Caterpillar. 3406C Industrial Engines. Operation and Maintenance Manual (2000)

i01097883

Important Safety Information

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

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

hazardous situations before an accident occurs. A person must be alert to potential hazards. This

person should also have the necessary training, skills and tools to perform these functions properly.

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

could result in injury or death.

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

read and understood the operation, lubrication, maintenance and repair information.

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

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

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

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

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

pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in

this publication.

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

warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,

work method or operating technique that is not specifically recommended by Caterpillar is used,

you must satisfy yourself that it is safe for you and for others. You should also ensure that the

product will not be damaged or be made unsafe by the operation, lubrication, maintenance or

repair procedures that you choose.

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

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

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

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

you start any job. Caterpillar dealers have the most current information available. For a list of the most

current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-

lar replacement parts or parts with equivalent

specifications including, but not limited to, phys-

ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

Foreword

Use fuel consumption or service hours to determine

intervals. Calendar intervals shown (daily, annually,

etc.) may be used instead of service meter intervals

Literature Information

if they provide more convenient schedules and

approximate the indicated service meter reading.

This manual contains safety, operation instructions,

lubrication and maintenance information. This

Recommended service should be performed

manual should be stored in or near the engine area

at the appropriate intervals as indicated in

in a literature holder or literature storage area. Read,

the Maintenance Interval Schedule. The actual

study and keep it with the literature and engine

operating environment of the engine also governs

information.

the Maintenance Interval Schedule. Therefore,

under extremely severe, dusty, wet or freezing cold

English is the primary language for all Caterpillar

operating conditions, more frequent lubrication and

publications. The English used facilitates translation

maintenance than is specified in the Maintenance

and consistency in electronic media delivery.

Interval Schedule may be necessary.

Some photographs or illustrations in this manual

The maintenance schedule items are organized

show details or attachments that may be different

for a preventive maintenance management

from your engine. Guards and covers may have

program. If the preventive maintenance program

been removed for illustrative purposes. Continuing

is followed, a periodic tune-up is not required.

improvement and advancement of product design

The implementation of a preventive maintenance

may have caused changes to your engine which are

management program should minimize operating

not included in this manual. Whenever a question

costs through cost avoidances resulting from

arises regarding your engine, or this manual, please

reductions in unscheduled downtime and failures.

consult with your Caterpillar dealer for the latest

available information.

Maintenance Intervals

Safety

Perform maintenance on items at multiples

of the original requirement. Each level and/or

This safety section lists basic safety precautions.

individual items in each level should be shifted

In addition, this section identifies hazardous,

ahead or back depending upon your specific

warning situations. Read and understand the basic

maintenance practices, operation and application.

precautions listed in the safety section before

We recommend that the maintenance schedules

operating or performing lubrication, maintenance

be reproduced and displayed near the engine as

and repair on this product.

a convenient reminder. We also recommend that a

maintenance record be maintained as part of the

Operation

engine’s permanent record.

Operating techniques outlined in this manual are

See the section in the Operation and Maintenance

basic. They assist with developing the skills and

Manual, “Maintenance Records” for information

techniques required to operate the engine more

regarding documents that are generally accepted

efficiently and economically. Skill and techniques

as proof of maintenance or repair. Your authorized

develop as the operator gains knowledge of the

Caterpillar dealer can assist you in adjusting your

engine and its capabilities.

maintenance schedule to meet the needs of your

operating environment.

The operation section is a reference for operators.

Photographs and illustrations guide the operator

Overhaul

through procedures of inspecting, starting,

operating and stopping the engine. This section

Major engine overhaul details are not covered in the

also includes a discussion of electronic diagnostic

Operation and Maintenance Manual except for the

information.

interval and the maintenance items in that interval.

Major repairs are best left to trained personnel or

Maintenance

an authorized Caterpillar dealer. Your Caterpillar

dealer offers a variety of options regarding overhaul

The maintenance section is a guide to engine

programs. If you experience a major engine failure,

care. The illustrated, step-by-step instructions are

there are also numerous after failure overhaul

grouped by fuel consumption, service hours and/or

options available from your Caterpillar dealer.

calendar time maintenance intervals. Items in the

Consult with your dealer for information regarding

maintenance schedule are referenced to detailed

these options.

instructions that follow.

Safety Section

Safety Signs and Labels

Battery

Safety Section

i01368857

Safety Signs and Labels

SMCS Code: 1000; 7405

There may be several specific safety signs on an

g00524010

Illustration 1

engine. The exact location of the hazards and the

Typical location of the batteries in the battery compartment

description of the hazards are reviewed in this

section. Please become familiar with all safety signs.

The warning label for the battery is installed on the

side of the engine or in a visible location near the

Ensure that all of the safety signs are legible. Clean

battery. If batteries are located on both sides of the

the safety signs or replace the safety signs if the

package, the warning label is located on both sides

words cannot be read or if the pictures are not

of the package.

visible. When the safety signs are cleaned, use a

cloth, water, and soap. Do not use solvent, gasoline,

or other harsh chemicals to clean the safety signs.

Solvents, gasoline, or harsh chemicals could loosen

the adhesive that secures the safety signs. The

safety signs that are loosened could drop off of

the engine.

Replace any damaged safety signs or missing

safety signs. If a safety sign is attached to a part of

the engine that is replaced, install a new safety sign

on the replacement part. Any Caterpillar dealer can

provide new safety signs.

g00455028

Do not operate or work on this engine unless you

have read and understand the instructions and

warnings in the Operation and Maintenance Man-

ual. Failure to follow the instructions or heed the

Improper jumper cable connections can cause an

warnings could result in injury or death. Contact

explosion resulting in personal injury.

any Caterpillar dealer for replacement manuals.

Proper care is your responsibility.

Batteries may be located in separate compartments.

When you are using jump start cables, always

The safety signs that may be found on the engine

connect the positive “+” cable to the positive “+”

are illustrated and described below.

terminal of the battery that is connected to the

starting motor solenoid. Connect the negative “-”

cable from the external source to the negative “-”

terminal of the starting motor. If the starting motor

does not have a negative “-” terminal, connect the

negative “-” cable from the external source to the

engine block. Follow the procedure in this Operation

and Maintenance Manual, “Engine Starting” topic

(Operation Section).

Safety Section

General Hazard Information

Attach a “Do Not Operate” warning tag or a similar

• Do not wear loose clothing or jewelry that can

warning tag to the start switch or to the controls

snag on controls or on other parts of the engine.

before the engine is serviced or before the engine

is repaired. These warning tags (Special Instruction,

• Ensure that all protective guards and all covers

SEHS7332) are available from your Caterpillar

are secured in place on the engine.

dealer. Attach the warning tags to the engine

and to each operator control station. When it is

• Never put maintenance fluids into glass

appropriate, disconnect the starting controls.

containers. Glass containers can break.

Do not allow unauthorized personnel on the engine,

• Use all cleaning solutions with care.

or around the engine when the engine is being

serviced.

• Report all necessary repairs.

Engine exhaust contains products of combustion

Unless other instructions are provided, perform

which may be harmful to your health. Always

the maintenance under the following conditions:

start the engine and operate the engine in a well

ventilated area. If the engine is in an enclosed area,

• The engine is stopped. Ensure that the engine

vent the engine exhaust to the outside.

cannot be started.

Cautiously remove the following parts. To help

• Disconnect the batteries when maintenance

prevent spraying or splashing of pressurized fluids,

is performed or when the electrical system is

hold a rag over the part that is being removed.

serviced. Disconnect the battery ground leads.

Tape the leads in order to help prevent sparks.

• Filler caps

•

Do not attempt any repairs that are not

• Grease fittings

understood. Use the proper tools. Replace

any equipment that is damaged or repair the

• Pressure taps

equipment.

• Breathers

California Proposition 65 Warning

• Drain plugs

Some engine exhaust constituents are known to the

State of California to cause cancer, birth defects,

Use caution when cover plates are removed.

and other reproductive harm.

Gradually loosen, but do not remove the last two

bolts or nuts that are located at opposite ends of

Pressure Air and Water

the cover plate or the device. Before removing the

last two bolts or nuts, pry the cover loose in order

Pressurized air and/or water can cause debris

to relieve any spring pressure or other pressure.

and/or hot water to be blown out. This could result

in personal injury.

When pressure air and/or pressure water is used

for cleaning, wear protective clothing, protective

shoes, and eye protection. Eye protection includes

goggles or a protective face shield.

The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi). The maximum

water pressure for cleaning purposes must be

below 275 kPa (40 psi).

g00702020

Illustration 5

• Wear a hard hat, protective glasses, and other

protective equipment, as required.

• When work is performed around an engine that

is operating, wear protective devices for ears in

order to help prevent damage to hearing.

Safety Section

General Hazard Information

Fluid Penetration

Asbestos Information

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g00702022

Illustration 6

Illustration 7

Always use a board or cardboard when you check

Caterpillar equipment and replacement parts that

for a leak. Leaking fluid that is under pressure can

are shipped from Caterpillar are asbestos free.

penetrate body tissue. Fluid penetration can cause

Caterpillar recommends the use of only genuine

serious injury and possible death. A pin hole leak

Caterpillar replacement parts. Use the following

can cause severe injury. If fluid is injected into your

guidelines when you handle any replacement parts

skin, you must get treatment immediately. Seek

that contain asbestos or when you handle asbestos

treatment from a doctor that is familiar with this type

debris.

of injury.

Use caution. Avoid inhaling dust that might be

generated when you handle components that

Containing Fluid Spillage

contain asbestos fibers. Inhaling this dust can

be hazardous to your health. The components

Care must be taken in order to ensure that fluids

that may contain asbestos fibers are brake pads,

are contained during performance of inspection,

brake bands, lining material, clutch plates, and

maintenance, testing, adjusting and repair of the

some gaskets. The asbestos that is used in these

engine. Prepare to collect the fluid with suitable

components is usually bound in a resin or sealed in

containers before opening any compartment or

some way. Normal handling is not hazardous unless

disassembling any component containing fluids.

airborne dust that contains asbestos is generated.

Refer to Special Publication, NENG2500, “Tools and

If dust that may contain asbestos is present, there

Shop Products Guide” for the following items:

are several guidelines that should be followed:

• Tools that are suitable for collecting fluids and

• Never use compressed air for cleaning.

equipment that is suitable for collecting fluids

• Avoid brushing materials that contain asbestos.

• Tools that are suitable for containing fluids and

equipment that is suitable for containing fluids

• Avoid grinding materials that contain asbestos.

Obey all local regulations for the disposal of liquids.

• 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.

Safety Section

Burn Prevention

• Comply with applicable rules and regulations

Any contact with hot coolant or with steam

for the work place. In the United States, use

can cause severe burns. Allow cooling system

Occupational Safety and Health Administration

components to cool before the cooling system is

(OSHA) requirements. These OSHA requirements

drained.

can be found in “29 CFR 1910.1001”.

Check the coolant level only after the engine has

• Obey environmental regulations for the disposal

been stopped.

of asbestos.

Ensure that the filler cap is cool before removing

• Stay away from areas that might have asbestos

the filler cap. The filler cap must be cool enough

particles in the air.

to touch with a bare hand. Remove the filler cap

slowly in order to relieve pressure.

Dispose of Waste Properly

Cooling system conditioner contains alkali. Alkali

can cause personal injury. Do not allow alkali to

contact the skin, the eyes, or the mouth.

Oils

Hot oil and hot components can cause personal

injury. Do not allow hot oil to contact the skin. Also,

do not allow hot components to contact the skin.

Batteries

Electrolyte is an acid. Electrolyte can cause

personal injury. Do not allow electrolyte to contact

g00706404

the skin or the eyes. Always wear protective glasses

Illustration 8

for servicing batteries. Wash hands after touching

the batteries and connectors. Use of gloves is

Improperly disposing of waste can threaten the

recommended.

environment. Potentially harmful fluids should be

disposed of according to local regulations.

i01359892

Always use leakproof containers when you drain

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

Fire Prevention and Explosion

drain, or into any source of water.

Prevention

SMCS Code: 1000; 7405

i01329129

Burn Prevention

SMCS Code: 1000; 7405

Do not touch any part of an operating engine.

Allow the engine to cool before any maintenance

is performed on the engine. Relieve all pressure

in the air system, in the hydraulic system, in the

lubrication system, in the fuel system, or in the

cooling system before any lines, fittings or related

items are disconnected.

Coolant

g00704000

Illustration 9

When the engine is at operating temperature, the

engine coolant is hot. The coolant is also under

All fuels, most lubricants, and some coolant mixtures

pressure. The radiator and all lines to the heaters or

are flammable.

to the engine contain hot coolant.

Safety Section

Fire Prevention and Explosion Prevention

Flammable fluids that are leaking or spilled onto hot

Inspect all lines and hoses for wear or for

surfaces or onto electrical components can cause

deterioration. The hoses must be properly routed.

a fire. Fire may cause personal injury and property

The lines and hoses must have adequate support

damage.

and secure clamps. Tighten all connections to the

recommended torque. Leaks can cause fires.

A flash fire may result if the covers for the engine

crankcase are removed within fifteen minutes after

Oil filters and fuel filters must be properly installed.

an emergency shutdown.

The filter housings must be tightened to the proper

torque.

Determine whether the engine will be operated in

an environment that allows combustible gases to be

drawn into the air inlet system. These gases could

cause the engine to overspeed. Personal injury ,

property damage, or engine damage could result.

If the application involves the presence of

combustible gases, consult your Caterpillar dealer

for additional information about suitable protection

devices.

Remove all flammable materials such as fuel, oil,

and debris from the engine. Do not allow any

flammable materials to accumulate on the engine.

Store fuels and lubricants in properly marked

containers away from unauthorized persons. Store

oily rags and any flammable materials in protective

containers. Do not smoke in areas that are used for

storing flammable materials.

Do not expose the engine to any flame.

g00704059

Illustration 10

Exhaust shields (if equipped) protect hot exhaust

Use caution when you are refueling an engine. Do

components from oil or fuel spray in case of a line,

not smoke while you are refueling an engine. Do

a tube, or a seal failure. Exhaust shields must be

not refuel an engine near open flames or sparks.

installed correctly.

Always stop the engine before refueling.

Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines or tanks that contain

flammable fluid. Clean any such lines or tanks

thoroughly with a nonflammable solvent prior to

welding or flame cutting.

Wiring must be kept in good condition. All electrical

wires must be properly routed and securely

attached. Check all electrical wires daily. Repair any

wires that are loose or frayed before you operate

the engine. Clean all electrical connections and

tighten all electrical connections.

Eliminate all wiring that is unattached or

unnecessary. Do not use any wires or cables that

are smaller than the recommended gauge. Do not

bypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and properly

maintained battery cables will help to prevent arcing

g00704135

or sparking.

Illustration 11

Safety Section

Crushing Prevention and Cutting Prevention

Gases from a battery can explode. Keep any open

Unless other maintenance instructions are provided,

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

never attempt adjustments while the engine is

not smoke in battery charging areas.

running.

Never check the battery charge by placing a metal

Stay clear of all rotating parts and of all moving

object across the terminal posts. Use a voltmeter or

parts. Leave the guards in place until maintenance

a hydrometer.

is performed. After the maintenance is performed,

reinstall the guards.

Improper jumper cable connections can cause

an explosion that can result in injury. Refer to

Keep objects away from moving fan blades. The

the Operation Section of this manual for specific

fan blades will throw objects or cut objects.

instructions.

When objects are struck, wear protective glasses in

Do not charge a frozen battery. This may cause

order to avoid injury to the eyes.

an explosion.

Chips or other debris may fly off objects when

The batteries must be kept clean. The covers (if

objects are struck. Before objects are struck, ensure

equipped) must be kept on the cells. Use the

that no one will be injured by flying debris.

recommended cables, connections, and battery

box covers when the engine is operated.

i01359622

Fire Extinguisher

Mounting and Dismounting

Make sure that a fire extinguisher is available. Be

SMCS Code: 1000; 7405

familiar with the operation of the fire extinguisher.

Inspect the fire extinguisher and service the fire

Inspect the steps, the handholds, and the work

extinguisher regularly. Obey the recommendations

area before mounting the engine. Keep these items

on the instruction plate.

clean and keep these items in good repair.

Mount the engine and dismount the engine only at

Ether

locations that have steps and/or handholds. Do not

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

Ether is flammable and poisonous.

Face the engine in order to mount the engine or

Use ether in well ventilated areas. Do not smoke

dismount the engine. Maintain a three-point contact

while you are replacing an ether cylinder or while

with the steps and handholds. Use two feet and one

you are using an ether spray.

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

any controls as handholds.

Do not store ether cylinders in living areas or in the

engine compartment. Do not store ether cylinders

Do not stand on components which cannot support

in direct sunlight or in temperatures above 49 C

your weight. Use an adequate ladder or use a work

(120

F). Keep ether cylinders away from open

platform. Secure the climbing equipment so that the

flames or sparks.

equipment will not move.

Dispose of used ether cylinders properly. Do not

Do not carry tools or supplies when you mount the

puncture an ether cylinder. Keep ether cylinders

machine or when you dismount the machine. Use a

away from unauthorized personnel.

hand line to raise and lower tools or supplies.

Do not spray ether into an engine if the engine

is equipped with a thermal starting aid for cold

i01072501

weather starting.

Before Starting Engine

i01359666

SMCS Code: 1000

Crushing Prevention and

Inspect the engine for potential hazards.

Cutting Prevention

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

SMCS Code: 1000; 7405

underneath, or close to the engine. Ensure that the

area is free of personnel.

Support the component properly when work

beneath the component is performed.

Safety Section

Engine Starting

Ensure that the engine is equipped with a lighting

Engine exhaust contains products of combustion

system that is suitable for the conditions. Ensure

that can be harmful to your health. Always start the

that all lights work properly.

engine and operate the engine in a well ventilated

area. If the engine is started in an enclosed area,

All protective guards and all protective covers must

vent the engine exhaust to the outside.

be installed if the engine must be started in order

to perform service procedures. To help prevent an

Ether

accident that is caused by parts in rotation, work

around the parts carefully.

Ether is poisonous and flammable.

Do not bypass the automatic shutoff circuits. Do not

Do not inhale ether, and do not allow ether to

disable the automatic shutoff circuits. The circuits

contact the skin. Personal injury could result.

are provided in order to help prevent personal

injury. The circuits are also provided in order to help

Do not smoke while ether cylinders are changed.

prevent engine damage.

Use ether in well ventilated areas.

For the initial start-up of a new engine and for

start-up of an engine that has been serviced,

Use ether with care in order to avoid fires.

prepare to stop the engine if an overspeed occurs.

This may be accomplished by shutting off the fuel

Keep ether cylinders out of the reach of

and the air supply to the engine.

unauthorized persons.

See the Service Manual for repairs and for

Store ether cylinders in authorized storage areas

adjustments.

only.

i01103904

Do not store ether cylinders in direct sunlight or at

temperatures above 49 C (120 F).

Engine Starting

Discard the ether cylinders in a safe place. Do not

SMCS Code: 1000

puncture the ether cylinders. Do not burn the ether

cylinders.

If a warning tag is attached to the engine start

switch or to the controls, DO NOT start the engine

i00062369

or move the controls. Consult with the person that

attached the warning tag before the engine is

Engine Stopping

started.

SMCS Code: 1000

All protective guards and all protective covers must

be installed if the engine must be started in order

Stop the engine according to the procedure in the

to perform service procedures. To help prevent an

Operation and Maintenance Manual in order to

accident that is caused by parts in rotation, work

avoid overheating of the engine and accelerated

around the parts carefully.

wear of the engine components.

Start the engine from the operator’s compartment or

Use the Emergency Stop Button (if equipped)

from the engine start switch.

ONLY in an emergency situation. Do not use the

Emergency Stop Button for normal engine stopping.

Always start the engine according to the procedure

After an emergency stop, DO NOT start the engine

that is described in this Operation and Maintenance

until the problem that caused the emergency stop

Manual, “Engine Starting” topic (Operation Section).

has been corrected.

Knowing the correct procedure will help to prevent

major damage to the engine components. Knowing

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

the procedure will also help to prevent personal

that has been overhauled, be prepared to stop the

injury.

engine if an overspeed condition occurs. This may

be accomplished by shutting off the fuel supply to

To ensure that the jacket water heater (if equipped)

the engine and/or shutting off the air supply to the

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

engine.

properly, check the water temperature gauge

and the oil temperature gauge during the heater

To stop an electronically controlled engine, cut the

operation.

power to the engine.

Product Information Section

Model Views

g00722253

Illustration 12

(1) Lifting eye

(7) Fuel filter

(13) Service hour meter

(2) Crankcase breather

(8) Air inlet

(14) Turbocharger

(3) Exhaust

(9) Fuel pump

(15) Oil drain plugs

(4) Fuel priming pump

(10) SCA element (if equipped)

(16) Oil filler cap

(5) Fuel pressure gauge

(11) Oil level gauge

(17) Crankshaft vibration damper

(6) Either starting aid (if equipped)

(12) Flywheel housing

(18) Oil filter

i01369284

A mechanical governor controls the fuel injection

pump output. The output maintains the desired

Engine Description

engine speed. An automatic timing advance

provides the best fuel injection timing over the full

SMCS Code: 1000

range of engine speeds.

Engine Information

The fuel ratio control is located on the governor. The

fuel ratio control restricts the fuel rack movement.

The 3406C Industrial Engine is designed

Only the proper amount of fuel is allowed to be

primarily for agricultural, petroleum, and auxiliary

injected into the cylinders during acceleration. This

applications.

minimizes exhaust smoke.

Product Information Section

Model Views

Inlet air is filtered by an air cleaner. The air is

• Fuel

compressed by a turbocharger before the air enters

the engine cylinders. The turbocharger is driven by

• Fuel filter

engine exhaust. The engines can be turbocharged.

The engines can also be turbocharged with jacket

Engine Specifications

water aftercooling.

Note: The front end of the engine is opposite the

The engine is a four cycle engine. Each cylinder

flywheel end of the engine. The left and the right

head has two inlet valves and two exhaust valves.

sides of the engine are determined from the flywheel

The rocker arms and the valves are actuated by the

end. The number 1 cylinder is the front cylinder.

camshaft. The action is performed by mechanical

lifters and push rods.

Engine Cooling and Lubrication

The cooling system consists of the following

components:

• Centrifugal pump that is driven by gears

• Thermostats which regulate the engine coolant

temperature

• Oil cooler

g00284836

• A radiator or expansion tank (incorporating a

Illustration 13

shunt system)

Cylinder and valve locations

(A) Inlet valves

The engine lubricating oil, that is supplied by a gear

(B) Exhaust valves

type pump, is cooled. The engine lubricating oil is

also filtered. Bypass valves provide unrestricted

Table 1

flow of lubrication oil to the engine components

3406C Industrial Engine Specifications

during the following conditions:

Cylinders and

6 cylinder in-line block

Arrangement

• High oil viscosity

Bore

137 mm (5.4 inch)

• Plugged oil cooler or plugged oil filter elements

Stroke

165 mm (6.5 inch)

(paper cartridge)

Compression Ratio

16:25:1

Engine efficiency, efficiency of emission

controls, and engine performance depend on

Aspiration

T or TA⁽¹⁾

adherence to proper operation and maintenance

Displacement

14.6 L (893 in³)

recommendations. Engine performance and

efficiency also depend on the following items:

Firing Order

1-5-3-6-2-4

Rotation (flywheel end)

Counterclockwise

• Use of recommended coolant/antifreeze

Valve Lash (inlet)

0.38 mm (.015 inch)

• Use of recommended fuels

Valve Lash (exhaust)

0.76 mm (.030 inch)

⁽¹⁾ Turbocharged or Turbocharged and Aftercooled

• Use of recommended lubrication oils

Refer to the recommended Maintenance Interval

Schedule found within this publication in order to

maintain the following emission related components:

• Air cleaner

• Engine oil

• Oil filter

Product Information Section

Product Identification Information

i00061495

Product Identification

Information Plate

Information

SMCS Code: 1000

i00826199

Engine Identification

SMCS Code: 1000

Caterpillar engines are identified with serial

numbers, with performance specification numbers,

and with arrangement numbers. In some of the

cases, modification numbers are used. These

numbers are shown on the serial number plate that

is mounted on the engine.

The numbers for fuel setting information for

electronic engines are stored within the personality

g00102789

module. These numbers can be read by using

Illustration 15

Caterpillar electronic service tools.

The Information Plate is on the valve cover. The

Caterpillar dealers need these numbers in order to

following information is stamped on the Information

determine the components that were included with

Plate: engine’s maximum altitude, horsepower,

the engine. This permits accurate identification of

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

replacement part numbers.

information.

i01369380

i00610276

Serial Number Plate

Reference Numbers

SMCS Code: 1000

Information for the following items may be needed

to order parts. Locate the information for your

engine. Record the information on the appropriate

space. Make a copy of this list for a record. Retain

the information for future reference.

Record for Reference

Engine Model

______________________________________________

Engine Serial No.

__________________________________________

Engine Arrangement No.

________________________________

g00722314

Illustration 14

Modification No.

___________________________________________

Typical serial number plate

Engine Low Idle rpm

_____________________________________

The Serial Number Plate is located on the left side

of the cylinder block near the rear of the engine.

____________________________________

Engine Full Load rpm

The following information is stamped on the Serial

Performance Specification No.

_________________________

Number Plate: engine serial number, model, and

arrangement number.

Primary Fuel Filter No.

___________________________________

Water Separator Element No.

__________________________

Secondary Fuel Filter Element No. ____________________

Product Information Section

Product Identification Information

Lubrication Oil Filter Element No.

_____________________

Auxiliary Oil Filter Element No.

_________________________

Supplemental Coolant Additive Maintenance

Element No. (Optional)

___________________________________

Total Lubrication System Capacity

____________________

Total Cooling System Capacity

________________________

Air Cleaner Element No.

_________________________________

Fan Drive Belt No.

________________________________________

Alternator Belt No.

________________________________________

i01193826

Emissions Certification Film

SMCS Code: 1000

g00638668

Illustration 16

EPA/EU Emissions Certification Film (typical example)

g00638373

Illustration 17

EPA/EU Emissions Certification Film (French-typical example)

The EPA/EU Emissions Certification Film (if

applicable) is located either on the side, the top, or

the front of the engine.

Operation Section

Engine Lifting and Storage

Engine Lifting with a Fuel Tank

Operation Section

Engine Lifting and Storage

Lift eyes or tank can fail when lifting tank con-

taining fluids resulting in possible personal injury.

Drain tank of all fluids before lifting.

i01028339

Engine Lifting

Lifting the engine with a fuel tank that is mounted

to the engine requires special equipment and

SMCS Code: 1000; 1122

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.

i00777190

Engine Storage

SMCS Code: 1000

If the engine will not be started for several weeks,

the lubricating oil will drain from the cylinder walls

and from the piston rings. Rust can form on the

cylinder liner surface. Rust on the cylinder liner

g00103219

Illustration 18

surface will cause increased engine wear and a

reduction in engine service life.

