c13 engine

SEBU8597-03June 2012

Operation andMaintenanceManualC13 Industrial EngineKWJ1-Up (C13 Engine)

SAFETY.CAT.COM

i03991620

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread 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 warningsare 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 pictoriallypresented.

A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labelson 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 mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. You should also ensure that the product will not be damaged or become unsafe bythe 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 thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Cat dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Cat re-placement parts or parts with equivalent speci-fications including, but not limited to, physicaldimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

In the United States, the maintenance, replacement, or repair of the emission control devices andsystems may be performed by any repair establishment or individual of the owner's choosing.

SEBU8597-03 3Table of Contents

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Messages .................................................... 6

General Hazard Information ................................... 8

Burn Prevention ..................................................... 11

Fire Prevention and Explosion Prevention ............. 11

Crushing Prevention and Cutting Prevention ........ 13

Mounting and Dismounting ................................... 13

Before Starting Engine .......................................... 14

Engine Starting ..................................................... 14

Engine Stopping ................................................... 14

Electrical System .................................................. 15

Engine Electronics ................................................ 16

Product Information Section

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

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

Operation Section

Lifting and Storage ................................................ 24

Features and Controls .......................................... 27

Engine Diagnostics ............................................... 32

Engine Starting ..................................................... 40

Engine Operation .................................................. 45

Cold Weather Operation ....................................... 50

Engine Stopping ................................................... 52

Maintenance Section

Refill Capacities .................................................... 53

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

Maintenance Interval Schedule ............................ 62

Maintenance Interval Schedule (Engines WithRatings Greater Than 439 hp) ............................ 63

Warranty Section

Warranty Information .......................................... 101

Reference Information Section

Engine Ratings ................................................... 102

Customer Service ............................................... 104

Reference Materials ............................................ 106

Index Section

Index .................................................................... 110

4 SEBU8597-03Foreword

ForewordLiterature InformationThis manual contains safety, operation instructions,lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.

English is the primary language for all Caterpillarpublications. The English used facilitates translationand consistency in electronic media delivery.

Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Caterpillar dealer for the latestavailable information.

SafetyThis safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance andrepair on this product.

OperationOperating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.

The operation section is a reference for operators.Photographs and illustrations guide the operatorthrough procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic information.

MaintenanceThe maintenance section is a guide to engine care.The illustrated, step-by-step instructions are groupedby fuel consumption, service hours and/or calendartime maintenance intervals. Items in the maintenanceschedule are referenced to detailed instructions thatfollow.

Use fuel consumption or service hours to determineintervals. Calendar intervals shown (daily, annually,etc.) may be used instead of service meter intervalsif they provide more convenient schedules andapproximate the indicated service meter reading.

Recommended service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more frequent lubrication and maintenance than isspecified in the Maintenance Interval Schedule maybe necessary.

The maintenance schedule items are organized fora preventive maintenance management program. Ifthe preventive maintenance program is followed, aperiodic tune-up is not required. The implementationof a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.

Maintenance IntervalsPerform maintenance on items at multiples of theoriginal requirement. Each level and/or individualitems in each level should be shifted ahead or backdepending upon your specific maintenance practices,operation and application. We recommend thatthe maintenance schedules be reproduced anddisplayed near the engine as a convenient reminder.We also recommend that a maintenance record bemaintained as part of the engine's permanent record.

See the section in the Operation and MaintenanceManual, “Maintenance Records” for informationregarding documents that are generally acceptedas proof of maintenance or repair. Your authorizedCaterpillar dealer can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.

OverhaulMajor engine overhaul details are not covered in theOperation and Maintenance Manual except for theinterval and the maintenance items in that interval.Major repairs are best left to trained personnel oran authorized Caterpillar dealer. Your Caterpillardealer offers a variety of options regarding overhaulprograms. If you experience a major engine failure,there are also numerous after failure overhaul optionsavailable from your Caterpillar dealer. Consult withyour dealer for information regarding these options.

SEBU8597-03 5Foreword

California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

6 SEBU8597-03Safety SectionSafety Messages

Safety Sectioni04058294

Safety MessagesSMCS Code: 1000; 7405

There may be several specific safety messages onyour engine. The exact location and a description ofthe safety messages are reviewed in this section.Become familiar with all safety messages.

Ensure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if the words cannot be read or if theillustrations are not visible. Use a cloth, water,and soap to clean the safety messages. Do notuse solvents, gasoline, or other harsh chemicals.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the safety messages. Thesafety messages that are loosened could drop offthe engine.

Replace any safety message that is damaged ormissing. If a safety message is attached to a partof the engine that is replaced, install a new safetymessage on the replacement part. Your Caterpillardealer can provide new safety messages.

g02292373Illustration 1

SEBU8597-03 7Safety Section

Safety Messages

Universal Warning (1)


One safety message is located on the left side of theengine. One safety message is located on the rightside of the engine.

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManual. Failure to follow the instructions or heedthe warnings could result in injury or death. Con-tact any Caterpillar dealer for replacement manu-als. Proper care is your responsibility.

Sulfuric Acid Burn (2)


One safety message for sulfuric acid burn is locatedon top of the exhaust cooler. One safety messagefor sulfuric acid burn is located on the right side ofthe exhaust cooler.

Sulfuric Acid Burn Hazard may cause serious per-sonal injury or death.

The exhaust gas cooler may contain a smallamount of sulfuric acid. The use of fuel with sul-fur levels greater than 15 ppm may increase theamount of sulfuric acid formed. The sulfuric acidmay spill from the cooler during service of theengine. The sulfuric acid will burn the eyes, skinand clothing on contact. Always wear the appro-priate personal protective equipment (PPE) thatis noted on a material safety data sheet (MSDS)for sulfuric acid. Always follow the directions forfirst aid that are noted on a material safety datasheet (MSDS) for sulfuric acid.

8 SEBU8597-03Safety SectionGeneral Hazard Information

i04074884

General Hazard InformationSMCS Code: 1000; 4450; 7405


Attach a “Do Not Operate” warning tag to the startswitch or controls before the engine is serviced orrepaired. These warning tags (Special Instruction,SEHS7332) are available from your Cat dealer.Attach the warning tags to the engine and toeach operator control station. When appropriate,disconnect the starting controls.

Do not allow unauthorized personnel on the engine,or around the engine when the engine is beingserviced.

Cautiously remove the following parts. To helpprevent spraying or splashing of pressurized fluids,hold a rag over the part that is being removed.

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed.Gradually loosen, but do not remove the last twobolts or nuts that are located at opposite ends ofthe cover plate or the device. Before removing thelast two bolts or nuts, pry the cover loose in order torelieve any spring pressure or other pressure.


• Wear a hard hat, protective glasses, and otherprotective equipment, as required.

• When work is performed around an engine that isoperating, wear protective devices for ears in orderto help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can snagon controls or on other parts of the engine.

• Ensure that all protective guards and all covers aresecured 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, performthe maintenance under the following conditions:

• The engine is stopped. Ensure that the enginecannot be started.

• The protective locks or the controls are in theapplied position.

• Disconnect the batteries when maintenanceis performed or when the electrical system isserviced. Disconnect the battery ground leads.Tape the leads in order to help prevent sparks.

• When starting a new engine or an engine whichhas not been started since service has beenperformed, make provisions to stop the engine if anoverspeed occurs. Shutting down the engine maybe accomplished by shutting off the fuel supplyand/or the air supply to the engine.

• Do not attempt any repairs that are not understood.Use the proper tools. Replace any equipment thatis damaged or repair the equipment.


General Hazard Information

• Start the engine with the operator controls. Nevershort across the starting motor terminals or thebatteries. This method of starting the engine couldbypass the engine neutral start system and/or theelectrical system could be damaged.

Pressurized Air and WaterPressurized air and/or water can cause debris and/orhot water to be blown out which could result inpersonal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded and used with effective chipguarding (if applicable) and personal protectiveequipment. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).Always wear eye protection for cleaning the coolingsystem.

Fluid Penetration


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid Spillage

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” or refer to Special Pub-lication, PECJ0003, “Caterpillar Shop Supplies andTools Catalog” for tools and supplies suitable to col-lect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations andmandates.

Lines, Tubes, and HosesDo not bend or strike high-pressure lines. Do notinstall lines, tubes, or hoses that are damaged.

Repair any fuel lines, oil lines, tubes, or hoses thatare loose or damaged. Leaks can cause fires.

Inspect all lines, tubes, and hoses carefully. Donot use bare hands to check for leaks. Alwaysuse a board or cardboard for checking enginecomponents for leaks. Tighten all connections to therecommended torque.

Check for the following conditions:

• 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

Ensure that all of the clamps, the guards, andthe heat shields are installed correctly. Correctinstallation of these components will help to preventthese effects: vibration, rubbing against other parts,and excessive heat during operation.

10 SEBU8597-03Safety SectionGeneral Hazard Information

Inhalation


Exhaust

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

Asbestos Information

Caterpillar equipment and replacement parts thatare shipped from Caterpillar are asbestos free.Caterpillar recommends the use of only genuineCat replacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.

If dust that may contain asbestos is present, thereare 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 asbestosmaterials.

• A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.

• Use exhaust ventilation on permanent machiningjobs.

• Wear an approved respirator if there is no otherway to control the dust.

• Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposalof asbestos.

• Stay away from areas that might have asbestosparticles in the air.

SoftwrapKeep the engine room ventilation operating at fullcapacity. Wear a particulate respirator that has beenapproved by the National Institute of OccupationalSafety and Health (NIOSH). Wear appropriateprotective clothing in order to minimize direct contact.Use good hygiene practices and wash handsthoroughly after handling Softwrapmaterial. Do notsmoke until washing hands thoroughly after handlingSoftwrap material. Clean up debris with a vacuumor by wet sweeping. Do not use pressurized air toclean up debris.

Reference: The applicable material safety datasheets can be found at the following web site bysearching by the part number or the name of theproduct:

http://dsf2ws.cat.com/msds/servlet/cat.cis.ecs.msdsSearch.controller.UserIdentificationDisplayServlet

Dispose of Waste Properly



Burn Prevention

Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

i03895768

Burn PreventionSMCS Code: 1000; 4450; 7405

Do not touch any part of an operating engine orengine aftertreatment system. Allow the engine orthe engine aftertreatment system to cool beforeany maintenance is performed on the engine or theengine aftertreatment system. Relieve all pressure inthe appropriate system before any lines, fittings orrelated items are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant. Any contact withhot coolant or with steam can cause severe burns.Allow cooling system components to cool before thecooling system is drained.

Check the coolant level after the engine has stoppedand the engine has been allowed to cool. Ensurethat the filler cap is cool before removing the fillercap. The filler cap must be cool enough to touch witha bare hand. Remove the filler cap slowly in orderto relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot oil and hot lubricating components can causepersonal injury. Do not allow hot oil or hot componentsto contact the skin.

If the application has a makeup tank, remove the capfor the makeup tank after the engine has stopped.The filler cap must be cool to the touch.

BatteriesThe liquid in a battery is an electrolyte. Electrolyte isan acid that can cause personal injury. Do not allowelectrolyte to contact the skin or the eyes.

Do not smoke while checking the battery electrolytelevels. Batteries give off flammable fumes which canexplode.

Always wear protective glasses when you work withbatteries. Wash hands after touching batteries. Theuse of gloves is recommended.

i04090689

Fire Prevention and ExplosionPreventionSMCS Code: 1000; 4450; 7405


Use of personal protection equipment (PPE) may beneeded.

All fuels, most lubricants, and some coolant mixturesare flammable.

Always perform a Walk-Around Inspection, whichmay help you identify a fire hazard. Do not operate aproduct when a fire hazard exists. Contact your Catdealer for service.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

A flash fire may result if the covers for the enginecrankcase are removed within 15 minutes after anemergency shutdown.

Determine whether the engine will be operated in anenvironment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.

If the application involves the presence ofcombustible gases, consult your Cat dealer foradditional information about suitable protectiondevices.

12 SEBU8597-03Safety SectionFire Prevention and Explosion Prevention

Remove all flammable materials such as fuel, oil, anddebris from the engine. Do not allow any flammablematerials to accumulate on the engine.

All fluids that are captured in the fluid spillcontainment basin should be cleaned up immediately.Failure to clean up spilled fluids can cause a fire. Firemay cause personal injury and property damage.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in a line, a tube,or a seal failure. Exhaust shields must be installedcorrectly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding or flame cutting.

Wiring must be kept in good condition. Properly routeand attach all electrical wires. Check all electricalwires daily. Repair any wires that are loose or frayedbefore you operate the engine. Clean all electricalconnections and tighten all electrical connections.

Eliminate all wiring that is unattached or unnecessary.Do not use any wires or cables that are smaller thanthe recommended gauge. Do not bypass any fusesand/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and properlymaintained battery cables will help to prevent arcingor sparking.

Inspect all lines and hoses for wear or fordeterioration. Properly route all hoses. The linesand hoses must have adequate support and secureclamps. Tighten all connections to the recommendedtorque. Leaks can cause fires.

Properly install all oil filters and fuel filters. The filterhousings must be tightened to the proper torque.


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.


Crushing Prevention and Cutting Prevention

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. Charging a frozenbattery may result in an explosion.

The batteries must be kept clean. The covers(if equipped) must be kept on the cells. Use therecommended cables, connections, and battery boxcovers when the engine is operated.

Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

EtherEther is flammable and poisonous.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

Do not store ether cylinders in living areas or in theengine compartment. Do not store ether cylindersin direct sunlight or in temperatures above 49 °C(120 °F). Keep ether cylinders away from openflames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Do not spray ether into an engine if the engine isequipped with a thermal starting aid for cold weatherstarting.

Lines, Tubes, and HosesDo not bend high-pressure lines. Do not strikehigh-pressure lines. Do not install any lines that arebent or damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Cat dealer for repairor for replacement parts.

Check lines, tubes, and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly in order to prevent vibration,rubbing against other parts, and excessive heat.

i01359666

Crushing Prevention andCutting PreventionSMCS Code: 1000; 4450; 7405

Support the component properly when work beneaththe component is performed.

Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.

Stay clear of all rotating parts and of all movingparts. Leave the guards in place until maintenanceis performed. After the maintenance is performed,reinstall the guards.

Keep objects away from moving fan blades. The fanblades will throw objects or cut objects.

When objects are struck, wear protective glasses inorder to avoid injury to the eyes.

Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.

i01372247

Mounting and DismountingSMCS Code: 1000; 4450; 7405

Inspect the steps, the handholds, and the work areabefore mounting the engine. Keep these items cleanand keep these items in good repair.

Mount the engine and dismount the engine only atlocations that have steps and/or handholds. Do notclimb on the engine, and do not jump off the engine.

14 SEBU8597-03Safety SectionBefore Starting Engine

Face the engine in order to mount the engine ordismount the engine. Maintain a three-point contactwith the steps and handholds. Use two feet and onehand or use one foot and two hands. Do not use anycontrols as handholds.

Do not stand on components which cannot supportyour weight. Use an adequate ladder or use a workplatform. Secure the climbing equipment so that theequipment will not move.

Do not carry tools or supplies when you mount theengine or when you dismount the engine. Use a handline to raise and lower tools or supplies.

i03560601

Before Starting EngineSMCS Code: 1000

NOTICEFor initial start-up of a new or rebuilt engine, and forstart-up of an engine that has been serviced, makeprovision to shut the engine off should an overspeedoccur. This may be accomplished by shutting off theair and/or fuel supply to the engine.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

Inspect the engine for potential hazards.

Do not start the engine or move any of the controlsif there is a “DO NOT OPERATE” warning tag orsimilar warning tag attached to the start switch or tothe controls.

Before starting the engine, ensure that no one is on,underneath, or close to the engine. Ensure that thearea is free of personnel.

If equipped, ensure that the lighting system for theengine is suitable for the conditions. Ensure that alllights work properly, if equipped.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuits areprovided in order to help prevent personal injury. Thecircuits are also provided in order to help preventengine damage.

See the Service Manual for repairs and foradjustments.

i04021433

Engine StartingSMCS Code: 1000

If a warning tag is attached to the engine start switchor to the controls, DO NOT start the engine or movethe controls. Consult with the person that attachedthe warning tag before the engine is started.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine from the operator's compartment orfrom the engine start switch.

Always start the engine according to the procedurethat is described in this Operation and MaintenanceManual, “Engine Starting” topic (Operation Section).Knowledge of the correct procedure will help toprevent major damage to the engine components.Knowledge of the procedure will also help to preventpersonal injury.

To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingproperly, check the water temperature gauge and theoil temperature gauge during the heater operation.

Engine exhaust contains products of combustionthat can be harmful to your health. Always start theengine and operate the engine in a ventilated area.If the engine is started in an enclosed area, vent theengine exhaust to the outside.

i01462046

Engine StoppingSMCS Code: 1000

Stop the engine according to the procedure inthe Operation and Maintenance Manual, “EngineStopping (Operation Section)” in order to avoidoverheating of the engine and accelerated wear ofthe engine components.


Electrical System

Use the Emergency Stop Button (if equipped) ONLYin an emergency situation. Do not use the EmergencyStop Button for normal engine stopping. After anemergency stop, DO NOT start the engine until theproblem that caused the emergency stop has beencorrected.

Stop the engine if an overspeed condition occursduring the initial start-up of a new engine or an enginethat has been overhauled. This may be accomplishedby shutting off the fuel supply to the engine and/orshutting off the air supply to the engine.

To stop an electronically controlled engine, cut thepower to the engine.

i02469632

Electrical SystemSMCS Code: 1000; 1400

Never disconnect any charging unit circuit or batterycircuit cable from the battery when the charging unitis operating. A spark can cause the combustiblegases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative “−” jump start cable should be connectedlast from the external power source to the negative“−” terminal of the starting motor. If the starting motoris not equipped with a negative “−” terminal, connectthe jump start cable to the engine block.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is started. Repair all frayedelectrical wires before the engine is started. Refer tothe “Engine Starting” section of this Operation andMaintenance Manual for specific starting instructions.

Grounding Practices


Typical exampleGrounding Stud To Battery Ground

16 SEBU8597-03Safety SectionEngine Electronics


Typical example

Alternate Grounding Stud To Battery Ground

Proper grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Improper grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearingjournal surfaces, and to aluminum components.

Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.

To ensure that the engine and the engine electricalsystems function properly, an engine-to-frame groundstrap with a direct path to the battery must be used.This path may be provided by way of a starting motorground, a starting motor ground to the frame, or adirect engine ground to the frame.

All grounds should be tight and free of corrosion. Theengine alternator must be grounded to the negative“-” battery terminal with a wire that is adequate tohandle the full charging current of the alternator.

i04021529

Engine ElectronicsSMCS Code: 1000; 1900

Tampering with the electronic system installationor the OEM wiring installation can be dangerousand could result in personal injury or death and/orengine damage.

The Electronic Control Module (ECM) provides acomprehensive, programmable engine monitoringsystem for this engine. The ECM monitors specificengine operating parameters in order to detectabnormal conditions that may develop. The ECM willgenerate an event code if a specific engine parameterexceeds an acceptable range that is defined by theengine monitoring system. The ECM will react withan action that is dependent on the severity of thecondition. For information on event codes, refer tothis Operation and Maintenance Manual, “EventCodes” topic (Operation Section) The followingactions may be initiated by the ECM. These actionsare dependent on the severity of the condition:

• Illumination of a warning lamp or warning alarm

• Engine derate

• Engine protection shutdown

The Engine Monitoring package can vary for differentengine models and different engine applications.However, the monitoring system and the enginemonitoring control will be similar for all engines.

Note:Many of the engine control systems and displaymodules that are available for Caterpillar Engineswill work in unison with the Engine MonitoringSystem. Together, the two controls will provide theengine monitoring function for the specific engineapplication. Refer to the Troubleshooting Manual formore information.

SEBU8597-03 17Product Information Section

General Information

Product InformationSection

General Informationi04270339

Model View IllustrationsSMCS Code: 1000

g02453214Illustration 14Left side view of a C13 industrial engine(1) Open crankcase ventilation filter(2) Charge air cooler outlet sensor(3) NRS temperature sensor(4) NRS valve

(5) Fuel temperature sensor(6) Fuel pressure sensor post-filter(7) Secondary fuel filter base(8) Engine control module (ECM)

(9) Crankcase pressure sensor(10) Transfer pump(11) Engine speed sensor

18 SEBU8597-03Product Information SectionGeneral Information

g02453216Illustration 15Right side view of a C13 industrial engine(12) NRS cooler(13) Turbocharger

(14) Oil filter base(15) Oil filler


General Information


Clean emissions module (CEM)(16) Aftertreatment Regeneration Device

(ARD) head(17) ARD combustion air valve(18) ARD ignition coil

(19) ARD fuel manifold

i04275070

Product DescriptionSMCS Code: 1000; 4450; 4491

The Cat C13 Industrial Engines have the followingcharacteristics:

• Four-stroke cycle

• Mechanically actuated, electronically controlledfuel injection system

• Turbocharged

Engine SpecificationsNote: The front end of the engine is opposite theflywheel end of the engine. The left and the rightsides of the engine are determined from the flywheelend. The number 1 cylinder is the front cylinder.

20 SEBU8597-03Product Information SectionGeneral Information

g01387009Illustration 17Cylinder and valve location(A) Exhaust valve(B) Inlet valve

Table 1

Engine Specifications

Engine C13

Arrangement andCylinders In-Line 6 cylinder

Bore 130 mm (5.1 inch)

Stroke 157 mm (6.2 inch)

Aspiration ATAAC(1)

Displacement 12.5 L (763 cubic inch)

Firing Order 1-5-3-6-2-4

Rotation (flywheel end) Counterclockwise(1) Air-to-air aftercooled

Electronic Engine FeaturesThe Cat C13 Industrial Engine is designed forelectronic controls. The integral on board computercontrols the operation of the engine. Currentoperating conditions are monitored. The ElectronicControl Module (ECM) controls the response of theengine to these conditions and to the demands of theoperator. These conditions and operator demandsdetermine the precise control of fuel injection by theECM. The electronic engine control system providesthe following features:

• Engine speed governor

• Automatic air/fuel ratio control

• Torque rise shaping

• Injection timing control

• System diagnostics

• Aftertreatment regeneration control

• NOX reduction system control

Additional Features

The following additional features provide increasedengine fuel economy and serviceability:

• Cold starting capability

• Tampering detection

• Diagnostics

Engine Service LifeEngine efficiency and maximum utilization of engineperformance depend on the adherence to properoperation and maintenance recommendations. Inaddition, use recommended fuels, coolants, andlubricants. Use the Operation and MaintenanceManual as a guide for required engine maintenance.

Expected engine life is predicted by the averagepower that is demanded. The average power thatis demanded is based on fuel consumption of theengine over a time. Reduced hours of operationat full throttle and/or operating at reduced throttlesettings result in a lower average power demand.Reduced hours of operation will increase the lengthof operating time before an engine overhaul isrequired. For more information, refer to the Operationand Maintenance Manual, “Overhaul Considerations”topic.

Aftermarket Products and CatEnginesWhen auxiliary devices, accessories, or consumables(filters, additives, catalysts, etc.) which are made byother manufacturers are used on Cat products, theCaterpillar warranty is not affected simply becauseof such use.

However, failures that result from the installationor use of devices, accessories, or consumablesfrom other manufacturers are NOT Cat defects.Therefore, the defects are NOT covered under theCaterpillar warranty.


Product Identification Information

Product IdentificationInformation

i04278189

Plate Locations and FilmLocationsSMCS Code: 1000; 4450


(1) Serial number plate(2) Information plate

The engine serial number plate is located on the rightside of the engine block, toward the back.

g00123229Illustration 19Serial number plate

The following information is stamped on the serialnumber plate: engine serial number, engine model,and arrangement number.

The engine information plate is located on top of thevalve cover near the middle of the engine.

g01347963Illustration 20Engine information plate

The following information is on the informationplate: engine serial number, engine model, enginearrangement number, maximum altitude of theengine that is necessary to achieve the rated power,horsepower, high idle, full load rpm, fuel settings, andother information

22 SEBU8597-03Product Information SectionProduct Identification Information

g02446896Illustration 21View of the exhaust system of a C13 Well Service Engine

The Clean Emission Module (CEM) identificationplate is located on the electronics plate for the CEM.

g02236574Illustration 22CEM plate

The CEM identification plate contains the followinginformation: part number, serial number, changelevel, and configuration ID code. This informationmay be needed by the Cat dealer when inquiries arebeing made on the CEM.

i03649981

Emissions Certification FilmSMCS Code: 1000; 7405

Note: This information is pertinent in the UnitedStates, in Canada and in Europe.

Consult your Caterpillar dealer for an EmissionControl Warranty Statement.

This label is located on the engine.

i01382270

Reference InformationSMCS Code: 1000; 4450

Identification of the items in Table 2 may be neededin order to obtain parts and service. Some of theinformation is on the engine Serial Number Plateand/or Information Plate. Locate the informationfor your engine. Record the information on theappropriate space in Table 2. Make a copy of thislist for a record. Retain the information for futurereference.

The top level part numbers in the Parts Manual forthe engine are listed with the engine arrangementnumber. Occasionally, an arrangement may beslightly modified before the product is shipped fromthe factory. In these cases, a modification numberindicates that the arrangement has been modified.

The packaging arrangement may also be called apricing arrangement or a customer arrangement. Thisis the total package with attachments and optionsthat are not included in the engine arrangement.

The performance specification can be used byyour Caterpillar dealer with the Technical MarketingInformation system. Before the engine leaves thefactory, the engine performance is tested. Detailedperformance data is recorded. The performancespecification number can be used for obtaining thedata.


Product Identification Information

Table 2

Reference Information

Engine Model

Serial Number

Arrangement Number

Modification Number

Packaging Arrangement

Turbocharger

Fuel Filter Element

Lubrication Oil FilterElement

Auxiliary Oil Filter Element

Air Cleaner Element

Fan Drive Belt

Alternator Belt

Capacity of the LubricationSystem

Capacity of the CoolingSystem

Performance SpecificationNumber

Personality Module

Low Idle rpm

High Idle rpm

Full Load rpm

Power Rating

24 SEBU8597-03Operation SectionLifting and Storage

Operation Section

Lifting and Storagei04037083

Product LiftingSMCS Code: 7000; 7002


NOTICENever bend the eyebolts and the brackets. Only loadthe eyebolts and the brackets under tension. Remem-ber that the capacity of an eyebolt is less as the anglebetween the supporting members and the object be-comes less than 90 degrees.

When it is necessary to remove a component at anangle, only use a link bracket that is properly rated forthe weight.

Use a hoist to remove heavy components. Usean adjustable lifting beam to lift the engine. Allsupporting members (chains and cables) should beparallel to each other. The chains and cables shouldbe perpendicular to the top of the object that is beinglifted.

