CAT. C15 and C18 Engines. Operation and Maintenance Manual (2014)

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Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe

basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous

situations before an accident occurs. A person must be alert to potential hazards, including human factors

that can affect safety. This person should also have the necessary training, skills and tools to perform these

functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could

result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you verify

that you are authorized to perform this work, and have read and understood the operation,

lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings

are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as

“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially

presented.

A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on

the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

The warnings in this publication and on the product are, therefore, not all inclusive. You must not

use this product in any manner different from that considered by this manual without first satisfying

yourself that you have considered all safety rules and precautions applicable to the operation of the

product in the location of use, including site-specific rules and precautions applicable to the

worksite. If a tool, procedure, work method or operating technique that is not specifically

recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others.

You should also ensure that you are authorized to perform this work, and that the product will not be

damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that

you intend to use.

The information, specifications, and illustrations in this publication are on the basis of information that was

available at the time that the publication was written. The specifications, torques, pressures,

measurements, adjustments, illustrations, and other items can change at any time. These changes can

affect the service that is given to the product. Obtain the complete and most current information before you

start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-

placement parts.

Failure to follow this warning may lead to pre-

mature failures, product damage, personal in-

jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and

systems may be performed by any repair establishment or individual of the owner's choosing.

SEBU8598

Table of Contents

Refill Capacities

Maintenance Recommendations

Foreword

Maintenance Interval Schedule (C15 Engines)54

Safety Section

Maintenance Interval Schedule (C15 Engines

Safety Messages

With Ratings Greater Than 579 hp)

General Hazard Information

Maintenance Interval Schedule (C18 Engines

With Ratings Greater Than 760 HP)

Burn Prevention

Maintenance Interval Schedule (C18 Engines)58

Fire Prevention and Explosion Prevention

Warranty Section

Crushing Prevention and Cutting Prevention . 13

Warranty Information

Mounting and Dismounting

Reference Information Section

Before Starting Engine

Engine Ratings

Engine Starting

Customer Service

Engine Stopping

Reference Materials

Electrical System

Engine Electronics

Index Section

Index

102

Product Information Section

General Information

Product Identification Information

Operation Section

Lifting and Storage

Features and Controls

Engine Diagnostics

Engine Starting

Engine Operation

Cold Weather Operation

Engine Stopping

Maintenance Section

SEBU8598

Foreword

Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance

Interval Schedule. The actual operating environment

of the engine also governs the Maintenance Interval

Literature Information

Schedule. Therefore, under extremely severe, dusty,

This manual contains safety, operation instructions,

wet or freezing cold operating conditions, more

lubrication and maintenance information. This manual

frequent lubrication and maintenance than is

should be stored in or near the engine area in a

specified in the Maintenance Interval Schedule may

literature holder or literature storage area. Read,

be necessary.

study and keep it with the literature and engine

The maintenance schedule items are organized for a

information.

preventive maintenance management program. If the

English is the primary language for all Cat

preventive maintenance program is followed, a

publications. The English used facilitates translation

periodic tune-up is not required. The implementation

and consistency in electronic media delivery.

of a preventive maintenance management program

should minimize operating costs through cost

Some photographs or illustrations in this manual

avoidances resulting from reductions in unscheduled

show details or attachments that may be different

downtime and failures.

from your engine. Guards and covers may have been

removed for illustrative purposes. Continuing

Maintenance Intervals

improvement and advancement of product design

may have caused changes to your engine which are

Perform maintenance on items at multiples of the

not included in this manual. Whenever a question

original requirement. Each level and/or individual

arises regarding your engine, or this manual, please

items in each level should be shifted ahead or back

consult with your Cat dealer for the latest available

depending upon your specific maintenance practices,

information.

operation and application. We recommend that the

maintenance schedules be reproduced and displayed

near the engine as a convenient reminder. We also

Safety

recommend that a maintenance record be maintained

as part of the engine's permanent record.

This safety section lists basic safety precautions. In

addition, this section identifies hazardous, warning

See the section in the Operation and Maintenance

situations. Read and understand the basic

Manual, “Maintenance Records” for information

precautions listed in the safety section before

regarding documents that are generally accepted as

operating or performing lubrication, maintenance and

proof of maintenance or repair. Your authorized Cat

repair on this product.

dealer can assist you in adjusting your maintenance

schedule to meet the needs of your operating

Operation

environment.

Operating techniques outlined in this manual are

Overhaul

basic. They assist with developing the skills and

techniques required to operate the engine more

Major engine overhaul details are not covered in the

efficiently and economically. Skill and techniques

Operation and Maintenance Manual except for the

develop as the operator gains knowledge of the

interval and the maintenance items in that interval.

engine and its capabilities.

Major repairs are best left to trained personnel or an

authorized Cat dealer. Your Cat dealer offers a variety

The operation section is a reference for operators.

of options regarding overhaul programs. If you

Photographs and illustrations guide the operator

experience a major engine failure, there are also

through procedures of inspecting, starting, operating

numerous after failure overhaul options available

and stopping the engine. This section also includes a

from your Cat dealer. Consult with your dealer for

discussion of electronic diagnostic information.

information regarding these options.

Maintenance

California Proposition 65 Warning

The maintenance section is a guide to engine care.

Diesel engine exhaust and some of its constituents

The illustrated, step-by-step instructions are grouped

are known to the State of California to cause cancer,

by fuel consumption, service hours and/or calendar

birth defects, and other reproductive harm.

time maintenance intervals. Items in the maintenance

schedule are referenced to detailed instructions that

Battery posts, terminals and related accessories

follow.

contain lead and lead compounds. Wash hands after

Use fuel consumption or service hours to determine

handling.

intervals. Calendar intervals shown (daily, annually,

etc.) may be used instead of service meter intervals if

they provide more convenient schedules and

approximate the indicated service meter reading.

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Safety Section

Safety Messages

Safety Section

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Safety Messages

SMCS Code: 1000; 7405

There may be several specific safety messages on

your engine. The exact location and a description of

the safety messages are reviewed in this section.

Become familiar with all safety messages.

Ensure that all of the safety messages are legible.

Clean the safety messages or replace the safety

messages if the words cannot be read or if the

illustrations are not visible. Use a cloth, water, and

soap to clean the safety messages. Do not use

solvents, gasoline, or other harsh chemicals.

Solvents, gasoline, or harsh chemicals could loosen

the adhesive that secures the safety messages. The

safety messages that are loosened could drop off the

engine.

Replace any safety message that is damaged or

missing. If a safety message is attached to a part of

the engine that is replaced, install a new safety

message on the replacement part. Your Caterpillar

dealer can provide new safety messages.

Illustration 1

g02295113

View of the right side of a typical C15 or C18 Industrial Engine

SEBU8598

Safety Section

Safety Messages

Universal Warning (1)

Sulfuric Acid Burn (2)

Illustration 2

g01370904

One safety message is located on the left side of the

valve cover. One safety message is located on the

right side of the valve cover.

Illustration 3

g01382725

Do not operate or work on this equipment unless

One safety message for sulfuric acid burn is located

you have read and understand the instructions

on top of the exhaust cooler. One safety message for

and warnings in the Operation and Maintenance

sulfuric acid burn is located on the right side of the

Manual. Failure to follow the instructions or heed

exhaust cooler.

the warnings could result in injury or death. Con-

tact any Caterpillar dealer for replacement man-

uals. Proper care is your responsibility.

Sulfuric Acid Burn Hazard may cause serious per-

sonal injury or death.

The exhaust gas cooler may contain a small

amount of sulfuric acid. The use of fuel with sulfur

levels greater than 15 ppm may increase the

amount of sulfuric acid formed. The sulfuric acid

may spill from the cooler during service of the en-

gine. The sulfuric acid will burn the eyes, skin and

clothing on contact. Always wear the appropriate

personal protective equipment (PPE) that is noted

on a material safety data sheet (MSDS) for sulfuric

acid. Always follow the directions for first aid that

are noted on a material safety data sheet (MSDS)

for sulfuric acid.

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Safety Section

General Hazard Information

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General Hazard Information

SMCS Code: 1000; 4450; 7405

Illustration 5

g00702020

• Wear a hard hat, protective glasses, and other

protective equipment, as required.

• When work is performed around an engine that is

Illustration 4

g00104545

operating, wear protective devices for ears in order

to help prevent damage to hearing.

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

switch or controls before the engine is serviced or

• Do not wear loose clothing or jewelry that can snag

repaired. These warning tags (Special Instruction,

on controls or on other parts of the engine.

SEHS7332) are available from your Cat dealer.

Attach the warning tags to the engine and to each

• Ensure that all protective guards and all covers are

operator control station. When appropriate,

secured in place on the engine.

disconnect the starting controls.

• Never put maintenance fluids into glass

Do not allow unauthorized personnel on the engine,

containers. Glass containers can break.

or around the engine when the engine is being

serviced.

• Use all cleaning solutions with care.

Cautiously remove the following parts. To help

• Report all necessary repairs.

prevent spraying or splashing of pressurized fluids,

hold a rag over the part that is being removed.

Unless other instructions are provided, perform

the maintenance under the following conditions:

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed.

Gradually loosen, but do not remove the last two bolts

or nuts that are located at opposite ends of the cover

plate or the device. Before removing the last two bolts

or nuts, pry the cover loose in order to relieve any

spring pressure or other pressure.

SEBU8598

Safety Section

General Hazard Information

• The engine is stopped. Ensure that the engine

Fluid Penetration

cannot be started.

• The protective locks or the controls are in the

applied position.

• Disconnect the batteries when maintenance is

performed or when the electrical system is

serviced. Disconnect the battery ground leads.

Tape the leads in order to help prevent sparks.

• When starting a new engine, make provisions to

stop the engine if an overspeed occurs. If an

engine has not been started since service has

been performed, make provisions to stop the

engine if an overspeed occurs. Shutting down the

engine may be accomplished by shutting off the

fuel supply and/or the air supply to the engine.

Illustration 6

g00687600

• Do not attempt any repairs that are not

Always use a board or cardboard when you check for

understood. Use the proper tools. Replace any

a leak. Leaking fluid that is under pressure can

equipment that is damaged or repair the

penetrate body tissue. Fluid penetration can cause

equipment.

serious injury and possible death. A pin hole leak can

cause severe injury. If fluid is injected into your skin,

• Start the engine with the operator controls. Never

you must get treatment immediately. Seek treatment

short across the starting motor terminals or the

from a doctor that is familiar with this type of injury.

batteries. This method of starting the engine could

bypass the engine neutral start system and/or the

Containing Fluid Spillage

electrical system could be damaged.

NOTICE

Pressurized Air and Water

Care must be taken to ensure that fluids are con-

tained during performance of inspection, mainte-

Pressurized air and/or water can cause debris and/or

nance, testing, adjusting, and repair of the product.

hot water to be blown out which could result in

Be prepared to collect the fluid with suitable contain-

personal injury.

ers before opening any compartment or disassem-

The maximum air pressure for cleaning purposes

bling any component containing fluids.

must be reduced to 205 kPa (30 psi) when the air

nozzle is deadheaded and used with effective chip

Refer to Special Publication, NENG2500, “Cat Dealer

guarding (if applicable) and personal protective

Service Tool Catalog” or refer to Special Publication,

PECJ0003, “Cat Shop Supplies and Tools Catalog”

equipment. The maximum water pressure for

for tools and supplies suitable to collect and contain

cleaning purposes must be below 275 kPa (40 psi).

fluids on Cat products.

When pressurized air and/or pressurized water is

used for cleaning, wear protective clothing, protective

Dispose of all fluids according to local regulations and

shoes, and eye protection. Eye protection includes

mandates.

goggles or a protective face shield. Always wear eye

protection for cleaning the cooling system.

Avoid direct spraying of water on electrical

connectors, connections, and components. When

using air for cleaning, allow the machine to cool to

reduce the possibility of fine debris igniting when

redeposited on hot surfaces.

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Safety Section

General Hazard Information

Static Electricity Hazard when

Ensure that all of the clamps, the guards, and the

heat shields are installed correctly. Correct installation

Fueling with Ultra-low Sulfur Diesel

of these components will help to prevent these

Fuel

effects: vibration, rubbing against other parts and

excessive heat during operation.

The removal of sulfur and other compounds in ultra-

low sulfur diesel fuel (ULSD fuel) decreases the

Inhalation

conductivity of ULSD and increases the ability of

ULSD to store static charge. Refineries may have

treated the fuel with a static dissipating additive.

Many factors can reduce the effectiveness of the

additive over time. Static charges can build up in

ULSD fuel while the fuel is flowing through fuel

delivery systems. Static electricity discharge when

combustible vapors are present could result in a fire

or explosion. Ensure that the entire system used to

refuel your machine (fuel supply tank, transfer pump,

transfer hose, nozzle, and others) is properly

grounded and bonded. Consult with your fuel or fuel

system supplier to ensure that the delivery system

complies with fueling standards for proper grounding

and bonding.

Illustration 7

g02159053

Avoid static electricity risk when fueling. Ultra-low

Exhaust

sulfur diesel fuel (ULSD fuel) poses a greater stat-

ic ignition hazard than earlier diesel formulations

Use caution. Exhaust fumes can be hazardous to

with a higher sulfur contents. Avoid death or seri-

your health. If you operate the equipment in an

ous injury from fire or explosion. Consult with

enclosed area, adequate ventilation is necessary.

your fuel or fuel system supplier to ensure the de-

livery system is in compliance with fueling stand-

Asbestos Information

ards for proper grounding and bonding practices.

Cat equipment and replacement parts that are

shipped from Caterpillar are asbestos free. Caterpillar

Lines, Tubes, and Hoses

recommends the use of only genuine Cat

replacement parts. Use the following guidelines when

Do not bend or strike high-pressure lines. Do not

you handle any replacement parts that contain

install lines, tubes, or hoses that are damaged.

asbestos or when you handle asbestos debris.

Repair any fuel lines, oil lines, tubes, or hoses that

Use caution. Avoid inhaling dust that might be

are loose or damaged. Leaks can cause fires.

generated when you handle components that contain

asbestos fibers. Inhaling this dust can be hazardous

Inspect all lines, tubes, and hoses carefully. Do not

to your health. The components that may contain

use bare hands to check for leaks. Always use a

asbestos fibers are brake pads, brake bands, lining

board or cardboard for checking engine components

material, clutch plates, and some gaskets. The

for leaks. Tighten all connections to the

asbestos that is used in these components is bound

recommended torque.

in a resin or sealed in some way. Normal handling is

not hazardous unless airborne dust that contains

Check for the following conditions:

asbestos is generated.

• End fittings that are damaged or leaking

If dust that may contain asbestos is present, there are

several guidelines that should be followed:

• 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

SEBU8598

Safety Section

Burn Prevention

• Never use compressed air for cleaning.

Dispose of Waste Properly

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos

materials.

• A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be

used.

• Use exhaust ventilation on permanent machining

jobs.

• Wear an approved respirator if there is no other

way to control the dust.

Illustration 8

g00706404

• Comply with applicable rules and regulations for

Improperly disposing of waste can threaten the

the work place. In the United States, use

environment. Potentially harmful fluids should be

Occupational Safety and Health Administration

disposed of according to local regulations.

(OSHA) requirements. These OSHA requirements

can be found in “29 CFR 1910.1001”.

Always use leakproof containers when you drain

fluids. Do not pour waste onto the ground, down a

• Obey environmental regulations for the disposal of

drain, or into any source of water.

asbestos.

• Stay away from areas that might have asbestos

i03895768

particles in the air.

Burn Prevention

Softwrap

SMCS Code: 1000; 4450; 7405

Keep the engine room ventilation operating at full

Do not touch any part of an operating engine or

capacity. Wear a particulate respirator that has been

engine aftertreatment system. Allow the engine or the

approved by the National Institute of Occupational

engine aftertreatment system to cool before any

Safety and Health (NIOSH). Wear appropriate

maintenance is performed on the engine or the

protective clothing in order to minimize direct contact.

engine aftertreatment system. Relieve all pressure in

Use good hygiene practices and wash hands

the appropriate system before any lines, fittings or

thoroughly after handling Softwrap material. Do not

related items are disconnected.

smoke until washing hands thoroughly after handling

Softwrap material. Clean up debris with a vacuum or

Coolant

by wet sweeping. Do not use pressurized air to clean

up debris.

When the engine is at operating temperature, the

engine coolant is hot. The coolant is also under

Reference: The applicable material safety data

pressure. The radiator and all lines to the heaters or

sheets can be found at the following web site by

to the engine contain hot coolant. Any contact with

searching using part number or the name:

hot coolant or with steam can cause severe burns.

Allow cooling system components to cool before the

http://dsf2ws.cat.com/msds/servlet/

cooling system is drained.

cat.cis.ecs.msdsSearch.controller.

UserIdentificationDisplayServlet

Check the coolant level after the engine has stopped

and the engine has been allowed to cool. Ensure that

the filler cap is cool before removing the filler cap.

The filler cap must be cool enough to touch with a

bare hand. Remove the filler cap slowly in order to

relieve pressure.

Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contact

the skin, the eyes, or the mouth.

SEBU8598

Safety Section

Fire Prevention and Explosion Prevention

Oils

A flash fire may result if the covers for the engine

crankcase are removed within 15 minutes after an

Hot oil and hot lubricating components can cause

emergency shutdown.

personal injury. Do not allow hot oil or hot

components to contact the skin.

Determine whether the engine will be operated in an

environment that allows combustible gases to be

If the application has a makeup tank, remove the cap

drawn into the air inlet system. These gases could

for the makeup tank after the engine has stopped.

cause the engine to overspeed. Personal injury,

The filler cap must be cool to the touch.

property damage, or engine damage could result.

Batteries

If the application involves the presence of

combustible gases, consult your Cat dealer for

The liquid in a battery is an electrolyte. Electrolyte is

additional information about suitable protection

an acid that can cause personal injury. Do not allow

devices.

electrolyte to contact the skin or the eyes.

Remove all flammable materials such as fuel, oil, and

Do not smoke while checking the battery electrolyte

debris from the engine. Do not allow any flammable

levels. Batteries give off flammable fumes which can

materials to accumulate on the engine.

explode.

All fluids that are captured in the fluid spill

Always wear protective glasses when you work with

containment basin should be cleaned up immediately.

batteries. Wash hands after touching batteries. The

Failure to clean up spilled fluids can cause a fire. Fire

use of gloves is recommended.

may cause personal injury and property damage.

Store fuels and lubricants in properly marked

i05626649

containers away from unauthorized persons. Store

oily rags and any flammable materials in protective

Fire Prevention and Explosion

containers. Do not smoke in areas that are used for

storing flammable materials.

Prevention

Do not expose the engine to any flame.

SMCS Code: 1000; 4450; 7405

Exhaust shields (if equipped) protect hot exhaust

components from oil or fuel spray in a line, a tube, or

a seal failure. Exhaust shields must be installed

correctly.

Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines or tanks that contain

flammable fluid. Clean any such lines or tanks

thoroughly with a nonflammable solvent prior to

welding or flame cutting.

Wiring must be kept in good condition. Properly route

and attach all electrical wires. Check all electrical

wires daily. Repair any wires that are loose or frayed

before you operate the engine. Clean all electrical

connections and tighten all electrical connections.

Eliminate all wiring that is unattached or unnecessary.

Illustration 9

g00704000

Do not use any wires or cables that are smaller than

the recommended gauge. Do not bypass any fuses

Use of personal protection equipment (PPE) may be

and/or circuit breakers.

needed.

Arcing or sparking could cause a fire. Secure

All fuels, most lubricants, and some coolant mixtures

connections, recommended wiring, and properly

are flammable.

maintained battery cables will help to prevent arcing

or sparking.

Always perform a Walk-Around Inspection, which

may help you identify a fire hazard. Do not operate a

Inspect all lines and hoses for wear or for

product when a fire hazard exists. Contact your Cat

deterioration. Properly route all hoses. The lines and

dealer for service.

hoses must have adequate support and secure

clamps. Tighten all connections to the recommended

Flammable fluids that are leaking or spilled onto hot

torque. Leaks can cause fires.

surfaces or onto electrical components can cause a

fire. Fire may cause personal injury and property

Properly install all oil filters and fuel filters. The filter

damage.

housings must be tightened to the proper torque.

SEBU8598

Safety Section

Fire Prevention and Explosion Prevention

Illustration 10

g00704059

Illustration 11

g02298225

Use caution when you are refueling an engine. Do not

Gases from a battery can explode. Keep any open

smoke while you are refueling an engine. Do not

flames or sparks away from the top of a battery. Do

refuel an engine near open flames or sparks. Always

not smoke in battery charging areas.

stop the engine before refueling.

Never check the battery charge by placing a metal

Avoid static electricity risk when fueling. Ultra Low

object across the terminal posts. Use a voltmeter or a

Sulfur Diesel (ULSD) poses a greater static ignition

hydrometer.

hazard than earlier diesel formulations with a higher

Sulfur content. Avoid death or serious injury from fire

Improper jumper cable connections can cause an

or explosion. Consult with your fuel or fuel system

explosion that can result in injury. Refer to the

supplier to ensure that the delivery system is in

Operation Section of this manual for specific

compliance with fueling standards for proper

instructions.

grounding and bonding practices.

Do not charge a frozen battery. Charging a frozen

battery may result in an explosion.

The batteries must be kept clean. The covers (if

equipped) must be kept on the cells. Use the

recommended cables, connections, and battery box

covers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be

familiar with the operation of the fire extinguisher.

Inspect the fire extinguisher and service the fire

extinguisher regularly. Obey the recommendations on

the instruction plate.

Ether

Ether is flammable and poisonous.

Use ether in ventilated areas. Do not smoke while

you are replacing an ether cylinder or while you are

using an ether spray.

SEBU8598

Safety Section

Crushing Prevention and Cutting Prevention

Do not store ether cylinders in living areas or in the

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

engine compartment. Do not store ether cylinders in

Leave the guards in place until maintenance is

direct sunlight or in temperatures above 49 °C

performed. After the maintenance is performed,

(120 °F). Keep ether cylinders away from open

reinstall the guards.

flames or sparks.

Keep objects away from moving fan blades. The fan

Dispose of used ether cylinders properly. Do not

blades will throw objects or cut objects.

puncture an ether cylinder. Keep ether cylinders away

from unauthorized personnel.

When objects are struck, wear protective glasses in

order to avoid injury to the eyes.

Do not spray ether into an engine if the engine is

equipped with a thermal starting aid for cold weather

Chips or other debris may fly off objects when objects

starting.

are struck. Before objects are struck, ensure that no

one will be injured by flying debris.

Lines, Tubes, and Hoses

i01372247

Do not bend high-pressure lines. Do not strike high-

pressure lines. Do not install any lines that are bent or

Mounting and Dismounting

damaged.

SMCS Code: 1000; 4450; 7405

Repair any lines that are loose or damaged. Leaks

can cause fires. Consult your Cat dealer for repair or

Inspect the steps, the handholds, and the work area

for replacement parts.

before mounting the engine. Keep these items clean

and keep these items in good repair.

Check lines, tubes, and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or

Mount the engine and dismount the engine only at

cardboard to check for leaks. Tighten all connections

locations that have steps and/or handholds. Do not

to the recommended torque.

climb on the engine, and do not jump off the engine.

Replace the parts if any of the following conditions

Face the engine in order to mount the engine or

are present:

dismount the engine. Maintain a three-point contact

with the steps and handholds. Use two feet and one

• End fittings are damaged or leaking.

hand or use one foot and two hands. Do not use any

controls as handholds.

• Outer coverings are chafed or cut.

Do not stand on components which cannot support

• Wires are exposed.

your weight. Use an adequate ladder or use a work

platform. Secure the climbing equipment so that the

• Outer coverings are ballooning.

equipment will not move.

• Flexible parts of the hoses are kinked.

Do not carry tools or supplies when you mount the

engine or when you dismount the engine. Use a hand

• Outer covers have embedded armoring.

line to raise and lower tools or supplies.

• End fittings are displaced.

i03560601

Make sure that all clamps, guards, and heat shields

are installed correctly in order to prevent vibration,

Before Starting Engine

rubbing against other parts, and excessive heat.

SMCS Code: 1000

i01359666

NOTICE

For initial start-up of a new or rebuilt engine, and for

Crushing Prevention and

start-up of an engine that has been serviced, make

Cutting Prevention

provision to shut the engine off should an overspeed

occur. This may be accomplished by shutting off the

SMCS Code: 1000; 4450; 7405

air and/or fuel supply to the engine.

Support the component properly when work beneath

the component is performed.

Unless other maintenance instructions are provided,

never attempt adjustments while the engine is

running.

SEBU8598

Safety Section

Engine Starting

To ensure that the jacket water heater (if equipped)

and/or the lube oil heater (if equipped) is working

properly, check the water temperature gauge and the

Engine exhaust contains products of combustion

oil temperature gauge during the heater operation.

which may be harmful to your health. Always start

and operate the engine in a well ventilated area

Engine exhaust contains products of combustion that

and, if in an enclosed area, vent the exhaust to the

can be harmful to your health. Always start the engine

outside.

and operate the engine in a ventilated area. If the

engine is started in an enclosed area, vent the engine

exhaust to the outside.

Inspect the engine for potential hazards.

i01462046

Do not start the engine or move any of the controls if

there is a “DO NOT OPERATE” warning tag or

similar warning tag attached to the start switch or to

Engine Stopping

the controls.

SMCS Code: 1000

Before starting the engine, ensure that no one is on,

Stop the engine according to the procedure in the

underneath, or close to the engine. Ensure that the

Operation and Maintenance Manual, “Engine

area is free of personnel.

Stopping (Operation Section)” in order to avoid

If equipped, ensure that the lighting system for the

overheating of the engine and accelerated wear of

engine is suitable for the conditions. Ensure that all

the engine components.

lights work properly, if equipped.

Use the Emergency Stop Button (if equipped) ONLY

in an emergency situation. Do not use the Emergency

All protective guards and all protective covers must

Stop Button for normal engine stopping. After an

be installed if the engine must be started in order to

perform service procedures. To help prevent an

emergency stop, DO NOT start the engine until the

accident that is caused by parts in rotation, work

problem that caused the emergency stop has been

around the parts carefully.

corrected.

Stop the engine if an overspeed condition occurs

Do not bypass the automatic shutoff circuits. Do not

during the initial start-up of a new engine or an engine

disable the automatic shutoff circuits. The circuits are

that has been overhauled. This may be accomplished

provided in order to help prevent personal injury. The

by shutting off the fuel supply to the engine and/or

circuits are also provided in order to help prevent

engine damage.

shutting off the air supply to the engine.

See the Service Manual for repairs and for

To stop an electronically controlled engine, cut the

adjustments.

power to the engine.

i03941639

i03896010

Engine Starting

Electrical System

SMCS Code: 1000

SMCS Code: 1000; 1400

If a warning tag is attached to the engine start switch

Never disconnect any charging unit circuit or battery

or to the controls, DO NOT start the engine or move

circuit cable from the battery when the charging unit is

the controls. Consult with the person that attached

operating. A spark can cause the combustible gases

the warning tag before the engine is started.

that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible

All protective guards and all protective covers must

gases that are produced by some batteries, the

be installed if the engine must be started in order to

perform service procedures. To help prevent an

negative “-” jump start cable should be connected

accident that is caused by parts in rotation, work

last from the external power source to the negative

around the parts carefully.

“-” terminal of the starting motor. If the starting motor

is not equipped with a negative “-” terminal, connect

Start the engine with the engine start switch.

the jump start cable to the engine block.

Always start the engine according to the procedure

Check the electrical wires daily for wires that are

that is described in this Operation and Maintenance

loose or frayed. Tighten all loose electrical wires

Manual, “Starting the Engine” for information about

before the engine is started. Repair all frayed

starting the engine. Know the correct procedure to

electrical wires before the engine is started. Refer to

prevent major damage to the engine components.

the “Engine Starting” section of this Operation and

Know the correct procedure to prevent personal

Maintenance Manual for specific starting instructions.

injury.

SEBU8598

Safety Section

Engine Electronics

Grounding Practices

The Engine Monitoring package can vary for different

engine models and different engine applications.

Proper grounding for the engine electrical system is

However, the monitoring system and the engine

necessary for optimum engine performance and

monitoring control will be similar for all engines.

reliability. Improper grounding will result in

uncontrolled electrical circuit paths and in unreliable

Note: Many of the engine control systems and

electrical circuit paths.

display modules that are available for Caterpillar

Engines will work in unison with the Engine

Uncontrolled electrical circuit paths can result in

Monitoring System. Together, the two controls will

damage to main bearings, to crankshaft bearing

provide the engine monitoring function for the specific

journal surfaces, and to aluminum components.

engine application. Refer to the Troubleshooting

Manual for more information.

Engines that are installed without engine-to-frame

ground straps can be damaged by electrical

discharge.

To ensure that the engine and the engine electrical

systems function properly, an engine-to-frame ground

strap with a direct path to the battery must be used.

This path may be provided by way of a starting motor

ground, a starting motor ground to the frame, or a

direct engine ground to the frame.

All grounds should be tight and free of corrosion. The

engine alternator must be grounded to the negative

“-” battery terminal with a wire that is adequate to

handle the full charging current of the alternator.

i04021529

Engine Electronics

SMCS Code: 1000; 1900

Tampering with the electronic system installation

or the OEM wiring installation can be dangerous

and could result in personal injury or death and/or

engine damage.

