 1901; 1902
When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will be If the diagnostic lamp starts to flash codes during
logged in the memory of the ECM. The codes that normal engine operation, the system has identified a
have been logged in the memory of the ECM can be situation that is not within the specification. Use
retrieved with Caterpillar electronic service tools. The Caterpillar electronic service tools to check the active
codes that have been logged can be cleared with diagnostic codes.
Caterpillar electronic service tools. The codes that
have been logged in the memory of the ECM will be Note: If the customer has selected “DERATE” and if
automatically cleared from the memory after 100 there is a low oil pressure condition, the Electronic
hours. The following faults cannot be cleared from Control Module (ECM) will limit the engine power
the memory of the ECM without using a factory until the problem is corrected. If the oil pressure is
password: overspeed, low engine oil pressure and within the normal range, the engine may be operated
high engine coolant temperature. 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.
SEBU7772-06 37
Operation Section
Engine Operation with Intermittent Diagnostic Codes
The active diagnostic code should be investigated. Parameter Descriptions

The cause of the problem should be corrected as
soon as possible. Operation of the engine and “ Equipment ID””
performance of the engine can be limited as a result
of the active diagnostic code that is generated. If the
“Equipment ID” allows the customer to enter a
cause of the active diagnostic code is repaired and
description into the Electronic Control Module (ECM)
there is only one active diagnostic code, the
in order to identify the machine. A maximum of 17
diagnostic lamp will turn off.
characters may be entered in the field. This
parameter is only for reference by the customer. This
i01456915 parameter is not required.
Engine Operation with “ Engine Serial Number””

Intermittent Diagnostic Codes Program the “Engine Serial Number” to match the
SMCS Code: 1000; 1900; 1901; 1902 engine serial number that is stamped on the engine
information plate. If the ECM is replaced, the engine
If the diagnostic lamp starts to flash codes during serial number from the engine information plate must
normal engine operation and the diagnostic lamp be programmed into the new ECM.
shuts off, an intermittent fault may have occurred. If a
fault has occurred, the fault will be logged into the Note: When you are requesting factory passwords,
memory of the Electronic Control Module (ECM). always use the engine serial number that is
programmed in the ECM.
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 “ Rating Number””
the operator should reference the appropriate
information in order to identify the nature of the event. Refer to this Operation and Maintenance Manual,
The operator should log any observation that could “Engine Rating Definitions” for more information
have caused the lamp to light. about engine ratings.
• Low power The “Rating Number” corresponds to the selected set

of performance maps for the application. This
• Limits of the engine speed selected set of performance maps comes out of
several unique sets of maps that are resident in the
• Excessive smoke, etc flash file. The dealer and/or the OEM will need to
select the appropriate rating tier, if more than one
This information can be useful to help troubleshoot rating tier is present. The rating tiers are “A” through
the situation. The information can also be used for “E” .
future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this Note: Factory passwords are required in order to
engine. change the “Rating Number” .
i04371259
Configuration Parameters
SMCS Code: 1000; 1900; 1901; 1902
System configuration parameters affect the
emissions and the power of the engine. Default
values for the parameters are programmed at the
factory. Some parameters may be changed by the
customer in order to suit the needs of the specific
application.
38 SEBU7772-06
Operation Section
“ Top Engine Limit”” (TEL) “ High Idle Speed””
Illustration 32 g00763900 Illustration 33 g00763900
“TEL” is a customer programmable parameter that “High Idle Speed” is the maximum no-load engine
defines the maximum allowable engine speed for speed when the throttle or the PTO switch is in the
maximum power. “TEL” can be programmed up to maximum position.
the maximum rated engine speed. “TEL” is defined
along the engine lug curve. Note: “High Idle Speed” cannot be programmed
lower than “TEL” .
“ Engine Accel. Rate””
“ Intermediate Engine Speed””
“Engine Accel. Rate” determines the rate of change
of the engine speed (acceleration or deceleration) “Intermediate Engine Speed” defines the speed for
during PTO operation. This rate of change is also the engine when the intermediate engine speed
used to achieve intermediate engine speed. switch is activated. This parameter can be
programmed to any engine speed between “Low Idle
“ Low Idle Speed”” Speed” and “TEL” . Engine speed will increase or
engine speed will decrease at the rate that is defined
“Low Idle Speed” is the minimum allowable operating by the programmed value for “Engine Accel. Rate” .
speed for the engine. This parameter can be
programmed between 600 and 1400 rpm.
“ PTO Mode””
“PTO Mode” allows the ECM to be programmed to
either one of the two PTO configurations that are
available.
“ Ramp Up/Ramp Down”” – When “PTO Mode” is
programmed to “Ramp Up/Ramp Down” , the ECM
allows PTO operation with traditional features.
“ Set/Resume”” – When “PTO Mode” is programmed
to “Set/Resume” , the ECM allows PTO operation
with enhanced features.
SEBU7772-06 39
Operation Section
“ Maximum Engine Torque Limit”” Note: If an engine overspeed occurs and “Air
Shutoff” is programmed to “Enabled” , the switched
power to the ECM must be cycled and the air shutoff
solenoid must be manually reset before the engine
will restart.
“ Maintenance Indicator Mode””

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

Program the “Throttle Position Sensor” to “Installed” if
“Engine Torque Limit” can be used to limit torque a throttle position sensor is used for desired speed
output to the programmed value when the torque limit control. Otherwise program this parameter to “Not
switch is activated. Installed” .
“ FLS”” (Full Load Setting) “ Coolant Level Sensor””
“FLS” is a number that represents the adjustment to Program the “Coolant Level Sensor” to “Installed” if a
the fuel system that was made at the factory in order coolant level sensor is installed on the engine.
to fine tune the fuel system. The correct value for this Otherwise program this parameter to “Not Installed” .
parameter is stamped on the engine information
plate. Factory passwords are required in order to “ Exhaust Valve Actuation System
change this parameter.
Instation Status””
“ FTS”” (Full Torque Setting) Program the “Exhaust Valve Actuation System
Instation Status” to “Installed” if an exhaust brake is
“FTS” is similar to “FLS” . Factory passwords are installed.
required in order to change this parameter.
Note: There are two modes of operation for the
“ Ether Control”” exhaust brake . The two modes are “Vehicle Brake”
and “Overspeed Protection” . These modes of
Program the “Ether Control” to “Enabled” if an ether operation are selectable via a switch input to the
injection system is installed on the engine. This ECM. Both modes of operation have programmable
allows the ECM to control ether injection. If the parameters. See “Offset Speed” and “Overspeed
engine is not equipped with ether, program this Trip” .
parameter to “Disabled” .
“ Offset Speed””
“ Air Shutoff””
“Air Shutoff” allows the ECM to be programmed for The exhaust brake will actuate If the engine speed is
operation of an air shutoff system. If this parameter is greater than the sum of the desired speed and the
programmed to “Installed” , the ECM will activate the “Offset Speed” . This mode of operation is “Vehicle
air shutoff solenoid in the event of an engine Brake” .
overspeed condition.
40 SEBU7772-06
Operation Section
“ Overspeed Trip””
The exhaust brake will actuate if the engine speed is
greater than the “Overspeed Trip” setting. This mode
of operation is “Overspeed Protection” .
“ Aux Press Sensor Installation Status””

Program “Aux Press Enable” to “Installed” if an
auxiliary pressure sensor is installed. This will allow
the display for the Engine Monitoring System (EMS)
to monitor the pressure of another system. Program
this parameter to “Not Installed” if an auxiliary
pressure sensor is not installed.
“ Aux Temp Sensor Installation Status””

Program “Aux Temp Enable” to “Installed” if an
auxiliary temperature sensor is installed. This will
allow the display for the EMS to monitor the
temperature of another system. Program this
parameter to “Not Installed” if an auxiliary
temperature sensor is not installed.
System Configuration Parameters

Table 4
Available Range or Options Required

Parameter Default
Password
ECM Identification Parameters
“Equipment ID” 17 alphanumeric characters “NOT PROGRAMMED” None
“Engine Serial Number” 0XX00000 or XXX00000 0XX00000 None
“ECM Serial Number” “Read Only” (1)
“Software Gp Part Number” Software Dependent Read Only (1)
“Software Gp Release Date” Software Dependent Read Only (1)
Selected Engine Rating
“Rating Number” Software Dependent Customer
“Rated Power” Software Dependent Read Only (1)
“Rated Peak Torque” Software Dependent Read Only (1)
“Top Engine Speed Range” Software Dependent Read Only (1)
“Test Spec” Software Dependent Read Only (1)
“Top Engine Limit” Software Dependent Customer
“Speed Control”
“Engine Governor Primary Mode” “Speed Control” None
“Min/Max”
“Engine Accel. Rate” 50 to 1000 50 None
“Low Idle Speed” 600 to 1400 700 None
(continued)
SEBU7772-06 41
Operation Section
(Table 4, contd)
Available Range or Options Required

Parameter Default
Password
“Ramp Up/Ramp Down”
“PTO Mode” “Ramp Up/Ramp Down” None
“Set/Resume”
“High Idle Speed” 1800 to 2310 2310 Customer
“Intermediate Engine Speed” Programmed “Low Idle” to “TEL” 1100 None
“Installed”
“Throttle Position Sensor” “Not Installed” None
“Not Installed”
“Maximum Engine Torque Limit” Software Dependent None
“Customer Password #1” 8 alphanumeric characters Blank Customer
“Customer Password #2” 8 alphanumeric characters Blank Customer
“FLS” (Full Load Setting) - 128 to 127 0 Factory
“FTS” (Full Torque Setting) -128 to 127 0 Factory
“No Ether”
“Ether Control” “No Ether” None
“Continuous Flow”
“Enabled”
“Air Shutoff” “Disabled” None
“Disabled”
“Installed”
“Exhaust Valve Actuation System” “Not Installed” None
“Not Installed”
“ Exhaust Offset Speed” 50 to 500 150 None
“Exhaust Over Speed Trip” High Idle to “PMS Max” 2800 None
“OFF”
“Auto Fuel”
“Maintenance Indicator Mode” “Auto Hour” “OFF” None
“Man Fuel”
“Man Hour”
100 to 750 Hours 250 Hours
“PM1 Interval” or or None
3785 to 28390 L (1000 to 7500 US gal) 9463 L (2500 US gal)
“Installed”
“Throttle Position Sensor” “Not Installed” None
“Not Installed”
“Installed”
“Coolant Level On” “Not Installed” None
“Not Installed”
“Last Tool to change Customer
Read Only (1)
Parameters”
“Last Tool to change System
Read Only (1)
Parameters”
“On”
“Aux Temp Sensor Installation Status” “Off” None
“Off”
“Aux Press Sensor Installation “On”
“Off” None
Status” “Off”
“Total Tattletale” Read Only (1)

(1) The parameter can only be viewed. No changes are allowed.
42 SEBU7772-06
Operation Section
Parameters Worksheet (Table 5, contd)

Engine Parameters
Note: A mistake in recording this information will
result in incorrect passwords. “FTS”
Table 5
“Ether Control”
Engine Parameters
ECM Identification Parameters “Air Shutoff”
“Equipment ID”
“Maintenance Indicator Mode”
“Engine Serial Number”

“PM1 Interval”
“ECM Serial Number”

“Throttle Position Sensor”
“Software Gp Part Number”

“Coolant Level Sensor”
“Software Gp Release Date”

“Last Tool to change Customer
Parameters”
Selected Engine Rating
“Last Tool to change System
“Rating Number” Parameters”
“Aux Press Temp Installation
“Rated Power” Status”
“Aux Press Sensor Installation
“Rated Peak Torque” Status”
“Total Tattletale”
“Top Engine Speed Range”
Information from Engine Information Plate

“Test Spec”
“Engine Serial Number”
“Top Engine Limit”
“FLS”
“Engine Accel Rate”
“FTS”
“Low Idle Speed”
Injector Codes
“PTO Mode”
Injector Code (1)
“High Idle Speed”

Injector Code (2)
“Intermediate Engine Speed”

Injector Code (3)
“Maximum Engine Torque Limit”

Injector Code (4)
“Customer Password #1”

Injector Code (5)
“Customer Password #2”

Injector Code (6)
“FLS”
(continued)
SEBU7772-06 43
Operation Section
Note: Compare the FLS and the FTS from the ECM
with the values that are listed on the engine
information plate. Only change the FLS and the FTS
because of a mechanical change in the engine. The
use of the wrong parameters could damage the
engine. The use of the wrong parameters may also
void the Caterpillar warranty.
44 SEBU7772-06
Operation Section
Engine Starting
Engine Starting • Ensure that the areas around the rotating parts are
clear.
i04363611 • All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair
Before Starting Engine any damaged guards. Replace damaged guards
and/or missing guards.
SMCS Code: 1000; 1400; 1450
• Disconnect any battery chargers that are not
Perform the required daily maintenance and other
protected against the high current drain that is
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can created when the electric starting motor (if
help prevent major repairs at a later date. equipped) is engaged. Check electrical cables and
check the battery for poor connections and for
• For the maximum service life of the engine, make corrosion.
a thorough inspection before starting the engine.
Look for the following items: oil leaks, coolant • Reset any of the shutoff components or alarm
leaks, loose bolts and trash buildup. Remove trash components.
buildup and arrange for repairs, as needed.
• Check the engine lubrication oil level. Maintain the
• Inspect the cooling system hoses for cracks and oil level between the “ADD” mark and the “FULL”
for loose clamps. mark on the oil level gauge.
• Inspect the alternator and accessory drive belts for • Check the coolant level. Observe the coolant level
cracks, breaks, and other damage. in the coolant recovery bottle (if equipped).
Maintain the coolant level to the “FULL” mark on
• Inspect the wiring for loose connections and for the coolant recovery bottle.
worn wires or frayed wires.
• If the engine is not equipped with a coolant
• Check the fuel supply. Drain water from the water recovery bottle, maintain the coolant level within
separator (if equipped). Open the fuel supply 13 mm (0.5 inch) of the bottom of the filler pipe. If
valve. the engine is equipped with a sight glass, maintain
the coolant level in the sight glass.
NOTICE • Observe the air cleaner service indicator (if
All valves in the fuel return line must be open before
equipped). Service the air cleaner when the yellow
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing diaphragm enters the red zone, or when the red
failure or other damage. piston locks in the visible position.
• Open the valve for the sea water on the engine
If the engine has not been run for several weeks, fuel jacket water heat exchanger (if equipped).
may have drained from the fuel system. Air may have
entered the filter housing. Also, when fuel filters have • Place the marine transmission in NEUTRAL.
been changed, some air space will be left in the
housing. In these instances, prime the fuel system. i01797227
Refer to the Operation and Maintenance Manual,
“Fuel System - Prime” for more information on Cold Weather Starting
priming the fuel system.
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Engine exhaust contains products of combustion

which may be harmful to your health. Always Do not use aerosol types of starting aids such as
start and operate the engine in a well ventilated ether. Such use could result in an explosion and
area and, if in an enclosed area, vent the exhaust personal injury.
to the outside.
Startability will be improved at temperatures below
−18 °C (0 °F) from the use of a jacket water heater or
• Do not start the engine or move any of the controls extra battery capacity.
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
to the controls.
SEBU7772-06 45
Operation Section
Starting the Engine
When No. 2 diesel fuel is used, the following items Initial Inspection
provide a means of minimizing starting problems and
fuel problems in cold weather: engine oil pan heaters, Perform the required daily maintenance and other
jacket water heaters, fuel heaters and fuel line periodic maintenance before you start the engine.
insulation. Inspect the engine compartment. This inspection can
help prevent major repairs at a later date. Refer to
Use the procedure that follows for cold weather the Operation and Maintenance Manual, “Walk-
starting. Around Inspection” topic (Maintenance Section) for
more information.
Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will • For the maximum service life of the engine, make
control the engine speed during start-up. a thorough inspection before you start the engine.
Look for the following items: oil leaks, coolant
1. Disengage any driven equipment. leaks, loose bolts and trash buildup. Remove trash
2. Turn the keyswitch to the RUN position. Leave the buildup and arrange for repairs, as needed.
keyswitch in the RUN position for 20 seconds.
• Inspect the cooling system hoses for cracks and
for loose clamps.
NOTICE
Do not engage the starting motor when flywheel is • Inspect the alternator and accessory drive belts for
turning. Do not start the engine under load.
cracks, breaks, and other damage.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to • Inspect the wiring for loose connections and for
allow the starting motor to cool before attempting to worn wires or frayed wires.
start the engine again.
• Check the fuel supply. Drain water from the water
separator (if equipped). Open the fuel supply
3. Turn the keyswitch to the START position in order valve.
to engage the starting motor and crank the engine.
4. Allow the keyswitch to return to the RUN position NOTICE
All valves in the fuel return line must be open before
after the engine starts. and during engine operation to help prevent high fuel
5. Repeat step 2 through step 4 if the engine fails to pressure. High fuel pressure may cause filter housing
failure or other damage.
start.
6. Allow the engine to idle for three to five minutes, or
allow the engine to idle until the water temperature • Do not start the engine or do not move any of the
controls if there is a “DO NOT OPERATE” warning
indicator begins to rise. The engine should run at
tag or similar warning tag attached to the start
low idle smoothly until speed is gradually switch or to the controls.
increased to high idle. Allow the white smoke to
disperse before proceeding with normal operation. • Ensure that the areas around the rotating parts are
clear.
7. Operate the engine at low load until all systems
reach operating temperature. Check the gauges • All of the guards must be put in place. Check for
during the warm-up period. damaged guards or for missing guards. Repair
any damaged guards. Replace damaged guards
i06226127 and/or missing guards.
Starting the Engine • Disconnect any battery chargers that are not
protected against the high current drain that is
SMCS Code: 1000; 1450 created when the electric starting motor (if
equipped) is engaged. Check electrical cables and
check the battery for poor connections and for
corrosion.
Engine exhaust contains products of combustion
which may be harmful to your health. Always • Reset all of the shutoffs or alarm components.
start and operate the engine in a well ventilated • Check the engine lubrication oil level. Maintain the
area and, if in an enclosed area, vent the exhaust
to the outside. oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
46 SEBU7772-06
Operation Section
Starting the Engine
• Check the coolant level. Observe the coolant level The “WARNING and DIAGNOSTIC” lamp (if
in the coolant recovery tank (if equipped). Maintain equipped) will flash while the engine is cranking.
the coolant level to the “FULL” mark on the coolant The lamp should turn off after proper engine oil
recovery tank. pressure is achieved. If the lamp fails to flash,
notify your authorized Caterpillar dealer. If the
• If the engine is not equipped with a coolant lamp continues to flash, the Electronic Control
recovery tank maintain the coolant level within Module (ECM) has detected a problem in the
13 mm (.5 inch) of the bottom of the filler pipe. If system. For more information, refer to the
the engine is equipped with a sight glass, maintain Operation and Maintenance Manual, “Diagnostic
the coolant level in the sight glass. Flash Code Retrieval” (Operation Section).
• Observe the air cleaner service indicator (if NOTICE

equipped). Service the air cleaner when the yellow Do not engage the starting motor when flywheel is
diaphragm enters the red zone, or when the red turning. Do not start the engine under load.
piston locks in the visible position. If the engine fails to start within 30 seconds, release
• Ensure that any driven equipment has been the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
disengaged. Remove any electrical loads. start the engine again.
Cold Weather Starting

3. Push the start button or turn the ignition switch to
Starting the engine and operation in cold weather is the START position in order to crank the engine.
dependent on the type of fuel that is used, the oil
viscosity, and other optional starting aids. For more Do not push down or hold the throttle down while
information, refer to the Operation and Maintenance the engine is cranked. The system will
Manual, “Cold Weather Operation” topic (Operation automatically provide the correct amount of fuel
Section). that is needed to start the engine.
4. If the engine fails to start within 30 seconds,
Air Inlet Heater 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.
DO NOT USE ETHER (starting fluids) unless spe- Note: The “WARNING and DIAGNOSTIC” lamps (if
cifically instructed to do so. If the engine is equipped) may come on after the engine is started. If
equipped with an Air Inlet Heater (electrically or this occurs, the ECM has detected a problem with the
fuel ignited manifold heater), DO NOT use ether system. For more information, refer to the Operation
(starting fluids) at any time. The use could result and Maintenance Manual, “Diagnostic Flash Code
in engine damage and/or personal injury. Retrieval” (Operation Section) .
NOTICE
Note: There will be an indicator lamp on the control Oil pressure should rise within 15 seconds after the
panel that is marked “AIR INLET HEATER” . engine starts. Do not increase engine rpm until the oil
pressure gauge indicates normal. If oil pressure is
For detailed information on the operation of the Air not indicated on the gauge within 15 seconds, DO
Inlet Heater, refer to Testing and Adjusting, “Air Inlet NOT operate the engine. STOP the engine, investi-
and Exhaust System - Inspect”. gate and correct the cause.
Refer to the Owner's Manual of the OEM for your
type of controls. Use the following procedure to start 5. Allow the engine to idle for approximately three
the engine.
minutes. Idle the engine until the water
1. Place the transmission in NEUTRAL. Disengage temperature gauge has begun to rise. Check all
the flywheel clutch in order to allow the engine to gauges during the warm-up period.
start faster. This also reduces the draining of the
battery.
2. Turn the ignition switch to the ON position.
SEBU7772-06 47
Operation Section
Starting the Engine
Note: Oil pressures and fuel pressures should be in If the engine fuel system has been run dry, fill the fuel
the normal range on the instrument panel. Engines tank and prime the fuel system. Refer to the
that are equipped with “WARNING” lamps do not Operation and Maintenance Manual, “Fuel System -
have an operating range. The “WARNING and Prime” topic (Maintenance Section).
DIAGNOSTIC” lamp (if equipped) will flash while the
engine is cranking. The lamp should turn off after If the other problems are suspected, perform the
appropriate procedure in order to start the engine.
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 Problems with the Wiring Harness
indicates at least normal pressure. Inspect the engine
for leaks and/or unusual noises.
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 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 Illustration 35 g01248812

from alcohol or starting fluids. ECM Connector J2/P2
Alcohol or starting fluids are highly flammable Locate the ECM. Check the connector in order to
and toxic and if improperly stored could result in ensure that the connector is secure. Lightly pull each
injury or property damage. 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
DO NOT USE ETHER (starting fluids) unless spe-
connector. Pull the wire again in order to ensure
cifically instructed to do so. If the engine is
equipped with an Air Inlet Heater (electrically or that the wire is secure.
fuel ignited manifold heater), DO NOT use ether
(starting fluids) at any time. The use could result
in engine damage and/or personal injury.
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