Some removals require lifting the fixtures in order toobtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes thatare on the engine.

Lifting eyes are designed and installed for the specificengine arrangement. Alterations to the lifting eyesand/or the engine make the lifting eyes and the liftingfixtures obsolete. If alterations are made, ensurethat proper lifting devices are provided. Consult yourCaterpillar dealer for information regarding fixturesfor proper engine lifting.

Engine Lifting with a Fuel Tank

Lift eyes or tank can fail when lifting tank con-taining fluids resulting in possible personal injury.Drain tank of all fluids before lifting.

Lifting the engine with a fuel tank that is mountedto the engine requires special equipment andprocedures. Do not lift the unit with fuel in the fueltank. Consult your Caterpillar dealer for informationregarding fixtures for proper lifting of your completepackage.

Clean Emission Module Lifting


The Clean Emission Module (CEM) should only belifted by the designated lifting eyes (1). Lifting eyelocations will be different depending on the CEMarrangement. Do not attempt to lift the CEM usingstraps around the diesel particulate filter.

SEBU8597-03 25Operation SectionLifting and Storage

i04137650

Product StorageSMCS Code: 7002

Storage (Less Than One Year)If an engine is not used, oil can run off the followingparts that normally receive lubrication: cylinder walls,piston rings, main bearings, connecting rod bearings,crankshaft, and gears.

This lack of lubricant allows corrosion to begin toappear on the metal. This condition is worse in areasof high humidity.

When the engine is started again, metal to metalcontact will cause wear before the surfaces receiveoil. To minimize this wear, use the starter to turn theengine with the throttle in the FUEL OFF position.When oil pressure is shown on the pressure gauge,start the engine.

1. Clean the engine of any dirt, rust, grease, and oil.Inspect the exterior. Paint areas that contain paintdamage with a good quality paint.

2. Remove dirt from the air cleaners. Check all seals,gaskets, and the filter element for damage.

3. Apply lubricant to all points in this Operationand Maintenance Manual, “Maintenance IntervalSchedule”.

4. Drain the crankcase oil. Replace the crankcase oiland change the oil filters. For the proper procedure,refer to this Operation and Maintenance Manual.

5. If the engine is equipped with an air startingmotor, fill the reservoir with the followingmixture: 50 percent volatile corrosion inhibitoroil (<nomen>VCI oil</nomen>) and 50 percentengine oil.

6. Add VCI oil to the crankcase oil. The volumeof VCI oil in the crankcase oil should be 3 to 4percent.

Note: If the engine crankcase is full, drain enoughengine oil so the mixture can be added.

7. Remove the air filter elements. Turn the engine atcranking speed with the throttle control in FUELOFF position. Use a sprayer to add a mixture of50 percent VCI oil and 50 percent engine oil intothe air inlet or turbocharger inlet.

Note: The mixture of VCI oil can be added to theinlet by removing the plug for checking turbochargerboost pressure. The minimum application rate for theVCI oil mixture is 5.5 mL per L (3 oz per 1000 cu in)of engine displacement.

8. Use a sprayer to apply a mixture of 50 percent VCIoil and 50 percent crankcase oil into the exhaustopenings. The minimum application rate for the oilmixture is 5.5 mL per L (3 oz per 1000 cu in) ofengine displacement. Seal the exhaust pipe andseal any drain holes in the muffler.

9. Remove the fuel from the secondary fuel filterhousing. Alternately, empty and reinstall thespin-on fuel filter element in order to remove anydirt and water. Drain any sleeve metering fuelpump.

Clean the primary fuel filter. Fill with calibrationfluid or kerosene. Install the primary fuel filterand operate the priming pump. This procedurewill send clean oil to the secondary filter and theengine.

Open the fuel tank drain valve in order to drainany water and dirt from the fuel tank. Apply aspray of calibration fluid or kerosene at the rateof 30 mL per 30 L (1 oz per 7.50 gal US) of fueltank capacity in order to prevent rust in the fueltank. Add 0.15 mL per L (.02 oz per 1 gal US) ofcommercial biocide such as Biobor JF to the fuel.

Apply a small amount of oil to the threads onthe fuel tank filler neck and install the cap. Sealall openings to the tank in order to preventevaporation of the fuel and as a preservative.

10.Remove the fuel nozzles or spark plugs. Apply30 mL (1 oz) of the mixture of oils (50 percent VCIoil and 50 percent engine oil) into each cylinder.

Use a bar or a turning tool in order to turn overthe engine slowly. This procedure puts the oil onthe cylinder walls. Install all fuel nozzles or sparkplugs and tighten to the correct torque.

11.Spray a thin amount of a mixture of 50 percentVCI oil and 50 percent engine oil onto the followingcomponents: flywheel, ring gear teeth, and starterpinion. Install the covers in order to preventevaporation of the vapors from the VCI oil.

12.Apply a heavy amount of Cat MultipurposeGrease (MPGM) to all outside parts that move,such as rod threads, ball joints, linkage.

Note: Install all covers. Ensure that tape has beeninstalled over all openings, air inlets, exhaustopenings, the flywheel housing, the crankcasebreathers, the dipstick tubes.

26 SEBU8597-03Operation SectionLifting and Storage

Ensure that all covers are airtight andweatherproof. Use a waterproof weather resistanttape such as Kendall No. 231 or an equivalent. Donot use duct tape. Duct tape will only seal for ashort time.

13.Under most conditions, removing the batteriesis the best procedure. As an alternative, placethe batteries in storage. As needed, periodicallycharge the batteries while the batteries are instorage.

If the batteries are not removed, wash the topsof the batteries until the tops are clean. Apply anelectrical charge to the batteries in order to obtaina specific gravity of 1.225.

Disconnect the battery terminals. Place a plasticcover over the batteries.

Note: For additional information, refer to SpecialInstruction, SEHS7633, “Battery Test Procedure”.

14. Loosen all belts.

15.Place a waterproof cover over the engine. Ensurethat the engine cover is secure. The cover shouldbe loose enough to allow air to circulate aroundthe engine in order to prevent damage fromcondensation.

16.Attach a tag with the storage date to the engine.

17.Remove the waterproof cover at 2 month or 3month intervals in order to check the engine forcorrosion. If the engine has signs of corrosion,repeat the protection procedure.

Coolant System

Completely fill the cooling system before storage.

Refer to this Operation and Maintenance Manual,“Fluid Recommendations” for more information aboutcoolants.

Removal from Storage1. Remove all outside protective covers.

2. Change the oil and filters.

3. Check the condition of the fan and alternatorbelts. Replace the belts, if necessary. Refer tothis 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 cleanerelements.

6. Use a bar or a turning tool in order to turn theengine in the normal direction of rotation. Theprocedure ensures that no hydraulic locks orresistance exist.

7. Before starting the engine, remove the valve coveror covers. Put a large amount of engine oil on thecamshaft, cam followers, and valve mechanism inorder to prevent damage to the mechanism.

8. Pressure-lubricate the engine before starting theengine. Pressure lubricating the engine ensuresimmediate lubrication and prevents damage tothe engine during the first few minutes of engineoperation. If the engine is not equipped witha prelube pump, contact your Cat dealer forinformation about lubrication of the engine beforestarting the engine.

9. Check the condition of all rubber hoses. Replaceany worn hoses. Replace any damaged hoses.

10.Before start-up, test the cooling system for a 3percent ro a 6 percent concentration of coolantconditioner. Add liquid coolant conditioner or acoolant conditioner element, if equipped.

Test the coolant mixture for proper nitrite level. Ifnecessary, adjust the coolant mixture.

Prime the engine with clean diesel fuel beforestarting.

11.Ensure that the cooling system is clean. Ensurethat the system is full. Ensure that the systemhas the correct amount of supplemental coolingsystem conditioner.

12.On the first day of operation, check the entireengine several times for leaks and correctoperation.

13. If the engine was removed from storage in whichtemperatures of less than -12°C (10°F) wereencountered, refer to Service Manual, SEBU5898,“Cold Weather Recommendations Operation andMaintenance”.

SEBU8597-03 27Operation Section

Features and Controls

Features and Controlsi03646563

Battery Disconnect Switch(If Equipped)SMCS Code: 1411

The battery disconnect switch and the engine startswitch perform different functions. Turn off the batterydisconnect switch in order to disable the entireelectrical system. The battery remains connected tothe electrical system when you turn off the enginestart switch.

Turn the battery disconnect switch to the OFFposition and remove the key when you service theelectrical system or any other components.

Also turn the battery disconnect switch to the OFFposition and remove the key when the engine will notbe used for an extended period of a month or more.This will prevent drainage of the battery.

NOTICENever move the battery disconnect switch to the OFFposition while the engine is operating. Serious dam-age to the electrical system could result.

To ensure that no damage to the engine occurs,verify that the engine is fully operational beforecranking the engine. Do not crank an engine that isnot fully operational.

Perform the following procedure in order to check thebattery disconnect switch for proper operation:

1. With the battery disconnect switch in the ONposition, verify that electrical components arefunctioning. Verify that the hour meter is displayinginformation. Verify that the engine will crank.

2. Turn the battery disconnect switch to the OFFposition.

3. Verify that the following items are not functioning:electrical components, hour meter, and enginecranking. If any of the items continue to functionwith the battery disconnect switch in the OFFposition, consult your Caterpillar dealer.

i04129351

Monitoring SystemSMCS Code: 1900; 7400; 7450; 7451

The monitoring system is designed to alert theoperator to an immediate problem with any of theengine systems that are monitored. The MonitoringSystem is also designed to alert the operator to animpending problem with any of the engine systemsthat are monitored.

The monitoring system parameters can be accessedvia the Cat ET service tool. Many of the parameterswithin the monitoring system can be tailored to suitthe operation of the engine.

An example of adjustments that may be made withinthe monitoring system is changing the setpoint of theengine overspeed indicator from the factory defaultsetting.

Indicators and GaugesThe instrument panel may look like the instrumentpanel that is pictured in illustration 25 or theinstrument panel may look like the instrument panelthat is pictured in illustration 26. The instrument panelmay not include all of the instruments that are shownin the illustration.


28 SEBU8597-03Operation SectionFeatures and Controls


Circuit Breaker (1) – Reset the circuitbreaker if a circuit breaker trips. Press thebutton in order to reset the circuit breaker. If

the electrical system is working properly, the buttonwill remain pressed. If the button does not remainpressed or if the circuit breaker trips soon after beingreset, check the appropriate electrical circuit. Repairthe electrical circuit, if necessary.

Resetting the circuit breakers in a flammable at-mosphere or a combustible atmosphere may leadto fire hazards or explosion hazards whichmay re-sult in personal injury or death. DO NOT reset thecircuit breaker when a flammable atmosphere or acombustible atmosphere is present and the pow-er has not been removed from the equipment.

Diesel Particulate Filter Lamp (2) –The DPF lamp will illuminate when aregeneration of the DPF is needed. Refer

to this Operation and Maintenance Manual, “DieselParticulate Filter Regeneration” for more informationon this lamp.

High Exhaust Temperature Lamp (3) –This lamp is illuminated when a DPFregeneration is active.

Regeneration Disabled (4) – This lampwill be illuminated if the regeneration ismanually disabled through the regeneration

switch or through the Cat (ET) service tool.

Start Switch (5) – The start switch hasthree positions: OFF, RUN, and START.When the start switch is turned clockwise to

the RUN position, the lamps will flash for 5 secondsduring the system test. The lamps will then shut off.In the RUN position, the ECM and electronic systemsare powered up.

Diagnostic Lamp (6) – The diagnosticlamp will illuminate when an active faultcode is present.

Shutdown Lamp (7) – The shutdownlamp will illuminate when a critical engineevent occurs which requires that the engine

be shut down. The event should be addressed asquickly as possible.

Shutdown Switch (8) – Use the engineshutdown switch in order to stop the engine.Push the shutdown switch in order to put

the switch in the OFF position. Moving the switch tothe OFF position will stop the engine. After the enginestops, turn the knob clockwise. Turning the knob willreset the engine shutdown switch to the ON position.

Service Hour Meter (9) – This gaugeindicates the total number of clock hoursof engine operation. Hours of operation

are logged in the ECM. A service tool is needed toretrieve the hours from the ECM. A Service HourMeter may be installed on the engine.

Idle Speed Switch (10) –When the switchis in the up position, the engine speedincreases to HIGH IDLE. When the switch

is in the down position, the engine speed decreasesto LOW IDLE.

Regeneration Switch (11) – Usedto activate a forced regeneration ormanually disable regeneration. Refer to

this Operation and Maintenance Manual, “DieselParticulate Filter Regeneration” for more informationon this switch.




High Speed Regeneration Enable Switch(12) – Pressing in and locking the “HIGH SPEEDREGENERATION ENABLE” switch enables anautomatic regeneration during normal engineoperation or normal engine working speed and load.If this switch is not in the IN and LOCKED position,an automatic regeneration may only occur when theengine is at the programmed low idle speed (lessthan 1500 rpm).

Tachometer (13) – This gauge indicatesengine speed (rpm). When the throttlecontrol lever is moved to the full throttle

position without load, the engine is running at highidle. The engine is running at the full load rpm whenthe throttle control lever is at the full throttle positionwith maximum rated load.

Voltmeter (14) – This gauge indicates thevoltage of the electrical system. The needlein the red range indicates low voltage or

high voltage.

Fuel Pressure (15) – This gauge indicatesfuel pressure to the fuel injection pump fromthe fuel filter. A decrease in fuel pressure

usually indicates a dirty fuel filter or a plugged fuelfilter. As the fuel filter becomes plugged, there willbe a noticeable reduction in the performance of theengine.

Engine Oil Pressure (16) – The oilpressure should be greatest after acold engine is started. The pressure will

decrease as the engine warms up. The pressure willincrease when the engine rpm is increased. Thepressure will stabilize when the engine rpm is stable.

A lower oil pressure is normal at low idle. If the loadis stable and the gauge reading changes, performthe following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

NOTICETo help prevent engine damage, never exceed thehigh idle rpm. An overspeed can result in serious dam-age to the engine. The engine can be operated at highidle without damage, but the engine should never beallowed to exceed the high idle rpm.

Note: The high idle rpm and the full load rpm arestamped on the Information Plate.

Jacket Water Coolant Temperature (17) –Typical temperature range is 87 to 98°C(189 to 208°F). Higher temperatures

may occur under certain conditions. The watertemperature reading may vary according to load. Thereading should never exceed the boiling point for thepressurized system that is being used.

Coolant Temperature (18) – When thecoolant temperature is above the normaloperating value, the coolant temperature

gauge will be in the red zone. Refer to the Messengerpanel for any additional information that may beavailable.

Warning Lamp (19) – There is a generalfault in the engine. Refer to the Messengerdisplay for any additional information that

may be available.

Service Tool Connector (20) – For more informationabout the use of Cat ET and the PC requirements forCat ET, refer to the documentation that accompaniesyour Cat ET software.

Mini Industrial Power Display(MIPD)The mini industrial power display provides for ameans to view various types of engine information.The information that can be viewed is describedbelow.

30 SEBU8597-03Operation SectionFeatures and Controls


“OK/Select” button (1) – The “OK/Select”button isused to confirm the selections that were made withthe “scroll left/right” buttons.

“Backlight” button (2) – This button is used to turnthe backlight of the display on or off.

“Scroll left/right button” (3) – This button is usedto advance through the various screens of the MIPD.

The MIPD comes with three preset user interfaces.The interfaces are labeled as “Operator_1”,“Operator_2”, and “Operator_3”.

“Operator_1” user interface is preset with variousengine, aftertreatment, and transmission informationover 14 screens. Diagnostic and system informationis also included. The information in “Operator_1” isdisplayed via ISO symbols and metric display units.

“Operator_2” user interface is preset with variousengine, aftertreatment, and transmission informationover 12 screens. Diagnostic and system informationis also included. The information is displayed inanalog style gauges and English display units.

“Operator_3” user interface is preset with variousengine, aftertreatment, and transmission informationover 12 screens. Diagnostic and system informationis also included. The information is displayed inanalog style gauges and English display units.

Note: Only use “Operator_1” and “Operator_2”interfaces on Tier 4 engines. The addedaftertreatment parameters in these interfaces arenecessary to ensure proper operation.

Parameters

Below are a list of all the parameters that areviewable through the three user interfaces usedwithin the MIPD.

Engine Speed – Displays the current engine speedin RPM.

Coolant Temperature – Displays the current coolanttemperature of the engine.

Engine Load – Displays the amount of load on theengine as a percentage.

Regen Disable Status – Displays whether theregeneration is manually disabled.

DPF Lamp – Displays when a DPF regeneration isneeded.

Soot Loading – Displays the amount of soot withinthe DPF as a percentage.

Air Inlet Temperature – Displays the temperature ofthe air entering the engine through the air filter.

Intake Manifold Air Temperature – Displays thetemperature of the air entering the engine at theintake manifold.

Boost Pressure – Displays the amount of pressureof the air entering the intake manifold of the engine.

Crankcase Pressure – Displays the amount ofpressure within the crankcase of the engine.

Atmospheric Pressure – Displays the amount ofatmospheric pressure that the engine is operating in.

Fuel Temp – Displays the temperature of the fuelentering the engine.

Fuel Rate – Displays the amount of fuel being usedby the engine.

Filtered Fuel Delta Pressure – Displays thepressure across the fuel filter.

Low Idle RPM – Displays the low idle speed setpointin RPM.

Hi Idle Speed – Displays the high idle speedsetpoint in RPM.

Desired Speed – Displays the desired engine speedin RPM.

Primary Throttle – Displays the primary throttleposition as a percentage.

Secondary Throttle – Displays the secondarythrottle position as a percentage.

Auxiliary Pressure Sensor 1 – Displays thepressure being measured by the #1 auxiliary sensorif one is being used.



Auxiliary Temperature Sensor 1 – Displays thetemperature being measured by the #1 auxiliarysensor if one is being used.

Battery Voltage – Displays the battery voltage.

Aftertreatment 1 Regeneration Status – Displaysthe status of the regeneration system as manual orautomatic.

HEST Lamp – Illuminates when a DPF regenerationis active.

DPF Intake Temperature – Displays thetemperature of the exhaust gas entering the DPF.

DPF Outlet Temperature – Displays thetemperature of the exhaust gas leaving the DPF.

Transmission Selected Gear – Displays thetransmission gear being requested.

Transmission Requested Gear – Displays thetransmission gear being requested.

Transmission Oil Pressure – Displays the oilpressure inside the transmission.

Transmission Oil Temperature – Displays the oiltemperature of the transmission.

Transmission Torque Limit – Displays the limit oftorque allowed by the transmission.

System Information

User Name – Displays the preset user name thatis selected.

Software Version – Displays the version of softwarethat is programmed in the MIPD.

Serial Number – Displays the serial number of theMIPD.

Display Units – Displays the units of measurementthat is selected for the given user.

Engine Location – Displays which engine data isbeing reported if more than one engine is connectedto the MIPD.

Language – Displays the selected language.

Alarm – Indicates whether audible alarm is set toON or OFF when an audible alarm is connected tothe MIPD.

32 SEBU8597-03Operation SectionEngine Diagnostics

Engine Diagnosticsi01563934

Self-DiagnosticsSMCS Code: 1000; 1900; 1901; 1902

Caterpillar Electronic Engines have the capability toperform a self-diagnostics test. When the systemdetects an active problem, the “DIAGNOSTIC”lamp is activated. Diagnostic codes will be stored inpermanent memory in the Electronic Control Module(ECM). The diagnostic codes can be retrieved byusing the following components:

• Caterpillar electronic service tools

• “DIAGNOSTIC” lamp

Note: The “DIAGNOSTIC” lamp must be installed bythe OEM or by the customer.

Some installations have electronic displays thatprovide direct readouts of the engine diagnosticcodes. Refer to the manual that is provided by theOEM for more information on retrieving enginediagnostic codes.

Active codes represent problems that currently exist.These problems should be investigated first. If a codeis active, the “DIAGNOSTIC” lamp will flash the flashcode at five second intervals.

Logged codes represent the following items:

• Intermittent problems

• Recorded events

• Performance history

The problems may have been repaired since thelogging of the code. These codes do not indicate thata repair is needed. The codes are guides or signalswhen a situation exists. Codes may be helpful totroubleshoot problems.

When the problems have been corrected, thecorresponding logged fault codes should be cleared.

i04224569

Diagnostic Flash CodeRetrievalSMCS Code: 1000; 1900; 1901; 1902

In order to read the diagnostic flash codes throughthe diagnostic lamp, cycle the key switch from off toon twice within 3 seconds.

The codes will be flashing in sequence. For exampleif the flash code equals 133, the diagnostic lamp willflash once, pause, flash three times, pause, and flashthree times.

After the complete code has flashed, a 3 secondpause will take place before the next code will beginto flash (if another code is present).

Note: Always refer to the Troubleshooting guidefor the latest information related to enginediagnostics and troubleshooting. Contact yourlocal Cat dealer for more information.

SEBU8597-03 33Operation SectionEngine Diagnostics

Table 3

Cross Reference for Diagnostic Codes and Event Codes

FlashCode SPN(1)/FMI Code

Diagnostic Codeor

Event CodeDescription of Code

651-5 1-5 Engine Injector Cylinder #1 : Current Below Normal651-6 1-6 Engine Injector Cylinder #1 : Current Above Normal3959-5 2602-5 Engine Injector Cylinder #1 Actuator #2: Current Below Normal

111/139

3959-6 2602-6 Engine Injector Cylinder #1 Actuator #2: Current Above Normal652-5 2-5 Engine Injector Cylinder #2 : Current Below Normal652-6 2-6 Engine Injector Cylinder #2 : Current Above Normal3660-5 2604-5 Engine Injector Cylinder #2 Actuator #2: Current Below Normal

112/139


113/139


114/139


115/139


116/139

3664-6 2612-6 Engine Injector Cylinder #6 Actuator #2: Current Above Normal105-15 539 (1) Engine Intake Manifold #1 Temperature : High - least severe (1)

105-16 539 (2) Engine Intake Manifold #1 Temperature : High -moderate severity (2)

110-3 110-3 Engine Coolant Temperature : Voltage Above Normal110-4 110-4 Engine Coolant Temperature : Voltage Below Normal172-3 2526-3 Engine Air Inlet Temperature : Voltage Above Normal

133

172-4 2526-4 Engine Air Inlet Temperature : Voltage Below Normal

135 102-18 1045 (2) Engine Intake Manifold #1 Pressure : Low - moderate severity (2)190-8 190-8 Engine Speed : Abnormal Frequency, Pulse Width, or Period190-0 362 (3) Engine Speed : High - most severe (3)141

190-15 362 (1) Engine Speed : High - least severe (1)

142 723-8 342-8 Engine Speed Sensor #2 : Abnormal Frequency,Pulse Width, or Period

637-11 261-11 Engine Timing Sensor : Other Failure Mode143

637-13 261-13 Engine Timing Sensor : Calibration Required(continued)


(Table 3, contd)



Diagnostic Codeor


100-3 100-3 Engine Oil Pressure : Voltage Above Normal

100-4 100-4 Engine Oil Pressure : Voltage Below Normal

108-3 274-3 Barometric Pressure : Voltage Above Normal152

108-4 274-4 Barometric Pressure : Voltage Below Normal

100-1 360 (3) Engine Oil Pressure : Low - most severe (3)

100-17 360 (1) Engine Oil Pressure : Low - least severe (1)157

100-18 360 (2) Engine Oil Pressure : Low - moderate severity (2)

174-3 174-3 Engine Fuel Temperature 1 : Voltage Above Normal

174-4 174-4 Engine Fuel Temperature 1 : Voltage Below Normal165

174-15 363 (1) Engine Fuel Temperature 1 : High - least severe (1)

110-15 361 (1) Engine Coolant Temperature : High - least severe (1)168

110-16 361 (2) Engine Coolant Temperature : High - moderate severity (2)

3241-4 3485-4 Exhaust Gas Temperature 1 : Voltage Below Normal186

3241-3 3485-3 Exhaust Gas Temperature 1 : Voltage Above Normal

100-13 100-13 Engine Oil Pressure : Calibration Required

108-13 274-13 Barometric Pressure : Calibration Required

3358-13 3385-13 Engine Exhaust Gas Recirculation Inlet Pressure: Calibration Required

3563-3 1785-3 Engine Intake Manifold #1 Absolute Pressure : VoltageAbove Normal

3563-4 1785-4 Engine Intake Manifold #1 Absolute Pressure : VoltageBelow Normal

197

3563-13 1785-13 Engine Intake Manifold #1 Absolute Pressure : Calibration Required

168-2 168-2 Battery Potential / Power Input 1 : Erratic, Intermittent, or Incorrect

168-3 168-3 Battery Potential / Power Input 1 : Voltage Above Normal422

168-4 168-4 Battery Potential / Power Input 1 : Voltage Below Normal

439 158-2 1834-2 Keyswitch Battery Potential : Erratic, Intermittent, or Incorrect

3509-3 262-3 Sensor Supply Voltage 1 : Voltage Above Normal

3509-4 262-4 Sensor Supply Voltage 1 : Voltage Below Normal

3510-3 2131-3 Sensor Supply Voltage 2 : Voltage Above Normal516

3510-4 2131-4 Sensor Supply Voltage 2 : Voltage Below Normal

527 630-2 268-2 Calibration Memory : Erratic, Intermittent, or Incorrect

NA 94-16 1218 (2) Engine Fuel Delivery Pressure : High - moderate severity (2)

NA 101-3 101-3 Engine Crankcase Pressure : Voltage Above Normal

NA 101-4 101-4 Engine Crankcase Pressure : Voltage Below Normal

NA 101-13 101-13 Engine Crankcase Pressure : Calibration Required

NA 101-15 1036 (1) Engine Crankcase Pressure : High - least severe (1)

NA 101-16 1036 (2) Engine Crankcase Pressure : High - moderate severity (2)

NA 105-0 539 (3) Engine Intake Manifold #1 Temperature : High - most severe (3)

NA 108-21 274-21 Barometric Pressure : Data Drifted Low

NA 110-0 361 (3) Engine Coolant Temperature : High - most severe (3)(continued)


(Table 3, contd)



Diagnostic Codeor


NA 152-0 254-0 Number Of ECU Resets : High - most severe (3)

NA 152-1 254-1 Number Of ECU Resets : Low - most severe (3)