NOTICE

Never bend the eyebolts and the brackets. Only load

To help prevent excessive engine wear, use the

the eyebolts and the brackets under tension. Remem-

following guidelines:

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

between the supporting members and the object be-

• Complete all of the lubrication recommendations

comes less than 90 degrees.

that are listed in this Operation and Maintenance

Manual, “Maintenance Interval Schedule”

When it is necessary to remove a component at an

(Maintenance Section).

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

the weight.

• If freezing temperatures are expected, check the

cooling system for adequate protection against

freezing. See this Operation and Maintenance

Use a hoist to remove heavy components. Use

Manual, “General Coolant Information”

an adjustable lifting beam to lift the engine. All

(Maintenance Section).

supporting members (chains and cables) should

be parallel to each other. The chains and cables

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

should be perpendicular to the top of the object

engine is not planned, special precautions should

that is being lifted.

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

one month, a complete protection procedure is

Some removals require lifting the fixtures in order to

recommended.

obtain proper balance and safety.

For more detailed information on engine storage,

To remove the engine ONLY, use the lifting eyes that

see Special Instruction, SEHS9031, “Storage

are on the engine.

Procedure For Caterpillar Products”.

Lifting eyes are designed and installed for the

Your Caterpillar dealer can assist in preparing the

specific engine arrangement. Alterations to the lifting

engine for extended storage periods.

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.

Operation Section

Gauges and Indicators

Jacket Water Coolant Temperature -

Typical temperature range is 87 to 98 C

i01369505

(189 to 208 F). The maximum allowable

temperature with the pressurized cooling system is

Gauges and Indicators

104

C (219 F). Higher temperatures may occur

under certain conditions. The water temperature

SMCS Code: 1900; 7450

reading may vary according to load. The reading

should never exceed the boiling point for the

Your engine may not have the same gauges or all of

pressurized system that is being used.

the gauges that are described. For more information

about the gauge package, see the OEM information.

If the engine is operating above the normal range

and steam becomes apparent, perform the following

Gauges provide indications of engine performance.

procedure:

Ensure that the gauges are in good working order.

Determine the normal operating range by observing

1. Reduce the load and the engine speed (rpm).

the gauges over a period of time.

2. Inspect the cooling system for leaks.

Noticeable changes in gauge readings indicate

a potential problem with a gauge or with the

3. Determine if the engine must be shut down

engine. Problems may also be indicated by gauge

immediately or if the engine can be cooled by

readings that change even if the readings are

reducing the load.

within specifications. Determine the cause of any

significant change in the readings, and/or correct

Tachometer - This gauge indicates engine

the cause of any significant change in the readings.

speed (rpm). When the throttle control

Consult your Caterpillar dealer for assistance.

lever is moved to the full throttle position

without load, the engine is running at high idle. The

NOTICE

engine is running at the full load rpm when the

Be ready to activate the engine shutoff manually, if

throttle control lever is at the full throttle position

there is no oil pressure . Damage to the engine will

with maximum rated load.

result if the engine continues to run without the correct

oil pressure.

NOTICE

Engine overspeed may cause serious damage.

Engine Oil Pressure - Typical oil pressure

for an engine at rated speed with

Keep the tachometer indicator in the green operating

SAE 10W30 or with SAE 15W40 is

range.

275 to 606 kPa (40 to 88 psi).

Note: The high idle speed (rpm) and the full load

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

speed (rpm) are stamped on the Information Plate.

is stable and the gauge reading changes, perform

the following procedure:

Ammeter - This gauge indicates the

amount of charge or discharge in the

1. Remove the load.

battery charging circuit. Operation of the

indicator should be to the right side of “0”(zero).

2. Reduce engine speed to low idle.

Service Hour Meter - This gauge indicates

3. Check and maintain the oil level.

the total number of clock hours that the

engine has operated.

The minimum recommended oil pressure at 600

rpm is 103 kPa (15 psi). If low oil pressure or no

oil pressure is indicated, stop the engine and

Fuel Pressure - This gauge indicates

determine the cause of the problem. Refer to

fuel pressure to the injection pump. The

Troubleshooting for further information or consult

indicator should indicate the “NORMAL”

with your Caterpillar dealer.

range. If the indicator moves to the “OUT” position

or registers below 160 kPa (23 psi) when equipped

with a numerical gauge, the engine will not operate

properly. A decrease in fuel pressure usually

indicates a plugged fuel filter.

Operation Section

Engine Features and Controls

Overspeed Shutoffs

Engine Features and

Controls

i01369587

Engine Shutoffs and Engine

Alarms

SMCS Code: 1900; 7400; 7418

Shutoffs

Shutoffs and alarms are electrically operated or

mechanically operated. The operation of all electric

g00293335

Illustration 19

shutoffs and alarms utilize components which

(1) Magnetic pickup

actuate switches in a sensing unit.

(2) Flywheel housing

Shutoffs are set at critical levels for the following

The magnetic pickup senses the passage of

items: operating temperature, operating pressure,

the teeth that are on the flywheel ring gear.

operating coolant level, and operating speed (rpm).

The Electronic Overspeed Switch is set at 118

The particular shutoff may need to be reset before

percent of the rated engine speed. If the engine

the engine will start.

speed increases above the overspeed setting, the

magnetic pickup will sense the overspeed. A signal

NOTICE

is sent to the Electronic Overspeed Switch. The

Always determine the cause of the engine shutdown.

Electronic Overspeed Switch activates both the air

Make necessary repairs before attempting to restart

shutoff solenoid (if equipped) and the fuel shutoff

the engine.

solenoid.

The shutoffs must be reset before the engine will

Be familiar with the following items:

restart. The air shutoff lever that is located at the

top of the air inlet housing must be manually reset.

• Types and locations of shutoff

The cause of the overspeed must be determined

before the engine is restarted.

• Conditions which cause each shutoff to function

• The resetting procedure that is required to restart

Alarms

the engine

Alarms consist of a switch and a contactor. The

switches are wired to the contactors. The contactors

Air Shutoff Solenoid (If Equipped)

activate alarm circuits in an annunciator panel.

Your engine may be equipped with the following

This optional solenoid is located on top of the

switches:

engine. The air shutoff is part of the air inlet

system. When the solenoid is activated, the

Engine oil pressure - The engine oil pressure switch

solenoid mechanically shuts off the inlet air to the

indicates when oil pressure drops below rated

engine. The solenoid can be activated only by the

system pressure.

overspeed switch or by the emergency stop push

button (ESPB). The cause of the shutoff should be

Coolant level - The low coolant level switch

determined before the engine is restarted.

indicates when the coolant level is low.

Fuel Shutoff Solenoid

Coolant temperature - The coolant temperature

switch indicates high jacket water coolant

The fuel shutoff solenoid is located on the governor

temperature.

or the fuel shutoff solenoid is located on the fuel

injection pump. When the fuel shutoff solenoid is

Note: The sensing element of the coolant

activated, the solenoid moves the fuel rack “OFF”.

temperature switch must be submerged in coolant

The fuel shutoff solenoid moves the fuel rack

in order to operate.

directly or the fuel shutoff solenoid moves the fuel

rack through the governor.

Operation Section

Engine Features and Controls

Engines may be equipped with alarms in order

The overspeed shutoff switch is located in the

to alert the operator when undesirable operating

junction box. The overspeed shutoff switch must be

conditions occur.

reset before you can restart the engine. To reset

the switch, push the “RESET” button. The button

will remain in this position unless an overspeed

NOTICE

condition occurs.

When an alarm is activated, corrective measures must

be taken before the situation becomes an emergency

in order to avoid possible engine damage.

The Electronic Overspeed Switch with Cranking

Termination has a 75 percent “VERIFY” button, a

“RESET” button, and an “OVERSPEED” indicator

If corrective measures are not taken within a

lamp.

reasonable time, engine damage could result. The

alarm will continue until the condition is corrected.

The Electronic Overspeed Shutoff Switch with

The alarm may need to be reset.

Cranking Termination has a sensing circuit which

prevents the starter pinion from remaining engaged

A switch may be installed in the alarm while the

in the flywheel at excessive rpm. Crank Termination

engine is stopped for repairs. Before the engine is

has an adjustable engine speed setting. This

started, ensure that the switch is moved to the ON

signals the starter motor when the engine is firing.

position and that the warning lights are flashing.

Cranking must be terminated. Once the speed

The engine will not be protected if the switch is left

setting is reached, a switch opens. This will start the

in the OFF position.

engine hour meter.

Once the starting motor cranks the engine, the

Testing the Shutoff and Alarm

pinion gear can remain engaged with the flywheel

System

as the engine speed increases. The magnetic

pickup opens the circuit to the starting motor at 400

Most control panels are equipped with a lamp test

rpm. This will allow the pinion gear to disengage.

switch. Turn the switch to the ON position in order

to check the indicator lights for proper operation.

The circuit will remain open until the flywheel stops.

Replace worn bulbs immediately.

This prevents energizing the starting motor circuit

again while the flywheel is turning.

NOTICE

During testing, abnormal operating conditions must be

The engine may be equipped with either an

simulated. Perform the tests correctly in order to help

Overspeed Shutoff Switch or an Electronic

prevent possible engine damage.

Overspeed Switch with Cranking Termination. Both

switches can be checked for proper operation at 75

percent of overspeed condition. Use the following

Refer to the Service Manual for more information on

procedure:

testing procedures or consult your Caterpillar dealer.

1. Determine full load speed (rpm) from the Engine

Testing of the Overspeed Switch

Information Plate.

2. Operate the engine at or slightly above the

corresponding speed (rpm) shown for the

engine. Refer to table 2.

3. Maintain the test speed (rpm). Push and hold the

“VERIFY” button. The engine should stop. If the

engine does not stop at the specified test speed

(rpm), contact your Caterpillar dealer.

g00291056

Illustration 20

Electronic Overspeed Switch

Operation Section

Engine Starting

• Do not start the engine or move any of the

Engine Starting

controls if there is a “DO NOT OPERATE” warning

tag or similar warning tag attached to the start

i01197471

switch or 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

damaged guards or for missing guards. Repair

other periodic maintenance before the engine is

any damaged guards. Replace damaged guards

started. Inspect the engine compartment. This

and/or missing guards.

inspection can help prevent major repairs at a

later date. Refer to the Operation and Maintenance

• Disconnect any battery chargers that are not

Manual, “Maintenance Interval Schedule” for more

protected against the high current drain that

information.

is created when the electric starting motor (if

equipped) is engaged. Check electrical cables

• For the maximum service life of the engine,

and check the battery for poor connections and

make a thorough inspection before the engine

for corrosion.

is started. Look for the following items: oil leaks,

coolant leaks, loose bolts, and trash buildup.

• Reset all of the shutoffs or alarm components.

Remove trash buildup and arrange for repairs,

as needed.

• Check the engine lubrication oil level. Maintain

the oil level between the “ADD” mark and the

• Inspect the cooling system hoses for cracks and

“FULL” mark on the oil level gauge.

for loose clamps.

•

Check the coolant level. Observe the coolant

• Inspect the alternator and accessory drive belts

level in the coolant recovery tank (if equipped).

for cracks, breaks, and other damage.

Maintain 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.

separator (if equipped). Open the fuel supply

If the engine is equipped with a sight glass,

valve.

maintain the coolant level in the sight glass.

NOTICE

• Observe the air cleaner service indicator (if

All valves in the fuel return line must be open before

equipped). Service the air cleaner when the

and during engine operation to help prevent high fuel

yellow diaphragm enters the red zone, or when

pressure. High fuel pressure may cause filter housing

the red piston locks in the visible position.

failure or other damage.

• Ensure that any driven equipment has been

disengaged. Remove any electrical loads.

If the engine has not been started for several

weeks, fuel may have drained from the fuel system.

Air may have entered the filter housing. Also, when

fuel filters have been changed, some air pockets

will be trapped in the engine. In these instances,

prime the fuel system. Refer to the Operation and

Maintenance Manual, “Fuel System - Prime” for

more information on priming the fuel system.

Engine exhaust contains products of combustion

which may be harmful to your health. Always start

and operate the engine in a well ventilated area

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

outside.

Operation Section

Engine Starting

i00970006

Starting the Engine

When using starting fluid (ether), follow the man-

ufacturer’s instructions carefully. Use the starting

SMCS Code: 1000; 1450

fluid sparingly and spray only while cranking the

Refer to the Service Manual for your type of controls.

engine. Failure to do so could result in an explo-

sion and/or fire and personal injury.

Use the following procedure to start the engine.

1. Place the manual stop control (if equipped) in

NOTICE

the RUN position. Turn the ignition switch to the

The optional ether starting aid is the only starting fluid

RUN position. Advance the throttle in order to

system that is recommended on the engine.

supply fuel to the engine.

2. Turn the ignition switch to the START position in

Startability will be improved at temperatures below

order to crank the engine.

-18

C (0 F) from the use of a jacket water heater

or extra battery capacity.

Allow the ignition switch to return to the RUN

position as soon as the engine starts.

When No. 2 diesel fuel is used, the following items

provide a means of minimizing starting problems

and fuel problems in cold weather: starting aids,

NOTICE

engine oil pan heaters, jacket water heaters, fuel

Oil pressure should rise within 15 seconds after the

heaters, and fuel line insulation.

engine starts. Do not increase engine speed until the

oil pressure gauge indicates normal. If oil pressure

For temperatures below -23 C (-10 F), consult

is not indicated on the gauge within 15 seconds, DO

your Caterpillar dealer.

NOT operate the engine. STOP the engine, investigate

and correct the cause.

Use the procedure that follows for cold weather

starting.

3. Move the throttle to approximately one quarter

of the engine rpm.

Note: If the engine has not been run for several

weeks, fuel may have drained. Air may have moved

4. Allow the engine to idle for three to five minutes,

into the filter housing. Also, when fuel filters have

or allow the engine to idle until the water

been changed, some air will be left in the filter

temperature indicator begins to rise. The engine

housing. Refer to the Operation and Maintenance

should run at low idle smoothly until speed

Manual for more information on priming the fuel

is gradually increased to high idle. Allow the

system.

white smoke to disperse before proceeding with

normal operation.

NOTICE

Do not engage the starting motor when flywheel is

To minimize white smoke for cold weather

turning. Do not start the engine under load.

starting, start the engine and allow the engine

to idle for 30 seconds. Increase the rpm until

If the engine fails to start within 30 seconds, release

the engine speed reaches 1200 rpm. Return the

the starter switch or button and wait two minutes to

engine to low idle rpm.

allow the starting motor to cool before attempting to

5. Operate the engine at low load until all systems

start the engine again.

reach operating temperature. Check the gauges

during the warm-up period.

1. Turn the ignition switch to the RUN position.

Advance the throttle in order to supply fuel to

the engine.

i00998863

Cold Weather Starting

NOTICE

Excessive ether can cause piston and piston ring dam-

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

age. Use ether for cold starting purposes only. Do not

use excessive starting fluid while starting the engine.

Refer to the Operation and Maintenance Manual

Do not use starting fluid after the engine is running.

that is for the control panels for detailed information

on the control panels.

Operation Section

Engine Starting

2. If equipped, press the “Starting Aid” switch in

Many batteries which are considered unusable are

order to improve cold weather starting. Release

still rechargeable. After jump starting, the alternator

the “Starting Aid” switch when the engine starts.

may not be able to fully recharge batteries that

Use the starting fluid sparingly. Carefully follow

are severely discharged. The batteries must be

the instructions of the OEM.

charged to the proper voltage with a battery

charger. For information on testing and charging,

refer to the Special Instruction, SEHS7633, “Battery

NOTICE

Oil pressure should rise within 15 seconds after the

Test Procedure”.

engine starts. Do not increase engine speed until the

oil pressure gauge indicates normal. If oil pressure

NOTICE

is not indicated on the gauge within 15 seconds, DO

Using a battery source with the same voltage as the

NOT operate the engine. STOP the engine, investigate

electric starting motor. Use ONLY equal voltage for

and correct the cause.

jump starting. The use of higher voltage will damage

the electrical system.

3. Increase the engine rpm to approximately 1/4 of

Do not reverse the battery cables. The alternator can

the full load rpm.

be damaged. Attach ground cable last and remove

first.

4. Allow the engine to idle for three to five minutes,

or allow the engine to idle until the water

When using an external electrical source to start the

temperature indicator begins to rise. The engine

engine, turn the engine control switch to the “OFF” po-

should run at low idle smoothly until speed

sition. Turn all electrical accessories OFF before at-

is gradually increased to high idle. Allow the

taching the jump start cables.

white smoke to disperse before proceeding with

normal operation.

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

tion before attaching the jump start cables to the en-

5. Operate the engine at low load until all systems

gine being started.

reach operating temperature. Check the gauges

during the warm-up period.

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

OFF position. Turn off all accessories.

i01037941

Starting with Jump Start

2. Connect one positive end of the jump start cable

to the positive cable terminal of the discharged

Cables

battery. Connect the other positive end of the

jump start cable to the positive cable terminal

SMCS Code: 1000; 1401; 1402; 1900

of the electrical source.

3. Connect one negative end of the jump start cable

to the negative cable terminal of the electrical

source. Connect the other negative end of the

Improper jump start cable connections can cause

jump start cable to the engine block or to the

an explosion resulting in personal injury.

chassis ground. This procedure helps to prevent

potential sparks from igniting combustible gases

Prevent sparks near the batteries. Sparks could

that are produced by some batteries.

cause vapors to explode. Do not allow jump start

cable ends to contact each other or the engine.

4. Charge the batteries. The engine will not

continue to run after starting if the batteries have

If the installation is not equipped with a backup

not been charged.

battery system, it may be necessary to start the

engine from an external electrical source.

5. Start the engine.

First, determine the reason that it is necessary to

6. Immediately after the stalled engine is started,

start with power from an external source. Refer to

disconnect the jump start cables in reverse order.

Special Instruction, SEHS7768, “Use of the 6V-2150

Starting/Charging Analyzer”.

Refer to the Electrical Schematic for your engine.

Consult your Caterpillar dealer for more information.

Operation Section

Engine Starting

i01043333

i00830307

After Starting Engine

Air Starting

SMCS Code: 1000

SMCS Code: 1451

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

For good life of the air starting motor, the air supply

the warm-up time is approximately five minutes. In

must be free from dirt and water.

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

time may be required.

1. Open the drain valve and close the drain valve

in order to drain condensation and oil carryover.

Note: Ensure that the self-test for the monitoring

This drain valve is located on the bottom of the

system (if equipped) is completed before operating

air tank.

the engine under load.

2. Check the air supply pressure. The air starting

When the engine idles during warm-up, observe

motor requires a minimum of 690 kPa (100 psi)

the following conditions:

air pressure to operate properly. The maximum

air pressure must not exceed 1550 kPa (225 psi).

• Check for any fluid or for any air leaks at idle rpm

The normal operating air pressure will be

and at one-half full rpm (no load on the engine)

758 to 965 kPa (110 to 140 psi).

before operating the engine under load.

• Operate the engine at low idle until all systems

achieve operating temperatures. Check all

gauges during the warm-up period.

Note: Gauge readings should be observed and the

data should be recorded frequently while the engine

is operating. Comparing the data over time will

help to determine normal readings for each gauge.

Comparing data over time will also help detect

abnormal operating developments. Significant

changes in the readings should be investigated.

g00381232

Illustration 21

(1) Air valve

(2) Lubricator bowl

(3) Adjustment knob

3. Check the oil level in lubricator bowl (2). Keep

the bowl at least half full and add lubricant, if

necessary.

4. Press air valve (1) or press the start button for

the engine in order to crank the engine. After

the engine starts, release the air valve or release

the start button.

Operation Section

Engine Operation

i00808595

Engine Operation

Engine Warm-up

i00718869

SMCS Code: 1000

Engine Operation

1. Run the engine at low idle for three to five

SMCS Code: 1000

minutes, or run the engine at low idle until the

jacket water temperature starts to rise.

Proper operation and maintenance are key factors

in obtaining the maximum life and economy of

More time may be necessary when the

the engine. If the directions in the Operation and

temperature is below -18 C (0 F).

Maintenance Manual are followed, costs can

be minimized and engine service life can be

2. Check all of the gauges during the warm-up

maximized.

period.

The time that is needed for the engine to reach

3. Perform another walk-around inspection. Check

normal operating temperature can be less than the

the engine for fluid leaks and air leaks.

time needed for a walk-around inspection of the

engine.

4. Increase the rpm to the rated rpm. Check for fluid

leaks and air leaks. The engine may be operated

After the engine is started and after the engine

at full rated rpm and at full load when the engine

reaches normal operating temperature, the engine

oil temperature reaches 60 C (140 F).

can be operated at the rated rpm. The engine will

reach normal operating temperature faster when

the engine is at rated speed. The engine will reach

normal operating temperature faster when the

engine is at low power demand. This procedure is

more effective than idling the engine at no load.

The engine should reach operating temperature in

a few minutes.

Gauge readings should be observed and the data

should be recorded frequently while the engine is

operating. Comparing the data over time will help

to determine normal readings for each gauge.

Comparing data over time will also help detect

abnormal operating developments. Significant

changes in the readings should be investigated.

Operation Section

Engine Operation

i00162260

Fuel expands when the fuel is warmed up. The fuel

may overflow from the fuel tank. Inspect fuel lines

Engaging the Driven

for leaks. Repair the fuel lines, as needed.

Equipment

Be aware of the properties of the different fuels.

•

Use only the recommended fuels.

SMCS Code: 1000

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

• Avoid unnecessary idling.

Shut off the engine rather than idle for long periods

Engage the driven equipment without a load on

of time.

the equipment.

Interrupted starts put excessive stress on the

• Observe the service indicator frequently. Keep

the air cleaner elements clean.

drive train. Interrupted starts also waste fuel. To

get the driven equipment in motion, engage the

clutch smoothly with no load on the equipment.

• Ensure that the turbochargers are operating

correctly so that the proper air/fuel ratio is

This method should produce a start that is

smooth and easy. The engine rpm should not

maintained. Clean exhaust indicates proper

functioning.

increase and the clutch should not slip.

Ensure that the engine gauges register in the

• Maintain a good electrical system.

normal ranges when the engine is operating

One defective battery cell will overwork the

at one-half of the rated rpm. Ensure that any

alternator. This will consume excess power and

gauges for the equipment register in the normal

excess fuel.

ranges.

Increase the engine rpm to the rated rpm. Always

• Ensure that the belts are properly adjusted. The

belts should be in good condition.

increase the engine rpm to the rated rpm before

the load is applied.

Ensure that all of the connections of the hoses

•

are tight. The connections should not leak.

Apply the load. Begin operating the engine at

low load. Check the gauges and equipment for

proper operation. After normal oil pressure is

• Ensure that the driven equipment is in good

working order.

reached and the temperature gauge begins to

move, the engine may be operated at full load.

Cold engines consume excess fuel. Utilize heat

•

from the jacket water system and the exhaust

Extended operation at low idle or at reduced

system, when possible. Keep cooling system

load may cause increased oil consumption and

components clean and keep cooling system

carbon buildup in the cylinders. This carbon

components in good repair. Never operate the

buildup results in a loss of power and/or poor

performance. When the engine is operated at

engine without water temperature regulators.

reduced load, the engine should be fully loaded

All of these items will help maintain operating

temperatures.

in four hour increments. This procedure burns

excess carbon from the cylinders. Check the

gauges and equipment frequently when the

• Settings for the fuel system and the limits for the

operating altitude are stamped on the Engine

engine is operated under load.

Information Plate. If an engine is moved to a

higher altitude, the settings must be changed

i00165110

by a Caterpillar dealer. Changing the settings

will help prevent damage to the turbocharger.

Fuel Conservation Practices

Changing the settings will help to provide the

maximum efficiency for the engine. Engines can

SMCS Code: 1000; 1250

be operated safely at higher altitudes, but the

engines will deliver less horsepower. The fuel

The efficiency of the engine can affect the fuel

settings should be changed by a Caterpillar

economy. Caterpillar’s design and technology in

dealer in order to obtain the rated horsepower.

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.

Operation Section

Engine Stopping

i01057253

Emergency Stopping

SMCS Code: 1000; 7418

NOTICE

Emergency shutoff controls are for EMERGENCY use

ONLY. DO NOT use emergency shutoff devices or

controls for normal stopping procedure.

g00723091

Ensure that any components for the external system

Illustration 23

that support the engine operation are secured after

Typical Woodward actuator control lever

the engine is stopped.

If the engine is equipped with a Woodward Actuator,

move the control lever to the “FUEL OFF” position.

Emergency Stop Button

g00723092

g00104303

Illustration 24

Illustration 22

Typical mechanical governor control

Typical emergency stop button

If the engine is equipped with a Mechanical

The emergency stop button is in the OUT position

governor control, move the control lever to the FUEL

for normal engine operation. Push the emergency

OFF position.

stop button. The engine will not start when the

button is locked. Turn the button clockwise in order

Hold the lever at the FUEL OFF position until the

to reset.

engine stops.

i01370486

Some engines are equipped with an air shutoff. The

air shutoff is located between the aftercooler and

Manual Stop Procedure

the turbocharger. If the engine is equipped with an

air shutoff lever, move the lever to the OFF position.

SMCS Code: 1000

Note: Individual applications will have different

A manual shutoff shaft will override the governor

control systems. Ensure that the shutoff procedures

control. The shaft will move the fuel control linkage

are understood. Use the following general

to the FUEL OFF position. Refer to the MODEL

guidelines in order to stop the engine.

VIEWS for the engine location of the shaft. The

engine may be stopped by using the shaft and

1. Reduce the engine speed (rpm) to low idle.

either the Woodward Actuator (if equipped) or the

Remove the load.

Mechanical Governor (if equipped).

Operation Section

Engine Stopping

2. Increase the engine speed (rpm) to no more

than one-half of the rated speed (rpm). Perform

this procedure for three to five minutes in order

to cool the engine. Reduce the engine speed

(rpm) to low idle.

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

to the OFF position.

i01197515

After Stopping Engine

SMCS Code: 1000

• Check the crankcase oil level. Maintain the oil

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

mark on the oil level gauge.

• If necessary, perform minor adjustments. Repair

any leaks and tighten any loose bolts.

• Note the service hour meter reading. Perform

the maintenance that is in the Operation and

Maintenance Manual, “Maintenance Interval

Schedule”.

• Fill the fuel tank in order to help prevent

accumulation of moisture in the fuel. Do not

overfill the fuel tank.

NOTICE

Only use antifreeze/coolant mixtures recommended in

the Coolant Specifications that are in the Operation

and Maintenance Manual. Failure to do so can cause

engine damage.

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

Maintain the cooling system at 13 mm (0.5 inch)

from the bottom of the pipe for filling.

• If freezing temperatures are expected, check

the coolant for proper antifreeze protection. The

cooling system must be protected against freezing

to the lowest expected outside temperature. Add

the proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in

the instructions from the OEM.

Operation Section

Cold Weather Operation

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

Cold Weather Operation

1 diesel fuels are usually available during the

months of the winter in the colder climates. During

i00169595

cold weather operation, if No. 1 diesel fuel is not

available, use No. 2 diesel fuel, if necessary.

Radiator Restrictions

There are three major differences between No. 1

SMCS Code: 1353; 1396

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

following properties:

Caterpillar discourages the use of airflow restriction

devices that are mounted in front of radiators. Airflow

• Lower cloud point

restriction can cause the following conditions:

• Lower pour point

• High exhaust temperatures

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

• Power loss

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

• Excessive fan usage

power and in fuel efficiency may be noticed. Other

operating effects should not be experienced.