The Electronic Control Module (ECM) provides a

comprehensive, programmable engine monitoring

system for this engine. The ECM monitors specific

engine operating parameters in order to detect

abnormal conditions that may develop. The ECM will

generate an event code if a specific engine parameter

exceeds an acceptable range that is defined by the

engine monitoring system. The ECM will react with an

action that is dependent on the severity of the

condition. For information on event codes, refer to

this Operation and Maintenance Manual, “Event

Codes” topic (Operation Section) The following

actions may be initiated by the ECM. These actions

are dependent on the severity of the condition:

• Illumination of a warning lamp or warning alarm

• Engine derate

• Engine protection shutdown

SEBU8598

General Information

Product Description

Electronic Engine Features

The Caterpillar C15 and C18 Engine are designed

for electronic controls. The integral on board

computer controls the operation of the engine.

Current operating conditions are monitored. The

Electronic Control Module (ECM) controls the

response of the engine to these conditions and to the

demands of the operator. These conditions and

operator demands determine the precise control of

fuel injection by the ECM. The electronic engine

control system provides the following features:

• Engine speed governor

• Automatic air/fuel ratio control

Illustration 14

g01387009

• Torque rise shaping

Cylinder and valve location

(A) Exhaust valve

• Injection timing control

(B) Inlet valve

• System diagnostics

Table 1

C15 Engine Specifications

• Aftertreatment regeneration control

Arrangement and Cylinders

In-line six cylinder

• NOx reduction system control

Bore

137 mm (5.4 inch)

Additional Features

Stroke

171 mm (6.7 inch)

The following additional features provide increased

Aspiration

ATAAC⁽¹⁾

engine fuel economy and serviceability:

Displacement

15.2 L (928 cubic inch)

• Cold starting capability

Firing Order

1-5-3-6-2-4

• Tampering detection

Rotation (flywheel end)

Counterclockwise

⁽¹⁾ Air-to-air aftercooled

• Diagnostics

Table 2

Engine Diagnostics

C18 Engine Specifications

The engine has built-in diagnostics in order to ensure

Arrangement and Cylinders

In-Line six cylinder

that all of the components are functioning properly.

Under certain conditions, the engine horsepower and

Bore

145 mm (5.7 inch)

the vehicle speed may be limited. A Caterpillar

Stroke

183 mm (7.2 inch)

electronic service tool may be used to display the

diagnostic code.

Aspiration

ATAAC⁽¹⁾

There are two categories of codes: diagnostic code

Displacement

18.1 L (1105 cubic inch)

and event code. These two categories of codes may

Firing Order

1-5-3-6-2-4

be in two different states: active and logged.

Rotation (flywheel end)

Counterclockwise

Most of the diagnostic codes are logged and stored in

the ECM. For additional information, refer to the

⁽¹⁾ Air-to-air aftercooled

Operation and Maintenance Manual, “Engine

Diagnostics” topic (Operation Section).

Engine Service Life

Engine efficiency and maximum utilization of engine

performance depend on the adherence to proper

operation and maintenance recommendations. In

addition, use recommended fuels, coolants, and

lubricants. Use the Operation and Maintenance

Manual as a guide for required engine maintenance.

SEBU8598

General Information

Product Description

Expected engine life is predicted by the average

power that is demanded. The average power that is

demanded is based on fuel consumption of the

engine over a time. Reduced hours of operation at full

throttle and/or operating at reduced throttle settings

result in a lower average power demand. Reduced

hours of operation will increase the length of

operating time before an engine overhaul is required.

For more information, refer to the Operation and

Maintenance Manual, “Overhaul Considerations”

topic (Maintenance Section).

Aftermarket Products and Caterpillar

Engines

NOTICE

In order to maximize fuel system life and prevent pre-

mature wear out from abrasive particles in the fuel, a

four micron[c] absolute high efficiency fuel filter is re-

quired for all Caterpillar common rail fuel systems.

Caterpillar High Efficiency Fuel Filters meet these re-

quirements. Consult your Caterpillar dealer for the

proper part numbers.

When auxiliary devices, accessories, or consumables

(filters, additives, catalysts, etc.) which are made by

other manufacturers are used on Caterpillar

products, the Caterpillar warranty is not affected

simply because of such use.

However, failures that result from the installation

or use of devices, accessories, or consumables

from other manufacturers are NOT Caterpillar

defects. Therefore, the defects are NOT covered

under the Caterpillar warranty.

SEBU8598

Product Identification Information

Plate Locations and Film Locations

Product Identification

Information

i04092302

Plate Locations and Film

Locations

SMCS Code: 1000; 4450

Illustration 17

g02272993

View of the top of a typical C15 or C18 Industrial

Engine

The engine information plate is located toward the

rear of the valve cover. The engine information plate

may be read from the right side of the engine.

Illustration 15

g02273593

View of the left side of a typical C15 or C18 Industrial

Engine

Illustration 18

g01347963

The serial number plate is located on the left side of

the cylinder block. The engine control module will

Engine information plate

obstruct the view of the serial number plate.

The following information is on the information plate:

engine serial number, engine model, engine

arrangement number, maximum altitude of the engine

that is necessary to achieve the rated power,

horsepower, high idle, full load rpm, fuel settings and

other information

Illustration 16

g00123229

Serial number plate

The following information is stamped on the serial

number plate: engine serial number, engine model

and arrangement number.

SEBU8598

Product Identification Information

Emissions Certification Film

This label is located on the engine.

i00844066

Emissions Certification Film

SMCS Code: 1000; 7405

S/N: BDN1-Up

Illustration 21

g00284658

EPA Emissions Certification Film

Illustration 19

g02236893

View of the exhaust system of a C15 or C18 Industrial

Engine

Illustration 22

g00415538

European Emissions Certification Film

The EPA Emissions Certification Film (if equipped)

and/or the European Emissions Certification Film (if

Illustration 20

g02236574

equipped) is located on the side of the engine.

CEM plate

The Clean Emission Module (CEM) identification

i01382270

plate contains the following information: part number,

serial number, change level and configuration ID

Reference Information

code. This information may be needed by the Cat

SMCS Code: 1000; 4450

dealer when inquiries are being made on the CEM.

Identification of the items in Table 3 may be needed

i04019095

in order to obtain parts and service. Some of the

information is on the engine Serial Number Plate and/

or Information Plate. Locate the information for your

Emissions Certification Film

engine. Record the information on the appropriate

SMCS Code: 1000; 7405

space in Table 3 . Make a copy of this list for a record.

Retain the information for future reference.

Note: This information is pertinent in the United

States, in Canada and in Europe.

Consult your Cat dealer for an Emission Control

Warranty Statement.

SEBU8598

Product Identification Information

Reference Information

The top level part numbers in the Parts Manual for the

engine are listed with the engine arrangement

number. Occasionally, an arrangement may be

slightly modified before the product is shipped from

the factory. In these cases, a modification number

indicates that the arrangement has been modified.

The packaging arrangement may also be called a

pricing arrangement or a customer arrangement. This

is the total package with attachments and options that

are not included in the engine arrangement.

The performance specification can be used by your

Caterpillar dealer with the Technical Marketing

Information system. Before the engine leaves the

factory, the engine performance is tested. Detailed

performance data is recorded. The performance

specification number can be used for obtaining the

data.

Table 3

Reference Information

Engine Model

Serial Number

Arrangement Number

Modification Number

Packaging Arrangement

Turbocharger

Fuel Filter Element

Lubrication Oil Filter Element

Auxiliary Oil Filter Element

Air Cleaner Element

Fan Drive Belt

Alternator Belt

Capacity of the Lubrication

System

Capacity of the Cooling System

Performance Specification

Number

Personality Module

Low Idle rpm

High Idle rpm

Full Load rpm

Power Rating

SEBU8598

Operation Section

Product Lifting

Engine Lifting with a Fuel Tank

Operation Section

Lifting and Storage

Lift eyes or tank can fail when lifting tank contain-

ing fluids resulting in possible personal injury.

i04037083

Drain tank of all fluids before lifting.

Product Lifting

Lifting the engine with a fuel tank that is mounted to

SMCS Code: 7000; 7002

the engine requires special equipment and

procedures. Do not lift the unit with fuel in the fuel

tank. Consult your Caterpillar dealer for information

regarding fixtures for proper lifting of your complete

package.

Clean Emission Module Lifting

Illustration 23

g00103219

NOTICE

Never bend the eyebolts and the brackets. Only load

the eyebolts and the brackets under tension. Remem-

ber that the capacity of an eyebolt is less as the angle

between the supporting members and the object be-

comes less than 90 degrees.

When it is necessary to remove a component at an

angle, only use a link bracket that is properly rated for

the weight.

Use a hoist to remove heavy components. Use an

adjustable lifting beam to lift the engine. All

supporting members (chains and cables) should be

parallel to each other. The chains and cables should

be perpendicular to the top of the object that is being

lifted.

Illustration 24

g02240095

Some removals require lifting the fixtures in order to

The Clean Emission Module (CEM) should only be

obtain proper balance and safety.

lifted by the designated lifting eyes (1). Lifting eye

locations will be different depending on the CEM

To remove the engine ONLY, use the lifting eyes that

arrangement. Do not attempt to lift the CEM using

are on the engine.

straps around the diesel particulate filter.

Lifting eyes are designed and installed for the specific

engine arrangement. Alterations to the lifting eyes

and/or the engine make the lifting eyes and the lifting

fixtures obsolete. If alterations are made, ensure that

proper lifting devices are provided. Consult your

Caterpillar dealer for information regarding fixtures

for proper engine lifting.

SEBU8598

Lifting and Storage

Product Storage

i05242858

Note: The mixture of VCI oil can be added to the inlet

by removing the plug for checking turbocharger boost

Product Storage

pressure. The minimum application rate for the VCI

oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of

SMCS Code: 7002

engine displacement.

Storage (Less Than One Year)

8. Use a sprayer to apply a mixture of 50 percent VCI

oil and 50 percent crankcase oil into the exhaust

If an engine is not used, oil can run off the following

openings. The minimum application rate for the oil

parts that normally receive lubrication: cylinder walls,

mixture is 5.5 mL per L (3 oz per 1000 cu in) of

piston rings, main bearings, connecting rod bearings,

engine displacement. Seal the exhaust pipe and

crankshaft and gears.

seal any drain holes in the muffler.

This lack of lubricant allows corrosion to begin to

appear on the metal. This condition is worse in areas

9. Remove the fuel from the secondary fuel filter

of high humidity.

housing. Alternately, empty and reinstall the spin-

on fuel filter element in order to remove any dirt

When the engine is started again, metal to metal

and water. Drain any sleeve metering fuel pump.

contact will cause wear before the surfaces receive

oil. To minimize this wear, use the starter to turn the

engine with the throttle in the FUEL OFF position.

Clean the primary fuel filter. Fill with calibration

When oil pressure is shown on the pressure gauge,

fluid or kerosene. Install the primary fuel filter and

start the engine.

operate the priming pump. This procedure will

send clean oil to the secondary filter and the

engine.

1. Clean the engine of any dirt, rust, grease, and oil.

Inspect the exterior. Paint areas that contain paint

Open the fuel tank drain valve in order to drain any

damage with a good quality paint.

water and dirt from the fuel tank. Apply a spray of

calibration fluid or kerosene at the rate of

2. Remove dirt from the air cleaners. Check all seals,

30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank

gaskets, and the filter element for damage.

capacity in order to prevent rust in the fuel tank.

Add 0.15 mL per L (.02 oz per 1 gal US) of

3. Apply lubricant to all points in this Operation and

commercial biocide such as Biobor JF to the fuel.

Maintenance Manual, “Maintenance Interval

Apply a small amount of oil to the threads on the

Schedule”.

fuel tank filler neck and install the cap. Seal all

openings to the tank in order to prevent

4. Drain the crankcase oil. Replace the crankcase oil

evaporation of the fuel and as a preservative.

and change the oil filters. For the proper

procedure, refer to this Operation and

10. Remove the fuel nozzles or spark plugs. Apply

Maintenance Manual.

30 mL (1 oz) of the mixture of oils (50 percent VCI

oil and 50 percent engine oil) into each cylinder.

5. If the engine is equipped with an air starting motor,

fill the reservoir with the following mixture: 50

Use a bar or a turning tool in order to turn over the

percent volatile corrosion inhibitor oil

engine slowly. This procedure puts the oil on the

cylinder walls. Install all fuel nozzles or spark plugs

(<nomen>VCI oil</nomen>) and 50 percent

and tighten to the correct torque.

engine oil.

11. Spray a thin amount of a mixture of 50 percent

6. Add VCI oil to the crankcase oil. The volume of VCI

VCI oil and 50 percent engine oil onto the following

oil in the crankcase oil should be 3 to 4 percent.

components: flywheel, ring gear teeth and starter

Note: If the engine crankcase is full, drain enough

pinion. Install the covers in order to prevent

engine oil so the mixture can be added.

evaporation of the vapors from the VCI oil.

7. Remove the air filter elements. Turn the engine at

12. Apply a heavy amount of Cat Multipurpose

cranking speed with the throttle control in FUEL

Grease (MPGM) to all outside parts that move,

OFF position. Use a sprayer to add a mixture of 50

such as rod threads, ball joints, linkage.

percent VCI oil and 50 percent engine oil into the

Note: Install all covers. Ensure that tape has been

air inlet or turbocharger inlet.

installed over all openings, air inlets, exhaust

openings, the flywheel housing, the crankcase

breathers, the dipstick tubes.

SEBU8598

Lifting and Storage

Product Storage

Ensure that all covers are airtight and

6. Use a bar or a turning tool in order to turn the

weatherproof. Use a waterproof weather resistant

engine in the normal direction of rotation. The

tape such as Kendall No. 231 or an equivalent.

procedure ensures that no hydraulic locks or

Do not use duct tape. Duct tape will only seal for a

resistance exist.

short time.

7. Before starting the engine, remove the valve cover

13. Under most conditions, removing the batteries is

or covers. Put a large amount of engine oil on the

the best procedure. As an alternative, place the

camshaft, cam followers, and valve mechanism in

batteries in storage. As needed, periodically

order to prevent damage to the mechanism.

charge the batteries while the batteries are in

storage.

8. Pressure-lubricate the engine before starting the

engine. Pressure lubricating the engine ensures

If the batteries are not removed, wash the tops of

the batteries until the tops are clean. Apply an

immediate lubrication and prevents damage to the

electrical charge to the batteries in order to obtain

engine during the first few minutes of engine

a specific gravity of 1.225.

operation. If the engine is not equipped with a

prelube pump, contact your Cat dealer for

Disconnect the battery terminals. Place a plastic

information about lubrication of the engine before

cover over the batteries.

starting the engine.

Note: For additional information, refer to Special

Instruction, SEHS7633, “Battery Test Procedure”.

9. Check the condition of all rubber hoses. Replace

any worn hoses. Replace any damaged hoses.

14. Loosen all belts.

10. Before start-up, test the cooling system for a 3

15. Place a waterproof cover over the engine. Ensure

percent ro a 6 percent concentration of coolant

that the engine cover is secure. The cover should

conditioner. Add liquid coolant conditioner or a

be loose enough to allow air to circulate around the

coolant conditioner element, if equipped.

engine in order to prevent damage from

condensation.

Test the coolant mixture for proper nitrite level. If

necessary, adjust the coolant mixture.

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

Prime the engine with clean diesel fuel before

17. Remove the waterproof cover at 2 month or 3

starting.

month intervals in order to check the engine for

11. Ensure that the cooling system is clean. Ensure

corrosion. If the engine has signs of corrosion,

that the system is full. Ensure that the system has

repeat the protection procedure.

the correct amount of supplemental cooling system

conditioner.

Coolant System

12. On the first day of operation, check the entire

Completely fill the cooling system before storage.

engine several times for leaks and correct

operation.

Refer to this Operation and Maintenance Manual,

“Fluid Recommendations” for more information about

coolants.

13. If the engine was removed from storage in which

temperatures of less than -12°C (10°F) were

Removal from Storage

encountered, refer to Service Manual, SEBU5898,

“Cold Weather Recommendations Operation and

1. Remove all outside protective covers.

Maintenance”.

2. Change the oil and filters.

Engines with 2 year preservation group

3. Check the condition of the fan and alternator belts.

from the factory

Replace the belts, if necessary. Refer to this

Operation and Maintenance Manual, “Belts -

Note: Engines that are stored more than 6 months

Inspect/Adjust/Replace” for the correct procedure.

must be prelubed and rotated in 6 month intervals.

For engines purchased with a factory applied, 2 year

4. Replace the fuel filter elements.

preservation group, follow the instructions from this

Operation and Maintenance Manual, “Removal From

5. Remove the plastic covers from the air cleaner

Storage”, step 8 and in this Operation and

elements.

Maintenance Manual, “Storage (less than 1 year)”

section.

SEBU8598

Features and Controls

Battery Disconnect Switch

i05316709

Features and Controls

Monitoring System

i03646563

SMCS Code: 1900; 7400; 7450; 7451

Battery Disconnect Switch

The monitoring system is designed to alert the

(If Equipped)

operator to an immediate problem with any of the

engine systems that are monitored. The Monitoring

SMCS Code: 1411

System is also designed to alert the operator to an

impending problem with any of the engine systems

The battery disconnect switch and the engine start

that are monitored.

switch perform different functions. Turn off the battery

disconnect switch in order to disable the entire

The monitoring system parameters can be accessed

electrical system. The battery remains connected to

via the Cat ET service tool. Many of the parameters

the electrical system when you turn off the engine

within the monitoring system can be tailored to suit

start switch.

the operation of the engine.

Turn the battery disconnect switch to the OFF

An example of adjustments that may be made within

position and remove the key when you service the

the monitoring system is changing the setpoint of the

electrical system or any other components.

engine overspeed indicator from the factory default

setting.

Also turn the battery disconnect switch to the OFF

position and remove the key when the engine will not

be used for an extended period of a month or more.

Indicators and Gauges

This will prevent drainage of the battery.

The instrument panel may look like the instrument

panel that is pictured in illustration 25 or the

NOTICE

instrument panel may look like the instrument panel

Never move the battery disconnect switch to the OFF

that is pictured in illustration 26 . The instrument

position while the engine is operating. Serious dam-

panel may not include all of the instruments that are

age to the electrical system could result.

shown in the illustration.

To ensure that no damage to the engine occurs, verify

that the engine is fully operational before cranking the

engine. Do not crank an engine that is not fully

operational.

Perform the following procedure in order to check the

battery disconnect switch for proper operation:

1. With the battery disconnect switch in the ON

position, verify that electrical components are

functioning. Verify that the hour meter is displaying

information. Verify that the engine will crank.

2. Turn the battery disconnect switch to the OFF

position.

3. Verify that the following items are not functioning:

electrical components, hour meter and engine

cranking. If any of the items continue to function

with the battery disconnect switch in the OFF

position, consult your Caterpillar dealer.

SEBU8598

Features and Controls

Monitoring System

Diesel Particulate Filter (DPF) Lamp (2) -

The DPF lamp will illuminate when a

regeneration of the DPF is needed. Refer

to this Operation and Maintenance Manual,

“Diesel Particulate Filter Regeneration” for more

information on this lamp.

High Exhaust Temperature Lamp (3) -

This lamp is illuminated when a DPF

regeneration is active.

Regeneration Disabled (4) - This lamp

will be illuminated if the regeneration is

manually disabled through the

regeneration switch or through the Cat (ET)

service tool.

Illustration 25

g02212133

Start Switch (5) - The start switch has

three positions: OFF, RUN and START.

When the start switch is turned

clockwise to the RUN position, the lamps will

flash for 5 seconds during the system test. The

lamps will then shut off. In the RUN position, the

Electronic Control Module (ECM) and electronic

systems are powered up.

Diagnostic Lamp (6) - The diagnostic

lamp will illuminate when an active fault

code is present.

Shutdown Lamp (7) - The shutdown

lamp will illuminate when a critical

engine event occurs which requires that

the engine be shut down. The event should be

addressed as quickly as possible.

Shutdown Switch (8) - Use the engine

shutdown switch in order to stop the

engine. Push the shutdown switch in

order to put the switch in the OFF position.

Illustration 26

g02215293

Moving the switch to the OFF position will stop

the engine. After the engine stops, turn the knob

Circuit Breaker (1) - Reset the circuit

clockwise. Turning the knob will reset the engine

breaker if a circuit breaker trips. Press

shutdown switch to the ON position.

the button in order to reset the circuit

breaker. If the electrical system is working

Service Hour Meter (9) - This gauge

properly, the button will remain pressed. If the

indicates the total number of clock hours

button does not remain pressed or if the circuit

of engine operation. Hours of operation

breaker trips soon after being reset, check the

are logged in the ECM. A service tool is needed to

appropriate electrical circuit. Repair the electrical

retrieve the hours from the ECM. A Service Hour

circuit, if necessary.

Meter may be installed on the engine.

Idle Speed Switch (10) - When the switch

is in the up position, the engine speed

increases to HIGH IDLE. When the

Resetting the circuit breakers in a flammable at-

switch is in the down position, the engine speed

mosphere or a combustible atmosphere may lead

decreases to LOW IDLE.

to fire hazards or explosion hazards which may

result in personal injury or death. DO NOT reset

the circuit breaker when a flammable atmosphere

or a combustible atmosphere is present and the

power has not been removed from the equipment.

SEBU8598

Features and Controls

Monitoring System

Regeneration Switch (11) - Used to

A lower oil pressure is normal at low idle. If the load is

activate a forced regeneration or

stable and the gauge reading changes, perform the

manually disable regeneration. Refer to

following procedure:

this Operation and Maintenance Manual, “Diesel

1. Remove the load.

Particulate Filter Regeneration” for more

information on this switch.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

NOTICE

To help prevent engine damage, never exceed the

high idle rpm. An overspeed can result in serious

damage to the engine. The engine can be operated at

high idle without damage, but the engine should

never be allowed to exceed the high idle rpm.

Note: The high idle rpm and the full load rpm are

stamped on the Information Plate.

Jacket Water Coolant Temperature (17) -

Illustration 27

g02333673

Typical temperature range is 87 to 98°C

(189 to 208°F). Higher temperatures may

OK to Elevate Idle Switch (12) - Pressing in and

occur under certain conditions. The water

locking the “OK to Elevate Idle” switch enables the

temperature reading may vary according to load.

engine ECM to elevate engine speed automatically

The reading should never exceed the boiling

when needed. For example, if the engine is running at

point for the pressurized system that is being

low idle and a DPF regeneration is activated, having

used.

the “OK to Elevate Idle” switch in the LOCKED

position will allow the engine speed to increase in

Coolant Temperature (18) - When the

order for the DPF regeneration to occur.

coolant temperature is above the normal

operating value, the coolant temperature

Tachometer (13) - This gauge indicates

gauge will be in the red zone. Refer to the

engine speed (rpm). When the throttle

Messenger panel for any additional information

control lever is moved to the full throttle

that may be available.

position without load, the engine is running at

high idle. The engine is running at the full load

Warning Lamp (19) - There is a general

rpm when the throttle control lever is at the full

fault in the engine. Refer to the

throttle position with maximum rated load.

Messenger display for any additional

information that may be available.

Voltmeter (14) - This gauge indicates the

voltage of the electrical system. The

Service Tool Connector (20) - For more information

needle in the red range indicates low

about the use of Cat ET and the PC requirements for

voltage or high voltage.

Cat ET, refer to the documentation that

accompanies your Cat ET software.

Fuel Pressure (15) - This gauge

indicates fuel pressure to the fuel

Mini Industrial Power Display

injection pump from the fuel filter. A

decrease in fuel pressure usually indicates a dirty

(MIPD)

fuel filter or a plugged fuel filter. As the fuel filter

becomes plugged, there will be a noticeable

The mini industrial power display provides for a

reduction in the performance of the engine.

means to view various types of engine information.

The information that can be viewed is described

below.

Engine Oil Pressure (16) - The oil

pressure should be greatest after a cold

engine is started. The pressure will

decrease as the engine warms up. The pressure

will increase when the engine rpm is increased.

The pressure will stabilize when the engine rpm is

stable.

SEBU8598

Features and Controls

Monitoring System

Engine Load - Displays the amount of load on the

engine as a percentage.

Regen Disable Status - Displays whether the

regeneration is manually disabled.

DPF Lamp - Displays when a DPF regeneration is

needed.

Soot Loading - Displays the amount of soot within

the DPF as a percentage.

Air Inlet Temperature - Displays the temperature of

the air entering the engine through the air filter.

Intake Manifold Air Temperature - Displays the

temperature of the air entering the engine at the

Illustration 28

g02216234

intake manifold.

“OK/Select” button (1) - The “OK/Select” button is

Boost Pressure - Displays the amount of pressure

used to confirm the selections that were made with

of the air entering the intake manifold of the engine.

the “scroll left/right” buttons.

Crankcase Pressure - Displays the amount of

“Backlight” button (2) - This button is used to turn

pressure within the crankcase of the engine.

the backlight of the display on or off.

Atmospheric Pressure - Displays the amount of

“Scroll left/right button” (3) - This button is used to

atmospheric pressure that the engine is operating in.

advance through the various screens of the MIPD.

Fuel Temp - Displays the temperature of the fuel

entering the engine.

The MIPD comes with three preset user interfaces.

The interfaces are labeled as “Operator_1” ,

Fuel Rate - Displays the amount of fuel being used

“Operator_2” , and “Operator_3” .

by the engine.

“Operator_1” user interface is preset with various

Filtered Fuel Delta Pressure - Displays the

engine, aftertreatment, and transmission information

pressure across the fuel filter.

over 14 screens. Diagnostic and system information

is also included. The information in “Operator_1” is

Low Idle RPM - Displays the low idle speed setpoint

displayed via ISO symbols and metric display units.

in RPM.

“Operator_2” user interface is preset with various

Hi Idle Speed - Displays the high idle speed setpoint

engine, aftertreatment, and transmission information

in RPM.

over 12 screens. Diagnostic and system information

Desired Speed - Displays the desired engine speed

is also included. The information is displayed in

analog style gauges and English display units.

in RPM.

Primary Throttle - Displays the primary throttle

“Operator_3” user interface is preset with various

position as a percentage.

engine, aftertreatment, and transmission information

over 12 screens. Diagnostic and system information

Secondary Throttle - Displays the secondary

is also included. The information is displayed in

throttle position as a percentage.

analog style gauges and English display units.

Auxiliary Pressure Sensor 1 - Displays the

Note: Only use “Operator_1” and “Operator_2”

pressure being measured by the #1 auxiliary sensor if

interfaces on Tier 4 engines. The added

one is being used.

aftertreatment parameters in these interfaces are

Auxiliary Temperature Sensor 1 - Displays the

necessary to ensure proper operation.

temperature being measured by the #1 auxiliary

sensor if one is being used.

Parameters

Battery Voltage - Displays the battery voltage.

Below are a list of all the parameters that are

viewable through the three user interfaces used

Aftertreatment 1 Regeneration Status - Displays

within the MIPD.

the status of the regeneration system as manual or

automatic.

Engine Speed - Displays the current engine speed

in RPM.

HEST Lamp - Illuminates when a DPF regeneration

is active.

Coolant Temperature - Displays the current coolant

temperature of the engine.

SEBU8598

Features and Controls

Monitoring System

DPF Intake Temperature - Displays the temperature

of the exhaust gas entering the DPF.

DPF Outlet Temperature - Displays the temperature

of the exhaust gas leaving the DPF.

Transmission Selected Gear - Displays the

transmission gear being requested.

Transmission Requested Gear - Displays the

transmission gear being requested.

Transmission Oil Pressure - Displays the oil

pressure inside the transmission.

Transmission Oil Temperature - Displays the oil

temperature of the transmission.

Transmission Torque Limit - Displays the limit of

torque allowed by the transmission.

System Information

User Name - Displays the preset user name that is

selected.

Software Version - Displays the version of software

that is programmed in the MIPD.

Serial Number - Displays the serial number of the

MIPD.

Display Units - Displays the units of measurement

that is selected for the given user.

Engine Location - Displays which engine data is

being reported if more than one engine is connected

to the MIPD.

Language - Displays the selected language.

Alarm - Indicates whether audible alarm is set to ON

or OFF when an audible alarm is connected to the

MIPD.

SEBU8598

Engine Diagnostics

Self-Diagnostics

Engine Diagnostics

i00863835

Self-Diagnostics

SMCS Code: 1000; 1900; 1901; 1902

The electronic control module has some self-

diagnostic ability. When an electronic problem with an

input or an output is detected, a diagnostic code is

generated. This indicates the specific problem with

the circuitry.

Diagnostic codes are also generated when an

abnormal engine operating condition is detected. For

example, a diagnostic code will be generated if the

low oil pressure alarm is activated. In this case, the

diagnostic code indicates the symptom of a problem.

This type of diagnostic code is called an event. An

event is triggered by the detection of an abnormal

engine operating condition.

A diagnostic code which represents a problem that

currently exists is called an active code.

A diagnostic code that is stored in memory is called a

logged code. Always service active codes prior to

servicing logged codes. Logged codes may include

the following categories:

• Intermittent problems

• Recorded events

• Performance history

Logged codes may not indicate that a repair is

needed. The problems may have been repaired since

the logging of the code. Logged codes may be helpful

to troubleshoot intermittent problems.

SEBU8598

Engine Starting

Before Starting Engine

•

Do not start the engine or move any of the controls

Engine Starting

if there is a “DO NOT OPERATE” warning tag or

similar warning tag attached to the start switch or

i02109067

to the controls.