NA 152-2 254-2 Number Of ECU Resets : Erratic, Intermittent, or Incorrect

NA 152-3 254-3 Number Of ECU Resets : Voltage Above Normal

NA 152-4 254-4 Number Of ECU Resets : Voltage Below Normal

NA 152-5 254-5 Number Of ECU Resets : Current Below Normal

NA 152-6 254-6 Number Of ECU Resets : Current Above Normal

NA 152-7 254-7 Number Of ECU Resets : Not Responding Properly

NA 152-8 254-8 Number Of ECU Resets : Abnormal Frequency,Pulse Width, or Period

NA 152-9 254-9 Number Of ECU Resets : Abnormal Update Rate

NA 152-10 254-10 Number Of ECU Resets : Abnormal Rate of Change

NA 152-11 254-11 Number Of ECU Resets : Other Failure Mode

NA 152-12 254-12 Number Of ECU Resets : Failure

NA 152-13 152-13 Number Of ECU Resets : Calibration Required

NA 173-15 E194(2) High Exhaust Temperature

NA 174-0 363 (3) Engine Fuel Temperature 1 : High - most severe (3)

NA 174-16 363 (2) Engine Fuel Temperature 1 : High - moderate severity (2)

NA 411-3 3387-3 Engine Exhaust Gas Recirculation Differential Pressure: Voltage Above Normal

NA 411-4 3387-4 Engine Exhaust Gas Recirculation Differential Pressure: Voltage Below Normal

NA 411-13 3387-13 Engine Exhaust Gas Recirculation Differential Pressure: Calibration Required

NA 411-15 1094 (1) Engine Exhaust Gas Recirculation Differential Pressure: High - least severe (1)

NA 411-17 1093 (1) Engine Exhaust Gas Recirculation Differential Pressure: Low - least severe (1)

NA 412-3 3386-3 Engine Exhaust Gas Recirculation Temperature :Voltage Above Normal

NA 412-4 3386-4 Engine Exhaust Gas Recirculation Temperature :Voltage Below Normal

NA 412-15 1092 (1) Engine Exhaust Gas Recirculation Temperature :High - least severe (1)

NA 412-16 1092 (2) Engine Exhaust Gas Recirculation Temperature : High- moderate severity (2)

NA 626-5 2417-5 Engine Start Enable Device 1 : Current Below Normal

NA 626-6 2417-6 Engine Start Enable Device 1 : Current Above Normal

NA 678-3 41-3 ECU 8 Volts DC Supply : Voltage Above Normal

NA 678-4 41-4 ECU 8 Volts DC Supply : Voltage Below Normal

NA 1239-0 499 (3) Engine Fuel Leakage 1 : High - most severe (3)

NA 2630-3 3372-3 Engine Charge Air Cooler Outlet Temperature : VoltageAbove Normal

(continued)


(Table 3, contd)



Diagnostic Codeor


NA 2630-4 3372-4 Engine Charge Air Cooler Outlet Temperature :Voltage Below Normal

NA 2659-15 1096 (1) Engine Exhaust Gas Recirculation (EGR) Mass FlowRate : High - least severe (1)

NA 2659-17 1095 (1) Engine Exhaust Gas Recirculation (EGR) Mass FlowRate : Low - least severe (1)

NA 2791-5 3405-5 Engine Exhaust Gas Recirculation (EGR) Valve Control: Current Below Normal

NA 2791-6 3405-6 Engine Exhaust Gas Recirculation (EGR) Valve Control: Current Above Normal

NA 3242-3 2452-3 Particulate Trap Intake Gas Temperature : Voltage Above Normal

NA 3242-4 2452-4 Particulate Trap Intake Gas Temperature : Voltage Below Normal

NA 3242-15 1008 (1) Particulate Trap Intake Gas Temperature : High - least severe (1)

NA 3242-16 1008 (2) Particulate Trap Intake Gas Temperature : High- moderate severity (2)

NA 3242-18 1014 (2) Particulate Trap Intake Gas Temperature : Low -moderate severity (2)

NA 3251-2 2458-2 Particulate Trap Differential Pressure : Erratic,Intermittent, or Incorrect

NA 3251-3 2458-3 Particulate Trap Differential Pressure : Voltage Above Normal

NA 3251-4 2458-4 Particulate Trap Differential Pressure : Voltage Below Normal

NA 3251-13 2458-13 Particulate Trap Differential Pressure : Calibration Required

NA 3358-3 3385-3 Engine Exhaust Gas Recirculation Inlet Pressure :Voltage Above Normal

NA 3358-4 3385-4 Engine Exhaust Gas Recirculation Inlet Pressure :Voltage Below Normal

NA 3358-16 1090 (2) Engine Exhaust Gas Recirculation Inlet Pressure :High - moderate severity (2)

NA 3358-21 3385-21 Engine Exhaust Gas Recirculation Inlet Pressure : Data Drifted LowNA 3473-31 1025 (2) Aftertreatment #1 Failed to IgniteNA 3474-14 1026 (1) Aftertreatment #1 Loss of Combustion : Special InstructionNA 3474-31 1026 (2) Aftertreatment #1 Loss of CombustionNA 3479-5 2461-5 Aftertreatment #1 Fuel Pressure Control : Current Below NormalNA 3479-6 2461-6 Aftertreatment #1 Fuel Pressure Control : Current Above NormalNA 3480-3 2460-3 Aftertreatment #1 Fuel Pressure #1 : Voltage Above NormalNA 3480-4 2460-4 Aftertreatment #1 Fuel Pressure #1 : Voltage Below NormalNA 3480-15 1050 (1) Aftertreatment #1 Fuel Pressure #1 : High - least severe (1)NA 3480-16 1050 (2) Aftertreatment #1 Fuel Pressure #1 : High - moderate severity (2)NA 3480-17 1052 (1) Aftertreatment #1 Fuel Pressure #1 : Low - least severe (1)NA 3480-18 1052 (2) Aftertreatment #1 Fuel Pressure #1 : Low - moderate severity (2)NA 3483-11 1305 (1) Aftertreatment #1 Regeneration Status : Other Failure ModeNA 3484-5 2465-5 Aftertreatment #1 Ignition : Current Below NormalNA 3484-6 2465-6 Aftertreatment #1 Ignition : Current Above NormalNA 3487-5 2489-5 Aftertreatment #1 Air Pressure Control : Current Below Normal

(continued)


(Table 3, contd)



Diagnostic Codeor


NA 3487-6 2489-6 Aftertreatment #1 Air Pressure Control : Current Above Normal

NA 3487-7 2489-7 Aftertreatment #1 Air Pressure Control : Not Responding Properly

NA 3487-8 2489-8 Aftertreatment #1 Air Pressure Control : AbnormalFrequency, Pulse Width, or Period

NA 3488-3 2490-3 Aftertreatment #1 Air Pressure Actuator Position :Voltage Above Normal

NA 3488-4 2490-4 Aftertreatment #1 Air Pressure Actuator Position :Voltage Below Normal

NA 3511-3 3482-3 Sensor Supply Voltage 3 : Voltage Above NormalNA 3511-4 3482-4 Sensor Supply Voltage 3 : Voltage Below NormalNA 3556-7 1070 (1) Aftertreatment Fuel Injector #1 : Not Responding ProperlyNA 3563-21 1785-21 Engine Intake Manifold #1 Absolute Pressure : Data Drifted LowNA 3609-3 3464-3 DPF #1 Intake Pressure : Voltage Above NormalNA 3609-4 3464-4 DPF #1 Intake Pressure : Voltage Below NormalNA 3609-13 3464-13 DPF #1 Intake Pressure : Calibration RequiredNA 3609-15 1156 (1) DPF #1 Intake Pressure : High - least severe (1)NA 3609-17 1154 (1) DPF #1 Intake Pressure : Low - least severe (1)NA 3609-21 3464-21 DPF #1 Intake Pressure : Data Drifted LowNA 3703-31 993 (20) Particulate Trap Active Regeneration Inhibited Due to Inhibit Switch

NA 3711-31 593 (2) Particulate Trap Active Regeneration Inhibited Due toLow Exhaust Gas Temperature

NA 3714-31 992 (3) Particulate Trap Active Regeneration Inhibited Due toTemporary System Lockout

NA 3715-31 991 (3) Particulate Trap Active Regeneration Inhibited Due toPermanent System Lockout

NA 3719-0 995 (3) Particulate Trap #1 Soot Load Percent : High - most severe (3)NA 3719-16 995 (2) Particulate Trap #1 Soot Load Percent : High - moderate severity (2)NA 3720-15 997 (1) Particulate Trap #1 Ash Load Percent : High - least severe (1)NA 3720-16 997 (2) Particulate Trap #1 Ash Load Percent : High - moderate severity (2)NA 3750-31 1239 (1) DPF #1 Conditions Not Met for Active RegenerationNA 3837-3 3493-3 Aftertreatment 1 Secondary Air Pressure : Voltage Above NormalNA 3837-4 3493-4 Aftertreatment 1 Secondary Air Pressure : Voltage Below NormalNA 3837-13 3493-13 Aftertreatment 1 Secondary Air Pressure : Calibration RequiredNA 3837-17 1170 (1) Aftertreatment 1 Secondary Air Pressure : Low - least severe (1)NA 3837-21 3493-21 Aftertreatment 1 Secondary Air Pressure : Data Drifted LowNA 4077-3 2497-3 Aftertreatment #1 Fuel Pressure #2 : Voltage Above NormalNA 4077-4 2497-4 Aftertreatment #1 Fuel Pressure #2 : Voltage Below NormalNA 4077-15 1051 (1) Aftertreatment #1 Fuel Pressure #2 : High - least severe (1)NA 4077-16 1051 (2) Aftertreatment #1 Fuel Pressure #2 : High - moderate severity (2)NA 4077-17 1053 (1) Aftertreatment #1 Fuel Pressure #2 : Low - least severe (1)NA 4077-18 1053 (2) Aftertreatment #1 Fuel Pressure #2 : Low - moderate severity (2)

NA 4265-5 3180-5 Aftertreatment #1 Transformer Secondary Output :Current Below Normal

(continued)


(Table 3, contd)



Diagnostic Codeor


NA 4301-5 3182-5 Aftertreatment #1 Fuel Injector #1 Heater Control :Current Below Normal

NA 4301-6 3182-6 Aftertreatment #1 Fuel Injector #1 Heater Control :Current Above Normal

NA 4783-3 3397-3 DPF #1 Mean Soot Signal : Voltage Above Normal

NA 4783-4 3397-4 DPF #1 Mean Soot Signal : Voltage Below Normal

NA 4783-9 3397-9 DPF #1 Mean Soot Signal : Abnormal Update Rate

NA 4783-12 3397-12 DPF #1 Mean Soot Signal : Failure

NA 4783-13 3397-13 DPF #1 Mean Soot Signal : Calibration Required

NA 4783-19 3397-19 DPF #1 Mean Soot Signal : Data Error

NA 4783-21 3397-21 DPF #1 Mean Soot Signal : Data Drifted Low

NA 5276-5 3409-5 Engine Exhaust Manifold Bank #1 Flow Balance ValveActuator Control : Current Below Normal

NA 5276-6 3409-6 Engine Exhaust Manifold Bank #1 Flow Balance ValveActuator Control : Current Above Normal

NA 5276-7 1123 (1) Engine Exhaust Manifold Bank #1 Flow Balance ValveActuator Control : Not Responding Properly

NA 5423-5 3427-5 Aftertreatment #1 Fuel Pump Relay Control : Current Below Normal

NA 5423-6 3427-6 Aftertreatment #1 Fuel Pump Relay Control : Current Above Normal

NA 5424-5 3413-5 Aftertreatment #1 Fuel Flow Diverter Valve Control: Current Below Normal

NA 5424-6 3413-6 Aftertreatment #1 Fuel Flow Diverter Valve Control: Current Above Normal

NA 5425-5 3391-5 Aftertreatment #1 Fuel Pressure #2 Actuator Control: Current Below Normal

NA 5425-6 3391-6 Aftertreatment #1 Fuel Pressure #2 Actuator Control: Current Above Normal

NA 5495-14 3397-14 Aftertreatment #1 DPF Soot Mean Calibration Offset: Special Instruction

NA 5576-2 3468-2 Aftertreatment #1 Identification : Erratic, Intermittent, or Incorrect

NA 5576-8 3468-8 Aftertreatment #1 Identification : Abnormal Frequency,Pulse Width, or Period

NA 5576-14 3468-14 Aftertreatment #1 Identification : Special InstructionNA 5578-3 289-3 Engine Fuel Delivery Absolute Pressure : Voltage Above Normal

NA 5578-4 289-4 Engine Fuel Delivery Absolute Pressure : Voltage Below Normal

NA 5578-13 289-13 Engine Fuel Delivery Absolute Pressure : Calibration RequiredNA 5578-21 289-21 Engine Fuel Delivery Absolute Pressure : Data Drifted Low

NA 5580-3 460-3 Engine Filtered Fuel Delivery Absolute Pressure :Voltage Above Normal

NA 5580-4 460-4 Engine Filtered Fuel Delivery Absolute Pressure :Voltage Below Normal

NA 5580-13 460-13 Engine Filtered Fuel Delivery Absolute Pressure: Calibration Required

NA 5580-16 96 (2) Engine Filtered Fuel Delivery Absolute Pressure: High- moderate severity (2)

(continued)


(Table 3, contd)



Diagnostic Codeor


NA 5580-18 198 (2) Engine Filtered Fuel Delivery Absolute Pressure : Low- moderate severity (2)

NA 5580-21 460-21 Engine Filtered Fuel Delivery Absolute Pressure : Data Drifted Low

NA 5584-0 390 (3) Fuel Filter Restriction : High - most severe (3)

NA 5584-15 390 (1) Fuel Filter Restriciton : Low - least severe (1)

NA 5584-16 390 (2) Fuel Filter Restriction : Low - moderate severity (2)

NA 5591-3 3472-3 Aftertreatment #1 DPF Air Control Module : Voltage Above Normal

NA 5591-4 3472-4 Aftertreatment #1 DPF Air Control Module : Voltage Below Normal

NA 5591-5 3471-5 Aftertreatment #1 DPF Air Control Module : Current Below Normal

NA 5591-6 3471-6 Aftertreatment #1 DPF Air Control Module : Current Above Normal

NA 5591-9 3472-9 Aftertreatment #1 DPF Air Control Module : Abnormal Update Rate

NA 5591-14 3472-14 Aftertreatment #1 DPF Air Control Module : Special Instruction(1) Suspect Parameter Number

Flash Code – A code that will be flashed throughthe diagnostic lamp in a sequence.

SPN/FMI Code – This type of code is used onproducts equipped with the J1939 communicationprotocol. The code will be displayed in this formaton Cat ET and the mini industrial display panel (ifequipped).

Diagnostic Code or Event Code – These typesof codes are used when the proprietary Cat CDLcommunication protocol is used. The codes will bedisplayed in this format on Cat Electronic Technician(ET) or the mini industrial display panel (if equipped).

Code Description – Provides a description of thesystem or component on the engine that has thefault. Code description will be displayed on Cat ET orthe mini industrial display panel (if equipped).

Note: Code descriptions may vary slightly betweenJ1939 and CDL communication protocols.

i03840813

Fault LoggingSMCS Code: 1000; 1900; 1901; 1902

The system provides the capability of Fault Logging.When the Electronic Control Module (ECM)generates an active diagnostic code, the code will belogged in the memory of the ECM. The codes thathave been logged in the memory of the ECM canbe retrieved with Caterpillar electronic service tools.The codes that have been logged can be clearedwith Caterpillar electronic service tools. The codesthat have been logged in the memory of the ECMwill be automatically cleared from the memory after100 hours. The following faults cannot be clearedfrom the memory of the ECM without using a factorypassword: overspeed, low engine oil pressure, andhigh engine coolant temperature.

40 SEBU8597-03Operation SectionEngine Starting

Engine Startingi02109067

Before Starting EngineSMCS Code: 1000; 1400; 1450

Perform the required daily maintenance and otherperiodic maintenance before the engine is started.Inspect the engine compartment. This inspection canhelp prevent major repairs at a later date. Refer to theOperation and Maintenance Manual, “MaintenanceInterval Schedule” for more information.

• For the maximum service life of the engine, makea thorough inspection before the engine is started.Look for the following items: oil leaks, coolantleaks, loose bolts, and trash buildup. Remove trashbuildup and arrange for repairs, as needed.

• Inspect the aftercooler for loose connections andfor debris buildup.

• Inspect the cooling system hoses for cracks andfor loose clamps.

• Inspect the alternator and accessory drive belts forcracks, breaks, and other damage.

• Inspect the wiring for loose connections and forworn wires or frayed wires.

• Check the fuel supply. Drain water from the waterseparator (if equipped). Open the fuel supply valve.

NOTICEAll valves in the fuel return line must be open beforeand during engine operation to help prevent high fuelpressure. High fuel pressure may cause filter housingfailure or other damage.

If the engine has not been started for several weeks,fuel may have drained from the fuel system. Airmay have entered the filter housing. Also, when fuelfilters have been changed, some air pockets will betrapped in the engine. In these instances, prime thefuel system. Refer to the Operation and MaintenanceManual, “Fuel System - Prime” for more informationon priming the fuel system.


• Do not start the engine or move any of the controlsif there is a “DO NOT OPERATE” warning tag orsimilar warning tag attached to the start switch orto the controls.

• Ensure that the areas around the rotating parts areclear.

• All of the guards must be put in place. Check fordamaged guards or for missing guards. Repairany damaged guards. Replace damaged guardsand/or missing guards.

• Disconnect any battery chargers that are notprotected against the high current drain thatis created when the electric starting motor (ifequipped) is engaged. Check electrical cablesand check the battery for poor connections andfor corrosion.

• Reset all of the shutoffs or alarm components.

• Check the engine lubrication oil level. Maintain theoil level between the “ADD” mark and the “FULL”mark on the oil level gauge.

• Check the coolant level. Observe the coolant levelin the coolant recovery tank (if equipped). Maintainthe coolant level to the “FULL” mark on the coolantrecovery tank.

• If the engine is not equipped with a coolantrecovery tank maintain the coolant level within13 mm (0.5 inch) of the bottom of the filler pipe. Ifthe engine is equipped with a sight glass, maintainthe coolant level in the sight glass.

• Observe the air cleaner service indicator (ifequipped). Service the air cleaner when the yellowdiaphragm enters the red zone, or when the redpiston locks in the visible position.

• Ensure that any driven equipment has beendisengaged. Minimize electrical loads or removeany electrical loads.

SEBU8597-03 41Operation SectionEngine Starting

i04132731

Cold Weather StartingSMCS Code: 1000; 1250; 1450; 1453; 1456; 1900

Startability will be improved at temperatures below10°C (50°F) from the use of a cylinder block coolantheater or from other means that are used to heatthe crankcase oil. Some engine applications use ajacket water heater to improve startability. Use of ajacket water heater will help reduce white smoke andmisfire during start-up in cold weather.

Note: If the engine has not been run for severalweeks, fuel may have drained. Air may have movedinto the filter housing. Also, when fuel filters havebeen changed, some air will be left in the filterhousing. Refer to the Operation and MaintenanceManual, “Fuel System - Prime” (Maintenance Section)for more information on priming the fuel system.

Ether Injection System (IfEquipped)The ether injection system is controlled by theECM. The ECM monitors the coolant temperature,intake air temperature, ambient air temperature,and barometric pressure to determine when etherinjection is needed. At sea level, ether will be usedif any of the temperatures fails to exceed 0° C(32° F). This temperature is subject to an increase asbarometric pressure increases.

Personal injury or property damage can resultfrom alcohol or starting fluids.

Alcohol or starting fluids are highly flammable andtoxic and if improperly stored could result in injuryor property damage.

Follow the procedure in this Operation andMaintenance Manual, “Starting the Engine”.

i04032033

Starting the EngineSMCS Code: 1000; 1450


Starting the EngineRefer to the Owner's Manual of the OEM for yourtype of controls. Use the following procedure to startthe engine.

1. Place the transmission in NEUTRAL. Disengagethe flywheel clutch in order to allow the engineto start faster, and to reduce the draining of thebattery.

2. Turn the ignition switch to the ON position.

During the key on, the diagnostic lamp, warninglamp, regeneration lamps, and DPF disabled lampwill be checked for proper bulb operation. If any ofthe lamps do not illuminate, replace the bulb.

NOTICEDo not engage the starting motor when flywheel isturning. Do not start the engine under load.

If the engine fails to start within 30 seconds, releasethe starter switch or button and wait two minutes toallow the starting motor to cool before attempting tostart the engine again.

3. Push the start button or turn the ignition switch tothe START position in order to crank the engine.

Do not push down or hold the throttle downwhile the engine is cranked. The system willautomatically provide the correct amount of fuelthat is needed to start the engine.

4. If the engine fails to start within 30 seconds,release the start button, or the ignition switch. Waitfor 2 minutes in order to allow the starting motor tocool before attempting to start the engine again.


NOTICEOil pressure should rise within 15 seconds after theengine starts. Do not increase engine rpm until the oilpressure gauge indicates normal. If oil pressure is notindicated on the gauge within 15 seconds, DO NOToperate the engine. STOP the engine, investigate andcorrect the cause.

5. Allow the engine to idle for approximately3 minutes. Idle the engine until the watertemperature gauge has begun to rise. Check allgauges during the warm-up period.

Note: Oil pressures and fuel pressures should be inthe normal range on the instrument panel. Enginesthat are equipped with “WARNING” lamps do nothave an operating range. The “WARNING andDIAGNOSTIC” lamp (if equipped) will flash whilethe engine is cranking. The lamp should turn offafter proper engine oil pressure or fuel pressureis achieved. Do not apply a load to the engine orincrease engine rpm until the oil pressure gaugeindicates at least normal pressure. Inspect the enginefor leaks and/or unusual noises.

If the engine is operated with a low load, the enginewill reach normal operating temperature sooner thanidling the engine with no load. When the engine isidled in cold weather, increase the engine rpm toapproximately 1000 to 1200 rpm in order to warmup the engine more quickly. Do not exceed therecommended rpm in order to increase the speedof the warm-up. Limit unnecessary idle time to 10minutes.

Starting ProblemsAn occasional starting problem may be caused byone of the following items:

• Low battery charge

• Lack of fuel

• Problem with the wiring harness

If the engine fuel system has been run dry, fill thefuel tank and prime the fuel system. Refer to theOperation and Maintenance Manual, “Fuel System -Prime” topic (Maintenance Section).

If the other problems are suspected, perform theappropriate procedure in order to start the engine.

Problems with the Wiring Harness

g01248812Illustration 29ECM Connector J2/P2

Locate the ECM. Check the connector in order toensure that the connector is secure. Lightly pull eachof the wires in the chassis harness.

1. Pull each wire with approximately 4.5 kg (10 lb) offorce. The wire should remain in the connector.

2. If a wire is loose, push the wire back into theconnector. Pull the wire again in order to ensurethat the wire is secure.

3. Start the engine. If the engine does not start,consult the nearest Caterpillar dealer forassistance.

SEBU8597-03 43Operation SectionEngine Starting

i04292191

Starting with Jump StartCables(Do Not Use This Procedure inHazardous Locations that haveExplosive Atmospheres)SMCS Code: 1000; 1401; 1402; 1900

The connection of battery cables to a battery andthe disconnection of battery cables from a batterymay cause an explosion whichmay result in injuryor death. The connection and the disconnectionof other electrical equipment may also cause anexplosion which may result in injury or death. Theprocedures for the connection and the disconnec-tion of battery cables and other electrical equip-ment should only be performed in a nonexplosiveatmosphere.

Improper jump start cable connections can causean explosion resulting in personal injury.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jump startcable ends to contact each other or the engine.

If the installation is not equipped with a backupbattery system, starting the engine from an externalelectrical source may be necessary.

First, determine the reason that starting the enginefrom an external electrical source is necessary. Referto Troubleshooting, KENR6849, “C13, C15, and C18Industrial Engines”.

Many batteries which are considered unusableare still rechargeable. After jump starting, thealternator may not be able to recharge batteriesthat are severely discharged. The batteries must becharged to the proper voltage with a battery charger.For information on testing and charging, refer tothe Special Instruction, SEHS7633, “Battery TestProcedure”.

NOTICEUsing a battery source with the same voltage as theelectric starting motor. Use ONLY equal voltage forjump starting. The use of higher voltage will damagethe electrical system.

Do not reverse the battery cables. The alternator canbe damaged. Attach ground cable last and removefirst.

When using an external electrical source to start theengine, turn the generator set control switch to the“OFF” position. Turn all electrical accessories OFF be-fore attaching the jump start cables.

Ensure that the main power switch is in the OFF posi-tion before attaching the jump start cables to the en-gine being started.

1. Turn the start switch on the stalled engine to OFF.Turn off all accessories.

2. Connect one positive end of the jump-start cableto the positive cable terminal of the dischargedbattery. Connect the other positive end of thejump-start cable to the positive cable terminal ofthe electrical source.

3. Connect one negative end of the jump-start cableto the negative cable terminal of the electricalsource. Connect the other negative end of thejump-start cable to the engine block or to thechassis ground. This procedure helps to preventpotential sparks from igniting combustible gasesthat are produced by some batteries.

4. Charge the batteries. The engine will not continueto run after starting if the batteries have not beencharged.

5. Start the engine.

6. Immediately after the stalled engine is started,disconnect the jump-start cables in reverse order.

Refer to the Electrical Schematic for your engine.Consult your Caterpillar dealer for more information.


i04285941

After Starting EngineSMCS Code: 1000

Note: In temperatures from 0 to 60°C (32 to 140°F),the warm-up time is approximately 3 minutes. Intemperatures below 0°C (32°F), additional warm-uptime may be required.

When the engine is idling during warm-up, observethe following conditions:

• Check for fluid or air leaks at idle rpm and atone-half full rpm (no load on the engine) beforeoperating the engine under load. Operating theengine at idle and at one-half full rpm with no loadis not possible in some applications.

• Operate the engine at low idle until all systemsachieve operating temperatures. Check all gaugesduring the warm-up period.

Note: Gauge readings should be observed andthe data should be recorded frequently while theengine is operating. Comparing the data over timewill help to determine normal readings for eachgauge. Comparing data over time will also helpdetect abnormal operating developments. Significantchanges in the readings should be investigated.

Extended Idle at Cold AmbientTemperatureThe engine may automatically change speeds whenthe engine is idling in cold ambient temperatures(typically less than 0° C (32° F) for extended periods.The purpose of the automatic speed change isthreefold: to maintain the desired operation of theNOx reduction system, to maintain the desiredoperation of the regeneration system, and to keepthe engine coolant warm. The engine speed may riseto 1600 rpm for as long as 20 minutes.

The high exhaust system temperature lamp mayilluminate during extended idling conditions. Thisillumination signals that a diesel particulate filter(DPF) regeneration is in progress. Regenerationsduring cold ambient extended idling conditionsmay activate when the soot level is below 30%.Regenerations during cold ambient extended idlingmay only last up to 10 minutes.