48 SEBU7772-06
Operation Section
Starting with Jump Start Cables
3. Start the engine. If the engine does not start, 2. Connect one positive end of the jump start cable to
consult the nearest Caterpillar dealer for the positive cable terminal of the discharged
assistance. battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the
i03640789 charging or starting source.
Starting with Jump Start 3. Connect one negative end of the jump start cable
to the negative cable terminal of the charging or
Cables starting source. Connect the other negative end of
SMCS Code: 1000; 1401; 1402; 1900 the jump start cable to the stalled engine block or
to the chassis ground. This procedure helps to
prevent potential sparks from igniting combustible
gases that are produced by some batteries.
Improper jump start cable connections can cause 4. Charge the batteries. The engine will not continue
an explosion resulting in personal injury.
to run after starting if the batteries have not been
Prevent sparks near the batteries. Sparks could charged.
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine. 5. Start the engine.
6. Immediately after the stalled engine is started,
If the installation is not equipped with a backup
battery system, it may be necessary to start the disconnect the jump start cables in reverse order.
engine from an external electrical source. Refer to the Electrical Schematic for your engine.
For information on troubleshooting the charging Consult your Caterpillar dealer for more information.
system, refer to Special Instruction, REHS0354,
“Charging System Troubleshooting”. i01646248
Many batteries which are considered unusable are

still rechargeable. After jump starting, the alternator
After Starting Engine
may not be able to fully recharge batteries that are SMCS Code: 1000
severely discharged. The batteries must be charged
to the proper voltage with a battery charger. For Note: In temperatures from 0 to 60°C (32 to 140°F),
information on testing and charging, refer to the the warm-up time is approximately three minutes. In
Special Instruction, SEHS7633, “Battery Test temperatures below 0°C (32°F), additional warm-up
Procedure”. time may be required.
NOTICE Note: Ensure that the self test for the monitoring
Use a battery that is sourced with the same voltage system (if equipped) is completed before operating
as the electric starting motor. Use ONLY equal volt- the engine under load.
age for jump starting. The use of higher voltage will
damage the electrical system. When the engine idles during warm-up, observe the
following conditions:
Do not reverse the battery cables. The alternator can
be damaged. Attach the negative battery cable last • Check for any fluid or for any air leaks at idle rpm
and remove the negative battery cable first. and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
When an external electrical source is used to start possible in some applications.
the engine, turn the control switch on the generator
set to the “OFF” position. Turn all electrical accesso- • Operate the engine at low idle until all systems
ries OFF before attaching the jump start cables.
achieve operating temperatures. Check all gauges
Ensure that the main power switch is in the OFF posi- during the warm-up period.
tion before jump start cables are attached to the en-
gine that is being started. 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
1. Turn the start switch on the stalled engine to the to determine normal readings for each gauge.
OFF position. Turn off all accessories. Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
SEBU7772-06 49
Operation Section
Engine Operation
Engine Operation Interrupted starts put excessive stress on the drive

train. Interrupted starts also waste fuel. To get the
driven equipment in motion, engage the clutch
i06545704 smoothly with no load on the equipment. This
method should produce a start that is smooth and
Engine Operation easy. The engine rpm should not increase and the
clutch should not slip.
SMCS Code: 1000
3. Ensure that the ranges of the gauges are normal
Proper operation and maintenance are key factors in when the engine is operating at one-half of the
obtaining the maximum life and economy of the rated rpm. Ensure that all gauges operate
engine. If the directions in the Operation and properly.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. 4. Increase the engine rpm to the rated rpm. Always
The time that is needed for the engine to reach increase the engine rpm to the rated rpm before
normal operating temperature can be less than the the load is applied.
time needed for a walk-around inspection of the
engine. 5. Apply the load. Begin operating the engine at low
load. Check the gauges and equipment for proper
After the engine is started and after the engine operation. After normal oil pressure is reached and
reaches normal operating temperature, the engine the temperature gauge begins to move, the engine
can be operated at the rated rpm. The engine will may be operated at full load. Check the gauges
reach normal operating temperature faster when the and equipment frequently when the engine is
engine is at rated speed. The engine will reach
normal operating temperature faster when the engine operated under load.
is at low-power demand. This procedure is more
Extended operation at low idle or at reduced load
effective than idling the engine at no load. The engine
may cause increased oil consumption and carbon
should reach operating temperature in a few minutes. buildup in the cylinders. This carbon buildup
Gauge readings should be observed and the data results in a loss of power and/or poor
should be recorded frequently while the engine is performance.
operating. Comparing the data over time will help to
determine normal readings for each gauge. i05893104
Comparing data over time will also help detect
abnormal operating developments. Significant Fuel Conservation Practices
changes in the readings should be investigated.
SMCS Code: 1000; 1250
Engines rated for constant speed use are allowed to
complete a starting sequence, an operation at a The efficiency of the engine can affect the fuel
single constant speed, and a shutdown sequence. economy. The design and technology used
Every time the engine is run, each of these byCaterpillar in manufacturing provides maximum
operations should occur only once. The starting fuel efficiency in all applications. Follow the
sequence and shutdown sequence can include a recommended procedures in order to attain optimum
short period of operation at the low idle speed for performance for the life of the engine.
purposes of warming up and cooling down the engine
or driven equipment. The emissions type approval is • Avoid spilling fuel.
not valid for operation of a constant speed engine in
a manner different from that described above. Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
i01646335
• Be aware of the properties of the different fuels.
Engaging the Driven Use only the recommended fuels.
Equipment • Avoid unnecessary operation at no load.
SMCS Code: 1000
Shut off the engine instead of operating the engine at
no load for long periods of time.
1. Operate the engine at one-half of the rated rpm,
when possible. • Observe the service indicator for the air cleaner
2. Engage the driven equipment without a load on the frequently, if equipped. Keep the air cleaner
elements clean.
equipment, when possible.
50 SEBU7772-06
Operation Section
Fuel Conservation Practices
• Do not remove the cover for the air cleaner unless

the air filter service indicator indicates the need for
cleaning of the filter.
• Maintain a good electrical system.

One bad battery cell will overwork the alternator. This
will consume excess power and excess fuel.
• Ensure that the belts are properly adjusted. The

belts should be in good condition.
• Ensure that all of the connections of the hoses are
tight. The connections should not leak.
• Ensure that the driven equipment is in good
working order.
• Cold engines consume excess fuel. Keep cooling

system components clean and keep cooling
system components in good repair. Never operate
the engine without water temperature regulators.
All of these items will help maintain operating
temperatures.
SEBU7772-06 51
Operation Section
Cold Weather Operation
Cold Weather Operation There are three major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
i01457051
• Lower cloud point
Radiator Restrictions • Lower pour point
SMCS Code: 1353; 1396
• Lower rating of kJ (BTU) per unit volume of fuel
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow When No. 1 diesel fuel is used, a decrease in power
restriction can cause the following conditions: and in fuel efficiency may be noticed. Other operating
effects should not be experienced.
• High exhaust temperatures
The cloud point is the temperature when a cloud of
• Power loss wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is the
• Excessive fan usage temperature when diesel fuel will thicken. The diesel
fuel becomes more resistant to flow through fuel
• Reduction in fuel economy pumps and through fuel lines.
If an airflow restriction device must be used, the Be aware of these values when diesel fuel is
device should have a permanent opening directly in purchased. Anticipate the average ambient
line with the fan hub. The device must have a temperature of the area. Engines that are fueled in
minimum opening dimension of at least 770 cm2 one climate may not operate well if the engines are
(120 in2). moved to another climate. Problems can result due to
changes in temperature.
A centered opening that is directly in line with the fan
hub is specified in order to prevent an interrupted Before troubleshooting for low power or for poor
airflow on the fan blades. Interrupted airflow on the performance in the winter, check the type of fuel that
fan blades could cause a fan failure. is being used.
Caterpillar recommends a warning device for the inlet When No. 2 diesel fuel is used the following
manifold temperature and/or the installation of an components provide a means of minimizing problems
inlet air temperature gauge. The warning device for in cold weather:
the inlet manifold temperature should be set at 75 °C
(167 °F). The inlet manifold air temperature should • Starting aids
not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential • Engine oil pan heaters
engine damage.
• Engine coolant heaters
i05264084
• Fuel heaters
Fuel and the Effect from Cold • Fuel line insulation
Weather For more information on cold-weather operation, see
SMCS Code: 1000; 1250; 1280 Special Publication, SEBU5898, “Cold Weather
Recommendations”.
The following fuels are the grades that are available
for Cat engines: i04369188
• No. 1
Fuel Related Components in
• No. 2 Cold Weather
• Blend of No. 1 and No. 2 SMCS Code: 1000; 1250; 1280
No. 2 diesel fuel is the most commonly used fuel.
Either No. 1 diesel fuel or a blend of No. 1 and No. 2 Fuel Tanks
is best suited for cold-weather operation.
Condensation can form in partially filled fuel tanks.
Quantities of No. 1 diesel fuel are limited. No. 1 Top off the fuel tanks after operating the engine.
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.
52 SEBU7772-06
Operation Section
Fuel Related Components in Cold Weather
Fuel tanks should contain some provision for draining Disconnect the fuel heater in warm weather.
water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water Note: Only use fuel heaters that are controlled by the
and sediment to settle below the end of the fuel water temperature regulator or fuel heaters that are
supply pipe. self-regulating. Fuel heaters that are not controlled by
the water temperature regulator can heat the fuel in
Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is excess of 65° C (149° F). A loss of engine power can
equipped with this system, regular maintenance of occur if the fuel supply temperature exceeds 37° C
the fuel system filter is important. (100° F).
Draining the fuel tank will help prevent water and/or Note: Heat exchanger type fuel heaters should have
sediment from being pumped from the fuel storage a bypass provision in order to prevent overheating of
tank and into the engine fuel tank. Drain the water the fuel when the engine operates in warm weather.
and sediment from any fuel storage tank at the
following intervals: For further information on fuel heaters, consult your
Cat dealer.
• Weekly
• Oil changes
• Refueling of the 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 con-
taminated. Contaminated fuel will cause accelerated
wear to fuel system parts.
NOTICE
Caterpillar requires the use of a 4 micron (c) secon-
dary fuel filter for the following reasons: to maximize
fuel system life and to prevent premature wear out
from abrasive particles in the fuel. Cat high efficiency
fuel filters meet these requirements. Consult your Cat
dealer for the proper part numbers.
When the engine is 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.
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in order for the fuel to be heated before
the fuel enters the primary fuel filter.
Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater
with a large heating surface. The fuel heater should
be practical in size. Small heaters can be too hot due
to the limited surface area.
SEBU7772-06 53
Operation Section
Engine Stopping
Engine Stopping Refer to Operation and Maintenance Manual,

“Features and Controls” for the location and the
operation of the emergency stop button.
i06171418
i04315380
Emergency Stopping
SMCS Code: 1000; 7418 Manual Stop Procedure
SMCS Code: 1000; 7418
NOTICE
Emergency shutoff controls are for EMERGENCY NOTICE
use ONLY. DO NOT use emergency shutoff devices Stopping the engine immediately after it has been
or controls for normal stopping procedure. working under load can result in overheating and ac-
celerated wear of the engine components.
Ensure that any components for the external system
that support the engine operation are secured after If the engine has been operating at high rpm and/or
the engine is stopped. high loads, run at low idle for at least three minutes to
reduce and stabilize internal engine temperature be-
Emergency Stop Button (If fore stopping the engine.
Equipped) Avoiding hot engine shutdowns will maximize turbo-
charger shaft and bearing life.
Note: Individual applications have different control

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

engine has no more than 30% power.
2. Run the engine at the programmed low idle speed
for at least 3 minutes.
3. After the cool down period, turn the start switch to
the OFF position.
i01465494
After Stopping Engine

SMCS Code: 1000
Note: Before you check the engine oil, do not

operate the engine for at least 10 minutes in order to
Typical emergency stop symbol located near the allow the engine oil to return to the oil pan.
emergency stop button
• Check the crankcase oil level. Maintain the oil
The emergency stop button is in the OUT position for level between the “ADD” mark and the “FULL”
normal engine operation. Push the emergency stop mark on the oil level gauge.
button. The engine will not start when the button is
locked. Turn the button clockwise in order to reset. • 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.
54 SEBU7772-06
Operation Section
After Stopping Engine
NOTICE
Only use antifreeze/coolant mixtures recommended
in the Coolant Specifications that are in the Operation
and Maintenance Manual. Failure to do so can cause
engine damage.
• Allow the engine to cool. Check the coolant level.
• If freezing temperatures are expected, check the

coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.
SEBU7772-06 55
Maintenance Section
Refill Capacities
Maintenance Section Note: The interval for changing the coolant varies
depending on the type of coolant being replaced.
Refer to this article, “Coolant Recommendations”, for
the intervals for changing the coolant.
Refill Capacities
Diesel Engine Oil
i04370726
For more information, refer to Special Publication,
Refill Capacities SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.
SMCS Code: 1000; 1348; 1395; 7560
Refer to this Operation and Maintenance Manual, Cat Diesel Engine Oil (Cat DEO)
“Fluid Recommendations” for information about the
correct lubricants and coolants for the engine. Cat oils have been developed and tested in order to
provide the full performance and service life that has
been designed and built into Cat engines. Cat oils
Engine Oil are currently used to fill Cat Diesel Engines at the
factory. These oils are offered by Cat dealers for
The refill capacity for the engine crankcase reflects continued use when the engine oil is changed.
the approximate capacity of the crankcase or sump Consult your Cat dealer for more information on
plus the standard engine oil filter. Auxiliary engine oil these oils.
filter systems require additional oil. Refer to the OEM
specifications for the capacity of an auxiliary engine Due to significant variations in the quality and in the
oil filter. performance of commercially available oils,
Table 6 Caterpillar makes the following recommendations:
C9 Industrial Engine Approximate Refill Capacity for Engine Oil Table 8
Refill capacity for Liters Quarts Cat Lubricants Viscosity Grade

changing the engine SAE 15W-40
oil and the engine oil 30 L 32 qt Cat DEO-ULS
filter Diesel Engine SAE 10W-30
Oil-Ultra Low Cat DEO-ULS SYN SAE 5W-40
Sulfur
Coolant Cat Cold Weather
SAE 0W-40
DEO-ULS
The total capacity of the cooling system must be
SAE 15W-40
known in order to maintain the cooling system. The Cat DEO
Diesel Engine
capacity of the total cooling system depends on the SAE 10W-30
Oil
size of the radiator that is provided by the OEM.
Cat DEO SYN SAE 5W-40
Complete Table 7 when the cooling system is filled
for the first time.
Table 7 Note: Cat DEO and Cat DEO-ULS multigrade oils
Approximate Capacity of the Cooling System are the preferred oils for use in this Cat Diesel
Engine.
Total Cooling Sys- Liters Quarts
tem(1) Commercial Oil
(1) The total cooling system capacity includes the following compo-
nents: the engine block, the radiator and all coolant lines and Note: Non-Cat commercial oils are second choice
hoses. oils for your engine.
i04327214 NOTICE
Caterpillar does not warrant the quality or perform-
Fluid Recommendations ance of non-Cat fluids.
SMCS Code: 1280; 1348; 1395; 7560 The three current Caterpillar ECF specifications are:
Cat ECF-1-a, Cat ECF-2 and Cat ECF-3. Each
Refer to this Operation and Maintenance Manual, higher Cat ECF specification provides increased
“Severe Service Application” for information about performance over lower Cat ECF specifications.
operating an engine in a severe service application.
A commercial oil must meet the following standards
to be considered an equivalent of a Cat Diesel
Engine Oil:
56 SEBU7772-06
Maintenance Section
Fluid Recommendations
Table 9
Cat Engine Crankcase Fluids (ECF) Definitions (Table 10, contd)
Cat Performance Lubricant Viscosities for Ambient Temperatures
Cat ECF Specifications Requirements
Requirement for Cat Diesel Engines
API CJ-4 Oil Category performance Cat ECF-1-a
Cat ECF-3
requirements Cat ECF-2 SAE 0W-30 −40 30 −40 86
Cat ECF-3
API CI-4 / CI-4 PLUS Oil Category per-
formance requirements Cat Cold Weather
DEO-ULS
Passing standard Cat C13 engine test Cat ECF-1-a SAE 0W-40 −40 40 −40 104
Cat ECF-2
per API requirements Cat ECF-2
Cat ECF-3
Oils of sulfated ash > 1.50 percent are
not allowed Cat DEO-ULS
Cat ECF-1-a
API CH-4 Oil Category performance SAE 5W-30 −30 30 −22 86
Cat ECF-2
requirements
Cat ECF-3
For oils that are between 1.30 percent Cat DEO-ULS SYN
and 1.50 percent sulfated ash, passing Cat DEO
Cat ECF-1-a
one additional Cat 1P SCOTE test Cat ECF-1-a SAE 5W-40 −30 50 −22 122
(“ASTM D6681”) is required Cat ECF-2
Cat ECF-3
Oils of sulfated ash > 1.50 percent are
not allowed Cat ECF-1-a
SAE 10W-
Cat ECF-2 −18 40 0 104
30
In selecting oil for any engine application, both of the Cat ECF-3
following must be satisfied: the oil viscosity and the SAE 10W-
category of oil performance or the specification for oil −18 50 0 122
Cat DEO-ULS 40
performance . Using only one of these parameters Cat DEO
will not sufficiently define oil for an engine SAE 15W-
−9.5 50 15 122
application. 40
The proper SAE viscosity grade of oil is determined Note: A cold soaked start occurs when the engine
by the following temperatures: minimum ambient
has not been operated recently, allowing the oil to
temperature during cold engine start-up and
maximum ambient temperature during engine become more viscous due to cooler ambient
operation. temperatures. Supplemental heat is recommended
for cold soaked starts below the minimum ambient
Refer to Table 10 (minimum temperature) in order to temperature. Supplemental heat may be necessary
determine the required oil viscosity for starting a cold for cold soaked starts that are above the minimum
engine. temperature depending on factors such as parasitic
load.
Refer to Table 10 (maximum temperature) in order to
select the oil viscosity for engine operation at the Total Base Number (TBN) and Fuel Sulfur
highest ambient temperature that is anticipated.
Levels
Note: Generally, use the highest oil viscosity that is
available to meet the requirement for the temperature The use of Cat S·O·S Services oil analysis is
at start-up. recommended strongly for determining oil life.
Table 10 The minimum required Total Base Number (TBN) for

oil depends on the fuel sulfur level. The TBN for new
Lubricant Viscosities for Ambient Temperatures oil is typically determined by the “ASTM D2896”
for Cat Diesel Engines procedure. For direct injection engines that use
Oil Type and Per- °C °F
distillate fuel, the following guidelines apply:
Viscosity
formance
Grade Min Max Min Max
Requirements
(continued)
SEBU7772-06 57
Maintenance Section
Table 11
TBN recommendations for applications in Cat engines
(1) NOTICE
Always use a designated pump for oil sampling, and
Fuel Sulfur Level per-
TBN of Com- use a separate designated pump for coolant sam-
Cat Engine Oils mercial Engine pling. Using the same pump for both types of sam-
cent (ppm)
Oils ples may contaminate the samples that are being
≤0.05 percent (≤500
drawn. This contaminate may cause a false analysis
Cat DEO-ULS
ppm) Cat DEO
Min 7 and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
0. 1- 0.05 percent Cat DEO-ULS
Min 7
(1000-500 ppm) Cat DEO
Refer to Special Publication, SEBU6251, “Cat
Above 0.1 percent
Cat DEO(3)
Commercial Diesel Engine Fluids
Min 10
(above 1000 ppm)(2) Recommendations” in order to obtain additional
(1)
information about S·O·S Services oil analysis. You
When using fuel with 0.10% sulfur (1000 ppm) or higher, refer
to this Operation and Maintenance Manual, “Severe Service
can also contact your local Cat dealer.
Application” for more information.
(2) For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
refer to TBN and engine oil guidelines given in this section.
Fuel
(3) Cat DEO-ULS may be used if an oil analysis program is fol-
lowed. Base the oil change interval on the analysis. Note: Caterpillar strongly recommends the filtration
of fuel through a fuel filter with a rating of four
microns(c) absolute or less. This filtration should be
S·O·S Services Oil Analysis located on the device that dispenses the fuel to the
fuel tank for the engine. This filtration should also be
Caterpillar has developed a maintenance tool that
evaluates oil degradation. the maintenance located on the device that dispenses fuel from the
management also detects the early signs of wear on bulk storage tank. Series filtration is recommended.
internal components. The Caterpillar tool for oil
analysis is called S·O·S oil analysis and the tool is NOTICE
part of the S·O·S Services program. S·O·S oil In order to meet expected fuel system component life,
analysis divides oil analysis into four categories: 4 micron (c) absolute or less secondary fuel filtration
is required for all Cat Diesel Engines that are
• Component wear rate equipped with unit injected fuel systems. All current
Cat Diesel Engines are factory equipped with Cat Ad-
• Oil condition vanced Efficiency 4 micron(c) absolute fuel filters.
• Oil contamination Caterpillar does not warrant the quality or perform-
ance of non-Cat fluids and filters.
• Identification of oil
Diesel engines can burn a wide variety of fuels.
These four types of analysis are used to monitor the These fuels are divided into two general groups. The
condition of your equipment. The four types of two groups are called the preferred fuels and the
analysis will also help you identify potential problems. permissible fuels.
A properly administered S·O·S oil analysis program
will reduce repair costs and the program will lessen Note: The permissible fuels are some crude oils,
the impact of downtime. some blends of crude oil with distillate fuel, some
The S·O·S Oil Analysis program uses a wide range biodiesel, and some marine diesel fuel. These fuels
of tests to determine the condition of the oil and the are not suitable for use in all engine applications. The
crankcase. Guidelines that are based on experience acceptability of these fuels for use is determined on
and a correlation to failures have been established an individual basis. A complete fuel analysis is
for these tests. Exceeding one or more of these required.
guidelines could indicate serious fluid degradation or
a pending component failure. A trained person at For more information, refer to Special Publication,
your Cat dealership should make the final analysis. SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations” or consult your Cat dealer for
further information.
Diesel Distillate Fuel