Before Starting Engine

•

Ensure that the areas around the rotating parts are

clear.

SMCS Code: 1000; 1400; 1450

•

All of the guards must be put in place. Check for

Perform the required daily maintenance and other

damaged guards or for missing guards. Repair any

periodic maintenance before the engine is started.

damaged guards. Replace damaged guards and/

Inspect the engine compartment. This inspection can

or missing guards.

help prevent major repairs at a later date. Refer to the

Operation and Maintenance Manual, “Maintenance

•

Disconnect any battery chargers that are not

Interval Schedule” for more information.

protected against the high current drain that is

• For the maximum service life of the engine, make

created when the electric starting motor (if

a thorough inspection before the engine is started.

equipped) is engaged. Check electrical cables and

Look for the following items: oil leaks, coolant

check the battery for poor connections and for

leaks, loose bolts and trash buildup. Remove trash

corrosion.

buildup and arrange for repairs, as needed.

•

Reset all of the shutoffs or alarm components.

• Inspect the aftercooler for loose connections and

•

Check the engine lubrication oil level. Maintain the

for debris buildup.

oil level between the “ADD” mark and the “FULL”

• Inspect the cooling system hoses for cracks and

mark on the oil level gauge.

for loose clamps.

•

Check the coolant level. Observe the coolant level

• Inspect the alternator and accessory drive belts for

in the coolant recovery tank (if equipped). Maintain

cracks, breaks, and other damage.

the coolant level to the “FULL” mark on the

coolant recovery tank.

• Inspect the wiring for loose connections and for

worn wires or frayed wires.

•

If the engine is not equipped with a coolant

recovery tank maintain the coolant level within

• Check the fuel supply. Drain water from the water

13 mm (0.5 inch) of the bottom of the filler pipe. If

separator (if equipped). Open the fuel supply

the engine is equipped with a sight glass, maintain

valve.

the coolant level in the sight glass.

NOTICE

•

Observe the air cleaner service indicator (if

equipped). Service the air cleaner when the yellow

All valves in the fuel return line must be open before

diaphragm enters the red zone, or when the red

and during engine operation to help prevent high fuel

piston locks in the visible position.

pressure. High fuel pressure may cause filter housing

failure or other damage.

•

Ensure that any driven equipment has been

disengaged. Minimize electrical loads or remove

If the engine has not been started for several weeks,

any electrical loads.

fuel may have drained from the fuel system. Air may

have entered the filter housing. Also, when fuel filters

i04132731

have been changed, some air pockets will be trapped

in the engine. In these instances, prime the fuel

Cold Weather Starting

system. Refer to the Operation and Maintenance

Manual, “Fuel System - Prime” for more information

SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900

on priming the fuel system.

Startability will be improved at temperatures below

10°C (50°F) from the use of a cylinder block coolant

heater or from other means that are used to heat the

crankcase oil. Some engine applications use a jacket

Engine exhaust contains products of combustion

water heater to improve startability. Use of a jacket

which may be harmful to your health. Always start

water heater will help reduce white smoke and misfire

and operate the engine in a well ventilated area

during start-up in cold weather.

and, if in an enclosed area, vent the exhaust to the

outside.

SEBU8598

Engine Starting

Starting the Engine

Note: If the engine has not been run for several

During the key on, the diagnostic lamp, warning

weeks, fuel may have drained. Air may have moved

lamp, regeneration lamps, and DPF disabled lamp

into the filter housing. Also, when fuel filters have

will be checked for proper bulb operation. If any of

the lamps do not illuminate, replace the bulb.

been changed, some air will be left in the filter

housing. Refer to the Operation and Maintenance

Manual, “Fuel System - Prime” (Maintenance

NOTICE

Section) for more information on priming the fuel

Do not engage the starting motor when flywheel is

system.

turning. Do not start the engine under load.

Ether Injection System (If

If the engine fails to start within 30 seconds, release

Equipped)

the starter switch or button and wait two minutes to al-

low the starting motor to cool before attempting to

The ether injection system is controlled by the ECM.

start the engine again.

The ECM monitors the coolant temperature, intake air

temperature, ambient air temperature, and barometric

3. Push the start button or turn the ignition switch to

pressure to determine when ether injection is needed.

At sea level, ether will be used if any of the

the START position in order to crank the engine.

temperatures fails to exceed 0° C (32° F). This

temperature is subject to an increase as barometric

Do not push down or hold the throttle down while

the engine is cranked. The system will

pressure increases.

automatically provide the correct amount of fuel

that is needed to start the engine.

4. If the engine fails to start within 30 seconds,

Personal injury or property damage can result

release the start button, or the ignition switch. Wait

from alcohol or starting fluids.

for 2 minutes in order to allow the starting motor to

cool before attempting to start the engine again.

Alcohol or starting fluids are highly flammable

and toxic and if improperly stored could result in

injury or property damage.

NOTICE

Oil pressure should rise within 15 seconds after the

Follow the procedure in this Operation and

engine starts. Do not increase engine rpm until the oil

Maintenance Manual, “Starting the Engine”.

pressure gauge indicates normal. If oil pressure is not

indicated on the gauge within 15 seconds, DO NOT

operate the engine. STOP the engine, investigate

i04032033

and correct the cause.

Starting the Engine

5. Allow the engine to idle for approximately 3

SMCS Code: 1000; 1450

minutes. Idle the engine until the water

temperature gauge has begun to rise. Check all

gauges during the warm-up period.

Engine exhaust contains products of combustion

Note: Oil pressures and fuel pressures should be in

which may be harmful to your health. Always start

the normal range on the instrument panel. Engines

and operate the engine in a well ventilated area

that are equipped with “WARNING” lamps do not

and, if in an enclosed area, vent the exhaust to the

have an operating range. The “WARNING and

outside.

DIAGNOSTIC” lamp (if equipped) will flash while the

engine is cranking. The lamp should turn off after

proper engine oil pressure or fuel pressure is

Starting the Engine

achieved. Do not apply a load to the engine or

increase engine rpm until the oil pressure gauge

Refer to the Owner's Manual of the OEM for your type

indicates at least normal pressure. Inspect the engine

of controls. Use the following procedure to start the

for leaks and/or unusual noises.

engine.

1. Place the transmission in NEUTRAL. Disengage

the flywheel clutch in order to allow the engine to

start faster, and to reduce the draining of the

battery.

2. Turn the ignition switch to the ON position.

SEBU8598

Engine Starting

Starting with Jump Start Cables

If the engine is operated with a low load, the engine

2. If a wire is loose, push the wire back into the

will reach normal operating temperature sooner than

connector. Pull the wire again in order to ensure

idling the engine with no load. When the engine is

that the wire is secure.

idled in cold weather, increase the engine rpm to

approximately 1000 to 1200 rpm in order to warm up

3. Start the engine. If the engine does not start,

the engine more quickly. Do not exceed the

consult the nearest Caterpillar dealer for

recommended rpm in order to increase the speed of

assistance.

the warm-up. Limit unnecessary idle time to 10

minutes.

i02049673

Starting Problems

Starting with Jump Start

An occasional starting problem may be caused by

one of the following items:

Cables

(Do Not Use This Procedure in

• Low battery charge

Hazardous Locations that have

• Lack of fuel

Explosive Atmospheres)

• Problem with the wiring harness

SMCS Code: 1000; 1401; 1402; 1900

If the engine fuel system has been run dry, fill the fuel

tank and prime the fuel system. Refer to the

Operation and Maintenance Manual, “Fuel System -

Prime” topic (Maintenance Section).

The connection of battery cables to a battery and

If the other problems are suspected, perform the

the disconnection of battery cables from a battery

appropriate procedure in order to start the engine.

may cause an explosion which may result in in-

jury or death. The connection and the disconnec-

Problems with the Wiring Harness

tion of other electrical equipment may also cause

an explosion which may result in injury or death.

The procedures for the connection and the dis-

connection of battery cables and other electrical

equipment should only be performed in a nonex-

plosive atmosphere.

Improper jump start cable connections can cause

an explosion resulting in personal injury.

Prevent sparks near the batteries. Sparks could

cause vapors to explode. Do not allow jump start

cable ends to contact each other or the engine.

If the installation is not equipped with a backup

battery system, it may be necessary to start the

engine from an external electrical source.

First, determine the reason that it is necessary to start

with power from an external source. Refer to Special

Instruction, SEHS7768, “Use of the 6V-2150 Starting/

Illustration 29

g01248812

Charging Analyzer”.

ECM Connector J2/P2

Many batteries which are considered unusable are

Locate the ECM. Check the connector in order to

still rechargeable. After jump starting, the alternator

ensure that the connector is secure. Lightly pull each

may not be able to fully recharge batteries that are

of the wires in the chassis harness.

severely discharged. The batteries must be charged

to the proper voltage with a battery charger. For

1. Pull each wire with approximately 4.5 kg (10 lb) of

information on testing and charging, refer to the

force. The wire should remain in the connector.

Special Instruction, SEHS7633, “Battery Test

Procedure”.

SEBU8598

Engine Starting

After Starting Engine

• Check for fluid or air leaks at idle rpm and at one-

NOTICE

half full rpm (no load on the engine) before

Using a battery source with the same voltage as the

operating the engine under load. Operating the

electric starting motor. Use ONLY equal voltage for

engine at idle and at one-half full rpm with no load

jump starting. The use of higher voltage will damage

is not possible in some applications.

the electrical system.

• Operate the engine at low idle until all systems

Do not reverse the battery cables. The alternator can

achieve operating temperatures. Check all gauges

be damaged. Attach ground cable last and remove

during the warm-up period.

first.

When using an external electrical source to start the

Note: Gauge readings should be observed and the

engine, turn the generator set control switch to the

data should be recorded frequently while the engine

“OFF” position. Turn all electrical accessories OFF

is operating. Comparing the data over time will help to

before attaching the jump start cables.

determine normal readings for each gauge.

Comparing data over time will also help detect

Ensure that the main power switch is in the OFF posi-

abnormal operating developments. Significant

tion before attaching the jump start cables to the en-

changes in the readings should be investigated.

gine being started.

Extended Idle at Cold Ambient

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

Temperature

OFF position. Turn off all accessories.

The engine may automatically change speeds when

2. Connect one positive end of the jump start cable to

the engine is idling in cold ambient temperatures

the positive cable terminal of the discharged

(typically less than 0° C (32° F) for extended periods.

The purpose of the automatic speed change is

battery. Connect the other positive end of the jump

threefold: to maintain the desired operation of the

start cable to the positive cable terminal of the

NOx reduction system, to maintain the desired

electrical source.

operation of the regeneration system and to keep the

engine coolant warm. The engine speed may rise to

3. Connect one negative end of the jump start cable

1600 rpm for as long as 20 minutes.

to the negative cable terminal of the electrical

source. Connect the other negative end of the

The high exhaust system temperature lamp may

jump start cable to the engine block or to the

illuminate during extended idling conditions. This

illumination signals that a diesel particulate filter

chassis ground. This procedure helps to prevent

(DPF) regeneration is in progress. Regenerations

potential sparks from igniting combustible gases

during cold ambient extended idling may only last up

that are produced by some batteries.

to 10 minutes.

4. Charge the batteries. The engine will not continue

to run after starting if the batteries have not been

charged.

5. Start the engine.

6. Immediately after the stalled engine is started,

disconnect the jump start cables in reverse order.

Refer to the Electrical Schematic for your engine.

Consult your Caterpillar dealer for more information.

i05359363

After Starting Engine

SMCS Code: 1000

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

the warm-up time is approximately 3 minutes. In

temperatures below 0°C (32°F), additional warm-up

time may be required.

When the engine is idling during warm-up, observe

the following conditions:

SEBU8598

Engine Operation

i06014851

Engine Operation

SMCS Code: 1000

Correct operation and maintenance are key factors in

obtaining the maximum life and economy of the

engine. If the directions in the Operation and

Maintenance Manual are followed, costs can be

minimized and engine service life can be maximized.

The engine can be operated at the rated rpm after the

engine reaches operating temperature. The engine

will reach normal operating temperature sooner

during a low engine speed (rpm) and during a low

power demand. This procedure is more effective than

idling the engine at no load. The engine should reach

operating temperature in a few minutes.

Gauge readings should be observed and the data

should be recorded frequently while the engine is

operating. Comparing the data over time will help to

determine normal readings for each gauge.

Comparing data over time will also help detect

abnormal operating developments. Significant

changes in the readings should be investigated.

i05317310

Diesel Particulate Filter

Regeneration

SMCS Code: 108F

Regeneration

Regeneration is the removal of soot from the diesel

particulate filter (DPF). The aftertreatment

regeneration device (ARD) is used to regenerate the

DPF. The DPF traps both soot and ash. The ash is

removed through a manual cleaning process. Refer

to this Operation and Maintenance Manual, “Diesel

Particulate Filter - Clean” for more information about

servicing the DPF.

SEBU8598

Engine Operation

Diesel Particulate Filter Regeneration

Regeneration Indicator Lamps and Controls

Illustration 30

g02334417

The engine may be equipped with one of the control panels pictured above.

(1) “DPF” Indicator lamp

(4) “START KEY” switch

(8) “REGENERATION” switch

(2) “HIGH EXHAUST TEMPERATURE”

(5) “DIAGNOSTIC” lamp

(9) “HIGH SPEED REGENERATION”

indicator lamp

(6) “SHUTDOWN” lamp

enable switch

(3) “REGENERATION DISABLED”

(7) “IDLE SPEED” switch

indicator lamp

Note: For further information about the monitoring

Regeneration Controls

system, refer to this Operation and Maintenance

Manual, “Monitoring System”.

Regeneration Control Switch

“HIGH EXHAUST SYSTEM

TEMPERATURE (HEST)” - This indicator

lamp illuminates to show that a

regeneration is active. This indicator lamp turns

off when the regeneration is complete.

“DPF” - This indicator lamp illuminates

to show that a regeneration is needed.

This indicator lamp illuminates when the

soot level reaches 80%.

“REGENERATION DISABLED” - This

indicator lamp illuminates to show that a

regeneration has been disabled.

Illustration 31

g02333653

“REGENERATION” control switch

The position of the “REGENERATION” switch in the

side view is the MIDDLE position.

Note: The MIDDLE position of the switch is the

default position for low and high speed regenerations.

Note: Some OEMs use other means of activating a

forced regeneration such as a touch screen interface.

SEBU8598

Engine Operation

Diesel Particulate Filter Regeneration

“FORCE REGENERATION” - Press and

Soot Level Monitoring

hold in the top of the switch for 3

seconds to start regeneration.

“DISABLE REGENERATION” - Press

and hold in the bottom of the switch for 3

seconds 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.

Illustration 33

g02228033

Note: If the engine “START SWITCH KEY” is cycled

The soot level monitor indicates the level of soot that

while the regeneration system is disabled via the

has accumulated within the DPF. The five marks on

“DISABLE REGENERATION” switch, press and hold

the monitor represent the percentage of soot within

in the “DISABLE REGENERATION” switch for 3

the DPF. The first mark indicates 0% soot level. The

second mark indicates 25% soot level. The third mark

seconds to reinitiate the disable regeneration.

indicates 50% soot level. The fourth mark indicates

75% soot level. The last mark indicates 100% soot

OK to Elevate Idle Switch

level. The soot level monitor may be used to optimize

DPF regenerations based upon the work cycle of the

engine. If operating conditions do not allow for

automatic regeneration, a manual regeneration

should be performed before the soot level gauge

indicates 100%

Note: The soot level monitor may not be applied to all

engines. Some OEM's may also use a different

method of displaying soot load of the DPF. Refer to

OEM operation manual for explanation.

Modes of Regeneration

Automatic

The engine control module (ECM) uses multiple

electrical inputs from the engine to determine the best

Illustration 32

g02333673

time for an automatic regeneration. An automatic

“OK to Elevate Idle Switch” switch

regeneration may take place throughout the operating

The position of the “OK to Elevate Idle Switch”

cycle of the engine. An automatic regeneration may

switch in the side view is the LOCKED position.

start when the engine is at the low idle speed or when

the engine is at normal operating speed. The “HEST”

OK to Elevate Idle Switch - Pressing in and locking

indicator lamp is illuminated when a regeneration is

the “OK to Elevate Idle” switch enables the engine

being performed.

ECM to elevate engine speed automatically when

If an automatic regeneration starts while the engine is

needed. For example, if the engine is running at low

at the low idle speed, the engine may be returned to

idle and a DPF regeneration is activated, having the

normal work at any time. Returning to normal work

“OK to Elevate Idle” switch in the LOCKED position

may stop the regeneration. The ECM will continue to

will allow the engine speed to increase in order for the

monitor inputs to determine the best time to restart

DPF regeneration to occur.

the regeneration.

Interruptions of the regeneration are acceptable. If a

Note: This switch is only available on engines with

regeneration needs to be stopped for any reason,

instrument panels supplied by Cat.

press the DISABLE REGENERATION switch or turn

off the engine.

Note: An automatic adjustment of engine speed may

be noticed during an automatic regeneration. If the

engine is taken to a low idle speed while a

regeneration is occurring, the engine speed may

remain elevated in order for the regeneration to

continue.

SEBU8598

Engine Operation

Engaging the Driven Equipment

Manual

A manual regeneration is initiated by pressing the

“FORCE REGENERATION” switch. A manual

regeneration may be performed at a low idle speed or

during normal engine operation. The soot loading

must be between 15% and 116% for a manual

regeneration to occur while the engine is at a low idle

speed. The soot loading must be between 15% and

105% for a manual regeneration to occur at normal

Illustration 35

g02117259

engine operating speed. The engine coolant

temperature should be at least 40° C (104° F).

The “DPF” indicator lamp illuminates and the

“DIAGNOSTIC” indicator lamp illuminates when the

engine control module (ECM) determines that the

Disabled

amount of soot collected in the DPF has reached a

level that requires a regeneration. Place the engine

When the regeneration system is in disabled mode,

into a low idle state immediately. Initiate a manual

automatic regeneration is not available.

regeneration. The engine power will be derated if the

engine continues to operate.

Regeneration System Warning

Indicators

Illustration 36

g02117261

When the soot load reaches 116%, the

Illustration 34

g02117258

“DIAGNOSTIC” indicator lamp illuminates, the “DPF”

indicator lamp illuminates and the audible horn

The “DPF” indicator lamp illuminates when the DPF

sounds. Not all applications have an audible horn.

soot load is greater than 80%

After 5 minutes of engine operation at 116% of soot

load, the engine is automatically taken to the

A regeneration should be performed as soon as

programmed low idle speed. A manual regeneration

possible. Engine operation may not be allowing

in the low speed region is then required. A complete

an automatic regeneration to occur. A manual

regeneration will unlock the forced low idle speed.

regeneration should be performed as soon as

Cycling the engine “START SWITCH KEY” unlocks

possible.

the forced low idle speed.

The “DPF” indicator lamp will turn off when DPF

After the engine operates at 116% of soot level for 10

regeneration starts.

minutes, all types of regeneration are locked out. A

service regeneration through the CAT ET service tool

Note: In some situations, the “DPF” indicator lamp

is the only form of regeneration allowed.

may remain illuminated when the soot load is below

80%. The illuminated “DPF” indicator lamp indicates

If the engine continues to operate without a

that a complete regeneration has not been

regeneration until a soot level of 140% is reached, the

completed. A complete regeneration reduces the soot

engine shuts down after 30 seconds. The engine may

level to 0%. If the “DPF” indicator lamp remains

be restarted but will only run for 30 seconds at a time

illuminated, perform a regeneration without

before shutting down. At this time, service level

interruption until the soot level is 0%. A complete

regeneration is locked out and the DPF must be

replaced.

regeneration resets the “DPF” indicator lamp.

i04038637

Engaging the Driven

Equipment

SMCS Code: 1000

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

when possible.

SEBU8598

Engine Operation

Fuel Conservation Practices

2. Engage the driven equipment without a load on the

• Observe the service indicator for the air cleaner

equipment, when possible.

frequently, if equipped. Keep the air cleaner

elements clean.

Interrupted starts put excessive stress on the drive

train. Interrupted starts also waste fuel. To get the

•

Do not remove the cover for the air cleaner unless

driven equipment in motion, engage the clutch

the air filter service indicator indicates the need for

smoothly with no load on the equipment. This

cleaning of the filter.

method should produce a start that is smooth and

easy. The engine rpm should not increase and the

•

Maintain a good electrical system.

clutch should not slip.

One bad battery cell will overwork the alternator. This

3. Ensure that the ranges of the gauges are normal

will consume excess power and excess fuel.

when the engine is operating at one-half of the

•

Ensure that the belts are properly adjusted. The

rated rpm. Ensure that all gauges operate properly.

belts should be in good condition.

4. Increase the engine rpm to the rated rpm. Always

•

Ensure that all of the connections of the hoses are

increase the engine rpm to the rated rpm before

tight. The connections should not leak.

the load is applied.

•

Ensure that the driven equipment is in good

5. Apply the load. Begin operating the engine at low

working order.

load. Check the gauges and equipment for proper

operation. After normal oil pressure is reached and

•

Cold engines consume excess fuel. Keep cooling

the temperature gauge begins to move, the engine

system components clean and keep cooling

may be operated at full load. Check the gauges

system components in good repair. Never operate

the engine without water temperature regulators.

and equipment frequently when the engine is

All of these items will help maintain operating

operated under load.

temperatures.

Extended operation at low idle or at reduced load

may cause increased oil consumption and carbon

buildup in the cylinders. This carbon buildup

results in a loss of power and/or poor performance.

i05893104

Fuel Conservation Practices

SMCS Code: 1000; 1250

The efficiency of the engine can affect the fuel

economy. The design and technology used

byCaterpillar in manufacturing provides maximum

fuel efficiency in all applications. Follow the

recommended procedures in order to attain optimum

performance for the life of the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel

may overflow from the fuel tank. Inspect fuel lines for

leaks. Repair the fuel lines, as needed.

• Be aware of the properties of the different fuels.

Use only the recommended fuels.

• Avoid unnecessary operation at no load.

Shut off the engine instead of operating the engine at

no load for long periods of time.

SEBU8598

Cold Weather Operation

Radiator Restrictions

There are three major differences between No. 1 and

Cold Weather Operation

No. 2 diesel fuel. No. 1 diesel fuel has the following

properties:

i01646447

• Lower cloud point

Radiator Restrictions

• Lower pour point

SMCS Code: 1353; 1396

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

Caterpillar discourages the use of airflow restriction

devices that are mounted in front of radiators. Airflow

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

restriction can cause the following conditions:

and in fuel efficiency may be noticed. Other operating

effects should not be experienced.

• High exhaust temperatures

The cloud point is the temperature when a cloud of

• Power loss

wax crystals begins to form in the fuel. These crystals

can cause the fuel filters to plug. The pour point is the

• Excessive fan usage

temperature when diesel fuel will thicken. The diesel

fuel becomes more resistant to flow through fuel

• Reduction in fuel economy

pumps and through fuel lines.

If an airflow restriction device must be used, the

Be aware of these values when diesel fuel is

device should have a permanent opening directly in

purchased. Anticipate the average ambient

line with the fan hub. A centered opening that is

temperature for the engine area. Engines that are

directly in line with the fan hub is specified in order to

fueled in one climate may not operate well if the

prevent an interrupted airflow on the fan blades.

engines are moved to another climate. Problems can

Interrupted airflow on the fan blades could cause a

result due to changes in temperature.

fan failure.

Before troubleshooting for low power or for poor

Caterpillar recommends a warning device for the inlet

performance during cold weather, check the type of

manifold temperature and/or the installation of an inlet

fuel that is being used.

air temperature gauge. The warning device for the

inlet manifold temperature should be set at 75 °C

(167 °F). The inlet manifold air temperature should

i03480664

not exceed 75 °C (167 °F). Temperatures that

exceed this limit can cause power loss and potential

Fuel Related Components in

engine damage.

Cold Weather

i03895851

SMCS Code: 1000; 1250; 1280

Fuel and the Effect from Cold

Fuel Tanks

Weather

Condensation can form in partially filled fuel tanks.

Top off the fuel tanks after you operate the engine.

SMCS Code: 1000; 1250; 1280

Fuel tanks should contain some provision for draining

The following fuels are the grades that are available

water and sediment from the bottom of the tanks.

for Caterpillar engines:

Some fuel tanks use supply pipes that allow water

and sediment to settle below the end of the fuel

• No. 1

supply pipe.

• No. 2

Some fuel tanks use supply lines that take fuel

directly from the bottom of the tank. If the engine is

• Blend of No. 1 and No. 2

equipped with this system, regular maintenance of

the fuel system filter is important.

No. 2 diesel fuel is the most commonly used fuel.

Either No. 1 diesel fuel or a blend of No. 1 and No. 2

is best suited for cold weather operation.

Fuel Filters

Cold fuel may contain wax which will block the fuel

Note: No. 2 diesel fuel can begin to form crystals at

filters. One of the following changes can prevent

approximately -9° C (15° F).

problems in many conditions: a change in the location

Quantities of No. 1 diesel fuel are limited. No. 1 diesel

of fuel filters and/or supply lines and the addition of

fuels are usually available during the months of the

insulation.

winter in the colder climates. During cold weather

operation, if No. 1 diesel fuel is not available, use No.

2 diesel fuel, if necessary.

SEBU8598

Cold Weather Operation

Fuel Related Components in Cold Weather

Fuel Heaters

In extreme temperatures, heating of the fuel may be

required to prevent the filters from plugging. There

are several types of fuel heaters that are available.

These systems may prevent filter waxing problems

without the use of de-icers or cold flow improvers.

These systems may be ineffective when the fuel

contains a large amount of dirt or of water. A fuel

heater should be installed so that the fuel is heated

before flowing into the fuel filter.

Note: Only use properly sized fuel heaters that are

controlled by thermostats or use fuel heaters that are

self-regulated. Thermostatically controlled fuel

heaters generally heat fuel to 15.5° C (60° F). Do not

use fuel heaters in warm temperatures.

Note: Do not allow the fuel to get too warm, because

fuel above 52°C (125°F) will affect the power output

of the engine. Never exceed 75°C (165°F) with

straight distillate fuel. The high fuel temperatures also

affect the fuel viscosity. When the fuel viscosity falls

below 1.4 cSt at the fuel injection pump, pump

damage may occur.

Overheating the fuel or the fuel filter can result in

personal injury and/or damage to the engine. Use

extreme care and caution for heating of the fuel

and/or the fuel filter.

Select a fuel heater that is mechanically simple, yet

adequate for the application. The fuel heater should

also prevent overheating of the fuel. Disconnect the

fuel heater or deactivate the fuel heater in warm

weather. An unacceptable loss of fuel viscosity and

engine power will occur if the fuel supply temperature

is allowed to become too hot.

For additional information on fuel heaters, consult

your Caterpillar dealer.

SEBU8598

Engine Stopping

Manual Stop Procedure

• If necessary, perform minor adjustments. Repair

Engine Stopping

any leaks and tighten any loose bolts.

i04315380

• Note the service hour meter reading. Perform the

maintenance that is in the Operation and

Manual Stop Procedure

Maintenance Manual, “Maintenance Interval

Schedule”.

SMCS Code: 1000; 7418

• Fill the fuel tank to prevent accumulation of

NOTICE

moisture in the fuel. Do not overfill the fuel tank.

Stopping the engine immediately after it has been

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

working under load can result in overheating and ac-

Maintain the cooling system at 13 mm (0.5 inch)

celerated wear of the engine components.

from the bottom of the pipe for filling.

If the engine has been operating at high rpm and/or

Note: Only use coolant that is recommended in this

high loads, run at low idle for at least three minutes to

Operation and Maintenance Manual, “Fluid

reduce and stabilize internal engine temperature be-

fore stopping the engine.

Recommendations” article. Failure to do so may

result in engine damage.

Avoiding hot engine shutdowns will maximize turbo-

charger shaft and bearing life.

• If freezing temperatures are expected, check the

coolant for proper antifreeze protection. The

cooling system must be protected against freezing

Note: Individual applications have different control

to the lowest expected outside temperature. Add

systems. Ensure that the shutoff procedures are

the proper coolant/water mixture, if necessary.

understood. Use the following general guidelines in

order to stop the engine.

• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in

1. Remove the load from the engine so that the

the instructions from the OEM.

engine has no more than 30% power.

2. Run the engine at the programmed low idle speed

for at least 3 minutes.

3. After the cool down period, turn the start switch to

the OFF position.

i04137729

After Stopping Engine

SMCS Code: 1000

Note: After operation, allow 10 minutes for the engine

oil to return to the oil pan before checking the engine

oil level.

• Check the crankcase oil level. Maintain the oil level

between the “ADD” mark and the “FULL” mark

on the oil level gauge.

Note: Only use oil that is recommended in this

Operation and Maintenance Manual, “Fluid

Recommendations” article. Failure to do so may

result in engine damage.

SEBU8598

Maintenance Section

Refill Capacities

The refill capacities for the engine crankcase reflect

Maintenance Section

the approximate capacity of the crankcase or sump

plus standard oil filters. Auxiliary oil filter systems will

require additional oil. Refer to the OEM specifications

Refill Capacities

for the capacity of the auxiliary oil filter.