• Reduction in fuel economy

The cloud point is the temperature when a cloud

If an airflow restriction device must be used, the

of wax crystals begins to form in the fuel. These

device should have a permanent opening directly

crystals can cause the fuel filters to plug. The

in line with the fan hub. The device must have a

pour point is the temperature when diesel fuel will

minimum opening dimension of at least 770 cm²

thicken. The diesel fuel becomes more resistant to

(120 in²).

flow through fuel pumps and through fuel lines.

A centered opening that is directly in line with

Be aware of these values when diesel fuel is

the fan hub is specified in order to prevent an

purchased. Anticipate the average ambient

interrupted airflow on the fan blades. Interrupted

temperature within the area that the engine will be

airflow on the fan blades could cause a fan failure.

operated. Engines that are fueled in one climate

may not operate well if the engines are moved

Caterpillar recommends a warning device for the

to another climate. Problems can result due to

inlet manifold temperature and/or the installation of

changes in temperature.

an inlet air temperature gauge. The warning device

for the inlet manifold temperature should be set at

Before troubleshooting for low power or for poor

65 C (150 F). The inlet manifold air temperature

performance in the winter, check the type of fuel

should not exceed 65 C (150 F). Temperatures

that is being used.

that exceed this limit can cause power loss and

potential engine damage.

When No. 2 diesel fuel is used the following

components provide a means of minimizing

problems in cold weather:

i01190421

Fuel and the Effect from Cold

• Starting aids

Weather

• Engine oil pan heaters

SMCS Code: 1000; 1250

• Engine coolant heaters

The following fuels are the grades that are available

• Fuel heaters

for Caterpillar engines:

Fuel line insulation

•

• No. 1

For more information on cold weather operation, see

• No. 2

Operation and Maintenance Manual, SEBU5898,

“Cold Weather Recommendations”.

• Blend of No. 1 and No. 2

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

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

2 is best suited for cold weather operation.

Operation Section

Cold Weather Operation

i01250450

Fuel Heaters

Fuel Related Components in

Fuel heaters help to prevent fuel filters from

plugging in cold weather due to waxing. A fuel

Cold Weather

heater should be installed in the fuel system before

the primary fuel filter.

SMCS Code: 1000; 1250

The following fuel heaters are recommended for

Fuel Tanks

Caterpillar engines:

Condensation can form in partially filled fuel tanks.

• 7C-3557 Fuel Heater Group

Top off the fuel tanks after you operate the engine.

7C-3558 Heater Kit

•

Fuel tanks should contain some provision for

draining water and sediment from the bottom of the

For further information on fuel heaters, consult your

tanks. Some fuel tanks use supply pipes that allow

Caterpillar dealer.

water and sediment to settle below the end of the

fuel supply pipe.

Disconnect the fuel heater in warm weather.

Some fuel tanks use supply lines that take fuel

Note: Fuel heaters that are controlled by the water

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

temperature regulator or self-regulating fuel heaters

equipped with this system, regular maintenance of

should be used with this engine. Fuel heaters

the fuel system filter is important.

that are not controlled by the water temperature

regulator can heat the fuel in excess of 65 C

Drain the water and sediment from any fuel storage

(149 F). A loss of engine power can occur if the fuel

tank at the following intervals: weekly, oil changes,

supply temperature exceeds 37 C (100 F).

and refueling of the fuel tank. This will help prevent

water and/or sediment from being pumped from the

Note: Heat exchanger type fuel heaters should have

fuel storage tank and into the engine fuel tank.

a bypass provision in order to prevent overheating

of the fuel in warm weather operation.

Fuel Filters

It is possible that a primary fuel filter is installed

between the fuel tank and the engine fuel inlet. After

you change the fuel filter, always prime the fuel

system in order to remove air bubbles from the fuel

system. Refer to the Operation and Maintenance

Manual in the Maintenance Section for more

information on priming the fuel system.

The micron rating and the location of a primary

fuel filter is important in cold weather operation.

The primary fuel filter and the fuel supply line are

the most common components that are affected by

cold fuel.

NOTICE

In order to maximize fuel system life and prevent

premature wear out from abrasive particles in the

fuel, a two micron absolute high efficiency fuel filter

is required for all Caterpillar Electronic Unit Injectors.

Caterpillar High Efficiency Fuel Filters meet these

requirements. Consult your Caterpillar dealer for the

proper part numbers.

Maintenance Section

Torque Specifications

i00621349

Maintenance Section

Standard Torque for Inch

Fasteners

Torque Specifications

SMCS Code: 7553

i01252954

Table 3

General Torque Information

Inch Nuts and Bolts

Thread Size

SMCS Code: 7553

Standard Torque

Inch

1/4

12 ± 3 N·m (9 ± 2 lb ft)

5/16

25 ± 6 N·m (18 ± 4 lb ft)

Mismatched or incorrect fasteners can result in

3/8

47 ± 9 N·m (35 ± 7 lb ft)

damage or malfunction, or personal injury.

7/16

70 ± 15 N·m (50 ± 11 lb ft)

Take care to avoid mixing metric dimensioned fas-

1/2

105 ± 20 N·m (75 ± 15 lb ft)

teners and inch dimensioned fasteners.

9/16

160 ± 30 N·m (120 ± 22 lb ft)

Exceptions to these torques are given in the Service

5/8

215 ± 40 N·m (160 ± 30 lb ft)

Manual, if necessary.

3/4

370 ± 50 N·m (275 ± 37 lb ft)

Prior to installation of any hardware, ensure that

7/8

620 ± 80 N·m (460 ± 60 lb ft)

components are in near new condition. Bolts and

900 ± 100 N·m (660 ± 75 lb ft)

threads must not be worn or damaged. Threads

must not have burrs or nicks. Hardware must be

1 1/8

1300 ± 150 N·m (960 ± 110 lb ft)

free of rust and corrosion. Clean the hardware with

1 1/4

1800 ± 200 N·m (1320 ± 150 lb ft)

a noncorrosive cleaner. Do not lubricate the fastener

threads except for the rust preventive. The rust

1 3/8

2400 ± 300 N·m (1780 ± 220 lb ft)

preventive should be applied by the supplier of that

1 1/2

3100 ± 350 N·m (2280 ± 260 lb ft)

component for purposes of shipping and storage.

Other applications for lubricating components may

also be specified in the Service Manual.

Table 4

Inch Taperlock Studs

Thread Size

Standard Torque

Inch

1/4

8 ± 3 N·m (6 ± 2 lb ft)

5/16

17 ± 5 N·m (13 ± 4 lb ft)

3/8

35 ± 5 N·m (26 ± 4 lb ft)

7/16

45 ± 10 N·m (33 ± 7 lb ft)

1/2

65 ± 10 N·m (48 ± 7 lb ft)

5/8

110 ± 20 N·m (80 ± 15 lb ft)

3/4

170 ± 30 N·m (125 ± 22 lb ft)

7/8

260 ± 40 N·m (190 ± 30 lb ft)

400 ± 60 N·m (300 ± 44 lb ft)

1 1/8

525 ± 60 N·m (390 ± 44 lb ft)

1 1/4

750 ± 80 N·m (550 ± 60 lb ft)

1 3/8

950 ± 125 N·m (700 ± 90 lb ft)

1 1/2

1200 ± 150 N·m (880 ± 110 lb ft)

Maintenance Section

Torque Specifications

i00621350

i01206505

Standard Torque for Metric

Standard Torque for Worm

Fasteners

Drive Band Hose Clamps

SMCS Code: 7553

SMCS Code: 7553; 7554

Table 5

Metric Nuts and Bolts

Thread Size

Standard Torque

Metric

12 ± 3 N·m (9 ± 2 lb ft)

28 ± 7 N·m (21 ± 5 lb ft)

g00280501

Illustration 25

M10

55 ± 10 N·m (41 ± 7 lb ft)

Table 7

M12

100 ± 20 N·m (75 ± 15 lb ft)

Initial Installation Torque

Width of Clamp

M14

160 ± 30 N·m (120 ± 22 lb ft)

On New Hose

M16

240 ± 40 N·m (175 ± 30 lb ft)

7.9 mm (0.31 inch)

0.9 ± 0.2 N·m (8 ± 2 lb in)

M20

460 ± 60 N·m (340 ± 44 lb ft)

13.5 mm (0.53 inch)

4.5 ± 0.5 N·m (40 ± 4 lb in)

M24

800 ± 100 N·m (590 ± 75 lb ft)

15.9 mm (0.63 inch)

7.5 ± 0.5 N·m (65 ± 4 lb in)

M30

1600 ± 200 N·m (1180 ± 150 lb ft)

Reassembly or Retightening

Width of Clamp

Torque

M36

2700 ± 300 N·m (2000 ± 220 lb ft)

7.9 mm (0.31 inch)

0.7 ± 0.2 N·m (6 ± 2 lb in)

Table 6

13.5 mm (0.53 inch)

3.0 ± 0.5 N·m (27 ± 4 lb in)

Metric Taperlock Studs

15.9 mm (0.63 inch)

4.5 ± 0.5 N·m (40 ± 4 lb in)

Thread Size

Standard Torque

Metric

i01206414

8 ± 3 N·m (6 ± 2 lb ft)

Standard Torque for Constant

17 ± 5 N·m (13 ± 4 lb ft)

M10

35 ± 5 N·m (26 ± 4 lb ft)

Torque Hose Clamps

M12

65 ± 10 N·m (48 ± 7 lb ft)

SMCS Code: 7553; 7554

M16

110 ± 20 N·m (80 ± 15 lb ft)

Use a constant torque hose clamp in place of any

M20

170 ± 30 N·m (125 ± 22 lb ft)

standard hose clamp. Ensure that the constant

torque hose clamp is the same size as the standard

M24

400 ± 60 N·m (300 ± 44 lb ft)

hose clamp. Due to extreme temperature changes,

M30

750 ± 80 N·m (550 ± 60 lb ft)

the hose will heat set. Heat setting can cause hose

clamps to loosen. Loose hose clamps can result

M36

1200 ± 150 N·m (880 ± 110 lb ft)

in leaks. There have been reports of component

failures that have been caused by hose clamps that

have loosened. The constant torque hose clamp will

help prevent these failures.

g00279591

Illustration 26

Maintenance Section

Lubricant Specifications

Table 8

Lubricant Specifications

API Classifications

i01111306

Current

Obsolete

CF-4, CG-4, CH-4

Lubricant Information

CC, CD

SMCS Code: 1000; 1300; 7581

CF-2⁽¹⁾

CD-2⁽¹⁾

⁽¹⁾ CD-2 and API CF-2 are classifications for two-cycle diesel

General Information

engines. Caterpillar does not sell engines that utilize CD-2 and

API CF-2 oils.

Because of government regulations regarding

the certification of engine exhaust emissions, the

Note: API CF is not the same classification as

lubricant recommendations must be followed.

API CF-4. API CF oils are only recommended

for Caterpillar 3600 Series Diesel Engines and

Caterpillar engines with precombustion chamber

Engine Manufacturers Association

(PC) fuel systems.

(EMA) Oils

Grease

The “Engine Manufacturers Association

Recommended Guideline on Diesel Engine Oil” is

The classifications of grease are based on the

recognized by Caterpillar. For detailed information

“ASTM D217” worked penetration characteristics.

about this guideline, see the latest edition of EMA

These characteristics for grease are given a defined

publication, “EMA LRG-1”.

consistency number.

API Oils

Terminology

The Engine Oil Licensing and Certification System

Certain abbreviations follow the nomenclature of

by the American Petroleum Institute (API) is

“SAE J754”. Some classifications follow “SAE J183”

recognized by Caterpillar. For detailed information

abbreviations, and some classifications follow the

about this system, see the latest edition of the “API

“EMA Recommended Guideline on Diesel Engine

publication No. 1509”. Engine oils that bear the API

Oil”. In addition to Caterpillar definitions, there

symbol are authorized by API.

are other definitions that will be of assistance in

purchasing lubricants. Recommended oil viscosities

can be found in this publication, “Engine Oil” topic

(Maintenance Section).

i01261682

Engine Oil

SMCS Code: 1300; 1348; 7581

Caterpillar Diesel Engine Oil

Caterpillar Oils have been developed and tested in

order to provide the full performance and service

g00546535

Illustration 27

life that has been designed and built into Caterpillar

Typical API symbol

Engines. Caterpillar Oils are currently used to fill

diesel engines at the factory. These oils are offered

Diesel engine oils CC, CD, CD-2, and CE have

by Caterpillar dealers for continued use when the

not been API authorized classifications since 1

engine oil is changed. Consult your Caterpillar

January 1996. Table 8 summarizes the status of the

dealer for more information on these oils.

classifications.

Due to significant variations in the quality and in

the performance of commercially available oils,

Caterpillar makes the following recommendations:

• Caterpillar Diesel Engine Oil (10W30)

Maintenance Section

Lubricant Specifications

• Caterpillar Diesel Engine Oil (15W40)

EMA LRG-1 - The Engine Manufacturers

Association (EMA) has developed lubricant

Caterpillar multigrade Diesel Engine Oil is

recommendations as an alternative to the API oil

formulated with the correct amounts of detergents,

classification system. LRG-1 is a Recommended

dispersants, and alkalinity in order to provide

Guideline that defines a level of oil performance

superior performance in Caterpillar Diesel Engines.

for these types of diesel engines: high speed, four

stroke cycle, heavy-duty, and light duty. LRG-1

Caterpillar multigrade Diesel Engine Oil is available

oils may be used in Caterpillar engines when the

in two viscosity grades (10W30 and 15W40).

following oils are recommended: API CH-4, API

For direct injection engines, see Table 9 in order

CG-4, and API CF-4. LRG-1 oils are intended to

to choose the correct viscosity grade for the

provide superior performance in comparison to API

ambient temperature. Multigrade oils provide the

CG-4 and API CF-4.

correct viscosity for a broad range of operating

temperatures.

LRG-1 oils will meet the needs of high performance

Caterpillar diesel engines that are operating in

Multigrade oils are effective in maintaining low oil

many applications. The tests and the test limits that

consumption and low levels of piston deposits.

are used to define LRG-1 are similar to the new

API CH-4 classification. Therefore, these oils will

Caterpillar multigrade Diesel Engine Oil can be

also meet the requirements of the low emissions

used in other diesel engines and in gasoline

diesel engines. LRG-1 oils are designed to control

engines. See the engine manufacturer’s guide for

the harmful effects of soot with improved wear

the recommended specifications. Compare the

resistance and improved resistance to oil filter

specifications to the specifications of Caterpillar

plugging. These oils will also provide superior piston

multigrade Diesel Engine Oil. The current industry

deposit control for engines with either two-piece

standards for Caterpillar Diesel Engine Oil are listed

steel pistons or aluminum pistons.

on the product label and on the data sheets for the

product.

All LRG-1 oils must complete a full test program

with the base stock and with the viscosity grade of

Consult your Caterpillar dealer for part numbers

the finished commercial oil. The use of “API Base

and for available sizes of containers.

Oil Interchange Guidelines” are not appropriate for

LRG-1 oils. This feature reduces the variation in

performance that can occur when base stocks are

Commercial Oils

changed in commercial oil formulations.

The performance of commercial diesel engine

LRG-1 oils are recommended for use in extended

oils is based on American Petroleum Institute

oil change interval programs that optimize oil life.

(API) classifications. These API classifications are

These oil change interval programs are based

developed in order to provide commercial lubricants

on oil analysis. LRG-1 oils are recommended

for a broad range of diesel engines that operate at

for conditions that demand a premium oil. Your

various conditions.

Caterpillar dealer has the specific guidelines for

optimizing oil change intervals.

If Caterpillar multigrade Diesel Engine Oil is not

used, only use commercial oils that meet the

API CH-4 - API CH-4 oils were developed in

following classifications:

order to meet the requirements of the new high

performance diesel engines. Also, the oil was

• EMA LRG-1 multigrade oil (preferred oil)

designed to meet the requirements of the low

emissions diesel engines. API CH-4 oils are also

• API CH-4 multigrade oil (preferred oil)

acceptable for use in older diesel engines and in

diesel engines that use high sulfur diesel fuel. API

• API CG-4 multigrade oil (preferred oil)

CH-4 oils may be used in Caterpillar engines that

use API CG-4 and API CF-4 oils. API CH-4 oils will

• API CF-4 multigrade oil (acceptable oil)

generally exceed the performance of API CG-4 oils

in the following criteria: deposits on pistons, control

In order to make the proper choice of a commercial

of oil consumption, wear of piston rings, valve train

oil, refer to the following explanations:

wear, viscosity control, and corrosion.

Maintenance Section

Lubricant Specifications

Three new engine tests were developed for the

Some commercial oils that meet the API

API CH-4 oil. The first test specifically evaluates

classifications may require reduced oil change

deposits on pistons for engines with the two-piece

intervals. To determine the oil change interval,

steel piston. This test (piston deposit) also measures

closely monitor the condition of the oil and perform a

the control of oil consumption. A second test is

wear metal analysis. Caterpillar’s S·O·S oil analysis

conducted with moderate oil soot. The second

program is the preferred method.

test measures the following criteria: wear of piston

rings, wear of cylinder liners, and resistance to

NOTICE

corrosion. A third new test measures the following

Failure to follow these oil recommendations can cause

characteristics with high levels of soot in the oil:

shortened engine service life due to deposits and/or

wear of the valve train, resistance of the oil in

excessive wear.

plugging the oil filter, and control of sludge.

In addition to the new tests, API CH-4 oils have

Total Base Number (TBN) and Fuel

tougher limits for viscosity control in applications

that generate high soot. The oils also have improved

Sulfur Levels for Direct Injection

oxidation resistance. API CH-4 oils must pass an

(DI) Diesel Engines

additional test (piston deposit) for engines that use

aluminum pistons (single piece). Oil performance is

The Total Base Number (TBN) for an oil depends on

also established for engines that operate in areas

the fuel sulfur level. For direct injection engines that

with high sulfur diesel fuel.

use distillate fuel, the minimum TBN of the new oil

must be 10 times the fuel sulfur level. The TBN is

All of these improvements allow the API CH-4 oil

defined by “ASTM D2896”. The minimum TBN of

to achieve optimum oil change intervals. API CH-4

the oil is 5 regardless of fuel sulfur level. Illustration

oils are recommended for use in extended oil

28 demonstrates the TBN.

change intervals. API CH-4 oils are recommended

for conditions that demand a premium oil. Your

Caterpillar dealer has specific guidelines for

optimizing oil change intervals.

API CG-4 - API CG-4 oils were developed primarily

for diesel engines that use a 0.05 percent level of

fuel sulfur. However, API CG-4 oils can be used

with higher sulfur fuels. The TBN of the new oil

determines the maximum fuel sulfur level for API

CG-4 and API CF-4 oils. See Illustration 28.

API CG-4 oils are the first oils that are required to

pass industry standard tests for foam control and

viscosity shear loss. API CG-4 oils must also pass

g00104890

tests that were developed for corrosion, wear and

Illustration 28

oxidation.

(Y) TBN by “ASTM D2896”

(X) Percentage of fuel sulfur by weight

API CF-4 - These oils service a wide variety of

(1) TBN of new oil

(2) Change the oil when the TBN deteriorates to 50 percent of

modern diesel engines. API CF-4 oils provide more

the original TBN.

stable oil control and reduced piston deposits in

comparison to API CF and the obsolete CE and CD

Use the following guidelines for fuel sulfur levels

classifications of oil. API CF-4 oils provide improved

that exceed 1.5 percent:

soot dispersancy in comparison to API CF and

obsolete CD oils. The API CF-4 classification was

• Choose an oil with the highest TBN that meets

developed with a 0.40 percent sulfur diesel fuel.

one of these classifications: EMA LRG-1, API

This represents the type of diesel fuels that are

CH-4, API CG-4, and API CF-4.

commonly available worldwide.

• Reduce the oil change interval. Base the oil

Note: Do not use single grade API CF oils or

change interval on the oil analysis. Ensure that

multigrade API CF oils in Caterpillar Direct Injection

the oil analysis includes the condition of the oil

(DI) Commercial Diesel Engines.

and a wear metal analysis.

Maintenance Section

Lubricant Specifications

Excessive piston deposits can be produced by an

i01111406

oil with a high TBN. These deposits can lead to a

Synthetic Base Stock Oils

loss of control of the oil consumption and to the

polishing of the cylinder bore.

SMCS Code: 1300; 1348; 7581

NOTICE

Synthetic base oils are acceptable for use

Operating Direct Injection (DI) diesel engines with fuel

in Caterpillar engines if these oils meet the

sulfur levels over 1.0 percent may require shortened

performance requirements that are specified for the

oil change intervals in order to help maintain adequate

engine compartment.

wear protection.

Synthetic base oils generally perform better than

conventional oils in the following two areas:

Lubricant Viscosity Recommendations

for Direct Injection (DI) Diesel Engines

• Synthetic base oils have improved flow at low

temperatures especially in arctic conditions.

The proper SAE viscosity grade of oil is determined

by the minimum ambient temperature during

• Synthetic base oils have improved oxidation

cold engine start-up, and the maximum ambient

stability especially at high operating temperatures.

temperature during engine operation.

Some synthetic base oils have performance

Refer to Table 9 (minimum temperature) in order

characteristics that enhance the service life of the

to determine the required oil viscosity for starting

oil. However, Caterpillar does not recommend the

a cold engine.

automatic extension of oil change intervals for

any type of oil. Oil change intervals for Caterpillar

Refer to Table 9 (maximum temperature) in order to

engines can only be adjusted after an oil analysis

select the oil viscosity for engine operation at the

program that contains the following tests: oil

highest ambient temperature that is anticipated.

condition and wear metal analysis (Caterpillar’s

S·O·S oil analysis), trend analysis, fuel consumption,

Generally, use the highest oil viscosity that

and oil consumption.

is available to meet the requirement for the

temperature at start-up.

i01111412

Table 9

Re-refined Base Stock Oils

Engine Oil Viscosity

Caterpillar DEO

Ambient Temperature

SMCS Code: 1300; 7581

Multigrade

EMA LRG-1

Re-refined base stock oils are acceptable for

API CH-4

use in Caterpillar engines if these oils meet the

API CG-4 and

Minimum

Maximum

performance requirements that are specified by

API CF-4

Caterpillar. Re-refined base stock oils can be used

Viscosity Grade

exclusively in finished oil or in a combination with

SAE 0W20

-40 C (-40 F)

C (50 F)

new base stock oils. The US military specifications

and the specifications of other heavy equipment

SAE 0W30

-40 C (-40 F)

C (86 F)

manufacturers also allow the use of re-refined base

stock oils that meet the same criteria.

SAE 0W40

-40 C (-40 F)

40 C (104 F)

SAE 5W30

-30 C (-22 F)

C (86 F)

The process that is used to make re-refined base

stock oil should adequately remove all wear metals

SAE 5W40

-30 C (-22 F)

40 C (104 F)

that are in the used oil and all additives that are

SAE 10W30

-20 C (-4 F)

40 C (104 F)

in the used oil. The process that is used to make

re-refined base stock oil generally involves the

SAE 15W40

-15 C (5 F)

50 C (122 F)

processes of vacuum distillation and hydrotreating

the used oil. Filtering is inadequate for the

production of high quality re-refined base stock oils

from used oil.

Maintenance Section

Lubricant Specifications

i01113213

i01123104

Cold Weather Lubricants

Aftermarket Oil Additives

SMCS Code: 1300; 1348; 7581

When an engine is started and an engine is

Caterpillar does not recommend the use of

operated in ambient temperatures below -20 C

aftermarket additives in oil. It is not necessary to

(-4

F), use multigrade oils that are capable of

use aftermarket additives in order to achieve the

flowing in low temperatures.

engine’s maximum service life or rated performance.

Fully formulated, finished oils consist of base oils

These oils have lubricant viscosity grades of SAE

and of commercial additive packages. These

0W or SAE 5W.

additive packages are blended into the base oils

at precise percentages in order to help provide

When an engine is started and operated in ambient

finished oils with performance characteristics that

temperatures below -30 C (-22 F), use a synthetic

meet industry standards.

base stock multigrade oil with a 0W viscosity grade

or with a 5W viscosity grade. Use an oil with a pour

There are no industry standard tests that evaluate

point that is lower than -50 C (-58 F).

the performance or the compatibility of aftermarket

additives in finished oil. Aftermarket additives may

The number of acceptable lubricants is limited in

not be compatible with the finished oil’s additive

cold weather conditions. Caterpillar recommends

package, which could lower the performance of the

the following lubricants for use in cold weather

finished oil. The aftermarket additive could fail to

conditions:

mix with the finished oil. This could produce sludge

in the crankcase. Caterpillar discourages the use of

First Choice - use an oil with an EMA LRG-1

aftermarket additives in finished oils.

Recommended Guideline or use a CH-4 oil that is

API licensed with an SAE 0W20, SAE 0W30, SAE

To achieve the best performance from a Caterpillar

0W40, SAE 5W30, or SAE 5W40 lubricant viscosity

engine, conform to the following guidelines:

grade. A CG-4 oil that is API licensed with an SAE

0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE

• Select the proper Caterpillar oil or a commercial

5W40 lubricant viscosity grade may also be used.

oil that meets the “EMA Recommended Guideline

A CF-4 oil that is API licensed with an SAE 0W20,

on Diesel Engine Oil” or the recommended API

SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40

classification.

lubricant viscosity grade may also be used.

•

See the appropriate “Lubricant Viscosities” table

Second Choice - use an oil that contains the CH-4,

in order to find the correct oil viscosity grade for

CG-4, or CF-4 additive package although the oil

your engine.

has not been tested for the requirements of the

API license. The oil must have an SAE 0W20,

• At the specified interval, service the engine

SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40

compartment. Use new oil and install a new oil

lubricant viscosity grade.

filter.

• Perform maintenance at the intervals that are

NOTICE

specified in the Operation and Maintenance

Shortened engine service life could result if second

Manual, “Maintenance Interval Schedule”.

choice oils are used.

i01164576

Lubricating Grease

SMCS Code: 7581

Caterpillar provides greases in order to cover a

variety of applications and extreme temperature

conditions. Consult your Caterpillar dealer for part

numbers and for available sizes of containers.

Maintenance Section

Lubricant Specifications

Note: Some greases may not be used with other

• Increased retention

greases. When a commercial grease is used,

ensure that the grease is compatible with the

• Resistance to heavy loads

grease that is currently used in the system. If the

commercial grease is not compatible, the system

This product is recommended for heavily loaded pin

must be purged. If any questions arise concerning

joints and for journal bearings. This product meets

the compatibility of a grease, consult the supplier.

the certification of “GC-LB”. Normal operating

temperatures for this product are -28 to 149 C

(-18 to 300 F) for the NLGI No. 0. Normal operating

Multipurpose Greases

temperatures for this product are -18 to 149 C

(0 to 300 F) for the NLGI No. 2.