Diesel engines may burn a wide variety of fuels.
These fuels are divided into two general groups. The
two groups are called the preferred fuels and the
permissible fuels.
58 SEBU7772-06
Maintenance Section
The preferred fuels provide maximum engine (Table 12, contd)

service life and performance. The preferred fuels Caterpillar Specification for Distillate Fuel for Nonroad
are distillate fuels. These fuels are commonly called Diesel Engines
diesel fuel, furnace oil, gas oil, or kerosene. These
fuels must meet the “Cat Specification for Distillate ASTM
Diesel Fuel for Off-Highway Diesel Engines” found in Specifications Requirements Test ISO Test
this Special Publication, “Distillate Diesel Fuel”
article. Minimum of 80%
reflectance after
No equiva-
Note: The permissible fuels are some crude oils, Thermal Stability aging for 180 mi- “D6468”
lent test
some blends of crude oil with distillate fuel, some nutes at 150 °C
(302 °F)
biodiesel, and some marine diesel fuel. These fuels
are not suitable for use in all engine applications. 30 minimum No equiva-
The acceptability of these fuels for use is determined API Gravity (2) “D287”
45 maximum lent test
on a case by case basis. A complete fuel analysis is
required. Consult your Cat dealer for further 6 °C (10 °F) mini-
information. Pour Point mum below ambi- “D97” “ISO 3016”
ent temperature
NOTICE “D5453” ISO 20846

The footnotes are a key part of the “Caterpillar Speci- Sulfur (3)(4)(5) or or
fication for Distillate Diesel Fuel for Off-Highway Die- “D2622” ISO 20884
sel Engines” Table. Read ALL of the footnotes.
1.4 cSt minimum
and 20.0 cSt max-
Table 12
imum as delivered
Caterpillar Specification for Distillate Fuel for Nonroad to the fuel injec-
Diesel Engines Kinematic tion pumps
- -
Viscosity 1.4 cSt minimum
ASTM
Specifications Requirements Test ISO Test and 4.5 cSt maxi-
mum as delivered
Aromatics 35% maximum “D1319” “ISO 3837” to the rotary fuel
0.01% maximum injection pumps
Ash “D482” “ISO 6245”
(weight) “D1796”
Water and
0.35% maximum 0.05% maximum or “ISO 3734”
Carbon Residue Sediment
“D524” “ISO 4262” “D2709”
on 10% Bottoms (weight)
No equiva-
40 minimum (DI Water 0.05% maximum “D6304”
lent test
engines) “D613”
Cetane Number (1) or “ISO 5165” 0.05% maximum
35 minimum (PC “D6890” Sediment “D473” “ISO 3735”
(weight)
engines)
Gums and Resins 10 mg per 100 mL
The cloud point (6) “D381” “ISO 6246”
maximum
must not exceed
Cloud Point the lowest ex- “D2500” “ISO 3015” 0.52 mm
pected ambient (0.0205 inch) No equiva-
Lubricity “D6079”
temperature. maximum at 60 °C lent test
(140 °F)
Copper Strip
No. 3 maximum “D130” “ISO 2160” (1) Alternatively, to ensure a minimum cetane number of 35 (PC
Corrosion
engines), and 40 (DI engines), distillate diesel fuel should have
10% at 282 °C a minimum cetane index of 37.5 (PC engines), and 44.2 (DI en-
(540 °F) gines) when the “ASTM D4737-96a” test method is used. A fuel
maximum with a higher cetane number may be required for operation at a
Distillation “D86” “ISO 3405” higher altitude or in cold weather.
90% at 360 °C (2) Via standards tables, the equivalent kg/m3 (kilograms per cubic
(680 °F) meter) using the “ASTM D287” test method temperature of
maximum 15.56° C (60° F) for the minimum API gravity of 30 is 875.7 kg/
m3, and for the maximum API gravity of 45 is 801.3 kg/m3.
Flash Point legal limit “D93” “ISO 2719” (3) ULSD 0.0015% (<15 ppm S) is required by law for Tier 4 en-
gines and engines with aftertreatment devices.
(continued)
(continued)
SEBU7772-06 59
Maintenance Section
(Table 12, contd) Refer to Special Publication, SEBU6251, “Cat

(4) Certain Cat fuel systems and engine components can operate Commercial Diesel Engine Fluids
on fuel with a maximum sulfur content of 3%. Contact your Cat Recommendations” for information about the use of
dealer for guidance about appropriate maintenance intervals Cat Diesel Fuel Conditioner.
and fluids for engines operating on fuel with sulfur levels be-
tween 0.1% and 3%. Cat Diesel Fuel System Cleaner
(5) An engine which operates on fuel with 0.1% (1000 ppm) of sul-
fur or more is operating in a severe service application. Refer to
this Operation and Maintenance Manual, “Severe Service Ap- Note: Cat Diesel Fuel System Cleaner is the only fuel
plication” for information about operating an engine in a severe system cleaner available to the end user that is
service application. tested and approved by Caterpillar for use in Cat
(6) Follow the test conditions and procedures for gasoline (motor).
Diesel Engines.
Biodiesel Cat Diesel Fuel System Cleaner is a proven high

performance detergent product designed specifically
A biodiesel blend of up to 20 percent may be used in for cleaning deposits that form in the fuel system.
the engine when the fuel blend meets the Deposits in the fuel system reduce system
recommendations in table 13 and meets the performance and can increase fuel consumption. Cat
recommendations in Special Publication, SEBU6251, Diesel Fuel System Cleaner addresses the deposits
“Biodiesel”. formed due to the use of degraded diesel fuel, poor
quality diesel fuel, and diesel fuel containing high
Note: A complete Cat S·O·S Services oil analysis quantities of high molecular weight compounds. Cat
program is recommended strongly when using Diesel Fuel System Cleaner addresses deposits
biodiesel blends above 5 percent. formed due to the use of biodiesel, biodiesel blends,
and biodiesel that does not meet the appropriate
Table 13 quality specifications. Continued use of Cat Diesel
Biodiesel Blends for Cat Commercial Diesel Engines Fuel System Cleaner is proven to inhibit the growth of
new deposits.
Distillate diesel fuel
Biodiesel blend stock Final blend Caterpillar strongly recommends that Cat Diesel
used for blend
Fuel System Cleaner be used with biodiesel and
Caterpillar distillate biodiesel blends. Cat Diesel Fuel System Cleaner is
Caterpillar biodiesel B20: “ASTM
diesel fuel specifica- suitable for use with biodiesel/biodiesel blends that
specification, “ASTM D7467” and “API”
tion, “ASTM D975” or meet Caterpillar biodiesel recommendations and
D6751” or “EN14214” gravity 30-45
“EN590” requirements. Not all fuel cleaners are suitable for
use with biodiesel/biodiesel blends. Read and follow
all applicable label usage instructions. Also, refer to
Fuel Additives Special Publication, SEBU6251, “Cat Commercial
Diesel Engine Fluids Recommendations” “Distillate
Cat Diesel Fuel Conditioner Diesel Fuel”, article and also refer to the “Biodiesel”
article, which includes Caterpillar biodiesel
Cat Diesel Fuel Conditioner is a proprietary recommendations and requirements.
formulation that has been extensively tested for use
with distillate diesel fuels for use in Cat Diesel Aftermarket Fuel Additives
Engines. Cat Diesel Fuel Conditioner is a high
performance diesel fuel conditioner for use with lower There are many different types of fuel additives that
quality fuels that do not meet the minimum are available to use. Caterpillar does not generally
requirements of any of the following: recommend the use of fuel additives.
• “Caterpillar Specification for Distillate Diesel Fuel” In special circumstances, Caterpillar recognizes the
need for fuel additives. Use fuel additives with
• National Conference on Weights and Measures caution. The additive may not be compatible with the
(NCWM) Premium Diesel definition (refer to the fuel. Some additives may precipitate. This action
2004 or newer National Institute of Standards & causes deposits in the fuel system. The deposits may
Technology (NIST) Handbook). cause seizure. Some additives may plug fuel filters.
Some additives may be corrosive, and some
• EN590 (non-arctic) additives may be harmful to the elastomers in the fuel
system. Some additives may damage emission
• ASTM D975 control systems. Some additives may raise fuel sulfur
levels above the maximum levels that are allowed by
Cat Diesel Fuel Conditioner is the only fuel the following agencies: EPA and other regulatory
conditioner/additive available to the end user that is agencies. Contact your fuel supplier for those
tested and approved by Caterpillar for use in Cat circumstances when fuel additives are required. Your
Diesel Engines. fuel supplier can make recommendations for
additives to use and for the proper level of treatment.
60 SEBU7772-06
Maintenance Section
Note: For best results, your fuel supplier should treat

the fuel when additives are needed.
Cooling System
Note: Refer to Special Publication , SEBU6251, “Cat
Recommendations” for complete information about
the proper fluids for use in the cooling system.
The cooling system operates under pressure

which is controlled by the radiator pressure cap.
Removing the cap while the system is hot may al-
low the escape of hot coolant and steam, causing
serious burns.
Before you remove the radiator cap, allow the
system to cool. Use a thick cloth and turn the ra-
diator cap slowly to the first stop to allow pres-
sure to escape before fully removing the cap.
Avoid contact with coolant.
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 tem-
perature or drained completely in order to prevent
damage caused by freezing coolant.
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. Removing the regulators allows some
coolant to bypass the radiator, potentially causing
overheating.
Coolant Recommendations
Note: A Cat Diesel Engine equipped with air-to-air
aftercooling (ATAAC) requires a minimum of 30
percent glycol to help prevent water pump cavitation.
SEBU7772-06 61
Maintenance Section
Table 14
Coolant Recommendations for use in Cat Diesel Engines
Service Hours
Recommendations Product (1)(2)(3)
Required Maintenance
Add Cat ELC Extender at

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

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

Min requirements for Com- Nitrite (as NO2) concentration: Minimum of 1200 ppm (70 grains/US
3000 hours or 1 SCA at initial fill and SCA
mercial coolants requiring gal) and maximum of 2400 ppm (140 grains/US gal)
year at maintenance intervals
SCA precharge Silicon concentration: minimum of 100 ppm and maximum of 275
ppm
(1) New Coolants at 50 volume percent diluted. Coolants that are prediluted at the coolant manufacturer must be diluted with water that meets
Reagent 4 “ASTM D1193” requirements.
(2) Maintain the in-service coolant at the given limits.
(3) When referring to the service hours, use the interval that occurs first. These coolant change intervals are only achievable with annual S·O·S
Services Level 2 coolant sampling analysis.
Table 15
Special Requirements
Cat C7-C32 Marine Engines with heat exchangers
Minimum of 30% glycol is required. 50% Glycol is recommended.
Cat diesel engines equipped with air-to-air aftercooling (ATAAC) Water alone or water with SCA or with ELI is NOT allowed.
62 SEBU7772-06
Maintenance Section
The following properties of the coolant are tested:

NOTICE
Use Only Approved SCAs and Extenders
• Glycol concentration for freeze protection and boil
Conventional coolants require the maintenance addi- protection
tion of SCA throughout the expected life of the cool-
ants. Do NOT use an SCA with a coolant unless • Ability to protect from erosion and corrosion
approved specifically by the coolant supplier. The
coolant manufacturer is responsible for ensuring • pH
compatibility and acceptable performance.
• Conductivity
To help ensure expected performance, EC-1 coolants
require the one time maintenance addition of an ex- • Visual analysis
tender at coolant service mid-life. Do not use an ex-
tender with a coolant unless the extender has been • Odor analysis
approved specifically for use by the coolant manufac-
turer. The coolant manufacturer is responsible for en- The results are reported, and appropriate
suring compatibility and acceptable performance. recommendations are made.
Failure to follow these recommendations can result in S·O·S Services Coolant Analysis (Level 2)
shortened cooling system component life.
A coolant analysis (Level 2) is a comprehensive
Cat ELC can be recycled into conventional coolants. chemical evaluation of the coolant. This analysis is
also a check of the overall condition of the cooling
For more information, refer to Special Publication, system.
SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”. The S·O·S coolant analysis (Level 2) has the
following features:
S·O·S Services Coolant Analysis
• Full coolant analysis (Level 1)
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and • Identification of metal corrosion and of
corrosion. The analysis also tests the ability of the contaminants
coolant to protect the engine from boiling and
freezing. S·O·S coolant analysis can be done at your • Identification of buildup of the impurities that
Cat dealer. Cat S·O·S coolant analysis is the best cause corrosion
way to monitor the condition of your coolant and your
cooling system. S·O·S coolant analysis is a program • Identification of buildup of the impurities that
that is based on periodic samples. cause scaling
Table 16 • Determination of the possibility of electrolysis
within the cooling system of the engine
Recommended Interval
The results are reported, and appropriate
Type of Level 1 Level 2 recommendations are made.
Coolant
For more information on S·O·S coolant analysis,
Cat DEAC consult your Cat dealer.
Conventional Heavy- Every 250 hours Yearly(1)
Duty Coolants
Greases
Cat ELC
Cat ELI
Optional Yearly(1)
If it is necessary to choose a single grease, always
Commercial EC-1 choose a grease that meets or exceeds the
Coolants requirements of the most demanding application.
(1) The Level 2 Coolant Analysis should be performed sooner if a Remember that the products which barely meet the
problem is suspected or identified. minimum performance requirements can be
expected to barely produce the minimum lives of your
Note: Check the SCA (Supplemental Coolant parts. False economy is being used if a grease is
Additive) of the conventional coolant at every oil purchased with the lowest cost as the only
consideration. Instead, use the grease that yields the
change or at every 250 hours. Perform this check at
lowest total operating cost. The cost should be based
the interval that occurs first. on an analysis that includes the costs of parts, labor,
downtime, and the cost of the amount of grease that
S·O·S Services Coolant Analysis (Level 1)
is required.
A coolant analysis (Level 1) is a test of the properties
of the coolant.
SEBU7772-06 63
Maintenance Section
For more information, refer to Special Publication,

SEBU6251, “Cat Commercial Diesel Engine Fluids
Recommendations”.
64 SEBU7772-06
Maintenance Section
Maintenance Recommendations
Maintenance Do not loosen the high pressure fuel lines in order to

remove air pressure from the fuel system.
Recommendations
Engine Oil
i02909163
To relieve pressure from the lubricating system, turn
System Pressure Release off the engine.
SMCS Code: 1250; 1300; 1350; 5050 i05909227
Coolant System Welding on Engines with

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

charged with high pressure. Note: Perform the welding in areas that are free from
explosive hazards.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system. 1. Stop the engine. Turn the switched power to the
OFF position.
Before any service or repair is performed on the
engine fuel lines, perform the following tasks: 2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
1. Stop the engine. open the switch.
2. Wait for ten minutes.
SEBU7772-06 65
Maintenance Section
Severe Service Application
3. Disconnect the J1/P1 and J2/P2 connectors from 5. Connect the welding ground cable directly to the
the ECM. Move the harness to a position that will part that will be welded. Place the ground cable as
not allow the harness to move back accidentally, close as possible to the weld. This location will
and contact any of the ECM pins. reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
4. Disconnect any component with a microprocessor
components, and ground straps.
from the engine harness, such as:
Note: If electrical/electronic components are used as
• Engine ECM a ground for the welder, current flow from the welder
could severely damage the component. Current flow
• Product Link
from the welder could also severely damage
electrical/electronic components that are located
• Cell/Sat Radio
between the welder ground and the weld.
• DOC Identity Modules
6. Protect the wiring harness from welding debris and
spatter.
7. Use standard welding practices to weld the
materials.
i05083249

SMCS Code: 1000
An engine which operates outside of normal
conditions is operating in a severe service
application.
An engine that operates in a severe service
application may need more frequent maintenance
intervals in order to maximize the following
conditions:
• Reliability
• Service life
The number of individual applications cause the
impossibility of identifying all of the factors which may
contribute to severe service operation. Consult your
Caterpillar dealer for the unique maintenance that
may be necessary for your engine.
An application is a severe service application if any of
Illustration 37 g01075639 the following conditions apply:
Use the example above. The current flow from the
welder to the ground clamp of the welder will not Severe Environmental Factors
damage any associated components.
(1) Engine • Frequent operation in dirty air
(2) Welding electrode
(3) Keyswitch in the OFF position • Frequent operation at an altitude which is above
(4) Battery disconnect switch in the open position 1525 m (5000 ft)
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
• Frequent operation in ambient temperatures which
(8) Minimum distance between the component that is being are above 32° C (90° F)
welded and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
66 SEBU7772-06
Maintenance Section
• Frequent operation in ambient temperatures which • Extending maintenance intervals for changing the
are below 0° C (32° F) engine oil and engine coolant without S·O·S
validation
Severe Operating Conditions • Extending maintenance intervals for changing air
filters, oil filters, and fuel filters
• Frequent operation with inlet air which has a
corrosive content • Failure to use a water separator
• Operation with inlet air which has a combustible • Using filters which are not recommended by
content Special Publication, PEWJ0074, “2008 Cat Filter
and Fluid Application Guide”
• Operation which is outside of the intended
application • Storing the engine for more than 3 months but less
than 1 yr (For information about engine storage,
• Operation with a plugged fuel filter
refer to Special Publication, SEHS9031, “Storage
• Extended operation at low idle (more than 20% of Procedure for Caterpillar Products”)
hours)
• Storing the engine for 1 yr to 2 years (For
• Frequent cold starts at temperatures below 0° C information about engine storage, refer to Special
(32° F) Instruction, REHS5001, “The Long Term Storage
and Recovery of Certain Commercial Engines”)
• Frequent dry starts (starting after more than 72
hours of shutdown)
• Frequent hot shutdowns (shutting down the
engine without the minimum of 2 minutes to 5
minutes of cool down time)
• Operation above the engine rated speed
• Operation below the peak torque speed

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

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

contains more than 5 percent biodiesel
Improper Maintenance Procedures

(Maintenance Procedures Which
May Contribute to a Severe Service
Application)
• Inadequate maintenance of fuel storage tanks
from causes such as excessive water, sediment,
and microorganism growth.
• Extending maintenance intervals beyond the
recommended intervals
• Using fluids which are not recommended in
Special Publication, SEBU6251, “Caterpillar
Recommendations”
SEBU7772-06 67
Maintenance Section
Maintenance Interval Schedule
i06545714 “ Cooling System Supplemental Coolant Additive

(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Maintenance Interval Schedule “ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 88
SMCS Code: 1000; 4450; 7500
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . . . . .
When Required “ Fan Drive Bearing - Lubricate” . . . . . . . . . . . . . . . 91
“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . “ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 92
“ Battery or Battery Cable - Disconnect” . . . . . . . . . . . .
“ Fuel System Secondary Filter - Replace”. . . . . . . 94
“ Coolant - Change” . . . . . . . . . . . . . . . . . . . . . . . . . 75
“ Fuel Tank Water and Sediment - Drain” . . . . . . . . 95
“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . . 77
“ Hoses and Clamps - Inspect/Replace”. . . . . . . . . . . .
“ Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . 83 “ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . 102
“ Engine Storage Procedure - Check”. . . . . . . . . . . 90 Initial 500 Service Hours

“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . . 91 “ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . 91
Daily Every 500 Service Hours

“ Air Tank Moisture and Sediment - Drain” . . . . . . . 71 “ Air Shutoff - Test” . . . . . . . . . . . . . . . . . . . . . . . . . . 70
“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . . 78
“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . . 82
Every 2000 Service Hours or 1 Year
“ Engine Air Cleaner Service Indicator - Inspect” . . 85 “ Aftercooler Core - Inspect/Clean/Test” . . . . . . . . . 69
“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 87 “ Alternator - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 71
“ Fuel System Primary Filter/Water Separator - “ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 80

Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
“ Engine Crankcase Breather - Clean” . . . . . . . . . . 87
“ Power Take-Off Clutch - Check” . . . . . . . . . . . . . 102
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . 91
“Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . 104
Every 4000 Service Hours or 2
Every Week Years
“ Battery Charger - Check” . . . . . . . . . . . . . . . . . . . 72 “ Air Compressor - Check”. . . . . . . . . . . . . . . . . . . . 70
“ Engine Air Precleaner - Check/Clean” . . . . . . . . . 86 “ Coolant Temperature Regulator - Replace” . . . . . 80
“ Jacket Water Heater - Check”. . . . . . . . . . . . . . . . 99 “ Crankshaft Vibration Damper - Inspect” . . . . . . . . 82
Initial 250 Service Hours “ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
“ Coolant Sample (Level 2) - Obtain” . . . . . . . . . . . 80 “ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 87
Every 250 Service Hours Every 208 000 L (55 000 US gal) of
Fuel or 5000 Service Hours
“ Air Compressor Filter - Clean/Replace” . . . . . . . . 70
“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . 103
“ Battery Electrolyte Level - Check” . . . . . . . . . . . . . . .
“ Turbocharger - Inspect” . . . . . . . . . . . . . . . . . . . . 104
“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 74
“ Coolant Sample (Level 1) - Obtain” . . . . . . . . . . . 79
68 SEBU7772-06
Maintenance Section
Maintenance Interval Schedule
“ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . 105
Every 340 000 L (90 000 US gal) of

Fuel or 10 000 Service Hours
“Grounding Stud - Inspect/Clean/Tighten” . . . . . . . 96
“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . . 99
SEBU7772-06 69
Maintenance Section
Aftercooler Core - Inspect/Clean/Test
i04371383 3. Steam clean the core in order to remove any

residue. Flush the fins of the aftercooler core.
Aftercooler Core - Inspect/ Remove any other trapped debris from the inside
Clean/Test and from the outside of the core.
SMCS Code: 1064-070; 1064-040; 1064-081 Note: Do not use high pressure when the fins are
cleaned. High pressure can damage the fins.
Inspect 4. Wash the core with hot, soapy water.
Inspect the aftercooler for these items: damaged fins, 5. Flush the core thoroughly in order to remove
corrosion, dirt, grease, insects, leaves, oil and other residue and remaining debris. Flush the core with
debris. Clean the aftercooler, if necessary. clean, fresh water until the water that is exiting the
Inspect these items for good condition: welds, core is clear and free of debris.
mounting brackets, oil lines, water lines, connections,
clamps and seals. Make repairs, if necessary.
Inspect the fins for damage. Bent fins may be opened Personal injury can result from air pressure.
with a “comb”.
Personal injury can result without following prop-
Clean er procedure. When using pressure air, wear a
protective face shield and protective clothing.
Note: Adjust the frequency of cleaning according to The maximum air pressure for cleaning purposes
the effects of the operating environment. Clean and must be reduced to 205 kPa (30 psi) when the air
test the aftercooler every 4000 service hours unless nozzle is deadheaded.
the inspection indicates the need for more frequent
cleaning. 6. Dry the core with compressed air. Direct the air in
Remove the core. Refer to the Disassembly and the reverse direction of the normal flow.
Assembly Manual, “Oil Cooler- Remove” for the
procedure. Test
1. Turn the aftercooler core on one side in order to
1. Inspect the core for trapped debris and
remove debris. Remove the debris that is
cleanliness. If necessary, remove the debris and
accessible.
repeat the cleaning procedure.
NOTICE 2. Inspect the core for damage and perform a
Do not use a high concentration of caustic cleaner to pressure test in order to detect leaks. Many shops
clean the core. A high concentration of caustic
cleaner can attack the internal metals of the core and that service radiators are equipped to perform
cause leakage. Only use the recommended concen- pressure tests.
tration of cleaner.
3. Plug both ends of the aftercooler core and
pressurize the core to 205 kPa (30 psi).
2. Back flush the core with cleaner. Submerge the core in water. Look for bubbles
which are being emitted from the core. The
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Table 17 lists Hydrosolv liquid bubbles are evidence of leaks.
cleaners that are available from your Cat dealer. 4. If any leaks are found, do not attempt to repair the
Table 17 core.
Hydrosolv Liquid Cleaners(1) Install a core that is clean and that passes the
pressure test in step 3. Refer to the Disassembly and
Part Number Description Size Assembly Manual, “Oil Cooler - Install” for the
procedure.
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
174-6854 Hydrosolv 100 19 L (5 US gallon)

(1) Use a 2 percent to a 5 percent concentration of the cleaner at
temperatures up to 93°C (200°F). Consult your Cat dealer for
more information.
70 SEBU7772-06
Maintenance Section
Air Compressor - Check
For more information on cleaning the core, consult Refer to the Disassembly and Assembly Manual, “Air
your Cat dealer. Compressor - Remove and Install” for more
information or consult with your Cat dealer.
i04371922
i01544231
Air Compressor - Check
SMCS Code: 1803-535
Air Compressor Filter - Clean/
Replace
(If Equipped)
Do not disconnect the air line from the air com- SMCS Code: 1054; 1803-510-FQ; 1803-070-FQ;
pressor governor without purging the air brake 1803; 5502
and the auxiliary air systems. Failure to purge the
air brake and the auxiliary air systems before re- One of the single most important aspects of
moving the air compressor and/or the air lines preventive maintenance for the air compressor is the
could cause personal injury. induction of clean air. The type of maintenance that is
required for the air compressor and the maintenance
interval depends on the type of air induction system
that is used. Operating conditions (dust, dirt and
debris) may require more frequent service.
Refer to the Service Manual for the type of air
compressor that is installed on the engine. Follow the
maintenance recommendations that are provided by
the OEM of the air compressor. Some engines use
boost air pressure so the engine air cleaner will
require servicing.
i05341564
Air Shutoff - Test

SMCS Code: 1078-081
To ensure that the air shutoff valve always shuts
Typical installation of an air compressor down when the engine ingests gaseous fumes,
perform the test below at each oil change. A test
failure can indicate wear in the block off plate to valve
body interface and/or the bearing system.
If the air compressor pressure relief valve that is 1. Place engine at low idle speed. Ensure all
mounted in the air compressor cylinder head is
bypassing compressed air, there is a malfunction accessories that are normally used for the
in the air system, possibly ice blockage. Under application are in use, like a fan, or power takeoffs.
these conditions, your engine may have insuffi- 2. Actuate the air shutoff manually. On electrical
cient air for normal brake operation.
operator air shutoffs, utilize an applicable power
Do not operate the engine until the reason for the supply or jumper cables from the battery to
air bypass is identified and corrected. Failure to energize the air shut-off solenoid. Ensure that the
heed this warning could lead to property damage, solenoid receives only a momentary signal to
personal injury, or death to the operator or prevent overheating. On hydraulic operator air
bystanders.
shutoffs, found on some hazardous location units,
The function of the air compressor pressure relief actuate by pulling the emergency stop handle.
valve is to bypass air when there is a malfunction in
the air compressor system. 3. Ensure that air shutoff was actuated and that the
engine comes to a complete stop.
The air compressor pressure relief valve releases air
at 1723 kPa (250 psi). All personnel must stand clear Note: As every application has different parasitic
of the air compressor pressure relief valve when loads and inertia, the duration for the problem to
compressed air is released. All personnel should also occur cannot be specified. However, if the engine
stay clear of the air compressor when the engine is stumbles or attempts to continue running, these
operating and the air compressor is exposed. symptoms may be an indication that worn
components may need replacement.
SEBU7772-06 71
Maintenance Section
Air Tank Moisture and Sediment - Drain
If additional help is needed, contact the Dealer i02676048

Solution Network.
Alternator - Inspect
NOTICE
Actuating the air shutoff valve may result in oil leak- SMCS Code: 1405-040
age past the shaft seal in some cases. Repeated ac-
tuation of the air shutoff valve during loaded Caterpillar recommends a scheduled inspection of
operation of the engine can result in mechanical the alternator. Inspect the alternator for loose
damage to the turbocharger and reduce turbocharger connections and proper battery charging. Inspect the
life. 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.
i00847451
Check the alternator and the battery charger for
Air Tank Moisture and proper operation. If the batteries are properly
charged, the ammeter reading should be very near
Sediment - Drain zero. All batteries should be kept charged. The
(If Equipped) batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
SMCS Code: 1466-543-M&S the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm.
Moisture and sediment in the air starting system can When the engine is not run for long periods of time or
cause the following conditions: if the engine is run for short periods, the batteries
may not fully charge. A battery with a low charge will
• Freezing freeze more easily than a battery with a full charge.
• Corrosion of internal parts
i06738473
• Malfunction of the air starting system

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

gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could Batteries give off combustible gases which can
cause debris to be blown and result in personal explode. A spark can cause the combustible
injury. gases to ignite. This can result in severe personal
injury or death.
1. Open the drain valve that is on the bottom of the Ensure proper ventilation for batteries that are in
air tank. Allow the moisture and sediment to drain. an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
2. Close the drain valve. near batteries. Do not smoke when batteries are
3. Check the air supply pressure. The air starting serviced.
motor requires a minimum of 620 kPa (90 psi) of
air pressure to operate properly. The maximum air
pressure must not exceed 1550 kPa (225 psi).
The normal air pressure will be 758 to 965 kPa The battery cables or the batteries should not be
(110 to 140 psi). removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
Note: Always recycle a battery. Never discard a

battery. Return used batteries to an appropriate
recycling facility.
72 SEBU7772-06
Maintenance Section
Battery Charger - Check
1. Turn the key start switch to the OFF position. Charging the Battery
Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the
charger.
Never disconnect any charging unit circuit or bat-
3. Turn battery isolator switch to OFF position. tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an
4. The NEGATIVE “-” cable connects the NEGATIVE explosion from the flammable vapor mixture of
“-” battery terminal to the ground plane. hydrogen and oxygen that is released from the
Disconnect the cable from the NEGATIVE “-” electrolyte through the battery outlets. Injury to
battery terminal. personnel can be the result.
5. The POSITIVE “+” cable connects the POSITIVE Perform the following procedure to charge the
“+” battery terminal to the starting motor. battery:
Disconnect the cable from the POSITIVE “+” 1. Ensure that the charger is turned OFF.
battery terminal.
2. Adjust the voltage of the charger in order to match
Note: Always recycle a battery. Never discard a the voltage of the battery.
battery. Return used batteries to an appropriate
recycling facility. 3. Connect the POSITIVE “+” lead of the charger to
the POSITIVE “+” battery terminal. Connect the
6. Remove the used battery. NEGATIVE “-” lead of the charger to the
7. Install the new battery. NEGATIVE “-” battery terminal.
4. Turn ON the battery charger.
Note: Before the cables are connected, ensure that
the key start switch is OFF. Overcharging of Batteries
8. Connect the cable from the starting motor to the Overcharging reduces the service life of batteries.
POSITIVE “+” battery terminal. Use a battery charger that will not overcharge the
battery. DO NOT charge the battery if the meter of the
9. Connect the cable from the ground plane to the battery charger is in the RED zone.
NEGATIVE “-” battery terminal.
Overcharging is indicated by the following symptoms:
i05264116
• The battery is warm to the touch.
Battery Charger - Check • A strong odor of acid is present.
SMCS Code: 1401-535
• The battery emits smoke or a dense vapor (gas).
Checking Before Start-Up Perform one of the following procedures if the battery
shows symptoms of overcharging:
Check the battery charger for proper operation. If the
batteries are properly charged, the needle of the • Reduce the rate of charging by a significant
ammeter will register near “0” (zero). amount. Complete the charging at the reduced
rate.
The battery charger must not produce excessive
current during start-up. Alternatively, the charger • Turn OFF the charger.
must be automatically disconnected for start-up. If
the engine has an alternator, the charger must be Table 18 describes the effects of overcharging on
automatically disconnected during start-up and different types of batteries.
during engine operation. Table 18
Effects of Overcharging Batteries
Type of Battery Effect
(continued)
SEBU7772-06 73
Maintenance Section
Battery Electrolyte Level - Check
(Table 18, contd) 3. Keep the batteries clean.

Cat General Service Batteries All of the battery cells have a
Clean the battery case with one of the following
Cat Premium High Output low level of electrolyte.
Batteries
cleaning solutions:
• A mixture of 0.1 kg (0.2 lb) of baking soda and

1 L (1 qt) of clean water
When the plates of the battery • A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
are inspected through the filler (1 qt) of clean water
holes, the plates may appear to
be warped. This is caused by an Thoroughly rinse the battery case with clean
excessive temperature. water.
The battery may not pass a load Use the 1U-9921 Battery Service Tool to clean
test. the battery terminals. Use a wire brush to clean
Cat Maintenance Free Batteries The battery may not accept a the cable clamps. Clean the items until the
charging current. surfaces are bright or shiny. DO NOT remove
material excessively. Excessive removal of
The battery may not pass a load material can cause the clamps to fit improperly.
test. Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
Checking After Stopping i06738663
Ensure that the battery charger is connected Battery or Battery Cable -

properly. Observe the meter of the charger. Record
the amperage. Disconnect
SMCS Code: 1401; 1402-029
i06845102
Battery Electrolyte Level -

Check The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
SMCS Code: 1401-535-FLV
tery cover should be removed before any servic-
When the engine has not run for long or short periods ing is attempted.
of time, the batteries may not fully recharge. Ensure a
Removing the battery cables or the batteries with
full charge to help prevent the battery from freezing.
the cover in place may cause a battery explosion
In warmer climates, check the electrolyte level more resulting in personal injury.
frequently.
Ensure that the electrolyte level is 13 mm (0.5 inch) 1. Turn the start switch to the OFF position. Turn the
above the top of the separators. ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
All lead-acid batteries contain sulfuric acid which the cable cannot contact the terminal. When four
can burn the skin and clothing. Always wear a
face shield and protective clothing when working 12 volt batteries are involved, the negative side of
on or near batteries. two batteries must be disconnected.
3. Tape the leads in order to help prevent accidental
1. Remove the filler caps. Maintain the electrolyte starting.
level to the “FULL” mark on the battery. 4. Proceed with necessary system repairs. Reverse
If the addition of water is necessary, use distilled the steps in order to reconnect all of the cables.
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
245-5829 Coolant Battery Tester Refractometer.
74 SEBU7772-06
Maintenance Section
Belts - Inspect/Adjust/Replace
i04372027 Alternator Belt

Belts - Inspect/Adjust/Replace
SMCS Code: 1357-040; 1357-025; 1357-510
Inspect
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.
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.
For applications that require multiple drive belts, Illustration 39 g02533519
replace the belts in matched sets. Replacing only one (1) Adjusting nuts
belt of a matched set will cause the new belt to carry (2) Mounting bolts
more load because the older belt is stretched. The
additional load on the new belt could cause the new
belt to break. 1. Slightly loosen the mounting bolts and the
adjusting nuts.
If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose 2. To check the belt tension on v-belts, apply 110 N
belts may slip enough to cause overheating. (25 lb ft) of force midway between the pulleys. A
correctly adjusted belt will deflect 9 mm
If the belts are too tight, unnecessary stresses are
placed on the pulley bearings and on the belts. This (0.35 inch) to 15 mm (0.59 inch).
may shorten the service life of the components. 3. If necessary, tighten or loosen the adjustment nuts
Remove the belt guard, if equipped. Inspect the to adjust the belt tension.
condition and adjustment of the alternator belts and 4. If necessary, remove the belt guard and replace
accessory drive belts (if equipped).
the belts.
If the belt does not require replacement or
adjustment, install the belt guard. If the belt requires Note: Always replace v-belts in sets. Never replace
adjustment or replacement, follow the procedure one belt from a set.
below.
5. Tighten adjusting the nuts and the mounting bolts.
Refer to the Specifications Manual, SENR3130,
Adjust/Replace (V-Belts) “Torque Specifications” topic.
The engine may be equipped with one of the belts 6. If new belts are installed, check the belt tension
below. after 30 minutes of engine operation at the rated
rpm.
7. Install the belt guard.
SEBU7772-06 75
Maintenance Section
Coolant - Change
Belt for the Water Pump
(6) Square hole
(3) Mounting bolt 1. Remove the front cover.
(4) Square hole
(5) Adjusting bolt 2. Insert a ratchet with a square drive into the square
hole that is located in the tensioner for the fan
1. Slightly loosen the mounting bolt and the adjusting drive belt. Rotate the tensioner clockwise in order
bolt. to relieve tension on the fan drive belt. Remove
the fan drive belt.
2. To check the belt tension on v-belts, apply 110 N
(25 lb ft) of force midway between the pulleys. A 3. Then insert a ratchet with a square drive into the
correctly adjusted belt will deflect 9 mm square hole that is located in the tensioner for the
(0.35 inch) to 15 mm (0.59 inch). alternator belt.
3. Adjust the belt tension with a square drive in the 4. Rotate the tensioner counterclockwise in order to
square hole. relieve tension on the alternator belt. Remove the
alternator belt.
4. If necessary, remove the belt guard and replace
the belts. 5. Install the new belt correctly, as shown. Be sure
that the belt is fully seated on the pulleys. The
Note: Always replace v-belts in sets. Never replace
correct tension will automatically be applied when
one belt from a set.
the ratchet is removed.
5. Tighten the adjusting bolt and mounting bolt. Refer 6. Replace the front cover.
to the Specifications Manual, SENR3130, “Torque
Specifications.” i04538352
6. If new belts are installed, check the belt tension

after 30 minutes of engine operation at the rated Coolant - Change
rpm. SMCS Code: 1350-044; 1352; 1395; 1395-044
7. Install the belt guard. Refer to this Operation and Maintenance Manual,
“Fluid Recommendations” for the correct intervals for
Replace (Serpentine Belt) changing the coolant.
Clean the cooling system and flush the cooling
The tension on the serpentine belt may not be system before the recommended maintenance
adjusted. 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.
76 SEBU7772-06
Maintenance Section
Coolant - Change
• The fuel has entered the cooling system and the Inside USA 1-800-542-TOOL
coolant is contaminated. Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL
Drain the Cooling System International 1-309-578-7372
Flush
Pressurized System: Hot coolant can cause seri- Systems Filled with Cat ELC, Cat ELI, or
ous burns. To open the cooling system filler cap, a Conventional Coolant that Meets the
stop the engine and wait until the cooling system Cat EC-1 Requirements and the
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the Standards of ASTM D6210
pressure.
1. Flush the cooling system with clean water in order
to remove any debris.
NOTICE
Care must be taken to ensure that fluids are con- 2. Close the drain valve (if equipped). Clean the drain
tained during performance of inspection, mainte- plugs. Install the drain plugs. Refer to the
nance, testing, adjusting, and repair of the product. Specifications Manual, SENR3130, “Torque
Be prepared to collect the fluid with suitable contain- Specifications” for more information on the proper
ers before opening any compartment or disassem-
bling any component containing fluids. torques.
Refer to Special Publication, NENG2500, “Cat Dealer NOTICE

Service Tool Catalog” or refer to Special Publication, Fill the cooling system no faster than 19 L (5 US gal)
PECJ0003, “Cat Shop Supplies and Tools Catalog” per minute to avoid air locks.
for tools and supplies suitable to collect and contain
fluids on Cat products.
3. Fill the cooling system with clean water. Install the
Dispose of all fluids according to local regulations cooling system filler cap.
and mandates.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the 5. Stop the engine and allow the engine to cool.
cooling system is drained. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
2. Loosen the cooling system filler cap slowly in order system filler cap. Open the drain valve (if
to relieve any pressure. Remove the cooling equipped) or remove the cooling system drain
system filler cap. plugs. Allow the water to drain. Flush the cooling
3. Open the cooling system drain valve (if equipped). system with clean water. Close the drain valve (if
If the cooling system is not equipped with a drain equipped). Clean the drain plugs. Install the drain
valve, remove one of the drain plugs. plugs. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more
Note: If equipped, be sure to drain the heater and information on the proper torques.
any related supply and return lines.
Systems Filled with Cat DEAC,
Allow the coolant to drain.
Conventional Coolant which does not
NOTICE Meet the Cat EC-1 Requirements, or
Dispose of used engine coolant properly or recycle. Supplemental Coolant Additive (SCA)
Various methods have been proposed to reclaim
used coolant for reuse in engine cooling systems. and Water
The full distillation procedure is the only method ac-
ceptable by Caterpillar to reclaim the used coolant. 3. Flush the cooling system with clean water in order
to remove any debris.
For information regarding the disposal and the
recycling of used coolant, consult your Cat dealer or 4. Close the drain valve (if equipped). Clean the drain
consult Cat Dealer Service Tool Group: plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper
torques.
SEBU7772-06 77
Maintenance Section
Coolant Extender (ELC) - Add
1. Fill the cooling system. Refer to this Operation and