SEBU8597-03 45Operation SectionEngine Operation

Engine Operationi00718869

Engine OperationSMCS Code: 1000

Proper operation and maintenance are key factorsin obtaining the maximum life and economy ofthe engine. If the directions in the Operation andMaintenance Manual are followed, costs can beminimized and engine service life can be maximized.

The time that is needed for the engine to reachnormal operating temperature can be less than thetime needed for a walk-around inspection of theengine.

After the engine is started and after the enginereaches normal operating temperature, the enginecan be operated at the rated rpm. The engine willreach normal operating temperature faster whenthe engine is at rated speed. The engine will reachnormal operating temperature faster when the engineis at low power demand. This procedure is moreeffective than idling the engine at no load. The engineshould reach operating temperature in a few minutes.

Gauge readings should be observed and the datashould be recorded frequently while the engineis operating. Comparing the data over time willhelp to determine normal readings for each gauge.Comparing data over time will also help detectabnormal operating developments. Significantchanges in the readings should be investigated.

i04147124

Diesel Particulate FilterRegenerationSMCS Code: 108F

RegenerationRegeneration is the removal of soot from thediesel particulate filter (DPF). The aftertreatmentregeneration device (ARD) is used to regenerate theDPF. The DPF traps both soot and ash. The ash isremoved through a manual cleaning process. Referto this Operation and Maintenance Manual, “DieselParticulate Filter - Clean” for more information aboutservicing the DPF.

46 SEBU8597-03Operation SectionEngine Operation

Regeneration Indicator Lamps andControls

g02334417Illustration 30The engine may be equipped with one of the control panels pictured above.(1) “DPF” Indicator lamp(2) “HIGH EXHAUST TEMPERATURE”

indicator lamp(3) “REGENERATION DISABLED” indicator

lamp

(4) “START KEY” switch(5) “DIAGNOSTIC” lamp(6) “SHUTDOWN” lamp(7) “IDLE SPEED” switch(8) “REGENERATION” switch

(9) “HIGH SPEED REGENERATION”enable switch

Note: For further information about the monitoringsystem, refer to this Operation and MaintenanceManual, “Monitoring System”.

“HIGH EXHAUST SYSTEMTEMPERATURE (HEST)” – Thisindicator lamp illuminates to show that a

regeneration is active. This indicator lamp turns offwhen the regeneration is complete.

“DPF” – This indicator lamp illuminatesto show that a regeneration is needed. Thisindicator lamp illuminates when the soot

level reaches 80%.

“REGENERATION DISABLED” – Thisindicator lamp illuminates to show that aregeneration has been disabled.

Regeneration Controls

Regeneration Control Switch

g02333653Illustration 31“REGENERATION” control switch

The position of the “REGENERATION” switch in the side viewis the MIDDLE position.

Note: The MIDDLE position of the switch is thedefault position for low and high speed regenerations.

Note: Some OEMs use other means of activating aforced regeneration such as a touch screen interface.


“FORCE REGENERATION” – Press andhold in the top of the switch for 3 secondsto start regeneration.

“DISABLE REGENERATION” – Pressand hold in the bottom of the switch for 3seconds to disable regeneration.

Note: To re-enable the regeneration, cycle the engine“START SWITCH KEY” or press and hold in the“FORCE REGENERATION” switch for 2 seconds.

Note: If the engine “START SWITCH KEY” is cycledwhile the regeneration system is disabled via the“DISABLE REGENERATION” switch, press and holdin the “DISABLE REGENERATION” switch for 3seconds to reinitiate the disable regeneration.

High Speed Regeneration Enable Switch

g02333673Illustration 32“HIGH SPEED REGENERATION ENABLE” switch

The position of the “HIGH SPEED REGENERATION ENABLE”switch in the side view is the LOCKED position.

“HIGH SPEED REGENERATION ENABLE”switch – Pressing in and locking this switch enablesan automatic regeneration during normal engineoperation or during normal engine working speedand load. If this switch is not in the IN and LOCKEDposition, an automatic regeneration may only occurwhen the engine is at the programmed low idle speed(lower than 1500 rpm).

Note: This switch is only available on engines withinstrument panels supplied by Cat.

Soot Level Monitoring


The soot level monitor indicates the level of soot thathas accumulated within the DPF. The five marks onthe monitor represent the percentage of soot withinthe DPF. The first mark indicates 0% soot level. Thesecond mark indicates 25% soot level. The third markindicates 50% soot level. The fourth mark indicates75% soot level. The last mark indicates 100% sootlevel. The soot level monitor may be used to optimizeDPF regenerations based upon the work cycle ofthe engine. If operating conditions do not allow forautomatic regeneration, a manual regenerationshould be performed before the soot level gaugeindicates 100%

Note: The soot level monitor may not be applied toall engines. Some OEM's may also use a differentmethod of displaying soot load of the DPF. Refer toOEM operation manual for explanation.

Modes of Regeneration

Automatic

The engine control module (ECM) uses multipleelectrical inputs from the engine to determinethe best time for an automatic regeneration. Anautomatic regeneration may take place throughoutthe operating cycle of the engine. An automaticregeneration may start when the engine is at the lowidle speed or when the engine is at normal operatingspeed. The “HEST” indicator lamp is illuminatedwhen a regeneration is being performed.

If an automatic regeneration starts while the engineis at the low idle speed, the engine may be returnedto normal work at any time. Returning to normal workmay stop the regeneration. The ECM will continue tomonitor inputs to determine the best time to restartthe regeneration.

Interruptions of the regeneration are acceptable. If aregeneration needs to be stopped for any reason,press the DISABLE REGENERATION switch or turnoff the engine.

48 SEBU8597-03Operation SectionEngine Operation

Note: An automatic adjustment of engine speedmay be noticed during an automatic regeneration.If the engine is taken to a low idle speed while aregeneration is occurring, the engine speed mayremain elevated in order for the regeneration tocontinue.

Manual

A manual regeneration is initiated by pressingthe “FORCE REGENERATION” switch. A manualregeneration may be performed at a low idle speedor during normal engine operation. The soot loadingmust be between 15% and 116% for a manualregeneration to occur while the engine is at a lowidle speed. The soot loading must be between 15%and 105% for a manual regeneration to occur atnormal engine operating speed. The engine coolanttemperature should be at least 40° C (104° F).

Disabled

When the regeneration system is in disabled mode,automatic regeneration is not available.

Regeneration System WarningIndicators


The “DPF” indicator lamp illuminates when the DPFsoot load is greater than 80%

A regeneration should be performed as soon aspossible. Engine operation may not be allowingan automatic regeneration to occur. A manualregeneration should be performed as soon aspossible.

The “DPF” indicator lamp will turn off when DPFregeneration starts.

Note: In some situations, the “DPF” indicator lampmay remain illuminated when the soot load isbelow 80%. The illuminated “DPF” indicator lampindicates that a complete regeneration has notbeen completed. A complete regeneration reducesthe soot level to 0%. If the “DPF” indicator lampremains illuminated, perform a regeneration withoutinterruption until the soot level is 0%. A completeregeneration resets the “DPF” indicator lamp.


The “DPF” indicator lamp illuminates and the“DIAGNOSTIC” indicator lamp illuminates when theengine control module (ECM) determines that theamount of soot collected in the DPF has reached alevel that requires a regeneration. Place the engineinto a low idle state immediately. Initiate a manualregeneration. The engine power will be derated if theengine continues to operate.


When the soot load reaches 116%, the“DIAGNOSTIC” indicator lamp illuminates, the “DPF”indicator lamp illuminates, and the audible hornsounds. Not all applications have an audible horn.After 5 minutes of engine operation at 116% ofsoot load, the engine is automatically taken to theprogrammed low idle speed. A manual regenerationin the low speed region is then required. A completeregeneration will unlock the forced low idle speed.Cycling the engine “START SWITCH KEY” unlocksthe forced low idle speed.

After the engine operates at 116% of soot level for 10minutes, all types of regeneration are locked out. Aservice regeneration through the CAT ET service toolis the only form of regeneration allowed.

If the engine continues to operate without aregeneration until a soot level of 140% is reached,the engine shuts down after 30 seconds. The enginemay be restarted but will only run for 30 seconds ata time before shutting down. At this time, servicelevel regeneration is locked out and the DPF mustbe replaced.


i04038637

Engaging the DrivenEquipmentSMCS Code: 1000

1. Operate the engine at one-half of the rated rpm,when possible.

2. Engage the driven equipment without a load onthe equipment, when possible.

Interrupted starts put excessive stress on the drivetrain. Interrupted starts also waste fuel. To get thedriven equipment in motion, engage the clutchsmoothly with no load on the equipment. Thismethod should produce a start that is smooth andeasy. The engine rpm should not increase and theclutch should not slip.

3. Ensure that the ranges of the gauges are normalwhen the engine is operating at one-half ofthe rated rpm. Ensure that all gauges operateproperly.

4. Increase the engine rpm to the rated rpm. Alwaysincrease the engine rpm to the rated rpm beforethe load is applied.

5. Apply the load. Begin operating the engine at lowload. Check the gauges and equipment for properoperation. After normal oil pressure is reachedand the temperature gauge begins to move,the engine may be operated at full load. Checkthe gauges and equipment frequently when theengine is operated under load.

Extended operation at low idle or at reduced loadmay cause increased oil consumption and carbonbuildup in the cylinders. This carbon buildupresults in a loss of power and/or poor performance.

i01136207

Fuel Conservation PracticesSMCS Code: 1000; 1250

The efficiency of the engine can affect the fueleconomy. Caterpillar's design and technology inmanufacturing provides maximum fuel efficiency inall applications. Follow the recommended proceduresin order to attain optimum performance for the lifeof the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuelmay overflow from the fuel tank. Inspect fuel lines forleaks. Repair the fuel lines, as needed.

• Be aware of the properties of the different fuels.Use only the recommended fuels.

• Avoid unnecessary idling.

Shut off the engine rather than idle for long periods oftime.

• Observe the service indicator frequently. Keep theair cleaner elements clean.

• Ensure that the turbochargers are operatingcorrectly so that the proper air/fuel ratio ismaintained. Clean exhaust indicates properfunctioning.

• Maintain a good electrical system.

One faulty battery cell will overwork the alternator.This will consume excess power and excess fuel.

• Ensure that the belts are properly adjusted. Thebelts should be in good condition.

• Ensure that all of the connections of the hoses aretight. The connections should not leak.

• Ensure that the driven equipment is in goodworking order.

• Cold engines consume excess fuel. Utilize heatfrom the jacket water system and the exhaustsystem, when possible. Keep cooling systemcomponents clean and keep cooling systemcomponents in good repair. Never operate theengine without water temperature regulators.All of these items will help maintain operatingtemperatures.

50 SEBU8597-03Operation SectionCold Weather Operation

Cold Weather Operationi03729720

Radiator RestrictionsSMCS Code: 1353; 1396

Caterpillar discourages the use of airflow restrictiondevices that are mounted in front of radiators. Airflowrestriction can cause the following conditions:

• High exhaust temperatures

• Power loss

• Excessive fan usage

• Reduction in fuel economy

If an airflow restriction device must be used, thedevice should have a permanent opening directlyin line with the fan hub. The device must have aminimum opening dimension of at least 770 cm2

(120 in2).

A centered opening that is directly in line with the fanhub is specified in order to prevent an interruptedairflow on the fan blades. Interrupted airflow on thefan blades could cause a fan failure.

Caterpillar recommends a warning device for theinlet manifold temperature and/or the installation ofan inlet air temperature gauge. The warning devicefor the inlet manifold temperature should be set at90° C (194° F). The inlet manifold air temperatureshould not exceed 75 °C (167 °F). Temperatures thatexceed this limit can cause power loss and potentialengine damage.

i02237624

Fuel and the Effect from ColdWeatherSMCS Code: 1000; 1250; 1280

The following fuels are the grades that are availablefor Caterpillar engines:

• No. 1

• No. 2

• Blend of No. 1 and No. 2

No. 2 diesel fuel is the most commonly used fuel.Either No. 1 diesel fuel or a blend of No. 1 and No. 2is best suited for cold weather operation.

Quantities of No. 1 diesel fuel are limited. No. 1 dieselfuels are usually available during the months of thewinter in the colder climates. During cold weatheroperation, if No. 1 diesel fuel is not available, use No.2 diesel fuel, if necessary.

There are three major differences between No. 1 andNo. 2 diesel fuel. No. 1 diesel fuel has the followingproperties:

• Lower cloud point

• Lower pour point

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

When No. 1 diesel fuel is used, a decrease in powerand in fuel efficiency may be noticed. Other operatingeffects should not be experienced.

The cloud point is the temperature when a cloud ofwax crystals begins to form in the fuel. These crystalscan cause the fuel filters to plug. The pour point isthe temperature when diesel fuel will thicken. Thediesel fuel becomes more resistant to flow throughfuel pumps and through fuel lines.

Be aware of these values when diesel fuel ispurchased. Anticipate the average ambienttemperature of the area. Engines that are fueled inone climate may not operate well if the engines aremoved to another climate. Problems can result dueto changes in temperature.

Before troubleshooting for low power or for poorperformance in the winter, check the type of fuel thatis being used.

When No. 2 diesel fuel is used the followingcomponents provide a means of minimizing problemsin cold weather:

• Starting aids

• Engine oil pan heaters

• Engine coolant heaters

• Fuel heaters

• Fuel line insulation

For more information on cold weather operation,see Special Publication, SEBU5898, “Cold WeatherRecommendations”.


Cold Weather Operation

i03728501

Fuel Related Components inCold WeatherSMCS Code: 1000; 1250; 1280

Fuel TanksCondensation can form in partially filled fuel tanks.Top off the fuel tanks after operating the engine.

Fuel tanks should contain some provision for drainingwater and sediment from the bottom of the tanks.Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe.

Some fuel tanks use supply lines that take fueldirectly from the bottom of the tank. If the engine isequipped with this system, regular maintenance ofthe fuel system filter is important.

Drain the water and sediment from any fuel storagetank at the following intervals:

• Weekly

• Oil changes

• Refueling of the fuel tank

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

Fuel HeatersFuel heaters help to prevent fuel filters from pluggingin cold weather due to waxing. A fuel heater shouldbe installed in order for the fuel to be heated beforethe fuel enters the primary fuel filter.

Select a fuel heater that is mechanically simple, yetadequate for the application. The fuel heater shouldalso help to prevent overheating of the fuel. High fueltemperatures reduce engine performance and theavailability of engine power. Choose a fuel heaterwith a large heating surface. The fuel heater shouldbe practical in size. Small heaters can be too hot dueto the limited surface area.

Disconnect the fuel heater in warm weather.

Note: Fuel heaters that are controlled by the watertemperature regulator or self-regulating fuel heatersshould be used with this engine. Fuel heaters thatare not controlled by the water temperature regulatorcan heat the fuel in excess of 65° C (149° F). Aloss of engine power can occur if the fuel supplytemperature exceeds 37° C (100° F).

Note: Heat exchanger type fuel heaters should havea bypass provision in order to prevent overheating ofthe fuel in warm weather operation.

For further information on fuel heaters, consult yourCaterpillar dealer.

52 SEBU8597-03Operation SectionEngine Stopping

Engine Stoppingi04315380

Manual Stop ProcedureSMCS Code: 1000; 7418

NOTICEStopping the engine immediately after it has beenworking under load can result in overheating and ac-celerated wear of the engine components.

If the engine has been operating at high rpm and/orhigh loads, run at low idle for at least three minutesto reduce and stabilize internal engine temperaturebefore stopping the engine.

Avoiding hot engine shutdowns will maximize tur-bocharger shaft and bearing life.

Note: Individual applications have different controlsystems. Ensure that the shutoff procedures areunderstood. Use the following general guidelines inorder to stop the engine.

1. Remove the load from the engine so that theengine has no more than 30% power.

2. Run the engine at the programmed low idle speedfor at least 3 minutes.

3. After the cool down period, turn the start switch tothe OFF position.

i01465494

After Stopping EngineSMCS Code: 1000

Note: Before you check the engine oil, do not operatethe engine for at least 10 minutes in order to allowthe engine oil to return to the oil pan.

• Check the crankcase oil level. Maintain the oil levelbetween the “ADD” mark and the “FULL” mark onthe oil level gauge.

• If necessary, perform minor adjustments. Repairany leaks and tighten any loose bolts.

• Note the service hour meter reading. Performthe maintenance that is in the Operation andMaintenance Manual, “Maintenance IntervalSchedule”.

• Fill the fuel tank in order to help preventaccumulation of moisture in the fuel. Do not overfillthe fuel tank.

NOTICEOnly use antifreeze/coolant mixtures recommended inthe Coolant Specifications that are in the Operationand Maintenance Manual. Failure to do so can causeengine damage.

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

• If freezing temperatures are expected, checkthe coolant for proper antifreeze protection. Thecooling system must be protected against freezingto the lowest expected outside temperature. Addthe proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on alldriven equipment. This maintenance is outlined inthe instructions from the OEM.

SEBU8597-03 53Maintenance Section

Refill Capacities

Maintenance Section

Refill Capacitiesi04423880

Refill CapacitiesSMCS Code: 1000; 1348; 1395; 7560

Refer to this Operation and Maintenance Manual,“Fluid Recommendations” for information about thefluids which are acceptable for this engine.

Note: Refer to Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engine FluidsRecommendations” for additional information.

Lubricant Refill Capacity

g02293575Illustration 37Standard and deep oil pans


Center oil pan

Table 4

C13 Industrial EngineApproximate Refill Capacities

Oil Sump(1) Liters Quarts

Standard Oil Pan 32 L 33.8 qt

Deep Oil Pan 37 L 39.1 qt

Center Oil Pan 30 L 31.7 qt(1) These values are approximate capacities for the crankcase oilsump which include the standard oil filters that are installedat the factory. Engines with auxiliary oil filters will requireadditional oil. Refer to the OEM specifications for the capacityof the auxiliary oil filter.

The refill capacities for the engine crankcase reflectthe approximate capacity of the crankcase or sumpplus standard oil filters. Auxiliary oil filter systems willrequire additional oil. Refer to the OEM specificationsfor the capacity of the auxiliary oil filter.

Coolant Refill CapacityTo maintain the cooling system, the total coolingsystem capacity must be known. The capacity ofthe total cooling system will vary. The capacitywill depend on the size of the radiator (capacity).Table 5should be completed by the customer for themaintenance of the cooling system.

Table 5

Approximate Capacity of the Cooling System

Compartmentor System Liters Quarts

Total CoolingSystem(1)

(1) The total cooling system capacity includes the followingcomponents:the engine block, the radiator, and all coolanthoses and lines.

i04606315

Fluid RecommendationsSMCS Code: 1280; 1348; 1395; 7560

NOTICEEvery attempt is made to provide accurate, up-to-dateinformation. By the use of this document, you agreethat Caterpillar Inc. is not responsible for errors oromissions.

NOTICEThese recommendations are subject to change with-out prior notice. Contact your Caterpillar dealer for themost up to date recommendations.

54 SEBU8597-03Maintenance SectionRefill Capacities

Refer to Special Publication, SEBU6251, “CatCommercial Diesel Engine Fluids Recommendations”for additional information.

Refer to this Operation and Maintenance Manual,“Severe Service Application” for information aboutoperating an engine in a severe service application.

Note: Instructions for the installation of the filter areprinted on the side of each Cat spin-on filter. Forfilters that are not Cat filters, refer to the installationinstructions that are provided by the supplier of thefilter.

Diesel Engine Oil

Cat DEO (Diesel Engine Oil)

Due to significant variations in the quality and inthe performance of commercially available oils,Caterpillar makes the following recommendations:

• Cat DEO-ULS (Diesel Engine Oil Ultra LowSulfur) (SAE 5W-40)



Engine Oil

Cat oils have been developed and tested in order toprovide the full performance and life that has beendesigned and built into Cat engines.

Cat DEO-ULS or oils that meet the Cat ECF-3specification and the API CJ-4 are required for use inthe applications listed below. Cat DEO-ULS and oilsmeeting Cat ECF-3 specification and the API CJ-4and ACEA E9 oil categories have been developedwith limited sulfated ash, phosphorus, and sulfur.These chemical limits are designed to maintain theexpected aftertreatment devices life, performance,and service interval. If oils meeting the Cat ECF-3specification and the API CJ-4 specifications are notavailable, oils meeting ACEA E9 may be used. ACEAE9 oils meet the chemical limits designed to maintainaftertreatment device life. ACEA E9 oils are validatedusing some but not all ECF-3 and API CJ-4 standardengine performance tests. Consult your oil supplierwhen considering use of an oil that is not Cat ECF-3or API CJ-4 qualified.

Failure to meet the listed requirements will damageaftertreatment-equipped engines and can negativelyimpact the performance of the aftertreatment devices.The Diesel Particulate Filter (DPF) will plug soonerand require more frequent DPF ash service intervals.

Typical aftertreatment systems include the following:

• Diesel Particulate Filters (DPF)

• Diesel Oxidation Catalysts (DOC)

• Selective Catalytic Reduction (SCR)

• Lean NOx Traps (LNT)

Other systems may apply.


Refill Capacities

Table 6

Lubricant Viscosities for Ambient Temperatures

°C °FCompartment or System Oil Type and Performance

Requirements Oil ViscositiesMin Max Min Max

Cat DEO-ULS Cold Weather SAE 0W-40 −40 40 −40 104

Cat DEO-ULS SAE 10W-30 −18 40 0 104Engine Crankcase

Cat DEO-ULS SAE 15W-40 −9.5 50 15 122

NOTICEOil Renewal systems should not be used in enginesequipped with aftertreatment systems. Reduced life ordamage to the aftertreatment may occur.

S·O·S Services Oil Analysis


Caterpillar has developed a maintenance toolthat evaluates oil degradation. the maintenancemanagement also detects the early signs of wear oninternal components. The Cat tool for oil analysis iscalled S·O·S Oil Analysis and the tool is part of theS·O·S Services program. S·O·S Oil Analysis dividesoil analysis into four categories:

• Component wear rate

• Oil condition

• Oil contamination

• Identification of oil

These four types of analysis are used to monitorthe condition of your equipment. The four types ofanalysis will also help you identify potential problems.A properly administered S·O·S Oil Analysis programwill reduce repair costs and the program will lessenthe impact of downtime.

The S·O·S Oil Analysis program uses a wide rangeof tests to determine the condition of the oil and thelubricated compartment. Guidelines that are basedon experience and a correlation to failures havebeen established for these tests. Exceeding oneor more of these guidelines could indicate seriousfluid degradation or a pending component failure. Atrained person at your Cat dealership should makethe final analysis.

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Refer to Special Publication, SEBU6251, “CatCommercial Diesel Engine Fluids Recommendations”in order to obtain additional information about S·O·SServices oil analysis. You can also contact your localCat dealer in order to obtain additional informationabout the S·O·S Services Oil Analysis program.

Diesel Fuel Recommendations

g02157153Illustration 39NACD Film


g02052934Illustration 40EAME Film

Diesel fuel must meet “Cat Specification for DistillateFuel” and the latest versions of “ASTM D975” or “EN590” in order to ensure optimum engine performance.Refer to Special Publication, SEBU6251, “CatCommercial Diesel Engine Fluids Recommendations”for the latest fuel information and for Cat fuelspecification. This manual may be found on the Webat Safety.Cat.com.

NOTICEUltra Low Sulfur Diesel (ULSD) fuel 0.0015 percent(≤15 ppm (mg/kg)) sulfur is required by regulation foruse in engines certified to nonroad Tier 4 standards(U.S. EPA Tier 4 certified) and that are equipped withexhaust aftertreatment systems.

European ULSD 0.0010 percent (≤10ppm (mg/kg))sulfur fuel is required by regulation for use in enginescertified to European nonroad Stage IIIB and newerstandards and are equipped with exhaust aftertreat-ment systems.

Misfueling with fuels of higher sulfur level canhave the following negative effects:

• Shorten the time interval betweenaftertreatment device service intervals(cause the need for more frequent serviceintervals)

• Adversely impact the performance and lifeof aftertreatment devices (cause loss ofperformance)

• Reduce regeneration intervals of aftertreatmentdevices

• Reduce engine efficiency and durability.

• Increase the wear.

• Increase the corrosion.

• Increase the deposits.

• Lower fuel economy

• Shorten the time period between oil drain intervals(more frequent oil drain intervals).

• Increase overall operating costs.

Failures that result from the use of improper fuels arenot Cat factory defects. Therefore the cost of repairswould not be covered by a Cat warranty.

Cat does not require the use of ULSD in off road andmachine applications that are not Tier 4/Stage IIIBcertified engines. ULSD is not required in enginesthat are not equipped with after treatment devices.For Tier 4/Stage IIIB/Stage IV certified enginesalways follow operating instructions. Fuel tank inletlabels are installed in order to ensure that the correctfuels are used.

Refer to Special Publication, SEBU6251, “CatCommercial Diesel Engine Fluids Recommendations”for more details about fuels, lubricants, and Tier 4requirements. This manual may be found on the Webat Safety.Cat.com.

Lubricating Grease


Cat provides various greases that vary in performancefrom a moderate performance to high performance.Cat greases service the entire line of Cat productsin the wide variety of climates throughout the world.From this variety of Cat grease products, you canfind a Cat grease that will meet or exceed theperformance requirements of most engines.

The performance requirements of your engine mustbe determined before you select any Cat grease.Consult the recommendations for greases that aremade by the OEM for the equipment. Then, consultwith your Cat dealer for a list of greases that have theperformance specifications and the available sizes ofcontainers.

Note: Always choose grease that meets or exceedsthe recommendations that are specified by theequipment manufacturer for the application.


Refill Capacities

If it is necessary to choose a single grease to usefor all of the equipment at one site, always choosea grease that meets or exceeds the requirementsof the most demanding application. Rememberthat the products which barely meet the minimumperformance requirements can be expected toproduce the minimum lives of your parts. Falseeconomy is being used if a grease is purchased withthe lowest cost as the only consideration. Instead,use the grease that yields the lowest total operatingcost. This cost should be based on an analysis thatincludes the costs of parts, labor, downtime, and thecost of the amount of grease that is required.

Note: Purge all of the old grease from a joint beforeyou change from one type of grease to anothertype of grease. Some greases are not chemicallycompatible with other greases. Consult your supplierin order to determine if the greases are compatible.

If you are not certain that the old grease is compatiblewith the new grease, purge the old grease from thesystem before applying the new grease.

Note: All Cat greases are chemically compatible witheach other. Mixing of Cat greases does not result inan adverse chemical reaction. However, mixing ofCat greases may result in reduced performance.

Non-Cat commercial greases are as a group secondchoice greases. Within this grouping of second choicegreases, there are tiered levels of performance.For more information, refer to Special Publication,SEBU6251, “Cat Commercial Diesel Engines FluidsRecommendations”.

Coolant


NOTICENever add coolant to an overheated engine. Enginedamage could result. Allow the engine to cool first.