Multipurpose Lithium Complex Grease

(MPGL)

Note: If MPGM is not available, use a multipurpose

type grease which contains three to five percent

Multipurpose Lithium Complex Grease (MPGL)

molybdenum.

is a general purpose lithium complex grease for

medium-duty applications. This product has good

Special Purpose Grease (SPG)

characteristics at high temperatures such as a

dropping point of 260 C (500 F). MPGL contains

Bearing Lubrication (SPG)

unleaded extreme pressure additives, antiwear

inhibitors, and corrosion inhibitors that provide extra

Bearing Lubricant (SPG) is available in a NLGI

protection in the following applications:

No. 2 grade with a polyurea thickener. This

grease is recommended for high temperature

• Construction

antifriction bearings in the following applications:

electric starting motors, alternators, fan drives,

• Agricultural

and generators. The Bearing Lubricant (SPG) has

an effective operating range of -29 to 177 C

• Automotive

(-20 to 350 F).

MPGL meets the requirements for extended service

intervals of automotive chassis points. MPGL also

Water and Temperature Resistant Grease

meets the requirements for extended service

(WTR)

intervals of wheel bearings with disc brakes in

automobiles, in vans and in light trucks. This

The Water and Temperature Resistant Grease is

product meets the NLGI certification of “GC-LB”.

designed for use whenever the following conditions

MPGL is also available in a NLGI No. 2 grade.

are a concern: water washout, severe corrosion,

Normal operating temperatures for this product are

and high operating temperatures. The Water and

-28 to 149 C (-18 to 300 F). This product is also

Temperature Resistant Grease provides extreme

available as a white lithium complex grease.

pressure protection, antiwear protection, rust

protection and corrosion protection. The Water and

Multipurpose Lithium Complex Grease

Temperature Resistant Grease is an environmentally

friendly grease which does not contain the following

with Molybdenum (MPGM)

materials: antimony, sulfur, barium, zinc, lead, and

phosphorous materials. The Water and Temperature

Multipurpose Lithium Complex Grease with

Resistant Grease has excellent shear stability. Water

Molybdenum (MPGM) is a general purpose

and Temperature Resistant Grease can also resist

lithium complex grease that is used for light-duty

breakdown in the presence of water. The Water

applications and for medium-duty applications. The

and Temperature Resistant Grease works well in

MPGM is available in the following grades: NLGI

the following applications:

No. 2 and NLGI No. 0. The MPGM is strengthened

with a molybdenum disulfide and a polymer for

extra lubrication and protection. MPGM contains

• Construction

unleaded additives. MPGM also contains antiwear

inhibitors, rust inhibitors, and corrosion inhibitors

• Agricultural

that are for protection and lubrication in many

environments. The MPGM is formulated with a base

• Automotive

fluid that has high viscosity.

• Industrial

The MPGM has the following features:

• Marine

• Increased protection against water washout

Maintenance Section

Lubricant Specifications

This product meets the NLGI certification of

i01065849

“GC-LB”. Normal operating temperatures for this

S·O·S Oil Analysis

product are -40 to 204 C (-40 to 400 F).

SMCS Code: 1348; 7542; 7581

Caterpillar Premium Grease (CPG)

Caterpillar recommends the use of the S·O·S

Desert Gold (CPG)

oil analysis program in order to monitor the

condition and the maintenance requirements of

Desert Gold is a heavy-duty, premium synthetic

the equipment. The S·O·S oil analysis program will

grease that is developed for the most extreme

complement the preventive maintenance program.

operating environments. This grease is formulated

with the following characteristics: high viscosity

The S·O·S oil analysis is a diagnostic tool that is

synthetic base fluid, polymers, molybdenum

used to determine oil performance and component

disulfide, high viscosity index, and high dropping

wear rates. Contamination can be identified and

point.

measured through the use of the S·O·S oil analysis.

The S·O·S oil analysis includes the following tests:

Desert Gold will protect equipment against

heavy shock loads. Desert Gold protects against

• The Wear Rate Analysis monitors the wear of the

corrosion in extreme heat, in moist conditions, or

engine’s metals. The amount of wear metal and

in dusty conditions. This product has excellent

type of wear metal that is in the oil is analyzed.

characteristics of adhesion and of stability.

The increase in the rate of engine wear metal in

Desert Gold provides longer protection than other

the oil is as important as the quantity of engine

greases. Desert Gold is an environmentally friendly

wear metal in the oil. For this reason, regular

grease which does not contain the following

sampling at specified intervals is necessary

materials: antimony, sulfur, barium, zinc, lead,

in order to establish wear rates. Intermittent

and phosphorous materials. Normal operating

sampling does not allow wear rate trend lines

temperatures are -6 to 230 C (21 to 450 F). Desert

to be established. Engine wear metals in the oil

Gold can operate at higher temperatures for short

sample are compared to established Caterpillar

time periods. Desert Gold has additional extreme

norms in order to determine acceptability.

pressure protection for highly loaded pin joints.

Tests are conducted in order to detect

•

contamination of the oil by water, glycol or fuel.

Arctic Platinum (CPG)

Arctic Platinum is a super-premium extreme

• The Oil Condition Analysis determines the loss

of the oil’s lubricating properties. An infrared

pressure lubricating grease that is developed for

analysis is used to compare the properties of

lubrication in temperatures that are below zero to

new oil to the properties of the used oil sample.

moderate operating temperatures. Arctic Platinum

This analysis allows technicians to determine

is available in grades 000, 00, 0, 1, and 2. These

grades ensure pumpability in central lube systems in

the amount of deterioration of the oil during use.

This analysis also allows technicians to verify

a variety of ambient temperatures from -60 to 18 C

the performance of the oil according to the

(-76 to 65 F). Arctic Platinum has a high dropping

specification during the entire oil change interval.

point. Arctic Platinum contains a five percent

concentrate of molybdenum disulfide for protection

The test results of the oil samples will then be used

against extra heavy loads. Arctic Platinum provides

as a basis for determining the oil change interval

excellent corrosion protection and rust protection.

for the engine. The results of the S·O·S oil analysis

Arctic Platinum is an environmentally friendly grease

may allow the engine to operate longer between oil

which does not contain the following materials:

changes without the risk of engine damage.

antimony, sulfur, barium, zinc, and phosphorous.

Table 10

Arctic Platinum is designed for long life lubrication

of the following components: horizontal pivot

S·O·S Oil Analysis Interval

bearings, lower link bearings, steering cylinders,

Compartment

Interval

kingbolt bearings, upper hitch link bearings, and

ejector carrier roller bearings. This grease is extra

Engine crankcase

Every 250 Service Hours

tacky for retention on excavator carbody bearings.

Arctic Platinum has additional extreme pressure

For more information, see Special Publication,

protection for highly loaded pin joints.

PEDP7036, “S·O·S Fluid Analysis”. Consult your

Caterpillar dealer for complete information and

assistance about the program.

Maintenance Section

Fuel Specifications

(Table 11, contd)

Fuel Specifications

Caterpillar Specifications for Distillate Diesel Fuel

Specifications

Requirements

ASTM

i01196007

Test

Fuel Recommendations

10% at 282 C (540 F)

“D86”

maximum

SMCS Code: 1250; 1280

Distillation

90% at 360 C (680 F)

Diesel engines have the ability to burn a wide

maximum

variety of fuels. These fuels are divided into two

Flash Point

legal limit

“D93”

general groups. The two groups are called the

preferred fuels and the permissible fuels.

30 minimum

“D287”

API Gravity

45 maximum

The preferred fuels provide maximum engine

service life and performance. The preferred fuels

C (10 F) minimum

“D97”

are distillate fuels. These fuels are commonly called

Pour Point

below ambient

temperature

diesel fuel, furnace fuel, gas oil, or kerosene.

3% maximum

“D3605”

The permissible fuels are crude oils or blended

Sulfur⁽¹⁾

fuels. Use of these fuels can result in higher

“D1552”

maintenance costs and in reduced engine service

1.4 cSt minimum and 20.0

“D445”

life.

Kinematic

cSt maximum at 40 C

Viscosity⁽²⁾

(104

Diesel fuels that meet the specifications in Table 11

will help to provide maximum engine service life

Water and

0.1% maximum

“D1796”

and performance. In North America, diesel fuel that

Sediment

is identified as No. 1-D or No. 2-D in “ASTM D975”

Water

0.1% maximum

“D1744”

generally meet the specifications. Table 11 is for

diesel fuels that are distilled from crude oil. Diesel

Sediment

0.05% maximum (weight)

“D473”

fuels from other sources could exhibit detrimental

Gums and

10 mg per 100 mL

“D381”

properties that are not defined or controlled by this

Resins⁽³⁾

maximum

specification.

3100 g minimum

“D6078”

Table 11

0.45 mm (0.018 inch)

Caterpillar Specifications for Distillate Diesel Fuel

maximum at 60 C

Lubricity⁽⁴⁾

(140

“D6079”

Specifications

Requirements

ASTM

Test

0.38 mm (0.015 inch)

maximum at 25 C (77 F)

Aromatics

35% maximum

“D1319”

⁽¹⁾ Caterpillar fuel systems and engine components can

Ash

0.02% maximum (weight)

“D482”

operate on high sulfur fuels. Fuel sulfur levels affect exhaust

emissions. High sulfur fuels also increase the potential for

Carbon

0.35% maximum (weight)

“D524”

corrosion of internal components. Fuel sulfur levels above 1.0

Residue on

percent may significantly shorten the oil change interval. For

10% Bottoms

additional information, see this publication, “Engine Oil” topic

(Maintenance Section).

40 minimum (DI engines)

“D613”

⁽²⁾ The values of the fuel viscosity are the values as the fuel

Cetane Number

is delivered to the fuel injection pumps. If a fuel with a low

35 minimum (PC engines)

viscosity is used, cooling of the fuel may be required to maintain

a 1.4 cSt viscosity at the fuel injection pump. Fuels with a high

The cloud point must

viscosity might require fuel heaters in order to bring down the

not exceed the lowest

Cloud Point

viscosity to a 20 cSt viscosity. For additional information, see

expected ambient

Special Publication, SEBD0717, “Diesel Fuel and Your Engine”.

temperature.

⁽³⁾ Follow the test conditions and procedures for gasoline (motor).

⁽⁴⁾ The lubricity of a fuel is a concern with low sulfur fuel. To

Copper Strip

No. 3 maximum

“D130”

determine the lubricity of the fuel, use either the “ASTM D6078

Corrosion

Scuffing Load Wear Test (SBOCLE)” or the “ASTM D6079 High

(continued)

Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a

fuel does not meet the minimum requirements, consult your

fuel supplier. Do not treat the fuel without consulting the fuel

supplier. Some additives are not compatible. These additives

can cause problems in the fuel system.

Maintenance Section

Fuel Specifications

There are many other diesel fuel specifications that

NOTICE

are published by governments and by technological

Operating with fuels that do not meet Caterpillar’s rec-

societies. Usually, those specifications do not

ommendations can cause the following effects: start-

review all the requirements that are addressed

ing difficulty, poor combustion, deposits in the fuel in-

in this specification. To ensure optimum engine

jectors, reduced service life of the fuel system, de-

performance, a complete fuel analysis should be

posits in the combustion chamber, and reduced ser-

obtained before engine operation. The fuel analysis

vice life of the engine.

should include all of the properties that are listed

in Table 11.

In the USA, 0.05 percent diesel fuels have been

used in all on-highway truck engines since 1

January 1994. This low sulfur diesel fuel was

mandated as a means of directly reducing

particulate emissions from diesel truck engines.

This low sulfur fuel will also be used in Caterpillar

commercial diesel engines when low emissions are

required or when the fuel supply sources provide

this type of fuel. Caterpillar has not seen any

detrimental effects with 0.05 percent sulfur fuel in

Caterpillar diesel engines.

NOTICE

Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel

must NOT be used in Caterpillar diesel engines (ex-

cept in 3600 Series HFO engines). Severe component

wear and component failures will result if HFO type fu-

els are used in engines that are configured to use dis-

tillate fuel.

In extreme cold ambient conditions, you may

use the distillate fuels that are specified in Table

12. However, the fuel that is selected must meet

the requirements that are specified in Table 11.

These fuels are intended to be used in operating

temperatures that are down to -54 C (-65 F).

Table 12

Distillate Fuels⁽¹⁾

Specification

Grade

“MIL-T-5624R”

JP-5

“ASTM D1655”

Jet-A-1

“MIL-T-83133D”

JP-8

⁽¹⁾ The fuels that are listed in this Table may not meet the

requirements that are specified in the “Caterpillar Specifications

for Distillate Diesel Fuel” Table. Consult the supplier for the

recommended additives in order to maintain the proper fuel

lubricity.

These fuels are lighter than the No. 2 grades of fuel.

The cetane number of the fuels in Table 12 must be

at least 40. If the viscosity is below 1.4 cSt at 38 C

(100

F), use the fuel only in temperatures below

0 C (32 F). Do not use any fuels with a viscosity

of less than 1.2 cSt at 38 C (100 F). Fuel cooling

may be required in order to maintain the minimum

viscosity of 1.4 cSt at the fuel injection pump.

Maintenance Section

Cooling System Specifications

Many engine failures are related to the cooling

Cooling System

system. The following problems are related to

Specifications

cooling system failures: overheating, leakage of the

water pump, plugged radiators or heat exchangers,

and pitting of the cylinder liners.

i01261719

These failures can be avoided with proper cooling

General Coolant Information

system maintenance. Cooling system maintenance

is as important as maintenance of the fuel system

SMCS Code: 1350; 1395

and the lubrication system. Quality of the coolant

is as important as the quality of the fuel and the

NOTICE

lubricating oil.

Never add coolant to an overheated engine. Engine

damage could result. Allow the engine to cool first.

Coolant is normally composed of three elements:

water, additives, and glycol.

NOTICE

Water

If the engine is to be stored in, or shipped to an area

with below freezing temperatures, the cooling system

must be either protected to the lowest outside temper-

NOTICE

ature or drained completely to prevent damage.

All Caterpillar diesel engines equipped with air-to-air

aftercooling (ATAAC) require a minimum of 30 percent

glycol to prevent water pump cavitation.

NOTICE

In cold weather, frequently check the specific gravity

of the coolant solution to ensure adequate protection.

NOTICE

Never use water alone without Supplemental Coolant

Additives (SCA) or without inhibited coolant. Water

Clean the cooling system for the following reasons:

alone is corrosive at engine operating temperatures.

Water alone does not provide adequate protection

• Contamination of the cooling system

against boiling or freezing.

• Overheating of the engine

Water is used in the cooling system in order to

transfer heat.

• Foaming of the coolant

Note: Air pockets can form in the cooling system if

Distilled water or deionized water is

the cooling system is filled at a rate that is greater

recommended for use in engine cooling systems.

than 20 L (5 US gal) per minute.

DO NOT use the following types of water in cooling

After you drain the cooling system and after you

systems: hard water, softened water that has been

refill the cooling system, operate the engine.

conditioned with salt, and sea water.

Operate the engine without the filler cap until the

coolant reaches normal operating temperature and

If distilled water or deionized water is not available,

the coolant level stabilizes. Ensure that the coolant

use water with the properties that are listed in Table

is maintained to the proper level.

13.

NOTICE

Never operate an engine without water temperature

regulators in the cooling system. Water temperature

regulators help to maintain the engine coolant at the

proper operating temperature. Cooling system prob-

lems can develop without water temperature regula-

tors.

Refer to Special Instruction, SEBD0518, “Know

Your Cooling System” and Special Instruction,

SEBD0970, “Coolant and Your Engine” for more

detailed information.

Maintenance Section

Cooling System Specifications

Table 13

• Formation of gel compounds

Caterpillar Minimum Acceptable Water Requirements

• Reduction of heat transfer

Property

Maximum Limit

ASTM Test

• Leakage of the water pump seal

40 mg/L

“D512”,

Chloride (Cl)

(2.4 grains/US gal)

“D4327”

• Plugging of radiators, coolers, and small

100 mg/L

passages

Sulfate (SO4)

“D516”

(5.9 grains/US gal)

170 mg/L

Glycol

Total Hardness

“D1126”

(10 grains/US gal)

Glycol in the coolant helps to provide protection

340 mg/L

Total Solids

“D1888”

(20 grain/US gal)

against the following conditions:

Acidity

pH of 5.5 to 9.0

“D1293”

• Boiling

For a water analysis, consult one of the following

• Freezing

sources:

• Cavitation of the water pump and the cylinder liner

• Caterpillar dealer

For optimum performance, Caterpillar recommends

a 1:1 mixture of a water/glycol solution.

• Local water utility company

• Agricultural agent

NOTICE

All Caterpillar diesel engines equipped with air-to-air

• Independent laboratory

aftercooling (ATAAC) require a minimum of 30 percent

glycol to prevent water pump cavitation.

Additives

Note: Use a mixture that will provide protection

Additives help to protect the metal surfaces of

against the lowest ambient temperature.

the cooling system. A lack of coolant additives

or insufficient amounts of additives enable the

Note: 100 percent pure glycol will freeze at a

following conditions to occur:

temperature of -23 C (-9 F).

• Corrosion

Most conventional heavy-duty coolant/antifreezes

use ethylene glycol. Propylene glycol may also be

• Formation of mineral deposits

used. In a 1:1 mixture with water, ethylene and

propylene glycol provide similar protection against

• Rust

freezing and boiling. See Tables 14 and 15.

• Scale

Table 14

Ethylene Glycol

• Pitting and erosion from cavitation of the cylinder

liner

Freeze

Boil

Concentration

Protection

• Foaming of the coolant

50 Percent

-36 C (-33 F)

106 C (223 F)

Many additives are depleted during engine

60 Percent

-51 C (-60 F)

111 C (232 F)

operation. These additives must be replaced

periodically. This can be done by adding

Supplemental Coolant Additives (SCA) to Diesel

NOTICE

Engine Antifreeze/Coolant (DEAC) or by adding

Do not use propylene glycol in concentrations that ex-

ELC Extender to Extended Life Coolant (ELC).

ceed 50 percent glycol because of propylene glycol’s

reduced heat transfer capability. Use ethylene glycol

Additives must be added at the proper

in conditions that require additional protection against

concentration. Overconcentration of additives can

boiling or freezing.

cause the inhibitors to drop out-of-solution. The

deposits can enable the following problems to

occur:

Maintenance Section

Cooling System Specifications

Table 15

NOTICE

Propylene Glycol

All Caterpillar diesel engines equipped with air-to-air

Freeze

Boil

Concentration

aftercooling (ATAAC) require a minimum of 30 percent

Protection

glycol to prevent water pump cavitation.

50 Percent

-29 C (-20 F)

106 C (223 F)

Table 16

To check the concentration of glycol, use the

Coolant Service Life

1U-7298 Coolant/Battery Tester (Degree Celsius)

Coolant Type

Service Life

or use the 1U-7297 Coolant/Battery Tester (Degree

Fahrenheit). The testers give readings that are

6000 Service Hours or

Caterpillar ELC

immediate and accurate. The testers can be used

Six Years

with ethylene or propylene glycol.

3000 Service Hours or

Caterpillar DEAC

Three Years

i01096597

Commercial Heavy-Duty

3000 Service Hours or

Coolant/Antifreeze that

Coolant Recommendations

Two Years

meets “ASTM D5345”

SMCS Code: 1350; 1395

Commercial Heavy-Duty

3000 Service Hours or

Coolant/Antifreeze that

One Year

The following two coolants are used in Caterpillar

meets “ASTM D4985”

diesel engines:

Caterpillar SCA and

3000 Service Hours or

Water

Two Years

Preferred - Caterpillar Extended Life Coolant (ELC)

Commercial SCA and

3000 Service Hours or

or a commercial extended life coolant that meets

Water

One Year

the Caterpillar EC-1 specification

Acceptable - A Caterpillar Diesel Engine

Antifreeze/Coolant (DEAC) or a commercial

i01200209

heavy-duty coolant/antifreeze that meets “ASTM

S·O·S Coolant Analysis

D4985” or “ASTM D5345” specifications

SMCS Code: 1352; 1395; 7542

NOTICE

Do not use a commercial coolant/antifreeze that only

Testing the engine coolant is important to ensure

meets the ASTM D3306 or D4656 specification. This

that the engine is protected from internal cavitation

type of coolant/antifreeze is made for light duty auto-

and from corrosion. The analysis also tests the

motive applications.

ability of the coolant to protect the engine from

boiling and from freezing. The S·O·S Coolant

Analysis can be done at your Caterpillar dealer.

Caterpillar recommends a 1:1 mixture of water

Caterpillar S·O·S Coolant Analysis is the best

and glycol. This mixture of water and glycol will

way to monitor the condition of your coolant and

provide optimum heavy-duty performance as a

your cooling system. S·O·S Coolant Analysis is a

coolant/antifreeze.

program that is based on periodic samples.

Note: Caterpillar DEAC DOES NOT require a

treatment with an SCA at the initial fill. Commercial

NOTICE

heavy-duty coolant/antifreeze that meets “ASTM

Do not use the same vacuum sampling pump for ex-

D4985” or “ASTM D5345” specifications MAY

tracting oil samples that is used for extracting coolant

require a treatment with an SCA at the initial fill.

samples.

Read the label or the instructions that are provided

by the OEM of the product.

A small residue of either type sample may remain in

the pump and may cause a false positive analysis for

In stationary engine applications and marine engine

the sample being taken.

applications that do not require anti-boil protection

or freeze protection, a mixture of SCA and water is

Always use a designated pump for oil sampling and a

acceptable. Caterpillar recommends a six percent

designated pump for coolant sampling.

to eight percent concentration of SCA in those

cooling systems. Distilled water or deionized water

Failure to do so may cause a false analysis which

is preferred. Water which has the recommended

could lead to customer and dealer concerns.

properties may be used.

Maintenance Section

Cooling System Specifications

New Systems, Refilled Systems,

• Identification of buildup of the impurities that

cause corrosion

and Converted Systems

• Identification of buildup of the impurities that

Perform a coolant analysis (Level 2) at 500 service

cause scaling

hours for new systems, for refilled systems, or for

converted systems that use ELC or use DEAC. This

• Determination of possible electrolysis within the

500 hour check will also check for any residual

engines’ cooling system

cleaner that may have contaminated the system.

The results are reported, and appropriate

Recommended Interval for S·O·S

recommendations are made.

Coolant Sample

For more information on S·O·S Coolant Analysis,

consult your Caterpillar dealer.

Perform a coolant analysis (Level 1) at every 500

service hour interval. Perform a coolant analysis

(Level 2) annually.

i01096605

Note: Check the standard coolant’s Supplemental

Extended Life Coolant (ELC)

Coolant Additive at every oil change.

SMCS Code: 1350; 1395

S·O·S Coolant Analysis (Level 1)

Caterpillar provides Extended Life Coolant (ELC) for

use in the following applications:

A coolant analysis (Level 1) is a test of the

properties of the coolant.

• Heavy-duty spark ignited gas engines

The following properties of the coolant are tested:

• Heavy-duty diesel engines

• Glycol Concentration for freeze protection

• Automotive applications

• Ability to protect from erosion and corrosion

The anti-corrosion package for Caterpillar ELC is

different from the anti-corrosion package for other

• pH

coolants. Caterpillar ELC is an ethylene glycol

base coolant. However, Caterpillar ELC contains

• Conductivity

organic corrosion inhibitors and antifoam agents

with low amounts of nitrite. Caterpillar ELC has

• Water hardness

been formulated with the correct amount of these

additives in order to provide superior corrosion

• Visual analysis

protection for all metals in engine cooling systems.

• Odor analysis

ELC extends the service life of the coolant to 6000

service hours or six years. ELC does not require

The results are reported, and appropriate

a frequent addition of a Supplemental Coolant

recommendations are made.

Additive (SCA). An Extender is the only additional

maintenance that is needed at 3000 service hours

S·O·S Coolant Analysis (Level 2)

or one half of the ELC service life.

Level 2 coolant analysis is a comprehensive

ELC is available in a 1:1 premixed cooling solution

chemical evaluation of the coolant. This analysis is

with distilled water. The Premixed ELC provides

also a check of the overall condition of the inside of

freeze protection to -36 C (-33 F). The Premixed

the cooling system.

ELC is recommended for the initial fill of the cooling

system. The Premixed ELC is also recommended

The S·O·S Coolant Analysis has the following five

for topping off the cooling system.

features:

ELC Concentrate is also available. ELC Concentrate

• Full analysis of Level 1

can be used to lower the freezing point to -51 C

(-60 F) for arctic conditions.

• Identification of the source of metal corrosion and

of contaminants

Containers of several sizes are available. Consult

your Caterpillar dealer for the part numbers.

Maintenance Section

Cooling System Specifications

Note: Caterpillar developed the EC-1 specification.

Caterpillar ELC Extender

The EC-1 specification is an industry standard. The

EC-1 specification defines all of the performance

Caterpillar ELC Extender is added to the cooling

requirements that are needed for an engine coolant

system halfway through the ELC service life. Treat

to be sold as an extended life coolant for Caterpillar

the cooling system with ELC Extender at 3000 hours

engines. ELC can be used in most OEM engines of

or one half of the coolant service life. Use Table 17

the following types: diesel, gasoline, and natural

in order to determine the proper amount of ELC

gas. ELC meets the performance requirements of

Extender that is required.

“ASTM D4985” and “ASTM D5345” for heavy-duty

low silicate antifreeze/coolants. ELC also meets the

Containers of several sizes are available. Consult

performance requirements of “ASTM D3306” and

your Caterpillar dealer for the part numbers.

“ASTM D4656” for automotive applications.

Table 17

Caterpillar ELC Extender Additions by

i01111712

Cooling System Capacity

Extended Life Coolant (ELC)

Addition of ELC

Cooling System Capacity

Extender

Cooling System Maintenance

22 to 30 L (6 to 8 US gal)

0.57 L (20 fl oz)

SMCS Code: 1350; 1352; 1395

31 to 38 L (9 to 10 US gal)

0.71 L (24 fl oz)

Proper additions to the Extended

39 to 49 L (11 to 13 US gal)

0.95 L (32 fl oz)

Life Coolant

50 to 64 L (14 to 17 US gal)

1.18 L (40 fl oz)

65 to 83 L (18 to 22 US gal)

1.60 L (54 fl oz)

NOTICE

84 to 114 L (23 to 30 US gal)

2.15 L (72 fl oz)

Use only Caterpillar products or commercial products

that have passed Caterpillar’s EC-1 specification for

115 to 163 L (31 to 43 US gal)

3.00 L (100 fl oz)

pre-mixed or concentrated coolants.

164 to 242 L (44 to 64 US gal)

4.40 L (148 fl oz)

Use only Caterpillar Extender with Extended Life

Coolant.

For cooling system capacities that exceed the

capacities that are specified in Table 17, use the

Mixing Extended Life Coolant with other products re-

equation that is in Table 18 in order to determine

duces the Extended Life Coolant service life. Failure to

the proper amount of ELC Extender that is required.

follow the recommendations can reduce cooling sys-

tem components life unless appropriate corrective ac-

Table 18

tion is performed.

Equation For Adding ELC Extender To ELC

V × 0.02 = X

In order to maintain the correct balance between

the antifreeze and the additives, you must maintain

V is the total volume of the cooling system.

the recommended concentration of Extended Life

X is the amount of ELC Extender that is required.