NOTICE
Fill the cooling system no faster than 19 L (5 US gal) Maintenance Manual, “Fluid Recommendations”
per minute to avoid air locks. for more information on cooling system
specifications Refer to this Operation and
Maintenance Manual, “Refill Capacities” for
5. Fill the cooling system with a mixture of clean
information about the capacity of the cooling
water and Cat Fast Acting Cooling System
system. Do not install the cooling system filler cap.
Cleaner.
2. Start and run the engine at low idle. Increase the
6. Choose 1 of the following options.
engine rpm to high idle. Run the engine at high
• Add 0.5 L (1 pint) of cleaner per 15 L idle for 1 minute in order to purge the air from the
(4 US gal) of the cooling system capacity. cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level
• For cooling systems with heavy deposits or
within 13 mm (0.5 inch) below the bottom of the
plugging, add 0.5 L (1 pint) of cleaner per
pipe for filling. Maintain the coolant level within
3.8 to 7.6 L (1 to 2 US gal) of the cooling
13 mm (0.5 inch) to the proper level on the sight
system capacity.
glass (if equipped).
7. Install the cooling system filler cap. 4. Clean the cooling system filler cap. Inspect the
8. Start and run the engine at low idle for a minimum gasket that is on the cooling system filler cap. Only
of 30 minutes. For cooling systems with heavy install the used filler cap if the gasket is not
deposits or plugging, run the engine for 90 damaged. Use a 9S-8140 Pressurizing Pump to
minutes. The coolant temperature should be at pressure test a reinstalled cooling system filler
least 82 °C (180 °F). cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
NOTICE system filler cap. If the cooling system filler cap
Improper or incomplete rinsing of the cooling system does not retain the correct pressure, install a new
can result in damage to copper and other metal cooling system filler cap.
components.
5. Start the engine. Inspect the cooling system for
To avoid damage to the cooling system, make sure to leaks and for proper operating temperature.
completely flush the cooling system with clear water.
Continue to flush the system until all signs of the
i04862631
cleaning agent are gone.
Coolant Extender (ELC) - Add
9. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in SMCS Code: 1352-544-NL
order to relieve any pressure. Remove the cooling Note: Refer to this Operation and Maintenance
system filler cap. Open the drain valve (if Manual, “Fluid Recommendations” (Cooling System)
equipped) or remove the cooling system drain for the maintenance interval for the addition of the
plugs. Allow the water to drain. Flush the cooling coolant extender.
system with clean water. If equipped, be sure to
flush the heater and any related supply and return Cat ELC (Extended Life Coolant) and Cat ELI
(Extended Life Inhibitor) do not require the frequent
lines. Close the drain valve (if equipped). Clean additions of any supplemental cooling additives. The
the drain plugs. Install the drain plugs. Refer to the Cat ELC Extender will only be added one time.
Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper Note: Do not use conventional supplemental coolant
torques. additive (SCA) with Cat ELC or with Cat ELI.
Check the cooling system only when the engine is
Fill the Cooling System stopped and cool.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
78 SEBU7772-06
Maintenance Section
Coolant Level - Check
i04156593
Personal injury can result from hot coolant, Coolant Level - Check
steam and alkali. SMCS Code: 1395-082
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to Check the coolant level when the engine is stopped
heaters or the engine contain hot coolant or and cool.
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
NOTICE
Care must be taken to ensure that fluids are con- Illustration 42 g00285520
tained during performance of inspection, mainte- Cooling system filler cap
nance, testing, adjusting, and repair of the product.
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer ous burns. To open the cooling system filler cap,
Service Tool Catalog” or refer to Special Publication, stop the engine and wait until the cooling system
PECJ0003, “Cat Shop Supplies and Tools Catalog” components are cool. Loosen the cooling system
for tools and supplies suitable to collect and contain pressure cap slowly in order to relieve the
fluids on Cat products. pressure.
Dispose of all fluids according to local regulations
and mandates. 1. Remove the cooling system filler cap slowly in
order to relieve pressure.
1. Loosen the cooling system filler cap slowly in order 2. Maintain the coolant level within 13 mm (0.5 inch)
to relieve pressure. Remove the cooling system of the bottom of the filler pipe. If the engine is
filler cap. equipped with a sight glass, maintain the coolant
2. If necessary, drain enough coolant from the level to the proper level in the sight glass.
cooling system in order to add the Cat ELC
Extender.
3. Add Cat ELC Extender according to the
requirements for the cooling system capacity.
Refer to this Operation and Maintenance Manual,
“Refill Capacities” for the coolant capacity.
4. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
For further information, refer to this Operation and
Maintenance Manual, , “Fluid Recommendations”.
Typical filler cap gaskets
SEBU7772-06 79
Maintenance Section
Coolant Sample (Level 1) - Obtain
3. Clean the cooling system filler cap and check the • Keep the lids on empty sampling bottles until you
condition of the filler cap gaskets. Replace the are ready to collect the sample.
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap. • Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
4. Inspect the cooling system for leaks. contamination.
• Never collect samples from expansion bottles.

i04333559
• Never collect samples from the drain for a system.

Coolant Sample (Level 1) -
Obtain Timing of the Sampling
SMCS Code: 1350-008; 1395-554; 1395-008; 7542 Table 19
Testing the engine coolant is important to ensure that Recommended Interval
the engine is protected from internal cavitation and
corrosion. The analysis also tests the ability of the Type of
coolant to protect the engine from boiling and Level 1 Level 2
freezing. S·O·S Systems Coolant Analysis can be Coolant
done at your Cat dealer. Cat S·O·S coolant analysis Cat DEAC
is the best way to monitor the condition of your Cat SCA
coolant and your cooling system. S·O·S coolant Every 250 hours Yearly(1)
Conventional Heavy-
analysis is a program that is based on periodic Duty Coolants
samples.
Cat ELC
Note: Obtaining a Coolant Sample (Level 1) is Cat ELI
Optional(1) Yearly(1)
optional if the cooling system is filled with one of Commercial EC-1
the following coolants: Cat ELC (Extended Life Coolants
Coolant)., Cat ELI (Extended Life Inhibitor) and (1) The Level 2 Coolant Analysis should be performed sooner if a
Conventional Heavy-Duty Coolant. problem is suspected or identified.
Note: Obtain a Coolant Sample (Level 1) if the Note: Check the SCA (Supplemental Coolant
cooling system is filled with any of the following Additive) of the conventional coolant at every oil
coolants: Cat DEAC, Cat SCA and Conventional change or at every 250 hours. Perform this check at
Heavy-Duty Coolants. the interval that occurs first.
For additional information about coolant analysis and Obtain the sample of the coolant as close as possible
about other coolants, see this Operation and to the recommended sampling interval. In order to
Maintenance Manual, “Fluid Recommendations” or receive the full effect of S·O·S analysis, establish a
consult your Cat dealer. consistent trend of data. In order to establish a
pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for
Sampling Conditions collecting samples can be obtained from your Cat
dealer.
If the engine is equipped with a sampling port, the
engine should be running at operating temperature
when the sample is obtained. NOTICE
Always use a designated pump for oil sampling, and
If the engine is not equipped with a sampling port, the use a separate designated pump for coolant sam-
coolant should be warm. pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
Use the following guidelines for proper sampling of drawn. This contaminate may cause a false analysis
the coolant: and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
• Complete the information on the label for the
sampling bottle before you begin to take the
samples. Submit the sample for Level 1 analysis.
• Keep the unused sampling bottles stored in plastic

bags.
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
80 SEBU7772-06
Maintenance Section
Coolant Sample (Level 2) - Obtain
Note: Level 1 results may indicate a need for Level 2 A water temperature regulator that fails in the closed
Analysis. position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
i04638756
head or piston seizure problems.
Coolant Sample (Level 2) - NOTICE

Failure to replace your water temperature regulator
Obtain on a regularly scheduled basis could cause severe
engine damage.
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Caterpillar engines incorporate a shunt design cool-
An S·O·S Coolant Analysis (Level 2) is a ing system and require operating the engine with a
comprehensive chemical evaluation of the coolant. water temperature regulator installed.
This analysis is also a check of the overall condition
of the cooling system. The S·O·S Coolant Analysis If the water temperature regulator is installed incor-
(Level 2) has the following features: rectly, the engine may overheat, causing cylinder
head damage. Ensure that the new water tempera-
• Full coolant analysis (Level 1) ture regulator is installed in the original position. En-
sure that the water temperature regulator vent hole is
• Identification of metal corrosion and contaminants open.
• Identification of buildup of the impurities that Do not use liquid gasket material on the gasket or cyl-
cause corrosion and scaling inder head surface.
• Determination of the possibility of electrolysis

within the cooling system of the engine NOTICE
The results are reported and appropriate tained during performance of inspection, mainte-
recommendations are made. nance, testing, adjusting, and repair of the product.
Obtaining the Sample ers before opening any compartment or disassem-
Refer to Operation and Maintenance Manual, Refer to Special Publication, NENG2500, “Cat Dealer
“Coolant Sample (Level 1) - Obtain” for the guidelines Service Tool Catalog” or refer to Special Publication,
for proper sampling of the coolant. PECJ0003, “Cat Shop Supplies and Tools Catalog”
Submit the sample for Level 2 analysis.
For further information, refer to this Operation and
Maintenance Manual, “Fluid Recommendations”.
and mandates.
i04240223
Note: If replacing only the water temperature
Coolant Temperature regulator, only drain the coolant to a level that is
Regulator - Replace below the water temperature regulator housing.
SMCS Code: 1355-510 Refer to two articles in the Disassembly and

Assembly Manual, “Water Temperature Regulator -
Replace the water temperature regulator before the Remove and Water Temperature Regulator - Install”
water temperature regulator fails. Replacing the for the replacement procedure or consult your Cat
water temperature regulator reduces the chances for dealer.
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 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.
SEBU7772-06 81
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
i04269112
NOTICE
Cooling System Supplemental tained during performance of inspection, mainte-
Coolant Additive (SCA) - Test/ Be prepared to collect the fluid with suitable contain-
Add ers before opening any compartment or disassem-
(Systems Which are Filled with
Refer to Special Publication, NENG2500, “Cat Dealer
Conventional Coolant) Service Tool Catalog” and to Special Publication,
SMCS Code: 1352-045; 1395-081 GECJ0003, “Cat Shop Supplies and Tools” for tools
and supplies suitable to collect and contain fluids on
This maintenance procedure is required for Cat products.
conventional coolants such as DEAC.Do not
perform this maintenance for cooling systems Dispose of all fluids according to applicable regula-
that are filled with Cat Extended Life Coolant (Cat tions and mandates.
ELC) or Cat Extended Life Inhibitor (Cat ELI).
Note: Caterpillar recommends that an S·O·S Coolant
Analysis (Level 1) be performed to check the
concentration of SCA.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact
with the skin and eyes. Do not drink cooling sys- Maintain the Proper Concentration
tem coolant additive. of SCA in the Coolant
NOTICE
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur- Pressurized System: Hot coolant can cause seri-
faces of the cooling system, reducing the engine's ous burns. To open the cooling system filler cap,
heat transfer characteristics. Reduced heat transfer stop the engine and wait until the cooling system
could cause cracking of the cylinder head and other components are cool. Loosen the cooling system
high temperature components. pressure cap slowly in order to relieve the
pressure.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat ex- 1. Remove the cooling system filler cap slowly.
changer, overheating, and/or accelerated wear of the
water pump seal. 2. Test the concentration of the SCA with a
286-2578 Nitrite Test Strip or review the results
Do not exceed the recommended amount of supple- of the S·O·S Coolant Analysis (Level 1).
mental coolant additive concentration.
3. If necessary, drain some coolant in order to allow
space for the addition of the SCA.
NOTICE
Do NOT mix brands or types of SCA. Do NOT mix 4. Add the amount of SCA required to maintain a
SCAs and extenders. concentration of 3 percent to 6 percent SCA in the
coolant.
Failure to follow the recommendations can result in
shortened cooling system component life. 5. Clean the cooling system filler cap. Install the
cooling system filler cap.
NOTICE
Use Only Approved SCAs. Conventional coolants
require the maintenance addition of SCA throughout
their expected life. Do NOT use an SCA with a cool-
ant unless specifically approved by the coolant sup-
plier for use with their coolant. It is the responsibility
of the coolant manufacturer to ensure compatibility
and acceptable performance.
Failure to follow the recommendations can result in
shortened cooling system component life.
82 SEBU7772-06
Maintenance Section
Crankshaft Vibration Damper - Inspect
For further information, refer to Special Publication, • The bolt holes are worn or there is a loose fit for
SEBU6251, “Cat Commercial Diesel Engine Fluids the bolts.
Recommendations”.
• The engine has had a crankshaft failure due to
i06103521 torsional forces.
Crankshaft Vibration Damper - • Extreme wear of the gear train.
Inspect Replace the damper if any of these conditions exist.

SMCS Code: 1205-040
Removal and Installation
Damage to the crankshaft vibration damper or failure
of the crankshaft vibration damper can increase Refer to this Operation and Maintenance Manual,
torsional vibrations. The vibrations can damage the “Belts - Inspect/Adjust/Replace” for information on
crankshaft and other engine components. A removing and on installing the belt. Refer to the
deteriorating damper can cause excessive gear train Disassembly and Assembly Manual, “Vibration
noise at variable points in the speed range. Damper and Pulley - Remove and Install” for
information on removing and installing the damper.
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the i00174798
engine.
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.
i06103535
Engine - Clean
SMCS Code: 1000-070
Viscous vibration damper
Typical example
(1) Crankshaft pulley Personal injury or death can result from high
(2) Weight voltage.
(3) Case
Moisture can create paths of electrical
Inspection conductivity.
Make sure that the electrical system is OFF. Lock
Inspect the damper for the following conditions: out the starting controls and tag the controls “ DO
NOT OPERATE”” .
• The damper is dented, cracked, or fluid is leaking
from the damper.
• The paint on the damper is discolored from
excessive heat.
• The damper is bent.
SEBU7772-06 83
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
• The air cleaner element may be cleaned up to six

NOTICE
Accumulated grease and oil on an engine is a fire times if the element is properly cleaned and
hazard. Keep the engine clean. Remove debris and inspected.
fluid spills whenever a significant quantity accumu-
lates on the engine. • The air cleaner element should be replaced at
least one time per year. This replacement should
Periodic cleaning of the engine is recommended. be performed regardless of the number of
Steam cleaning the engine will remove accumulated cleanings.
oil and grease. A clean engine provides the following
benefits: Replace the dirty paper air cleaner elements with
clean air cleaner elements. Before installation,
• Easy detection of fluid leaks thoroughly check the air cleaner elements for tears
and/or holes in the filter material. Inspect the gasket
• Maximum heat transfer characteristics or the seal of the air cleaner element for damage.
Maintain a supply of suitable air cleaner elements for
• Ease of maintenance replacement purposes.
Note: Caution must be used in order to prevent Dual Element Air Cleaners
electrical components from being damaged by
excessive water when you clean the engine. Avoid The dual element air cleaner contains a primary air
electrical components such as the alternator, the cleaner element and a secondary air cleaner
starter, and the ECM. element. The primary air cleaner element can be
used up to six times if the element is properly
i04322011
cleaned and inspected. The primary air cleaner
element should be replaced at least one time per
year. This replacement should be performed
Engine Air Cleaner Element regardless of the number of cleanings.
(Dual Element) - Inspect/Clean/ The secondary air cleaner element is not serviceable
Replace or washable. The secondary air cleaner element
should be removed and discarded for every three
SMCS Code: 1051; 1054-510; 1054-070; 1054-040 cleanings of the primary air cleaner element. When
the engine is operating in environments that are
NOTICE dusty or dirty, air cleaner elements may require more
Never run the engine without an air cleaner element frequent replacement.
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 pre-
vent airborne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air Illustration 45 g00736431
can split the material of the air cleaner element. (1) Cover
Unfiltered air will drastically accelerate internal (2) Primary air cleaner element
engine wear. Your Cat dealer has the proper air (3) Secondary air cleaner element
cleaner elements for your application. Consult your (4) Turbocharger air inlet
Cat dealer for the correct air cleaner element.
1. Remove the cover. Remove the primary air cleaner
• Check the precleaner (if equipped) daily for element.
accumulation of dirt and debris. Remove any dirt
and debris, as needed. 2. The secondary air cleaner element should be
removed and discarded for every three cleanings
• Operating conditions (dust, dirt, and debris) may of the primary air cleaner element.
require more frequent service of the air cleaner
element.
84 SEBU7772-06
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace
Note: Refer to “Cleaning the Primary Air Cleaner Visually inspect the primary air cleaner elements
Elements”. before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
3. Cover the turbocharger air inlet with tape in order Discard any damaged air cleaner elements.
to keep out dirt.
There are two common methods that are used to
4. Clean the inside of the air cleaner cover and body clean primary air cleaner elements:
with a clean, dry cloth.
• Pressurized air
5. Remove the tape for the turbocharger air inlet.
Install the secondary air cleaner element. Install a • Vacuum cleaning
primary air cleaner element that is new or cleaned.
Pressurized Air
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.
Personal injury can result from air pressure.
Cleaning the Primary Air Cleaner
Elements Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
NOTICE
Caterpillar recommends certified air filter cleaning Maximum air pressure at the nozzle must be less
services that are available at Cat dealers. The Cat than 205 kPa (30 psi) for cleaning purposes.
cleaning process uses proven procedures to assure
consistent quality and sufficient filter life. Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
Observe the following guidelines if you attempt to than two times. Pressurized air will not remove
clean the filter element: deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
Do not tap or strike the filter element in order to re-
move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
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 Illustration 46 g00281692
inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material. Note: When the primary air cleaner elements are
The primary air cleaner element should be replaced cleaned, always begin with the clean side (inside) in
at least one time per year. This replacement should order to force dirt particles toward the dirty side
be performed regardless of the number of cleanings. (outside).
Use clean primary air cleaner elements while dirty To help prevent damage to the paper pleats, aim the
elements are being cleaned. hose so that the air flows inside the element along
the length of the filter. Do not aim the stream of air
NOTICE directly at the primary air cleaner element. Dirt could
Do not clean the air cleaner elements by bumping or be forced further into the pleats.
tapping. This could damage the seals. Do not use el-
ements with damaged pleats, gaskets or seals. Dam- Note: Refer to “Inspecting the Primary Air Cleaner
aged elements will allow dirt to pass through. Engine Elements”.
damage could result.
SEBU7772-06 85
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
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”.
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.
Inspect the clean, dry primary air cleaner element.
Use a 60W blue light in a dark room or in a similar i06103548
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/
Engine Air Cleaner Service
or holes. Inspect the primary air cleaner element for Indicator - Inspect
light that may show through the filter material. If
necessary, compare the primary air cleaner element (If Equipped)
to a new primary air cleaner element that has the SMCS Code: 7452-040
same part number.
Some engines may be equipped with a different
Do not use a primary air cleaner element that has service indicator.
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged Some engines are equipped with a differential gauge
pleats, gaskets, or seals. Discard damaged primary for inlet air pressure. The differential gauge for inlet
air cleaner elements. air pressure displays the difference in the pressure
that is measured before and after the air cleaner
Storing Primary Air Cleaner Elements element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
If a primary air cleaner element that passes equipped with a different type of service indicator,
inspection will not be used, the primary air cleaner follow the OEM recommendations in order to service
the air cleaner service indicator.
element can be stored for future use.
The service indicator may be mounted on the clean
side of the air cleaner housing or in a remote
location.
86 SEBU7772-06
Maintenance Section
Engine Air Precleaner - Check/Clean
Note: When a new service indicator is installed,

excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque of
2 N·m (18 lb in).
i04398072
Engine Air Precleaner - Check/

Clean
SMCS Code: 1055-070; 1055-535
Typical service indicator
Observe the service indicator. The air cleaner

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

Service indicators are important instruments. Typical precleaner
(1) Wing nut
• Check for ease of resetting. The service indicator (2) Cover
should reset in less than three pushes. (3) Body
• Check the movement of the service indicator core Check the engine air precleaner weekly for debris
when the engine is run at full load speed. The core and dirt. Clean the precleaner when any material
should latch approximately at the greatest vacuum which would impair the performance of the engine is
that is attained. found. Check and clean the precleaner by performing
the following steps:
If the service indicator does not reset easily, or if the
core does not latch at the greatest vacuum, the 1. Remove the wing nut and the cover .
service indicator should be replaced. If the new
service indicator will not reset, the hole for the service 2. Check for an accumulation of dirt and debris in the
indicator may be plugged. body.
If necessary, replace the service indicator more 3. Clean the body, if necessary.
frequently in environments that are severely dusty.
Replace the service indicator annually regardless of 4. After cleaning the precleaner, install the cover and
the operating conditions. Replace the service the wing nut .
indicator when the engine is overhauled, and
whenever major engine components are replaced. Your precleaner may vary from the precleaner which
is pictured above. For further information about
maintaining your precleaner, see your Cat dealer.
Note: When the engine is operated in dusty

applications, more frequent cleaning is required.
SEBU7772-06 87
Maintenance Section
Engine Crankcase Breather - Clean
i01724662 6. Install hose (4) on breather assembly (1). Tighten

hose clamp (3). Refer to Specifications,
Engine Crankcase Breather - SENR3130, “Torque Specifications” for the correct
Clean torques.
SMCS Code: 1317-070 i02436689
NOTICE Engine Mounts - Inspect

Perform this maintenance with the engine stopped.
SMCS Code: 1152-040; 1152
Inspect the engine mounts for deterioration and for
NOTICE proper bolt torque. Engine vibration can be caused
If the crankcase breather is not maintained on a regu- by the following conditions:
lar basis, it can become plugged. A plugged breather
will cause excessive crankcase pressure that may • Improper mounting of the engine
cause crankshaft seal leakage.
• Deterioration of the engine mounts
• Loose mounting bolts
Any engine mount that shows deterioration should be
replaced. Refer to the Specifications Manual,
SENR3130, “Torque Specifications”. Refer to your
Caterpillar dealer for more information.
i04369322
Engine Oil Level - Check

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

injury. Do not allow hot oil or hot components to
contact the skin.
(1) Breather assembly
(2) Bolt
(3) Hose clamp
(4) Hose
1. Loosen hose clamp (3) and remove hose (4) from Illustration 52 g00110310
breather assembly (1). (Y) “ADD” mark
(X) “FULL” mark
2. Remove bolt (2) and the washer. Remove the
breather assembly (1) and the seal.
NOTICE
3. Wash the breather element in solvent that is clean Perform this maintenance with the engine stopped.
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
Specifications, SENR3130, “Torque
Specifications” for the correct torque.
88 SEBU7772-06
Maintenance Section
Engine Oil Sample - Obtain
i04237495
NOTICE
tained during performance of inspection, mainte- Engine Oil Sample - Obtain
Be prepared to collect the fluid with suitable contain- SMCS Code: 1348-554-SM
ers before opening any compartment or disassem- In addition to a good preventive maintenance
bling any component containing fluids. program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals. S·O·S oil
Service Tool Catalog” or refer to Special Publication, analysis provides infrared analysis, which is required
PECJ0003, “Cat Shop Supplies and Tools Catalog” for determining nitration and oxidation levels.
fluids on Cat products. Obtain the Sample and the
Dispose of all fluids according to local regulations Analysis
and mandates.
1. Maintain the oil level between “ADD” mark (Y) and