Table 4

i04133774

C15 and C18 Industrial Engines

Approximate Refill Capacities

Refill Capacities

Engine with 1

Engine with 2

Oil Sump⁽¹⁾

SMCS Code: 1000; 1348; 1395; 7560

Filter

Filters

Refer to this Operation and Maintenance Manual,

“Fluid Recommendations” for information about the

Standard pan

34 L (36 qt)

36 L (38 qt)

fluids which are acceptable for this engine.

Center pan

60 L (63 qt)

62 L (66 qt)

Note: Refer to Special Publication, SEBU6251,

Deep pan

68 L (72 qt)

70 L (74 qt)

“CaterpillarCommercial Diesel Engine Fluids

Recommendations” for additional information.

⁽¹⁾ These values are approximate capacities for the crankcase oil

sump which include the standard oil filters that are installed at

the factory. Engines with auxiliary oil filters will require additional

Lubricant Refill Capacity

oil. Refer to the OEM specifications for the capacity of the auxili-

ary oil filter.

Coolant Refill Capacity

To maintain the cooling system, the total cooling

system capacity must be known. The capacity of the

total cooling system will vary. The capacity will

depend on the size of the radiator (capacity). Table 5

should be completed by the customer for the

maintenance of the cooling system.

Table 5

Approximate Capacity of the Cooling System

Compartment or

Liters

Quarts

System

Illustration 37

g02300456

Total Cooling System

Standard pan

(1)

⁽¹⁾ The total cooling system capacity includes the following compo-

nents:the engine block, the radiator and all coolant hoses and

lines.

i05489209

Fluid Recommendations

SMCS Code: 1280; 1348; 1395; 7560

Illustration 38

g02300473

Center pan

NOTICE

Every attempt is made to provide accurate, up-to-date

information. By the use of this document, you agree

that Caterpillar Inc. is not responsible for errors or

omissions.

NOTICE

These recommendations are subject to change with-

out prior notice. Contact your Caterpillar dealer for the

most up to date recommendations.

Illustration 39

g02300474

Deep pan

SEBU8598

Refill Capacities

Fluid Recommendations

Refer to Special Publication, SEBU6251, “Cat

• Diesel Particulate Filters (DPF)

Commercial Diesel Engine Fluids Recommendations”

for additional information.

• Diesel Oxidation Catalysts (DOC)

Refer to this Operation and Maintenance Manual,

• Selective Catalytic Reduction (SCR)

“Severe Service Application” for information about

operating an engine in a severe service application.

• Lean NOx Traps (LNT)

Note: Instructions for the installation of the filter are

Other systems may apply.

printed on the side of each Cat spin-on filter. For

filters that are not Cat filters, refer to the installation

instructions that are provided by the supplier of the

filter.

Diesel Engine Oil

Cat DEO (Diesel Engine Oil)

Due to significant variations in the quality and in the

performance of commercially available oils,

Caterpillar makes the following recommendations:

• Cat DEO-ULS (Diesel Engine Oil Ultra Low

Sulfur) (SAE 5W-40)

• Cat DEO-ULS (Diesel Engine Oil Ultra Low

Sulfur) (SAE 10W-30)

• Cat DEO-ULS (Diesel Engine Oil Ultra Low

Sulfur) (SAE 15W-40)

Engine Oil

Cat oils have been developed and tested in order to

provide the full performance and life that has been

designed and built into Cat engines.

Cat DEO-ULS or oils that meet the Cat ECF-3

specification and the API CJ-4 are required for use in

the applications listed below. Cat DEO-ULS and oils

meeting Cat ECF-3 specification and the API CJ-4

and ACEA E9 oil categories have been developed

with limited sulfated ash, phosphorus, and sulfur.

These chemical limits are designed to maintain the

expected aftertreatment devices life, performance,

and service interval. If oils meeting the Cat ECF-3

specification and the API CJ-4 specifications are not

available, oils meeting ACEA E9 may be used. ACEA

E9 oils meet the chemical limits designed to maintain

aftertreatment device life. ACEA E9 oils are validated

using some but not all ECF-3 and API CJ-4 standard

engine performance tests. Consult your oil supplier

when considering use of an oil that is not Cat ECF-3

or API CJ-4 qualified.

Failure to meet the listed requirements will damage

aftertreatment-equipped engines and can negatively

impact the performance of the aftertreatment devices.

The Diesel Particulate Filter (DPF) will plug sooner

and require more frequent DPF ash service intervals.

Typical aftertreatment systems include the following:

SEBU8598

Refill Capacities

Fluid Recommendations

Table 6

Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance

°C

°F

Compartment or System

Oil Viscosities

Requirements

Min

Max

Min

Max

Cat DEO-ULS Cold Weather

SAE 0W-40

-40

104

Engine Crankcase

Cat DEO-ULS

SAE 10W-30

-18

104

Cat DEO-ULS

SAE 15W-40

-9.5

122

NOTICE

Oil Renewal systems should not be used in engines

Always use a designated pump for oil sampling, and

equipped with aftertreatment systems. Reduced life

use a separate designated pump for coolant sam-

or damage to the aftertreatment may occur.

pling. Using the same pump for both types of samples

may contaminate the samples that are being drawn.

This contaminate may cause a false analysis and an

incorrect interpretation that could lead to concerns by

S·O·S Services Oil Analysis

both dealers and customers.

NOTICE

These recommendations are subject to change with-

Refer to Special Publication, SEBU6251, “Cat

Commercial Diesel Engine Fluids Recommendations”

out prior notice. Contact your Caterpillar dealer for the

in order to obtain additional information about S·O·S

most up to date recommendations.

Services oil analysis. You can also contact your local

Cat dealer in order to obtain additional information

about the S·O·S Services Oil Analysis program.

Caterpillar has developed a maintenance tool that

evaluates oil degradation. the maintenance

Diesel Fuel Recommendations

management also detects the early signs of wear on

internal components. The Cat tool for oil analysis is

called S·O·S Oil Analysis and the tool is part of the

S·O·S Services program. S·O·S Oil Analysis divides

oil analysis into four categories:

• Component wear rate

• Oil condition

• Oil contamination

• Identification of oil

These four types of analysis are used to monitor the

condition of your equipment. The four types of

analysis will also help you identify potential problems.

A properly administered S·O·S Oil Analysis program

will reduce repair costs and the program will lessen

Illustration 40

g02157153

the impact of downtime.

NACD Film

The S·O·S Oil Analysis program uses a wide range of

tests to determine the condition of the oil and the

lubricated compartment. Guidelines that are based on

experience and a correlation to failures have been

established for these tests. Exceeding one or more of

these guidelines could indicate serious fluid

degradation or a pending component failure. A

trained person at your Cat dealership should make

the final analysis.

SEBU8598

Refill Capacities

Fluid Recommendations

• Shorten the time interval between

aftertreatment device service intervals (cause

the need for more frequent service intervals)

• Adversely impact the performance and life of

aftertreatment devices (cause loss of

performance)

• Reduce regeneration intervals of

aftertreatment devices

• Reduce engine efficiency and durability.

• Increase the wear.

• Increase the corrosion.

Illustration 41

g02052934

EAME Film

• Increase the deposits.

Diesel fuel must meet “Cat Specification for Distillate

• Lower fuel economy

Fuel” and the latest versions of “ASTM D975” or “EN

590” in order to ensure optimum engine performance.

• Shorten the time period between oil drain intervals

Refer to Special Publication, SEBU6251, “Cat

(more frequent oil drain intervals).

Commercial Diesel Engine Fluids Recommendations”

for the latest fuel information and for Cat fuel

• Increase overall operating costs.

specification. This manual may be found on the Web

at Safety.Cat.com.

Failures that result from the use of improper fuels are

not Cat factory defects. Therefore the cost of repairs

would not be covered by a Cat warranty.

NOTICE

Ultra Low Sulfur Diesel (ULSD) fuel 0.0015 percent

Cat does not require the use of ULSD in off road and

(≤15 ppm (mg/kg)) sulfur is required by regulation for

machine applications that are not Tier 4/Stage IIIB

use in engines certified to nonroad Tier 4 standards

certified engines. ULSD is not required in engines

(U.S. EPA Tier 4 certified) and that are equipped with

that are not equipped with after treatment devices.

exhaust aftertreatment systems.

For Tier 4/Stage IIIB/Stage IV certified engines

always follow operating instructions. Fuel tank inlet

European ULSD 0.0010 percent (≤10ppm (mg/kg))

labels are installed in order to ensure that the correct

sulfur fuel is required by regulation for use in engines

fuels are used.

certified to European nonroad Stage IIIB and newer

standards and are equipped with exhaust aftertreat-

Refer to Special Publication, SEBU6251, “Cat

ment systems.

Commercial Diesel Engine Fluids Recommendations”

for more details about fuels, lubricants, and Tier 4

requirements. This manual may be found on the Web

Misfueling with fuels of higher sulfur level can

at Safety.Cat.com.

have the following negative effects:

Lubricating Grease

NOTICE

These recommendations are subject to change with-

out prior notice. Contact your Caterpillar dealer for the

most up to date recommendations.

Cat provides various greases that vary in

performance from a moderate performance to high

performance. Cat greases service the entire line of

Cat products in the wide variety of climates

throughout the world. From this variety of Cat grease

products, you can find a Cat grease that will meet or

exceed the performance requirements of most

engines.

SEBU8598

Refill Capacities

Fluid Recommendations

The performance requirements of your engine must

NOTICE

be determined before you select any Cat grease.

Frequently check the specific gravity of the coolant for

Consult the recommendations for greases that are

proper freeze protection or for anti-boil protection.

made by the OEM for the equipment. Then, consult

with your Cat dealer for a list of greases that have the

performance specifications and the available sizes of

containers.

NOTICE

Never operate an engine without water temperature

Note: Always choose grease that meets or exceeds

regulators in the cooling system. Water temperature

the recommendations that are specified by the

regulators help to maintain the engine coolant at the

equipment manufacturer for the application.

proper operating temperature. Cooling system prob-

lems can develop without water temperature

If choosing a single grease to use for all of the

regulators.

equipment at one site is necessary , always choose a

grease that meets or exceeds the requirements of the

most demanding application. Remember that the

products which barely meet the minimum

NOTICE

performance requirements can be expected to

Never use water alone as a coolant. Water alone is

produce the minimum lives of your parts. False

corrosive at engine operating temperatures. In addi-

economy is being used if a grease is purchased with

tion, water alone does not provide adequate protec-

the lowest cost as the only consideration. Instead,

tion against boiling or freezing.

use the grease that yields the lowest total operating

cost. This cost should be based on an analysis that

includes the costs of parts, labor, downtime, and the

NOTICE

cost of the amount of grease that is required.

All Cat engines that are equipped with a Cat NOx Re-

duction System require a minimum of 50 percent gly-

Note: Purge all of the old grease from a joint before

col to help prevent cavitation damage and boiling of

you change from one type of grease to another type

the engine coolant. These engines include Tier 4

of grease. Some greases are not chemically

engines.

compatible with other greases. Consult your supplier

in order to determine if the greases are compatible.

The following two coolants are used in Cat Diesel

If you are not certain that the old grease is compatible

Engines :

with the new grease, purge the old grease from the

system before applying the new grease.

Preferred - Cat ELC (Extended Life Coolant) or a

commercial extended life coolant that meets the Cat

Note: All Cat greases are chemically compatible

Engine Coolant-1 (EC-1) specification.

with each other. Mixing of Cat greases does not

result in an adverse chemical reaction. However,

mixing of Cat greases may result in reduced

Acceptable - Cat DEAC (Diesel Engine Antifreeze/

Coolant) or a commercial heavy-duty coolant that

performance.

meets “ASTM D4985”, or “ASTM D6210”

Non-Cat commercial greases are as a group second

specifications

choice greases. Within this grouping of second

choice greases, there are tiered levels of

Note: Cat DEAC does not require a treatment with a

performance. For more information, refer to Special

Supplemental Coolant Additive (SCA) at the initial fill.

Publication, SEBU6251, “Cat Commercial Diesel

Engines Fluids Recommendations”.

However, a commercial heavy-duty coolant that only

meets the “ASTM D4985” specification will require a

Coolant

treatment with an SCA at the initial fill. A commercial

heavy-duty coolant that meets the “ASTM D6210”

specification will not require a treatment with an SCA

NOTICE

at the initial fill. Read the label or the instructions that

These recommendations are subject to change with-

are provided by the manufacturer of the commercial

out prior notice. Contact your Caterpillar dealer for the

heavy-duty coolant.

most up to date recommendations.

Note: These coolants will require a treatment with a

supplemental coolant additive on a maintenance

NOTICE

basis.

Never add coolant to an overheated engine. Engine

damage could result. Allow the engine to cool first.

SEBU8598

Refill Capacities

Fluid Recommendations

Table 7

For more information, refer to Special Publication,

SEBU6251, “Cat Commercial Diesel Engines Fluids

Service Life Before Flushing and Before Refilling

Recommendations”

Coolant

Service Life⁽¹⁾

Cat ELC

12,000 hours, or 6 years

Commercial coolant that meets the

6000 hours, or 6 years

Cat EC-1 specification

Cat DEAC

3000 hours, or 3 years

Commercial Heavy-Duty Coolant

that meets “ASTM D4985” or

3000 hours, or 1 year

“ASTM D6210”

⁽¹⁾ Use the interval that occurs first.

Note: Add the Cat ELC Extender at the halfway

point of the coolant change interval.

Note: These coolant change intervals are only

possible with annual S·O·S Services Level 2 coolant

sampling and analysis.

S·O·S Services Coolant Analysis

Table 8

Recommended Interval

Type of

Level 1

Level 2

Coolant

Every 500 Hours

(1)

Every 2000 Hours

DEAC

(2)

or Yearly⁽¹⁾⁽³⁾

ELC

Optional⁽³⁾

Yearly⁽³⁾

⁽¹⁾ This interval is recommended for the sampling of all convention-

al heavy-duty coolant.

⁽²⁾ This interval is also recommended for the sampling of a com-

mercial coolant that meets the Cat (Engine Coolant specifica-

tion - 1) requirement.

⁽³⁾ The Level 2 coolant analysis should be performed sooner if a

problem is suspected or identified.

Testing the engine coolant is important to ensure that

the engine is protected from internal cavitation and

from corrosion. The analysis also tests the ability of

the coolant to protect the engine from boiling and

from freezing. The S·O·S Coolant Analysis can be

performed at your Cat dealer. Cat S·O·S Coolant

Analysis is the best way to monitor the condition of

your coolant and your cooling system. S·O·S Coolant

Analysis is a program that is based on periodic

samples.

NOTICE

Always use a designated pump for oil sampling, and

use a separate designated pump for coolant sam-

pling. Using the same pump for both types of samples

may contaminate the samples that are being drawn.

This contaminate may cause a false analysis and an

incorrect interpretation that could lead to concerns by

both dealers and customers.

SEBU8598

Maintenance Recommendations

System Pressure Release

Do not loosen the high pressure fuel lines in order to

Maintenance

remove air pressure from the fuel system.

Recommendations

Engine Oil

i02909163

To relieve pressure from the lubricating system, turn

off the engine.

System Pressure Release

SMCS Code: 1250; 1300; 1350; 5050

i05182568

Coolant System

Welding on Engines with

Electronic Controls

SMCS Code: 1000

Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-

NOTICE

diator is cool. Then loosen cap slowly to relieve

Because the strength of the frame may decrease,

the pressure.

some manufacturers do not recommend welding onto

a chassis frame or rail. Consult the OEM of the equip-

ment or your Cat dealer regarding welding on a chas-

To relieve the pressure from the coolant system, turn

sis frame or rail.

off the engine. Allow the cooling system pressure cap

to cool. Remove the cooling system pressure cap

slowly in order to relieve pressure.

Proper welding procedures are necessary in order to

avoid damage to the engine Electronic Control

Fuel System

Module (ECM), Clean Emissions Module (CEM),

sensors, and associated components. When

To relieve the pressure from the fuel system, turn off

possible, remove the component from the unit and

the engine.

then weld the component. If removal of the

component is not possible, the following procedure

must be followed when you weld on a unit that is

High Pressure Fuel Lines (If Equipped)

equipped with a Caterpillar Electronic Engine. The

following procedure is considered to be the safest

procedure to weld on a component. This procedure

should provide a minimum risk of damage to

electronic components.

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel

NOTICE

spray may cause a fire hazard. Failure to follow

Do not ground the welder to electrical components

these inspection, maintenance and service in-

such as the ECM or sensors. Improper grounding can

structions may cause personal injury or death.

cause damage to the drive train, the bearings, hy-

draulic components, electrical components, and other

The high pressure fuel lines are the fuel lines that are

components.

between the high pressure fuel pump and the high

pressure fuel manifold and the fuel lines that are

Do not ground the welder across the centerline of the

package. Improper grounding could cause damage to

between the fuel manifold and cylinder head. These

the bearings, the crankshaft, the rotor shaft, and other

fuel lines are different from fuel lines on other fuel

systems.

components.

This is because of the following differences:

Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close

• The high pressure fuel lines are constantly

as possible to the weld. This will help reduce the pos-

sibility of damage.

charged with high pressure.

• The internal pressures of the high pressure fuel

Note: Perform the welding in areas that are free from

lines are higher than other types of fuel system.

explosive hazards.

Before any service or repair is performed on the

engine fuel lines, perform the following tasks:

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

OFF position.

1. Stop the engine.

2. Wait for ten minutes.

SEBU8598

Maintenance Recommendations

Severe Service Application

2. Disconnect the negative battery cable from the

Note: If electrical/electronic components are used as

battery. If a battery disconnect switch is provided,

a ground for the welder, or electrical/electronic

open the switch.

components are located between the welder ground

and the weld, current flow from the welder could

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

severely damage the component.

the ECM and. Disconnect the wiring from the CEM.

5. Protect the wiring harness from welding debris and

Move the harnesses to a position that will not allow

spatter.

the harnesses to contact with any of the ECM,

CEM, or pins accidentally.

6. Use standard welding practices to weld the

materials.

i04889860

Severe Service Application

SMCS Code: 1000

An engine which operates outside of normal

conditions is operating in a severe service

application.

An engine that operates in a severe service

application may need more frequent maintenance

intervals in order to maximize the following

conditions:

• Reliability

• Service life

The number of individual applications cause the

impossibility of identifying all of the factors which may

contribute to severe service operation. Consult your

Cat dealer for the unique maintenance that may be

necessary for your engine.

An application is a severe service application if any of

the following conditions apply:

Severe Environmental Factors

Illustration 42

g01075639

• Frequent operation in dirty air

Use the example above. The current flow from the

welder to the ground clamp of the welder will not

• Frequent operation at an altitude which is above

damage any associated components.

1525 m (5000 ft)

(1) Engine

(2) Welding electrode

• Frequent operation in ambient temperatures which

(3) Keyswitch in the OFF position

(4) Battery disconnect switch in the open position

are above 32° C (90° F)

(5) Disconnected battery cables

(6) Battery

• Frequent operation in ambient temperatures which

(7) Electrical/Electronic component

are below 0° C (32° F)

(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 the

part that will be welded. Place the ground cable as

close as possible to the weld in order to reduce the

possibility of welding current damage to bearings,

hydraulic components, electrical components, and

ground straps.

SEBU8598

Maintenance Recommendations

Severe Service Application

Severe Operating Conditions

Improper Maintenance Procedures

(Maintenance Procedures Which

•

Frequent operation with inlet air which has a

corrosive content

May Contribute to a Severe Service

Application)

•

Operation with inlet air which has a combustible

content

•

Inadequate maintenance of fuel storage tanks from

causes such as excessive water, sediment, and

•

Operation which is outside of the intended

microorganism growth.

application

•

Extending maintenance intervals beyond the

•

Operation with a plugged fuel filter

recommended intervals

•

Extended operation at low idle (more than 20% of

•

Using fluids which are not recommended in

hours)

Special Publication, SEBU6251, “Cat Commercial

•

Frequent cold starts at temperatures below 0° C

Diesel Engine Fluids Recommendations”

(32° F)

•

Extending maintenance intervals for changing the

•

Frequent dry starts (starting after more than 72

engine oil and engine coolant without S·O·S

hours of shutdown)

validation

•

Frequent hot shutdowns (shutting down the engine

•

Extending maintenance intervals for changing air

without the minimum of 2 minutes to 5 minutes of

filters, oil filters, and fuel filters

cool down time)

•

Failure to use a water separator

•

Operation above the engine rated speed

•

Using filters which are not recommended by

•

Operation below the peak torque speed

Special Publication, PEWJ0074, “2008 Cat Filter

and Fluid Application Guide”

•

Operating with fuel which does not meet the

standards for distillate diesel fuel as stated in

Special Publication, SEBU6251, “Cat Commercial

Diesel Engine Fluids Recommendations”,

“Distillate Diesel Fuel”

•

Operating with a blend of distillate fuel which

contains more than 20 percent biodiesel

SEBU8598

Maintenance Recommendations

Maintenance Interval Schedule

i06002369

“Fuel System - Prime”

“Fuel Tank Water and Sediment - Drain”

Maintenance Interval Schedule

“Radiator - Clean”

(C15 Engines)

SMCS Code: 1000; 4450; 7500

Daily

S/N: LDN1-Up

“Air Tank Moisture and Sediment - Drain”

Ensure that all safety information, warnings, and

“Coolant Level - Check”

instructions are read and understood before any

operation or any maintenance procedures are

“Driven Equipment - Check”

performed.

“Engine Air Cleaner Service Indicator - Inspect”

The user is responsible for the performance of all

“Engine Oil Level - Check”

maintenance which includes the following items:

performing all adjustments, using proper lubricants,

“Fuel System Primary Filter/Water Separator -

fluids, and filters and replacing old components with

Drain”

new components due to normal wear and aging .

“Power Take-Off Clutch - Check”

Failure to adhere to proper maintenance intervals and

procedures may result in diminished performance of

“Walk-Around Inspection”

the product and/or accelerated wear of components.

Every 250 Service Hours

Before each consecutive interval is performed, all

maintenance from the previous intervals must be

“Engine Oil Sample - Obtain”

performed.

“Grounding Stud - Inspect/Clean/Tighten”

Choose the interval that occurs first in order to

determine the correct maintenance interval: fuel

consumption, service hours and calendar time .

Every 500 Service Hours

Products that operate in severe operating conditions

may require more frequent maintenance.

“Battery Electrolyte Level - Check”

All of the following will affect the oil change interval:

“Belts - Inspect/Replace”

operating conditions, fuel type, oil type and size of the

“Coolant Sample (Level 1) - Obtain”

oil sump . Scheduled oil sampling analyzes used oil in

order to determine if the oil change interval is suitable

“Cooling System Supplemental Coolant Additive

for your specific engine.

(SCA) - Test/Add”

Refer to this Operation and Maintenance Manual,

“Engine Oil and Filter - Change”

“Engine Oil and Filter - Change” in order to determine

the oil change interval that is suitable for your specific

“Fuel System Primary Filter (Water Separator)

engine.

Element - Replace”

To determine the maintenance intervals for the

“Fuel System Secondary Filter - Replace”

overhauls, refer to this Operation and Maintenance

Manual, “Maintenance Recommendations” .

“Hoses and Clamps - Inspect/Replace”

When Required

Every 2000 Service Hours

“Battery - Recycle”

“Air Shutoff - Test”

“Battery - Replace”

“Fumes Disposal Filter Element - Replace”

“Battery or Battery Cable - Disconnect”

Every 2000 Service Hours or 1 Year

“Engine - Clean”

“Coolant Sample (Level 2) - Obtain”

“Engine Air Cleaner Element (Dual Element/Box

Type) - Replace”

Every 2500 Service Hours

“Engine Air Cleaner Element (Single Element) -

“Compression Brake - Inspect/Adjust/Replace”

Inspect/Clean/Replace”

“Electronic Unit Injector - Check/Replace”

“Engine Storage Procedure - Check”

“Engine Valve Lash - Check”

SEBU8598

Maintenance Recommendations

Maintenance Interval Schedule

“Valve Actuators - Check”

Failure to adhere to proper maintenance intervals and

procedures may result in diminished performance of

Every 3000 Service Hours or 3

the product and/or accelerated wear of components.

Years

Before each consecutive interval is performed, all

maintenance from the previous intervals must be

“Coolant (DEAC) - Change”

performed.

“Electronic Unit Injector - Check/Replace”

Choose the interval that occurs first in order to

determine the correct maintenance interval: fuel

Every 4000 Service Hours

consumption, service hours and calendar time .

Products that operate in severe operating conditions

“Air Compressor - Check”

may require more frequent maintenance.

“Engine Mounts - Inspect”

All of the following will affect the oil change interval:

operating conditions, fuel type, oil type and size of the

“Starting Motor - Inspect”

oil sump . Scheduled oil sampling analyzes used oil in

order to determine if the oil change interval is suitable

Every 5000 Service Hours

for your specific engine.

“ARD Spark Plug - Replace”

Refer to this Operation and Maintenance Manual,

“Engine Oil and Filter - Change” in order to determine

“Diesel Particulate Filter - Clean/Replace”

the oil change interval that is suitable for your specific

engine.

“Fuel Priming Pump - Replace”

To determine the maintenance intervals for the

Every 6000 Service Hours or 3

overhauls, refer to this Operation and Maintenance

Manual, “Maintenance Recommendations” .

Years

When Required

“Coolant Extender (ELC) - Add”

“Battery - Recycle”

Every 12 000 Service Hours or 6

“Battery - Replace”

Years

“Coolant (ELC) - Change”

“Battery or Battery Cable - Disconnect”

“Engine - Clean”

Every 585 000 L (154 540 US gal) of

Fuel or 10 000 Service Hours

“Engine Air Cleaner Element (Dual Element/Box

Type) - Replace”

“Overhaul Considerations”

“Engine Air Cleaner Element (Single Element) -

Inspect/Clean/Replace”

i06002281

“Engine Storage Procedure - Check”

Maintenance Interval Schedule

“Fuel System - Prime”

(C15 Engines With Ratings

“Fuel Tank Water and Sediment - Drain”

Greater Than 579 hp)

SMCS Code: 1000; 4450; 7500

“Radiator - Clean”

S/N: LDN1-Up

Daily

Ensure that all safety information, warnings, and

“Air Tank Moisture and Sediment - Drain”

instructions are read and understood before any

“Coolant Level - Check”

operation or any maintenance procedures are

performed.

“Driven Equipment - Check”

The user is responsible for the performance of all

“Engine Air Cleaner Service Indicator - Inspect”

maintenance which includes the following items:

performing all adjustments, using proper lubricants,

“Engine Oil Level - Check”

fluids, and filters and replacing old components with

new components due to normal wear and aging .

“Fuel System Primary Filter/Water Separator -

Drain”

SEBU8598

Maintenance Recommendations

Maintenance Interval Schedule

“Power Take-Off Clutch - Check”

Every 5000 Service Hours

“Walk-Around Inspection”

“ARD Spark Plug - Replace”

Every 250 Service Hours

“Diesel Particulate Filter - Clean/Replace”

“Engine Oil Sample - Obtain”

“Fuel Priming Pump - Replace”

“Grounding Stud - Inspect/Clean/Tighten”

Every 6000 Service Hours or 3

Years

Initial 500 Service Hours

“Coolant Extender (ELC) - Add”

“Engine Valve Lash - Check”

Every 12 000 Service Hours or 6

Every 500 Service Hours

Years

“Battery Electrolyte Level - Check”

“Coolant (ELC) - Change”

“Belts - Inspect/Replace”

Every 585 000 L (154 540 US gal) of

“Coolant Sample (Level 1) - Obtain”

Fuel or 10 000 Service Hours

“Cooling System Supplemental Coolant Additive

“Overhaul Considerations”

(SCA) - Test/Add”

“Engine Oil and Filter - Change”

i06002437

“Fuel System Primary Filter (Water Separator)

Maintenance Interval Schedule

Element - Replace”

(C18 Engines With Ratings

“Fuel System Secondary Filter - Replace”

Greater Than 760 HP)

“Hoses and Clamps - Inspect/Replace”

SMCS Code: 1000; 4450; 7500

Every 2000 Service Hours

S/N: BDN1-Up

“Air Shutoff - Test”

Ensure that all safety information, warnings, and

“Fumes Disposal Filter Element - Replace”

instructions are read and understood before any

operation or any maintenance procedures are

Every 2000 Service Hours or 1 Year

performed.

The user is responsible for the performance of all

“Coolant Sample (Level 2) - Obtain”

maintenance which includes the following items:

performing all adjustments, using proper lubricants,

Every 2500 Service Hours

fluids, and filters and replacing old components with

new components due to normal wear and aging .

“Compression Brake - Inspect/Adjust/Replace”

Failure to adhere to proper maintenance intervals and

“Electronic Unit Injector - Check/Replace”

procedures may result in diminished performance of

the product and/or accelerated wear of components.

“Engine Valve Lash - Check”

Before each consecutive interval is performed, all

“Valve Actuators - Check”

maintenance from the previous intervals must be

performed.

Every 3000 Service Hours or 3

Years

Choose the interval that occurs first in order to

determine the correct maintenance interval: fuel

“Coolant (DEAC) - Change”

consumption, service hours and calendar time .

Products that operate in severe operating conditions

may require more frequent maintenance.

Every 4000 Service Hours

All of the following will affect the oil change interval:

“Air Compressor - Check”

operating conditions, fuel type, oil type and size of the

oil sump . Scheduled oil sampling analyzes used oil in

“Engine Mounts - Inspect”

order to determine if the oil change interval is suitable

“Starting Motor - Inspect”

for your specific engine.