Coolant (ELC). Lowering the proportion of antifreeze

lowers the proportion of additive. This will lower

Table 19 is an example for using the equation that

the ability of the coolant to protect the system from

pitting, from cavitation, from erosion, and from

is in Table 18.

deposits.

Table 19

Example Of The Equation For Adding ELC

NOTICE

Extender To ELC

Do not use a conventional coolant to top-off a cooling

system that is filled with Extended Life Coolant (ELC).

Total Volume

Multiplication

Amount of ELC

of the Cooling

Factor

Extender that is

Do not use standard supplemental coolant additive

System (V)

Required (X)

(SCA). Only use ELC Extender in cooling systems that

946 L

× 0.02

19 L

are filled with ELC.

(250 US gal)

(5 US gal)

Maintenance Section

Cooling System Specifications

NOTICE

When using Caterpillar ELC, do not use standard

Do not leave an empty SCA filter on an ELC system.

SCA’s or SCA filters. To avoid SCA contamination of

an ELC system, remove the SCA filter base and plug

The filter housing may corrode and leak causing an

off or by-pass the coolant lines.

engine failure.

Remove the SCA filter base and plug off or by-pass

ELC Cooling System Cleaning

the coolant lines.

Note: If the cooling system is already using ELC,

3. Remove the empty SCA filter and remove the

cleaning agents are not required to be used at

filter base. Plug the coolant lines or bypass the

the specified coolant change interval. Cleaning

coolant lines.

agents are only required if the system has been

contaminated by the addition of some other type of

4. Flush the system with clean water in order to

coolant or by cooling system damage.

remove any debris.

Clean water is the only cleaning agent that is

5. Use Caterpillar cleaner to clean the system.

required when ELC is drained from the cooling

Follow the instruction on the label.

system.

6. Drain the cleaner into a suitable container. Flush

ELC can be recycled. The drained coolant mixture

the cooling system with clean water.

can be distilled in order to remove the ethylene

glycol and the water. The ethylene glycol and the

7. Fill the cooling system with clean water and

water can be reused. Consult your Caterpillar dealer

operate the engine until the engine is warmed to

for more information.

to 66 C (120 to 150 F).

After the cooling system is drained and after the

NOTICE

cooling system is refilled, operate the engine while

the cooling system filler cap is removed. Operate

Improper or incomplete rinsing of the cooling system

the engine until the coolant level reaches the normal

can result in damage to copper and other metal com-

ponents.

operating temperature and until the coolant level

stabilizes. As needed, add the coolant mixture in

order to fill the system to the proper level.

To avoid damage to the cooling system, make sure

to completely flush the cooling system with clear wa-

ter. Continue to flush the system until all signs of the

Changing to Caterpillar ELC

cleaning agent are gone.

To change from heavy-duty coolant/antifreeze to the

Caterpillar ELC, perform the following steps:

8. Drain the cooling system into a suitable container

and flush the cooling system with clean water.

NOTICE

Note: The cooling system cleaner must be

Care must be taken to ensure that fluids are contained

thoroughly flushed from the cooling system. Cooling

during performance of inspection, maintenance, test-

system cleaner that is left in the system will

ing, adjusting and repair of the product. Be prepared to

contaminate the coolant. The cleaner may also

collect the fluid with suitable containers before open-

corrode the cooling system.

ing any compartment or disassembling any compo-

nent containing fluids.

9. Repeat Steps 7 and 8 until the system is

completely clean.

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies

10. Fill the cooling system with the Caterpillar

suitable to collect and contain fluids on Caterpillar

premixed ELC.

products.

11. Attach the Special Publication, PEEP5027,

Dispose of all fluids according to local regulations and

“Label” to the cooling system filler for the engine

mandates.

in order to indicate the use of Caterpillar ELC.

1. Drain the coolant into a suitable container.

2. Dispose of the coolant according to local

regulations.

Maintenance Section

Cooling System Specifications

ELC Cooling System

i01111753

Contamination

Diesel Engine Antifreeze/

Coolant (DEAC)

NOTICE

Mixing ELC with other products reduces the effective-

SMCS Code: 1350; 1395

ness of the ELC and shortens the ELC service life.

Use only Caterpillar products or commercial products

Caterpillar recommends using Caterpillar

that have passed the Caterpillar EC-1 specification for

Diesel Engine Antifreeze/Coolant (DEAC) for

premixed or concentrate coolants. Use only Caterpillar

cooling systems that require a heavy-duty

ELC Extender with Caterpillar ELC. Failure to follow

coolant/antifreeze. Caterpillar DEAC is an alkaline

these recommendations can result in shortened cool-

single-phase ethylene glycol type antifreeze that

ing system component life.

contains corrosion inhibitors and antifoam agents.

ELC cooling systems can withstand contamination

Caterpillar DEAC is formulated with the correct

to a maximum of ten percent of conventional

amount of Caterpillar Supplemental Coolant Additive

heavy-duty coolant/antifreeze or SCA. If the

(SCA). Do no use SCA at the initial fill when DEAC

contamination exceeds ten percent of the total

is used.

system capacity, perform ONE of the following

procedures:

Containers of several sizes are available. Consult

your Caterpillar dealer for the part numbers.

• Drain the cooling system into a suitable container.

Dispose of the coolant according to local

If concentrated DEAC is used, Caterpillar

regulations. Flush the system with clean water. Fill

recommends mixing the concentrate with distilled

the system with the Caterpillar ELC.

water or with deionized water. If distilled water is

not available or deionized water is not available,

• Drain a portion of the cooling system into a

use water which has the required properties. For

suitable container according to local regulations.

the water properties, see this publication, “General

Then, fill the cooling system with premixed ELC.

Coolant Information” topic (Maintenance Section).

This should lower the contamination to less than

10 percent.

i01069295

• Maintain the system as a conventional Diesel

Supplemental Coolant Additive

Engine Antifreeze/Coolant (DEAC). Treat the

system with an SCA. Change the coolant at the

(SCA)

interval that is recommended for the conventional

Diesel Engine Antifreeze/Coolant (DEAC).

SMCS Code: 1350; 1352; 1395

The use of SCA helps to prevent the following

Commercial ELC

conditions from occurring:

If Caterpillar ELC is not used, then select a

• Corrosion

commercial ELC that meets the Caterpillar

specification of EC-1 and either the “ASTM D5345”

• Formation of mineral deposits

specification or the “ASTM D4985” specification. Do

not use an extended life coolant that does not meet

• Cavitation erosion of the cylinder liners

the EC-1 specification. Follow the maintenance

guide for the coolant from the supplier of the

• Foaming of the coolant

commercial ELC. Follow the Caterpillar guidelines

for the quality of water and the specified coolant

Caterpillar Diesel Engine Antifreeze/Coolant (DEAC)

change interval.

is formulated with the correct level of Caterpillar

SCA. When the cooling system is initially filled with

DEAC, adding more SCA is not necessary until the

concentration of SCA has been depleted. To ensure

that the correct amount of SCA is in the cooling

system, the concentration of SCA must be tested

on a scheduled basis. Refer to the specific engine’s

Operation and Maintenance Manual, “Maintenance

Interval Schedule”.

Maintenance Section

Cooling System Specifications

Containers of SCA are available in several sizes.

Consult your Caterpillar dealer for the part numbers.

NOTICE

Never use water alone without Supplemental Coolant

Additives (SCA) or without inhibited coolant. Water

i01164588

alone is corrosive at engine operating temperatures.

Commercial Heavy-Duty

Water alone does not provide adequate protection

against boiling or freezing.

Coolant/Antifreeze and SCA

SMCS Code: 1350; 1395

Note: Premix the coolant solution in order to provide

protection to the lowest ambient temperature that

If Caterpillar DEAC is not used, select a

is expected.

coolant/antifreeze with low silicate content for

heavy-duty applications that meets “ASTM D5345”

Note: Pure undiluted antifreeze freezes at -23 C

or “ASTM D4985” specifications.

(-9

F).

Note: When you are not using Caterpillar DEAC the

In engine cooling systems that use water alone,

cooling system must be drained one time during

Caterpillar recommends the use of SCA. SCA helps

every year. The cooling system must be flushed at

to prevent the following conditions from occurring:

this time as well.

• Corrosion

When a heavy-duty coolant/antifreeze is used,

treat the cooling system with three to six

• Formation of mineral deposits

percent Caterpillar SCA by volume. For more

information, see this publication, “Conventional

• Cavitation erosion of the cylinder liner

Coolant/Antifreeze Cooling System Maintenance”

topic (Maintenance Section).

• Foaming of the coolant

If Caterpillar SCA is not used, select a commercial

SCA. The commercial SCA must provide a minimum

of 1200 mg/L or 1200 ppm (70 grains/US gal) of

of 2400 mg/L or 2400 ppm (140 grains/US gal) of

nitrites in the final coolant mixture.

Coolant/antifreeze that meets “ASTM D5345” or

The quality of the water is a very important factor

“ASTM D4985” specifications MAY require treatment

in this type of cooling system. Distilled water

with SCA at the initial fill. These coolants WILL

or deionized water is recommended for use in

require treatment with SCA on a maintenance basis.

cooling systems. If distilled water or deionized

water is not available, use water that meets the

When concentrated coolant/antifreeze is mixed,

minimum requirements that are listed in the table for

Caterpillar recommends mixing the concentrate with

recommended water properties in this publication,

distilled water or with deionized water. If distilled

“General Coolant Information” topic (Maintenance

water or deionized water is not available, water

Section).

which has the required properties may be used. For

the water properties, see this publication, “General

A cooling system that uses a mixture of SCA

Coolant Information” topic (Maintenance Section).

and water only needs more SCA than a cooling

system that uses a mixture of glycol and water. The

SCA concentration in a cooling system that uses

i01318169

SCA and water should be six to eight percent by

volume. Refer to Table 20 for the amount of SCA

Water/Supplemental Coolant

that is required for various capacities of the cooling

Additive (SCA)

system.

SMCS Code: 1350; 1352; 1395

NOTICE

All Caterpillar diesel engines equipped with air-to-air

aftercooling (ATAAC) require a minimum of 30 percent

glycol to prevent water pump cavitation.

Maintenance Section

Cooling System Specifications

Table 20

Cooling Systems with Larger

Caterpillar SCA Requirements for SCA and

Capacities

Water Cooling Systems

Cooling System

Caterpillar SCA

Adding the SCA to Water at the Initial Fill

Capacity

at Initial Fill

at 250 Hours

Use the equation that is in Table 22 to determine

22 to 30 L

1.75 L (64 fl oz)

0.44 L (15 fl oz)

the amount of Caterpillar SCA that is required at

(6 to 8 US gal)

the initial fill. This equation is for a mixture of only

31 to 38 L

SCA and water.

2.30 L (80 fl oz)

0.57 L (20 fl oz)

(9 to 10 US gal)

Table 22

39 to 49 L

3.00 L (100 fl oz)

0.75 L (25 fl oz)

(11 to 13 US gal)

Equation For Adding The SCA To Water

At The Initial Fill

50 to 64 L

3.90 L (128 fl oz)

0.95 L (32 fl oz)

(14 to 17 US gal)

V × 0.07 = X

65 to 83 L

V is the total volume of the cooling system.

5.00 L (168 fl oz)

1.25 L (42 fl oz)

(18 to 22 US gal)

X is the amount of SCA that is required.

84 to 110 L

6.60 L (224 fl oz)

1.65 L (56 fl oz)

(23 to 29 US gal)

Table 23 is an example for using the equation that

111 to 145 L

is in Table 22.

8.75 L (296 fl oz)

2.19 L (74 fl oz)

(30 to 38 US gal)

Table 23

146 to 190 L

11.50 L

2.88 L (98 fl oz)

(39 to 50 US gal)

(392 fl oz)

Example Of The Equation For Adding The SCA

To Water At The Initial Fill

191 to 250 L

15.00 L

3.75 L (128 fl oz)

(51 to 66 US gal)

(512 fl oz)

Total Volume

Multiplication

Amount of SCA

of the Cooling

Factor

that is Required

System (V)

(X)

Refer to Table 21 for part numbers and for quantities

of SCA.

946 L

× 0.07

66 L

(250 US gal)

(18 US gal)

Table 21

Caterpillar Liquid SCA

Adding the SCA to Water for Maintenance

Part Number

Quantity

For the recommended service interval, refer to the

6V-3542

0.24 L (8 oz)

Operation and Maintenance Manual, “Maintenance

Interval Schedule” for your engine.

111-2372

0.36 L (12 oz)

8T-1589

0.47 L (16 oz)

Use the 8T-5296 Coolant Conditioner Test Kit to

test the concentration of SCA. Make the following

3P-2044

0.94 L (32 oz)

modifications to Steps 3 and 5 of the 8T-5296

8C-3680

19 L (5 US gal)

Coolant Conditioner Test Kit instructions:

5P-2907

208 L (55 US gal)

STEP 3 - Add tap water to the vial up to the “20

ml” mark.

Maintain the SCA in the same way as you would

maintain a cooling system that uses heavy-duty

STEP 5 - When the defined procedure is used,

coolant/antifreeze. Adjust the maintenance for the

a concentration of six to eight percent will yield

amount of SCA additions. See Table 20 for the

between 20 drops and 27 drops. If the number of

amount of SCA that is required.

drops is below 20 drops, the concentration of SCA

is low. If the number of drops is above 27 drops, the

concentration of SCA is high. Make the appropriate

adjustments to the concentration of SCA.

Test the concentration of SCA or submit a

coolant sample to your Caterpillar dealer. See

this publication, “S·O·S Coolant Analysis” topic

(Maintenance Section).

Maintenance Section

Cooling System Specifications

Additions of SCA are based on the results of the

Check the coolant/antifreeze (glycol concentration)

test or based on the results of the coolant analysis.

in order to ensure adequate protection against

The size of the cooling system determines the

boiling or freezing. Caterpillar recommends the

amount of SCA that is required.

use of a refractometer for checking the glycol

concentration. Use the 1U-7298 Coolant/Battery

Use the equation that is in Table 22 to determine

Tester (Celsius) or use the 1U-7297 Coolant/Battery

the amount of Caterpillar SCA that is required for

Tester (Fahrenheit). The testers give readings that

maintenance, if necessary:

are immediate and accurate. The testers can be

used with ethylene or with propylene glycol.

Table 24

SCA To Water Addition Equation For Maintenance

Caterpillar engine cooling systems should be

tested at 250 hour intervals for the concentration of

V × 0.023 = X

Supplemental Coolant Additive (SCA). SCA test kits

V is the total volume of the cooling system.

are available from your Caterpillar dealer. Test the

concentration of SCA or submit a coolant sample to

X is the amount of SCA that is required.

your Caterpillar dealer at 250 hour intervals. Refer

to S·O·S Coolant Analysis for more information on

Table 25 is an example for using the equation that

this topic.

is in Table 22.

Additions of SCA are based on the results of the

Table 25

test or based on the results of the coolant analysis.

An SCA that is liquid or a maintenance element for

SCA To Water Addition Equation Example

an SCA (if equipped) may be needed at 250 hour

For Maintenance

intervals.

Total Volume

Multiplication

Amount of SCA

of the Cooling

Factor

that is Required

Table 26 lists the amount of Caterpillar SCA

System (V)

(X)

that is needed at the initial fill in order to treat

coolant/antifreeze. These amounts of SCA are for

946 L

× 0.023

22 L

(250 US gal)

(6 US gal)

systems that use heavy-duty coolant/antifreeze.

Table 26 also lists additions of SCA for liquid

Note: Specific engine applications may require

and for maintenance elements at 250 hours. The

maintenance practices to be periodically evaluated

additions are required for Caterpillar DEAC and for

in order to properly maintain the engine’s cooling

commercial coolant/antifreezes.

system.

Table 21 lists part numbers and quantities of SCA

that is available from your Caterpillar dealer.

i01111872

Conventional Coolant/

Antifreeze Cooling System

Maintenance

SMCS Code: 1350; 1352; 1395

NOTICE

Never operate an engine without water temperature

regulators in the cooling system. Water temperature

regulators help to maintain the engine coolant at the

proper operating temperature. Cooling system prob-

lems can develop without water temperature regula-

tors.

Maintenance Section

Cooling System Specifications

Table 26

Caterpillar SCA Requirements for Heavy-Duty Coolant/Antifreeze

Spin-on

250 Service

Cooling System

Element at 250

Initial Fill⁽¹⁾

Hour

Capacity

Service Hour

Maintenance⁽²⁾

Maintenance⁽³⁾

22 to 30 L

0.95 L (32 fl oz)

0.24 L (8 fl oz)

111-2370 (1)

(6 to 8 US gal)

31 to 38 L

1.18 L (40 fl oz)

0.36 L (12 fl oz)

111-2369 (1)

(9 to 10 US gal)

39 to 49 L

1.42 L (48 fl oz)

0.36 L (12 fl oz)

111-2369 (1)

(11 to 13 US gal)

50 to 64 L

1.90 L (64 fl oz)

0.47 L (16 fl oz)

9N-3368 (1)

(14 to 17 US gal)

65 to 83 L

2.37 L (80 fl oz)

0.60 L (20 fl oz)

111-2371 (1)

(18 to 22 US gal)

84 to 114 L

3.32 L (112 fl oz)

0.95 L (32 fl oz)

9N-3718 (1)

(23 to 30 US gal)

115 to 163 L

4.75 L (160 fl oz)

1.18 L (40 fl oz)

111-2371 (2)

(31 to 43 US gal)

164 to 242 L

7.60 L (256 fl oz)

1.90 L (64 fl oz)

9N-3718 (2)

(44 to 64 US gal)

⁽¹⁾ When the coolant system is first filled, the SCA is not required to be used with

Caterpillar DEAC.

⁽²⁾ Do not exceed the six percent maximum concentration. Check the concentration

of SCA with a SCA test kit.

⁽³⁾ Do not use the maintenance element for the SCA and the liquid for the SCA at the

same time.

Note: Specific engine applications may require

Cooling Systems with Larger

maintenance practices to be periodically evaluated

Capacities

in order to properly maintain the engine’s cooling

system.

Adding the SCA to Conventional

Refer to Table 27 for part numbers and for quantities

Coolant/Antifreeze at the Initial Fill

of SCA.

Note: Caterpillar DEAC DOES NOT require an

Table 27

addition of SCA when the cooling system is initially

filled.

Caterpillar Liquid SCA

Part Number

Quantity

Commercial heavy duty coolant/antifreeze that meet

“ASTM D4985” or “ASTM D5345” specifications

6V-3542

0.24 L (8 oz)

MAY require an addition of SCA at the initial fill.

111-2372

0.36 L (12 oz)

Read the label or the instructions that are provided

by the OEM of the product.

8T-1589

0.47 L (16 oz)

3P-2044

0.94 L (32 oz)

Use the equation that is in Table 28 to determine

the amount of Caterpillar SCA that is required when

8C-3680

19 L (5 US gal)

the cooling system is initially filled with the following

5P-2907

208 L (55 US gal)

fluids:

• “ASTM D4985”

• “ASTM D5345”

Maintenance Section

Cooling System Specifications

Table 28

Table 31

Equation For Adding The SCA To Conventional

Example Of The Equation For Adding The SCA To

Coolant/Antifreeze At The Initial Fill

Conventional Coolant/Antifreeze For Maintenance

V × 0.045 = X

Total Volume

Multiplication

Amount of SCA

of the Cooling

Factor

that is Required

V is the total volume of the cooling system.

System (V)

(X)

X is the amount of SCA that is required.

946 L

× 0.014

9 L

(250 US gal)

(4 US gal)

Table 29 is an example for using the equation that

is in Table 28.

Note: Specific engine applications may require

maintenance practices to be periodically evaluated

Table 29

in order to properly maintain the engine’s cooling

Example Of The Equation For Adding The SCA To

system.

Conventional Coolant/Antifreeze At The Initial Fill

Table 27 lists part numbers and quantities of SCA

Total Volume

Multiplication

Amount of SCA

that is available from your Caterpillar dealer.

of the Cooling

Factor

that is Required

System (V)

(X)

Cleaning the System of Heavy-Duty

946 L

× 0.045

43 L

(250 US gal)

(11 US gal)

Coolant/Antifreeze

Caterpillar cooling system cleaners are designed

Adding the SCA to Conventional

to clean the cooling system of harmful scale and

Coolant/Antifreeze For Maintenance

corrosion. Caterpillar cooling system cleaners

dissolve mineral scale, corrosion products, light oil

Heavy duty coolant/antifreeze of all types REQUIRE

contamination and sludge.

periodic additions of an SCA.

•

Clean the cooling system after used coolant is

Test the coolant/antifreeze periodically for the

drained or before the cooling system is filled with

concentration of SCA. For the interval, see the

new coolant.

Operation and Maintenance Manual, “Maintenance

Interval Schedule” (Maintenance Section). SCA

• Clean the cooling system whenever the coolant is

test kits are available from your Caterpillar

contaminated or whenever the coolant is foaming.

dealer. Test the concentration of SCA or submit

a coolant sample to your Caterpillar dealer. See

• For the recommended service interval, refer

this publication, “S·O·S Coolant Analysis” topic

to the Operation and Maintenance Manual,

(Maintenance Section).

“Maintenance Interval Schedule” for your engine.

Additions of SCA are based on the results of the

test or based on the results of the coolant analysis.

The size of the cooling system determines the

amount of SCA that is needed.

Use the equation that is in Table 30 to determine

the amount of Caterpillar SCA that is required, if

necessary:

Table 30

Equation For Adding The SCA To Conventional

Coolant/Antifreeze For Maintenance

V × 0.014 = X

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Table 31 is an example for using the equation that

is in Table 30.

Maintenance Section

Refill Capacities

i01369854

Refill Capacities

SMCS Code: 1348; 1395; 7560

Lubrication System

The refill capacities for the engine crankcase

reflect the approximate capacity of the crankcase

or sump plus standard oil filters. Auxiliary oil filter

systems will require additional oil. Refer to the

OEM specifications for the capacity of the auxiliary

oil filter. Refer to the Operation and Maintenance

Manual, “Lubricant Specifications” (Maintenance

Section) for more information.

Table 32

3406C Industrial Engine

Approximate Refill Capacities

Compartment or System

Liters

Quarts

Crankcase Oil Sump (Standard)⁽¹⁾

34.1

36.0

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

oil sump which include the standard oil filters that are installed

at the factory. Engines with auxiliary oil filters will require

additional oil. Refer to the OEM specifications for the capacity

of the auxiliary oil filter.

Cooling System

To maintain the cooling system, the total cooling

system capacity must be known. The approximate

capacity for the engine only cooling system is

listed. External system capacities will vary among

applications. Refer to the OEM specifications for the

external system capacity. This capacity information

will be needed in order to determine the amount

of coolant/antifreeze that is required for the total

cooling system.

Table 33

3406C Industrial Engine

Approximate Refill Capacities

Compartment or System

Liters

Quarts

Engine Only

22.7

24.0

External System (OEM)⁽¹⁾

Total Cooling System⁽²⁾

⁽¹⁾ The External System includes a radiator or an expansion tank

with the following components: heat exchanger, aftercooler,

and piping. Refer to Caterpillar specifications or to the OEM

specifications and enter the capacity for the External System

in this row.

⁽²⁾ The Total Cooling System includes the capacity for the Engine

Only cooling system plus the capacity for the External System.

Enter the total in this row.

Maintenance Section

Maintenance Interval Schedule

i01369886

Radiator - Clean

Maintenance Interval Schedule

Every 114 000 L (30 000 US gal) of Fuel or

3000 Service Hours or 2 Years

SMCS Code: 1000; 7500

Cooling System Coolant (DEAC) - Change

Before performing any operation or maintenance

Cooling System Coolant Extender (ELC) - Add

procedures, ensure that the Safety Information,

Cooling System Water Temperature Regulator -

warnings, and instructions are read and

Replace

understood.

Crankshaft Vibration Damper - Inspect

Engine Mounts - Inspect

To determine the maintenance intervals, use fuel

Engine Valve Lash - Inspect/Adjust

consumption, service hours, or calendar time, which

Engine Valve Rotators - Inspect

ever occurs first.

Fuel Ratio Control - Inspect/Adjust

Turbocharger - Inspect

Before each consecutive interval is performed, all

of the maintenance requirements from the previous

Every 190 000 L (50 000 US gal) of Fuel or

interval must be performed.

5000 Service Hours

When Required

Air Compressor - Inspect

Alternator - Inspect

Battery - Replace

Fuel Injection Nozzles - Test/Exchange

Battery or Battery Cable - Disconnect

Starting Motor - Inspect

Engine - Clean

Water Pump - Inspect

Engine Air Cleaner Element (Single Element) -

Inspect/Replace

Every 228 000 L (60 000 US gal) of Fuel or

Fuel System - Prime

6000 Service Hours or 6 Years

Daily

Cooling System Coolant (ELC) - Change

Air Starting Motor Lubricator Oil Level - Check

Every 380 000 L (100 000 US gal) of Fuel or

Air Tank Moisture and Sediment - Drain

10 000 Service Hours

Cooling System Coolant Level - Check

Driven Equipment - Check

Overhaul Considerations

Engine Air Cleaner Service Indicator - Inspect

Engine Oil Level - Check

Power Take-Off Clutch - Check/Adjust/Lubricate ..

Walk-Around Inspection

Every Week

Battery Charger - Check

Every 1000 Service Hours

Engine Protective Devices - Check

Fuel Control Linkage - Check/Lubricate

Every 9500 L (2500 US gal) of Fuel or 250

Service Hours or Yearly

Aftercooler Core - Clean/Test

Alternator Belt - Inspect/Adjust/Replace

Battery Electrolyte Level - Check

Cooling System Supplemental Coolant Additive

(SCA) - Test/Add

Engine Crankcase Breather - Clean

Engine Oil Sample - Obtain

Engine Oil and Filter - Change

Fan Drive Bearing - Lubricate

Fuel System Primary Filter - Clean/Replace

Fuel Tank Water and Sediment - Drain

Hoses and Clamps - Inspect/Replace

Maintenance Section

Aftercooler Core - Clean/Test

i01371758

Inspect these items for good condition: welds,

mounting brackets, air lines, connections, clamps,

Aftercooler Core - Clean/Test

and seals. Make repairs, if necessary.

(Air-To-Air Aftercooler)

For more detailed information on cleaning and

inspection, see Special Publication, SEBD0518,

SMCS Code: 1064-070; 1064-081

“Know Your Cooling System”.

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

i01183385

Inspect the aftercooler for these items: damaged

Air Compressor - Inspect

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

other debris. Clean the aftercooler, if necessary.

SMCS Code: 1803-040

For air-to-air aftercoolers, use the same methods

that are used for cleaning radiators.

Do not disconnect the air line from the air com-

pressor governor without purging the air brake

and the auxiliary air systems. Failure to purge the

Personal injury can result from air pressure.

air brake and the auxiliary air systems before re-

moving the air compressor and/or the air lines

Personal injury can result without following prop-

could cause personal injury.

er procedure. When using pressure air, wear a pro-

tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction

of the fan’s air flow. Hold the nozzle approximately

6 mm (0.25 inch) away from the fins. Slowly move

the air nozzle in a direction that is parallel with the

tubes. This will remove debris that is between the

tubes.