NOTICEFrequently check the specific gravity of the coolant forproper freeze protection or for anti-boil protection.

NOTICENever operate an engine without water temperatureregulators in the cooling system. Water temperatureregulators help to maintain the engine coolant at theproper operating temperature. Cooling system prob-lems can develop without water temperature regula-tors.

The following two coolants are used in Cat DieselEngines:

Preferred – Cat ELC (Extended Life Coolant) or acommercial extended life coolant that meets the CatEngine Coolant -1 (EC-1) specification.

Acceptable – Cat DEAC (Diesel EngineAntifreeze/Coolant) or a commercial heavy-dutycoolant that meets “ASTM D4985”, or “ASTM D6210”specifications

Note: Cat DEAC does not require a treatment with aSupplemental Coolant Additive (SCA) at the initial fill.However, a commercial heavy-duty coolant that onlymeets the “ASTM D4985” specification will require atreatment with an SCA at the initial fill. A commercialheavy-duty coolant that meets the “ASTM D6210”specification will not require a treatment with an SCAat the initial fill. Read the label or the instructions thatare provided by the manufacturer of the commercialheavy-duty coolant.

Note: These coolants will require a treatment witha supplemental coolant additive on a maintenancebasis.

Table 7

Service Life Before Flushing and Before Refilling

Coolant Service Life(1)

Cat ELC 12,000 hours, or 6years

Commercial coolant thatmeets the Cat EC-1

specification

6000 hours, or 6 years

Cat DEAC 3000 hours, or 3 years

Commercial Heavy-DutyCoolant that meets “ASTMD4985” or “ASTM D6210”

3000 hours, or 1 year

(1) Use the interval that occurs first.

Note: Add the Cat ELC Extender at the halfway pointof the coolant change interval.

Note: These coolant change intervals are onlypossible with annual S·O·S Services Level 2 coolantsampling and analysis.


S·O·S Services Coolant AnalysisTable 8

Recommended Interval

Type of Coolant Level 1 Level 2

DEACEvery 500Hours(1)

(2)

Every 2000Hours orYearly(1)(3)

ELC Optional(3) Yearly(3)

(1) This interval is recommended for the sampling of allconventional heavy-duty coolant.

(2) This interval is also recommended for the sampling of acommercial coolant that meets the Cat (Engine Coolantspecification - 1) requirement.

(3) The Level 2 coolant analysis should be performed sooner if aproblem is suspected or identified.

Testing the engine coolant is important to ensure thatthe engine is protected from internal cavitation andfrom corrosion. The analysis also tests the ability ofthe coolant to protect the engine from boiling andfrom freezing. The S·O·S Coolant Analysis can beperformed at your Cat dealer. Cat S·O·S CoolantAnalysis is the best way to monitor the condition ofyour coolant and your cooling system. S·O·S CoolantAnalysis is a program that is based on periodicsamples.


For more information, refer to Special Publication,SEBU6251, “Cat Commercial Diesel Engines FluidsRecommendations”


Maintenance Recommendations

MaintenanceRecommendations

i02909163

System Pressure ReleaseSMCS Code: 1250; 1300; 1350; 5050

Coolant System

Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.

To relieve the pressure from the coolant system, turnoff the engine. Allow the cooling system pressure capto cool. Remove the cooling system pressure capslowly in order to relieve pressure.

Fuel SystemTo relieve the pressure from the fuel system, turn offthe engine.

High Pressure Fuel Lines (If Equipped)

Contact with high pressure fuel may cause fluidpenetration and burn hazards. High pressure fu-el spray may cause a fire hazard. Failure to fol-low these inspection, maintenance and service in-structions may cause personal injury or death.

The high pressure fuel lines are the fuel lines thatare between the high pressure fuel pump and thehigh pressure fuel manifold and the fuel lines that arebetween the fuel manifold and cylinder head. Thesefuel lines are different from fuel lines on other fuelsystems.

This is because of the following differences:

• The high pressure fuel lines are constantly chargedwith high pressure.

• The internal pressures of the high pressure fuellines are higher than other types of fuel system.

Before any service or repair is performed on theengine fuel lines, perform the following tasks:

1. Stop the engine.

2. Wait for ten minutes.

Do not loosen the high pressure fuel lines in order toremove air pressure from the fuel system.

Engine OilTo relieve pressure from the lubricating system, turnoff the engine.

i03642798

Welding on Engines withElectronic ControlsSMCS Code: 1000

NOTICEBecause the strength of the frame may decrease,some manufacturers do not recommend welding ontoa chassis frame or rail. Consult the OEM of the equip-ment or your Caterpillar dealer regarding welding ona chassis frame or rail.

Proper welding procedures are necessary in orderto avoid damage to the engine's ECM, sensors,and associated components. When possible,remove the component from the unit and thenweld the component. If removal of the componentis not possible, the following procedure must befollowed when you weld on a unit that is equippedwith a Caterpillar Electronic Engine. The followingprocedure is considered to be the safest procedure toweld on a component. This procedure should providea minimum risk of damage to electronic components.

NOTICEDo not ground the welder to electrical componentssuch as the ECM or sensors. Improper grounding cancause damage to the drive train, the bearings, hy-draulic components, electrical components, and othercomponents.

Do not ground the welder across the centerline of thepackage. Improper grounding could cause damage tothe bearings, the crankshaft, the rotor shaft, and othercomponents.

Clamp the ground cable from the welder to the com-ponent that will be welded. Place the clamp as closeas possible to the weld. This will help reduce the pos-sibility of damage.

Note: Perform the welding in areas that are free fromexplosive hazards.

60 SEBU8597-03Maintenance SectionMaintenance Recommendations

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

2. Disconnect the negative battery cable from thebattery. If a battery disconnect switch is provided,open the switch.

3. Disconnect the J1/P1 and J2/P2 connectors fromthe ECM. Move the harness to a position that willnot allow the harness to accidentally move backand make contact with any of the ECM pins.


Use the example above. The current flow from the welder tothe ground clamp of the welder will not cause damage to anyassociated components.

(1) Engine(2) Welding electrode(3) Keyswitch in the OFF position(4) Battery disconnect switch in the open position(5) Disconnected battery cables(6) Battery(7) Electrical/Electronic component(8) Minimum distance between the component that is being welded

and any electrical/electronic component(9) The component that is being welded(10) Current path of the welder(11) Ground clamp for the welder

4. Connect the welding ground cable directly to thepart that will be welded. Place the ground cable asclose as possible to the weld in order to reduce thepossibility of welding current damage to bearings,hydraulic components, electrical components, andground straps.

Note: If electrical/electronic components are usedas a ground for the welder, or electrical/electroniccomponents are located between the welder groundand the weld, current flow from the welder couldseverely damage the component.

5. Protect the wiring harness from welding debrisand spatter.

6. Use standard welding practices to weld thematerials.

i04889860

Severe Service ApplicationSMCS Code: 1000

An engine which operates outside of normalconditions is operating in a severe serviceapplication.

An engine that operates in a severe serviceapplication may need more frequent maintenanceintervals in order to maximize the following conditions:

• Reliability

• Service life

The number of individual applications cause theimpossibility of identifying all of the factors which maycontribute to severe service operation. Consult yourCat dealer for the unique maintenance that may benecessary for your engine.

An application is a severe service application if anyof the following conditions apply:

Severe Environmental Factors• Frequent operation in dirty air

• Frequent operation at an altitude which is above1525 m (5000 ft)

• Frequent operation in ambient temperatures whichare above 32° C (90° F)

• Frequent operation in ambient temperatures whichare below 0° C (32° F)

Severe Operating Conditions• Frequent operation with inlet air which has acorrosive content

• Operation with inlet air which has a combustiblecontent


Maintenance Recommendations

• Operation which is outside of the intendedapplication

• Operation with a plugged fuel filter

• Extended operation at low idle (more than 20% ofhours)

• Frequent cold starts at temperatures below 0° C(32° F)

• Frequent dry starts (starting after more than 72hours of shutdown)

• Frequent hot shutdowns (shutting down the enginewithout the minimum of 2 minutes to 5 minutes ofcool down time)

• Operation above the engine rated speed

• Operation below the peak torque speed

• Operating with fuel which does not meet thestandards for distillate diesel fuel as stated inSpecial Publication, SEBU6251, “Cat CommercialDiesel Engine Fluids Recommendations”, “DistillateDiesel Fuel”

• Operating with a blend of distillate fuel whichcontains more than 20 percent biodiesel

Improper Maintenance Procedures(Maintenance Procedures WhichMay Contribute to a Severe ServiceApplication)• Inadequate maintenance of fuel storage tanks fromcauses such as excessive water, sediment, andmicroorganism growth.

• Extending maintenance intervals beyond therecommended intervals

• Using fluids which are not recommended in SpecialPublication, SEBU6251, “Cat Commercial DieselEngine Fluids Recommendations”

• Extending maintenance intervals for changingthe engine oil and engine coolant without S·O·Svalidation

• Extending maintenance intervals for changing airfilters, oil filters, and fuel filters

• Failure to use a water separator

• Using filters which are not recommended bySpecial Publication, PEWJ0074, “2008 Cat Filterand Fluid Application Guide”

62 SEBU8597-03Maintenance SectionMaintenance Interval Schedule

i04379933

Maintenance Interval ScheduleSMCS Code: 1000; 4450; 7500

Ensure that all safety information, warnings,and instructions are read and understood beforeany operation or any maintenance proceduresare performed. The user is responsible for theperformance of all maintenance including thefollowing procedures: all adjustments, the use ofproper lubricants, fluids, filters, and the installationof new components due to normal wear and aging .The performance of this product may be diminished ifproper maintenance intervals and procedures are notfollowed. Components may experience acceleratedwear if proper maintenance intervals and proceduresare not followed.

Note: Use whichever of the following that occursfirst in order to determine the maintenance intervals:fuel consumption, service hours, and calendar time. Before each consecutive interval is performed, allmaintenance from the previous intervals must beperformed.

Products that operate in severe operating conditionsmay require more frequent maintenance.

When Required

Battery - Recycle .................................................. 66Battery - Replace .................................................. 66Battery or Battery Cable - Disconnect .................. 67Engine - Clean ...................................................... 78Engine Air Cleaner Element (Dual Element/BoxType) - Replace ................................................... 79Engine Air Cleaner Element (Dual Element/CanisterType) - Clean/Replace ........................................ 80Engine Air Cleaner Element (Single Element/CanisterType) - Clean/Replace ........................................ 83Engine Storage Procedure - Check ...................... 88Fuel System - Prime ............................................. 89Fuel Tank Water and Sediment - Drain ................. 92

Daily

Air Tank Moisture and Sediment - Drain ............... 66Coolant Level - Check .......................................... 75Driven Equipment - Check .................................... 78Engine Air Cleaner Service Indicator - Inspect ..... 84Engine Oil Level - Check ...................................... 85Fuel System Primary Filter/Water Separator -Drain ................................................................... 90Power Take-Off Clutch - Check ............................ 99Walk-Around Inspection ...................................... 100

Every 250 Service Hours

Belts - Inspect/Replace ......................................... 69Engine Oil Sample - Obtain .................................. 86

Grounding Stud - Inspect/Clean/Tighten ............... 93


Battery Electrolyte Level - Check .......................... 67Belts - Inspect/Adjust/Replace .............................. 68Coolant Sample (Level 1) - Obtain ....................... 75Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 77Engine Oil and Filter - Change ............................. 86Fuel System Primary Filter (Water Separator)Element - Replace .............................................. 89Fuel System Secondary Filter - Replace .............. 91Hoses and Clamps - Inspect/Replace .................. 93


Air Shutoff - Test ................................................... 65

Every 2000 Service Hours or 1 Year

Coolant Sample (Level 2) - Obtain ....................... 76Fumes Disposal Filter Element - Replace ............ 92


Compression Brake - Inspect/Adjust/Replace ...... 70Engine Valve Lash - Check ................................... 88

Every 3000 Service Hours or 3 Years

Coolant (DEAC) - Change .................................... 70


Air Compressor - Check ....................................... 65Engine Mounts - Inspect ....................................... 85Starting Motor - Inspect ...................................... 100


ARD Spark Plug - Replace ................................... 64Diesel Particulate Filter - Clean ............................ 78Fuel Priming Pump - Replace ............................... 89


Coolant Extender (ELC) - Add .............................. 74

Every 12 000 Service Hours or 6 Years

Coolant (ELC) - Change ....................................... 72

Every 378 540 L (100 000 US gal) of Fuel or8500 Service Hours

Overhaul Considerations ...................................... 96


Maintenance Interval Schedule

i04937866

Maintenance Interval Schedule(Engines With Ratings GreaterThan 439 hp)SMCS Code: 1000; 4450; 7500

Ensure that all safety information, warnings,and instructions are read and understood beforeany operation or any maintenance proceduresare performed. The user is responsible for theperformance of all maintenance including thefollowing procedures: all adjustments, the use ofproper lubricants, fluids, filters, and the installationof new components due to normal wear and aging .The performance of this product may be diminished ifproper maintenance intervals and procedures are notfollowed. Components may experience acceleratedwear if proper maintenance intervals and proceduresare not followed.

Note: Use whichever of the following that occursfirst in order to determine the maintenance intervals:fuel consumption, service hours, and calendar time. Before each consecutive interval is performed, allmaintenance from the previous intervals must beperformed.

Products that operate in severe operating conditionsmay require more frequent maintenance.

When Required

Battery - Recycle .................................................. 66Battery - Replace .................................................. 66Battery or Battery Cable - Disconnect .................. 67Engine - Clean ...................................................... 78Engine Air Cleaner Element (Dual Element/BoxType) - Replace ................................................... 79Engine Air Cleaner Element (Dual Element/CanisterType) - Clean/Replace ........................................ 80Engine Air Cleaner Element (Single Element/CanisterType) - Clean/Replace ........................................ 83Engine Storage Procedure - Check ...................... 88Fuel System - Prime ............................................. 89Fuel Tank Water and Sediment - Drain ................. 92

Daily

Air Tank Moisture and Sediment - Drain ............... 66Coolant Level - Check .......................................... 75Driven Equipment - Check .................................... 78Engine Air Cleaner Service Indicator - Inspect ..... 84Engine Oil Level - Check ...................................... 85Fuel System Primary Filter/Water Separator -Drain ................................................................... 90Power Take-Off Clutch - Check ............................ 99Walk-Around Inspection ...................................... 100


Engine Oil Sample - Obtain .................................. 86Grounding Stud - Inspect/Clean/Tighten ............... 93

Initial 500 Service Hours

Engine Valve Lash - Check ................................... 88


Battery Electrolyte Level - Check .......................... 67Belts - Inspect/Adjust/Replace .............................. 68Coolant Sample (Level 1) - Obtain ....................... 75Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 77Engine Oil and Filter - Change ............................. 86Fuel System Primary Filter (Water Separator)Element - Replace .............................................. 89Fuel System Secondary Filter - Replace .............. 91Hoses and Clamps - Inspect/Replace .................. 93


Air Shutoff - Test ................................................... 65

Every 2000 Service Hours or 1 Year

Coolant Sample (Level 2) - Obtain ....................... 76Fumes Disposal Filter Element - Replace ............ 92


Compression Brake - Inspect/Adjust/Replace ...... 70


Coolant (DEAC) - Change .................................... 70


Air Compressor - Check ....................................... 65Engine Mounts - Inspect ....................................... 85Starting Motor - Inspect ...................................... 100


ARD Spark Plug - Replace ................................... 64Diesel Particulate Filter - Clean ............................ 78Fuel Priming Pump - Replace ............................... 89


Coolant Extender (ELC) - Add .............................. 74

Every 12 000 Service Hours or 6 Years

Coolant (ELC) - Change ....................................... 72

Every 378 540 L (100 000 US gal) of Fuel or8500 Service Hours

Overhaul Considerations ...................................... 96

64 SEBU8597-03Maintenance SectionARD Spark Plug - Replace

i04024244

ARD Spark Plug - ReplaceSMCS Code: 1555-510

Removing the Spark Plug

NOTICEIf the engine is running or the key is in the ON positionthe ARD plug will continue to fire. Turn the key to theOFF position before servicing the ARD plug.

g02139990Illustration 42(1) Wiring harness(2) Spark plug

1. Remove wire harness (1) from spark plug (2).

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure.When using pressure air, wear a pro-tective face shield and protective clothing.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded.

2. Debris may have collected in the spark plug well.Thoroughly remove any debris. Use compressedair. The maximum air pressure for cleaningpurposes must be below 205 kPa (30 psi). Ensurethat the area around the spark plug is clean andfree of dirt and debris.

3. Use a deep well socket and a breaker bar toloosen the spark plug. If necessary, see yourCaterpillar dealer for the part number of thesocket. After the spark plug has been loosened,use the socket to remove the spark plug by handin order to detect problems with the threads. Afterthe spark plug has been removed, inspect theused spark plug and the gasket.

If the spark plug could not be removed by hand,clean the threads with a 305-2389 brush. This toolscrapes debris from the seat and from the threads.

NOTICEDo not use a thread tap. A thread tap will removemetalunnecessarily. The threads could be stripped and thecombustion group could be damaged.

Installing the Spark PlugNote: Do not use anti-seize compound on the sparkplug. Most of the heat is transferred through thethreads and the seat area of the spark plug. Contactof the metal surfaces must be maintained in order toprovide the heat transfer that is required.

1. Ensure that the spark plug is clean and free of dirtand oil.

NOTICEDo not overtighten the spark plug. The shell can becracked and the gasket can be deformed. The met-al can deform and the gasket can be damaged. Theshell can be stretched. This will loosen the seal that isbetween the shell and the insulator, allowing combus-tion pressure to blow past the seal. Serious damageto the engine can occur.

Use the proper torque.

2. Install the spark plug by hand until the sparkplug contacts the ARD. Torque the spark plug tothe proper specification. Refer to Specifications,“Spark Plug” for the proper torque specification.

3. Connect the wiring harness.


Air Compressor - Check

i03966490

Air Compressor - Check(If equipped)SMCS Code: 1803-535

Do not disconnect the air line from the air com-pressor governor without purging the air brakeand the auxiliary air systems. Failure to purge theair brake and the auxiliary air systems before re-moving the air compressor and/or the air linescould cause personal injury.


Typical example

(1) Pressure relief valve

If the air compressor pressure relief valve that ismounted in the air compressor cylinder head isbypassing compressed air, there is a malfunctionin the air system, possibly ice blockage. Underthese conditions, your engine may have insuffi-cient air for normal brake operation.

Do not operate the engine until the reason for theair bypass is identified and corrected. Failure toheed this warning could lead to property damage,personal injury, or death to the operator or by-standers.

The function of the pressure relief valve is to bypassair when there is a malfunction in the system for theair compressor.

The pressure relief valve for the air compressorreleases air at 1723 kPa (250 psi). If the pressurerelief valve for the air compressor exhausts, allpersonnel should be at a safe distance away from theair compressor. All personnel should also stay clearof the air compressor when the engine is operatingand the air compressor is exposed.

Refer to the Service Manual or refer to the OEMspecifications in order to find information concerningthe air compressor. Consult your Caterpillar dealerfor assistance.

i03154013

Air Shutoff - Test(If Equipped)SMCS Code: 1078-081

Caterpillar Provided Controls


Air shutoff with the valve mechanism in the OPEN position

Note: Do not start the engine. Ensure that the enginecontrol is in the “OFF” position.

1. Ensure that the valve mechanism is latched in theOPEN position. Turn on the power to the enginecontrol panel. The valve mechanism shouldremain open. If the valve mechanism does notremain open, check the wiring for the air shutoffswitches.

2. With the power for the engine control panel in theON position, activate the “EMERGENCY STOP”switch. If the valve mechanism closes, proceed tostep 3. If the valve mechanism does not close,check the wiring for the air shutoff switch andcheck the wiring for the solenoids. Activate the“EMERGENCY STOP” switch again. When thevalve mechanism closes, proceed to step 3.

66 SEBU8597-03Maintenance SectionAir Tank Moisture and Sediment - Drain

3. Reset the valve mechanism to the CLOSEDposition. Operate the engine normally. Ensure thatthe valve mechanism continues to be latched.

Refer to the Troubleshooting Guide, “Air ShutoffSystem” information in your Service Manual forfurther information about the electrical system for theair shutoff system.

OEM ControlsIf the controls for the air shutoffs are provided byan original equipment manufacturer (OEM), use theguidelines that are provided by the OEM factory inorder to test the air shutoffs.

i00847451

Air Tank Moisture andSediment - Drain(If Equipped)SMCS Code: 1466-543-M&S

Moisture and sediment in the air starting system cancause the following conditions:

• Freezing

• Corrosion of internal parts

• Malfunction of the air starting system

When opening the drain valve, wear protectivegloves, a protective face shield, protective cloth-ing, and protective shoes. Pressurized air couldcause debris to be blown and result in personalinjury.

1. Open the drain valve that is on the bottom of theair tank. Allow the moisture and sediment to drain.

2. Close the drain valve.

3. Check the air supply pressure. The air startingmotor requires a minimum of 620 kPa (90 psi) ofair pressure to operate properly. The maximumair pressure must not exceed 1550 kPa (225 psi).The normal air pressure will be 758 to 965 kPa(110 to 140 psi).

i02039199

Battery - RecycleSMCS Code: 1401-005; 1401-510; 1401-535;1401-561; 1401

Always recycle a battery. Never discard a battery.Return used batteries to one of the followinglocations:

• A battery supplier

• An authorized battery collection facility

• A recycling facility

i01878164

Battery - ReplaceSMCS Code: 1401-510

Batteries give off combustible gases which canexplode. A spark can cause the combustible gas-es to ignite. This can result in severe personal in-jury or death.

Ensure proper ventilation for batteries that are inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

The battery cables or the batteries should not beremoved 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 withthe cover in place may cause a battery explosionresulting in personal injury.

1. Switch the engine to the OFF position. Removeall electrical loads.

2. Turn off any battery chargers. Disconnect anybattery chargers.

3. The NEGATIVE “-” cable connects the NEGATIVE“-” battery terminal to the NEGATIVE “-” terminalon the starter motor. Disconnect the cable fromthe NEGATIVE “-” battery terminal.


Battery Electrolyte Level - Check

4. The POSITIVE “+” cable connects the POSITIVE“+” battery terminal to the POSITIVE “+” terminalon the starting motor. Disconnect the cable fromthe POSITIVE “+” battery terminal.

Note: Always recycle a battery. Never discard abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure thatthe engine start switch is OFF.

7. Connect the cable from the starting motor to thePOSITIVE “+” battery terminal.

8. Connect the cable from the NEGATIVE “-” terminalon the starter motor to the NEGATIVE “-” batteryterminal.

i02601752

Battery Electrolyte Level -CheckSMCS Code: 1401-535-FLV

When the engine is not run for long periods of time orwhen the engine is run for short periods, the batteriesmay not fully recharge. Ensure a full charge in orderto help prevent the battery from freezing.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

1. Remove the filler caps. Maintain the electrolytelevel to the “FULL” mark on the battery.

If the addition of water is necessary, use distilledwater. If distilled water is not available use cleanwater that is low in minerals. Do not use artificiallysoftened water.

2. Check the condition of the electrolyte with the245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and1 L (1 qt) of clean water

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L(1 qt) of clean water

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fit properly.Coat the clamps and the terminals with 5N-5561Silicone Lubricant, petroleum jelly or MPGM.

i01492654

Battery or Battery Cable -DisconnectSMCS Code: 1401; 1402-029

The battery cables or the batteries should not beremoved 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 withthe cover in place may cause a battery explosionresulting in personal injury.

1. Turn the start switch to the OFF position. Turn theignition switch (if equipped) to the OFF positionand remove the key and all electrical loads.

2. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal. When four12 volt batteries are involved, the negative side oftwo batteries must be disconnected.

3. Tape the leads in order to help prevent accidentalstarting.

4. Proceed with necessary system repairs. Reversethe steps in order to reconnect all of the cables.

68 SEBU8597-03Maintenance SectionBelts - Inspect/Adjust/Replace

i02782163

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

InspectionBelt tension should be checked initially betweenthe first 20 to 40 hours of engine operation.

To maximize the engine performance, inspect thebelts for wear and for cracking. Replace belts that areworn or damaged.

For applications that require multiple drive belts,replace the belts in matched sets. Replacing onlyone belt of a matched set will cause the new belt tocarry more load because the older belt is stretched.The additional load on the new belt could cause thenew belt to break.

If the belts are too loose, vibration causesunnecessary wear on the belts and pulleys. Loosebelts may slip enough to cause overheating.

If the belts are too tight, unnecessary stresses areplaced on the pulley bearings and on the belts. Thismay shorten the service life of the components.

Inspect the condition and adjustment of the alternatorbelts and accessory drive belts (if equipped).

To check the belt tension, apply 110 N (25 lb ft)of force midway between the pulleys. A correctlyadjusted belt will deflect 9 mm (0.35 inch) to 15 mm(0.59 inch).

Alternator Belt


Typical alternator mounting(1) Adjusting nuts(2) Mounting bolt(3) Mounting bolts

1. Slightly loosen mounting bolt (2) and mountingbolt (3). Slightly loosen adjusting nut (1).

2. Move the pulley in order to adjust the belt tension.

3. Tighten the following: adjusting nuts (1), mountingbolt (2), and mounting bolt (3). Refer to theSpecifications, SENR3130 for the proper torques.

4. Install the belt guard. Refer to the Specifications,SENR3130 for the proper torques.

If new belts are installed, check the belt tension againafter 30 minutes of engine operation at the rated rpm.

Drive Belt for the Air Compressor(If Equipped)

g01389673Illustration 46(4) Drive belt for the air compressor(5) Mounting bolts

Loosen the four mounting bolts from the bracket thatholds the air compressor.


Belts - Inspect/Replace

g01389675Illustration 47Side view of the air compressor and pulley

(6) Bolt(7) Adjusting bolt

Loosen bolt 6. Loosen bolt 7. Slide the air compressorcloser to the pulley. Remove the old belt. Install anew belt.

Slide the air compressor into position. Tightenbolt 7. Refer to Specification, SENR3130, “TorqueSpecifications” for the correct torque.

Tension the belt.

Tighten the four mounting bolts (5). Refer toSpecification, SENR3130, “Torque Specifications” forthe correct torque.

i04322187

Belts - Inspect/Replace(If Equipped)SMCS Code: 1397-040; 1397-510

The engine may be equipped with one of the followingtypes of belts and belt tensioners.

Single BeltThe belt on the engine may look like the belt inIllustration 48 or like the belt in Illustration 48.

g02294633Illustration 48View of the front of a C15 or a C18 Industrial Engine

(1) Belt(2) Belt tensioner(3) Alternator(4) Idler pulley(5) Crankshaft pulley

g02294634Illustration 49View of the front of a C15 or a C18 Industrial Engine

(1) Belt(2) Belt tensioner

For maximum engine performance and maximumutilization of your engine, inspect the belts for wearand for cracking. Replace the belts, if necessary.