SEBU8598

Maintenance Recommendations

Maintenance Interval Schedule

Refer to this Operation and Maintenance Manual,

“Coolant Sample (Level 1) - Obtain”

“Engine Oil and Filter - Change” in order to determine

the oil change interval that is suitable for your specific

“Cooling System Supplemental Coolant Additive

engine.

(SCA) - Test/Add”

To determine the maintenance intervals for the

“Engine Oil and Filter - Change”

overhauls, refer to this Operation and Maintenance

Manual, “Maintenance Recommendations” .

“Fuel System Primary Filter (Water Separator)

Element - Replace”

When Required

“Fuel System Secondary Filter - Replace”

“Battery - Recycle”

“Hoses and Clamps - Inspect/Replace”

“Battery - Replace”

Every 2000 Service Hours

“Battery or Battery Cable - Disconnect”

“Air Shutoff - Test”

“Engine - Clean”

“Fumes Disposal Filter Element - Replace”

“Engine Air Cleaner Element (Dual Element/Box

Type) - Replace”

Every 2000 Service Hours or 1 Year

“Engine Air Cleaner Element (Single Element) -

“Coolant Sample (Level 2) - Obtain”

Inspect/Clean/Replace”

Every 2500 Service Hours

“Engine Storage Procedure - Check”

“Compression Brake - Inspect/Adjust/Replace”

“Fuel System - Prime”

“Electronic Unit Injector - Check/Replace”

“Fuel Tank Water and Sediment - Drain”

“Engine Valve Lash - Check”

“Radiator - Clean”

“Valve Actuators - Check”

Daily

Every 3000 Service Hours or 3

“Air Tank Moisture and Sediment - Drain”

Years

“Coolant Level - Check”

“Coolant (DEAC) - Change”

“Driven Equipment - Check”

Every 4000 Service Hours

“Engine Air Cleaner Service Indicator - Inspect”

“Air Compressor - Check”

“Engine Oil Level - Check”

“Engine Mounts - Inspect”

“Fuel System Primary Filter/Water Separator -

Drain”

“Starting Motor - Inspect”

“Power Take-Off Clutch - Check”

Every 6000 Service Hours or 3

“Walk-Around Inspection”

Years

Every 250 Service Hours

“Coolant Extender (ELC) - Add”

“Engine Oil Sample - Obtain”

Every 12 000 Service Hours or 6

“Grounding Stud - Inspect/Clean/Tighten”

Years

Initial 500 Service Hours

“Coolant (ELC) - Change”

“Engine Valve Lash - Check”

Every 760 000 L (200 770 US gal) of

Fuel or 10 000 Service Hours

Every 500 Service Hours

“Overhaul Considerations”

“Battery Electrolyte Level - Check”

“Belts - Inspect/Replace”

SEBU8598

Maintenance Recommendations

Maintenance Interval Schedule

i06002391

“Fuel System - Prime”

“Fuel Tank Water and Sediment - Drain”

Maintenance Interval Schedule

“Radiator - Clean”

(C18 Engines)

SMCS Code: 1000; 4450; 7500

Daily

S/N: BDN1-Up

“Air Tank Moisture and Sediment - Drain”

Ensure that all safety information, warnings, and

“Coolant Level - Check”

instructions are read and understood before any

operation or any maintenance procedures are

“Driven Equipment - Check”

performed.

“Engine Air Cleaner Service Indicator - Inspect”

The user is responsible for the performance of all

“Engine Oil Level - Check”

maintenance which includes the following items:

performing all adjustments, using proper lubricants,

“Fuel System Primary Filter/Water Separator -

fluids, and filters and replacing old components with

Drain”

new components due to normal wear and aging .

“Power Take-Off Clutch - Check”

Failure to adhere to proper maintenance intervals and

procedures may result in diminished performance of

“Walk-Around Inspection”

the product and/or accelerated wear of components.

Every 250 Service Hours

Before each consecutive interval is performed, all

maintenance from the previous intervals must be

“Engine Oil Sample - Obtain”

performed.

“Grounding Stud - Inspect/Clean/Tighten”

Choose the interval that occurs first in order to

determine the correct maintenance interval: fuel

consumption, service hours and calendar time .

Every 500 Service Hours

Products that operate in severe operating conditions

may require more frequent maintenance.

“Battery Electrolyte Level - Check”

All of the following will affect the oil change interval:

“Belts - Inspect/Replace”

operating conditions, fuel type, oil type and size of the

“Coolant Sample (Level 1) - Obtain”

oil sump . Scheduled oil sampling analyzes used oil in

order to determine if the oil change interval is suitable

“Cooling System Supplemental Coolant Additive

for your specific engine.

(SCA) - Test/Add”

Refer to this Operation and Maintenance Manual,

“Engine Oil and Filter - Change”

“Engine Oil and Filter - Change” in order to determine

the oil change interval that is suitable for your specific

“Fuel System Primary Filter (Water Separator)

engine.

Element - Replace”

To determine the maintenance intervals for the

“Fuel System Secondary Filter - Replace”

overhauls, refer to this Operation and Maintenance

Manual, “Maintenance Recommendations” .

“Hoses and Clamps - Inspect/Replace”

When Required

Every 2000 Service Hours

“Battery - Recycle”

“Air Shutoff - Test”

“Battery - Replace”

“Fumes Disposal Filter Element - Replace”

“Battery or Battery Cable - Disconnect”

Every 2000 Service Hours or 1 Year

“Engine - Clean”

“Coolant Sample (Level 2) - Obtain”

“Engine Air Cleaner Element (Dual Element/Box

Type) - Replace”

Every 2500 Service Hours

“Engine Air Cleaner Element (Single Element) -

“Compression Brake - Inspect/Adjust/Replace”

Inspect/Clean/Replace”

“Electronic Unit Injector - Check/Replace”

“Engine Storage Procedure - Check”

“Engine Valve Lash - Check”

SEBU8598

Maintenance Recommendations

ARD Spark Plug - Replace

“Valve Actuators - Check”

Every 3000 Service Hours or 3

Years

“Coolant (DEAC) - Change”

Every 4000 Service Hours

“Air Compressor - Check”

“Engine Mounts - Inspect”

“Starting Motor - Inspect”

Every 5000 Service Hours

“ARD Spark Plug - Replace”

“Diesel Particulate Filter - Clean/Replace”

“Fuel Priming Pump - Replace”

Illustration 43

g02139990

Every 6000 Service Hours or 3

(1) Wiring harness

Years

(2) Spark plug

“Coolant Extender (ELC) - Add”

1. Remove wire harness (1) from spark plug (2).

Every 12 000 Service Hours or 6

Years

“Coolant (ELC) - Change”

Personal injury can result from air pressure.

Every 760 000 L (200 770 US gal) of

Personal injury can result without following prop-

Fuel or 10 000 Service Hours

er procedure. When using pressure air, wear a

protective face shield and protective clothing.

“Overhaul Considerations”

The maximum air pressure for cleaning purposes

i04880449

must be reduced to 205 kPa (30 psi) when the air

nozzle is deadheaded.

ARD Spark Plug - Replace

2. Debris may have collected in the spark plug well.

(If Equipped)

Thoroughly remove any debris. Use compressed

SMCS Code: 1555-510

air. The maximum air pressure for cleaning

purposes must be below 205 kPa (30 psi). Ensure

that the area around the spark plug is clean and

Removing the Spark Plug

free of dirt and debris.

NOTICE

3. Use a deep well socket and a breaker bar to loosen

If the engine is running or the key is in the ON position

the spark plug. If necessary, see your Caterpillar

the ARD plug will continue to fire. Turn the key to the

dealer for the part number of the socket. After the

OFF position before servicing the ARD plug.

spark plug has been loosened, use the socket to

remove the spark plug by hand in order to detect

problems with the threads. After the spark plug has

been removed, inspect the used spark plug and

the gasket.

If the spark plug could not be removed by hand, clean

the threads with a 305-2389 brush. This tool

scrapes debris from the seat and from the threads.

SEBU8598

Maintenance Recommendations

Air Compressor - Check

NOTICE

Do not use a thread tap. A thread tap will remove met-

al unnecessarily. The threads could be stripped and

the combustion group could be damaged.

Installing the Spark Plug

Note: Do not use anti-seize compound on the spark

plug. Most of the heat is transferred through the

threads and the seat area of the spark plug. Contact

of the metal surfaces must be maintained in order to

provide the heat transfer that is required.

1. Ensure that the spark plug is clean and free of dirt

Illustration 44

g01212654

and oil.

Typical example

(1) Pressure relief valve

NOTICE

Do not overtighten the spark plug. The shell can be

cracked and the gasket can be deformed. The metal

can deform and the gasket can be damaged. The

If the air compressor pressure relief valve that is

shell can be stretched. This will loosen the seal that is

mounted in the air compressor cylinder head is

between the shell and the insulator, allowing combus-

bypassing compressed air, there is a malfunction

tion pressure to blow past the seal. Serious damage

in the air system, possibly ice blockage. Under

to the engine can occur.

these conditions, your engine may have insuffi-

Use the proper torque.

cient air for normal brake operation.

Do not operate the engine until the reason for the

2. Install the spark plug by hand until the spark plug

air bypass is identified and corrected. Failure to

contacts the ARD. Torque the spark plug to the

heed this warning could lead to property damage,

personal injury, or death to the operator or

proper specification. Refer to Specifications,

bystanders.

“Spark Plug” for the proper torque specification.

3. Connect the wiring harness.

The function of the pressure relief valve is to bypass

air when there is a malfunction in the system for the

air compressor.

i03966490

The pressure relief valve for the air compressor

Air Compressor - Check

releases air at 1723 kPa (250 psi). If the pressure

relief valve for the air compressor exhausts, all

(If equipped)

personnel should be at a safe distance away from the

SMCS Code: 1803-535

air compressor. All personnel should also stay clear

of the air compressor when the engine is operating

and the air compressor is exposed.

Refer to the Service Manual or refer to the OEM

Do not disconnect the air line from the air com-

specifications in order to find information concerning

pressor governor without purging the air brake

the air compressor. Consult your Caterpillar dealer

and the auxiliary air systems. Failure to purge the

for assistance.

air brake and the auxiliary air systems before re-

moving the air compressor and/or the air lines

i05341564

could cause personal injury.

Air Shutoff - Test

SMCS Code: 1078-081

To ensure that the air shutoff valve always shuts

down when the engine ingests gaseous fumes,

perform the test below at each oil change. A test

failure can indicate wear in the block off plate to valve

body interface and/or the bearing system.

SEBU8598

Maintenance Recommendations

Air Tank Moisture and Sediment - Drain

1. Place engine at low idle speed. Ensure all

1. Open the drain valve that is on the bottom of the air

accessories that are normally used for the

tank. Allow the moisture and sediment to drain.

application are in use, like a fan, or power takeoffs.

2. Close the drain valve.

2. Actuate the air shutoff manually. On electrical

3. Check the air supply pressure. The air starting

operator air shutoffs, utilize an applicable power

motor requires a minimum of 620 kPa (90 psi) of

supply or jumper cables from the battery to

air pressure to operate properly. The maximum air

energize the air shut-off solenoid. Ensure that the

pressure must not exceed 1550 kPa (225 psi).

solenoid receives only a momentary signal to

The normal air pressure will be 758 to 965 kPa

prevent overheating. On hydraulic operator air

(110 to 140 psi).

shutoffs, found on some hazardous location units,

actuate by pulling the emergency stop handle.

i02039199

3. Ensure that air shutoff was actuated and that the

engine comes to a complete stop.

Battery - Recycle

SMCS Code: 1401-005; 1401-510; 1401-535; 1401-

Note: As every application has different parasitic

561; 1401

loads and inertia, the duration for the problem to

occur cannot be specified. However, if the engine

Always recycle a battery. Never discard a battery.

stumbles or attempts to continue running, these

Return used batteries to one of the following

symptoms may be an indication that worn

locations:

components may need replacement.

• A battery supplier

If additional help is needed, contact the Dealer

Solution Network.

• An authorized battery collection facility

NOTICE

• A recycling facility

Actuating the air shutoff valve may result in oil leak-

age past the shaft seal in some cases. Repeated ac-

i01878164

tuation of the air shutoff valve during loaded operation

of the engine can result in mechanical damage to the

Battery - Replace

turbocharger and reduce turbocharger life.

SMCS Code: 1401-510

i00847451

Air Tank Moisture and

Batteries give off combustible gases which can

explode. A spark can cause the combustible

Sediment - Drain

gases to ignite. This can result in severe personal

injury or death.

(If Equipped)

SMCS Code: 1466-543-M&S

Ensure proper ventilation for batteries that are in

an enclosure. Follow the proper procedures in or-

Moisture and sediment in the air starting system can

der to help prevent electrical arcs and/or sparks

cause the following conditions:

near batteries. Do not smoke when batteries are

serviced.

• Freezing

• Corrosion of internal parts

• Malfunction of the air starting system

The battery cables or the batteries should not be

removed with the battery cover in place. The bat-

tery cover should be removed before any servic-

ing is attempted.

When opening the drain valve, wear protective

Removing the battery cables or the batteries with

gloves, a protective face shield, protective cloth-

the cover in place may cause a battery explosion

ing, and protective shoes. Pressurized air could

resulting in personal injury.

cause debris to be blown and result in personal

injury.

SEBU8598

Maintenance Recommendations

Battery Electrolyte Level - Check

1. Switch the engine to the OFF position. Remove all

2. Check the condition of the electrolyte with the

electrical loads.

245-5829 Coolant Battery Tester Refractometer.

2. Turn off any battery chargers. Disconnect any

3. Keep the batteries clean.

battery chargers.

Clean the battery case with one of the following

3. The NEGATIVE “-” cable connects the NEGATIVE

cleaning solutions:

“-” battery terminal to the NEGATIVE “-” terminal

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

on the starter motor. Disconnect the cable from the

1 L (1 qt) of clean water

NEGATIVE “-” battery terminal.

• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L

4. The POSITIVE “+” cable connects the POSITIVE

(1 qt) of clean water

“+” battery terminal to the POSITIVE “+” terminal

on the starting motor. Disconnect the cable from

Thoroughly rinse the battery case with clean water.

the POSITIVE “+” battery terminal.

Use a fine grade of sandpaper to clean the

terminals and the cable clamps. Clean the items

Note: Always recycle a battery. Never discard a

until the surfaces are bright or shiny. DO NOT

battery. Return used batteries to an appropriate

remove material excessively. Excessive removal of

recycling facility.

material can cause the clamps to not fit properly.

5. Remove the used battery.

Coat the clamps and the terminals with 5N-5561

Silicone Lubricant, petroleum jelly or MPGM.

6. Install the new battery.

i01492654

Note: Before the cables are connected, ensure that

Battery or Battery Cable -

the engine start switch is OFF.

7. Connect the cable from the starting motor to the

Disconnect

POSITIVE “+” battery terminal.

SMCS Code: 1401; 1402-029

8. Connect the cable from the NEGATIVE “-”

terminal on the starter motor to the NEGATIVE “-”

battery terminal.

The battery cables or the batteries should not be

removed with the battery cover in place. The bat-

i02601752

tery cover should be removed before any servic-

ing is attempted.

Battery Electrolyte Level -

Removing the battery cables or the batteries with

Check

the cover in place may cause a battery explosion

SMCS Code: 1401-535-FLV

resulting in personal injury.

When the engine is not run for long periods of time or

when the engine is run for short periods, the batteries

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

may not fully recharge. Ensure a full charge in order

ignition switch (if equipped) to the OFF position

to help prevent the battery from freezing.

and remove the key and all electrical loads.

2. Disconnect the negative battery terminal at the

battery that goes to the start switch. Ensure that

All lead-acid batteries contain sulfuric acid which

the cable cannot contact the terminal. When four

can burn the skin and clothing. Always wear a

12 volt batteries are involved, the negative side of

face shield and protective clothing when working

two batteries must be disconnected.

on or near batteries.

3. Tape the leads in order to help prevent accidental

starting.

1. Remove the filler caps. Maintain the electrolyte

level to the “FULL” mark on the battery.

4. Proceed with necessary system repairs. Reverse

the steps in order to reconnect all of the cables.

If the addition of water is necessary, use distilled

water. If distilled water is not available use clean

water that is low in minerals. Do not use artificially

softened water.

SEBU8598

Maintenance Recommendations

Belts - Inspect/Replace

i04322187

Belts - Inspect/Replace

(If Equipped)

SMCS Code: 1397-040; 1397-510

The engine may be equipped with one of the

following types of belts and belt tensioners.

Single Belt

The belt on the engine may look like the belt in

Illustration 45 or like the belt in Illustration 45 .

Illustration 46

g02294634

View of the front of a C15 or a C18 Industrial Engine

(1) Belt

(2) Belt tensioner

For maximum engine performance and maximum

utilization of your engine, inspect the belts for wear

and for cracking. Replace the belts, if necessary.

To replace the belt, perform the following steps:

1. Insert a ratchet with a square drive into the square

hole that is located in the tensioner for the belt.

Rotate the tensioner clockwise in order to relieve

Illustration 45

g02294633

tension on the belt. Remove the belt.

View of the front of a C15 or a C18 Industrial Engine

2. Install the new belt correctly, as shown. Be sure

(1) Belt

that the belt is fully seated on the pulleys. The

(2) Belt tensioner

(3) Alternator

correct tension will automatically be applied when

(4) Idler pulley

the ratchet is removed.

(5) Crankshaft pulley

SEBU8598

Maintenance Recommendations

Compression Brake - Inspect/Adjust/Replace

Two or More Belts

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 replacement

procedure.

i03965390

Compression Brake - Inspect/

Adjust/Replace

SMCS Code: 1119-025; 1119-040; 1119-510

Contact your Cat dealer for the proper procedure.

Illustration 47

g02478261

Belt tensioner

i04156977

(1) Adjustment bolt

(2) 46 mm (1-13/16 inch) jamming locknut (jam nut)

(A) 22 mm (0.87 inch)

Coolant (DEAC) - Change

SMCS Code: 1350-070; 1395-044

Inspection of the Belts

Clean the cooling system and flush the cooling

Inspect the fan drive belts for wear and for cracking.

system before the recommended maintenance

Replace the belts if the belts are not in good

interval if the following conditions exist:

condition.

• The engine overheats frequently.

Belt Replacement

• Foaming is observed.

For applications that require multiple drive belts,

• The oil has entered the cooling system and the

replace the drive belts in matched sets. Replacing

coolant is contaminated.

one drive belt of a matched set will cause the new

drive belt to carry more load because the older drive

• The fuel has entered the cooling system and the

belts are stretched. The additional load on the new

coolant is contaminated.

drive belt could cause the new drive belt to fail.

Use the following procedure to change the belts.

NOTICE

Use of commercially available cooling system

1. Using a 46 mm (1-13/16 inch) wrench, loosen the

cleaners may cause damage to cooling system com-

jam nut (2).

ponents. Use only cooling system cleaners that are

approved for Caterpillar engines.

Note: See figure 47 , dimension (A).

2. Loosen the adjustment bolt (1).

Note: Inspect the water pump and the water

temperature regulator after the cooling system has

3. Remove the old belt and replace with a new belt.

been drained.

Contact your Cat dealer for assistance in choosing

and ordering new belts.

4. Tighten the adjustment bolt (1). Use a 144-0235

Belt Tension Gauge to ensure that belt is tensioned

according to table 9 .

SEBU8598

Maintenance Recommendations

Coolant (DEAC) - Change

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

Loosen the cooling system filler cap slowly in order

to relieve any pressure. Remove the cooling

system filler cap.

2. Open the cooling system drain valve.

Allow the coolant to drain.

NOTICE

Dispose of used engine coolant properly or recycle.

Various methods have been proposed to reclaim used

coolant for reuse in engine cooling systems. The full

distillation procedure is the only method acceptable

by Caterpillar to reclaim the used coolant.

For information regarding the disposal and the

recycling of used coolant, consult your Cat dealer or

consult Cat Dealer Service Tools Group :

Outside Illinois 1-800-542-TOOL

Inside Illinois 1-800-541-TOOL

Canada 1-800-523-TOOL

International 1-309-578-7372

Flush

Illustration 48

g02351659

1. Flush the cooling system with clean water in order

The cooling system drain valve is towards the bottom

to remove any debris.

of the radiator.

2. Close the drain valve.

Drain

NOTICE

Fill the cooling system no faster than 19 L (5 US gal)

per minute to avoid air locks.

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,

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

stop the engine and wait until the cooling system

and Cat Fast Acting Cooling System Cleaner. Add

components are cool. Loosen the cooling system

pressure cap slowly in order to relieve the

0.5 L (1 pt) of cleaner per 15 L (4 US gal) of the

pressure.

cooling system capacity. Install the cooling system

filler cap.

NOTICE

4. Start and run the engine at low idle for a minimum

Care must be taken to ensure that fluids are con-

of 30 minutes. The coolant temperature should be

tained during performance of inspection, mainte-

at least 82 °C (180 °F).

nance, testing, adjusting and repair of the product. Be

prepared to collect the fluid with suitable containers

before opening any compartment or disassembling

NOTICE

any component containing fluids.

Improper or incomplete rinsing of the cooling system

can result in damage to copper and other metal

Refer to Special Publication, NENG2500, “Caterpillar

components.

Dealer Service Tool Catalog” or refer to Special Publi-

cation, PECJ0003, “Caterpillar Shop Supplies and

To avoid damage to the cooling system, make sure to

Tools Catalog” for tools and supplies suitable to col-

completely flush the cooling system with clear water.

lect and contain fluids on Caterpillar products.

Continue to flush the system until all signs of the

cleaning agent are gone.

Dispose of all fluids according to local regulations and

mandates.

SEBU8598

Maintenance Recommendations

Coolant (ELC) - Change

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

NOTICE

Loosen the cooling system filler cap slowly in order

Fill the cooling system no faster than 19 L (5 US gal)

to relieve any pressure. Remove the cooling

per minute to avoid air locks.

system filler cap. Open the drain valve. Allow the

water to drain. Flush the cooling system with clean

1. Fill the cooling system with coolant/antifreeze.

water. If equipped, be sure to flush the heater and

Refer to this Operation and Maintenance Manual,

any related supply and return lines. Close the drain

“Fluid Recommendations” topic for more

valve.

information on cooling system specifications. Do

Cooling Systems with Heavy

not install the cooling system filler cap.

Deposits or Plugging

2. Start and run the engine at low idle. Increase the

engine rpm to 1500 rpm. Run the engine at high

Note: For the following procedure to be effective,

idle for 1 minute in order to purge the air from the

there must be some active flow through the cooling

system components.

cavities of the engine block. Stop the engine.

1. Flush the cooling system with clean water in order

3. Check the coolant level. Maintain the coolant level

to remove any debris.

within 13 mm (0.5 inch) below the bottom of the

pipe for filling. Maintain the coolant level within

2. Close the drain valve.

13 mm (0.5 inch) to the proper level on the sight

glass.

NOTICE

4. Clean the cooling system filler cap. Inspect the

Fill the cooling system no faster than 19 L (5 US gal)

gasket that is on the cooling system filler cap. If the

per minute to avoid air locks.

gasket that is on the cooling system filler cap is

damaged, discard the old filler cap and install a

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

new filler cap. If the gasket that is on the cooling

and Cat Fast Acting Cooling System Cleaner. Add

system filler cap is not damaged, perform a

0.5 L (1 pt) of cleaner per 3.8 to 7.6 L

pressure test. A 9S-8140 Pressurizing Pump is

(1 to 2 US gal) of the cooling system capacity.

used to perform the pressure test. The correct

Install the cooling system filler cap.

pressure for the cooling system filler cap is

stamped on the face of the cooling system filler

4. Start and run the engine at low idle for a minimum

cap. If the cooling system filler cap does not retain

of 90 minutes. The coolant temperature should be

the correct pressure, install a new cooling system

at least 82 °C (180 °F).

filler cap.

5. Start the engine. Inspect the cooling system for

NOTICE

leaks and for proper operating temperature.

Improper or incomplete rinsing of the cooling system

can result in damage to copper and other metal

components.

i04156979

To avoid damage to the cooling system, make sure to

Coolant (ELC) - Change

completely flush the cooling system with clear water.

Continue to flush the system until all signs of the

SMCS Code: 1350-070; 1395-044

cleaning agent are gone.

Clean the cooling system and flush the cooling

system before the recommended maintenance

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

interval if the following conditions exist:

Loosen the cooling system filler cap slowly in order

• The engine overheats frequently.

to relieve any pressure. Remove the cooling

system filler cap. Open the drain valve. Allow the

• Foaming is observed.

water to drain. Flush the cooling system with clean

water.

• The oil has entered the cooling system and the

coolant is contaminated.

Fill

• The fuel has entered the cooling system and the

coolant is contaminated.

SEBU8598

Maintenance Recommendations

Coolant (ELC) - Change

Note: When the cooling system is cleaned, only

NOTICE

clean water is needed when the ELC is drained and

Dispose of used engine coolant properly or recycle.

replaced.

Various methods have been proposed to reclaim used

coolant for reuse in engine cooling systems. The full

Note: Inspect the water pump and the water

distillation procedure is the only method acceptable

temperature regulator after the cooling system has

by Caterpillar to reclaim the used coolant.

been drained.

NOTICE

Care must be taken to ensure that fluids are con-

tained during performance of inspection, mainte-

nance, testing, adjusting and repair of the product. Be

prepared to collect the fluid with suitable containers

before opening any compartment or disassembling

any component containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” or refer to Special Publi-

cation, PECJ0003, “Caterpillar Shop Supplies and

Tools Catalog” for tools and supplies suitable to col-

lect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and

mandates.

For information regarding the disposal and the

recycling of used coolant, consult your Cat dealer or

consult Cat Dealer Service Tool Group :

OutsideIllinois 1-800-542-TOOL

InsideIllinois 1-800-541-TOOL

Canada 1-800-523-TOOL

International 1-309-578-7372

Flush

Illustration 49

g02351659

1. Flush the cooling system with clean water in order

to remove any debris.

Drain

2. Close the drain valve.

Pressurized System: Hot coolant can cause seri-

NOTICE

ous burns. To open the cooling system filler cap,

Fill the cooling system no faster than 19 L (5 US gal)

stop the engine and wait until the cooling system

per minute to avoid air locks.

components are cool. Loosen the cooling system

pressure cap slowly in order to relieve the

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

pressure.

cooling system filler cap.

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

4. Start and run the engine at low idle until the

Loosen the cooling system filler cap slowly in order

temperature reaches49 to 66 °C (120 to 150 °F).

to relieve any pressure. Remove the cooling

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

system filler cap.

Loosen the cooling system filler cap slowly in order

2. Open the cooling system drain valve.

to relieve any pressure. Remove the cooling

system filler cap. Open the drain valve. Allow the

Allow the coolant to drain.

water to drain. Flush the cooling system with clean

water. Close the drain valve.

Fill

SEBU8598

Maintenance Recommendations

Coolant Extender (ELC) - Add

NOTICE

Fill the cooling system no faster than 19 L (5 US gal)

per minute to avoid air locks.

Personal injury can result from hot coolant, steam

and alkali.

1. Fill the cooling system with Extended Life Coolant

At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines to

(ELC). Refer to this Operation and Maintenance

heaters or the engine contain hot coolant or

Manual, “Fluid Recommendations” for more

steam. Any contact can cause severe burns.

information on cooling system specifications. Do

not install the cooling system filler cap.

Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and

2. Start and run the engine at low idle. Increase the

cooling system pressure cap is cool enough to

touch with your bare hand.

engine rpm to high idle. Run the engine at high idle

for 1 minute in order to purge the air from the

Do not attempt to tighten hose connections when

cavities of the engine block. Stop the engine.

the coolant is hot, the hose can come off causing

burns.

3. Check the coolant level. Maintain the coolant level

within 13 mm (0.5 inch) below the bottom of the

Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.

pipe for filling. Maintain the coolant level within

13 mm (0.5 inch) to the proper level on the sight

glass.

NOTICE

Care must be taken to ensure that fluids are con-

4. Clean the cooling system filler cap. Inspect the

tained during performance of inspection, mainte-

gasket that is on the cooling system filler cap. Only

nance, testing, adjusting, and repair of the product.

install the used filler cap if the gasket is not

Be prepared to collect the fluid with suitable contain-

damaged. Use a 9S-8140 Pressurizing Pump to

ers before opening any compartment or disassem-

pressure test a reinstalled cooling system filler cap.

bling any component containing fluids.

The correct pressure for the cooling system filler

cap is stamped on the face of the cooling system

Refer to Special Publication, NENG2500, “Cat Dealer

Service Tool Catalog” or refer to Special Publication,

filler cap. If the cooling system filler cap does not

PECJ0003, “Cat Shop Supplies and Tools Catalog”

retain the correct pressure, install a new cooling

for tools and supplies suitable to collect and contain

system filler cap.

fluids on Cat products.

5. Start the engine. Inspect the cooling system for

Dispose of all fluids according to local regulations and

leaks and for proper operating temperature.

mandates.

i04745732

1. Loosen the cooling system filler cap slowly in order

to relieve pressure. Remove the cooling system

Coolant Extender (ELC) - Add

filler cap.

SMCS Code: 1352-544-NL

2. If necessary, drain enough coolant from the cooling

Cat ELC (Extended Life Coolant) does not require

system in order to add the Cat ELC Extender .

the frequent additions of any supplemental cooling

additives which are associated with the present

3. Add Cat ELC Extender according to the

conventional coolants. The Cat ELC Extender will

requirements for the cooling system capacity.

only be added one time.