Pressurized water may also be used for cleaning.

g00633741

Illustration 29

The maximum water pressure for cleaning purposes

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

(1) Air compressor pressure relief valve

water in order to soften mud. Clean the core from

both sides.

Use a degreaser and steam for removal of oil and

If the air compressor pressure relief valve that is

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

mounted in the air compressor cylinder head is

with detergent and hot water. Thoroughly rinse the

bypassing compressed air, there is a malfunction

core with clean water.

in the air system, possibly ice blockage. Under

these conditions, your engine may have insuffi-

After cleaning, start the engine and accelerate the

cient air for normal brake operation.

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

of debris and drying of the core. Stop the engine.

Do not operate the engine until the reason for the

Use a light bulb behind the core in order to inspect

air bypass is identified and corrected. Failure to

the core for cleanliness. Repeat the cleaning, if

heed this warning could lead to property damage,

necessary.

personal injury, or death to the operator or by-

standers.

Inspect the fins for damage. Bent fins may be

opened with a “comb”.

The function of the air compressor pressure relief

Note: If parts of the aftercooler system are repaired

valve is to bypass air when there is a malfunction in

or replaced, a leak test is highly recommended.

the air compressor system.

Maintenance Section

Air Starting Motor Lubricator Oil Level - Check

The air compressor pressure relief valve releases

Oiler Feed Adjustment

air at 1723 kPa (250 psi). It is very important that

all personnel stand clear of the air compressor

If necessary, adjust the lubricator in order to release

pressure relief valve when compressed air is

approximately two drops of fluid per 30 seconds

released. All personnel should also stay clear of the

into the starting motor air stream.

air compressor when the engine is operating and

the air compressor is exposed.

1. Ensure that the fuel supply to the engine is OFF.

Refer to the Service Manual or refer to the OEM

2. Turn adjustment knob (3) clockwise until the

specifications in order to find information concerning

adjustment knob locks.

the air compressor. Consult your Caterpillar dealer

for assistance.

3. Turn adjustment knob (3) counterclockwise for

1/4 turns.

i00805129

NOTICE

Air Starting Motor Lubricator

Do not crank the engine continuously for more than

30 seconds. Allow the starting motor to cool for two

Oil Level - Check

minutes before cranking the engine again.

(If Equipped)

4. Crank the starting motor for ten seconds and

SMCS Code: 1451-535

observe the exhaust air from the mufflers of the

starting motor. Look for oil mist. A slight oil mist

NOTICE

should be barely visible.

Never allow the lubricator bowl to become empty. The

air starting motor will be damaged by a lack of lubrica-

If no mist is observed, or if the mist is excessive,

tion. Ensure that sufficient oil is in the lubricator bowl.

rotate adjustment knob (3) in increments of 1/16 in

order to increase or decrease the oil mist. Repeat

the starting motor cranking and observe until the

mist is satisfactory.

Note: Drip rates should only be made under an

average steady flow condition. Once a steady

flow condition is established, the lubricator will

automatically adjust the drip rate in proportion to

the variations in air flow.

i00847451

Air Tank Moisture and

Sediment - Drain

g00381232

Illustration 30

(If Equipped)

(1) Air valve

(2) Lubricator bowl

SMCS Code: 1466-543-M&S

(3) Adjustment knob

Moisture and sediment in the air starting system

1. The vanes of the air starting motor are lubricated

can cause the following conditions:

with a fine mist of oil from the air starting motor

lubricator. Check the level of oil in lubricator bowl

(2). If the oil level is less than 1/2, add oil to the

• Freezing

lubricator bowl.

• Corrosion of internal parts

2. Ensure that the air supply to the lubricator is OFF.

• Malfunction of the air starting system

3. Remove the plug. Pour oil into lubricator bowl

(2). Use “10W” oil for temperatures that are

greater than 0 C (32 F). Use air tool oil for

temperatures that are below 0 C (32 F).

4. Install the plug.

Maintenance Section

Alternator - Inspect

i00165437

Alternator Belt -

When opening the drain valve, wear protective

gloves, a protective face shield, protective cloth-

Inspect/Adjust/Replace

ing, and protective shoes. Pressurized air could

SMCS Code: 1357-036; 1357-510

cause debris to be blown and result in personal

injury.

Inspection

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

To maximize the engine performance, inspect the

the air tank. Allow the moisture and sediment

belt for wear and for cracking. Check the belt

to drain.

tension. Adjust the belt tension in order to minimize

belt slippage. Belt slippage will decrease the life

2. Close the drain valve.

of the belt.

3. Check the air supply pressure. The air starting

To check the belt tension, apply 110 N (25 lb)

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

of force midway between the pulleys. A

air pressure to operate properly. The maximum

correctly adjusted belt will deflect 13 to 19 mm

air pressure must not exceed 1550 kPa (225 psi).

(0.50 to 0.75 inch).

The normal air pressure will be 758 to 965 kPa

(110 to 140 psi).

Adjustment

i00072207

Alternator - Inspect

SMCS Code: 1405-040

Caterpillar recommends a scheduled inspection

of the alternator. Inspect the alternator for loose

connections and proper battery charging. Inspect

the ammeter (if equipped) during engine operation

in order to ensure proper battery performance

and/or proper performance of the electrical system.

Make repairs, as required. Refer to the Service

Manual.

g00122875

Check the alternator and the battery charger for

Illustration 31

proper operation. If the batteries are properly

Typical Adjusting Nuts (1) and Mounting Bolt (2)

charged, the ammeter reading should be very near

zero. All batteries should be kept charged. The

1. Remove the belt guard.

batteries should be kept warm because temperature

affects the cranking power. If the battery is too cold,

2. Loosen mounting bolt (2) and adjusting nuts (1).

the battery will not crank the engine. The battery will

not crank the engine, even if the engine is warm.

3. Turn adjusting nuts (1) in order to increase or

When the engine is not run for long periods of time

decrease the belt tension.

or if the engine is run for short periods, the batteries

may not fully charge. A battery with a low charge will

4. Tighten adjusting nuts (1). Tighten mounting bolt

freeze more easily than a battery with a full charge.

(2). Refer to the Operation and Maintenance

Manual for the proper torques.

5. Reinstall the belt guard.

If new belts are installed, check the belt adjustment

again after 30 minutes of engine operation at the

rated rpm.

Maintenance Section

Battery - Replace

Replacement

7. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.

For applications that require multiple drive belts,

replace the belts in matched sets. Replacing only

8. Connect the cable from the ground plane to the

one belt of a matched set will cause the new belt

NEGATIVE “-” battery terminal.

to carry more load because the older belts are

stretched. The additional load on the new belt could

i01206348

cause the new belt to break.

Battery Electrolyte Level -

Refer to the Service Manual for more information on

the procedures for the following topics: belt removal

Check

and belt installation.

SMCS Code: 1401-535

i01179608

When the engine is not run for long periods of

time or when the engine is run for short periods,

Battery - Replace

the batteries may not fully recharge. Ensure a full

charge in order to help prevent the battery from

SMCS Code: 1401-510

freezing. If batteries are properly charged, ammeter

reading should be very near zero.

Batteries give off combustible gases which can

explode. A spark can cause the combustible gas-

All lead-acid batteries contain sulfuric acid which

es to ignite. This can result in severe personal in-

can burn the skin and clothing. Always wear a face

jury or death.

shield and protective clothing when working on or

near batteries.

Ensure proper ventilation for batteries that are in

an enclosure. Follow the proper procedures in or-

der to help prevent electrical arcs and/or sparks

1. Remove the filler caps. Maintain the electrolyte

near batteries. Do not smoke when batteries are

level to the “FULL” mark on the battery.

serviced.

If the addition of water is necessary, use distilled

water. If distilled water is not available use

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

clean water that is low in minerals. Do not use

Remove the key and all electrical loads.

artificially softened water.

2. Turn OFF the battery charger. Disconnect the

2. Check the condition of the electrolyte with the

charger.

1U-7298 Coolant/Battery Tester ( C) or the

1U-7297 Coolant/Battery Tester ( F).

3. The NEGATIVE “-” cable connects the NEGATIVE

“-” battery terminal to the ground plane.

3. Keep the batteries clean.

Disconnect the cable from the NEGATIVE “-”

battery terminal.

Clean the battery case with one of the following

cleaning solutions:

4. The POSITIVE “+” cable connects the POSITIVE

“+” battery terminal to the starting motor.

Disconnect the cable from the POSITIVE “+”

• A mixture of 0.1 L (0.11 qt) of baking soda and

1 L (1 qt) of clean water

battery terminal.

Note: Always recycle a battery. Never discard a

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

1 L (1 qt) of clean water

battery. Return used batteries to an appropriate

recycling facility.

Thoroughly rinse the battery case with clean

water.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure that

the key start switch is OFF.

Maintenance Section

Battery or Battery Cable - Disconnect

Use a fine grade of sandpaper to clean the

Charging the Battery

terminals and the cable clamps. Clean the items

until the surfaces are bright or shiny. DO NOT

remove material excessively. Excessive removal

of material can cause the clamps to not fit

Never disconnect any charging unit circuit or bat-

properly. Coat the clamps and the terminals with

tery circuit cable from the battery when the charg-

5N-5561 Silicone Lubricant, petroleum jelly or

ing unit is operated. A spark can cause an explo-

MPGM grease.

sion from the flammable vapor mixture of hydro-

gen and oxygen that is released from the elec-

i00095575

trolyte through the battery outlets. Injury to per-

sonnel can be the result.

Battery or Battery Cable -

Disconnect

Perform the following procedure to charge the

battery:

SMCS Code: 1402-029

1. Ensure that the charger is turned OFF.

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

ignition switch (if equipped) to the OFF position

2. Adjust the voltage of the charger in order to

and remove the key and all electrical loads.

match the voltage of the battery.

2. Disconnect the negative battery terminal at the

3. Connect the POSITIVE “+” lead of the charger

battery that goes to the start switch. Ensure that

to the POSITIVE “+” battery terminal. Connect

the cable cannot contact the terminal. When four

the NEGATIVE “-” lead of the charger to the

12 volt batteries are involved, the negative side

NEGATIVE “-” battery terminal.

of two batteries must be disconnected.

4. Turn ON the battery charger.

3. Tape the leads in order to help prevent accidental

starting.

Overcharging of Batteries

4. Proceed with necessary system repairs. Reverse

Overcharging reduces the service life of batteries.

the steps in order to reconnect all of the cables.

Use a battery charger that will not overcharge the

battery. DO NOT charge the battery if the meter of

the battery charger is in the RED zone.

i01039758

Battery Charger - Check

Overcharging is indicated by the following

symptoms:

SMCS Code: 1401-535

• The battery is very warm to the touch.

Checking Before Start-Up

• A strong odor of acid is present.

Check the battery charger for proper operation. If

• The battery emits smoke or a dense vapor (gas).

the batteries are properly charged, the needle of

the ammeter will register near “0” (zero).

Perform one of the following procedures if the

battery shows symptoms of overcharging:

The battery charger must not produce excessive

current during start-up. Alternatively, the charger

• Reduce the rate of charging by a significant

must be automatically disconnected for start-up.

amount. Complete the charging at the reduced

If the engine has an alternator, the charger must

rate.

be automatically disconnected during start-up and

during engine operation.

• Turn OFF the charger.

Table 34 describes the effects of overcharging on

different types of batteries.

Maintenance Section

Cooling System Coolant (DEAC) - Change

Table 34

Note: Inspect the water pump and the water

temperature regulator after the cooling system has

Effects of Overcharging Batteries

been drained. This is a good opportunity to replace

Type of Battery

Effect

the water pump, the water temperature regulator

and the hoses, if necessary.

Caterpillar General Service

All of the battery cells have

Batteries

a low level of electrolyte.

Drain

Caterpillar Premium High

Output Batteries

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,

When the plates of the

stop the engine and wait until the cooling system

battery are inspected

components are cool. Loosen the cooling system

through the filler holes, the

pressure cap slowly in order to relieve the pres-

plates may appear to be

warped. This is caused by

sure.

an excessive temperature.

The battery may not pass

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

a load test.

Loosen the cooling system filler cap slowly

in order to relieve any pressure. Remove the

Caterpillar Maintenance

The battery may not accept

cooling system filler cap.

Free Batteries

a charging current.

The battery may not pass

2. Open the cooling system drain valve (if

a load test.

equipped). If the cooling system is not equipped

with a drain valve, remove one of the drain plugs.

Checking After Stopping

Allow the coolant to drain.

Ensure that the battery charger is connected

NOTICE

properly. Observe the meter of the charger. Record

Dispose of used engine coolant properly or recycle.

the amperage.

Various methods have been proposed to reclaim used

coolant for reuse in engine cooling systems. The full

i01206425

distillation procedure is the only method acceptable by

Caterpillar to reclaim the used coolant.

Cooling System Coolant

(DEAC) - Change

For information regarding the disposal and the

recycling of used coolant, consult your Caterpillar

SMCS Code: 1350-070; 1395-044

dealer or consult Caterpillar Service Technology

Group:

Clean the cooling system and flush the cooling

system before the recommended maintenance

Outside Illinois: 1-800-542-TOOL

interval if the following conditions exist:

Inside Illinois: 1-800-541-TOOL

Canada: 1-800-523-TOOL

• The engine overheats frequently.

Flush

• Foaming is observed.

1. Flush the cooling system with clean water in

• The oil has entered the cooling system and the

order to remove any debris.

coolant is contaminated.

2. Close the drain valve (if equipped). Clean the

• The fuel has entered the cooling system and the

drain plugs. Install the drain plugs. Refer to the

coolant is contaminated.

Operation and Maintenance Manual, “Torque

Specifications” topic (Maintenance Section) for

NOTICE

more information on the proper torques.

Use of commercially available cooling system clean-

ers may cause damage to cooling system compo-

nents. Use only cooling system cleaners that are ap-

NOTICE

proved for Caterpillar engines.

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

per minute to avoid air locks.

Maintenance Section

Cooling System Coolant (DEAC) - Change

3. Fill the cooling system with a mixture of clean

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

water and Caterpillar Fast Acting Cooling System

minimum of 90 minutes. The coolant temperature

Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L

should be at least 82 C (180 F).

(4 US gal) of the cooling system capacity. Install

the cooling system filler cap.

NOTICE

Improper or incomplete rinsing of the cooling system

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

can result in damage to copper and other metal com-

minimum of 30 minutes. The coolant temperature

ponents.

should be at least 82 C (180 F).

To avoid damage to the cooling system, make sure

NOTICE

to completely flush the cooling system with clear wa-

Improper or incomplete rinsing of the cooling system

ter. Continue to flush the system until all signs of the

can result in damage to copper and other metal com-

cleaning agent are gone.

ponents.

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

To avoid damage to the cooling system, make sure

Loosen the cooling system filler cap slowly

to completely flush the cooling system with clear wa-

in order to relieve any pressure. Remove the

ter. Continue to flush the system until all signs of the

cooling system filler cap. Open the drain valve

cleaning agent are gone.

(if equipped) or remove the cooling system

drain plugs. Allow the water to drain. Flush the

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

cooling system with clean water. Close the drain

Loosen the cooling system filler cap slowly

valve (if equipped). Clean the drain plugs. Install

in order to relieve any pressure. Remove the

the drain plugs. Refer to the Operation and

cooling system filler cap. Open the drain valve

Maintenance Manual, “Torque Specifications”

(if equipped) or remove the cooling system

topic (Maintenance Section) for more information

drain plugs. Allow the water to drain. Flush the

on the proper torques.

cooling system with clean water. Close the drain

valve (if equipped). Clean the drain plugs. Install

Fill

the drain plugs. Refer to the Operation and

Maintenance Manual, “Torque Specifications”

NOTICE

topic (Maintenance Section) for more information

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

on the proper torques.

per minute to avoid air locks.

Cooling Systems with Heavy

1. Fill the cooling system with coolant/antifreeze.

Deposits or Plugging

Refer to the Operation and Maintenance

Manual, “Cooling System Specifications” topic

Note: For the following procedure to be effective,

(Maintenance Section) for more information on

there must be some active flow through the cooling

cooling system specifications. Do not install the

system components.

cooling system filler cap.

1. Flush the cooling system with clean water in

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

order to remove any debris.

engine rpm to 1500 rpm. Run the engine at high

idle for one minute in order to purge the air from

2. Close the drain valve (if equipped). Clean the

the cavities of the engine block. Stop the engine.

drain plugs. Install the drain plugs. Refer to the

Operation and Maintenance Manual, “Torque

3. Check the coolant level. Maintain the coolant

Specifications” topic (Maintenance Section) for

level within 13 mm (0.5 inch) below the bottom

more information on the proper torques.

of the pipe for filling. Maintain the coolant level

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

NOTICE

sight glass (if equipped).

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

per minute to avoid air locks.

3. Fill the cooling system with a mixture of clean

water and Caterpillar Fast Acting Cooling System

Cleaner. Add 0.5 L (1 pint) of cleaner per

3.8 to 7.6 L (1 to 2 US gal) of the cooling system

capacity. Install the cooling system filler cap.

Maintenance Section

Cooling System Coolant (ELC) - Change

4. Clean the cooling system filler cap. Inspect the

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

gasket that is on the cooling system filler cap. If

Loosen the cooling system filler cap slowly

the gasket that is on the cooling system filler cap

in order to relieve any pressure. Remove the

is damaged, discard the old cooling system filler

cooling system filler cap.

cap and install a new cooling system filler cap.

If the gasket that is on the cooling system filler

2. Open the cooling system drain valve (if

cap is not damaged, perform a pressure test. A

equipped). If the cooling system is not equipped

9S-8140 Pressurizing Pump is used to perform

with a drain valve, remove the cooling system

the pressure test. The correct pressure for the

drain plugs.

cooling system filler cap is stamped on the face

of the cooling system filler cap. If the cooling

Allow the coolant to drain.

system filler cap does not retain the correct

pressure, install a new cooling system filler cap.

NOTICE

Dispose of used engine coolant properly or recycle.

5. Start the engine. Inspect the cooling system for

Various methods have been proposed to reclaim used

leaks and for proper operating temperature.

coolant for reuse in engine cooling systems. The full

distillation procedure is the only method acceptable by

Caterpillar to reclaim the used coolant.

i01206445

Cooling System Coolant (ELC)

For information regarding the disposal and the

- Change

recycling of used coolant, consult your Caterpillar

dealer or consult Caterpillar Service Technology

SMCS Code: 1350-070; 1395-044

Group:

Clean the cooling system and flush the cooling

Outside Illinois: 1-800-542-TOOL

system before the recommended maintenance

Inside Illinois: 1-800-541-TOOL

interval if the following conditions exist:

Canada: 1-800-523-TOOL

• The engine overheats frequently.

Flush

• Foaming is observed.

1. Flush the cooling system with clean water in

order to remove any debris.

• The oil has entered the cooling system and the

coolant is contaminated.

2. Close the drain valve (if equipped). Clean the

drain plugs. Install the drain plugs. Refer to the

• The fuel has entered the cooling system and the

Operation and Maintenance Manual, “Torque

coolant is contaminated.

Specifications” topic (Maintenance Section) for

more information on the proper torques.

Note: When the cooling system is cleaned, only

clean water is needed when the ELC is drained

NOTICE

and replaced.

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

Note: Inspect the water pump and the water

per minute to avoid air locks.

temperature regulator after the cooling system has

been drained. This is a good opportunity to replace

3. Fill the cooling system with clean water. Install

the water pump, the water temperature regulator

the cooling system filler cap.

and the hoses, if necessary.

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

Drain

temperature reaches 49 to 66 C (120 to 150 F).

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

pressure cap slowly in order to relieve the pres-

sure.

Maintenance Section

Cooling System Coolant Extender (ELC) - Add

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

i00259474

Loosen the cooling system filler cap slowly

Cooling System Coolant

in order to relieve any pressure. Remove the

cooling system filler cap. Open the drain valve

Extender (ELC) - Add

(if equipped) or remove the cooling system

drain plugs. Allow the water to drain. Flush the

SMCS Code: 1352-045; 1395-081

cooling system with clean water. Close the drain

valve (if equipped). Clean the drain plugs. Install

Caterpillar Extended Life Coolant (ELC) does not

the drain plugs. Refer to the Operation and

require the frequent Supplemental Coolant Additive

Maintenance Manual, “Torque Specifications”

(SCA) additions associated with the present

topic (Maintenance Section) for more information

conventional coolants. The Extender only needs to

on the proper torques.

be added once.

Fill

Check the cooling system only when the engine is

stopped and cool.

NOTICE

1. Loosen the cooling system filler cap slowly in

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

order to relieve pressure. Remove the cooling

per minute to avoid air locks.

system filler cap.

1. Fill the cooling system with Extended Life Coolant

2. It may be necessary to drain enough coolant

(ELC). Refer to the Operation and Maintenance

from the cooling system in order to add the

Manual, “Cooling System Specifications” topic

Extender.

(Maintenance Section) for more information on

cooling system specifications. Do not install the

3. Add Extender according to the requirements for

cooling system filler cap.

your engine’s cooling system capacity. Refer to

the Operation and Maintenance Manual, “Refill

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

Capacities” in the Maintenance Section for the

engine rpm to high idle. Run the engine at high

capacity of the cooling system for your engine.

idle for one minute in order to purge the air from

Refer to the Operation and Maintenance Manual,

the cavities of the engine block. Stop the engine.

“Cooling System Specifications” information for

the Caterpillar ELC Extender additions.

3. Check the coolant level. Maintain the coolant

level within 13 mm (0.5 inch) below the bottom

4. Clean the cooling system filler cap. Inspect the

of the pipe for filling. Maintain the coolant level

cooling system filler cap gaskets. Replace the

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

cooling system filler cap if the cooling system

sight glass (if equipped).

filler cap gaskets are damaged. Install the

cooling system filler cap.

4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If

i01197583

the gasket that is on the cooling system filler cap

is damaged, discard the old cooling system filler

Cooling System Coolant Level

cap and install a new cooling system filler cap. If

the gasket that is on the cooling system filler cap

- Check

is not damaged, use a 9S-8140 Pressurizing

Pump in order to pressure test the cooling

SMCS Code: 1395-082

system filler cap. The correct pressure for the

cooling system filler cap is stamped on the face

Check the coolant level when the engine is stopped

of the cooling system filler cap. If the cooling

and cool.

system filler cap does not retain the correct

pressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system for

leaks and for proper operating temperature.

Maintenance Section

Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i00992487

Cooling System Supplemental

Coolant Additive (SCA) -

Test/Add

SMCS Code: 1352-045; 1395-081

Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact with

the skin and the eyes. Do not drink cooling system

g00285520

coolant additive.

Illustration 32

Cooling system filler cap

Note: Test the concentration of the Supplemental

Coolant Additive (SCA) or test the SCA concentration

as part of an S·O·S Coolant Analysis.

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,

Test for SCA Concentration

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

Coolant/Antifreeze and SCA

pressure cap slowly in order to relieve the pres-

sure.

NOTICE

Do not exceed the recommended six percent supple-

1. Remove the cooling system filler cap slowly in

mental coolant additive concentration.

order to relieve pressure.

Use the 8T-5296 Coolant Conditioner Test Kit

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

or use the 4C-9301 Coolant Conditioner Test Kit

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

in order to check the concentration of the SCA.

equipped with a sight glass, maintain the coolant

Refer to the Operation and Maintenance Manual for

level to the proper level in the sight glass.

more information on conventional coolant/antifreeze

cooling system maintenance.

Water and SCA

NOTICE

Do not exceed the recommended eight percent sup-

plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296

Coolant Conditioner Test Kit. Refer to the Operation

and Maintenance Manual, “Water/Supplemental

Coolant Additive (SCA)” topic (Maintenance

Section). Refer to the Operation and Maintenance

g00103639

Manual, “Conventional Coolant/Antifreeze Cooling

Illustration 33

System Maintenance” topic (Maintenance Section).

Typical filler cap gaskets

3. Clean the cooling system filler cap and check the

S·O·S Coolant Analysis

condition of the filler cap gaskets. Replace the

S·O·S coolant samples can be analyzed at your

cooling system filler cap if the filler cap gaskets

are damaged. Reinstall the cooling system filler

Caterpillar dealer. S·O·S Coolant Analysis is a

cap.

program that is based on periodic samples.

4. Inspect the cooling system for leaks.

Maintenance Section

Cooling System Water Temperature Regulator - Replace

Level 1

3. Add the proper amount of SCA. Refer to the

Operation and Maintenance Manual for more

Level 1 is a basic analysis of the coolant. The

information on SCA requirements.

following items are tested:

4. Clean the cooling system filler cap. Inspect the

• Glycol Concentration

gaskets of the cooling system filler cap. If the

gaskets are damaged, replace the old cooling

• Concentration of SCA

system filler cap with a new cooling system filler

cap. Install the cooling system filler cap.

• pH

i00912898

• Conductivity

Cooling System Water

The results are reported, and recommendations

are made according to the results. Consult your

Temperature Regulator -

Caterpillar dealer for information on the benefits of

Replace

managing your equipment with an S·O·S Coolant

Analysis.

SMCS Code: 1355-510

Add the SCA, If Necessary

Replace the water temperature regulator before

the water temperature regulator fails. This is a

recommended preventive maintenance practice.

NOTICE

Replacing the water temperature regulator reduces

Do not exceed the recommended amount of sup-

the chances for unscheduled downtime.

plemental coolant additive concentration. Excessive

supplemental coolant additive concentration can form

A water temperature regulator that fails in a

deposits on the higher temperature surfaces of the

partially opened position can cause overheating or

cooling system, reducing the engine’s heat transfer

overcooling of the engine.

characteristics. Reduced heat transfer could cause

cracking of the cylinder head and other high temper-

A water temperature regulator that fails in the

ature components. Excessive supplemental coolant

closed position can cause excessive overheating.

additive concentration could also result in radiator

Excessive overheating could result in cracking of

tube blockage, overheating, and/or accelerated water

the cylinder head or piston seizure problems.

pump seal wear. Never use both liquid supplemental

coolant additive and the spin-on element (if equipped)

A water temperature regulator that fails in the open

at the same time. The use of those additives together

position will cause the engine operating temperature

could result in supplemental coolant additive concen-

to be too low during partial load operation. Low

tration exceeding the recommended maximum.

engine operating temperatures during partial loads

could cause an excessive carbon buildup inside

the cylinders. This excessive carbon buildup could

result in an accelerated wear of the piston rings and

wear of the cylinder liner.

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

NOTICE

components are cool. Loosen the cooling system

Failure to replace your water temperature regulator

pressure cap slowly in order to relieve the pres-

on a regularly scheduled basis could cause severe

sure.

engine damage.

Caterpillar engines incorporate a shunt design cooling

1. Slowly loosen the cooling system filler cap in

system and require operating the engine with a water

order to relieve the pressure. Remove the cooling

temperature regulator installed.

system filler cap.

If the water temperature regulator is installed incor-

Note: Always discard drained fluids according to

rectly, the engine may overheat, causing cylinder head

local regulations.

damage. Ensure that the new water temperature reg-

ulator is installed in the original position. Ensure that

2. If necessary, drain some coolant from the cooling

the water temperature regulator vent hole is open.

system into a suitable container in order to allow

space for the extra SCA.