“FULL” mark (X) on the oil level gauge. Do not fill Hot oil and hot components can cause personal
the crankcase above “FULL” mark (X). contact the skin.
NOTICE Before you take the oil sample, complete the Label,
Engine damage can occur if the crankcase is filled PEEP5031 for identification of the sample. In order to
above the “FULL” mark on the oil level gauge help obtain the most accurate analysis, provide the
(dipstick). following information:
An overfull crankcase can cause the crankshaft to dip • Engine model
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These • Service hours on the engine
bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil • The number of hours that have accumulated since
pressure, inadequate cooling, oil blowing out of the the last oil change
crankcase breathers and excessive oil consumption.
• The amount of oil that has been added since the
Excessive oil consumption will cause deposits to form last oil change
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the follow- To ensure that the sample is representative of the oil
ing problems: guttering of the valves, packing of in the crankcase, obtain a warm, mixed oil sample.
carbon under the piston rings and wear of the cylin-
der liner. To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
If the oil level is above the “FULL” mark on the oil lev- samples must be clean.
el gauge, drain some of the oil immediately.
Caterpillar recommends using the sampling valve in
order to obtain oil samples. The quality and the
2. Remove the oil filler cap and add oil, if necessary.
consistency of the samples are better when the
For information about choosing the correct oil for sampling valve is used. The location of the sampling
the engine, refer to one of the following articles: valve allows oil that is flowing under pressure to be
Operation and Maintenance Manual, “Refill obtained during normal engine operation.
Capacities and Recommendations” or Operation
and Maintenance Manual, “Fluid The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
Recommendations”. Do not fill the crankcase fluid sampling bottle includes the parts that are
above “FULL” mark (X) on the oil level gauge. needed for obtaining oil samples. Instructions are
Clean the oil filler cap. Install the oil filler cap. also provided.
3. Record the amount of oil that is added. For the
next oil sample and analysis, include the total
amount of oil that has been added since the
previous sample. This information will help to
provide the most accurate oil analysis.
SEBU7772-06 89
Maintenance Section
Engine Oil and Filter - Change
Table 20
NOTICE
Always use a designated pump for oil sampling, and Intervals for Changing the Engine Oil and Engine Oil Filter(1)
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam- C9 Every 250 service hours or 1 yr
ples may contaminate the samples that are being (1) Choose the interval that occurs first.
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers. Drain the Engine Oil
If the engine is not equipped with a sampling valve, NOTICE

use the 1U-5718 Vacuum Pump. The pump is Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion into
the sump.
For instructions, see Special Publication, PEGJ0047, bling any component containing fluids.
“How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and Refer to Special Publication, NENG2500, “Cat Dealer
assistance in establishing an S·O·S program for your Service Tool Catalog” or refer to Special Publication,
engine. PECJ0003, “Cat Shop Supplies and Tools Catalog”
i06657326
Engine Oil and Filter - Change and mandates.
SMCS Code: 1318-510 After the engine has been run at the normal
operating temperature, stop the engine. Use one of
the following methods to drain the engine crankcase
oil:
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to • If the engine is equipped with a drain valve, turn
contact the skin. the drain valve knob counterclockwise in order to
drain the oil. After the oil has drained, turn the
Do not drain the oil when the engine is cold. As the oil drain valve knob clockwise in order to close the
cools, suspended waste particles settle on the drain valve.
bottom of the oil pan. The waste particles are not
removed with the draining cold oil. Drain the • If the engine is not equipped with a drain valve,
crankcase with the engine stopped. Drain the remove the oil drain plug in order to allow the oil to
crankcase with the oil warm. This draining method drain. If the engine is equipped with a shallow
allows the waste particles that are suspended in the sump, remove the bottom oil drain plugs from both
oil to be drained properly. ends of the oil pan.
Failure to follow this recommended procedure will After the oil has drained, the oil drain plugs should be
cause the waste particles to be recirculated through cleaned and installed.
the engine lubrication system with the new oil.
Replace the Oil Filter
Interval for Engine Oil and Engine
Oil Filter Change NOTICE
Caterpillar oil filters are built to Caterpillar specifica-
Note: The intervals stated in Table 20 are only valid tions. Use of an oil filter not recommended by Cater-
when preferred lubricants are used. Using fluids pillar could result in severe engine damage to the
other than the preferred fluids causes the engine to engine bearings, crankshaft, etc., as a result of the
operate in a severe service application. Refer to this larger waste particles from unfiltered oil entering the
Operation and Maintenance Manual, “Fluid engine lubricating system. Only use oil filters recom-
Recommendations” for information about which mended by Caterpillar.
engine oils are preferred. Refer to this Operation and
Maintenance Manual, “Severe Service Application” 1. Remove the oil filter with a 1U-8760 Chain
for information about the effect of using fluids which
Wrench.
are not preferred on the maintenance intervals.
90 SEBU7772-06
Maintenance Section
Engine Storage Procedure - Check
2. Cut the oil filter open with a 175-7546 Oil Filter 5. Install the oil filter. Tighten the oil filter until the oil
Cutter Gp. Break apart the pleats and inspect the filter gasket contacts the base. Tighten the oil filter
oil filter for metal debris. An excessive amount of by hand according to the instructions that are
metal debris in the oil filter may indicate early wear shown on the oil filter. Do not overtighten the oil
or a pending failure. filter.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in Fill the Engine Crankcase
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine. 1. Remove the oil filler cap.
Nonferrous metals may indicate wear on the 2. Refer to the Operation and Maintenance Manual,
aluminum parts, brass parts, or bronze parts of the “Refill Capacities” for the amount of oil required to
engine. Parts that may be affected include the fill the crankcase. Fill the crankcase and replace
following items: main bearings, rod bearings, the oil filler cap.
turbocharger bearings and cylinder heads.
Due to normal wear and friction, small amounts of NOTICE
debris may be found in the oil filter. Consult your If equipped with an auxiliary oil filter system or a re-
Cat dealer in order to arrange for a further analysis mote oil filter system, follow the OEM or filter manu-
if an excessive amount of debris is found in the oil facturer's recommendations. Under filling or
filter. overfilling the crankcase with oil can cause engine
damage.
NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
3. Start the engine and run the engine at “LOW IDLE”

for 2 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.
4. Stop the engine and allow the oil to drain back to
the sump for a minimum of 10 minutes.
Typical filter mounting base and filter gasket
5. Remove the oil level gauge in order to check the oil
3. Clean the sealing surface of the filter mounting level. Maintain the oil level between the “ADD” and
base. Ensure that all of the old oil filter gasket is “FULL” marks on the oil level gauge.
removed.
i04369360
4. Apply clean engine oil to the new oil filter gasket.
NOTICE
Engine Storage Procedure -
Do not fill the oil filters with oil before installing them. Check
This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear SMCS Code: 1000-535
to engine components or engine damage.
Caterpillar recommends storage procedures and
start-up procedures for all engines that are stored for
more than 1 month. These procedures provide
maximum protection for internal engine components.
Refer to the following sources for information about
engine storage:
• This Operation and Maintenance Manual,

“Product Storage”
SEBU7772-06 91
Maintenance Section
Engine Valve Lash - Check
• Special Instruction, SEHS9031, “Storage

Procedure for Cat Products”
• Your Cat dealer
i04242309
Engine Valve Lash - Check

SMCS Code: 1105-535
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. Illustration 54 g00746166
Typical location of the grease fitting (if equipped) that
The maintenance is recommended by Caterpillar as is for the fan drive bearing
part of a lubrication and preventive maintenance
schedule to help provide maximum engine life. The pulley is shown with the belt guards that have
been removed.
Note: Only qualified service personnel should
perform this maintenance. For procedures on Lubricate the grease fitting that is on the fan drive
adjusting the valve lash and adjusting the valve bearing with High Speed Ball Bearing Grease or the
equivalent.
bridge, see System Systems Operation/Testing and
Adjusting, “Engine Valve Lash - Inspect/Adjust”. Inspect the fan drive pulley assembly for wear or for
Consult your Cat dealer for assistance. damage. If the shaft is loose, an inspection of the
internal components should be performed. Refer to
the Systems Operation Testing and Adjusting Manual
for additional information.
Ensure that the engine can not be started while
this maintenance is being performed. To help pre- i04369429
vent possible injury, do not use the starting motor
to turn the flywheel. Fuel System - Prime
Hot engine components can cause burns. Allow SMCS Code: 1250-548; 1258-548
additional time for the engine to cool before
measuring/adjusting valve lash clearance.
Fuel leaked or spilled onto hot surfaces or electri-

i02784507 cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
Fan Drive Bearing - Lubricate changing fuel filters or water separator elements.
Clean up fuel spills immediately.
SMCS Code: 1359-086-BD
Some of the fan drives have grease fittings and some
of the fan drives do not have grease fittings. If there is NOTICE
no grease fitting, periodic lubrication is not required. Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
The fan drive requires grease only if the fan drive is nance, testing, adjusting, and repair of the product.
equipped with a zerk. Be prepared to collect the fluid with suitable contain-
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
and mandates.
92 SEBU7772-06
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
Refer to this Operation and Maintenance Manual ,

“General Hazard Information” before any NOTICE
Do not crank the engine continuously for more than
adjustments or repairs are performed 30 seconds. Allow the starting motor to cool for two
If necessary, perform minor adjustments. Repair any minutes before cranking the engine again.
leaks from the fuel system and from the cooling,
lubrication, or air systems. Ensure that all 3. Promptly start the engine. If the engine runs rough,
adjustments and repairs are performed by authorized
personnel that have had the correct training. continue to operate the engine at low idle. Do not
raise the engine rpm above an idle until the engine
The fuel system should be primed under the following is operating smoothly.
conditions:
4. If the engine does not start, open the fuel priming
• The fuel tank is empty or the fuel tank has been pump and repeat Steps 2 and 3 in order to start
partially drained. the engine.
• The engine has been in storage.
Engines that are Not Equipped with
• The fuel filter has been replaced. a Fuel Priming Pump
• The pressure fuel lines have been disconnected. If the engine is not equipped with a fuel priming
pump, you may use the following procedures to
Engines that are Equipped with a prime the fuel system. These procedures will only
allow filtered fuel to enter the fuel system.
Fuel Priming Pump
NOTICE
NOTICE Do not crank the engine continuously for more than
Do not loosen the fuel lines at the fuel manifold. The 30 seconds. Allow the starting motor to cool for two
fittings may be damaged and/or a loss of priming minutes before cranking the engine again.
pressure may occur when the fuel lines are loosened.
1. Operate the starting motor in order to 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 low idle
until the engine is operating smoothly.
i04370502
Fuel System Primary Filter

(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Illustration 55 g01327092 Water in the fuel can cause the engine to run rough.
Secondary fuel filter and optional fuel priming pump Water in the fuel may cause an electronic unit injector
to fail. If the fuel has been contaminated with water,
(1) Fuel priming pump the element should be changed before the regularly
(2) Secondary fuel filter scheduled interval.
1. Check that the fuel supply valve (if equipped) is in The primary filter/water separator also provides
the “ON” position. filtration in order to help extend the life of the
secondary fuel filter. The element should be changed
2. Open the fuel priming pump and operate the fuel regularly. If a vacuum gauge is installed, the primary
priming pump until a strong pressure is felt. This filter/water separator should be changed at 50 to 70
procedure will require considerable strokes. Lock kPa (15 to 20 inches hg).
the fuel priming pump.
SEBU7772-06 93
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
Replace the Element 3. Dispose of the fuel in the fuel filter element.
Remove the bowl from the element . The bowl is
reusable. Do not discard the bowl. Dispose of the
used element.
Fuel leaked or spilled onto hot surfaces or electri- 4. Remove the O-ring from the bowl. Clean the
cal components can cause a fire. To help prevent
possible injury, turn the start switch off when following components:
changing fuel filters or water separator elements.
Clean up fuel spills immediately. • Bowl
• O-ring
NOTICE • Mounting base
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that Inspect the O-ring for damage and for
will be disconnected. Fit a suitable cover over any deterioration. Replace the O-ring, if necessary.
disconnected fuel system components.
NOTICE
The primary filter/water separator may be prefilled
NOTICE with fuel to avoid rough running/stalling of the engine
Care must be taken to ensure that fluids are con- due to air. Do not fill the secondary filter with fuel be-
tained during performance of inspection, mainte- fore installation. The fuel would not be filtered and
nance, testing, adjusting, and repair of the product. could be contaminated. Contaminated fuel will cause
Be prepared to collect the fluid with suitable contain- accelerated wear to fuel system parts.
5. Lubricate the O-ring with clean diesel fuel. The
Refer to Special Publication, NENG2500, “Cat Dealer element may be filled with fuel at this time.
PECJ0003, “Cat Shop Supplies and Tools Catalog” 6. Install the bowl on a new element. Tighten the bowl
for tools and supplies suitable to collect and contain by hand. Do not use tools in order to tighten the
fluids on Cat products. bowl.
and mandates. NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
1. Close the main fuel supply valve. ened securely to help prevent air from entering the
fuel system.
7. Open the main fuel supply valve.

8. Start the engine and check for leaks. Run the
engine for 1 minute. Stop the engine and check for
leaks again.
Typical primary fuel filter/water separator
(1) Primary fuel filter element
(2) Collection bowl for the water separator
(3) Drain for the water separator
2. Remove the element from the element mounting

base while the bowl is attached.
94 SEBU7772-06
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
Detection of leaks is difficult while the engine is

running. The primary filter/water separator is under NOTICE
suction. A leak will allow air to enter the fuel. The tained during performance of inspection, mainte-
air in the fuel can cause low power due to aeration nance, testing, adjusting, and repair of the product.
of the fuel. If air enters the fuel, check the Be prepared to collect the fluid with suitable contain-
components for overtightening or under tightening.
i04370506
Fuel System Primary Filter/ Service Tool Catalog” or refer to Special Publication,
Water Separator - Drain for tools and supplies suitable to collect and contain
SMCS Code: 1260-543; 1263-543 fluids on Cat products.
and mandates.

cal components can cause a fire. To help prevent 1. Open the drain. The drain is a self-ventilated drain.
possible injury, turn the start switch off when Catch the draining water in a suitable container.
changing fuel filters or water separator elements. Dispose of the water properly.
Clean up fuel spills immediately.
2. Close the drain.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the
fuel system.
i03478081
Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE
Typical primary fuel filter/water separator
(1) Primary fuel filter element
(2) Collection bowl for the water separator cal components can cause a fire. To help prevent
(3) Drain for the water separator possible injury, turn the start switch off when
changing fuel filters or water separator elements.
The bowl should be monitored daily for signs of Clean up fuel spills immediately.
water. If water is present, drain the water from the
bowl.
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.
SEBU7772-06 95
Maintenance Section
Fuel Tank Water and Sediment - Drain
6. Install the new fuel filter. Spin the fuel filter onto the
NOTICE
Care must be taken to ensure that fluids are con- fuel filter base until the gasket contacts the base.
tained during performance of inspection, mainte- Use the rotation index marks on the filters as a
nance, testing, adjusting, and repair of the product. guide for proper tightening. Tighten the filter
Be prepared to collect the fluid with suitable contain- according to the instructions that are on the fuel
ers before opening any compartment or disassem- filter. Do not overtighten the filter.
7. Open the fuel supply valve. The engine will need to
be purged of air. Refer to the Operation and
PECJ0003, “Cat Shop Supplies and Tools Catalog” Maintenance Manual, “Fuel System - Prime” topic
for tools and supplies suitable to collect and contain (Maintenance Section) for more information.
i06104305
and mandates.
Fuel Tank Water and Sediment
1. Stop the engine. Turn the ignition switch to the
- Drain
OFF position or disconnect the battery. Refer to SMCS Code: 1273-543-M&S
the Operation and Maintenance Manual, “Battery
or Battery Cable - Disconnect” topic (Maintenance NOTICE
Section) for more information. Shut off the fuel Care must be taken to ensure that fluids are con-
supply valve (if equipped). tained during performance of inspection, mainte-
2. It may be necessary to relieve residual fuel Be prepared to collect the fluid with suitable contain-
pressure from the fuel system before the fuel filter ers before opening any compartment or disassem-
is removed. Wait for one to five minutes until the
fuel pressure has lowered. Use a suitable Refer to Special Publication, NENG2500, “Cat Dealer
container in order to catch any fuel that may spill. Service Tool Catalog” or refer to Special Publication,
3. Remove the used fuel filter and discard the used for tools and supplies suitable to collect and contain
fuel filter. fluids on Cat products.
4. Clean the gasket sealing surface of the fuel filter Dispose of all fluids according to local regulations
base. Ensure that all of the old gasket is removed. and mandates.
5. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE Fuel Tank

Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be Fuel quality is critical to the performance and to the
contaminated. Contaminated fuel will cause acceler- service life of the engine. Water in the fuel can cause
ated wear to fuel system parts. excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
NOTICE fuel system and the fuel returns to the fuel tank. This
In order to meet expected fuel system component life, causes water to accumulate in fuel tanks. Draining
4 micron (c) absolute or less secondary fuel filtration the fuel tank regularly and obtaining fuel from reliable
is required for all Cat Diesel Engines that are sources can help to eliminate water in the fuel. The
equipped with unit injected fuel systems. All current fuel tank utilizes a fuel tank vent to prevent an air lock
Cat Diesel Engines are factory equipped with Cat Ad- or vacuum. Ensure that the vent is free of debris and
vanced Efficiency 4 micron(c) absolute fuel filters. not damaged.
Caterpillar does not warrant the quality or perform- Drain the Water and the Sediment
ance of non-Cat fluids and filters.
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Prepare to catch water and sediment in an
appropriate container. Connect a hose (if necessary)
to the valve prior to opening the valve.
96 SEBU7772-06
Maintenance Section
Grounding Stud - Inspect/Clean/Tighten
Open the drain valve on the bottom of the fuel tank in If a bulk storage tank has been refilled or moved
order to drain the water and the sediment. Close the recently, allow adequate time for the sediment to
drain valve. settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
Note: Failure to close the drain properly could result sediment. Filtering fuel that is pumped from the
in fuel leakage, which could have detrimental results storage tank helps to ensure the quality of the fuel.
to performance. When possible, water separators should be used.
Check the fuel daily. Drain the water and sediment
i04337750
from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow 5 to 10 minutes before Grounding Stud - Inspect/
performing this procedure.
Clean/Tighten
Fill the fuel tank after operating the engine in order to SMCS Code: 7423-079; 7423-070; 7423-040
drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
overflow.
The connection of battery cables to a battery and
Some fuel tanks use stand pipes that allow water and the disconnection of battery cables from a battery
sediment to settle below the end of the fuel stand may cause an explosion which may result in in-
pipe. Some fuel tanks use supply lines that take fuel jury or death. The connection and the disconnec-
directly from the bottom of the tank. If the engine is tion of other electrical equipment may also cause
equipped with this system, regular maintenance of an explosion which may result in injury or death.
the fuel system filter is important. The procedures for the connection and the dis-
connection of battery cables and other electrical
Fuel Storage Tanks equipment should only be performed in a nonex-
plosive atmosphere.
Drain the water and the sediment from the fuel
storage tank during the following conditions:
• Weekly
• Refill of the tank

This procedure will help prevent water or sediment
from being pumped from the storage tank into the
engine fuel tank. A four micron(c) absolute filter for
the breather vent on the fuel tank is also
recommended.
The electronics grounding stud is located on the
upper left corner of the engine control module.
Inspect the OEM harness for good connections.