To replace the belt, perform the following steps:

70 SEBU8597-03Maintenance SectionCompression Brake - Inspect/Adjust/Replace

1. Insert a ratchet with a square drive into the squarehole that is located in the tensioner for the belt.Rotate the tensioner clockwise in order to relievetension on the belt. Remove the belt.

2. Install the new belt correctly, as shown. Be surethat the belt is fully seated on the pulleys. Thecorrect tension will automatically be applied whenthe ratchet is removed.

Two or More Belts


Belt tensioner(1) Adjustment bolt(2) 46 mm (1-13/16 inch) jamming locknut (jam nut)(A) 22 mm (0.87 inch)

Inspection of the Belts

Inspect the fan drive belts for wear and for cracking.Replace the belts if the belts are not in goodcondition.

Belt Replacement

For applications that require multiple drive belts,replace the drive belts in matched sets. Replacingone drive belt of a matched set will cause the newdrive belt to carry more load because the older drivebelts are stretched. The additional load on the newdrive belt could cause the new drive belt to fail.

Use the following procedure to change the belts.

1. Using a 46 mm (1-13/16 inch) wrench, loosen thejam nut (2).

Note: See figure 50, dimension (A).

2. Loosen the adjustment bolt (1).

3. Remove the old belt and replace with a new belt.Contact your Cat dealer for assistance in choosingand ordering new belts.

4. Tighten the adjustment bolt (1). Use a 144-0235Belt Tension Gauge to ensure that belt is tensionedaccording to table 9.

5. Tighten the jam nut to a torque of 200 ± 25 N·m(148 ± 18 lb ft)

Table 9

Fan Drive Belt Adjustment

Belt Tension (Initial) Belt Tension (Used)(1)

801 ± 44 N (180 ± 10 lb) 378 ± 44 N (85 ± 10 lb)(1) Belt with over 30 minutes of operation at a rated speed

Belt Adjustment

Repeat steps 1, 4, and 5 from the belt replacementprocedure.

i03965390

Compression Brake -Inspect/Adjust/ReplaceSMCS Code: 1129-025; 1129-040; 1129-510

Contact your Cat dealer for the proper procedure.

i04156977

Coolant (DEAC) - ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

NOTICEUse of commercially available cooling system clean-ers may cause damage to cooling system compo-nents. Use only cooling system cleaners that are ap-proved for Caterpillar engines.


Coolant (DEAC) - Change

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained.


The cooling system drain valve is towards the bottom of theradiator.

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.




1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

2. Open the cooling system drain valve.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Cat dealer orconsult Cat Dealer Service Tools Group:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOLInternational: 1-309-578-7372

Flush1. Flush the cooling system with clean water in orderto remove any debris.


NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

3. Fill the cooling system with a mixture of cleanwater and Cat Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pt) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

72 SEBU8597-03Maintenance SectionCoolant (ELC) - Change

4. Start and run the engine at low idle for a minimumof 30 minutes. The coolant temperature should beat least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap. Open the drain valve. Allow thewater to drain. Flush the cooling system with cleanwater. If equipped, be sure to flush the heater andany related supply and return lines. Close thedrain valve.

Cooling Systems with HeavyDeposits or PluggingNote: For the following procedure to be effective,there must be some active flow through the coolingsystem components.

1. Flush the cooling system with clean water in orderto remove any debris.



3. Fill the cooling system with a mixture of cleanwater and Cat Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pt) of cleaner per 3.8 to 7.6 L(1 to 2 US gal) of the cooling system capacity.Install the cooling system filler cap.

4. Start and run the engine at low idle for a minimumof 90 minutes. The coolant temperature should beat least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap. Open the drain valve. Allow thewater to drain. Flush the cooling system with cleanwater.

Fill


1. Fill the cooling system with coolant/antifreeze.Refer to this Operation and MaintenanceManual, “Fluid Recommendations” topic for moreinformation on cooling system specifications. Donot install the cooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to 1500 rpm. Run the engine at highidle for 1 minute in order to purge the air from thecavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass.

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap.If the gasket that is on the cooling system fillercap is damaged, discard the old filler cap andinstall a new filler cap. If the gasket that is onthe cooling system filler cap is not damaged,perform a pressure test. A 9S-8140 PressurizingPump is used to perform the pressure test. Thecorrect pressure for the cooling system filler capis stamped on the face of the cooling system fillercap. If the cooling system filler cap does not retainthe correct pressure, install a new cooling systemfiller cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i04156979

Coolant (ELC) - ChangeSMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.


Coolant (ELC) - Change

• The oil has entered the cooling system and thecoolant is contaminated.

• The fuel has entered the cooling system and thecoolant is contaminated.

Note: When the cooling system is cleaned, onlyclean water is needed when the ELC is drained andreplaced.

Note: Inspect the water pump and the watertemperature regulator after the cooling system hasbeen drained.


Drain


1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

2. Open the cooling system drain valve.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.




For information regarding the disposal and therecycling of used coolant, consult your Cat dealer orconsult Cat Dealer Service Tool Group:

Outside Illinois: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOLInternational: 1-309-578-7372

Flush1. Flush the cooling system with clean water in orderto remove any debris.



3. Fill the cooling system with clean water. Install thecooling system filler cap.

4. Start and run the engine at low idle until thetemperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap. Open the drain valve. Allow thewater to drain. Flush the cooling system with cleanwater. Close the drain valve.

74 SEBU8597-03Maintenance SectionCoolant Extender (ELC) - Add

Fill


1. Fill the cooling system with Extended Life Coolant(ELC). Refer to this Operation and MaintenanceManual, “Fluid Recommendations” for moreinformation on cooling system specifications. Donot install the cooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to high idle. Run the engine at highidle for 1 minute in order to purge the air from thecavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant levelwithin 13 mm (0.5 inch) below the bottom of thepipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass.

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap.Only install the used filler cap if the gasket is notdamaged. Use a 9S-8140 Pressurizing Pump topressure test a reinstalled cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install a newcooling system filler cap.

5. Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i04745732

Coolant Extender (ELC) - AddSMCS Code: 1352-544-NL

Cat ELC (Extended Life Coolant) does not requirethe frequent additions of any supplemental coolingadditives which are associated with the presentconventional coolants. The Cat ELC Extender willonly be added one time.

NOTICEUse only Cat Extended Life Coolant (ELC) Extenderwith Cat ELC.

Do NOT use conventional supplemental coolant addi-tive (SCA) with Cat ELC. Mixing Cat ELC with conven-tional coolants and/or conventional SCA reduces theCat ELC service life.

Check the cooling system only when the engine isstopped and cool.

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, “Cat DealerService Tool Catalog” or refer to Special Publication,PECJ0003, “Cat Shop Supplies and Tools Catalog” fortools and supplies suitable to collect and contain fluidson Cat products.


1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. If necessary, drain enough coolant from thecooling system in order to add the Cat ELCExtender.

3. Add Cat ELC Extender according to therequirements for the cooling system capacity.Refer to this Operation and Maintenance Manual,“Refill Capacities” or to this Operation andMaintenance Manual, “Fluid Recommendations”for more information.

SEBU8597-03 75Maintenance SectionCoolant Level - Check

4. Clean the cooling system filler cap. Inspect thegaskets on the cooling system filler cap. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

i03842450

Coolant Level - CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

g00285520Illustration 53Cooling system filler cap


1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel to the proper level in the sight glass.

g00103639Illustration 54Typical filler cap gaskets

3. Clean the cooling system filler cap and check thecondition of the filler cap gaskets. Replace thecooling system filler cap if the filler cap gaskets aredamaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i04134625

Coolant Sample (Level 1) -ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Obtaining a Coolant Sample (Level 1) isoptional if the cooling system is filled with CatELC (Extended Life Coolant).

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC including the following:

• Commercial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze

76 SEBU8597-03Maintenance SectionCoolant Sample (Level 2) - Obtain

Table 10

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEAC orany coolant otherthan Cat ELC

Every 500Hours(1) Yearly(2)

Cat ELC Optional Yearly(2)

(1) This interval is the recommended interval for coolant samplesfor all conventional heavy-duty coolant/antifreeze. This intervalis also the recommended interval for coolant samples ofcommercial coolants that meet the Cat EC-1 specification forengine coolant.

(2) The Level 2 Coolant Analysis should be performed sooner if aproblem is suspected or identified.


Note: Level 1 results may indicate a need forLevel 2 Analysis.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In order toreceive the full effect of S·O·S analysis, establisha consistent trend of data. In order to establisha pertinent history of data, perform consistentsamplings that are evenly spaced. Supplies forcollecting samples can be obtained from your Catdealer.

Use the following guidelines for proper sampling ofthe coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis,see this Operation and Maintenance Manual, “FluidRecommendations” or consult your Cat dealer.

i03907892

Coolant Sample (Level 2) -ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542





Refer to Operation and Maintenance Manual,“Cooling System Coolant Sample (Level 1) - Obtain”for the guidelines for a proper sampling of the coolant.

Submit the sample for Level 2 analysis.

For additional information about coolantanalysis, see Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engines FluidsRecommendations” or consult your Caterpillar dealer.


Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i04269112

Cooling System SupplementalCoolant Additive (SCA) -Test/Add(Systems Which are Filled withConventional Coolant)SMCS Code: 1352-045; 1395-081

This maintenance procedure is required forconventional coolants such as DEAC.Do notperform this maintenance for cooling systemsthat are filled with Cat Extended Life Coolant (CatELC) or Cat Extended Life Inhibitor (Cat ELI).

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and eyes. Do not drink cooling systemcoolant additive.

NOTICEExcessive supplemental coolant additive concentra-tion can form deposits on the higher temperature sur-faces of the cooling system, reducing the engine'sheat transfer characteristics. Reduced heat transfercould cause cracking of the cylinder head and otherhigh temperature components.

Excessive supplemental coolant additive concentra-tion could also result in blockage of the heat exchang-er, overheating, and/or accelerated wear of the waterpump seal.

Do not exceed the recommended amount of supple-mental coolant additive concentration.

NOTICEDo NOT mix brands or types of SCA. Do NOT mixSCAs and extenders.

Failure to follow the recommendations can result inshortened cooling system component life.

NOTICEUse Only Approved SCAs. Conventional coolantsrequire the maintenance addition of SCA throughouttheir expected life. Do NOT use an SCA with a coolantunless specifically approved by the coolant supplierfor use with their coolant. It is the responsibility of thecoolant manufacturer to ensure compatibility and ac-ceptable performance.

Failure to follow the recommendations can result inshortened cooling system component life.


Refer to Special Publication, NENG2500, “Cat Deal-er Service Tool Catalog” and to Special Publication,GECJ0003, “Cat Shop Supplies and Tools” for toolsand supplies suitable to collect and contain fluids onCat products.

Dispose of all fluids according to applicable regula-tions and mandates.

Note: Caterpillar recommends that an S·O·S CoolantAnalysis (Level 1) be performed to check theconcentration of SCA.

Maintain the Proper Concentrationof SCA in the Coolant


1. Remove the cooling system filler cap slowly.

2. Test the concentration of the SCA with a286-2578 Nitrite Test Strip or review the resultsof the S·O·S Coolant Analysis (Level 1).

3. If necessary, drain some coolant in order to allowspace for the addition of the SCA.

4. Add the amount of SCA required to maintain aconcentration of 3 percent to 6 percent SCA inthe coolant.

78 SEBU8597-03Maintenance SectionDiesel Particulate Filter - Clean

5. Clean the cooling system filler cap. Install thecooling system filler cap.

For further information, refer to Special Publication,SEBU6251, “Cat Commercial Diesel Engine FluidsRecommendations”.

i04024262

Diesel Particulate Filter - CleanSMCS Code: 108F-070

Note: Consult your local Cat dealer for informationon cleaning the diesel particulate filer.

i00934883

Driven Equipment - CheckSMCS Code: 3279-535

Check the AlignmentTo minimize bearing problems and vibration of theengine crankshaft and the driven equipment, thealignment between the engine and driven equipmentmust be properly maintained.

Check the alignment according to the instructionsthat are provided by the following manufacturers:

• Caterpillar

• OEM of the drive coupling

• OEM of the driven equipment

Torque all of the fasteners to the proper specifications.

Inspect the Drive CouplingInspect the drive coupling according to theinstructions that are provided by the OEM of thecoupling. For the following service information, seethe literature that is provided by the OEM of thecoupling:

• Lubrication requirements

• Specifications for the end play

• “Reusability Guidelines”

• Replacement instructions

Inspect the Rear Gear TrainInspect the crankshaft gear. If excessive wear isfound, replace the crankshaft gear and the largecluster idler.

If any gear causes damage to other gears throughfailure, replace the entire rear gear train.

For the correct parts, see the Parts Manual for theengine. For removal and replacement instructions,see the Service Manual, “Disassembly andAssembly” module. Consult your Caterpillar dealerfor assistance.

i01646701

Engine - CleanSMCS Code: 1000-070

Personal injury or death can result from high volt-age.

Moisture can create paths of electrical conductiv-ity.

Make sure that the electrical system is OFF. Lockout the starting controls and tag the controls “DONOT OPERATE”.

NOTICEAccumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Periodic cleaning of the engine is recommended.Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides the followingbenefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

Note: Caution must be used in order to preventelectrical components from being damaged byexcessive water when you clean the engine. Avoidelectrical components such as the alternator, thestarter, and the ECM.


Engine Air Cleaner Element (Dual Element/Box Type) - Replace

i04134990

Engine Air Cleaner Element(Dual Element/Box Type) -ReplaceSMCS Code: 1054-510

Primary Filter

NOTICEService the primary filter element only when the alertindicator for the intake air filter is flashing. Do not openthe filter compartment unless it is time for service.Opening the filter compartment can cause dirt to getinto the clean side of the filter housing.

NOTICEExtremely short air filter life can result if the preclean-er system malfunctions. If air filter life is drastically re-duced from typical for the operating conditions, con-sult your Caterpillar Dealer. The exhaust system dustejector for the strata tube precleaner must pull a min-imum vacuum of 508 mm (20 inch) of water.

NOTICEService the engine air filters with the engine stopped.Engine damage could result.

NOTICEDo not use the filter for longer than one year.


1. Remove the air cleaner cover (1). Pull out in orderto remove the element.

2. Remove the primary filter element (2) from the aircleaner housing (4).

3. Mark the secondary filter element (3) in order toshow that the primary filter element has beenserviced. The secondary filter element shouldbe replaced when the primary filter element isserviced for the third time. Refer to the section“Secondary Filter”.

4. Clean the inside of the air cleaner housing (4).Keep the secondary filter element in place whileyou clean the housing.

5. Install a new primary air filter. Push the filterelement firmly in order to properly seat theelement. Write the date on the element, if theprimary element is replaced.

6. Install the air cleaner cover.

Secondary Filter

NOTICEAlways replace the secondary filter element. Neverattempt to reuse the filter by cleaning.

The secondary filter element should be replaced at thetime the primary element is serviced for the third time.

NOTICEThe filter should be kept in service for no longer than1 year.

NOTICEAlways leave the secondary filter element in placewhile you clean the air cleaner housing.

1. Open the engine access door.

80 SEBU8597-03Maintenance SectionEngine Air Cleaner Element (Dual Element/Canister Type) - Clean/Replace


2. Remove the air cleaner housing cover (1).

3. Remove the primary filter element (2). Refer to thesection “Primary Filter”.

4. Clean the inside of the air cleaner housing (4).

5. Remove the secondary filter element (3). Pull outin order to remove the element.

6. Install a new secondary filter element. Pushthe element firmly in order to properly seat theelement. Write the date on the element, if theelement is replaced.

7. Install the primary filter element and the air cleanerhousing cover.

i04775542

Engine Air Cleaner Element(Dual Element/Canister Type) -Clean/Replace(If Equipped)SMCS Code: 1054-070; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

Servicing the Air Cleaner ElementsIf the air cleaner element becomes plugged, the aircan split the material of the air cleaner element.Unfiltered air will drastically accelerate internalengine wear. Your Cat dealer has the proper aircleaner elements for your application. Consult yourCat dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

• Operating conditions (dust, dirt, and debris) mayrequire more frequent service of the air cleanerelement.

• The air cleaner element may be cleaned up to sixtimes if the element has been properly cleanedand inspected.

• The air cleaner element should be replaced at leastone time per year. This replacement should beperformed regardless of the number of cleanings.

Replace the dirty paper air cleaner elements withclean air cleaner elements. Before installation, checkthe air cleaner elements thoroughly for tears and/orholes in the filter material. Inspect the gasket orthe seal of the air cleaner element for damage.Maintain a supply of suitable air cleaner elementsfor replacement purposes.

Dual Element Air Cleaners

The dual element air cleaner contains a primary aircleaner element and a secondary air cleaner element.The primary air cleaner element can be used up tosix times if the element has been properly cleanedand inspected. The primary air cleaner elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

The secondary air cleaner element is not serviceableor washable. The secondary air cleaner elementshould be removed and discarded for every threecleanings of the primary air cleaner element. Whenthe engine is operating in environments that aredusty or dirty, air cleaner elements may require morefrequent replacement.


Engine Air Cleaner Element (Dual Element/Canister Type) - Clean/Replace

g00736431Illustration 57(1) Cover(2) Primary air cleaner element(3) Secondary air cleaner element(4) Air inlet for the turbocharger

1. Remove the cover. Remove the primary aircleaner element.

2. The secondary air cleaner element should beremoved and discarded for every three cleaningsof the primary air cleaner element.

Note: Refer to “Cleaning the Primary Air CleanerElements”.

3. Cover the air inlet to the turbocharger with tapein order to keep out dirt.

4. Clean the inside of the air cleaner cover and bodywith a clean, dry cloth.

5. Remove the tape from the air inlet of theturbocharger. Install the secondary air cleanerelement. Install a primary air cleaner element thatis new or cleaned.


7. Reset the air cleaner service indicator.

Cleaning the Primary Air CleanerElements

NOTICECaterpillar recommends certified air filter cleaning ser-vices that are available at Cat dealers. The Cat clean-ing process uses proven procedures to assure consis-tent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary air cleaner element can be used up tosix times if the element has been properly cleanedand inspected. When the primary air cleaner elementis cleaned, check for rips or tears in the filter material.The primary air cleaner element should be replacedat least one time per year. This replacement shouldbe performed regardless of the number of cleanings.

Use clean primary air cleaner elements while dirtyelements are being cleaned.

NOTICEDo not clean the air cleaner elements by bumping ortapping. This could damage the seals. Do not use el-ements with damaged pleats, gaskets or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air cleaner elementsbefore cleaning. Inspect the air cleaner elements fordamage to the seal, the gaskets, and the outer cover.Discard any damaged air cleaner elements.

There are two common methods that are used toclean primary air cleaner elements:

• Pressurized air

• Vacuum cleaning

82 SEBU8597-03Maintenance SectionEngine Air Cleaner Element (Dual Element/Canister Type) - Clean/Replace

Pressurized Air

Pressurized air can be used to clean primary aircleaner elements that have not been cleaned morethan two times. Pressurized air will not removedeposits of carbon and oil. Use filtered, dry air with amaximum pressure of 207 kPa (30 psi).


Note: When the primary air cleaner elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter to prevent damage to thepaper pleats. Do not aim the stream of air directly atthe primary air cleaner element. Dirt could be forcedfurther into the pleats.

Note: Refer to “Inspecting the Primary Air CleanerElements”.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningprimary air cleaner elements which require dailycleaning because of a dry, dusty environment.Cleaning with pressurized air is recommended priorto vacuum cleaning. Vacuum cleaning will not removedeposits of carbon and oil.

Note: Refer to “Inspecting the Primary Air CleanerElements”.

Inspecting the Primary Air CleanerElements


Inspect the clean, dry primary air cleaner element.Use a 60w blue light in a dark room or in a similarfacility. Place the blue light in the primary air cleanerelement. Rotate the primary air cleaner element.Inspect the primary air cleaner element for tearsand/or holes. Inspect the primary air cleaner elementfor light that may show through the filter material. Toconfirm the result, compare the primary air cleanerelement to a new air cleaner element that has thesame part number.

Do not use a primary air cleaner element that hasany tears and/or holes in the filter material. Do notuse a primary air cleaner element with damagedpleats, gaskets, or seals. Discard damaged primaryair cleaner elements.

Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes inspectionwill not be used, the primary air cleaner element canbe stored for future use.



Engine Air Cleaner Element (Single Element/Canister Type) - Clean/Replace

Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An air flow restrictionmay result. To protect against dirt and damage, wrapthe primary air cleaner elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary air cleaner element into a boxfor storage. For identification, mark the outside ofthe 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.

i04281531

Engine Air Cleaner Element(Single Element/Canister Type)- Clean/Replace(If Equipped)SMCS Code: 1054-070; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

Note: Use of a platform may be necessary to reachthe air cleaner element.

Clean the air cleaner elements or replace the aircleaner elements when the following conditionsoccur:

• Inspect the air cleaner elements before the air filterrestriction reaches 2.5 kPa (10 inches of H2O). Aloss of engine performance may occur when theair filter restriction exceeds this limit.

• The air cleaner elements must be cleaned orreplaced before the air filter restriction exceeds3.75 kPa (15 inches of H2O).

Note: The air filter restriction is measured before theair inlet to the turbocharger compressor.

Servicing the Air Cleaner ElementsNote: If the air cleaner is not manufactured byCaterpillar, follow the instructions that are providedby the OEM of the air cleaner.

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

• Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

Replace the dirty paper air cleaner elements withclean air cleaner elements. Before installation,thoroughly inspect the air cleaner elements for tearsand/or holes in the filter material. Inspect the gasketor the seal of the air cleaner element for damage.Maintain a supply of suitable air cleaner elementsfor replacement purposes.

1. Remove the air cleaner cover. Remove the aircleaner element.

2. Cover the air inlet to the turbocharger with tapein order to keep dirt out.

3. Clean the inside of the air cleaner cover and bodywith a clean, dry cloth.

4. Remove the tape for the air inlet to theturbocharger. Install an air cleaner element thatis new or cleaned.


Inspecting Air Cleaner Elements


84 SEBU8597-03Maintenance SectionEngine Air Cleaner Service Indicator - Inspect

Inspect the clean, dry air cleaner element. Use a60 watt blue light in a dark room or in a similarfacility. Place the blue light in the element. Rotate theelement. Inspect the element for tears and/or holes.Inspect the element for light that may show throughthe filter material. If it is necessary in order to confirmthe result, compare the element to a new elementthat has the same part number.

Do not use an element that has any tears and/orholes in the filter material. Do not use an element withdamaged pleats, gaskets or seals. Discard damagedelements.

Storing Air Cleaner Elements

If an element that passes inspection will not be used,the element can be stored for future use.


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. Restricted air flowmay result. To protect against dirt and damage, wrapthe elements in Volatile Corrosion Inhibited (VCI)paper.

Place the element into a box for storage. Foridentification, mark the outside of the box.

Store the box in a dry location.

i01900118

Engine Air Cleaner ServiceIndicator - Inspect(If Equipped)SMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differential gaugefor inlet air pressure. The differential gauge for inletair pressure displays the difference in the pressurethat is measured before the air cleaner element andthe pressure that is measured after the air cleanerelement. As the air cleaner element becomes dirty,the pressure differential rises. If your engine isequipped with a different type of service indicator,follow the OEM recommendations in order to servicethe air cleaner service indicator.

The service indicator may be mounted on the aircleaner housing or in a remote location.

g00103777Illustration 63Typical service indicator

Observe the service indicator. The air cleanerelement should be cleaned or the air cleaner elementshould be replaced when one of the followingconditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service IndicatorService indicators are important instruments.

• Check for ease of resetting. The service indicatorshould reset in less than three pushes.

• Check the movement of the yellow core when theengine is accelerated to the engine rated speed.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If the newservice indicator will not reset, the hole for the serviceindicator may be plugged.


Engine Mounts - Inspect

The service indicator may need to be replacedfrequently in environments that are severely dusty, ifnecessary. Replace the service indicator annuallyregardless of the operating conditions. Replace theservice indicator when the engine is overhauled, andwhenever major engine components are replaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 N·m (18 lb in).

i02436689

Engine Mounts - InspectSMCS Code: 1152-040; 1152

Inspect the engine mounts for deterioration and forproper bolt torque. Engine vibration can be causedby the following conditions:

• Improper mounting of the engine

• Deterioration of the engine mounts

• Loose mounting bolts

Any engine mount that shows deterioration shouldbe replaced. Refer to the Specifications Manual,SENR3130, “Torque Specifications”. Refer to yourCaterpillar dealer for more information.

i04288290

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

g02455244Illustration 64Typical installation of the oil level gauge(1) Oil filler cap(2) Oil level gauge

g00110310Illustration 65Partial view of the oil level gauge

(Y) “ADD” mark(X) “FULL” mark

NOTICEPerform this maintenance with the engine stopped.

NOTICEEngine damage can occur if the crankcase is filledabove the “FULL” mark on the oil level gauge (dip-stick).

An overfull crankcase can cause the crankshaft to dipinto the oil. This will reduce the power that is devel-oped and also force air bubbles into the oil. Thesebubbles (foam) can cause the following problems: re-duction of the oil's ability to lubricate, reduction of oilpressure, inadequate cooling, oil blowing out of thecrankcase breathers, and excessive oil consumption.

Excessive oil consumption will cause deposits to formon the pistons and in the combustion chamber. De-posits in the combustion chamber lead to the followingproblems: guttering of the valves, packing of carbonunder the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil levelgauge, drain some of the oil immediately.

86 SEBU8597-03Maintenance SectionEngine Oil Sample - Obtain

1. Remove the oil filler cap and check the oil level.Maintain the oil level between the “ADD” mark (Y)and the “FULL” mark (X) on the oil level gauge (1).Do not fill the crankcase above “FULL” mark (X).

2. In order to choose the correct type of oil for thisengine, refer to this Operation and MaintenanceManual, “Fluid Recommendations”.

3. Clean the oil filler cap. Install the oil filler cap.

4. Record the amount of oil that is added. For thenext oil sample and analysis, include the totalamount of oil that has been added since theprevious sample. Recording this information helpsto provide the most accurate oil analysis.

i04237495

Engine Oil Sample - ObtainSMCS Code: 1348-554-SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regularly scheduled intervals. S·O·S oilanalysis provides infrared analysis, which is requiredfor determining nitration and oxidation levels.

Obtain the Sample and the Analysis


Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

• Engine model

• Service hours on the engine

• The number of hours that have accumulated sincethe last oil change

• The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of the oilin the crankcase, obtain a warm, mixed oil sample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.