Do not use liquid gasket material on the gasket or

cylinder head surface.

Maintenance Section

Crankshaft Vibration Damper - Inspect

Refer to the Service Manual for the replacement

Visconic Damper

procedure of the water temperature regulator, or

consult your Caterpillar dealer.

Your engine may be equipped with a visconic

damper. The visconic damper has a weight that is

Note: If only the water temperature regulators are

located inside a fluid filled case. The weight moves

replaced, drain the coolant from the cooling system

in the case in order to limit torsional vibration.

to a level that is below the water temperature

regulator housing.

Inspect the damper for evidence of fluid leaks. If

a fluid leak is found, determine the type of fluid.

The fluid in the damper is silicone. Silicone has

i00894991

the following characteristics: transparent, viscous,

smooth, and difficult to remove from surfaces.

Crankshaft Vibration Damper

- Inspect

If the fluid leak is oil, inspect the crankshaft seals for

leaks. If a leak is observed, replace the crankshaft

SMCS Code: 1205-040

seals.

Damage to the crankshaft vibration damper or

Inspect the damper and repair or replace the

failure of the crankshaft vibration damper can

damper for any of the following reasons:

increase torsional vibrations. This can result in

damage to the crankshaft and to other engine

• The damper is dented, cracked, or leaking.

components. A deteriorating damper can cause

excessive gear train noise at variable points in the

• The paint on the damper is discolored from heat.

speed range.

The engine has had a failure because of a broken

•

The damper is mounted to the crankshaft which is

crankshaft.

located behind the belt guard on the front of the

engine.

• Analysis of the oil has revealed that the front main

bearing is badly worn.

Rubber Damper

There is a large amount of gear train wear that is

•

not caused by a lack of oil.

Your engine may be equipped with a rubber

damper. The rubber damper uses a ring which is

Refer to the Service Manual or consult your

mounted in rubber in order to reduce vibrations in

Caterpillar dealer for information about damper

the crankshaft.

replacement.

Inspect the damper and repair or replace the

damper for any of the following reasons:

i00174798

• There is deterioration and cracking of the rubber.

Driven Equipment - Check

• There is slippage of the outer ring from the

SMCS Code: 3279-535

original position.

Refer to the OEM specifications for more information

• The engine has had a failure because of a broken

on the following maintenance recommendations for

crankshaft.

the driven equipment:

• Analysis of the oil has revealed that the front main

• Inspection

bearing is badly worn.

• Adjustment

• There is a large amount of gear train wear that is

not caused by lack of oil.

• Lubrication

Refer to the Service Manual or consult your

• Other maintenance recommendations

Caterpillar dealer for information about damper

replacement.

Perform any maintenance for the driven equipment

which is recommended by the OEM.

Maintenance Section

Engine - Clean

i01239442

NOTICE

Engine - Clean

Never run the engine without an air cleaner element

installed. Never run the engine with a damaged air

SMCS Code: 1000-070

cleaner element. Do not use air cleaner elements with

damaged pleats, gaskets or seals. Dirt entering the

engine causes premature wear and damage to engine

components. Air cleaner elements help to prevent air-

Personal injury or death can result from high volt-

borne debris from entering the air inlet.

age.

Moisture can create paths of electrical conductiv-

NOTICE

ity.

Never service the air cleaner element with the engine

running since this will allow dirt to enter the engine.

Make sure that the electrical system is OFF. Lock

out the starting controls and tag the controls “DO

NOT OPERATE”.

NOTICE

Water and/or condensation can cause damage to

electrical components. Protect all electrical compo-

nents from exposure to water.

NOTICE

Accumulated grease and oil on an engine is a fire haz-

ard. Keep the engine clean. Remove debris and fluid

spills whenever a significant quantity accumulates on

the engine.

g00310663

Illustration 34

Periodic cleaning of the engine is recommended.

Steam cleaning the engine will remove accumulated

oil and grease. A clean engine provides the

following benefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

i01173387

Engine Air Cleaner

g00310664

Illustration 35

Element (Single Element) -

1. Remove the air cleaner cover (1) and remove

Inspect/Replace

the element (2).

SMCS Code: 1054-040; 1054-510

2. Seal the air inlet (3) so that debris cannot enter

the air inlet. Tape or a clean cloth can be used

Perform the Operation and Maintenance Manual,

to cover the opening.

“Engine Air Cleaner Service Indicator-Inspect”

procedure and perform the Operation and

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

Maintenance Manual, “Engine Air Precleaner

the body that holds the air cleaner element.

Check/Clean” procedure (if equipped) before

performing the following procedure.

4. Inspect the replacement element for the following

items:damage, dirt, and debris.

5. Remove the seal from the opening of the air inlet.

Maintenance Section

Engine Air Cleaner Service Indicator - Inspect

6. Install a clean, undamaged element.

• Check for ease of resetting. The service indicator

should reset in less than three pushes.

7. Install the air cleaner cover (1).

Check the movement of the yellow core when the

•

8. Reset the service indicator.

engine is accelerated to the engine rated speed.

The yellow core should latch approximately at the

greatest vacuum that is attained.

i01175055

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

Engine Air Cleaner Service

yellow core does not latch at the greatest vacuum,

Indicator - Inspect

the service indicator should be replaced. If the

new service indicator will not reset, the hole for the

SMCS Code: 7452-040

service indicator may be plugged.

Some engines may be equipped with a different

The service indicator may need to be replaced

service indicator.

frequently in environments that are severely dusty, if

necessary. Replace the service indicator annually

Some engines are equipped with a differential

regardless of the operating conditions. Replace the

gauge for inlet air pressure. The differential gauge

service indicator when the engine is overhauled,

for inlet air pressure displays the difference in the

and whenever major engine components are

pressure that is measured before the air cleaner

replaced.

element and the pressure that is measured after

the air cleaner element. As the air cleaner element

Note: When a new service indicator is installed,

becomes dirty, the pressure differential rises. If your

excessive force may crack the top of the service

engine is equipped with a different type of service

indicator. Tighten the service indicator to a torque

indicator, follow the OEM recommendations in order

of 2 N·m (18 lb in).

to service the air cleaner service indicator.

i00906289

The service indicator may be mounted on the air

cleaner element or in a remote location.

Engine Crankcase Breather -

Clean

SMCS Code: 1317-070

NOTICE

Perform this maintenance with the engine stopped.

If the crankcase breather is not maintained on a

regular basis, the crankcase breather will become

plugged. A plugged crankcase breather will cause

excessive crankcase pressure that may cause

crankshaft seal leakage.

g00103777

Illustration 36

Typical service indicator

Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner

element should be replaced when one of the

following conditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service Indicator

Service indicators are important instruments.

Maintenance Section

Engine Mounts - Inspect

i00623423

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to

contact the skin.

g00463048

Illustration 37

Typical example

(1) Hose clamp

(2) Breather assembly

(3) Retaining clamp

g00110310

Illustration 38

1. Loosen hose clamp (1) and remove the hose

(Y) “ADD” mark. (X) “FULL” mark.

from breather assembly (2).

NOTICE

2. Loosen the retaining clamp (3). Remove breather

Perform this maintenance with the engine stopped.

assembly (2) and the seal.

3. Wash the breather element in solvent that is

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

clean and nonflammable. Allow the breather

and “FULL” mark (X) on oil level gauge (1). Do

element to dry before installation.

not fill the crankcase above “FULL” mark (X).

4. Install a breather element that is clean and

dry. Install breather assembly and seal (2) and

NOTICE

Operating your engine when the oil level is above the

install clamp (3). Refer to the Operation and

Maintenance Manual, “Torque Specifications”

“FULL” mark could cause your crankshaft to dip into

topic (Maintenance Section) for the proper

the oil. The air bubbles created from the crankshaft

dipping into the oil reduces the oil’s lubricating char-

torques.

acteristics and could result in the loss of power.

5. Install the hose. Install hose clamp (1). Refer to

the Operation and Maintenance Manual, “Torque

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

Specifications” topic (Maintenance Section) for

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

the proper torques.

i01070756

i00687861

Engine Oil Sample - Obtain

Engine Mounts - Inspect

SMCS Code: 1000-008; 1348-554-SM;

SMCS Code: 1152-040

7542-554-OC, SM

Inspect the engine mounts for deterioration and for

In addition to a good preventive maintenance

proper bolt torque. Engine vibration can be caused

program, Caterpillar recommends using S·O·S oil

by the following conditions:

analysis at regularly scheduled intervals in order

to monitor the condition of the engine and the

• Improper mounting of the engine

maintenance requirements of the engine.

• Deterioration of the engine mounts

Any engine mount that shows deterioration should

be replaced. Refer to the Service Manual for the

recommended torques. Refer to your Caterpillar

dealer for more information.

Maintenance Section

Engine Oil and Filter - Change

Obtain the Sample and the Analysis

If the engine is not equipped with a sampling valve,

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

designed to accept sampling bottles. Disposable

tubing must be attached to the pump for insertion

into the sump.

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to

For instructions, see Special Publication, PEHP6001,

contact the skin.

“How To Take A Good Oil Sample”. Consult your

Caterpillar dealer for complete information and

assistance in establishing an S·O·S program for

Before you take the oil sample, complete the Label,

your engine.

PEEP5031 for identification of the sample. In order

to help obtain the most accurate analysis, provide

the following information:

i00652130

• Engine model

Engine Oil and Filter - Change

• Service hours on the engine

SMCS Code: 1318-510; 1348-044

• The number of hours that have accumulated

since the last oil change

Hot oil and hot components can cause personal

• The amount of oil that has been added since the

injury. Do not allow hot oil or hot components to

last oil change

contact the skin.

To ensure that the sample is representative of the

oil in the crankcase, obtain a warm, well mixed oil

Do not drain the oil when the engine is cold. As

sample.

the oil cools, suspended waste particles settle

on the bottom of the oil pan. The waste particles

To avoid contamination of the oil samples, the tools

are not removed with the draining cold oil. Drain

and the supplies that are used for obtaining oil

the crankcase with the engine stopped. Drain the

samples must be clean.

crankcase with the oil warm. This draining method

allows the waste particles that are suspended in the

Caterpillar recommends using the sampling valve

oil to be drained properly.

in order to obtain oil samples. The quality and the

consistency of the samples are better when the

Failure to follow this recommended procedure will

sampling valve is used. The location of the sampling

cause the waste particles to be recirculated through

valve allows oil that is flowing under pressure to be

the engine lubrication system with the new oil.

obtained during normal engine operation.

Drain the Engine Oil

The 8T-9190 Fluid Sampling Bottle Group is

recommended for use with the sampling valve. The

After the engine has been run at the normal

bottle group includes the parts that are needed

operating temperature, stop the engine. Use one of

for obtaining oil samples. Instructions are also

the following methods to drain the engine crankcase

provided.

oil:

NOTICE

• If the engine is equipped with a drain valve, turn

Do not use the same vacuum sampling pump for ex-

the drain valve knob counterclockwise in order to

tracting oil samples that is used for extracting coolant

drain the oil. After the oil has drained, turn the

samples.

drain valve knob clockwise in order to close the

drain valve.

A small residue of either type sample may remain in

the pump and may cause a false positive analysis for

• If the engine is not equipped with a drain valve,

the sample being taken.

remove the oil drain plug in order to allow the oil

to drain. If the engine is equipped with a shallow

Always use a designated pump for oil sampling and a

sump, remove the bottom oil drain plugs from

designated pump for coolant sampling.

both ends of the oil pan.

Failure to do so may cause a false analysis which

After the oil has drained, the oil drain plugs should

could lead to customer and dealer concerns.

be cleaned and installed.

Maintenance Section

Engine Oil and Filter - Change

Replace the Oil Filter

NOTICE

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

NOTICE

This oil would not be filtered and could be contaminat-

Caterpillar oil filters are built to Caterpillar speci-

ed. Contaminated oil can cause accelerated wear to

fications. Use of an oil filter not recommended by

engine components.

Caterpillar could result in severe engine damage to

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

the larger waste particles from unfiltered oil entering

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

the engine lubricating system. Only use oil filters

oil filter gasket contacts the base. Tighten the oil

recommended by Caterpillar.

filter by hand according to the instructions that

are shown on the oil filter. Do not overtighten the

oil filter.

Remove the oil filter with a 1U-8760 Chain

Wrench.

Fill the Engine Crankcase

Cut the oil filter open with a 4C-5084 Oil Filter

Cutter. Break apart the pleats and inspect the oil

1. Remove the oil filler cap. Refer to the Operation

filter for metal debris. An excessive amount of

and Maintenance Manual for more information on

metal debris in the oil filter may indicate early

lubricant specifications. Fill the crankcase with

wear or a pending failure.

the proper amount of oil. Refer to the Operation

and Maintenance Manual for more information

Use a magnet to differentiate between the

on refill capacities.

ferrous metals and the nonferrous metals that

are found in the oil filter element. Ferrous metals

NOTICE

may indicate wear on the steel and cast iron

If equipped with an auxiliary oil filter system or a re-

parts of the engine.

mote oil filter system, follow the OEM or filter manu-

facturer’s recommendations. Under filling or overfilling

Nonferrous metals may indicate wear on the

the crankcase with oil can cause engine damage.

aluminum parts, brass parts or bronze parts of

the engine. Parts that may be affected include

the following items: main bearings, rod bearings,

NOTICE

turbocharger bearings, and cylinder heads.

To prevent crankshaft bearing damage, crank the en-

gine with the fuel OFF. This will fill the oil filters before

Due to normal wear and friction, it is not

starting the engine. Do not crank the engine for more

uncommon to find small amounts of debris in the

than 30 seconds.

oil filter. Consult your Caterpillar dealer in order

to arrange for a further analysis if an excessive

amount of debris is found in the oil filter.

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

IDLE” for two minutes. Perform this procedure in

order to ensure that the lubrication system has

oil and that the oil filters are filled. Inspect the oil

filter for oil leaks.

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

to the sump for a minimum of ten minutes.

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

oil level. Maintain the oil level between the “ADD”

and “FULL” marks on the oil level gauge.

g00103713

Illustration 39

Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mounting

base. Ensure that all of the old oil filter gasket

is removed.

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

Maintenance Section

Engine Protective Devices - Check

i00626013

NOTICE

Engine Protective Devices -

Only qualified service personnel should perform this

Check

maintenance. Refer to the Service Manual or your

Caterpillar dealer for the complete valve lash adjust-

SMCS Code: 7400-535

ment procedure.

Alarms and shutoffs must function properly. Alarms

Operation of Caterpillar engines with improper valve

provide timely warning to the operator. Shutoffs help

adjustments can reduce engine efficiency. This re-

to prevent damage to the engine. It is impossible

duced efficiency could result in excessive fuel usage

to determine if the engine protective devices are

and/or shortened engine component life.

in good working order during normal operation.

Malfunctions must be simulated in order to test the

engine protective devices.

A calibration check of the engine protective devices

Ensure that the engine can not be started while

will ensure that the alarms and shutoffs activate

this maintenance is being performed. To help pre-

at the setpoints. Ensure that the engine protective

vent possible injury, do not use the starting motor

devices are functioning properly.

to turn the flywheel.

Hot engine components can cause burns. Allow

NOTICE

additional time for the engine to cool before mea-

During testing, abnormal operating conditions must be

suring/adjusting valve lash clearance.

simulated.

The tests must be performed correctly in order to pre-

Ensure that the engine is stopped before measuring

vent possible damage to the engine.

the valve lash. To obtain an accurate measurement,

allow the valves to cool before this maintenance

is performed.

To prevent damage to the engine, only authorized

service personnel or your Caterpillar dealer should

Refer to the Service Manual for more information.

perform the tests.

i00937014

Visual Inspection

Engine Valve Rotators - Inspect

Visually check the condition of all gauges, sensors

and wiring. Look for wiring and components that

SMCS Code: 1109-040

are loose, broken, or damaged. Damaged wiring

or components should be repaired or replaced

immediately.

When inspecting the valve rotators, protective

i00869628

glasses or face shield and protective clothing

must be worn, to help prevent being burned by

Engine Valve Lash -

hot oil or spray.

Inspect/Adjust

NOTICE

SMCS Code: 1102-025

A valve rotator which does not operate properly will

accelerate valve face wear and valve seat wear and

The initial valve lash adjustment on new engines,

shorten valve life. If a damaged rotator is not replaced,

rebuilt engines, or remanufactured engines is

valve face guttering could result and cause pieces of

recommended at the first scheduled oil change.

the valve to fall into the cylinder. This can cause piston

The adjustment is necessary due to the initial wear

and cylinder head damage.

of the valve train components and to the seating of

the valve train components.

Valve rotators cause the valves to rotate when the

This maintenance is recommended by Caterpillar

engine runs. This helps to prevent deposits from

as part of a lubrication and preventive maintenance

building up on the valves and the valve seats.

schedule in order to help provide maximum engine

life.

Perform the following steps after the valve lash is

set, but before the valve covers are installed:

Maintenance Section

Fan Drive Bearing - Lubricate

1. Start the engine according to this Operation

and Maintenance Manual, “Engine Starting”

procedure (Operation Section).

Operate the engine at low idle.

2. Observe the top surface of each valve rotator.

The valve rotators should turn slightly when the

valves close.

If a valve fails to rotate, consult your Caterpillar

dealer.

i00175571

g00723120

Illustration 41

Fan Drive Bearing - Lubricate

Typical grease fittings on the fuel control linkage

SMCS Code: 1359-086-BD

Some fuel control linkages require lubrication.

Lubricate the grease fittings with 1P-0808

Multipurpose Grease or the equivalent.

i00626014

Fuel Injection Nozzles -

Test/Exchange

SMCS Code: 1254-013; 1254-081

Fuel leaked or spilled onto hot surfaces or electri-

g00123252

Illustration 40

cal components can cause a fire.

Typical Fan Drive Bearing Grease Fitting

Lubricate the fan drive bearing grease fitting with

NOTICE

Bearing Lubricant Special Purpose Grease or the

Do not allow dirt to enter the fuel system. Thoroughly

equivalent.

clean the area around a fuel system component that

will be disconnected. Fit a suitable cover over discon-

nected fuel system component.

Inspect the fan drive pulley assembly. If the shaft

is loose, an inspection of the internal components

should be performed. Refer to the Service Manual.

Fuel injection nozzles are subject to tip wear. Tip

wear is a result of fuel contamination. Tip wear can

cause the following problems:

i01370585

Fuel Control Linkage -

• Increased fuel consumption

Check/Lubricate

• Black smoke

SMCS Code: 1257-086; 1257-535

• Misfire

Check the fuel control linkage for proper operation.

• Rough running

If necessary, adjust the fuel control linkage . Refer to

the Service Manual for the adjustment procedures.

Fuel Injection nozzles should be cleaned, inspected,

tested, and replaced, if necessary. Refer to Special

Instruction, SEHS7292 for using the 8S-2245

Injection Cleaning Tool Group. Consult your

Caterpillar dealer about cleaning the fuel injection

nozzle and testing the fuel injection nozzle.

Maintenance Section

Fuel Ratio Control - Inspect/Adjust

i00908934

NOTICE

Fuel Ratio Control -

Never wire brush or scrape a fuel injection nozzle.

Wire brushing or scraping a fuel injection nozzle will

Inspect/Adjust

damage the finely machine orifice. Proper tools for

cleaning and testing the fuel injection nozzles can be

SMCS Code: 1278-025; 1278-040

obtained from Caterpillar dealers.

Slow engine response and low power may indicate

a need for adjustment or repair of the fuel ratio

The following items are symptoms of a malfunction

control. Refer to the Service Manual or your

of the fuel injection nozzle:

Caterpillar dealer for the complete adjustment

procedure on the fuel ratio control.

• Abnormal engine operation

• Smoke emission

i00891826

• Engine knock

Fuel System - Prime

Each fuel injection nozzle must be isolated one at a

SMCS Code: 1258-548

time in order to determine the malfunctioning fuel

injection nozzle.

1. Start the engine.

Personal injury or death can result from a fire.

2. Loosen each fuel line nut one at a time at the fuel

Fuel leaked or spilled onto hot surfaces or electri-

injection pump. A cloth or similar material must

cal components can cause a fire.

be used in order to prevent fuel from spraying on

the hot exhaust components. Tighten each nut

Clean up all leaked or spilled fuel. Do not smoke

before loosening the next nut.

while working on the fuel system.

3. A defective fuel injection nozzle may be identified

Turn the disconnect switch OFF or disconnect the

when a fuel line nut is loosened and the following

battery when changing fuel filters.

conditions are present:

Prime the fuel system in order to fill dry fuel filters.

• The exhaust smoke is partially eliminated or

the exhaust smoke is completely eliminated.

You must also prime the fuel system after any one

of the following conditions exist:

• Engine performance is not affected.

• The fuel system has run dry.

A fuel injection nozzle that is suspected of

being defective should be removed. A new

• The engine has been in prolonged storage.

fuel injection nozzle should be installed in the

cylinder in order to determine if the removed fuel

• The fuel filter has been cleaned.

injection nozzle is defective.

• The fuel filter has been replaced.

Removal and Installation of the

Note: If the engine does not have a fuel priming

Fuel Injection Nozzles

pump, refer to Step 4.

For the removal and the installation of fuel injection

1. Unlock the priming pump, and operate the

nozzles, special tooling is required. Refer to the

priming pump until a resistance is felt. This

Service Manual for more information. Consult your

procedure will probably require a considerable

Caterpillar dealer for assistance.

amount of priming.

2. Push in the plunger, and hand tighten the

plunger.

Maintenance Section

Fuel System Primary Filter - Clean/Replace

NOTICE

Do not crank the engine for more than 30 seconds. Al-

low the starter to cool for two minutes before cranking

again. Turbocharger damage can result if the engine

rpm is not kept low until the oil gauge display verifies

that the oil pressure is sufficient.

3. Crank the engine.

If the engine starts and the engine runs rough,

run the engine at low idle. Continue running the

engine until the engine runs smoothly.

g00290109

Illustration 42

NOTICE

During periodic service, DO NOT remove the fuel filter

8. Loosen the fuel line nuts at the valve cover base.

plug that is in the fuel filter base in order to purge air

Loosen these line nuts one at a time.

from the fuel system. The periodic removal of the fuel

filter plug will result in increased wear on the threads

9. Operate the priming pump until the flow of fuel

in the fuel filter base. This wear leads to fuel leakage.

from the fuel line is continuous and the flow of

fuel is free of air bubbles.

4. Open the vent valve (if equipped) on the fuel

injection pump’s housing.

10. Push in the plunger, and hand tighten the

plunger. If the engine does not have a fuel

5. Operate the priming pump until the flow of fuel

priming pump, crank the engine.

from the vent valve is continuous and the flow of

fuel is free of air bubbles.

11. Tighten each fuel line nut before you loosen the

next fuel line nut. Tighten the fuel line nuts to a

If the engine does not have a fuel priming pump,

torque of 40 ± 7 N·m (30 ± 5 lb ft).

crank the engine. Crank the engine until the

fuel flows freely and until the fuel is free of air

Continue this procedure until all of the fuel lines

bubbles.

have been cleared of any air. Before you start

the engine, make sure that the fuel line nuts

6. Close the vent valve. Then, push in the plunger.

are properly tightened. Also make sure that the

Hand tighten the plunger.

priming is locked.

7. Crank the engine. If the engine starts and if the

i00951418

engine runs rough, run the engine at low idle.

Continue running the engine until the engine

Fuel System Primary Filter -

runs smoothly.

Clean/Replace

Note: If the engine will not start, more priming is

necessary. If the engine continues to run rough,

SMCS Code: 1260-070; 1260-510

more priming is necessary as well.

NOTICE

Do not let the tops of fuel nozzles turn when the fuel

Fuel leaked or spilled onto hot surfaces or elec-

line nuts are loosened or tightened.

trical components can cause a fire. To help pre-

vent possible injury, turn the start switch off when

The nozzles will be damaged if the top of the nozzle

changing fuel filters or water separator elements.

turns in the body.

Clean up fuel spills immediately.

The engine will be damaged if a defective fuel injec-

1. Stop the engine.

tion nozzle is used because the shape of fuel (spray

pattern) that comes out of the nozzles will not be cor-

2. Turn the start switch to the “OFF” position.

rect.

Disconnect the battery.

3. Shut off the fuel tank supply valve to the engine.

Maintenance Section

Fuel Tank Water and Sediment - Drain

4. If the primary fuel filter is equipped with a drain

i00073301

valve, open the drain valve in order to drain any

Fuel Tank Water and Sediment

fuel from the filter case. Close the drain valve.

- Drain

NOTICE

Use a suitable container to catch any fuel that might

SMCS Code: 1273-543-M&S

spill. Clean up any spilled fuel immediately.

Fuel Tank

Fuel quality is critical to the performance and to

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

cause excessive fuel system wear. Condensation

occurs during the heating and cooling of fuel. The

condensation occurs as the fuel passes through

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

This causes water to accumulate in fuel tanks.

Draining the fuel tank regularly and obtaining fuel

from reliable sources can help to eliminate water

in the fuel.

Drain the Water and the Sediment

g00485293

Illustration 43

Fuel tanks should contain some provision for

(1) Bolt

draining water and draining sediment from the

(2) Element

(3) Case

bottom of the fuel tanks.

5. Loosen the bolt (1) that is on the filter housing.

Open the drain valve on the bottom of the fuel tank

Remove the filter case (3).

in order to drain the water and the sediment. Close

the drain valve.

6. Remove the element (2) and wash the element

in clean, nonflammable solvent.

Check the fuel daily. Drain the water and sediment

from the fuel tank after operating the engine or drain

the water and sediment from the fuel tank after the

NOTICE

fuel tank has been filled. Allow five to ten minutes

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

before performing this procedure.

The fuel would not be filtered and could be contami-

nated. Contaminated fuel will cause accelerated wear

Fill the fuel tank after operating the engine in

to fuel system parts.

order to drive out moist air. This will help prevent

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

7. Install the element (2) and the filter case (3).

fuel expands as the fuel gets warm. The tank may

Tighten the bolt (1) to a torque of 24 ± 4 N·m

overflow.

(18 ± 3 lb ft).

Some fuel tanks use supply pipes that allow water

and sediment to settle below the end of the fuel

supply pipe. Some fuel tanks use supply lines that

take fuel directly from the bottom of the tank. If

the engine is equipped with this system, regular

maintenance of the fuel system filter is important.

Fuel Storage Tanks

Drain the water and the sediment from the fuel

storage tank during the following conditions:

• Weekly

• Oil change

• Refill of the tank

Maintenance Section

Hoses and Clamps - Inspect/Replace

This will help prevent water or sediment from being

Due to extreme temperature changes, the hose

pumped from the storage tank into the engine fuel

will heat set. Heat setting causes hose clamps to

tank.

loosen. This can result in leaks. A constant torque

hose clamp will help to prevent loose hose clamps.

If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to

Each installation application can be different. The

settle before filling the engine fuel tank. Internal

differences depend on the following factors:

baffles in the bulk storage tank will also help trap

sediment. Filtering fuel that is pumped from the

• Type of hose

storage tank helps to ensure the quality of the fuel.

When possible, water separators should be used.