Refer to this Operation and Maintenance Manual,

“Refill Capacities” or to this Operation and

NOTICE

Maintenance Manual, “Fluid Recommendations”

Use only Cat Extended Life Coolant (ELC) Extender

for more information.

with Cat ELC.

Do NOT use conventional supplemental coolant addi-

4. Clean the cooling system filler cap. Inspect the

tive (SCA) with Cat ELC. Mixing Cat ELC with con-

gaskets on the cooling system filler cap. Replace

ventional coolants and/or conventional SCA reduces

the cooling system filler cap if the gaskets are

the Cat ELC service life.

damaged. Install the cooling system filler cap.

Check the cooling system only when the engine is

stopped and cool.

SEBU8598

Maintenance Recommendations

Coolant Level - Check

i03842450

Coolant Level - Check

SMCS Code: 1395-082

Check the coolant level when the engine is stopped

and cool.

Illustration 51

g00103639

Typical filler cap gaskets

3. Clean the cooling system filler cap and check the

condition of the filler cap gaskets. Replace the

cooling system filler cap if the filler cap gaskets are

damaged. Reinstall the cooling system filler cap.

Illustration 50

g00285520

Cooling system filler cap

4. Inspect the cooling system for leaks.

i04134625

Pressurized System: Hot coolant can cause seri-

Coolant Sample (Level 1) -

ous burns. To open the cooling system filler cap,

Obtain

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

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

pressure cap slowly in order to relieve the

pressure.

Note: Obtaining a Coolant Sample (Level 1) is

optional if the cooling system is filled with Cat

ELC (Extended Life Coolant).

1. Remove the cooling system filler cap slowly in

order to relieve pressure.

Note: Obtain a Coolant Sample (Level 1) if the

cooling system is filled with any other coolant

2. Maintain the coolant level within 13 mm (0.5 inch)

instead of Cat ELC including the following:

of the bottom of the filler pipe. If the engine is

equipped with a sight glass, maintain the coolant

• Commercial long life coolants that meet the

Caterpillar Engine Coolant Specification -1

level to the proper level in the sight glass.

(Caterpillar EC-1)

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze

Table 10

Recommended Interval

Type of

Level 1

Level 2

Coolant

Cat DEAC or any

coolant other than

Every 500 Hours⁽¹⁾

Yearly⁽²⁾

Cat ELC

Optional

Yearly(2)

(continued)

SEBU8598

Maintenance Recommendations

Coolant Sample (Level 2) - Obtain

(Table 10, contd)

i05378320

⁽¹⁾ This interval is the recommended interval for coolant samples

for all conventional heavy-duty coolant/antifreeze. This interval

Coolant Sample (Level 2) -

is also the recommended interval for coolant samples of com-

mercial coolants that meet the Cat EC-1 specification for engine

Obtain

coolant.

⁽²⁾ The Level 2 Coolant Analysis should be performed sooner if a

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

problem is suspected or identified.

NOTICE

Always use a designated pump for oil sampling, and

use a separate designated pump for coolant sam-

pling. Using the same pump for both types of samples

may contaminate the samples that are being drawn.

This contaminate may cause a false analysis and an

incorrect interpretation that could lead to concerns by

both dealers and customers.

NOTICE

Note: Level 1 results may indicate a need for

Care must be taken to ensure that fluids are con-

Level 2 Analysis.

tained during performance of inspection, mainte-

nance, testing, adjusting, and repair of the product.

Obtain the sample of the coolant as close as possible

to the recommended sampling interval. In order to

Be prepared to collect the fluid with suitable contain-

receive the full effect of S·O·S analysis, establish a

ers before opening any compartment or disassem-

consistent trend of data. In order to establish a

bling any component containing fluids.

pertinent history of data, perform consistent

samplings that are evenly spaced. Supplies for

Refer to Special Publication, NENG2500, “Cat Dealer

collecting samples can be obtained from your Cat

Service Tool Catalog” or refer to Special Publication,

dealer.

PECJ0003, “Cat Shop Supplies and Tools Catalog”

for tools and supplies suitable to collect and contain

Use the following guidelines for proper sampling of

fluids on Cat products.

the coolant:

Dispose of all fluids according to local regulations and

• Complete the information on the label for the

mandates.

sampling bottle before you begin to take the

samples.

Refer to Operation and Maintenance Manual,

• Keep the unused sampling bottles stored in plastic

“Cooling System Coolant Sample (Level 1) - Obtain”

for the guidelines for a proper sampling of the coolant.

bags.

Submit the sample for Level 2 analysis.

• Obtain coolant samples directly from the coolant

sample port. You should not obtain the samples

For additional information about coolant analysis, see

from any other location.

Special Publication, SEBU7003, “Cat 3600 Series

and C280 Series Diesel Engine Fluids

• Keep the lids on empty sampling bottles until you

Recommendations” or consult your Cat dealer.

are ready to collect the sample.

• Place the sample in the mailing tube immediately

i04269112

after obtaining the sample in order to avoid

contamination.

Cooling System Supplemental

Coolant Additive (SCA) - Test/

• Never collect samples from expansion bottles.

Add

• Never collect samples from the drain for a system.

(Systems Which are Filled with

Submit the sample for Level 1 analysis.

Conventional Coolant)

For additional information about coolant analysis, see

SMCS Code: 1352-045; 1395-081

this Operation and Maintenance Manual, “Fluid

Recommendations” or consult your Cat dealer.

This maintenance procedure is required for

conventional coolants such as DEAC.Do not

perform this maintenance for cooling systems

that are filled with Cat Extended Life Coolant (Cat

ELC) or Cat Extended Life Inhibitor (Cat ELI).

SEBU8598

Maintenance Recommendations

Diesel Particulate Filter - Clean/Replace

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

Analysis (Level 1) be performed to check the

concentration of SCA.

Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact

Maintain the Proper Concentration

with the skin and eyes. Do not drink cooling sys-

tem coolant additive.

of SCA in the Coolant

NOTICE

Excessive supplemental coolant additive concentra-

tion can form deposits on the higher temperature sur-

Pressurized System: Hot coolant can cause seri-

faces of the cooling system, reducing the engine's

ous burns. To open the cooling system filler cap,

heat transfer characteristics. Reduced heat transfer

stop the engine and wait until the cooling system

could cause cracking of the cylinder head and other

components are cool. Loosen the cooling system

high temperature components.

pressure cap slowly in order to relieve the

pressure.

Excessive supplemental coolant additive concentra-

tion could also result in blockage of the heat exchang-

1. Remove the cooling system filler cap slowly.

er, overheating, and/or accelerated wear of the water

pump seal.

2. Test the concentration of the SCA with a

286-2578 Nitrite Test Strip or review the results

Do not exceed the recommended amount of supple-

mental coolant additive concentration.

of the S·O·S Coolant Analysis (Level 1).

3. If necessary, drain some coolant in order to allow

NOTICE

space for the addition of the SCA.

Do NOT mix brands or types of SCA. Do NOT mix

4. Add the amount of SCA required to maintain a

SCAs and extenders.

concentration of 3 percent to 6 percent SCA in the

Failure to follow the recommendations can result in

coolant.

shortened cooling system component life.

5. Clean the cooling system filler cap. Install the

cooling system filler cap.

NOTICE

Use Only Approved SCAs. Conventional coolants

For further information, refer to Special Publication,

require the maintenance addition of SCA throughout

SEBU6251, “Cat Commercial Diesel Engine Fluids

Recommendations”.

their expected life. Do NOT use an SCA with a cool-

ant unless specifically approved by the coolant suppli-

er for use with their coolant. It is the responsibility of

i04880440

the coolant manufacturer to ensure compatibility and

acceptable performance.

Diesel Particulate Filter - Clean/

Failure to follow the recommendations can result in

Replace

shortened cooling system component life.

(If Equipped)

SMCS Code: 108F-070; 108F-510; 1091-070; 1091-

NOTICE

510

Care must be taken to ensure that fluids are con-

tained during performance of inspection, mainte-

Consult your Cat dealer when the DPF needs to be

cleaned.

nance, testing, adjusting, and repair of the product.

Be prepared to collect the fluid with suitable contain-

The approved Caterpillar DPF maintenance

ers before opening any compartment or disassem-

procedure requires that one of the following actions

bling any component containing fluids.

be taken when the DPF needs to be cleaned:

Refer to Special Publication, NENG2500, “Cat Dealer

Service Tool Catalog” and to Special Publication,

GECJ0003, “Cat Shop Supplies and Tools” for tools

and supplies suitable to collect and contain fluids on

Cat products.

Dispose of all fluids according to applicable regula-

tions and mandates.

SEBU8598

Maintenance Recommendations

Driven Equipment - Check

• The DPF from your engine can be replaced with a

Inspect the Rear Gear Train

new DPF

Inspect the crankshaft gear. If excessive wear is

• The DPF from your engine can be replaced with a

found, replace the crankshaft gear and the large

remanufactured DPF

cluster idler.

If any gear causes damage to other gears through

• The DPF from your engine can be cleaned by your

failure, replace the entire rear gear train.

local authorized Cat dealer, or a Caterpillar

approved DPF cleaning machine, and reinstalled

For the correct parts, see the Parts Manual for the

engine. For removal and replacement instructions,

Note: In order to maintain emissions documentation,

see the Service Manual, “Disassembly and

the DPF that is removed from the engine when the

Assembly” module. Consult your Caterpillar dealer for

DPF is cleaned must be reinstalled on the same

assistance.

engine.

i04230004

Note: A specific ash service regeneration must be

performed before removing a DPF that will be

cleaned. All three scenarios listed above require a

Electronic Unit Injector -

reset of the ash monitoring system in the engine

Check/Replace

ECM.

SMCS Code: 1251-510; 1251-535; 1290-510; 1290-

535

i00934883

Driven Equipment - Check

SMCS Code: 3279-535

Be sure the engine cannot be started while this

maintenance is being performed. To prevent pos-

Check the Alignment

sible injury, do not use the starting motor to turn

the flywheel.

To minimize bearing problems and vibration of the

engine crankshaft and the driven equipment, the

Hot engine components can cause burns. Allow

alignment between the engine and driven equipment

additional time for the engine to cool before meas-

must be properly maintained.

uring/adjusting the unit injectors.

Check the alignment according to the instructions that

The electronic unit injectors use high voltage. Dis-

are provided by the following manufacturers:

connect the unit injector enable circuit connector

in order to prevent personal injury. Do not come

• Caterpillar

in contact with the injector terminals while the en-

gine is running.

• OEM of the drive coupling

• OEM of the driven equipment

The operation of a Cat Engine with an electronic unit

injector which is improperly adjusted may reduce

Torque all of the fasteners to the proper

engine efficiency. This reduced efficiency may result

specifications.

in excessive fuel usage and/or shortened engine

component life.

Inspect the Drive Coupling

Note: Only qualified service personnel should

Inspect the drive coupling according to the

perform this maintenance.

instructions that are provided by the OEM of the

coupling. For the following service information, see

Refer to the Systems Operation, Testing and

the literature that is provided by the OEM of the

Adjusting, “Electronic Unit Injector - Test” for the test

coupling:

procedure. Refer to Systems Operation, Testing and

Adjusting, “Electronic Unit Injector - Adjust” for the

• Lubrication requirements

adjustment procedure.

• Specifications for the end play

Refer to the Disassembly and Assembly Manual for

the procedure for the removal and replacement of the

• “Reusability Guidelines”

injector.

• Replacement instructions

SEBU8598

Maintenance Recommendations

Engine - Clean

i04134990

NOTICE

The camshafts must be correctly timed with the crank-

Engine Air Cleaner Element

shaft before an adjustment of the lash for the fuel in-

jector is made. The timing pins must be removed from

(Dual Element/Box Type) -

the camshafts before the crankshaft is turned or dam-

Replace

age to the cylinder block will be the result.

SMCS Code: 1054-510

i01646701

Primary Filter

Engine - Clean

NOTICE

Service the primary filter element only when the alert

SMCS Code: 1000-070

indicator for the intake air filter is flashing. Do not

open the filter compartment unless it is time for serv-

ice. Opening the filter compartment can cause dirt to

get into the clean side of the filter housing.

Personal injury or death can result from high

voltage.

NOTICE

Moisture

can

create

paths

electrical

conductivity.

Extremely short air filter life can result if the pre-

cleaner system malfunctions. If air filter life is drasti-

Make sure that the electrical system is OFF. Lock

cally reduced from typical for the operating

out the starting controls and tag the controls “DO

conditions, consult your Caterpillar Dealer. The ex-

NOT OPERATE” .

haust system dust ejector for the strata tube pre-

cleaner must pull a minimum vacuum of 508 mm

(20 inch) of water.

NOTICE

Accumulated grease and oil on an engine is a fire

hazard. Keep the engine clean. Remove debris and

NOTICE

fluid spills whenever a significant quantity accumu-

Service the engine air filters with the engine stopped.

lates on the engine.

Engine damage could result.

Periodic cleaning of the engine is recommended.

Steam cleaning the engine will remove accumulated

NOTICE

Do not use the filter for longer than one year.

oil and grease. A clean engine provides the following

benefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

Note: Caution must be used in order to prevent

electrical components from being damaged by

excessive water when you clean the engine. Avoid

electrical components such as the alternator, the

starter, and the ECM.

SEBU8598

Maintenance Recommendations

Engine Air Cleaner Element (Dual Element/Box Type) - Replace

NOTICE

The filter should be kept in service for no longer than

1 year.

NOTICE

Always leave the secondary filter element in place

while you clean the air cleaner housing.

1. Open the engine access door.

Illustration 52

g02105115

1. Remove the air cleaner cover (1). Pull out in order

to remove the element.

2. Remove the primary filter element (2) from the air

cleaner housing (4).

3. Mark the secondary filter element (3) in order to

show that the primary filter element has been

serviced. The secondary filter element should be

replaced when the primary filter element is

serviced for the third time. Refer to the section

Illustration 53

g02105115

“Secondary Filter”.

2. Remove the air cleaner housing cover (1).

4. Clean the inside of the air cleaner housing (4).

Keep the secondary filter element in place while

3. Remove the primary filter element (2). Refer to the

you clean the housing.

section “Primary Filter”.

5. Install a new primary air filter. Push the filter

4. Clean the inside of the air cleaner housing (4).

element firmly in order to properly seat the

5. Remove the secondary filter element (3). Pull out in

element. Write the date on the element, if the

order to remove the element.

primary element is replaced.

6. Install a new secondary filter element. Push the

6. Install the air cleaner cover.

element firmly in order to properly seat the

element. Write the date on the element, if the

Secondary Filter

element is replaced.

NOTICE

7. Install the primary filter element and the air cleaner

Always replace the secondary filter element. Never

housing cover.

attempt to reuse the filter by cleaning.

The secondary filter element should be replaced at

the time the primary element is serviced for the third

time.

SEBU8598

Maintenance Recommendations

Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace

i04342930

Replace the dirty paper air cleaner elements with

clean air cleaner elements. Before installation,

thoroughly inspect the air cleaner elements for tears

Engine Air Cleaner Element

and/or holes in the filter material. Inspect the gasket

(Single Element) - Inspect/

or the seal of the air cleaner element for damage.

Maintain a supply of suitable air cleaner elements for

Clean/Replace

replacement purposes.

SMCS Code: 1051; 1054-040; 1054-070; 1054-510

1. Remove the air cleaner cover. Remove the air

cleaner element.

NOTICE

Never run the engine without an air cleaner element

2. Cover the air inlet to the turbocharger with tape in

installed. Never run the engine with a damaged air

order to keep dirt out.

cleaner element. Do not use air cleaner elements with

damaged pleats, gaskets or seals. Dirt entering the

3. Clean the inside of the air cleaner cover and body

engine causes premature wear and damage to en-

with a clean, dry cloth.

gine components. Air cleaner elements help to pre-

vent airborne debris from entering the air inlet.

4. Remove the tape for the air inlet to the

turbocharger. Install an air cleaner element that is

new or cleaned.

NOTICE

Never service the air cleaner element with the engine

5. Install the air cleaner cover.

running since this will allow dirt to enter the engine.

Inspecting Air Cleaner Elements

Note: Use of a platform may be necessary to reach

the air cleaner element.

Clean the air cleaner elements or replace the air

cleaner elements when the following conditions

occur:

• Inspect the air cleaner elements before the air filter

restriction reaches 2.5 kPa (10 inches of H2O). A

loss of engine performance may occur when the

air filter restriction exceeds this limit.

• The air cleaner elements must be cleaned or

replaced before the air filter restriction exceeds

3.75 kPa (15 inches of H₂O).

Illustration 54

g00281693

Note: The air filter restriction is measured before the

air inlet to the turbocharger compressor.

Inspect the clean, dry air cleaner element. Use a 60

watt blue light in a dark room or in a similar facility.

Servicing the Air Cleaner Elements

Place the blue light in the element. Rotate the

element. Inspect the element for tears and/or holes.

Note: If the air cleaner is not manufactured by

Inspect the element for light that may show through

Caterpillar, follow the instructions that are provided by

the filter material. If it is necessary in order to confirm

the OEM of the air cleaner.

the result, compare the element to a new element that

has the same part number.

If the air cleaner element becomes plugged, the air

can split the material of the air cleaner element.

Do not use an element that has any tears and/or

Unfiltered air will drastically accelerate internal engine

holes in the filter material. Do not use an element with

wear. Your Cat dealer has the proper air cleaner

damaged pleats, gaskets or seals. Discard damaged

elements for your application. Consult your Caterpillar

elements.

dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily for

Storing Air Cleaner Elements

accumulation of dirt and debris. Remove any dirt

If an element that passes inspection will not be used,

and debris, as needed.

the element can be stored for future use.

SEBU8598

Maintenance Recommendations

Engine Air Cleaner Service Indicator - Inspect

Illustration 55

g00281694

Illustration 56

g00103777

Typical service indicator

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

protective covering for storage. Restricted air flow

Observe the service indicator. The air cleaner

may result. To protect against dirt and damage, wrap

element should be cleaned or the air cleaner element

the elements in Volatile Corrosion Inhibited (VCI)

should be replaced when one of the following

paper.

conditions occur:

Place the element into a box for storage. For

• The yellow diaphragm enters the red zone.

identification, mark the outside of the box.

• The red piston locks in the visible position.

Store the box in a dry location.

Test the Service Indicator

i01900118

Service indicators are important instruments.

Engine Air Cleaner Service

• Check for ease of resetting. The service indicator

Indicator - Inspect

should reset in less than three pushes.

(If Equipped)

• Check the movement of the yellow core when the

SMCS Code: 7452-040

engine is accelerated to the engine rated speed.

The yellow core should latch approximately at the

Some engines may be equipped with a different

greatest vacuum that is attained.

service indicator.

If the service indicator does not reset easily, or if the

Some engines are equipped with a differential gauge

yellow core does not latch at the greatest vacuum,

for inlet air pressure. The differential gauge for inlet

the service indicator should be replaced. If the new

air pressure displays the difference in the pressure

service indicator will not reset, the hole for the service

that is measured before the air cleaner element and

indicator may be plugged.

the pressure that is measured after the air cleaner

element. As the air cleaner element becomes dirty,

The service indicator may need to be replaced

the pressure differential rises. If your engine is

frequently in environments that are severely dusty, if

equipped with a different type of service indicator,

necessary. Replace the service indicator annually

follow the OEM recommendations in order to service

regardless of the operating conditions. Replace the

the air cleaner service indicator.

service indicator when the engine is overhauled, and

whenever major engine components are replaced.

The service indicator may be mounted on the air

cleaner housing or in a remote location.

Note: When a new service indicator is installed,

excessive force may crack the top of the service

indicator. Tighten the service indicator to a torque of

2 N·m (18 lb in).

SEBU8598

Maintenance Recommendations

Engine Mounts - Inspect

i02436689

Engine Mounts - Inspect

SMCS Code: 1152-040; 1152

Inspect the engine mounts for deterioration and for

proper bolt torque. Engine vibration can be caused by

the following conditions:

Illustration 58

g00110310

• Improper mounting of the engine

Partial view of the oil level gauge

• Deterioration of the engine mounts

(Y) “ADD” mark

(X) “FULL” mark

• Loose mounting bolts

NOTICE

Any engine mount that shows deterioration should be

Perform this maintenance with the engine stopped.

replaced. Refer to the Specifications Manual,

SENR3130, “Torque Specifications”. Refer to your

Caterpillar dealer for more information.

NOTICE

i04137771

Engine damage can occur if the crankcase is filled

above the “FULL” mark on the oil level gauge

Engine Oil Level - Check

(dipstick).

SMCS Code: 1348-535-FLV

An overfull crankcase can cause the crankshaft to dip

into the oil. This will reduce the power that is devel-

oped and also force air bubbles into the oil. These

bubbles (foam) can cause the following problems: re-

duction of the oil's ability to lubricate, reduction of oil

Hot oil and hot components can cause personal

pressure, inadequate cooling, oil blowing out of the

injury. Do not allow hot oil or hot components to

crankcase breathers and excessive oil consumption.

contact the skin.

Excessive oil consumption will cause deposits to form

on the pistons and in the combustion chamber. De-

posits in the combustion chamber lead to the follow-

ing problems: guttering of the valves, packing of

carbon under the piston rings and wear of the cylinder

liner.

If the oil level is above the “FULL” mark on the oil lev-

el gauge, drain some of the oil immediately.

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).

Illustration 57

g01414582

2. In order to choose the correct type of oil for this

Typical installation of the oil level gauge

engine, refer to this Operation and Maintenance

(1) Oil filler cap

Manual, “Fluid Recommendations”.

(2) Oil level gauge

3. Clean the oil filler cap. Install the oil filler cap.

4. Record the amount of oil that is added. For the next

oil sample and analysis, include the total amount of

oil that has been added since the previous sample.

Recording this information helps to provide the

most accurate oil analysis.

SEBU8598

Maintenance Recommendations

Engine Oil Sample - Obtain

i04237495

NOTICE

Always use a designated pump for oil sampling, and

Engine Oil Sample - Obtain

use a separate designated pump for coolant sam-

SMCS Code: 1348-554-SM

pling. Using the same pump for both types of samples

may contaminate the samples that are being drawn.

In addition to a good preventive maintenance

This contaminate may cause a false analysis and an

program, Caterpillar recommends using S·O·S oil

incorrect interpretation that could lead to concerns by

analysis at regularly scheduled intervals. S·O·S oil

both dealers and customers.

analysis provides infrared analysis, which is required

for determining nitration and oxidation levels.

If the engine is not equipped with a sampling valve,

Obtain the Sample and the Analysis

use the 1U-5718 Vacuum Pump. The pump is

designed to accept sampling bottles. Disposable

tubing must be attached to the pump for insertion into

the sump.

Hot oil and hot components can cause personal

For instructions, see Special Publication, PEGJ0047,

injury. Do not allow hot oil or hot components to

“How To Take A Good S·O·S Oil Sample”. Consult

your Cat dealer for complete information and

contact the skin.

assistance in establishing an S·O·S program for your

engine.

Before you take the oil sample, complete the Label,

PEEP5031 for identification of the sample. In order to

i05295270

help obtain the most accurate analysis, provide the

following information:

Engine Oil and Filter - Change

• Engine model

SMCS Code: 1318-510

• Service hours on the engine

• The number of hours that have accumulated since

the last oil change

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to

• The amount of oil that has been added since the

contact the skin.

last oil change

To ensure that the sample is representative of the oil

Selection of Oil Change Interval

in the crankcase, obtain a warm, mixed oil sample.

To avoid contamination of the oil samples, the tools

Refer to this Operation and Maintenance Manual,

and the supplies that are used for obtaining oil

“Fluid Recommendations” for further information

about oils that may be used in Caterpillar engines.

samples must be clean.

Refer to this Operation and Maintenance Manual,

Caterpillar recommends using the sampling valve in

“Severe Service Application” to determine if the oil

order to obtain oil samples. The quality and the

change interval should be reduced from the normal

consistency of the samples are better when the

change interval. If operating in any of the conditions

sampling valve is used. The location of the sampling

or environments outlined in the Severe Service

valve allows oil that is flowing under pressure to be

Application, use S·O·S Services oil analysis to

obtained during normal engine operation.

determine the oil change interval. If S·O·S Services

oil analysis is not being used, the oil change interval

The 169-8373 Fluid Sampling Bottle is

should be reduced to 250 hrs.

recommended for use with the sampling valve. The

fluid sampling bottle includes the parts that are

Table 11

needed for obtaining oil samples. Instructions are

Oil Change Interval⁽¹⁾

also provided.

Multigrade Oil Type

Operating Conditions

Normal

Severe Service

Application

(continued)

SEBU8598

Maintenance Recommendations

Engine Oil and Filter - Change

(Table 11, contd)

Cat DEO-ULS

500 hr

250 hr

Preferred

Oil meeting the requirements

500 hr

250 hr

of the Cat ECF-3 Specifica-

tion or the API CJ-4

classification

8 minimum TBN

Preferred

Oil meeting the requirements

500 hr

250 hr

of the ACEA C9/E6

Specification

TBN below 10.4

⁽¹⁾ Refer to Special Publication, PEHJ0192, “Optimizing Oil

Illustration 59

g00103713

Change Intervals” for further information..

Typical filter mounting base and filter gasket

Drain the Engine Oil

1. Remove the oil filter with a 185-3630 Strap

Wrench.

After the engine has been run at the normal operating

temperature, stop the engine. Attach a “DO NOT

2. Cut the oil filter open with a 175-7546 Oil Filter

OPERATE” or a similar warning tag to the ignition

Cutter Gp. Break apart the pleats and inspect the

keyswitch before the engine is serviced.

oil filter for metal debris. An excessive amount of

metal debris in the oil filter may indicate early wear

NOTICE

or a pending failure.

Care must be taken to ensure that fluids are con-

tained during performance of inspection, mainte-

Use a magnet to differentiate between the ferrous

nance, testing, adjusting, and repair of the product.

metals and the nonferrous metals that are found in

Be prepared to collect the fluid with suitable contain-

the oil filter element. Ferrous metals may indicate

ers before opening any compartment or disassem-

wear on the steel and cast iron parts of the engine.

bling any component containing fluids.

Nonferrous metals may indicate wear on the

Refer to Special Publication, NENG2500, “Cat Dealer

aluminum parts, brass parts, or bronze parts of the

Service Tool Catalog” or refer to Special Publication,

engine. Parts that may be affected include the

PECJ0003, “Cat Shop Supplies and Tools Catalog”

following items: main bearings, rod bearings,

for tools and supplies suitable to collect and contain

turbocharger bearings and cylinder heads.

fluids on Cat products.

Due to normal wear and friction, small amounts of

Dispose of all fluids according to local regulations and

debris may be found in the oil filter. Consult your

mandates.

Cat dealer in order to arrange for a further

analysis if an excessive amount of debris is found

in the oil filter.

1. Remove the oil drain plug in order to allow the oil to

3. Clean the sealing surface of the filter mounting

drain.

base. Ensure that all of the old oil filter gasket is

2. After the oil has drained, the oil drain plug should

removed.

be cleaned and installed.

4. Apply clean engine oil to the new oil filter gasket.

Replace the Oil Filter

NOTICE

Do not fill the oil filters with oil before installing them.

Caterpillar oil filters are built to Caterpillar specifica-

This oil would not be filtered and could be contami-

tions. Use of an oil filter not recommended by Cater-

nated. Contaminated oil can cause accelerated wear

pillar could result in severe engine damage to the

to engine components.

engine bearings, crankshaft, etc., as a result of the

larger waste particles from unfiltered oil entering the

engine lubricating system. Only use oil filters recom-

mended by Caterpillar .

SEBU8598

Maintenance Recommendations

Engine Storage Procedure - Check

5. Install the oil filter. Tighten the oil filter until the oil

• Mileage

filter gasket contacts the base. Tighten the oil filter

• Operating hours

by hand according to the instructions that are

shown on the oil filter. Do not overtighten the oil

• Fuel consumption

filter.

If an engine is out of operation and if use of the

Fill the Engine Crankcase

engine is not planned, special precautions should be

made. If the engine will be stored for more than three

months, a complete protection procedure is

1. Remove the oil filler cap. Fill the crankcase with the

recommended. For more detailed information on

proper amount of oil. Refer to the Operation and

engine storage, see Special Instruction, SEHS9031,

Maintenance Manual, “Fluid Recommendations”

“Storage Procedure For Caterpillar Products”.

topic (Maintenance Section) for more information.

If the engine will not be started for several weeks, the

lubricating oil will drain from the cylinder walls and

NOTICE

from the piston rings. Rust can form on the cylinder

If equipped with an auxiliary oil filter or system, extra

liner surface. Rust on the cylinder liner surface will

oil must be added when filling the crankcase. Follow

cause increased engine wear and a reduction in

engine service life. Caterpillar recommends the use

the OEM or filter manufacturer's recommendations. If

of volatile corrosion inhibitor (VCI) oil in order to

the extra oil is not added, the engine may starve for

prevent internal engine damage due to moisture

oil.

during storage. These inhibitors in the VCI oil act by

evaporating inside the engine. The inhibitors then

condense over the inside surfaces of the engine. The

NOTICE

evaporation process and the condensing process

To help prevent crankshaft or bearing damage, crank

offers full protection to surfaces that cannot be

engine to fill all filters before starting. Do not crank en-

reached with preservatives. 0.9 L (1.0 qt) of

gine for more than 30 seconds.