If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEGJ0047,“How To Take A Good S·O·S Oil Sample”. Consultyour Cat dealer for complete information andassistance in establishing an S·O·S program for yourengine.

i04092890

Engine Oil and Filter - ChangeSMCS Code: 1318-510


Selection of Oil Change IntervalRefer to this Operation and Maintenance Manual,“Fluid Recommendations” for further informationabout oils that may be used in Caterpillar engines.


Engine Oil and Filter - Change

Refer to this Operation and Maintenance Manual,“Severe Service Application ” to determine if the oilchange interval should be reduced from the normalchange interval. If operating in any of the conditionsor environments outlined in the Severe ServiceApplication, use S·O·S Services oil analysis todetermine the oil change interval. If S·O·S Servicesoil analysis is not being used, the oil change intervalshould be reduced to 250 hrs.

Table 11

Oil Change Interval (1)

Operating ConditionsMultigrade Oil Type

Normal Severe ServiceApplication

Cat DEO-ULSPreferred

500 hr 250 hr

Oil meeting therequirements of the CatECF-3 Specificationor the API CJ-4classification

8 minimum TBNPreferred

500 hr 250 hr

Oil meeting therequirements ofthe ACEA C9/E6Specification

TBN below 10.4

500 hr 250 hr

(1) Refer to Special Publication, PEHJ0192, “Optimizing OilChange Intervals” for further information..

Drain the Engine OilAfter the engine has been run at the normal operatingtemperature, stop the engine. Attach a “DO NOTOPERATE” or a similar warning tag to the ignitionkeyswitch before the engine is serviced.




1. Remove the oil drain plug in order to allow the oilto drain.

2. After the oil has drained, the oil drain plug shouldbe cleaned and installed.

Replace the Oil Filter

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.


Typical filter mounting base and filter gasket

1. Remove the oil filter with a 185-3630 StrapWrench.

2. Clean the sealing surface of the filter mountingbase. Ensure that all of the old oil filter gasket isremoved.

3. Apply clean engine oil to the new oil filter gasket.

NOTICEDo not fill the oil filters with oil before installing them.This oil would not be filtered and could be contaminat-ed. Contaminated oil can cause accelerated wear toengine components.

4. Install the oil filter. Tighten the oil filter until theoil filter gasket contacts the base. Tighten the oilfilter by hand according to the instructions that areshown on the oil filter. Do not overtighten the oilfilter.

88 SEBU8597-03Maintenance SectionEngine Storage Procedure - Check

Fill the Engine Crankcase1. Remove the oil filler cap. Fill the crankcase with theproper amount of oil. Refer to the Operation andMaintenance Manual, “Fluid Recommendations”topic (Maintenance Section) for more information.

NOTICEIf equipped with an auxiliary oil filter or system, extraoil must be added when filling the crankcase. Followthe OEM or filter manufacturer's recommendations. Ifthe extra oil is not added, the engine may starve foroil.

NOTICETo help prevent crankshaft or bearing damage, crankengine to fill all filters before starting. Do not crankengine for more than 30 seconds.

2. Start the engine and run the engine at “LOWIDLE” for 2 minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain back tothe sump for a minimum of 10 minutes.

4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the “ADD”and “FULL” marks on the “ENGINE STOPPED”side of the oil level gauge.

i01458399

Engine Storage Procedure -CheckSMCS Code: 1000-535

The oil change interval may be extended to 12months for a vehicle that is operated seasonallyand placed in storage for the remainder of the yearby using the required storage procedures and therequired start-up procedures. This extension ispermitted if the following categories for oil changeintervals in the Operation and Maintenance Manual,“Maintenance Interval Schedule” have not beenreached:

• Mileage

• Operating hours

• Fuel consumption

If an engine is out of operation and if use of theengine is not planned, special precautions shouldbe made. If the engine will be stored for more thanthree months, a complete protection procedure isrecommended. For more detailed information onengine storage, see Special Instruction, SEHS9031,“Storage Procedure For Caterpillar Products”.

If the engine will not be started for several weeks, thelubricating oil will drain from the cylinder walls andfrom the piston rings. Rust can form on the cylinderliner surface. Rust on the cylinder liner surface willcause increased engine wear and a reduction inengine service life. Caterpillar recommends theuse of volatile corrosion inhibitor (VCI) oil in orderto prevent internal engine damage due to moistureduring storage. These inhibitors in the VCI oil act byevaporating inside the engine. The inhibitors thencondense over the inside surfaces of the engine. Theevaporation process and the condensing processoffers full protection to surfaces that cannot bereached with preservatives. 0.9 L (1.0 qt) of 4C-6792VCI oil will treat 28.4 L (30.0 qt) of engine oil. Thiswill give a 3 percent concentration of VCI oil. Theengine must be completely sealed when the engineis stored in order for the VCI oil to function properly.The VCI oil is easily cleaned from the engine whenyou remove the engine from storage. The volatilevapors are removed by simply running the engineto operating temperature. A mineral oil base is leftbehind after the volatile vapors are removed.

i03964791

Engine Valve Lash - CheckSMCS Code: 1105-535

Note: Procedures for adjusting the valve lash can befound in Systems Operation/Testing and Adjusting,“Valve Lash Adjustment”. Consult your Cat dealerfor assistance.

Ensure that the engine cannot be startedwhile thismaintenance is being performed. To help preventpossible injury, do not use the starting motor toturn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.


Fuel Priming Pump - Replace

i03927830

Fuel Priming Pump - ReplaceSMCS Code: 1258-510

A replacement kit is available for the electronic fuelpriming pump. Contact your Cat dealer for the correctpart number and details for your application.

i02096133

Fuel System - PrimeSMCS Code: 1250-548; 1258-548

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

1. Turn the engine start switch to the ON position.Leave the engine start switch in the ON positionfor two minutes.

2. Verify that the water separator is full of fuel.

3. If the water separator is not full of fuel, turn theengine start switch OFF and then turn the enginestart switch ON. This will cycle the fuel primingpump again.

4. When the water separator is full of fuel, attemptto start the engine. If the engine starts and theengine runs rough or the engine misfires, operateat low idle until the engine is running smoothly.If the engine cannot be started, or if the enginecontinues to misfire or smoke, repeat Step 1.

i02927282

Fuel System Primary Filter(Water Separator) Element -ReplaceSMCS Code: 1260-510-FQ; 1263-510-FQ

Water in the fuel can cause the engine to run rough.Water in the fuel may cause an electronic unit injectorto fail. If the fuel has been contaminated with water,the element should be changed before the regularlyscheduled interval.

The primary filter/water separator also providesfiltration in order to help extend the life of thesecondary fuel filter. The element should be changedregularly. If a vacuum gauge is installed, theprimary filter/water separator should be changed at50 to 70 kPa (15 to 20 inches Hg).

Replace the Element

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.


Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.



1. Close the main fuel supply valve.


(1) Element(2) Bowl(3) Drain

90 SEBU8597-03Maintenance SectionFuel System Primary Filter/Water Separator - Drain

2. Remove element (1) from the element mountingbase while bowl (2) is attached.

3. Dispose of the contents of the filter. Remove bowl(2) from element (1). The bowl is reusable. Do notdiscard the bowl. Dispose of the used element.

4. Remove the O-ring from the gland of the bowl.Clean the following components:

• Bowl

• O-ring

• Mounting base

Inspect the O-ring for damage and fordeterioration. Replace the O-ring, if necessary.

5. Lubricate the O-ring with clean diesel fuel.

6. Install bowl (2) on a new element. Tighten thebowl by hand. Do not use tools in order to tightenthe bowl.

NOTICEThe primary filter/water separator may be prefilled withfuel to avoid rough running/stalling of the engine dueto air. Do not fill the secondary filter with fuel beforeinstallation. The fuel would not be filtered and couldbe contaminated. Contaminated fuel will cause accel-erated wear to fuel system parts.

7. Lubricate the top seal of element (1) with cleandiesel fuel. The element may be filled with fuel atthis time. Install the new element on the mountingbase. Tighten the element by hand.

NOTICEThe water separator is under suction during normalengine operation. Ensure that the vent plug is tight-ened securely to help prevent air from entering the fu-el system.

8. Open the main fuel supply valve.

9. Start the engine and check for leaks. Run theengine for one minute. Stop the engine and checkfor leaks again.

Detecting leaks is difficult while the engine isrunning. The primary filter/water separator isunder suction. A leak will allow air to enter the fuel.The air in the fuel can cause low power due toaeration of the fuel. If air enters the fuel, check thecomponents for overtightening or undertightening.

i02927285

Fuel System PrimaryFilter/Water Separator - DrainSMCS Code: 1260-543; 1263-543



Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.



g01453091Illustration 68(1) Element(2) Bowl(3) Drain

Bowl (2) should be monitored daily for signs of water.If water is present, drain the water from the bowl.


Fuel System Secondary Filter - Replace

1. Open drain (3). The drain is a self-ventilated drain.Catch the draining water in a suitable container.Dispose of the water properly.

2. Close drain (3).

NOTICEThe water separator is under suction during normalengine operation. Ensure that the drain valve is tight-ened securely to help prevent air from entering the fuelsystem.

i04158105

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE


NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over any dis-connected fuel system components.




1. Stop the engine. Turn the ignition switch to theOFF position or disconnect the battery. Referto this Operation and Maintenance Manual,“Battery or Battery Cable - Disconnect” for moreinformation. Shut off the fuel supply valve (ifequipped).

2. It may be necessary to relieve residual fuelpressure from the fuel system before the fuel filtersare removed. Wait from 1 minute to 5 minutesuntil the fuel pressure has lowered. Use a suitablecontainer in order to catch any fuel that may spill.

3. Remove the used fuel filters and discard the usedfuel filters.

4. Apply clean diesel fuel to the new fuel filter o-rings.

NOTICEDo not fill the secondary fuel filter with fuel before in-stalling. The fuel would not be filtered and could becontaminated. Contaminated fuel will cause acceler-ated wear to fuel system parts.

NOTICEIn order to meet expected fuel system componentlife, 4 micron(c) absolute or less secondary fuel fil-tration is required for all Caterpillar Diesel Enginesthat are equipped with unit injected fuel systems. Notethat all current Caterpillar Diesel Engines are factoryequipped with Caterpillar Advanced Efficiency 4 mi-cron(c) absolute fuel filters.

Caterpillar does not warrant the quality or perfor-mance of non-Caterpillar fluids and filters.

5. Install the new fuel filters. Spin the fuel filters ontothe fuel filter bases until the o-rings contact thebases. Use the rotation index marks on the filtersas a guide for proper tightening. Tighten the filtersaccording to the instructions that are on the fuelfilters. Do not overtighten the filters.

6. Open the fuel supply valve. The engine will needto be purged of air. Refer to this Operation andMaintenance Manual, “Fuel System - Prime” formore information.

92 SEBU8597-03Maintenance SectionFuel Tank Water and Sediment - Drain

i04363480

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S




Fuel TankFuel quality is critical to the performance and to theservice life of the engine. Water in the fuel can causeexcessive wear to the fuel system. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes through thefuel system and the fuel returns to the fuel tank. Thiscauses water to accumulate in fuel tanks. Drainingthe fuel tank regularly and obtaining fuel from reliablesources can help to eliminate water in the fuel.

Drain the Water and the SedimentFuel tanks should contain some provision for drainingwater and draining sediment from the bottom of thefuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

Note: Failure to properly close the drain can allow airinto the system, which could have detrimental resultsto performance.

Check the fuel daily. Drain the water and sedimentfrom the fuel tank after operating the engine or drainthe water and sediment from the fuel tank after thefuel tank has been filled. Allow five to ten minutesbefore performing this procedure.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayoverflow.

Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel directly from the bottom of the tank. Ifthe engine is equipped with this system, regularmaintenance of the fuel system filter is important.

Fuel Storage TanksDrain the water and the sediment from the fuelstorage tank during the following conditions:

• Weekly

• Oil change

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank. A four micron(c) absolute filter for the breathervent on the fuel tank is also recommended.

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaffles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from thestorage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

i04281191

Fumes Disposal Filter Element- ReplaceSMCS Code: 1074

The filter for the open crankcase ventilation system(OCV) may be located toward the front or toward therear of the left side of the engine. A filter that hasbeen used may contain a small amount of engine oil.


Grounding Stud - Inspect/Clean/Tighten

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the machine. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide”, for tools and sup-plies suitable to collect and contain fluids in Caterpillarmachines.


g02021434Illustration 69(1) Cap(2) Housing for the filter element(3) Filter element(4) Cup

Remove either the cap or the cup from the housingfor the OCV filter. Remove the OCV filter. The filtermay not be used again. Dispose of the filter. Place anew OCV filter inside the filter housing. If the cap wasremoved, replace the cap. If the cup was removed,replace the cup. Tighten hand tight.

Note: Caterpillar will not be held liable for an enginethat does not comply with EPA emissions standardsdue to modification of the OCV filter or due to the useof a filter that is not approved by Caterpillar.

i03965989

Grounding Stud -Inspect/Clean/TightenSMCS Code: 7423-040; 7423-070; 7423-079


The grounding stud is located on the upper left corner of theengine control module.

Inspect the OEM harness for good connections.Inspect the condition of the OEM harness.

The grounding stud must have a wire ground tothe battery. Tighten the grounding stud at everyoil change. Ground wires and straps should becombined at engine grounds. All grounds should betight and free of corrosion.

• Clean the grounding stud and the terminals for theground strap with a clean cloth.

• If the connections are corroded, clean theconnections with a solution of baking soda andwater.

• Keep the grounding stud and the strap clean andcoated with MPGM grease or petroleum jelly.

i04301694

Hoses and Clamps -Inspect/ReplaceSMCS Code: 7554-040; 7554-510

Hoses and clamps must be inspected periodicallyin order to ensure safe operation and continuousoperation of the engine. Take proper safetyprecautions before inspecting or replacing hoses andclamps.

94 SEBU8597-03Maintenance SectionHoses and Clamps - Inspect/Replace

Note: Always use a board or cardboard when theengine components are checked for leaks. Leakingfluid that is under pressure can cause seriousinjury or possible death. Leaks that are the sizeof a pin hole are included. Refer to Operation andMaintenance Manual, “General Hazard Information”for more information.

Inspect the Hoses and the ClampsInspect all hoses for leaks that are caused by thefollowing conditions. Replace any hose which exhibitsany of the following conditions. Failure to replace ahose which exhibits any of the following conditionsmay result in a hazardous situation.

• Hoses which are cracked

• Hoses which are soft

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

• Hoses which exhibit signs of leakage which are notthe result of loose couplings or clamps

Inspect all clamps for the following conditions.Replace any clamp which exhibits signs of any of thefollowing conditions.

• Cracking

• Looseness

• Damage

Inspect all couplings for leaks. Replace any couplingwhich exhibits signs of leaks.

Each installation application can be different. Thedifferences depend on the following factors:

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Due to extreme temperature changes, the hose willheat set. Heat setting causes hose clamps to loosenwhich can result in leaks. A constant torque hoseclamp will help to prevent loose hose clamps.

Replace hoses that are cracked or soft. Replacehoses that show signs of leakage. Replace hosesthat show signs of damage. Replace hose clampsthat are cracked or damaged. Tighten or replacehose clamps which are loose.

Replace the Hoses and the Clamps




Cooling System


Personal injury can result from removing hoses orfittings in a pressure system.

Failure to relieve pressure can cause personal in-jury.

Do not disconnect or remove hoses or fittings un-til all pressure in the system has been relieved.

1. Stop the engine.

2. Allow the engine to cool.


Hoses and Clamps - Inspect/Replace

3. Before servicing a coolant hose, slowly loosen thefiller cap for the cooling system in order to relieveany pressure.

4. Remove the filler cap for the cooling system.

5. Drain the coolant from the cooling system to alevel that is below the hose that is being replaced.Drain the coolant into a suitable clean container.The coolant can be reused.

6. Remove the hose clamps.

7. Disconnect the old hose.

8. Replace the old hose with a new hose.

9. Install hose clamps which have been inspected orinstall new hose clamps. Refer to Specifications,SENR3130, “Torque Specifications”, “HoseClamps” for information about selecting andinstalling the proper hose clamps.

10.Refill the cooling system.

11.Clean the filler cap for the cooling system. Inspectthe gaskets on the filler cap. Replace the filler capif the gaskets are damaged. Install the filler cap.

12.Start the engine. Inspect the cooling system forleaks.

Fuel System

Personal injury can result from removing hoses orfittings in a pressure system.

Failure to relieve pressure can cause personal in-jury.

Do not disconnect or remove hoses or fittings un-til all pressure in the system has been relieved.

Contact with high pressure fuel may cause fluidpenetration and burn hazards. High pressure fu-el spray may cause a fire hazard. Failure to fol-low these inspection, maintenance and service in-structions may cause personal injury or death.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubesand hoses carefully. Tighten all connections to the rec-ommended torque.

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over any dis-connected fuel system components.

Note: High-pressure fuel lines may be installedbetween the high-pressure fuel pump and the fuelinjectors. High-pressure fuel lines are constantlycharged with high pressure. Do not check thehigh-pressure fuel lines with the engine or the startingmotor in operation. Wait for 10 minutes after theengine stops before you perform any service or repairon high-pressure fuel lines. Waiting for 10 minuteswill to allow the pressure to be purged.

1. Drain the fuel from the fuel system to a level thatis below the hose that is being replaced.





6. Carefully inspect the engine for any spilled fuel.Make sure that no fuel remains on or close to theengine.

Note: Fuel must be added to the fuel system aheadof the fuel filter.

7. Refill the fuel system. Refer to this Operation andMaintenance Manual, “Fuel System - Prime” forinformation about priming the engine with fuel.

8. Start the engine. Inspect the fuel system for leaks.

96 SEBU8597-03Maintenance SectionOverhaul Considerations

Lubrication System


1. Drain the oil from the lubrication system to a levelthat is below the hose that is being replaced.





6. Refill the lubrication system. Refer to thisOperation and Maintenance Manual, “EngineOil Level - Check” in order to ensure that thelubrication system is filled with the proper amountof engine oil.

7. Start the engine. Inspect the lubrication systemfor leaks.

Air System





Note: The bellows and the V-clamps that are usedon the bellows should never be reused.

5. Start the engine. Inspect the air lines for leaks.

i04138631

Overhaul ConsiderationsSMCS Code: 7595-043

Reduced hours of operation at full load will result ina lower average power demand and reduced fuelconsumption. A decreased average power demandshould increase both the engine service life and theoverhaul interval.

The need for an overhaul is indicated by increasedfuel consumption, increased oil consumption,excessive engine blowby, and reduced power. Arctictemperatures, extreme high temperatures, corrosiveenvironments, or extreme dusty conditions contributeto premature wear and the need for an overhaul.

The following factors are important when a decisionis being made on the proper time for an engineoverhaul:

• The need for preventive maintenance

• The quality of the fuel that is being used

• The operating conditions

• The results of the S·O·S analysis

Note: The aftertreatment system can be expectedto function properly for the useful life of theengine (emissions durability period), as definedby regulation, subject to prescribed maintenancerequirements being followed.

Oil Consumption as an OverhaulIndicatorOil consumption, fuel consumption, and maintenanceinformation can be used to estimate the totaloperating cost for your Caterpillar engine. Oilconsumption can also be used to estimate therequired capacity of a makeup oil tank that is suitablefor the maintenance intervals.

Oil consumption is in proportion to the percentageof the rated engine load. As the percentage of theengine load is increased, the amount of oil that isconsumed per hour also increases.

The oil consumption rate (brake-specific oilconsumption) is measured in grams per kW/h (lb perbhp). The brake-specific oil consumption (BSOC)depends on the engine load. Consult your Caterpillardealer for assistance in determining the typical oilconsumption rate for your engine.


Overhaul Considerations

When the oil consumption of an engine has risento three times the original oil consumption ratedue to normal wear, an engine overhaul should bescheduled. There may be a corresponding increasein blowby and a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

A planned overhaul before failure may be the bestvalue for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according to thestandards for reusable parts.

• The service life of the engine can be extendedwithout the risk of a major catastrophe due toengine failure.

• The best cost/value relationship per hour ofextended life can be attained.

After Failure Overhaul

If a major engine failure occurs and the enginemust be removed, many options are available. Anoverhaul should be performed if the engine block orthe crankshaft needs to be repaired.

If the engine block is repairable and/or the crankshaftis repairable, the overhaul cost should be between 40percent and 50 percent of the cost of a new enginewith a similar exchange core.

This lower cost can be attributed to three aspects:

• Specially designed Caterpillar engine features

• Caterpillar dealer exchange components

• Caterpillar Inc. remanufactured exchangecomponents

Overhaul RecommendationTo minimize downtime, Caterpillar Inc. recommends ascheduled engine overhaul by your Caterpillar dealerbefore the engine fails. A scheduled engine overhaulwill provide you with the best cost/value relationship.

Note: Overhaul programs vary according to theengine application and according to the dealer thatperforms the overhaul. Consult your Caterpillardealer for specific information about the availableoverhaul programs and about overhaul services forextending the engine life.

If an overhaul is performed without overhaul servicefrom your Caterpillar dealer, be aware of the followingmaintenance recommendations.

Rebuild or Exchange

Cylinder Head Assembly, Cylinder Packs, OilPump, and Fuel Transfer Pump

These components should be inspected according tothe instructions that are found in various Caterpillarreusability publications. The Special Publication,SEBF8029 lists the reusability publications that areneeded for inspecting the engine parts.

If the parts comply with the established inspectionspecifications that are expressed in the reusableparts guideline, the parts should be reused.

Parts that are not within the established inspectionspecifications should be dealt with in one of thefollowing manners:

• Salvaging

• Repairing

• Replacing

Using out-of-spec parts can result in the followingproblems:

• Unscheduled downtime

• Costly repairs

• Damage to other engine parts

• Reduced engine efficiency

• Increased fuel consumption

Reduced engine efficiency and increased fuelconsumption translates into higher operating costs.Therefore, Caterpillar Inc. recommends repairingout-of-spec parts or replacing out-of-spec parts.

Inspection and/or Replacement

Crankshaft Bearings, Valve Rotators, andCrankshaft Seals

The following components may not last until thesecond overhaul.

• Thrust bearings

• Main bearings

• Rod bearings

98 SEBU8597-03Maintenance SectionOverhaul Considerations

• Valve rotators

• Crankshaft seals

Caterpillar Inc. recommends the installation of newparts at each overhaul period.

Inspect these parts while the engine is disassembledfor an overhaul.

Inspect the crankshaft for any of the followingconditions:

• Deflection

• Damage to the journals

• Bearing material that has seized to the journals

Check the journal taper and the profile of thecrankshaft journals. Check these components byinterpreting the wear patterns on the followingcomponents:

• Rod bearing

• Main bearings

Inspect the camshaft for damage to the journals andto the lobes.

Note: If the camshaft is removed for any reason, usethe magnetic particle inspection process to check forcracks in the camshaft.

Inspect the following components for signs of wear orfor signs of scuffing:

• Camshaft bearings

• Camshaft followers

Caterpillar Inc. recommends replacing the crankshaftvibration damper.

Oil Cooler Core

During an overhaul, Caterpillar Inc. recommends theremoval of the oil cooler core. Clean the oil coolercore. Then, pressure test the oil cooler core.

NOTICEDo not use caustic cleaners to clean the core.

Caustic cleaners can attack the internal metals of thecore and cause leakage.

Note: Use this cleaning procedure to clean the oilcooler core.

1. Remove the oil cooler core.

2. Remove any debris from the oil cooler core. Toremove debris from the oil cooler core, turn the oilcooler core onto one end.

3. Flush the oil cooler core internally with cleaner inorder to loosen foreign substances. Flushing theoil cooler will also help to remove oil from the oilcooler core.

Note: Caterpillar Inc. recommends the use ofHydrosolv Liquid Cleaners. Table 12 lists theHydrosolv Liquid Cleaners that are available fromyour Caterpillar dealer.

Table 12

HydrosolvLiquid Cleaners

PartNumber Description Size

1U-5490 Hydrosolv4165 19 L (5 US gallon)

174-6854 Hydrosolv100 19 L (5 US gallon)

4. Use steam to clean the oil cooler core.Steam-cleaning the oil cooler core removes anyremaining residue from the cleaner. Flush the finsof the oil cooler core. Remove any other trappeddebris.

5. Wash the oil cooler core with hot, soapy water.Rinse the oil cooler core thoroughly with cleanwater.

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure.When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

6. Dry the oil cooler core with compressed air. Directthe air in the reverse direction of the normal flow.

7. Inspect the components in order to ensurecleanliness. The oil cooler core should bepressure tested. Repair the oil cooler core, ifnecessary. Install the oil cooler core.

For more information about cleaning the cores,consult your Caterpillar dealer.


Power Take-Off Clutch - Check

Obtain Coolant Analysis

The concentration of supplemental coolant additive(SCA) should be checked regularly with test kitsor with S·O·S Coolant Analysis (Level 1). Furthercoolant analysis is recommended when the engineis overhauled.

For example, considerable deposits are found in thewater jacket areas on the external cooling system, butthe concentrations of coolant additives were carefullymaintained. The coolant water probably containedminerals that were deposited on the engine over time.

A coolant analysis can be conducted in order to verifythe condition of the water that is being used in thecooling system. A full water analysis can be obtainedby consulting your local water utility company oran agricultural agent. Private laboratories are alsoavailable for water analysis.

Caterpillar Inc. recommends an S·O·S CoolantAnalysis (Level 2).

S·O·S Coolant Analysis (Level 2)

An S·O·S Coolant Analysis (Level 2) is acomprehensive coolant analysis which completelyanalyzes the coolant and the effects on the coolingsystem. An S·O·S Coolant Analysis (Level 2) providesthe following information:

• Complete S·O·S Coolant Analysis (Level 1)

• Visual inspection of properties

• Identification of metal corrosion

• Identification of contaminants

• Identification of built up impurities (corrosion andscale)

S·O·S Coolant Analysis (Level 2) provides a report ofthe results of both the analysis and the maintenancerecommendations.

For more information about coolant analysis, seeyour Caterpillar dealer.

i03901481

Power Take-Off Clutch - CheckSMCS Code: 3055-535

NOTICENew power take-offs should have the clutch adjust-ment checked before being placed into service. Theclutch adjustment should be checked again after thefirst ten hours of operation. New clutch plates have a“wear in” period, and the clutch may require severaladjustments until the new plates are “worn in”.


(1) Instruction plate(2) Serial number plate

Check the clutch adjustment regularly after “wear in”.Heavy-duty applications which have engagementsthat are frequent and relatively long periods ofclutch slippage require more frequent adjustmentthan light-duty applications. The operating torqueshould be measured in order to determine if a clutchadjustment is required.