Inspect the condition of the OEM harness.
The electronics grounding stud must have a wire
ground to the battery. Tighten the electronics
grounding stud at every oil change. Ground wires
and straps should be combined at engine grounds.
All grounds should be tight and free of corrosion.
• Clean the electronics grounding stud and the
terminals for the ground strap with a clean cloth.
• If the connections are corroded, clean the
connections with a solution of baking soda and
water.
SEBU7772-06 97
Maintenance Section
Hoses and Clamps - Inspect/Replace
• Keep the electronics grounding stud and the strap • Cracking

clean and coated with MPGM grease or petroleum
jelly. • Looseness
• Damage
i06825542
Inspect all couplings for leaks. Replace any coupling
Hoses and Clamps - Inspect/ which exhibits signs of leaks.
Replace Each installation application can be different. The
SMCS Code: 7554-510; 7554-040 differences depend on the following factors:
Hoses and clamps must be inspected periodically • Type of hose

and replaced at the recommended interval to ensure
safe and continuous operation of the engine. Failure • Type of fitting material
to replace a fuel hose at the recommended change
interval may result in a hazardous situation. Take • Anticipated expansion and contraction of the hose
proper safety precautions before inspecting or
replacing hoses and clamps. • Anticipated expansion and contraction of the
fittings
Note: Always use a board or cardboard when the
Due to extreme temperature changes, the hose will
engine components are checked for leaks. Leaking
heat set. Heat setting causes hose clamps to loosen
fluid that is under pressure can cause serious injury which can result in leaks. A constant torque hose
or possible death. Leaks that are the size of a pin clamp will help to prevent loose hose clamps.
hole are included. Refer to Operation and
Maintenance Manual, “General Hazard Information” Replace hoses that are cracked or soft. Replace
for more information. hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps
Note: Ensure that the hose is compatible with the that are cracked or damaged. Tighten or replace
application. hose clamps which are loose.
Inspect Tubes, Hoses, Bellows, and Replace the Hoses and the Clamps
Clamps
NOTICE
Inspect all tubes and hoses for leaks that are caused Care must be taken to ensure that fluids are con-
by the following conditions. Replace any tube or hose tained during performance of inspection, mainte-
which exhibits any of the following conditions. Failure nance, testing, adjusting, and repair of the product.
to replace a tube or hose which exhibits any of the Be prepared to collect the fluid with suitable contain-
following conditions may result in a hazardous ers before opening any compartment or disassem-
situation. bling any component containing fluids.
• Hoses which are cracked Refer to Special Publication, NENG2500, “Cat Dealer
• Hoses which are soft PECJ0003, “Cat Shop Supplies and Tools Catalog”
• Outer covering that is chafed or cut fluids on Cat products.
• Exposed wire that is used for reinforcement Dispose of all fluids according to local regulations
and mandates.
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed Cooling System
• Armoring that is embedded in the outer covering
• Exhaust bellows for leaks or damage
• Hoses which exhibit signs of leakage which are ous burns. To open the cooling system filler cap,
not the result of loose couplings or clamps stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
Inspect all clamps for the following conditions. pressure cap slowly in order to relieve the
Replace any clamp which exhibits signs of any of the pressure.
following conditions.
98 SEBU7772-06
Maintenance Section
Hoses and Clamps - Inspect/Replace
Personal injury can result from removing hoses Contact with high pressure fuel may cause fluid
or fittings in a pressure system. penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
Failure to relieve pressure can cause personal these inspection, maintenance and service in-
injury. structions may cause personal injury or death.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
NOTICE
Do not bend or strike high pressure lines. Do not in-
1. Stop the engine. stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
2. Allow the engine to cool. hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the
3. Before servicing a coolant hose, slowly loosen the recommended torque.
filler cap for the cooling system to relieve any
pressure.
NOTICE
4. Remove the filler cap for the cooling system. Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
5. Drain the coolant from the cooling system to a will be disconnected. Fit a suitable cover over any
level that is below the hose that is being replaced. disconnected fuel system components.
Drain the coolant into a suitable clean container.
The coolant can be reused.
Note: High-pressure fuel lines may be installed
6. Remove the hose clamps. between the high-pressure fuel pump and the fuel
7. Disconnect the old hose. injectors. High-pressure fuel lines are constantly
charged with high pressure. Do not check the high-
8. Replace the old hose with a new hose. pressure fuel lines with the engine or the starting
motor in operation. Wait for 10 minutes after the
9. Install hose clamps which have been inspected or engine stops before you perform any service or
install new hose clamps. Refer to Specifications, repair on high-pressure fuel lines. Waiting for 10
SENR3130, “Torque Specifications” “Hose minutes will allow the pressure to be purged.
Clamps” for information about selecting and
installing the proper hose clamps. 1. Drain the fuel from the fuel system to a level that is
below the hose that is being replaced.
10. Refill the cooling system.
2. Remove the hose clamps.
11. Clean the coolant filler cap. Inspect the gaskets
on the filler cap. Inspect the gasket seat. Inspect 3. Disconnect the old hose.
the vacuum valve and seat for debris or damage.
Replace the filler cap if the gaskets are damaged. Note: When servicing fuel system, use cap/s or
cover/s as required to protect the system and
Install the filler cap.
maintain fuel system cleanliness.
12. Start the engine. Inspect the cooling system for
leaks. 4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or
Fuel System install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications” “Hose
installing the proper hose clamps.
Personal injury can result from removing hoses
or fittings in a pressure system. 6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
Failure to relieve pressure can cause personal engine.
injury.
Note: Fuel must be added to the fuel system ahead
Do not disconnect or remove hoses or fittings un- of the fuel filter.
til all pressure in the system has been relieved.
SEBU7772-06 99
Maintenance Section
Jacket Water Heater - Check
7. Refill the fuel system. Refer to this Operation and 5. Start the engine. Inspect the air lines for leaks.
Maintenance Manual, “Fuel System - Prime” for
information about priming the engine with fuel. i03230758
8. Start the engine. Inspect the fuel system for leaks.

Jacket Water Heater - Check
Lubrication System 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
Hot oil and hot components can cause personal have jacket water heaters.
contact the skin. Check the operation of the jacket water heater.
Check the operation of the circulation pump, if
equipped. For an ambient temperature of 0 °C
1. Drain the oil from the lubrication system to a level (32 °F), the heater should maintain the jacket water
that is below the hose that is being replaced. coolant temperature at approximately 32 °C (90 °F).
2. Remove the hose clamps. i02436705
3. Disconnect the old hose.
Overhaul Considerations
4. Replace the old hose with a new hose.
SMCS Code: 7595-043
install new hose clamps. Refer to Specifications, Reduced hours of operation at full load will result in a
SENR3130, “Torque Specifications” “Hose lower average power demand and reduced fuel
consumption. A decreased average power demand
Clamps” for information about selecting and should increase both the engine service life and the
installing the proper hose clamps. overhaul interval.
6. Refill the lubrication system. Refer to this The need for an overhaul is generally indicated by
Operation and Maintenance Manual, “Engine Oil increased fuel consumption, increased oil
Level - Check” to ensure that the lubrication consumption, excessive engine blowby, and reduced
system is filled with the proper amount of engine power. Arctic temperatures, extremely high
oil. temperatures, corrosive environments, or extremely
dusty conditions contribute to premature wear and
7. Start the engine. Inspect the lubrication system for the need for an overhaul.
leaks. The following factors are important when a decision
is being made on the proper time for an engine
Air System overhaul:
1. Remove the hose clamps. • The need for preventive maintenance

2. Disconnect the old hose. • The quality of the fuel that is being used
3. Replace the old hose with a new hose. • The operating conditions
• The results of the S·O·S analysis
install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications” “Hose
Oil Consumption as an Overhaul
installing the proper hose clamps. Indicator
Note: The bellows and the V-clamps that are used on Oil consumption, fuel consumption, and maintenance
the exhaust bellows should never be reused. 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.
100 SEBU7772-06
Maintenance Section
The oil consumption rate (brake specific oil Note: Overhaul programs vary according to the
consumption) is measured in grams per kW/h (lb per engine application and according to the dealer that
bhp). The brake specific oil consumption (BSOC) performs the overhaul. Consult your Caterpillar
depends on the engine load. Consult your Caterpillar dealer for specific information about the available
dealer for assistance in determining the typical oil overhaul programs and about overhaul services for
consumption rate for your engine. extending the engine life.
When an engine's oil consumption has risen to three If an overhaul is performed without overhaul service
times the original oil consumption rate due to normal from your Caterpillar dealer, be aware of the following
wear, an engine overhaul should be scheduled. maintenance recommendations.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
Rebuild or Exchange
Overhaul Options Cylinder Head Assembly, Cylinder Packs, Oil
Pump, and Fuel Transfer Pump
Before Failure Overhaul
These components should be inspected according to
A planned overhaul before failure may be the best
the instructions that are found in various Caterpillar
value for the following reasons: reusability publications. The Special Publication,
• Costly unplanned downtime can be avoided. SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
• Many original parts can be reused according to the
If the parts comply with the established inspection
standards for reusable parts. specifications that are expressed in the reusable
parts guideline, the parts should be reused.
• The engine's service life can be extended without
the risk of a major catastrophe due to engine Parts that are not within the established inspection
failure. specifications should be dealt with in one of the
following manners:
• The best cost/value relationship per hour of
extended life can be attained. • Salvaging
After Failure Overhaul • Repairing
If a major engine failure occurs and the engine must • Replacing
be removed, many options are available. An overhaul
should be performed if the engine block or the Using out-of-spec parts can result in the following
crankshaft needs to be repaired. problems:
If the engine block is repairable and/or the crankshaft • Unscheduled downtime
is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine • Costly repairs
with a similar exchange core.
• Damage to other engine parts
This lower cost can be attributed to three aspects:
• Reduced engine efficiency
• Specially designed Caterpillar engine features
• Increased fuel consumption
• Caterpillar dealer exchange components
Reduced engine efficiency and increased fuel
• Caterpillar Inc. remanufactured exchange consumption translates into higher operating costs.
components Therefore, Caterpillar Inc. recommends repairing out-
of-spec parts or replacing out-of-spec parts.
Overhaul Recommendation
Inspection and/or Replacement
To minimize downtime, Caterpillar Inc. recommends
a scheduled engine overhaul by your Caterpillar Crankshaft Bearings, Valve Rotators, and
dealer before the engine fails. This will provide you Crankshaft Seals
with the best cost/value relationship.
The following components may not last until the
second overhaul.
• Thrust bearings
• Main bearings
SEBU7772-06 101
Maintenance Section
• Rod bearings 2. Remove any debris from the oil cooler core. To
remove debris from the oil cooler core, turn the oil
• Valve rotators cooler core onto one end.
• Crankshaft seals 3. Flush the oil cooler core internally with cleaner in
Caterpillar Inc. recommends the installation of new order to loosen foreign substances. This will also
parts at each overhaul period. help to remove oil from the oil cooler core.
Inspect these parts while the engine is disassembled Note: Caterpillar Inc. recommends the use of
for an overhaul. Hydrosolv Liquid Cleaners. Table 21 lists the
Hydrosolv Liquid Cleaners that are available from
Inspect the crankshaft for any of the following your Caterpillar dealer.
conditions:
Table 21
• Deflection
HydrosolvLiquid Cleaners
• Damage to the journals Part Number Description Size
• Bearing material that has seized to the journals 1U-8812 4 L (1 US gallon)
Check the journal taper and the profile of the 1U-5490 Hydrosolv4165 19 L (5 US gallon)
crankshaft journals. Check these components by
interpreting the wear patterns on the following 8T-7570 208 L (55 US gallon)
components: 1U-8804 4 L (1 US gallon)
• Rod bearing 1U-5492 Hydrosolv100 19 L (5 US gallon)
• Main bearings 8T-5571 208 L (55 US gallon)
Inspect the camshaft for damage to the journals and

to the lobes. 4. Use steam to clean the oil cooler core. This
removes any remaining residue from the cleaner.
Note: If the camshaft is removed for any reason, use Flush the fins of the oil cooler core. Remove any
the magnetic particle inspection process to check for other trapped debris.
cracks in the camshaft.
5. Wash the oil cooler core with hot, soapy water.
Inspect the following components for signs of wear or Rinse the oil cooler core thoroughly with clean
for signs of scuffing:
water.
• Camshaft bearings
• Camshaft followers
Personal injury can result from air pressure.
Caterpillar Inc. recommends replacing the crankshaft
vibration damper. Personal injury can result without following prop-
er procedure. When using pressure air, wear a
Oil Cooler Core protective face shield and protective clothing.
During an overhaul, Caterpillar Inc. recommends the Maximum air pressure at the nozzle must be less
removal of the oil cooler core. Clean the oil cooler than 205 kPa (30 psi) for cleaning purposes.
core. Then, pressure test the oil cooler core.
6. Dry the oil cooler core with compressed air. Direct
NOTICE
Do not use caustic cleaners to clean the core. the air in the reverse direction of the normal flow.
Caustic cleaners can attack the internal metals of the 7. Inspect the components in order to ensure
core and cause leakage. cleanliness. The oil cooler core should be
pressure tested. Repair the oil cooler core, if
necessary. Install the oil cooler core.
Note: Use this cleaning procedure to clean the oil
cooler core. For more information about cleaning the cores,
consult your Caterpillar dealer.
1. Remove the oil cooler core.
102 SEBU7772-06
Maintenance Section
Power Take-Off Clutch - Check
Obtain Coolant Analysis

The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits or
with S·O·S Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine is
overhauled.
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 Illustration 59 g00781502
cooling system. A full water analysis can be obtained
(1) Instruction plate
by consulting your local water utility company or an (2) Serial number plate
agricultural agent. Private laboratories are also
available for water analysis. Check the clutch adjustment regularly after “wear in”.
Heavy-duty applications which have engagements
Caterpillar Inc. recommends an S·O·S Coolant that are frequent and relatively long periods of clutch
Analysis (Level 2). slippage require more frequent adjustment than light-
S·O·S Coolant Analysis (Level 2) duty applications. The operating torque should be
measured in order to determine if a clutch adjustment
is required.
An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely Refer to the OEM information and instruction plate
analyzes the coolant and the effects on the cooling (1) for instructions on lubrication, adjustment, and
system. An S·O·S Coolant Analysis (Level 2) other recommendations for service. Perform the
provides the following information: maintenance that is specified on the instruction plate.
• Complete S·O·S Coolant Analysis (Level 1)
• Visual inspection of properties

Do not operate the engine with the Instruction
• Identification of metal corrosion Plate cover removed from the clutch. Personal in-
jury may result.
• Identification of contaminants
If the clutch is damaged to the point of burst fail-
• Identification of built up impurities (corrosion and ure, expelled pieces can cause personal injury to
scale) anyone in the immediate area. Proper safeguards
must be followed to help prevent accidents.
S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
recommendations. i04020194
For more information about coolant analysis, see

your Caterpillar dealer. Radiator - Clean
SMCS Code: 1353-070
i03901481
Note: Adjust the frequency of cleaning according to
Power Take-Off Clutch - Check the effects of the operating environment.
SMCS Code: 3055-535 Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary.
NOTICE
New power take-offs should have the clutch adjust-
ment 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”.
SEBU7772-06 103
Maintenance Section
Starting Motor - Inspect
Inspect the starting motor for proper operation. Listen

for grinding when the engine is started. Inspect the
Personal injury can result from air pressure. teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth.
Personal injury can result without following prop- Look for teeth that are broken or chipped. If damaged
er procedure. When using pressure air, wear a teeth are found, the starting motor pinion and the
protective face shield and protective clothing. flywheel ring gear must be replaced.
The maximum air pressure for cleaning purposes

must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded. Personal injury or death can result from improp-
erly checking for a leak.
Pressurized air is the preferred method for removing
Always use a board or cardboard when checking
loose debris. Direct the air in the opposite direction of
for a leak. Escaping air or fluid under pressure,
the air flow. Hold the nozzle approximately 6 mm
even a pin-hole size leak, can penetrate body tis-
(0.25 inch) away from the fins. Slowly move the air sue causing serious injury, and possible death.
nozzle in a direction that is parallel with the tubes.
This movement will remove debris that is between If fluid is injected into your skin, it must be
the tubes.
treated immediately by a doctor familiar with this
Pressurized water may also be used for cleaning. type of injury.
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 Inspect all of the components in the air circuit for the
both sides. starting motor. Inspect all of the air lines and
connections for leaks.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core If damaged teeth are found, the air circuit for the
with detergent and hot water. Thoroughly rinse the starting motor must be examined in order to
core with clean water. determine the cause of the problem.
After cleaning, start the engine and accelerate the Electric Starting Motor
engine to high idle rpm. This procedure 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 If the starting motor fails, the engine may not start in
inspect the core for cleanliness. Repeat the cleaning, an emergency situation. A scheduled inspection of
if necessary. the starting motor is recommended.
Inspect the fins for damage. Bent fins may be opened The starting motor pinion and the flywheel ring gear
with a “comb”. Inspect these items for good condition: must be in good condition in order for the engine to
welds, mounting brackets, air lines, connections, start properly. The engine will not start if the starting
clamps and seals. Make repairs, if necessary. motor pinion does not engage the flywheel ring gear.
The teeth of the starting motor pinion and the
flywheel ring gear can be damaged because of
i05264216 irregular engagement.
Starting Motor - Inspect Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
(If equipped) teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth.
SMCS Code: 1451-040; 1453-040 Look for teeth that are broken or chipped. If damaged
teeth are found, the starting motor pinion and the
Air Starting Motor flywheel ring gear must be replaced.
If the starting motor fails, the engine may not start in Problems with the electric starting motor can be
an emergency situation. A scheduled inspection of caused by the following conditions: malfunction of the
the starting motor is recommended. solenoid and malfunction of the electric starting
system.
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine to Inspect the electrical system for the following
start properly. The engine will not start if the starting conditions:
motor pinion does not engage the flywheel ring gear.
The teeth of the starting motor pinion and the • Loose connections
flywheel ring gear can be damaged because of
irregular engagement. • Corrosion
104 SEBU7772-06
Maintenance Section
Turbocharger - Inspect
• Wires that are worn or frayed Removal and Installation

• Cleanliness For options regarding the removal, installation, and
replacement, consult your Cat dealer. Refer to the
Removal and Installation of the Disassembly and Assembly, “Turbocharger - Remove
and Turbocharger - Install” and Systems Operation,
Starting Motor Testing and Adjusting, “Turbocharger - Inspect” for
further information.
Refer to the Service Manual, “Disassembly and
Assembly” module for information on removing the Inspecting
starting motor and installing the starting motor.
Consult your Cat dealer for assistance and/or for NOTICE
options on replacement of the starting motor. The compressor housing for the turbocharger must
not be removed from the turbocharger for inspection
i04219023 or removed for the cleaning of the compressor.
Turbocharger - Inspect 1. Remove the pipe from the turbocharger exhaust

SMCS Code: 1052-040 outlet and remove the air intake pipe to the
turbocharger. Visually inspect the piping for the
A regular visual inspection of the turbocharger is presence of oil. Clean the interior of the pipes in
recommended. If the turbocharger fails during engine order to prevent dirt from entering during
operation, damage to the turbocharger compressor
wheel and/or to the engine may occur. Damage to reassembly.
the turbocharger compressor wheel can cause 2. Check for obvious heat discoloration of the
additional damage to the pistons, the valves, and the
cylinder head. turbocharger. Check for any loose bolts or any
missing bolts. Check for damage to the oil supply
NOTICE line and the oil drain line. Check for cracks in the
Turbocharger bearing failures can cause large quan- housing of the turbocharger. Ensure that the
tities of oil to enter the air intake and exhaust sys- compressor wheel can rotate freely.
tems. Loss of engine lubricant can result in serious
engine damage. 3. Check for the presence of oil. If oil is leaking from
the back side of the compressor wheel, there is a
Minor leakage of oil into a turbocharger under ex- possibility of a failed turbocharger oil seal.
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not The presence of oil may be the result of extended
occured. engine operation at low idle. The presence of oil
may also be the result of a restriction of the line for
When a turbocharger bearing failure is accompanied the intake air (clogged air filters), which causes the
by a significant engine performance loss (exhaust turbocharger to slobber.
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is renewed. 4. Inspect the bore of the housing of the turbine outlet
for corrosion.
A visual inspection of the turbocharger can minimize 5. Fasten the air intake pipe and the exhaust outlet
unscheduled downtime. A visual inspection of the pipe to the turbocharger housing. Ensure that all
turbocharger can also reduce the chance for potential
damage to other engine parts. clamps are installed correctly and that all clamps
are tightened securely.
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.
SEBU7772-06 105
Maintenance Section
Water Pump - Inspect
For maximum engine service life, make a thorough Belts for multiple groove pulleys must be replaced as
inspection of the engine compartment before starting matched sets. If only one belt is replaced, the belt will
the engine. Look for items such as oil leaks or carry more load than the belts that are not replaced.
coolant leaks, loose bolts, worn belts, loose The older belts are stretched. The additional load on
connections and trash buildup. Make repairs, as the new belt could cause the belt to break.
needed:
• Drain the water and the sediment from fuel tanks
• The guards must be in the proper place. Repair on a daily basis in order to ensure that only clean
damaged guards or replace missing guards. fuel enters the fuel system.
• Wipe all caps and plugs before the engine is • Inspect the wiring and the wiring harnesses for
serviced in order to reduce the chance of system loose connections and for worn wires or frayed
contamination. wires.
• Inspect the ground strap for a good connection

NOTICE
For any type of leak (coolant, lube, or fuel) clean up and for good condition.
the fluid. If leaking is observed, find the source and
correct the leak. If leaking is suspected, check the flu- • Inspect the ECM to the cylinder head ground strap
id levels more often than recommended until the leak for a good connection and for good condition.
is found or fixed, or until the suspicion of a leak is
proved to be unwarranted. • Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte
NOTICE level of the batteries, unless the engine is
Accumulated grease and/or oil on an engine or deck equipped with a maintenance free battery.
is a fire hazard. Remove this debris with steam clean-
ing or high pressure water. • Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauge that
can not be calibrated.
• Ensure that the cooling lines are properly clamped
and that the cooling lines are tight. Check for i05264233
leaks. Check the condition of all pipes.
• Inspect the water pumps for coolant leaks.
SMCS Code: 1361-040
Note: The water pump seal is lubricated by coolant in
the cooling system. It is normal for a small amount of A failed water pump might cause severe engine
leakage to occur as the engine cools down and the overheating problems that could result in the
parts contract. following conditions:
Excessive coolant leakage may indicate the need to • Cracks in the cylinder head
replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/ • A piston seizure
or seals, refer to the Service Manual for the engine or
consult your Caterpillar dealer. • Other potential damage to the engine
• Inspect the lubrication system for leaks at the front A failed water pump might cause severe engine
crankshaft seal, the rear crankshaft seal, the oil overheating problems. Overheating could result in
pan, the oil filters and the valve cover. cracks in the cylinder head, a piston seizure, or other
potential damage to the engine.
• Inspect the fuel system for leaks. Look for loose Visually inspect the water pump for leaks. If leaking
fuel line clamps or for loose fuel line tie-wraps. of the water pump seals is observed, replace all of
the water pump seals. Refer to two articles in the
• Inspect the piping for the air inlet system and the Disassembly and Assembly Manual, “Water Pump -
elbows for cracks and for loose clamps. Ensure Disassemble and Water Pump - Assemble” for the
that hoses and tubes are not contacting other disassembly and assembly procedure. If necessary
hoses, tubes, wiring harnesses, etc. to remove the water pump, refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
• Inspect the alternator belt and the accessory drive Remove and Water Pump - Install”.
belts for cracks, breaks or other damage.
106 SEBU7772-06
Maintenance Section
Inspect the water pump for wear, cracks, pin holes,

and proper operation. Refer to the Parts Manual for
the correct part numbers for your engine or consult
your Cat dealer if repair is needed or replacement is
needed.
SEBU7772-06 107
Warranty Section
Warranty Information
Warranty Section The aftertreatment system can be expected to