4C-6792 VCI oil will treat 28.4 L (30.0 qt) of engine

oil. This will give a 3 percent concentration of VCI oil.

The engine must be completely sealed when the

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

engine is stored in order for the VCI oil to function

for 2 minutes. Perform this procedure in order to

properly. The VCI oil is easily cleaned from the engine

ensure that the lubrication system has oil and that

when you remove the engine from storage. The

volatile vapors are removed by simply running the

the oil filters are filled. Inspect the oil filter for oil

engine to operating temperature. A mineral oil base is

leaks.

left behind after the volatile vapors are removed.

3. Stop the engine and allow the oil to drain back to

the sump for a minimum of 10 minutes.

i03964791

4. Remove the oil level gauge in order to check the oil

Engine Valve Lash - Check

level. Maintain the oil level between the “ADD”

SMCS Code: 1105-535

and “FULL” marks on the “ENGINE STOPPED”

side of the oil level gauge.

Note: Procedures for adjusting the valve lash can be

found in Systems Operation/Testing and Adjusting,

i01458399

“Valve Lash Adjustment”. Consult your Cat dealer for

assistance.

Engine Storage Procedure -

Check

SMCS Code: 1000-535

Ensure that the engine cannot be started while

this maintenance is being performed. To help pre-

The oil change interval may be extended to 12

vent possible injury, do not use the starting motor

months for a vehicle that is operated seasonally and

to turn the flywheel.

placed in storage for the remainder of the year by

using the required storage procedures and the

Hot engine components can cause burns. Allow

required start-up procedures. This extension is

additional time for the engine to cool before meas-

permitted if the following categories for oil change

uring/adjusting valve lash clearance.

intervals in the Operation and Maintenance Manual,

“Maintenance Interval Schedule” have not been

reached:

SEBU8598

Maintenance Recommendations

Fuel Priming Pump - Replace

i03927830

NOTICE

Care must be taken to ensure that fluids are con-

Fuel Priming Pump - Replace

tained during performance of inspection, mainte-

SMCS Code: 1258-510

nance, testing, adjusting and repair of the product. Be

prepared to collect the fluid with suitable containers

A replacement kit is available for the electronic fuel

before opening any compartment or disassembling

priming pump. Contact your Cat dealer for the correct

any component containing fluids.

part number and details for your application.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies

i02096133

suitable to collect and contain fluids on Caterpillar

products.

Fuel System - Prime

Dispose of all fluids according to local regulations and

SMCS Code: 1250-548; 1258-548

mandates.

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly

NOTICE

clean the area around a fuel system component that

Do not allow dirt to enter the fuel system. Thoroughly

will be disconnected. Fit a suitable cover over discon-

clean the area around a fuel system component that

nected fuel system component.

will 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 position for

two minutes.

2. Verify that the water separator is full of fuel.

3. If the water separator is not full of fuel, turn the

engine start switch OFF and then turn the engine

start switch ON. This will cycle the fuel priming

pump again.

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

start the engine. If the engine starts and the engine

runs rough or the engine misfires, operate at low

idle until the engine is running smoothly. If the

engine cannot be started, or if the engine

Illustration 60

g01453091

continues to misfire or smoke, repeat Step 1.

(1) Element

(2) Bowl

i02927285

(3) Drain

Bowl (2) should be monitored daily for signs of water.

Fuel System Primary Filter/

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

Water Separator - Drain

1. Open drain (3). The drain is a self-ventilated drain.

SMCS Code: 1260-543; 1263-543

Catch the draining water in a suitable container.

Dispose of the water properly.

2. Close drain (3).

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent

NOTICE

possible injury, turn the start switch off when

The water separator is under suction during normal

changing fuel filters or water separator elements.

engine operation. Ensure that the drain valve is tight-

Clean up fuel spills immediately.

ened securely to help prevent air from entering the

fuel system.

SEBU8598

Maintenance Recommendations

Fuel System Primary Filter (Water Separator) Element - Replace

i05354209

NOTICE

Do not fill fuel filters with fuel before installing

Fuel System Primary Filter

them. The fuel will not be filtered and could be

(Water Separator) Element -

contaminated. Contaminated fuel will cause accel-

erated wear to fuel system parts. The fuel system

Replace

should be primed prior to starting the engine.

SMCS Code: 1260-510-FQ; 1263-510-FQ

1. Close the main fuel supply valve.

Water in the fuel can cause the engine to run rough.

Water in the fuel may cause an electronic unit injector

to fail. If the fuel has been contaminated with water,

the element should be changed before the regularly

scheduled interval.

The primary filter/water separator also provides

filtration in order to help extend the life of the

secondary fuel filter. The element should be changed

regularly. If a vacuum gauge is installed, the primary

filter/water separator should be changed at

50 to 70 kPa (15 to 20 inches Hg).

Replace the Element

Fuel leaked or spilled onto hot surfaces or electri-

Illustration 61

g01453091

cal components can cause a fire. To help prevent

(1) Element

possible injury, turn the start switch off when

(2) Bowl

changing fuel filters or water separator elements.

(3) Drain

Clean up fuel spills immediately.

2. Remove element (1) from the element mounting

base while bowl (2) is attached.

NOTICE

Care must be taken to ensure that fluids are con-

3. Dispose of the contents of the filter. Remove bowl

tained during performance of inspection, mainte-

(2) from element (1). The bowl is reusable. Do not

nance, testing, adjusting, and repair of the product.

discard the bowl. Dispose of the used element.

Be prepared to collect the fluid with suitable contain-

ers before opening any compartment or disassem-

4. Remove the O-ring from the gland of the bowl.

bling any component containing fluids.

Clean the following components:

Refer to Special Publication, NENG2500, “Dealer

• Bowl

Service Tool Catalog” for tools and supplies suitable

to collect and contain fluids on Cat products.

• O-ring

Dispose of all fluids according to local regulations and

mandates.

• Mounting base

Inspect the O-ring for damage and for

deterioration. Replace the O-ring, if necessary.

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly

5. Lubricate the O-ring with clean diesel fuel.

clean the area around a fuel system component that

will be disconnected. Fit a suitable cover over discon-

6. Install bowl (2) on a new element. Tighten the bowl

nected fuel system component.

by hand. Do not use tools in order to tighten the

bowl.

7. Lubricate the top seal of element (1) with clean

diesel fuel. Install the new element on the

mounting base. Tighten the element by hand.

SEBU8598

Maintenance Recommendations

Fuel System Secondary Filter - Replace

1. Stop the engine. Turn the ignition switch to the OFF

NOTICE

position or disconnect the battery. Refer to this

The water separator is under suction during normal

Operation and Maintenance Manual, “Battery or

engine operation. Ensure that the vent plug is tight-

Battery Cable - Disconnect” for more information.

ened securely to help prevent air from entering the

fuel system.

Shut off the fuel supply valve (if equipped).

2. It may be necessary to relieve residual fuel

8. Open the main fuel supply valve.

pressure from the fuel system before the fuel filters

are removed. Wait from 1 minute to 5 minutes until

9. Start the engine and check for leaks. Run the

the fuel pressure has lowered. Use a suitable

engine for 1 minute. Stop the engine and check for

container in order to catch any fuel that may spill.

leaks again.

3. Remove the used fuel filters and discard the used

Detecting leaks is difficult while the engine is

fuel filters.

running. The primary filter/water separator is under

suction. A leak will allow air to enter the fuel. The

4. Apply clean diesel fuel to the new fuel filter o-rings.

air in the fuel can cause low power due to aeration

of the fuel. Ensure that the components are

correctly installed to prevent air from entering the

fuel system.

NOTICE

Do not fill the secondary fuel filter with fuel before in-

stalling. The fuel would not be filtered and could be

i04158105

contaminated. Contaminated fuel will cause acceler-

ated wear to fuel system parts.

Fuel System Secondary Filter -

Replace

NOTICE

SMCS Code: 1261-510-SE

In order to meet expected fuel system component life,

4 micron(c) absolute or less secondary fuel filtration is

required for all Caterpillar Diesel Engines that are

equipped with unit injected fuel systems. Note that all

Fuel leaked or spilled onto hot surfaces or electri-

current Caterpillar

Diesel Engines are factory

cal components can cause a fire. To help prevent

equipped with Caterpillar Advanced Efficiency 4 mi-

possible injury, turn the start switch off when

cron(c) absolute fuel filters.

changing fuel filters or water separator elements.

Caterpillar does not warrant the quality or perform-

Clean up fuel spills immediately.

ance of non-Caterpillar fluids and filters.

NOTICE

5. Install the new fuel filters. Spin the fuel filters onto

Do not allow dirt to enter the fuel system. Thoroughly

the fuel filter bases until the o-rings contact the

clean the area around a fuel system component that

bases. Use the rotation index marks on the filters

will be disconnected. Fit a suitable cover over any dis-

as a guide for proper tightening. Tighten the filters

connected fuel system components.

according to the instructions that are on the fuel

filters. Do not overtighten the filters.

NOTICE

6. Open the fuel supply valve. The engine will need to

Care must be taken to ensure that fluids are con-

be purged of air. Refer to this Operation and

tained during performance of inspection, mainte-

Maintenance Manual, “Fuel System - Prime” for

nance, testing, adjusting and repair of the product. Be

more information.

prepared to collect the fluid with suitable containers

before opening any compartment or disassembling

any component containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” or refer to Special Publi-

cation, PECJ0003, “Caterpillar Shop Supplies and

Tools Catalog” for tools and supplies suitable to col-

lect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and

mandates.

SEBU8598

Maintenance Recommendations

Fuel Tank Water and Sediment - Drain

i06007431

Fill the fuel tank after operating the engine in order to

drive out moist air. This procedure will help prevent

condensation. Do not fill the tank to the top. The fuel

Fuel Tank Water and Sediment

expands as the fuel gets warm. The tank may

- Drain

overflow.

SMCS Code: 1273-543-M&S

Some fuel tanks use supply pipes that allow water

and sediment to settle below the end of the fuel

supply pipe. Some fuel tanks use supply lines that

NOTICE

take fuel directly from the bottom of the tank. If the

Care must be taken to ensure that fluids are con-

engine is equipped with this system, regular

tained during performance of inspection, mainte-

maintenance of the fuel system filter is important.

nance, testing, adjusting, and repair of the product.

Be prepared to collect the fluid with suitable contain-

Fuel Storage Tanks

ers before opening any compartment or disassem-

bling any component containing fluids.

Drain the water and the sediment from the fuel

storage tank during the following conditions:

Refer to Special Publication, NENG2500, “Cat Dealer

Service Tool Catalog” or refer to Special Publication,

• Weekly

PECJ0003, “Cat Shop Supplies and Tools Catalog”

for tools and supplies suitable to collect and contain

• Oil change

fluids on Cat products.

• Refill of the tank

Dispose of all fluids according to local regulations and

mandates.

This procedure will help prevent water or sediment

from being pumped from the storage tank into the

engine fuel tank. A four micron(c) absolute filter for

the breather vent on the fuel tank is also

Fuel Tank

recommended.

Fuel quality is critical to the performance and to the

If a bulk storage tank has been refilled or moved

service life of the engine. Water in the fuel can cause

recently, allow adequate time for the sediment to

excessive wear to the fuel system. Condensation

settle before filling the engine fuel tank. Internal

occurs during the heating and cooling of fuel. The

baffles in the bulk storage tank will also help trap

condensation occurs as the fuel passes through the

sediment. Filtering fuel that is pumped from the

fuel system and the fuel returns to the fuel tank. This

storage tank helps to ensure the quality of the fuel.

causes water to accumulate in fuel tanks. Draining

When possible, water separators should be used.

the fuel tank regularly and obtaining fuel from reliable

sources can help to eliminate water in the fuel.

i03735862

Drain the Water and the Sediment

Fumes Disposal Filter Element

Fuel tanks should contain some provision for draining

water and draining sediment from the bottom of the

- Replace

fuel tanks.

(Open Crankcase Ventilation

Prepare to catch water and sediment in an

(OCV) Filter)

appropriate container. Connect a hose (if necessary)

to the valve prior to opening the valve.

Open the drain valve on the bottom of the fuel tank in

order to drain the water and the sediment. Close the

drain valve.

Note: Failure to close the drain can allow air into the

system, which could have detrimental results to

performance.

Check the fuel daily. Drain the water and sediment

from the fuel tank after operating the engine. Drain

the water and sediment from the fuel tank after the

fuel tank has been filled. Allow 5 to 10 minutes before

performing this procedure.

SEBU8598

Maintenance Recommendations

Fumes Disposal Filter Element - Replace

SMCS Code: 1074

Illustration 63

g02021434

(1) Cap

Illustration 62

g02021473

(2) Housing for the filter element

(3) Filter element

The filter for the open crankcase ventilation system

(4) Cup

may be located toward the front or toward the rear of

the left side of the engine. A filter that has been used

Remove either the cap or the cup from the housing

may contain a small amount of engine oil.

for the OCV filter. Remove the OCV filter. The filter

may not be used again. Dispose of the filter. Place a

new OCV filter inside the filter housing. If the cap was

NOTICE

removed, replace the cap. If the cup was removed,

Care must be taken to ensure that fluids are con-

replace the cup. Tighten hand tight.

tained during performance of inspection, mainte-

nance, testing, adjusting and repair of the machine.

Note: Caterpillar will not be held liable for an engine

Be prepared to collect the fluid with suitable contain-

that does not comply with EPA emissions standards

ers before opening any compartment or disassem-

due to modification of the OCV filter or due to the use

bling any component containing fluids.

of a filter that is not approved by Caterpillar.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide”, for tools and sup-

plies suitable to collect and contain fluids in Caterpil-

lar machines.

Dispose of all fluids according to local regulations and

mandates.

SEBU8598

Maintenance Recommendations

Grounding Stud - Inspect/Clean/Tighten

i03965989

Note: Always use a board or cardboard when the

engine components are checked for leaks. Leaking

Grounding Stud - Inspect/

fluid that is under pressure can cause serious injury

or possible death. Leaks that are the size of a pin

Clean/Tighten

hole are included. Refer to Operation and

SMCS Code: 7423-040; 7423-070; 7423-079

Maintenance Manual, “General Hazard Information”

for more information.

Inspect the Hoses and the Clamps

Inspect all hoses for leaks that are caused by the

following conditions. Replace any hose which exhibits

any of the following conditions. Failure to replace a

hose which exhibits any of the following conditions

may 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

Illustration 64

g01376112

• Outer covering that is ballooning locally

The grounding stud is located on the upper left corner

of the engine control module.

• Flexible part of the hose that is kinked or crushed

Inspect the OEM harness for good connections.

• Armoring that is embedded in the outer covering

Inspect the condition of the OEM harness.

• Hoses which exhibit signs of leakage which are not

The grounding stud must have a wire ground to the

the result of loose couplings or clamps

battery. Tighten the grounding stud at every oil

change. Ground wires and straps should be

Inspect all clamps for the following conditions.

combined at engine grounds. All grounds should be

Replace any clamp which exhibits signs of any of the

tight and free of corrosion.

following conditions.

• Clean the grounding stud and the terminals for the

• Cracking

ground strap with a clean cloth.

• Looseness

• If the connections are corroded, clean the

connections with a solution of baking soda and

• Damage

water.

Inspect all couplings for leaks. Replace any coupling

• Keep the grounding stud and the strap clean and

which exhibits signs of leaks.

coated with MPGM grease or petroleum jelly.

Each installation application can be different. The

differences depend on the following factors:

i05909284

• Type of hose

Hoses and Clamps - Inspect/

• Type of fitting material

Replace

• Anticipated expansion and contraction of the hose

SMCS Code: 7554-040; 7554-510

• Anticipated expansion and contraction of the

Hoses and clamps must be inspected periodically

fittings

and replaced at the recommended interval to ensure

safe and continuous operation of the engine. Failure

Due to extreme temperature changes, the hose will

to replace a fuel hose at the recommended change

heat set. Heat setting causes hose clamps to loosen

interval may result in a hazardous situation. Take

which can result in leaks. A constant torque hose

proper safety precautions before inspecting or

clamp will help to prevent loose hose clamps.

replacing hoses and clamps.

SEBU8598

Maintenance Recommendations

Hoses and Clamps - Inspect/Replace

Replace hoses that are cracked or soft. Replace

5. Drain the coolant from the cooling system to a level

hoses that show signs of leakage. Replace hoses

that is below the hose that is being replaced. Drain

that show signs of damage. Replace hose clamps

the coolant into a suitable clean container. The

that are cracked or damaged. Tighten or replace hose

coolant can be reused.

clamps which are loose.

6. Remove the hose clamps.

Replace the Hoses and the Clamps

7. Disconnect the old hose.

NOTICE

Care must be taken to ensure that fluids are con-

8. Replace the old hose with a new hose.

tained during performance of inspection, mainte-

nance, testing, adjusting, and repair of the product.

9. Install hose clamps which have been inspected or

Be prepared to collect the fluid with suitable contain-

install new hose clamps. Refer to Specifications,

ers before opening any compartment or disassem-

SENR3130, “Torque Specifications”, “Hose

bling any component containing fluids.

Clamps” for information about selecting and

installing the proper hose clamps.

Refer to Special Publication, NENG2500, “Cat Dealer

Service Tool Catalog” or refer to Special Publication,

10. Refill the cooling system.

PECJ0003, “Cat Shop Supplies and Tools Catalog”

for tools and supplies suitable to collect and contain

11. Clean the filler cap for the cooling system. Inspect

fluids on Cat products.

the gaskets on the filler cap. Replace the filler cap

Dispose of all fluids according to local regulations and

if the gaskets are damaged. Install the filler cap.

mandates.

12. Start the engine. Inspect the cooling system for

leaks.

Cooling System

Fuel System

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,

Personal injury can result from removing hoses

stop the engine and wait until the cooling system

or fittings in a pressure system.

components are cool. Loosen the cooling system

Failure to relieve pressure can cause personal

pressure cap slowly in order to relieve the

injury.

pressure.

Do not disconnect or remove hoses or fittings un-

til all pressure in the system has been relieved.

Personal injury can result from removing hoses

or fittings in a pressure system.

Contact with high pressure fuel may cause fluid

Failure to relieve pressure can cause personal

penetration and burn hazards. High pressure fuel

injury.

spray may cause a fire hazard. Failure to follow

Do not disconnect or remove hoses or fittings un-

these inspection, maintenance and service in-

til all pressure in the system has been relieved.

structions may cause personal injury or death.

1. Stop the engine.

NOTICE

Do not bend or strike high pressure lines. Do not in-

2. Allow the engine to cool.

stall bent or damaged lines, tubes or hoses. Repair

any loose or damaged fuel and oil lines, tubes and

3. Before servicing a coolant hose, slowly loosen the

hoses. Leaks can cause fires. Inspect all lines, tubes

filler cap for the cooling system in order to relieve

and hoses carefully. Tighten all connections to the

any pressure.

recommended torque.

4. Remove the filler cap for the cooling system.

SEBU8598

Maintenance Recommendations

Overhaul Considerations

NOTICE

2. Remove the hose clamps.

Do not allow dirt to enter the fuel system. Thoroughly

clean the area around a fuel system component that

3. Disconnect the old hose.

will be disconnected. Fit a suitable cover over any dis-

connected fuel system components.

4. Replace the old hose with a new hose.

5. Install hose clamps which have been inspected or

Note: High-pressure fuel lines may be installed

install new hose clamps. Refer to Specifications,

between the high-pressure fuel pump and the fuel

SENR3130, “Torque Specifications”, “Hose

injectors. High-pressure fuel lines are constantly

Clamps” for information about selecting and

charged with high pressure. Do not check the high-

installing the proper hose clamps.

pressure fuel lines with the engine or the starting

motor in operation. Wait for 10 minutes after the

6. Refill the lubrication system. Refer to this

engine stops before you perform any service or repair

Operation and Maintenance Manual, “Engine Oil

on high-pressure fuel lines. Waiting for 10 minutes will

Level - Check” in order to ensure that the

to allow the pressure to be purged.

lubrication system is filled with the proper amount

1. Drain the fuel from the fuel system to a level that is

of engine oil.

below the hose that is being replaced.

7. Start the engine. Inspect the lubrication system for

2. Remove the hose clamps.

leaks.

3. Disconnect the old hose.

Air System

Note: When servicing fuel system, use cap/s or

cover/s as required to protect the system and

1. Remove the hose clamps.

maintain fuel system cleanliness.

2. Disconnect the old hose.

4. Replace the old hose with a new hose.

3. Replace the old hose with a new hose.

5. Install hose clamps which have been inspected or

install new hose clamps. Refer to Specifications,

4. Install hose clamps which have been inspected or

SENR3130, “Torque Specifications”, “Hose

install new hose clamps. Refer to Specifications,

Clamps” for information about selecting and

SENR3130, “Torque Specifications”, “Hose

installing the proper hose clamps.

Clamps” for information about selecting and

installing the proper hose clamps.

6. Carefully inspect the engine for any spilled fuel.

Note: The bellows and the V-clamps that are used on

Make sure that no fuel remains on or close to the

the bellows should never be reused.

engine.

5. Start the engine. Inspect the air lines for leaks.

Note: Fuel must be added to the fuel system ahead

of the fuel filter.

i04138631

7. Refill the fuel system. Refer to this Operation and

Maintenance Manual, “Fuel System - Prime” for

Overhaul Considerations

information about priming the engine with fuel.

SMCS Code: 7595-043

8. Start the engine. Inspect the fuel system for leaks.

Reduced hours of operation at full load will result in a

lower average power demand and reduced fuel

Lubrication System

consumption. A decreased average power demand

should increase both the engine service life and the

overhaul interval.

The need for an overhaul is indicated by increased

fuel consumption, increased oil consumption,

Hot oil and hot components can cause personal

excessive engine blowby, and reduced power. Arctic

injury. Do not allow hot oil or hot components to

temperatures, extreme high temperatures, corrosive

contact the skin.

environments, or extreme dusty conditions contribute

to premature wear and the need for an overhaul.

1. Drain the oil from the lubrication system to a level

that is below the hose that is being replaced.

SEBU8598

Maintenance Recommendations

Overhaul Considerations

The following factors are important when a decision is

After Failure Overhaul

being made on the proper time for an engine

overhaul:

If a major engine failure occurs and the engine must

be removed, many options are available. An overhaul

• The need for preventive maintenance

should be performed if the engine block or the

crankshaft needs to be repaired.

• The quality of the fuel that is being used

If the engine block is repairable and/or the crankshaft

• The operating conditions

is repairable, the overhaul cost should be between 40

percent and 50 percent of the cost of a new engine

• The results of the S·O·S analysis

with a similar exchange core.

Note: The aftertreatment system can be expected to

This lower cost can be attributed to three aspects:

function properly for the useful life of the engine

• Specially designed Caterpillar engine features

(emissions durability period), as defined by

regulation, subject to prescribed maintenance

• Caterpillar dealer exchange components

requirements being followed.

• Caterpillar Inc. remanufactured exchange

Oil Consumption as an Overhaul

components

Indicator

Overhaul Recommendation

Oil consumption, fuel consumption, and maintenance

information can be used to estimate the total

To minimize downtime, Caterpillar Inc. recommends a

operating cost for your Caterpillar engine. Oil

scheduled engine overhaul by your Caterpillar dealer

consumption can also be used to estimate the

before the engine fails. A scheduled engine overhaul

required capacity of a makeup oil tank that is suitable

will provide you with the best cost/value relationship.

for the maintenance intervals.

Note: Overhaul programs vary according to the

Oil consumption is in proportion to the percentage of

engine application and according to the dealer that

the rated engine load. As the percentage of the

performs the overhaul. Consult your Caterpillar dealer

engine load is increased, the amount of oil that is

for specific information about the available overhaul

consumed per hour also increases.

programs and about overhaul services for extending

The oil consumption rate (brake-specific oil

the engine life.

consumption) is measured in grams per kW/h (lb per

If an overhaul is performed without overhaul service

bhp). The brake-specific oil consumption (BSOC)

from your Caterpillar dealer, be aware of the following

depends on the engine load. Consult your Caterpillar

maintenance recommendations.

dealer for assistance in determining the typical oil

consumption rate for your engine.

Rebuild or Exchange

When the oil consumption of an engine has risen to

three times the original oil consumption rate due to

normal wear, an engine overhaul should be

Cylinder Head Assembly, Cylinder Packs,

scheduled. There may be a corresponding increase

Oil Pump, and Fuel Transfer Pump

in blowby and a slight increase in fuel consumption.

These components should be inspected according to

Overhaul Options

the instructions that are found in various Caterpillar

reusability publications. The Special Publication,

SEBF8029 lists the reusability publications that are

Before Failure Overhaul

needed for inspecting the engine parts.

A planned overhaul before failure may be the best

If the parts comply with the established inspection

value for the following reasons:

specifications that are expressed in the reusable

parts guideline, the parts should be reused.

• Costly unplanned downtime can be avoided.

Parts that are not within the established inspection

• Many original parts can be reused according to the

specifications should be dealt with in one of the

standards for reusable parts.

following manners:

• The service life of the engine can be extended

• Salvaging

without the risk of a major catastrophe due to

engine failure.

• Repairing

• The best cost/value relationship per hour of

• Replacing

extended life can be attained.

SEBU8598

Maintenance Recommendations

Overhaul Considerations

Using out-of-spec parts can result in the following

Note: If the camshaft is removed for any reason, use

problems:

the magnetic particle inspection process to check for

cracks in the camshaft.

• Unscheduled downtime

Inspect the following components for signs of wear or

• Costly repairs

for signs of scuffing:

• Damage to other engine parts

• Camshaft bearings

• Reduced engine efficiency

• Camshaft followers

• Increased fuel consumption

Caterpillar Inc. recommends replacing the crankshaft

vibration damper.

Reduced engine efficiency and increased fuel

consumption translates into higher operating costs.

Oil Cooler Core

Therefore, Caterpillar Inc. recommends repairing out-

of-spec parts or replacing out-of-spec parts.

During an overhaul, Caterpillar Inc. recommends the

removal of the oil cooler core. Clean the oil cooler

Inspection and/or Replacement

core. Then, pressure test the oil cooler core.

NOTICE

Crankshaft Bearings, Valve Rotators, and

Do not use caustic cleaners to clean the core.

Crankshaft Seals

Caustic cleaners can attack the internal metals of the

core and cause leakage.

The following components may not last until the

second overhaul.

Note: Use this cleaning procedure to clean the oil

• Thrust bearings

cooler core.

• Main bearings

1. Remove the oil cooler core.

• Rod bearings

2. Remove any debris from the oil cooler core. To

• Valve rotators

remove debris from the oil cooler core, turn the oil

cooler core onto one end.

• Crankshaft seals

3. Flush the oil cooler core internally with cleaner in

Caterpillar Inc. recommends the installation of new

order to loosen foreign substances. Flushing the oil

parts at each overhaul period.

cooler will also help to remove oil from the oil

cooler core.

Inspect these parts while the engine is disassembled

for an overhaul.

Note: Caterpillar Inc. recommends the use of

Inspect the crankshaft for any of the following

Hydrosolv Liquid Cleaners. Table 12 lists the

conditions:

Hydrosolv Liquid Cleaners that are available from

your Caterpillar dealer.

• Deflection

Table 12

• Damage to the journals

Hydrosolv Liquid Cleaners

• Bearing material that has seized to the journals

Part Number

Description

Size

1U-5490

Hydrosolv 4165

19 L (5 US gallon)

Check the journal taper and the profile of the

crankshaft journals. Check these components by

174-6854

Hydrosolv 100

19 L (5 US gallon)

interpreting the wear patterns on the following

components:

4. Use steam to clean the oil cooler core. Steam-

• Rod bearing

cleaning the oil cooler core removes any remaining

residue from the cleaner. Flush the fins of the oil

• Main bearings

cooler core. Remove any other trapped debris.

Inspect the camshaft for damage to the journals and

to the lobes.

5. Wash the oil cooler core with hot, soapy water.

Rinse the oil cooler core thoroughly with clean

water.

SEBU8598

Maintenance Recommendations

Power Take-Off Clutch - Check

S·O·S Coolant Analysis (Level 2) provides a report of

the results of both the analysis and the maintenance

recommendations.

Personal injury can result from air pressure.

For more information about coolant analysis, see your

Personal injury can result without following prop-

Caterpillar dealer.

er procedure. When using pressure air, wear a

protective face shield and protective clothing.

i03901481

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Power Take-Off Clutch - Check

SMCS Code: 3055-535

6. Dry the oil cooler core with compressed air. Direct

the air in the reverse direction of the normal flow.

NOTICE

7. Inspect the components in order to ensure

New power take-offs should have the clutch adjust-

cleanliness. The oil cooler core should be pressure

ment checked before being placed into service. The

tested. Repair the oil cooler core, if necessary.

clutch adjustment should be checked again after the

Install the oil cooler core.

first ten hours of operation. New clutch plates have a

“wear in” period, and the clutch may require several

For more information about cleaning the cores,

adjustments until the new plates are “worn in”.

consult your Caterpillar dealer.

Obtain Coolant Analysis

The concentration of supplemental coolant additive

(SCA) should be checked regularly with test kits or

with S·O·S Coolant Analysis (Level 1). Further

coolant analysis is recommended when the engine is

overhauled.