Refer to the OEM information and instruction plate(1) for instructions on lubrication, adjustment, andother recommendations for service. Perform themaintenance that is specified on the instruction plate.

Do not operate the engine with the InstructionPlate cover removed from the clutch. Personalinjury may result.

If the clutch is damaged to the point of burst fail-ure, expelled pieces can cause personal injury toanyone in the immediate area. Proper safeguardsmust be followed to help prevent accidents.

100 SEBU8597-03Maintenance SectionStarting Motor - Inspect

i00651416

Starting Motor - InspectSMCS Code: 1451-040; 1453-040

Caterpillar Inc. recommends a scheduled inspectionof the starting motor. If the starting motor fails, theengine may not start in an emergency situation.

Check the starting motor for proper operation. Checkthe electrical connections and clean the electricalconnections. Refer to the Service Manual for moreinformation on the checking procedure and forspecifications or consult your Caterpillar dealer forassistance.

i01185304

Walk-Around InspectionSMCS Code: 1000-040

Inspect the Engine for Leaks andfor Loose ConnectionsA walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thoroughinspection of the engine compartment before startingthe engine. Look for items such as oil leaks or coolantleaks, loose bolts, worn belts, loose connections andtrash buildup. Make repairs, as needed:

• The guards must be in the proper place. Repairdamaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICEAccumulated grease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaningor high pressure water.

• Ensure that the cooling lines are properly clampedand that the cooling lines are tight. Check for leaks.Check the condition of all pipes.

• Inspect the water pumps for coolant leaks.

Note: The water pump seal is lubricated by coolantin the cooling system. It is normal for a small amountof leakage to occur as the engine cools down andthe parts contract.

Excessive coolant leakage may indicate the needto replace the water pump seal. For the removal ofwater pumps and the installation of water pumpsand/or seals, refer to the Service Manual for theengine or consult your Caterpillar dealer.

• Inspect the lubrication system for leaks at the frontcrankshaft seal, the rear crankshaft seal, the oilpan, the oil filters and the valve cover.

• Inspect the fuel system for leaks. Look for loosefuel line clamps or for loose fuel line tie-wraps.

• Inspect the piping for the air inlet system and theelbows for cracks and for loose clamps. Ensurethat hoses and tubes are not contacting otherhoses, tubes, wiring harnesses, etc.

• Inspect the alternator belt and the accessory drivebelts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced asmatched sets. If only one belt is replaced, the belt willcarry more load than the belts that are not replaced.The older belts are stretched. The additional load onthe new belt could cause the belt to break.

• Drain the water and the sediment from fuel tankson a daily basis in order to ensure that only cleanfuel enters the fuel system.

• Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

• Inspect the ground strap for a good connection andfor good condition.

• Inspect the ECM to the cylinder head ground strapfor a good connection and for good condition.

• Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolyte levelof the batteries, unless the engine is equipped witha maintenance free battery.

• Check the condition of the gauges. Replace anygauges that are cracked. Replace any gauge thatcan not be calibrated.

SEBU8597-03 101Warranty Section

Warranty Information

Warranty Section

Warranty Informationi04141951

Emissions WarrantyInformationSMCS Code: 1000

Caterpillar Inc. (Caterpillar) warrants to the ultimatepurchaser and each subsequent purchaser that:

1. New non-road diesel engines and stationary dieselengines less than 10 liters per cylinder operatedand 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 emissionstandards prescribed by the United StatesEnvironmental Protection Agency (EPA) byway of regulation.

b. Free from defects in materials and workmanshipin emission-related components that can causethe engine to fail to conform to applicableemission standards for the warranty period.

2. New non-road diesel engines operated andserviced in the state of California, including allparts of their emission control systems (“emissionrelated components”), are:

a. Designed, built, and equipped so as to conform,at the time of sale, to all applicable regulationsadopted by the California Air Resources Board(ARB).

b. Free from defects in materials and workmanshipwhich cause the failure of an emission-relatedcomponent to be identical in all materialrespects to the component as described in theCaterpillar application for certification for thewarranty period.

A detailed explanation of the Emission ControlWarranty that is applicable to new non-road andstationary diesel engines, including the componentscovered and the warranty period, is found insupplement Special Publication, SELF9001, “FederalEmission Control Warranty” and “Emission ControlWarranty for California”. Consult your authorized Catdealer to determine if your engine is subject to anEmission Control Warranty.

102 SEBU8597-03Reference Information SectionEngine Ratings

Reference InformationSection

Engine Ratingsi01097462

Engine Rating ConditionsSMCS Code: 1000

All engine ratings are based on“SAE J1349”.

Ratings relate to the standard conditions of “AS1501”,of “ISO3046/1”, of “DIN6271”, and of “BS5514”.

The engine ratings are gross output ratings.

Gross Output Ratings – The total output capabilityof the engine that is equipped with standardaccessories.

Standard accessories include the followingcomponents:

• Oil pumps

• Fuel pumps

• Water pumps

Subtract the power that is required to drive auxiliarycomponents from the gross output. This will producethe net power that is available for the external load(flywheel).

i04291338

Engine Rating DefinitionsSMCS Code: 1000

In selecting a rating for a specific application, themost important consideration is the time that is spentat full throttle. These rating definitions identify thepercent of time at full throttle. The definitions alsoidentify the corresponding times below rated rpm.

Note: The examples of the applications are onlyfor reference. For an exact determination of theappropriate rating, follow the OEM specifications orconsult your Cat dealer.

SEBU8597-03 103Reference Information Section

Engine Ratings

Table 13

Engine Rating Information

Time at Rated Load(1)PerformanceRating

LoadFactor Overall Any One

Instance

Examples ofApplications

A 100% 100% n/a Pipe line pumpingVentilation

B 85% 75% n/a

Irrigation pumpsDrilling applicationsPlant aircompressors

C 70% 50% Less than1 hour

Fire pumpsChippersRock crushersPortable aircompressors

D 50% 10% Less than 30minutes

SnowgroomerSnowblowersCranesWater well drills

E 35% 5% Less than 15minutes

Standby centrifugalpumpsOil well servicing

(1) Both the overall time at rated load and the time the engine is operated in any oneinstance must be considered.

NOTICEOperating engines above the rating definitions can re-sult in shorter service life before overhaul.

104 SEBU8597-03Reference Information SectionCustomer Service

Customer Servicei03910306

Customer AssistanceSMCS Code: 1000; 4450

USA and CanadaWhen a problem arises concerning the operation orthe service of an engine, the problem will normally bemanaged by the dealer in your area.

Your satisfaction is a primary concern to Caterpillarand to Caterpillar dealers. If you have a problem thathas not been handled to your complete satisfaction,follow these steps:

1. Discuss your problem with a manager from thedealership.

2. If your problem cannot be resolved at the dealerlevel, use the phone number that is listed below totalk with a Field Service Coordinator:

1-800-447-4986

The normal hours are from 8:00 to 4:30 Mondaythrough Friday Central Standard Time.

3. If your needs have not been met still, submit thematter in writing to the following address:

Caterpillar Inc.Manager, Customer Service, Engine DivisionMossville Bldg ACP.O. Box 610Mossville, Illinois 61552-0610

Please keep in mind: probably, your problem willultimately be solved at the dealership, using thedealership facilities, equipment, and personnel.Therefore, follow the steps in sequence when aproblem is experienced.

Outside of the USA and of CanadaIf a problem arises outside the USA and outsideCanada, and if the problem cannot be resolved at thedealer level, consult the appropriate Caterpillar office.

Latin America, Mexico, CarribeanCaterpillar Americas Co.701 Waterford Way, Suite 200Miami, FL 33126-4670USAPhone: 305-476-6800Fax: 305-476-6801

Europe, Africa, and Middle EastCaterpillar Overseas S.A.76 Route de FrontenexP.O. Box 6000CH-1211 Geneva 6SwitzerlandPhone: 22-849-4444Fax: 22-849-4544

Far EastCaterpillar Asia Pte. Ltd.7 Tractor RoadJurong, Singapore 627968Republic of SingaporePhone: 65-662-8333Fax: 65-662-8302

ChinaCaterpillar China Ltd.37/F., The Lee Gardens33 Hysan AvenueCauseway BayG.P.O. Box 3069Hong KongPhone: 852-2848-0333Fax: 852-2848-0440

JapanShin Caterpillar Mitsubishi Ltd.SBS Tower10-1, Yoga 4-ChomeSetagaya-Ku, Tokyo 158-8530JapanPhone: 81-3-5717-1150Fax: 81-3-5717-1177

JapanCaterpillar Power Systems, Inc.SBS Tower (14th floor)4-10-1, YogaSetagaya-Ku, Tokyo 158-0097Phone: 81-3-5797-4300Fax: 81-3-5797-4359

Australia and New ZealandCaterpillar of Australia Ltd.1 Caterpillar DrivePrivate Mail Bag 4Tullamarine, Victoria 3043AustraliaPhone: 03-9953-9333Fax: 03-9335-3366


Customer Service

i01028392

Ordering Replacement PartsSMCS Code: 4450; 7567

When replacement parts are required for thisproduct Caterpillar recommends using Caterpillarreplacement parts or parts with equivalent spec-ifications including, but not limited to, physicaldimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

Quality Caterpillar replacement parts are availablefrom Caterpillar dealers throughout the world.Caterpillar dealers' parts inventories are up-to-date.The parts stocks include all of the parts that arenormally needed to protect your Caterpillar engineinvestment.

When you order parts, please specify the followinginformation:

• Part number

• Part name

• Quantity

If there is a question concerning the part number,please provide your dealer with a completedescription of the needed item.

When a Caterpillar engine requires maintenanceand/or repair, provide the dealer with all theinformation that is stamped on the Information Plate.This information is described in this Operation andMaintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform thedealer about the conditions of the problem and thenature of the problem. Inform the dealer about whenthe problem occurs. This will help the dealer introubleshooting the problem and solving the problemfaster.

106 SEBU8597-03Reference Information SectionReference Materials

Reference Materialsi00912149

Maintenance RecordsSMCS Code: 1000; 4450

Caterpillar Inc. recommends the retention of accuratemaintenance records. Accurate maintenance recordscan be used for the following purposes:

• Determine operating costs.

• Establish maintenance schedules for other enginesthat are operated in the same environment.

• Show compliance with the required maintenancepractices and maintenance intervals.

Maintenance records can be used for a variety ofother business decisions that are related to enginemaintenance.

Maintenance records are a key element of amaintenance program that is well managed. Accuratemaintenance records can help your Caterpillar dealerto fine tune the recommended maintenance intervalsin order to meet the specific operating situation. Thisshould result in a lower engine operating cost.

Records should be kept for the following items:

Fuel Consumption – A record of fuel consumptionis essential in order to determine when the loadsensitive components should be inspected orrepaired. Fuel consumption also determines overhaulintervals.

Service Hours – A record of service hours isessential to determine when the speed sensitivecomponents should be inspected or repaired.

Documents – These items should be easy toobtain, and these items should be kept in the enginehistory file. All of the documents should show thisinformation: date, service hours, fuel consumption,unit number, and engine serial number. The followingtypes of documents should be kept as proof ofmaintenance or repair for warranty:

Keep the following types of documents as proof ofmaintenance for warranty. Also, keep these types ofdocuments as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owner's repair costs

• Owner's receipts

• Maintenance log


Reference Materials

i01176304

Maintenance LogSMCS Code: 1000; 4450

Table 14

Engine Model Customer Identifier

Serial Number Arrangement Number

ServiceHours

QuantityOf Fuel Service Item Date Authorization

108 SEBU8597-03Reference Information SectionReference Materials

i04291189

Reference MaterialSMCS Code: 1000; 4450

The following publications can be obtained from anyCaterpillar dealer.

Coolants• Special Publication, PMEP5027, “Label - ELCRadiator Label”

• Data Sheet, PEHJ0067, “Cat ELC (Extended LifeCoolant)”

• Data Sheet, PEHP7057, “Coolant Analysis”

• Data Sheet, PEHP9554, “Cat DEAC (DieselEngine Antifreeze/Coolant)”

• Special Publication, PELJ0176, “Cat ELC(Extended Life Coolant) 223-9116 Dilution Test Kit”

Fuels• Engine Data Sheet, LEKQ4219, “FuelRecommendations for Caterpillar Diesel Engines”

Greases• Data Sheet, NEHP6010, “Cat Ultra 5Moly Grease”

• Special Instruction, NEHP6011, “Arctic PlatinumGrease Spec Sheet”

• Data Sheet, NEHP6012, “Cat Desert Gold Grease”

• Data Sheet, NEHP6015, “Caterpillar SpecialPurpose Grease”

• Special Publication, PEGJ0035, “Grease SelectionGuide”

• Data Sheet, PEHP0002, “Molybdenum GreaseData Sheet”

• Data Sheet, PEHJ0088, “Cat Multipurpose Grease”

Lubricants• Special Publication, PEDP7035, “Optimizing OilChange Intervals”

• Data Sheet, PEHJ0008, “Cat Arctic DEO SYN ”

• Data Sheet, PEHJ0021, “Cat DEO (Diesel EngineOil) APD, EAME, LACD Only”

• Data Sheet, PEHJ0059, “Cat DEO (for NorthAmerica Only)”

• Special Publication, PEHP6001, “How To Take AGood Oil Sample”

• Special Instruction, PEHP7062, “Full SyntheticDiesel Engine Oil Data Sheet”

• Special Publication, PPHJ0072, “Cat DEO” (Brasil)

S·O·S Services• Special Publication, NEHP6013, “S·O·S FluidsAnalysis Products”

• Special Publication, PEDP7035, “Optimizing OilChange Intervals”

• Special Publication, PEDP7036, “S·O·S FluidsAnalysis Cornerstone”

• Special Publication, PEHP7057, “S·O·S CoolantAnalysis”

• Special Instruction, PEHP7058, “S·O·S TrendAnalysis Module Data Sheet”

• Special Instruction, PEHP7076, “UnderstandingS·O·S Services Tests”

Miscellaneous• Service Manual, SENR9910, “C9 Acert PetrolEngine”

• Special Instruction, NENG2500, “Caterpillar DealerService Tool Catalog”

• Special Publication, PECP9067, “One SafeSource”

• Special Publication, SEBF8029, “Index ofPublications on Reusability or Salvage of UsedParts”

• Special Publication, SEBF8062, “Procedure toInspect and Clean Air Filters”

• Special Publication, SEBU5898, “Cold WeatherRecommendations”

• Special Publication, SEBU6251, “CaterpillarCommercial Diesel Engine FluidsRecommendations”

• Special Instruction, SEHS7332, “Warning Tag - DoNot Operate”

• Special Instruction, SEHS7633, “Battery TestProcedure”


Reference Materials

• Special Instruction, SEHS9031, “StorageProcedure for Caterpillar Products”

• Specifications, SENR3130, “Torque Specifications”

• Special Instruction, SMHS7001, “Assembly of FanDrive Pulley Assemblies”

Additional Reference MaterialThe “Engine Fluids Data Book” can be obtained fromthe following locations: local technological society,local library, and local college. If necessary, consultEMA at the following address:

Engine Manufacturers AssociatonTwo North LaSalle Street, Suite 2200Chicago, IL, USA 60602E-mail: [email protected]: (312) 827-8700Facsimile: (312) 827-8737

The “Society of Automotive Engineers (SAE)Specifications” can be found in your SAE handbook.This publication can also be obtained from thefollowing locations: local technological society, locallibrary, and local college. If necessary, consult SAEat the following address:

SAE International400 Commonwealth DriveWarrendale, PA, USA 15096-0001Telephone: (724) 776-4841

The “American Petroleum Institute Publication No.1509” can be obtained from the following locations:local technological society, local library, and localcollege. If necessary, consult API at the followingaddress:

American Petroleum Institute1220 L St. N.W.Washington, DC, USA 20005Telephone: (202) 682-8000

The International Organization for Standardization(ISO) offers information and customer serviceregarding international standards and standardizingactivities. ISO can also supply information on thefollowing subjects that are not controlled by ISO:national standards, local standards, regulations,certification, and related activities. Consult themember of ISO in your country.

International Organization for Standardization(ISO)1, rue de VarembéCase postale 56CH-1211 Genève 20SwitzerlandTelephone: +41 22 749 01 11Facsimile: +41 22 733 34 30E-mail: [email protected] site: http://www.iso.ch

European classifications are established by theCounseil International Des Machines a Combustion(CIMAC) (International Council on CombustionEngines).

CIMAC Central SecretariatLyoner Strasse 1860528 FrankfurtGermanyTelephone: +49 69 6603 1567Facsimile: +49 69 6603 1566

i03989612

Decommissioning andDisposalSMCS Code: 1000

When the product is removed from service, localregulations for the product decommissioning willvary. Disposal of the product will vary with localregulations. Consult the nearest Cat dealer foradditional information.

110 SEBU8597-03Index Section

Index

A

After Starting Engine ............................................. 44Extended Idle at Cold Ambient Temperature ..... 44

After Stopping Engine............................................ 52Air Compressor - Check (If equipped) ................... 65Air Shutoff - Test (If Equipped) .............................. 65Caterpillar Provided Controls ............................. 65OEM Controls .................................................... 66

Air Tank Moisture and Sediment - Drain (IfEquipped) ............................................................ 66ARD Spark Plug - Replace .................................... 64Installing the Spark Plug .................................... 64Removing the Spark Plug .................................. 64

B

Battery - Recycle ................................................... 66Battery - Replace................................................... 66Battery Disconnect Switch (If Equipped) ............... 27Battery Electrolyte Level - Check .......................... 67Battery or Battery Cable - Disconnect ................... 67Before Starting Engine .................................... 14, 40Belts - Inspect/Adjust/Replace............................... 68Alternator Belt .................................................... 68Drive Belt for the Air Compressor (If Equipped).. 68Inspection........................................................... 68

Belts - Inspect/Replace (If Equipped) .................... 69Single Belt.......................................................... 69Two or More Belts .............................................. 70

Burn Prevention...................................................... 11Batteries.............................................................. 11Coolant................................................................ 11Oils...................................................................... 11

C

Cold Weather Operation........................................ 50Cold Weather Starting ........................................... 41Ether Injection System (If Equipped) ................. 41

Compression Brake - Inspect/Adjust/Replace....... 70Coolant (DEAC) - Change..................................... 70Cooling Systems with Heavy Deposits orPlugging ........................................................... 72Drain .................................................................. 71Fill ...................................................................... 72Flush .................................................................. 71

Coolant (ELC) - Change........................................ 72Drain .................................................................. 73Fill ...................................................................... 74Flush .................................................................. 73

Coolant Extender (ELC) - Add............................... 74Coolant Level - Check ........................................... 75Coolant Sample (Level 1) - Obtain ........................ 75Coolant Sample (Level 2) - Obtain ........................ 76

Cooling System Supplemental Coolant Additive(SCA) - Test/Add (Systems Which are Filled withConventional Coolant) ......................................... 77Maintain the Proper Concentration of SCA in theCoolant............................................................. 77

Crushing Prevention and Cutting Prevention ........ 13Customer Assistance........................................... 104Outside of the USA and of Canada.................. 104USA and Canada............................................. 104

Customer Service ................................................ 104

D

Decommissioning and Disposal .......................... 109Diagnostic Flash Code Retrieval ........................... 32Diesel Particulate Filter - Clean............................. 78Diesel Particulate Filter Regeneration ................... 45Modes of Regeneration...................................... 47Regeneration ..................................................... 45Regeneration Controls ....................................... 46Regeneration Indicator Lamps and Controls ..... 46Regeneration System Warning Indicators ......... 48Soot Level Monitoring ........................................ 47

Driven Equipment - Check..................................... 78Check the Alignment.......................................... 78Inspect the Drive Coupling................................. 78Inspect the Rear Gear Train .............................. 78

E

Electrical System................................................... 15Grounding Practices .......................................... 15

Emissions Certification Film .................................. 22Emissions Warranty Information.......................... 101Engaging the Driven Equipment............................ 49Engine - Clean....................................................... 78Engine Air Cleaner Element (Dual Element/BoxType) - Replace ................................................... 79Primary Filter...................................................... 79Secondary Filter................................................. 79

Engine Air Cleaner Element (Dual Element/CanisterType) - Clean/Replace (If Equipped) ................... 80Cleaning the Primary Air Cleaner Elements ...... 81Servicing the Air Cleaner Elements ................... 80

Engine Air Cleaner Element (Single Element/CanisterType) - Clean/Replace (If Equipped) ................... 83Inspecting Air Cleaner Elements........................ 83Servicing the Air Cleaner Elements ................... 83

Engine Air Cleaner Service Indicator - Inspect (IfEquipped) ............................................................ 84Test the Service Indicator................................... 84

Engine Diagnostics................................................ 32Engine Electronics................................................. 16Engine Mounts - Inspect........................................ 85

SEBU8597-03 111Index Section

Engine Oil and Filter - Change .............................. 86Drain the Engine Oil........................................... 87Fill the Engine Crankcase.................................. 88Replace the Oil Filter ......................................... 87Selection of Oil Change Interval ........................ 86

Engine Oil Level - Check....................................... 85Engine Oil Sample - Obtain ................................... 86Obtain the Sample and the Analysis.................. 86

Engine Operation................................................... 45Engine Rating Conditions.................................... 102Engine Rating Definitions .................................... 102Engine Ratings .................................................... 102Engine Starting ................................................ 14, 40Engine Stopping .............................................. 14, 52Engine Storage Procedure - Check....................... 88Engine Valve Lash - Check ................................... 88

F

Fault Logging......................................................... 39Features and Controls ........................................... 27Fire Prevention and Explosion Prevention ............. 11Ether .................................................................. 13Fire Extinguisher ................................................ 13Lines, Tubes, and Hoses ................................... 13

Fluid Recommendations........................................ 53Coolant............................................................... 57Diesel Engine Oil ............................................... 54Diesel Fuel Recommendations.......................... 55Lubricating Grease............................................. 56

Foreword ................................................................. 5California Proposition 65 Warning ....................... 5Literature Information........................................... 4Maintenance ........................................................ 4Maintenance Intervals.......................................... 4Operation ............................................................. 4Overhaul .............................................................. 4Safety................................................................... 4

Fuel and the Effect from Cold Weather ................. 50Fuel Conservation Practices.................................. 49Fuel Priming Pump - Replace................................ 89Fuel Related Components in Cold Weather .......... 51Fuel Heaters ...................................................... 51Fuel Tanks.......................................................... 51

Fuel System - Prime.............................................. 89Fuel System Primary Filter (Water Separator)Element - Replace ............................................... 89Replace the Element.......................................... 89

Fuel System Primary Filter/Water Separator -Drain .................................................................... 90Fuel System Secondary Filter - Replace............... 91Fuel Tank Water and Sediment - Drain ................. 92Drain the Water and the Sediment..................... 92Fuel Storage Tanks............................................ 92Fuel Tank ........................................................... 92

Fumes Disposal Filter Element - Replace ............. 92

G

General Hazard Information .................................... 8Containing Fluid Spillage ..................................... 9Dispose of Waste Properly ................................ 10Fluid Penetration.................................................. 9Inhalation ........................................................... 10Lines, Tubes, and Hoses ..................................... 9Pressurized Air and Water ................................... 9Softwrap............................................................. 10

General Information............................................... 17Grounding Stud - Inspect/Clean/Tighten ............... 93

H

Hoses and Clamps - Inspect/Replace ................... 93Inspect the Hoses and the Clamps .................... 94Replace the Hoses and the Clamps .................. 94

I

Important Safety Information ................................... 2

L

Lifting and Storage ................................................ 24

M

Maintenance Interval Schedule ............................. 62Maintenance Interval Schedule (Engines WithRatings Greater Than 439 hp) ............................. 63Maintenance Log................................................. 107Maintenance Recommendations........................... 59Maintenance Records.......................................... 106Maintenance Section............................................. 53Manual Stop Procedure......................................... 52Model View Illustrations......................................... 17Monitoring System................................................. 27Indicators and Gauges....................................... 27Mini Industrial Power Display (MIPD) ................ 29

Mounting and Dismounting.................................... 13

O

Operation Section.................................................. 24Ordering Replacement Parts ............................... 105Overhaul Considerations....................................... 96Oil Consumption as an Overhaul Indicator ........ 96Overhaul Recommendation ............................... 97

P

Plate Locations and Film Locations....................... 21Power Take-Off Clutch - Check ............................. 99

112 SEBU8597-03Index Section

Product Description ............................................... 19Aftermarket Products and Cat Engines.............. 20Electronic Engine Features................................ 20Engine Service Life ............................................ 20Engine Specifications......................................... 19

Product Identification Information .......................... 21Product Information Section .................................. 17Product Lifting........................................................ 24Clean Emission Module Lifting........................... 24Engine Lifting with a Fuel Tank .......................... 24

Product Storage..................................................... 25Removal from Storage....................................... 26Storage (Less Than One Year) .......................... 25

R

Radiator Restrictions ............................................. 50Reference Information ........................................... 22Reference Information Section ............................ 102Reference Material .............................................. 108Additional Reference Material.......................... 109Coolants........................................................... 108Fuels ................................................................ 108Greases ........................................................... 108Lubricants ........................................................ 108Miscellaneous .................................................. 108S·O·S Services................................................. 108

Reference Materials ............................................ 106Refill Capacities..................................................... 53Coolant Refill Capacity....................................... 53Lubricant Refill Capacity .................................... 53

S

Safety Messages..................................................... 6Safety Section ......................................................... 6Self-Diagnostics..................................................... 32Severe Service Application.................................... 60Improper Maintenance Procedures (MaintenanceProcedures Which May Contribute to a SevereService Application) ......................................... 61Severe Environmental Factors........................... 60Severe Operating Conditions............................. 60

Starting Motor - Inspect ....................................... 100Starting the Engine................................................ 41Problems with the Wiring Harness..................... 42Starting Problems .............................................. 42Starting the Engine ............................................ 41

Starting with Jump Start Cables (Do Not Use ThisProcedure in Hazardous Locations that haveExplosive Atmospheres) ...................................... 43System Pressure Release..................................... 59Coolant System.................................................. 59Engine Oil .......................................................... 59Fuel System....................................................... 59

T

Table of Contents..................................................... 3

W

Walk-Around Inspection ...................................... 100Inspect the Engine for Leaks and for LooseConnections ................................................... 100

Warranty Information ........................................... 101Warranty Section ................................................. 101Welding on Engines with Electronic Controls ........ 59

Product and Dealer InformationNote: For product identification plate locations, see the section “Product Identification Information” in the Operationand Maintenance Manual.

Delivery Date:

Product InformationModel:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer InformationName: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:

©2012 CaterpillarAll Rights Reserved

Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edgetrade dress, as well as corporate and product identity used herein, are trademarksof Caterpillar and may not be used without permission.