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

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

in emission-related components that can cause
the engine to fail to conform to applicable
emission standards for the warranty period.
2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to conform,
at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
(ARB).
b. Free from defects in materials and workmanship

which cause the failure of an emission-related
component to be identical in all material
respects to the component as described in the
engine manufacturer's application for
certification for the warranty period.
108 SEBU7772-06
Reference Information Section
Engine Ratings
Reference Information i03880100
Section Engine Rating Definitions

SMCS Code: 1000
Engine Ratings 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
i00727327 percent of time at full throttle. The definitions also
identify the corresponding times below rated rpm.
Engine Rating Conditions Refer to this Operation and Maintenance Manual,
“Configuration Parameters” for information about the
SMCS Code: 1000 rating for this engine.
All engine ratings are in compliance with the following Note: The examples of the applications are only for
standard ambient air conditions of “SAE J1349”: reference. For an exact determination of the
• 99 kPa (29.3 inches of Hg) appropriate rating, follow the OEM specifications or
consult your Caterpillar dealer.
• 30 percent relative humidity Table 22
• A temperature of 25 °C (77 °F) Engine Rating Information
Ratings relate to the standard conditions of Perform- Time at Rated Load(1)

Load Examples of
“ISO8665”, of “ISO3046/1”, of “DIN6271”, and of ance
Any One
“BS5514”. Factor Applications
Rating Overall
Instance
The engine ratings are based on the following fuel Pipe line
specifications: A 100% 100% n/a pumping
Ventilation
• Low heat value (LHV) of the fuel of 42 780 kJ/kg
(18,390 Btu/lb) at 29 °C (84 °F) Irrigation pumps
Drilling
• Gravity (API) of 35 degrees at 15 °C (60 °F) B 85% 75% n/a applications
Plant air
• Specific gravity of .849 at 15 °C (60 °F) compressors
Fire pumps
• Density of 850 kg/m3 (7.085 lb/US gal) Chippers
Less than1
C 70% 50% Rock crushers
The engine ratings are gross output ratings. hour
Portable air
Gross Output Ratings – The total output capability compressors
of the engine that is equipped with standard Snowgroomer
accessories. Less than 30 Snowblowers
D 50% 10%
minutes Cranes
Water well drills
Standard accessories include the following
components: Standby centrifu-
Less than 15
E 35% 5% gal pumps
• Oil pumps minutes
Oil well servicing
(1) Both the overall time at rated load and the time the engine is
• Fuel pumps
operated in any one instance must be considered.
• Water pumps
Subtract the power that is required to drive auxiliary NOTICE
Operating engines above the rating definitions can
components from the gross output. This will produce result in shorter service life before overhaul.
the net power that is available for the external load
(flywheel).
SEBU7772-06 109
Customer Service
Customer Service Europe, Africa, and Middle East

Caterpillar Overseas S.A.
76 Route de Frontenex
i03910306
P.O. Box 6000
CH-1211 Geneva 6
Customer Assistance Switzerland
SMCS Code: 1000; 4450 Phone: 22-849-4444
Fax: 22-849-4544
USA and Canada Far East
Caterpillar Asia Pte. Ltd.
When a problem arises concerning the operation or 7 Tractor Road
the service of an engine, the problem will normally be
managed by the dealer in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level, use the phone number that is listed below to Hong Kong
talk with a Field Service Coordinator: Phone: 852-2848-0333
Fax: 852-2848-0440
1-800-447-4986
The normal hours are from 8:00 to 4:30 Monday Japan
through Friday Central Standard Time. Shin Caterpillar Mitsubishi Ltd.
SBS Tower
3. If your needs have not been met still, submit the 10-1, Yoga 4-Chome
matter in writing to the following address: Setagaya-Ku, Tokyo 158-8530
Japan
Caterpillar Inc. Phone: 81-3-5717-1150
Manager, Customer Service, Engine Division Fax: 81-3-5717-1177
Mossville Bldg AC
P.O. Box 610 Japan
Mossville, Illinois 61552-0610 Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
Please keep in mind: probably, your problem will 4-10-1, Yoga
ultimately be solved at the dealership, using the Setagaya-Ku, Tokyo 158-0097
dealership facilities, equipment, and personnel. Phone: 81-3-5797-4300
Therefore, follow the steps in sequence when a
problem is experienced. Fax: 81-3-5797-4359
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
110 SEBU7772-06
Ordering Replacement Parts
Australia and New Zealand

Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
i01028392
Ordering Replacement Parts

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

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent speci-
fications including, but not limited to, physical di-
mensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
Quality 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.
SEBU7772-06 111
Reference Materials
Reference Materials
i05264255
Maintenance Records
SMCS Code: 1000; 4450
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 various other
business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is managed. Accurate
maintenance records can help your Cat dealer to
fine-tune the recommended maintenance intervals 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:
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
• Owner repair costs
• Owner receipts
• Maintenance log
112 SEBU7772-06
Maintenance Log
i01176304
Maintenance Log
SMCS Code: 1000; 4450
Table 23
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity Of
Service Item Date Authorization
Hours Fuel
SEBU7772-06 113
Reference Material
i04374863 • Special Publications, PEDP7036, “S·O·S Fluids

Analysis Cornerstone”
Reference Material
• Special Publications, PEHP7076, “Understanding
SMCS Code: 1000; 4450 S·O·S Services Tests”
The following literature can be obtained through any • Special Publication, PEHP7052, “Making the Most
Cat dealer. of S·O·S Services”
Coolants • Special Publication, PEGJ0045, “Reporting

Particle Count by ISO Code”
• Special Publication, PMEP5027, “Label - Cat ELC
Radiator Label” • Special Publication, PEGJ0046, “Understanding
Your S·O·S Services Results”
• Datasheet, PEHJ0067, “Cat ELC (Extended Life
Coolant)” (Worldwide) Miscellaneous
• Datasheet, PEHP9554, “Cat DEAC (Diesel • Service Manual, RENR7600, “C9 Industrial
Engine Antifreeze/Coolant) (Concentrate)” Engines”
Fuels • Special Publication, SEBU6251, “Caterpillar

• Special Publication, SEBD0717, “Diesel Fuels and Recommendations”
Your Engine”
• Special Publication, PECP9067, “One Safe
• Special Publication, SENR9620, “Improving Fuel Source”
System Durability”
• Special Instruction, REHS0354, “Charging System
Troubleshooting”
Lubricants
• Special Publication, SEBF8029, “Index to
• Datasheet, PEHJ0159, “Cat DEO-ULS (SAE Guidelines for Reusable Parts and Salvage
15W-40)” (North America - Canada, Mexico, and Operations”
United States)
• Special Publication, SEBF8062, “Guideline for
• Datasheet, PEHJ0059, “Cat DEO (SAE 10W-30 Reusable Parts - Cleaning and Inspection of Air
and SAE 15W-40)” (North America - Canada, Filters”
Mexico, and United States)
• Special Publication, SEBU5898, “Cold Weather
• Datasheet, PEHJ0021, “Cat DEO (SAE 10W-30 Recommendations for all Cat Machines”
and SAE 15W-40)” (Worldwide - except North
America, Egypt, Saudi Arabia, and Brazil) • Special Instruction, SEHS9031, “Storage
Procedure for Cat Products”
• Datasheet, PEHJ0072, “Cat DEO (SAE 10W-30
and SAE 15W-40)” (Brazil) • Special Instruction, SEHS8622, “Using the FT-
1984 Air-To-Air Aftercooler Leak Test Group”
• Datasheet, PEHJ0091, “Cat DEO (SAE 10W-30
and SAE 15W-40)” (Egypt and Saudi Arabia) • Special Instruction, SEHS7633, “Battery Test
Procedure”
• Datasheet, PEHP7062, “Cat DEO SYN (SAE 5W-
40)” • Special Instruction, SEHS7332, “Do Not Operate
Tag”
• Datasheet, PEHJ0008, “Cat Arctic DEO (SAE 0W-
30)” (Canada and United States)
S·O·S Services
• Special Publication, PEHJ0191, “S·O·S Coolant
Analysis”
• Special Publication, PEGJ0047, “How To Take A
Good Oil Sample”
114 SEBU7772-06
Index Section
Index
A Coolant Sample (Level 2) - Obtain.................. 80
Obtaining the Sample .................................. 80
After Starting Engine ....................................... 48
Coolant Temperature Regulator - Replace ..... 80
After Stopping Engine ..................................... 53
Cooling System Supplemental Coolant
Aftercooler Core - Inspect/Clean/Test ............. 69
Additive (SCA) - Test/Add (Systems
Clean............................................................ 69
Which are Filled with Conventional
Inspect ......................................................... 69
Coolant) ......................................................... 81
Test .............................................................. 69
Maintain the Proper Concentration of SCA in
Air Compressor - Check .................................. 70
the Coolant................................................. 81
Air Compressor Filter - Clean/Replace (If
Crankshaft Vibration Damper - Inspect........... 82
Equipped) ...................................................... 70
Inspection .................................................... 82
Air Shutoff - Test .............................................. 70
Removal and Installation ............................. 82
Air Tank Moisture and Sediment - Drain (If
Crushing Prevention and Cutting Prevention.. 13
Equipped) ...................................................... 71
Customer Assistance .................................... 109
Alternator - Inspect .......................................... 71
Outside of the USA and of Canada ........... 109
USA and Canada....................................... 109
B Customer Service.......................................... 109
Battery - Replace............................................. 71
Battery Charger - Check.................................. 72 D
Checking After Stopping.............................. 73
Diagnostic Flash Code Retrieval..................... 34
Checking Before Start-Up............................ 72
“Diagnostic” Lamp ....................................... 34
Battery Electrolyte Level - Check .................... 73
Diagnostic Lamp.............................................. 34
Battery or Battery Cable - Disconnect............. 73
Driven Equipment - Check .............................. 82
Before Starting Engine .............................. 14, 44
Belts - Inspect/Adjust/Replace ........................ 74
Adjust/Replace (V-Belts) ............................. 74 E
Inspect ......................................................... 74 Electrical System............................................. 15
Replace (Serpentine Belt) ........................... 75 Grounding Practices .................................... 15
Burn Prevention................................................11 Emergency Stopping....................................... 53
Batteries........................................................11 Emergency Stop Button (If Equipped)......... 53
Coolant .........................................................11 Emissions Certification Film ............................ 24
Oils................................................................11 Emissions Warranty Information ................... 107
Engaging the Driven Equipment ..................... 49
C Engine - Clean................................................. 82
Engine Air Cleaner Element (Dual Element)
Cold Weather Operation ................................. 51
- Inspect/Clean/Replace ................................ 83
Cold Weather Starting ..................................... 44
Cleaning the Primary Air Cleaner
Configuration Parameters ............................... 37
Elements .................................................... 84
Parameter Descriptions ............................... 37
Servicing the Air Cleaner Elements............. 83
System Configuration Parameters .............. 40
Engine Air Cleaner Service Indicator -
Coolant - Change ............................................ 75
Inspect (If Equipped) ..................................... 85
Drain the Cooling System............................ 76
Test the Service Indicator ............................ 86
Fill the Cooling System ................................ 77
Engine Air Precleaner - Check/Clean ............. 86
Flush ............................................................ 76
Engine Crankcase Breather - Clean ............... 87
Coolant Extender (ELC) - Add ........................ 77
Engine Diagnostics ......................................... 34
Coolant Level - Check ..................................... 78
Engine Electronics........................................... 16
Coolant Sample (Level 1) - Obtain.................. 79
Engine Mounts - Inspect.................................. 87
Sampling Conditions.................................... 79
Engine Oil and Filter - Change ........................ 89
Timing of the Sampling ................................ 79
SEBU7772-06 115
Index Section
Drain the Engine Oil..................................... 89 Engines that are Equipped with a Fuel
Fill the Engine Crankcase............................ 90 Priming Pump ............................................ 92
Interval for Engine Oil and Engine Oil Filter Engines that are Not Equipped with a Fuel
Change ...................................................... 89 Priming Pump ............................................ 92
Replace the Oil Filter ................................... 89 Fuel System Primary Filter (Water
Engine Oil Level - Check................................. 87 Separator) Element - Replace....................... 92
Engine Oil Sample - Obtain............................. 88 Replace the Element ................................... 93
Obtain the Sample and the Analysis ........... 88 Fuel System Primary Filter/Water
Engine Operation ............................................ 49 Separator - Drain ........................................... 94
Engine Operation with Active Diagnostic Fuel System Secondary Filter - Replace ........ 94
Codes ............................................................ 36 Fuel Tank Water and Sediment - Drain ........... 95
Engine Operation with Intermittent Drain the Water and the Sediment .............. 95
Diagnostic Codes .......................................... 37 Fuel Storage Tanks...................................... 96
Engine Rating Conditions.............................. 108 Fuel Tank ..................................................... 95
Engine Rating Definitions.............................. 108
Engine Ratings .............................................. 108 G
Engine Starting.......................................... 14, 44
Engine Stopping ........................................ 15, 53 Gauges and Indicators .................................... 28
Engine Storage Procedure - Check ................ 90 General Hazard Information.............................. 7
Engine Valve Lash - Check ............................. 91 Containing Fluid Spillage............................... 9
Dispose of Waste Properly ...........................11
Fluid Penetration ........................................... 9
F
Inhalation ..................................................... 10
Fan Drive Bearing - Lubricate ......................... 91 Lines, Tubes, and Hoses ............................... 9
Fault Logging................................................... 36 Pressurized Air and Water............................. 8
Features and Controls..................................... 28 Softwrap....................................................... 10
Fire Prevention and Explosion Prevention.......11 Static Electricity Hazard when Fueling with
Ether ............................................................ 13 Ultra-low Sulfur Diesel Fuel ......................... 9
Fire Extinguisher.......................................... 13 General Information ........................................ 17
Lines, Tubes, and Hoses ............................. 13 Grounding Stud - Inspect/Clean/Tighten......... 96
Fluid Recommendations ................................. 55
Cooling System............................................ 60 H
Diesel Engine Oil ......................................... 55
Fuel .............................................................. 57 Hoses and Clamps - Inspect/Replace............. 97
Greases ....................................................... 62 Inspect Tubes, Hoses, Bellows, and
Foreword ........................................................... 4 Clamps....................................................... 97
California Proposition 65 Warning ................. 4 Replace the Hoses and the Clamps ............ 97
Literature Information .................................... 4
Maintenance .................................................. 4 I
Maintenance Intervals ................................... 4
Important Safety Information............................. 2
Operation ....................................................... 4
Overhaul ........................................................ 4
Safety............................................................. 4 J
Fuel and the Effect from Cold Weather ........... 51 Jacket Water Heater - Check .......................... 99
Fuel Conservation Practices ........................... 49
Fuel Related Components in Cold Weather ... 51
L
Fuel Filters ................................................... 52
Fuel Heaters ................................................ 52 Lifting and Storage .......................................... 25
Fuel Tanks ................................................... 51
Fuel System - Prime ........................................ 91 M
Maintenance Interval Schedule....................... 67
116 SEBU7772-06
Index Section
Daily ............................................................. 67 R
Every 2000 Service Hours or 1 Year ........... 67
Radiator - Clean ............................................ 102
Every 208 000 L (55 000 US gal) of Fuel or
Radiator Restrictions....................................... 51
5000 Service Hours ................................... 67
Reference Information..................................... 24
Every 250 Service Hours ............................. 67
Record for Reference .................................. 24
Every 340 000 L (90 000 US gal) of Fuel or
Reference Information Section ..................... 108
10 000 Service Hours ................................ 68
Reference Material .........................................113
Every 4000 Service Hours or 2 Years ......... 67
Coolants......................................................113
Every 500 Service Hours ............................. 67
Fuels ...........................................................113
Every Week ................................................. 67
Lubricants ...................................................113
Initial 250 Service Hours.............................. 67
Miscellaneous .............................................113
Initial 500 Service Hours.............................. 67
S·O·S Services ...........................................113
When Required............................................ 67
Reference Materials ....................................... 111
Maintenance Log............................................112
Refill Capacities............................................... 55
Maintenance Recommendations .................... 64
Coolant ........................................................ 55
Maintenance Records .................................... 111
Engine Oil .................................................... 55
Maintenance Section....................................... 55
Manual Stop Procedure .................................. 53
Model View Illustrations .................................. 17 S
Monitoring System (If Equipped)..................... 29 Safety Messages............................................... 5
Cat Messenger Display .............................. 31 (1) Universal Warning .................................... 7
Indicators and Gauges ................................ 29 Safety Section ................................................... 5
Mounting and Dismounting ............................. 14 Self-Diagnostics .............................................. 34
Severe Service Application ............................. 65
O Improper Maintenance Procedures
(Maintenance Procedures Which May
Operation Section............................................ 25
Contribute to a Severe Service
Ordering Replacement Parts..........................110
Application) ................................................ 66
Overhaul Considerations................................. 99
Severe Environmental Factors .................... 65
Oil Consumption as an Overhaul Indicator.. 99
Severe Operating Conditions ...................... 66
Overhaul Recommendation....................... 100
Starting Motor - Inspect (If equipped)............ 103
Air Starting Motor....................................... 103
P Electric Starting Motor ............................... 103
Plate Locations and Film Locations ................ 23 Removal and Installation of the Starting
Information Plate (2) .................................... 24 Motor ........................................................ 104
Serial Number Plate (1) ............................... 24 Starting the Engine.......................................... 45
Power Take-Off Clutch - Check..................... 102 Air Inlet Heater............................................. 46
Product Description ......................................... 20 Cold Weather Starting ................................. 46
Aftermarket Products and Cat Engines ...... 22 Ether Injection System................................. 47
Electronic Engine Features ......................... 21 Initial Inspection ........................................... 45
Engine Cooling and Lubrication .................. 21 Problems with the Wiring Harness .............. 47
Engine Service Life...................................... 22 Starting Problems ........................................ 47
Engine Specifications .................................. 20 Starting with Jump Start Cables...................... 48
Welding and Cat Electronic Engines .......... 22 System Pressure Release............................... 64
Product Identification Information ................... 23 Coolant System ........................................... 64
Product Information Section............................ 17 Engine Oil .................................................... 64
Product Lifting ................................................. 25 Fuel System................................................. 64
Product Storage .............................................. 25
Removal from Storage................................. 27 T
Storage (Less Than One Year).................... 25
Table of Contents .............................................. 3
SEBU7772-06 117
Index Section
Turbocharger - Inspect .................................. 104

Inspecting .................................................. 104
Removal and Installation ........................... 104
W
Walk-Around Inspection ................................ 104
Inspect the Engine for Leaks and for Loose
Connections ............................................. 104
Warranty Information..................................... 107
Warranty Section........................................... 107
Water Pump - Inspect.................................... 105
Welding on Engines with Electronic
Controls ......................................................... 64
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
SEBU7772 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2017 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.
120 July 2017

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SEBU7772-06 (en-us)

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Refill Capacities............................................... 55

Maintenance Recommendations .................... 64

Warranty Information..................................... 107

Burn Prevention................................................11 Reference Information Section

Fire Prevention and Explosion Prevention.......11 Engine Ratings .............................................. 108

Crushing Prevention and Cutting Prevention.. 13 Customer Service.......................................... 109

Mounting and Dismounting ............................. 14 Reference Materials ....................................... 111

Before Starting Engine .................................... 14 Index Section

Engine Starting................................................ 14 Index...............................................................114

Engine Stopping .............................................. 15

Product Information Section

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

Product Identification Information ................... 23

Lifting and Storage .......................................... 25

Features and Controls..................................... 28

Engine Diagnostics ......................................... 34

Engine Operation ............................................ 49

Cold Weather Operation ................................. 51

Engine Stopping .............................................. 53

Foreword Recommended service should be performed at the

Maintenance California Proposition 65 Warning

The following section describes the safety messages

(1) Universal Warning

The universal safety messages are located on each

General Hazard Information

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

• Pressure taps • When starting a new engine, make provisions to

Pressurized Air and Water

• Use all cleaning solutions with care.

Avoid direct spraying of water on electrical Static Electricity Hazard when

• Wire that is exposed in reinforced hose

• Flexible part of the hose that is kinked or crushed

• Stay away from areas that might have asbestos

• Never use compressed air for cleaning.

• Avoid grinding materials that contain asbestos.

Dispose of Waste Properly Oils

Illustration 8 g00706404 Fire Prevention and Explosion

Always use leakproof containers when you drain

Wiring must be kept in good condition. Properly route

Do not store ether cylinders in living areas or in the

Lines, Tubes, and Hoses

Stay clear of all rotating parts and of all moving parts.

Do not carry tools or supplies when you mount the

i04257031 If a warning tag is attached to the engine start switch

All grounds should be tight and free of corrosion. The

Tampering with the electronic system installation

Uncontrolled electrical circuit paths can result in • Engine Coolant Temperature

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

Model View Illustrations

Model View Illustrations

Illustration 16 g01460598 Illustration 17 g01460603

i04368417 Engine Specifications

• Hydraulically Actuated Electronic Unit Injection

Hydraulic Electronic Unit Injectors

Aspiration ATAAC The engine has built-in diagnostics in order to ensure

• Automatic air/fuel ratio control Engine Cooling and Lubrication