For example, considerable deposits are found in the

water jacket areas on the external cooling system, but

the concentrations of coolant additives were carefully

maintained. The coolant water probably contained

minerals that were deposited on the engine over time.

A coolant analysis can be conducted in order to verify

the condition of the water that is being used in the

cooling system. A full water analysis can be obtained

Illustration 65

g00781502

by consulting your local water utility company or an

(1) Instruction plate

agricultural agent. Private laboratories are also

(2) Serial number plate

available for water analysis.

Check the clutch adjustment regularly after “wear in”.

Caterpillar Inc. recommends an S·O·S Coolant

Heavy-duty applications which have engagements

Analysis (Level 2).

that are frequent and relatively long periods of clutch

slippage require more frequent adjustment than light-

duty applications. The operating torque should be

S·O·S Coolant Analysis (Level 2)

measured in order to determine if a clutch adjustment

is required.

An S·O·S Coolant Analysis (Level 2) is a

comprehensive coolant analysis which completely

Refer to the OEM information and instruction plate (1)

analyzes the coolant and the effects on the cooling

for instructions on lubrication, adjustment, and other

system. An S·O·S Coolant Analysis (Level 2)

recommendations for service. Perform the

provides the following information:

maintenance that is specified on the instruction plate.

• Complete S·O·S Coolant Analysis (Level 1)

• Visual inspection of properties

• Identification of metal corrosion

• Identification of contaminants

• Identification of built up impurities (corrosion and

scale)

SEBU8598

Maintenance Recommendations

Radiator - Clean

Inspect the fins for damage. Bent fins may be opened

with a “comb”. Inspect these items for good condition:

welds, mounting brackets, air lines, connections,

Do not operate the engine with the Instruction

clamps and seals. Make repairs, if necessary.

Plate cover removed from the clutch. Personal in-

jury may result.

i00651416

If the clutch is damaged to the point of burst fail-

ure, expelled pieces can cause personal injury to

Starting Motor - Inspect

anyone in the immediate area. Proper safeguards

SMCS Code: 1451-040; 1453-040

must be followed to help prevent accidents.

Caterpillar Inc. recommends a scheduled inspection

of the starting motor. If the starting motor fails, the

i04020194

engine may not start in an emergency situation.

Check the starting motor for proper operation. Check

Radiator - Clean

the electrical connections and clean the electrical

SMCS Code: 1353-070

connections. Refer to the Service Manual for more

information on the checking procedure and for

specifications or consult your Caterpillar dealer for

Note: Adjust the frequency of cleaning according to

assistance.

the effects of the operating environment.

Inspect the radiator for these items: damaged fins,

i03965991

corrosion, dirt, grease, insects, leaves, oil and other

debris. Clean the radiator, if necessary.

Valve Actuators - Check

SMCS Code: 1105-535

The valve actuators should be inspected and

Personal injury can result from air pressure.

adjusted when adjustments to the following

components occur.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a

• Valves

protective face shield and protective clothing.

• Injectors

The maximum air pressure for cleaning purposes

must be reduced to 205 kPa (30 psi) when the air

• Compression brakes

nozzle is deadheaded.

Contact your Cat dealer for the proper procedure.

Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction of

i01185304

the air flow. Hold the nozzle approximately 6 mm

(0.25 inch) away from the fins. Slowly move the air

Walk-Around Inspection

nozzle in a direction that is parallel with the tubes.

This movement will remove debris that is between the

SMCS Code: 1000-040

tubes.

Inspect the Engine for Leaks and

Pressurized water may also be used for cleaning. The

maximum water pressure for cleaning purposes must

for Loose Connections

be less than 275 kPa (40 psi). Use pressurized water

in order to soften mud. Clean the core from both

A walk-around inspection should only take a few

sides.

minutes. When the time is taken to perform these

checks, costly repairs and accidents can be avoided.

Use a degreaser and steam for removal of oil and

grease. Clean both sides of the core. Wash the core

For maximum engine service life, make a thorough

with detergent and hot water. Thoroughly rinse the

inspection of the engine compartment before starting

core with clean water.

the engine. Look for items such as oil leaks or coolant

leaks, loose bolts, worn belts, loose connections and

After cleaning, start the engine and accelerate the

trash buildup. Make repairs, as needed:

engine to high idle rpm. This procedure will help in the

removal of debris and drying of the core. Stop the

engine. Use a light bulb behind the core in order to

inspect the core for cleanliness. Repeat the cleaning,

if necessary.

SEBU8598

Maintenance Recommendations

Walk-Around Inspection

• The guards must be in the proper place. Repair

•

Drain the water and the sediment from fuel tanks

damaged guards or replace missing guards.

on a daily basis in order to ensure that only clean

fuel enters the fuel system.

• Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system

•

Inspect the wiring and the wiring harnesses for

contamination.

loose connections and for worn wires or frayed

wires.

NOTICE

•

Inspect the ground strap for a good connection

For any type of leak (coolant, lube, or fuel) clean up

and for good condition.

the fluid. If leaking is observed, find the source and

correct the leak. If leaking is suspected, check the flu-

•

Inspect the ECM to the cylinder head ground strap

id levels more often than recommended until the leak

for a good connection and for good condition.

is found or fixed, or until the suspicion of a leak is

proved to be unwarranted.

•

Disconnect any battery chargers that are not

protected against the current drain of the starting

motor. Check the condition and the electrolyte

NOTICE

level of the batteries, unless the engine is

Accumulated grease and/or oil on an engine or deck

equipped with a maintenance free battery.

is a fire hazard. Remove this debris with steam clean-

ing or high pressure water.

•

Check the condition of the gauges. Replace any

gauges that are cracked. Replace any gauge that

can not be calibrated.

• Ensure that the cooling lines are properly clamped

and that the cooling lines are tight. Check for

leaks. Check the condition of all pipes.

• Inspect the water pumps for coolant leaks.

Note: The water pump seal is lubricated by coolant in

the cooling system. It is normal for a small amount of

leakage to occur as the engine cools down and the

parts contract.

Excessive coolant leakage may indicate the need to

replace the water pump seal. For the removal of

water pumps and the installation of water pumps and/

or seals, refer to the Service Manual for the engine or

consult your Caterpillar dealer.

• Inspect the lubrication system for leaks at the front

crankshaft seal, the rear crankshaft seal, the oil

pan, the oil filters and the valve cover.

• Inspect the fuel system for leaks. Look for loose

fuel line clamps or for loose fuel line tie-wraps.

• Inspect the piping for the air inlet system and the

elbows for cracks and for loose clamps. Ensure

that hoses and tubes are not contacting other

hoses, tubes, wiring harnesses, etc.

• Inspect the alternator belt and the accessory drive

belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced as

matched sets. If only one belt is replaced, the belt will

carry more load than the belts that are not replaced.

The older belts are stretched. The additional load on

the new belt could cause the belt to break.

SEBU8598

Warranty Section

Emissions Warranty Information

A detailed explanation of the Emission Control

Warranty Section

Warranty that is applicable to new non-road and

stationary diesel engines, including the components

covered and the warranty period, is found in a

Warranty Information

supplemental Special Publication. Consult your

authorized Cat dealer to determine if your engine is

subject to an Emission Control Warranty and to

i05627331

obtain a copy of the applicable Special Publication.

Emissions Warranty

Information

SMCS Code: 1000

The certifying engine manufacturer warrants to the

ultimate purchaser and each subsequent purchaser

that:

1. New non-road diesel engines and stationary diesel

engines less than 10 liters per cylinder (including

Tier 1 and Tier 2 marine engines < 37 kW, but

excluding locomotive and other marine engines)

operated and serviced in the United States and

Canada, including all parts of their emission control

systems (“emission related components”), are:

a. Designed, built, and equipped so as to

conform, at the time of sale, with applicable

emission standards prescribed by the United

States Environmental Protection Agency

(EPA) by way of regulation.

b. Free from defects in materials and

workmanship in emission-related components

that can cause the engine to fail to conform to

applicable emission standards for the warranty

period.

2. New non-road diesel engines (including Tier 1 and

Tier 2 marine propulsion engines < 37 kW and Tier

1 through Tier 4 marine auxiliary engines < 37 kW,

but excluding locomotive and other marine

engines) operated and serviced in the state of

California, including all parts of their emission

control systems (“emission related components”),

are:

a. Designed, built, and equipped so as to

conform, at the time of sale, to all applicable

regulations adopted by the California Air

Resources Board (ARB).

b. Free from defects in materials and

workmanship which cause the failure of an

emission-related component to be identical in

all material respects to the component as

described in the engine manufacturer's

application for certification for the warranty

period.

SEBU8598

Reference Information Section

Engine Rating Conditions

Table 13

Reference Information

Engine Rating Information

Section

Time at Rated Load⁽¹⁾

Perform-

Load

Examples of

ance

Factor

Any One

Applications

Rating

Overall

Engine Ratings

Instance

Pipe line

100%

n/a

pumping

i01097462

Ventilation

Engine Rating Conditions

Irrigation pumps

Drilling

SMCS Code: 1000

85%

75%

n/a

applications

Plant air

All engine ratings are based on “SAE J1349”.

compressors

Ratings relate to the standard conditions of

Fire pumps

“AS1501”, of “ISO3046/1”, of “DIN6271”, and of

Chippers

“BS5514”.

Less than1

70%

50%

Rock crushers

hour

Portable air

The engine ratings are gross output ratings.

compressors

Gross Output Ratings - The total output capability

Snowgroomer

of the engine that is equipped with standard

Less than 30

Snowblowers

50%

10%

accessories.

minutes

Cranes

Water well drills

Standard accessories include the following

Standby centrifu-

Less than 15

components:

35%

gal pumps

minutes

Oil well servicing

• Oil pumps

Both the overall time at rated load and the time the engine is op-

(1)

erated in any one instance must be considered.

• Fuel pumps

• Water pumps

NOTICE

Operating engines above the rating definitions can re-

Subtract the power that is required to drive auxiliary

sult in shorter service life before overhaul.

components from the gross output. This will produce

the net power that is available for the external load

(flywheel).

i03880100

Engine Rating Definitions

SMCS Code: 1000

In selecting a rating for a specific application, the

most important consideration is the time that is spent

at full throttle. These rating definitions identify the

percent of time at full throttle. The definitions also

identify the corresponding times below rated rpm.

Refer to this Operation and Maintenance Manual,

“Configuration Parameters” for information about the

rating for this engine.

Note: The examples of the applications are only for

reference. For an exact determination of the

appropriate rating, follow the OEM specifications or

consult your Caterpillar dealer.

SEBU8598

Customer Service

Customer Assistance

Europe, Africa, and Middle East

Customer Service

Caterpillar Overseas S.A.

76 Route de Frontenex

i03910306

P.O. Box 6000

CH-1211 Geneva 6

Customer Assistance

Switzerland

SMCS Code: 1000; 4450

Phone: 22-849-4444

Fax: 22-849-4544

USA and Canada

Far East

Caterpillar Asia Pte. Ltd.

When a problem arises concerning the operation or

7 Tractor Road

the service of an engine, the problem will normally be

Jurong, Singapore 627968

managed by the dealer in your area.

Republic of Singapore

Your satisfaction is a primary concern to Caterpillar

Phone: 65-662-8333

and to Caterpillar dealers. If you have a problem that

Fax: 65-662-8302

has not been handled to your complete satisfaction,

follow these steps:

China

Caterpillar China Ltd.

1. Discuss your problem with a manager from the

37/F., The Lee Gardens

dealership.

33 Hysan Avenue

Causeway Bay

2. If your problem cannot be resolved at the dealer

G.P.O. Box 3069

level, use the phone number that is listed below to

Hong Kong

talk with a Field Service Coordinator:

Phone: 852-2848-0333

Fax: 852-2848-0440

1-800-447-4986

Japan

The normal hours are from 8:00 to 4:30 Monday

Shin Caterpillar Mitsubishi Ltd.

through Friday Central Standard Time.

SBS Tower

10-1, Yoga 4-Chome

3. If your needs have not been met still, submit the

Setagaya-Ku, Tokyo 158-8530

matter in writing to the following address:

Japan

Phone: 81-3-5717-1150

Caterpillar Inc.

Fax: 81-3-5717-1177

Manager, Customer Service, Engine Division

Mossville Bldg AC

Japan

P.O. Box 610

Caterpillar Power Systems, Inc.

Mossville, Illinois 61552-0610

SBS Tower (14th floor)

4-10-1, Yoga

Please keep in mind: probably, your problem will

ultimately be solved at the dealership, using the

Setagaya-Ku, Tokyo 158-0097

dealership facilities, equipment, and personnel.

Phone: 81-3-5797-4300

Therefore, follow the steps in sequence when a

Fax: 81-3-5797-4359

problem is experienced.

Australia and New Zealand

Outside of the USA and of Canada

Caterpillar of Australia Ltd.

1 Caterpillar Drive

If a problem arises outside the USA and outside

Private Mail Bag 4

Canada, and if the problem cannot be resolved at the

Tullamarine, Victoria 3043

dealer level, consult the appropriate Caterpillar

Australia

office.

Phone: 03-9953-9333

Fax: 03-9335-3366

Latin America, Mexico, Carribean

Caterpillar Americas Co.

701 Waterford Way, Suite 200

Miami, FL 33126-4670

USA

Phone: 305-476-6800

Fax: 305-476-6801

SEBU8598

Customer Service

Ordering Replacement Parts

i01028392

Ordering Replacement Parts

SMCS Code: 4450; 7567

When replacement parts are required for this

product Caterpillar recommends using Caterpillar

replacement parts or parts with equivalent specifi-

cations including, but not limited to, physical di-

mensions, type, strength and material.

Failure to heed this warning can lead to premature

failures, product damage, personal injury or

death.

Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.

Caterpillar dealers' parts inventories are up-to-date.

The parts stocks include all of the parts that are

normally needed to protect your Caterpillar engine

investment.

When you order parts, please specify the following

information:

• Part number

• Part name

• Quantity

If there is a question concerning the part number,

please provide your dealer with a complete

description of the needed item.

When a Caterpillar engine requires maintenance

and/or repair, provide the dealer with all the

information that is stamped on the Information Plate.

This information is described in this Operation and

Maintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform the

dealer about the conditions of the problem and the

nature of the problem. Inform the dealer about when

the problem occurs. This will help the dealer in

troubleshooting the problem and solving the problem

faster.

SEBU8598

Reference Materials

Maintenance Records

Reference Materials

i05264255

Maintenance Records

SMCS Code: 1000; 4450

Caterpillar Inc. recommends the retention of accurate

maintenance records. Accurate maintenance records

can be used for the following purposes:

• Determine operating costs.

• Establish maintenance schedules for other

engines that are operated in the same

environment.

• Show compliance with the required maintenance

practices and maintenance intervals.

Maintenance records can be used for various other

business decisions that are related to engine

maintenance.

Maintenance records are a key element of a

maintenance program that is managed. Accurate

maintenance records can help your Cat dealer to fine-

tune the recommended maintenance intervals in

order to meet the specific operating situation. This

should result in a lower engine operating cost.

Records should be kept for the following items:

Fuel Consumption - A record of fuel consumption is

essential in order to determine when the load

sensitive components should be inspected or

repaired. Fuel consumption also determines overhaul

intervals.

Service Hours - A record of service hours is

essential to determine when the speed sensitive

components should be inspected or repaired.

Documents - These items should be easy to obtain,

and these items should be kept in the engine history

file. All of the documents should show this

information: date, service hours, fuel consumption,

unit number and engine serial number. The following

types of documents should be kept as proof of

maintenance or repair for warranty:

Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of

documents as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owner repair costs

• Owner receipts

• Maintenance log

100

SEBU8598

Reference Materials

Reference Material

i04785009

Lubricants

• Special Publication, PEHJ0192, “Optimizing S·O·S

Reference Material

Oil Change Intervals”

SMCS Code: 1000; 4450

• Data Sheet, PEHJ0021, “Product Data Sheet for

The following literature can be obtained through any

Cat DEO (Diesel Engine Oil) APD, EAME, LACD

Cat dealer.

Only”

Coolants

• Data Sheet, PEHJ0059, “Cat DEO (for North

America)”

• Data Sheet, PEHJ0067, “Cat ELC (Extended Life

Coolant) (Worldwide Formulation)”

• Data Sheet, PEHJ0072, “Cat DEO (Brazil Only)”

• Data Sheet, PEHP9554, “Diesel Engine

• Special Publication, PEHP6001, “How To Take A

Antifreeze/Coolant (DEAC)”

Good Oil Sample”

• Special Publication, PMEP5027, “Label - ELC

• Data Sheet, PEHP7062, “Full Synthetic Diesel

Radiator Label”

Engine Oil Data Sheet”

• Special Publication, SEBD0518, “Know Your

• Special Publication, PELJ0179, “FLU03-02

Cooling System”

Caterpillar Engine Crankcase Fluid-1

Specifications (All World Market Areas)”

Fuels

S·O·S Services

• Special Publication, SENR9620, “Improving Fuel

System Durability”

• Data Sheet, NEHP6013, “S·O·S Fluids Analysis

Products”

Greases

• Special Publication, PEHJ0191, “Cat S·O·S Fluids

• Data Sheet, NEHP6010, “Cat Ultra 5Moly Grease”

Analysis”

• Data Sheet, NEHP6011, “Arctic Platinum Grease

• Special Publication, PEHP7076, “Understanding

Spec Sheet”

S·O·S Services Tests”

• Data Sheet, NEHP6012, “Cat Desert Gold Grease”

• Data Sheet, NEHP6015, “Cat Special Purpose

Grease”

• Special Publication, PEGJ0035, “Grease Selection

Guide”

• Data Sheet, PEHJ0088, “Cat Multipurpose

Grease”

• Data Sheet, PEHP0002, “Molybdenum Grease

Data Sheet”

• Data Sheet, PEHP6002, “Cat Advanced 3Moly

Grease”

SEBU8598

101

Reference Materials

Decommissioning and Disposal

Miscellaneous

SAE International

400 Commonwealth Drive

•

Special Instruction, NENG2500, “Cat dealer

Warrendale, PA, USA 15096-0001

Service Tool Catalog”

Telephone (724) 776-4841

•

Special Publication, PECP9067, “One Safe

The “American Petroleum Institute Publication No.

Source”

1509” can be obtained from the following locations:

local technological society, local library and local

•

Special Instruction, REHS0354, “Charging System

college. If necessary, consult API at the following

Troubleshooting for All Engines”

address:

•

Special Instruction, REHS0871, “Electronic

American Petroleum Institute

Installation Guide”.

1220 L St. N.W.

Washington, DC, USA 20005

•

Special Publication, SEBF8029, “Index to

Telephone (202) 682-8000

Guidelines for Reusable Parts and Salvage

Operations”

The International Organization for Standardization

(ISO) offers information and customer service

•

Special Publication, SEBF8062, “Guideline for

regarding international standards and standardizing

Reusable Parts - Procedure to Inspect and Clean

activities. ISO can also supply information on the

following subjects that are not controlled by ISO:

Air Filters”

national standards, local standards, regulations,

•

Special Publication, SEBU6251, “Caterpillar

certification and related activities. Consult the

member of ISO in your country.

Commercial Diesel Engine Fluids

Recommendations”

International Organization for Standardization

(ISO)

•

Special Instruction, SEHS7332, “Warning Tag -

1, rue de Varembé

Danger Do Not Operate”

Case postale 56

CH-1211 Genève 20

•

Special Instruction, SEHS7633, “Battery Test

Switzerland

Procedure”

Telephone +41 22 749 01 11

•

Special Instruction, SEHS9031, “Storage

Facsimile +41 22 733 34 30

Procedure for Caterpillar Products”

E-mail central@iso.ch

web site http://www.iso.ch

•

Specifications, SENR3130, “Torque Specifications

Module”

European classifications are established by the

Counseil International Des Machines a Combustion

(CIMAC) (International Council on Combustion

•

Service Manual, SENR9840, “C15 and C18

Industrial Engines”

Engines).

•

Special Instruction, SMHS7001, “Assembly of Fan

CIMAC Central Secretariat

Drive Pulley Assemblies”

Lyoner Strasse 18

60528 Frankfurt

Additional Reference Material

Germany

Telephone +49 69 6603 1567

The “Engine Fluids Data Book” can be obtained from

Facsimile +49 69 6603 1566

the following locations: local technological society,

local library and local college. If necessary, consult

i03989612

EMA at the following address:

Engine Manufacturers Associaton

Decommissioning and

Two North LaSalle Street, Suite 2200

Disposal

Chicago, IL, USA 60602

E-mail: ema@enginemanufacturers.org

SMCS Code: 1000

Telephone (312) 827-8700

When the product is removed from service, local

Facsimile (312) 827-8737

regulations for the product decommissioning will vary.

Disposal of the product will vary with local

The “Society of Automotive Engineers (SAE)

Specifications” can be found in your SAE handbook.

regulations. Consult the nearest Cat dealer for

This publication can also be obtained from the

additional information.

following locations: local technological society, local

library and local college. If necessary, consult SAE at

the following address:

102

SEBU8598

Index Section

Index

Coolant Sample (Level 1) - Obtain

Coolant Sample (Level 2) - Obtain

After Starting Engine

Cooling System Supplemental Coolant

Extended Idle at Cold Ambient Temperature

Additive (SCA) - Test/Add (Systems Which

................................................................... 36

are Filled with Conventional Coolant)

After Stopping Engine

Maintain the Proper Concentration of SCA in

Air Compressor - Check (If equipped)

the Coolant

Air Shutoff - Test

Crushing Prevention and Cutting Prevention .. 13

Air Tank Moisture and Sediment - Drain (If

Customer Assistance

Equipped)

Outside of the USA and of Canada

ARD Spark Plug - Replace (If Equipped)

USA and Canada

Installing the Spark Plug

Customer Service

Removing the Spark Plug

Decommissioning and Disposal

101

Battery - Recycle

Diesel Particulate Filter - Clean/Replace (If

Battery - Replace

Equipped)

Battery Disconnect Switch (If Equipped)

Diesel Particulate Filter Regeneration

Battery Electrolyte Level - Check

Modes of Regeneration

Battery or Battery Cable - Disconnect

Regeneration

Before Starting Engine

13, 33

Regeneration Controls

Belts - Inspect/Replace (If Equipped)

Regeneration Indicator Lamps and Controls

Single Belt

................................................................... 38

Two or More Belts

Regeneration System Warning Indicators ... 40

Burn Prevention

Soot Level Monitoring

Batteries

Driven Equipment - Check

Coolant

Check the Alignment

Oils

Inspect the Drive Coupling

Inspect the Rear Gear Train

Cold Weather Operation

Cold Weather Starting

Electrical System

Ether Injection System (If Equipped)

Grounding Practices

Compression Brake - Inspect/Adjust/

Electronic Unit Injector - Check/Replace

Replace

Emissions Certification Film

Coolant (DEAC) - Change

Emissions Warranty Information

Cooling Systems with Heavy Deposits or

Engaging the Driven Equipment

Plugging

Engine - Clean

Drain

Engine Air Cleaner Element (Dual Element/

Fill

Box Type) - Replace

Flush

Primary Filter

Coolant (ELC) - Change

Secondary Filter

Drain

Engine Air Cleaner Element (Single

Fill

Element) - Inspect/Clean/Replace

Flush

Inspecting Air Cleaner Elements

Coolant Extender (ELC) - Add

Servicing the Air Cleaner Elements

Coolant Level - Check

SEBU8598

103

Index Section

Engine Air Cleaner Service Indicator -

Fuel System Primary Filter (Water Separator)

Inspect (If Equipped)

Element - Replace

Test the Service Indicator

Replace the Element

Engine Diagnostics

Fuel System Primary Filter/Water Separator

Engine Electronics

- Drain

Engine Mounts - Inspect

Fuel System Secondary Filter - Replace

Engine Oil and Filter - Change

Fuel Tank Water and Sediment - Drain

Drain the Engine Oil

Drain the Water and the Sediment

Fill the Engine Crankcase

Fuel Storage Tanks

Replace the Oil Filter

Fuel Tank

Selection of Oil Change Interval

Fumes Disposal Filter Element - Replace

Engine Oil Level - Check

(Open Crankcase Ventilation (OCV) Filter)

Engine Oil Sample - Obtain

Obtain the Sample and the Analysis

Engine Operation

Engine Rating Conditions

General Hazard Information

Engine Rating Definitions

Containing Fluid Spillage

Engine Ratings

Dispose of Waste Properly

Engine Starting

14, 33

Fluid Penetration

Engine Stopping

14, 44

Inhalation

Engine Storage Procedure - Check

Lines, Tubes, and Hoses

Engine Valve Lash - Check

Pressurized Air and Water

Softwrap

Static Electricity Hazard when Fueling with

Ultra-low Sulfur Diesel Fuel

Features and Controls

General Information

Fire Prevention and Explosion Prevention

Grounding Stud - Inspect/Clean/Tighten

Ether

Fire Extinguisher

Lines, Tubes, and Hoses

Fluid Recommendations

Hoses and Clamps - Inspect/Replace

Coolant

Inspect the Hoses and the Clamps

Diesel Engine Oil

Replace the Hoses and the Clamps

Diesel Fuel Recommendations

Lubricating Grease

Foreword

California Proposition 65 Warning

Important Safety Information

Literature Information

Maintenance

Maintenance Intervals

Operation

Lifting and Storage

Overhaul

Safety

Fuel and the Effect from Cold Weather

Fuel Conservation Practices

Maintenance Interval Schedule (C15

Fuel Priming Pump - Replace

Engines With Ratings Greater Than 579

Fuel Related Components in Cold Weather

hp)

Fuel Filters

Daily

Fuel Heaters

Every 12 000 Service Hours or 6 Years

Fuel Tanks

Every 2000 Service Hours

Fuel System - Prime

104

SEBU8598

Index Section

Every 2000 Service Hours or 1 Year

Every 250 Service Hours

Every 2500 Service Hours

Every 3000 Service Hours or 3 Years

Every 4000 Service Hours

Every 500 Service Hours

Every 5000 Service Hours

Every 6000 Service Hours or 3 Years

Every 585 000 L (154 540 US gal) of Fuel or

Every 760 000 L (200 770 US gal) of Fuel or

10 000 Service Hours

Every 6000 Service Hours or 3 Years

When Required

Initial 500 Service Hours

Maintenance Log

When Required

Maintenance Recommendations

Maintenance Interval Schedule (C15

Maintenance Records

Engines)

Maintenance Section

Daily

Manual Stop Procedure

Every 12 000 Service Hours or 6 Years

Model View Illustrations

Every 2000 Service Hours

Monitoring System

Every 2000 Service Hours or 1 Year

Indicators and Gauges

Every 250 Service Hours

Mini Industrial Power Display (MIPD)

Every 2500 Service Hours

Mounting and Dismounting

Every 3000 Service Hours or 3 Years

Every 4000 Service Hours

Every 500 Service Hours

Every 5000 Service Hours

Operation Section

Every 585 000 L (154 540 US gal) of Fuel or

Ordering Replacement Parts

10 000 Service Hours

Overhaul Considerations

Every 6000 Service Hours or 3 Years

Oil Consumption as an Overhaul Indicator .. 89

When Required

Overhaul Recommendation

Maintenance Interval Schedule (C18

Engines With Ratings Greater Than 760

HP)

Daily

Plate Locations and Film Locations

Every 12 000 Service Hours or 6 Years

Power Take-Off Clutch - Check

Every 2000 Service Hours

Product Description

Every 2000 Service Hours or 1 Year

Engine Description

Every 250 Service Hours

Product Identification Information

Every 2500 Service Hours

Product Information Section

Every 3000 Service Hours or 3 Years

Product Lifting

Every 4000 Service Hours

Clean Emission Module Lifting

Every 500 Service Hours

Engine Lifting with a Fuel Tank

Every 6000 Service Hours or 3 Years

Product Storage

Every 760 000 L (200 770 US gal) of Fuel or

Removal from Storage

10 000 Service Hours

Storage (Less Than One Year)

Initial 500 Service Hours

When Required

Maintenance Interval Schedule (C18

Engines)

Radiator - Clean

Daily

Radiator Restrictions

Every 12 000 Service Hours or 6 Years

Reference Information

Every 2000 Service Hours

Reference Information Section

Every 2000 Service Hours or 1 Year

Reference Material

100

SEBU8598

105

Index Section

Additional Reference Material

101

Coolants

100

Walk-Around Inspection

Fuels

100

Inspect the Engine for Leaks and for Loose

Greases

100

Connections

Lubricants

100

Warranty Information

Miscellaneous

101

Warranty Section

S·O·S Services

100

Welding on Engines with Electronic Controls.. 51

Reference Materials

Refill Capacities

Coolant Refill Capacity

Lubricant Refill Capacity

Safety Messages

Sulfuric Acid Burn (2)

Universal Warning (1)

Safety Section

Self-Diagnostics

Severe Service Application

Improper Maintenance Procedures

(Maintenance Procedures Which May

Contribute to a Severe Service Application)

................................................................... 53

Severe Environmental Factors

Severe Operating Conditions

Starting Motor - Inspect

Starting the Engine

Problems with the Wiring Harness

Starting Problems

Starting the Engine

Starting with Jump Start Cables (Do Not

Use This Procedure in Hazardous

Locations that have Explosive

Atmospheres)

System Pressure Release

Coolant System

Engine Oil

Fuel System

Table of Contents

Valve Actuators - Check