• Type of fitting material

Anticipated expansion and contraction of the

•

i00907072

hose

Hoses and Clamps -

• Anticipated expansion and contraction of the

Inspect/Replace

fittings

SMCS Code: 7554-040; 7554-510

Replace the Hoses and the Clamps

Inspect all hoses for leaks that are caused by the

following conditions:

• Cracking

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,

• Softness

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

• Loose clamps

pressure cap slowly in order to relieve the pres-

sure.

Replace hoses that are cracked or soft. Tighten any

loose clamps.

1. Stop the engine. Allow the engine to cool.

NOTICE

2. Loosen the cooling system filler cap slowly

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

in order to relieve any pressure. Remove the

stall bent or damaged lines, tubes or hoses. Repair

cooling system filler cap.

any loose or damaged fuel and oil lines, tubes and

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

Note: Drain the coolant into a suitable, clean

and hoses carefully. Tighten all connections to the rec-

container. The coolant can be reused.

ommended torque.

3. Drain the coolant from the cooling system to

a level that is below the hose that is being

Check for the following conditions:

replaced.

• End fittings that are damaged or leaking

4. Remove the hose clamps.

• Outer covering that is chafed or cut

5. Disconnect the old hose.

• Exposed wire that is used for reinforcement

6. Replace the old hose with a new hose.

• Outer covering that is ballooning locally

Note: For torques on hose clamps, see this

Operation and Maintenance Manual, “Torque

• Flexible part of the hose that is kinked or crushed

Specifications” (Maintenance Section).

• Armoring that is embedded in the outer covering

7. Install the hose clamps with a torque wrench.

A constant torque hose clamp can be used in

Note: For the proper coolant to use, see this

place of any standard hose clamp. Ensure that the

Operation and Maintenance Manual, “Coolant

constant torque hose clamp is the same size as

Recommendations” (Maintenance Section).

the standard clamp.

8. Refill the cooling system.

Maintenance Section

Overhaul Considerations

9. Clean the cooling system filler cap. Inspect the

When an engine’s oil consumption has risen to

cooling system filler cap’s gaskets. Replace

three times the original oil consumption rate due

the cooling system filler cap if the gaskets are

to normal wear, an engine overhaul should be

damaged. Install the cooling system filler cap.

scheduled. There may be a corresponding increase

in blowby and a slight increase in fuel consumption.

10. Start the engine. Inspect the cooling system for

leaks.

Overhaul Options

Before Failure Overhaul

i01037896

Overhaul Considerations

A planned overhaul before failure may be the best

value for the following reasons:

SMCS Code: 7595-043

• Costly unplanned downtime can be avoided.

Reduced hours of operation at full load will result

in a lower average power demand. A decreased

• Many original parts can be reused according to

average power demand should increase both the

the standards for reusable parts.

engine service life and the overhaul interval.

•

The engine’s service life can be extended without

The need for an overhaul is generally indicated by

the risk of a major catastrophe due to engine

increased fuel consumption and by reduced power.

failure.

The following factors are important when a decision

• The best cost/value relationship per hour of

is being made on the proper time for an engine

extended life can be attained.

overhaul:

After Failure Overhaul

• The need for preventive maintenance

If a major engine failure occurs and the engine

• The quality of the fuel that is being used

must be removed, many options are available. An

overhaul should be performed if the engine block

• The operating conditions

or the crankshaft needs to be repaired.

• The results of the S·O·S analysis

If the engine block is repairable and/or the

crankshaft is repairable, the overhaul cost should

be between 40 percent and 50 percent of the cost

Oil Consumption as an Overhaul

of a new engine with a similar exchange core.

Indicator

This lower cost can be attributed to three aspects:

Oil consumption, fuel consumption, and

maintenance information can be used to estimate

• Specially designed Caterpillar engine features

the total operating cost for your Caterpillar engine.

Oil consumption can also be used to estimate

• Caterpillar dealer exchange components

the required capacity of a makeup oil tank that is

suitable for the maintenance intervals.

• Caterpillar Inc. remanufactured exchange

components

Oil consumption is in proportion to the percentage

of the rated engine load. As the percentage of the

Overhaul Recommendation

engine load is increased, the amount of oil that is

consumed per hour also increases.

To minimize downtime, Caterpillar Inc. recommends

a scheduled engine overhaul by your Caterpillar

The oil consumption rate (brake specific oil

dealer before the engine fails. This will provide you

consumption) is measured in grams per kW/h

with the best cost/value relationship.

(lb per bhp). The brake specific oil consumption

(BSOC) depends on the engine load. Consult your

Note: Overhaul programs vary according to the

Caterpillar dealer for assistance in determining the

engine application and according to the dealer

typical oil consumption rate for your engine.

that performs the overhaul. Consult your Caterpillar

dealer for specific information about the available

overhaul programs and about overhaul services for

extending the engine life.

Maintenance Section

Overhaul Considerations

If an overhaul is performed without overhaul service

• Valve rotators

from your Caterpillar dealer, be aware of the

following maintenance recommendations.

• Crankshaft seals

Caterpillar Inc. recommends the installation of new

Rebuild or Exchange

parts at each overhaul period.

Cylinder Head Assembly, Cylinder Packs, Oil

Inspect these parts while the engine is disassembled

Pump, and Fuel Transfer Pump

for an overhaul.

These components should be inspected according

Inspect the crankshaft for any of the following

to the instructions that are found in various

conditions:

Caterpillar reusability publications. The Special

Publication, SEBF8029 lists the reusability

publications that are needed for inspecting the

• Deflection

engine parts.

• Damage to the journals

If the parts comply with the established inspection

specifications that are expressed in the reusable

• Bearing material that has seized to the journals

parts guideline, the parts should be reused.

Check the journal taper and the profile of the

crankshaft journals. Check these components by

Parts that are not within the established inspection

interpreting the wear patterns on the following

specifications should be dealt with in one of the

components:

following manners:

• Rod bearing

• Salvaging

• Main bearings

• Repairing

Inspect the camshaft for damage to the journals

• Replacing

and to the lobes.

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

• Costly repairs

or 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

Inspection and/or Replacement

cooler core. Then, pressure test the oil cooler core.

Crankshaft Bearings, Valve Rotators, and

Crankshaft Seals

NOTICE

Do not use caustic cleaners to clean the core.

The following components may not last until the

second overhaul.

Caustic cleaners can attack the internal metals of the

core and cause leakage.

• Thrust bearings

Note: Use this cleaning procedure to clean the oil

• Main bearings

cooler core.

• Rod bearings

Maintenance Section

Overhaul Considerations

1. Remove the oil cooler core.

6. Dry the oil cooler core with compressed air.

Direct the air in the reverse direction of the

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

normal flow.

remove debris from the oil cooler core, turn the

oil cooler core onto one end.

7. Inspect the components in order to ensure

cleanliness. The oil cooler core should be

3. Flush the oil cooler core internally with cleaner in

pressure tested. Repair the oil cooler core, if

order to loosen foreign substances. This will also

necessary. Install the oil cooler core.

help to remove oil from the oil cooler core.

For more information about cleaning the cores,

Note: Caterpillar Inc. recommends the use of

consult your Caterpillar dealer.

Hydrosolv Liquid Cleaners. Table 35 lists the

Hydrosolv Liquid Cleaners that are available from

Obtain Coolant Analysis

your Caterpillar dealer.

The concentration of supplemental coolant additive

Table 35

(SCA) should be checked regularly with test kits

HydrosolvLiquid Cleaners

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

coolant analysis is recommended when the engine

Part

Description

Size

is overhauled.

Number

For example, considerable deposits are found in the

water jacket

areas on the external cooling system,

but the conc

entrations of coolant additives were

1U-8812

4 L (1 US gallon)

carefully maintained. The coolant water probably

Hydrosolv4165

contained minerals that were deposited on the

engine over

time.

1U-5490

19 L (5 US gallon)

A coolant analysis can be conducted in order

to verify the condition of the water that is being

8T-7570

208 L (55 US gallon)

used in the cooling system. A full water analysis

can be obtained by consulting your local water

1U-8804

4 L (1 US gallon)

utility compa

ny or an agricultural agent. Private

laboratories are also available for water analysis.

Hydrosolv100

1U-5492

19 L (5 US gallon)

Caterpillar Inc. recommends an S·O·S Coolant

Analysis (Level 2).

8T-5571

208 L (55 US gallon)

S·O·S Coolant Analysis (Level 2)

4. Use steam to clean the oil cooler core. This

removes any remaining residue from the cleaner.

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

Flush the fins of the oil cooler core. Remove any

comprehensive coolant analysis which completely

other trapped debris.

analyzes the coolant and the effects on the cooling

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

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

provides the following information:

Rinse the oil cooler core thoroughly with clean

water.

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

• Visual inspection of properties

Personal injury can result from air pressure.

• Identification of metal corrosion

Personal injury can result without following prop-

• Identification of contaminants

er procedure. When using pressure air, wear a pro-

tective face shield and protective clothing.

• Identification of built up impurities (corrosion and

scale)

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

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

the results of both the analysis and the maintenance

recommendations.

Maintenance Section

Power Take-Off Clutch - Check/Adjust/Lubricate

For more information about coolant analysis, see

your Caterpillar dealer.

Do not operate the engine with the Instruction

i00339617

Plate cover removed from the clutch. Personal

injury may result.

Power Take-Off Clutch -

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

Check/Adjust/Lubricate

ure, expelled pieces can cause personal injury to

anyone in the immediate area. Proper safeguards

SMCS Code: 3055-036; 3055-086

must be followed to help prevent accidents.

NOTICE

New power take-offs should have the clutch adjust-

i01206548

ment checked before being placed into service. The

clutch adjustment should be checked again after the

Radiator - Clean

first ten hours of operation. New clutch plates have a

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

SMCS Code: 1353-070

adjustments until the new plates are “worn in”.

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

Inspect the radiator for these items: damaged fins,

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

other debris. Clean the radiator, if necessary.

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-

tective face shield and protective clothing.

g00108044

Illustration 44

Maximum air pressure at the nozzle must be less

(1) Typical instruction plate for the clutch. (2) Typical serial number

than 205 kPa (30 psi) for cleaning purposes.

plate for the clutch.

The clutch adjustment should be checked regularly

Pressurized air is the preferred method for removing

after “wear in”. Heavy-duty applications which

loose debris. Direct the air in the opposite direction

have engagements that are frequent and relatively

of the fan’s air flow. Hold the nozzle approximately

long periods of clutch slippage require more

6 mm (0.25 inch) away from the fins. Slowly move

frequent adjustment than light-duty applications.

the air nozzle in a direction that is parallel with the

The operating torque should be measured in order

tubes. This will remove debris that is between the

to determine if a clutch adjustment is required.

tubes.

Refer to the OEM information and instruction plate

Pressurized water may also be used for cleaning.

(1) for instructions on the following items: lubrication,

The maximum water pressure for cleaning purposes

adjustment, and other service recommendations.

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

Perform the maintenance that is specified on the

water in order to soften mud. Clean the core from

instruction plate.

both sides.

Use a degreaser and steam for removal of oil and

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

with detergent and hot water. Thoroughly rinse the

core with clean water.

Maintenance Section

Starting Motor - Inspect

After cleaning, start the engine and accelerate the

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

NOTICE

of debris and drying of the core. Stop the engine.

Turbocharger bearing failures can cause large quan-

Use a light bulb behind the core in order to inspect

tities of oil to enter the air inlet and exhaust systems.

the core for cleanliness. Repeat the cleaning, if

Loss of engine lubricant can result in serious engine

necessary.

damage.

Inspect the fins for damage. Bent fins may be

Minor leakage of a turbocharger housing under ex-

opened with a “comb”. Inspect these items for

tended low idle operation should not cause problems

good condition: welds, mounting brackets, air lines,

as long as a turbocharger bearing failure has not oc-

connections, clamps, and seals. Make repairs, if

curred.

necessary.

When a turbocharger bearing failure is accompanied

For more detailed information on cleaning and

by a significant engine performance loss (exhaust

inspection, see Special Publication, SEBD0518,

smoke or engine rpm up at no load), do not continue

“Know Your Cooling System”.

engine operation until the turbocharger is repaired or

replaced.

i00651416

An inspection of the turbocharger can minimize

Starting Motor - Inspect

unscheduled downtime. An inspection of the

turbocharger can also reduce the chance for

SMCS Code: 1451-040; 1453-040

potential damage to other engine parts.

Caterpillar Inc. recommends a scheduled inspection

Note: Turbocharger components require precision

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

clearances. The turbocharger cartridge must

engine may not start in an emergency situation.

be balanced due to high rpm. Severe Service

Applications can accelerate component wear.

Check the starting motor for proper operation.

Severe Service Applications require more frequent

Check the electrical connections and clean the

inspections of the cartridge.

electrical connections. Refer to the Service Manual

for more information on the checking procedure and

for specifications or consult your Caterpillar dealer

Removal and Installation

for assistance.

For options regarding the removal, installation,

repair and replacement, consult your Caterpillar

i00912946

dealer. Refer to the Service Manual for this engine

for the procedure and specifications.

Turbocharger - Inspect

SMCS Code: 1052-040

Cleaning and Inspecting

Periodic inspection and cleaning is recommended

1. Remove the exhaust outlet piping and remove

for the turbocharger compressor housing (inlet

the air inlet piping from the turbocharger. Visually

side). Any fumes from the crankcase are filtered

inspect the piping for the presence of oil.

through the air inlet system. Therefore, by-products

from oil and from combustion can collect in the

2. Turn the compressor wheel and the turbine

turbocharger compressor housing. Over time, this

wheel by hand. The assembly should turn freely.

buildup can contribute to loss of engine power,

Inspect the compressor wheel and the turbine

increased black smoke and overall loss of engine

wheel for contact with the turbocharger housing.

efficiency.

There should not be any visible signs of contact

between the turbine wheel or compressor

If the turbocharger fails during engine operation,

wheel and the turbocharger housing. If there is

damage to the turbocharger compressor wheel

any indication of contact between the rotating

and/or to the engine may occur. Damage to

turbine wheel or the compressor wheel and the

the turbocharger compressor wheel can cause

turbocharger housing, the turbocharger must be

additional damage to the pistons, the valves, and

reconditioned.

the cylinder head.

Maintenance Section

Walk-Around Inspection

Check the compressor wheel for cleanliness.

• Wipe all caps and plugs before the engine is

If only the blade side of the wheel is dirty,

serviced in order to reduce the chance of system

dirt and/or moisture is passing through the air

contamination.

filtering system. If oil is found only on the back

side of the wheel, there is a possibility of a failed

NOTICE

turbocharger oil seal.

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

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

The presence of oil may be the result of extended

the leak. If leaking is suspected, check the fluid levels

engine operation at low idle. The presence of oil

more often than recommended until the leak is found

may also be the result of a restriction of the line

or fixed, or until the suspicion of a leak is proved to be

for the inlet air (plugged air filters), which causes

unwarranted.

the turbocharger to slobber.

Use a dial indicator to check the end clearance

NOTICE

on the shaft. If the measured end play is greater

Accumulated grease and/or oil on an engine or deck is

than the Service Manual specifications, the

a fire hazard. Remove this debris with steam cleaning

turbocharger should be repaired or replaced.

or high pressure water.

An end play measurement that is less than the

minimum Service Manual specifications could

• Ensure that cooling lines are properly clamped

indicate carbon buildup on the turbine wheel.

and tight. Check for leaks. Check the condition

The turbocharger should be disassembled for

of all pipes.

cleaning and for inspection if the measured end

play is less than the minimum Service Manual

• Inspect the water pump for coolant leaks.

specifications.

Note: The water pump seal is lubricated by coolant

Inspect the bore of the turbine housing for

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

corrosion.

of leakage to occur as the engine cools down and

the parts contract.

Clean the turbocharger housing with standard

shop solvents and a soft bristle brush.

Excessive coolant leakage may indicate the need

to replace the water pump seal. For the removal

Fasten the air inlet piping and the exhaust outlet

of water pump and the installation of water pump

piping to the turbocharger housing.

and/or seals, refer to the Service Manual for the

engine or consult your Caterpillar dealer.

i00632301

• Inspect the lubrication system for leaks at the

Walk-Around Inspection

front crankshaft seal, the rear crankshaft seal, the

oil pan, the oil filters and the valve cover.

SMCS Code: 1000-040

Inspect the fuel system for leaks. Look for loose

•

fuel line clamps.

Inspect the Engine for Leaks and

for Loose Connections

• Inspect the piping for the air inlet system and the

elbows for cracks and for loose clamps.

A walk-around inspection should only take a few

minutes. When the time is taken to perform these

• Inspect the alternator belt and the accessory

checks, costly repairs and accidents can be

drive belts for cracks, breaks or other damage.

avoided.

Belts for multiple groove pulleys must be replaced

For maximum engine service life, make a thorough

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

inspection of the engine compartment before

belt will carry more load than the belts that are

starting the engine. Look for items such as oil leaks

not replaced. The older belts are stretched. The

or coolant leaks, loose bolts, worn belts, loose

additional load on the new belt could cause the

connections and trash buildup. Make repairs, as

belt to break.

needed:

•

Drain the water and the sediment from fuel tanks

• The guards must be in the proper place. Repair

on a daily basis in order to ensure that only clean

damaged guards or replace missing guards.

fuel enters the fuel system.

Maintenance Section

Water Pump - Inspect

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed

wires.

• Inspect the ground strap for a good connection

and for good condition.

• Inspect the engine-to-frame ground strap for a

good connection and for good condition.

• Disconnect any battery chargers that are not

protected against the current drain of the starting

motor. Check the condition and the electrolyte

level of the batteries, unless the engine is

equipped with a maintenance free battery.

• Check the condition of the gauges. Replace

any gauges which are cracked or can not be

calibrated.

i01057943

Water Pump - Inspect

SMCS Code: 1361-040; 1361

A failed water pump might cause severe engine

overheating problems that could result in the

following conditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine

Visually inspect the water pump for leaks. If any

leaking is observed, replace the water pump

seal or the water pump assembly. Refer to the

Service Manual for the disassembly and assembly

procedure.

Note: Refer to the Service Manual or consult your

Caterpillar dealer if any repair is needed or any

replacement is needed.

Reference Information Section

Customer Service

Central America and Caribbean

Reference Information

Caterpillar Americas Co.

Section

15550 NW 59th Avenue

Miami Lakes, FL 33014

USA

Phone: 305-816-3306

Customer Service

Fax: 305-816-3307

Mexico

i00790127

Grupo Financiero Caterpillar Mexico, S.A. de

C.V.

Customer Assistance

Primer piso del Arco Oriente de Arco Bosques

Corporativa,

SMCS Code: 1000

Bosques del Alisos 45A

Bosques de Las Lomas

USA and Canada

Mexico, D.F. 05120

Phone (from within Mexico): 915-258-1515

When a problem arises concerning the operation of

Fax (from within Mexico): 915-258-1530

an engine or concerning the service of an engine,

Phone (from within USA): 011-525-258-1515

the problem will normally be managed by the dealer

Fax (from within USA): 011-525-258-1530

in your area.

Ecuador, Colombia, Venezuela, Guyana, and

Your satisfaction is a primary concern to Caterpillar

Suriname

and to Caterpillar dealers. If you have a problem

Caterpillar Americas Co.

that has not been handled to your complete

15550 NW 59th Avenue

satisfaction, follow these steps:

Miami Lakes, FL 33014

USA

1. Discuss your problem with a manager from the

Phone: 305-816-3316

dealership.

Fax: 305-816-3317

2. If your problem cannot be resolved at the dealer

Peru, Chile, and Bolivia

level without additional assistance, use the

Caterpillar Americas Co.

phone number that is listed below to talk with a

Edificio Centro Santa Maria

Field Service Coordinator:

Av. Los Conquistadores 1700

Piso 14, Oficina A

1-800-447-4986

Santiago, Chile

Phone: 011-562-366-5100

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

Fax: 011-562-366-5125

through Friday Central Standard Time.

Brazil, Argentina, Paraguay, and Uruguay

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

Caterpillar Americas Co.

matter in writing to the following address:

Birmann II

Rua Aleandre Dumas, 1.711-9.0

Caterpillar Inc.

Chac., Sto. Antonio

Manager, Customer Service, Engine Division

04717-004-Sao Paulo, SP

Mossville Bldg A

Phone: 55-11-5180-2000

P.O. Box 600

Fax: 55-11-5182-9694

Peoria, Illinois 61552-0600

Europe, Africa, and Middle East

Please keep in mind: probably, your problem will

Caterpillar Overseas S.A.

ultimately be solved at the dealership, using the

76 Route de Frontenex

dealership’s facilities, equipment, and personnel.

P.O. Box 6000

Therefore, follow the steps in sequence when a

1211 Geneva 6

problem is experienced.

Switzerland

Phone: 22-849-4444

Outside of the USA and of Canada

Fax: 22-849-4544

If a problem arises outside the USA and outside

Canada, and if the problem cannot be resolved at

the dealer level, consult the appropriate Caterpillar

office.

Reference Information Section

Customer Service

Far East

i01028392

Caterpillar Asia Pte. Ltd.

Ordering Replacement Parts

7 Tractor Road

Jurong, Singapore 627968

SMCS Code: 7567

Republic of Singapore

Phone: 65-662-8333

Fax: 65-662-8302

China

When replacement parts are required for this

Caterpillar China Ltd.

product Caterpillar recommends using Caterpillar

37/F, The Lee Gardens

replacement parts or parts with equivalent spec-

33 Hysan Avenue

ifications including, but not limited to, physical

Causeway Bay, Hong Kong

dimensions, type, strength and material.

China

Phone: 852-2848-0333

Failure to heed this warning can lead to prema-

Fax: 852-2848-0440

ture failures, product damage, personal injury or

death.

Japan

Shin Caterpillar Mitsubishi Ltd.

Quality Caterpillar replacement parts are available

Setagaya Business Square Tower

from Caterpillar dealers throughout the world.

10-1, Yoga 4-chome

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

Setagaya, Tokyo

The parts stocks include all of the parts that are

Japan

normally needed to protect your Caterpillar engine

Phone: 81-3-5717-1121

investment.

Fax: 81-3-5717-1177

When you order parts, please specify the following

Japan

information:

Caterpillar Power Systems, Inc.

Japan Branch Sanno Grand Bldg.

2-14-2 Nagatacho

• Part number

Chiyoda-ku, Tokyo, 100

Japan

• Part name

Phone: 81-335-93-3237

Fax: 81-335-93-3238

• Quantity

If there is a question concerning the part number,

Australia and New Zealand

please provide your dealer with a complete

Caterpillar of Australia Ltd.

description of the needed item.

1 Caterpillar Drive

Private Mail Bag 4

When a Caterpillar engine requires maintenance

Tullamarine, Victoria 3043

and/or repair, provide the dealer with all the

Australia

information that is stamped on the Information Plate.

Phone: 03-9339-9333

This information is described in this Operation and

Fax: 03-9335-3366

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.

Reference Information Section

Reference Materials

Coolants

Special Publication, SEBD0970, “Coolant and

•

i01370327

Your Engine”

Reference Material

• Special Publication, PEHP4036, “Data Sheet-

Extended Life Coolant”

SMCS Code: 1000

• Special Publication, SEBD0518, “Knowing Your

The following literature can be obtained through any

Cooling System”

Caterpillar dealer.

Special Publication, PEEP5027, “Label ELC

•

Lubricants

Radiator Label”

• Special Publication, PEHP7041, “Data Sheet

• Special Publication, PEHP7057, “S·O·S Coolant

- Caterpillar Diesel Engine Oils (DEO) (CG-4)

Analysis”

(International only)”

Miscellaneous

• Special Publication, PEHP1026, “Data Sheet

- Caterpillar Diesel Engine Oil (DEO) (CF-4)

• Service Manual, SENR1110, “3406C Industrial

(International only)”

Engine”

• Special Publication, PEHP1027, “Data Sheet -

• Special Publication, SEBU6251, “Caterpillar

Caterpillar Diesel Engine Oil (CD)”

Commercial Diesel Engine Fluids

Recommendations”

• Special Publication, PEHP8038, “Data Sheet

- Caterpillar Diesel Engine Oils (DEO) (CH-4)

• Special Publication, PECP6026, “One Safe

(North America and Australia)”

Source”

• Special Publication, PEWP9733, “Cat Fluids

• Special Publication, SEHS7654, “Alignment -

Selector Dial”

General Instructions”

• Special Publication, PEWP3014, “Cat Fluids

• Operation and Maintenance Manual, SEBU5898,

Selector Dial (International)”

“Cold Weather Recommendations”

• Special Publication, NEDG6022, “Data Sheet -

• Special Instruction, SMHS7001, “Assembly of Fan

Multipurpose Lithium Complex Grease (MPG)”

Drive Pulley Assemblies”

• Special Publication, PEHP0002, “Data Sheet

• Special Instruction, SEHS7633, “Battery Test

- Multipurpose Lithium Complex Grease with

Procedure”

Molybdenum (MPGM)”

• Special Instruction, SEHS7332, “Do Not Operate

• Special Publication, PEHP0017, “Data Sheet -

Tag”

Special Purpose Grease (SPG) Bearing Lubricant”

• Special Publication, SEBF8062, “Guideline for

• Special Publication, NEHP5621, “How To Select

Reusable Parts - Cleaning and Inspection of Air

The Right Grease For Any Job”

Filters”

• Special Publication, PEHP6001, “How To Take A

• Special Publication, SEBF8029, “Index of

Good Oil Sample”

Publications for Reusable Parts and Salvage

Operations”

• Special Publication, SEBD0640, “Oil and Your

Engine”

• Special Publication, LEBH9324, “Industrial

Application and Installation Guide”

• Special Publications, PEDP7036, “SOS Fluids

Analysis Cornerstone”

• Service Manual, REG1139F, “Service Manual

Contents Microfiche”

Fuels

Special Instruction, SEHS9031, “Storage

•

• Special Publication, SEBD0717, “Diesel Fuels and

Procedure for Caterpillar Products”

Your Engine”

Reference Information Section

Reference Materials

• Special Instruction, NENG2500, “Tools and Shop

The “American Petroleum Institute Publication No.

Products Guide”

1509” can be obtained from the following locations:

local technological society, local library, and local

• Specifications, SENR3130, “Torque Specifications”

college. If necessary, consult API at the following

address:

• Special Instruction, SEHS7292, “Using the

5P-4150 Nozzle Testing Group”

American Petroleum Institute

1220 L St. N.W.

• Special Instruction, SEHS8024, “Governor

Washington, DC, USA 20005

Adjusting Tool Group”

Telephone: (202) 682-8000

• Special Instruction, SEHS8094, “Using the Nozzle

The International Organization for Standardization

Puller Group”

(ISO) offers information and customer service

regarding international standards and standardizing

• Special Instruction, SEHS8622, “Using the FT-

activities. ISO can also supply information on the

1984 Air-To-Air Aftercooler Leak Test Group”

following subjects that are not controlled by ISO:

national standards, regional standards, regulations,

certification, and related activities. Consult the

Emissions Warranty

member of ISO in your country.

This engine may be Certified and this engine

International Organization for Standardization

may be covered by an Emissions Warranty. A

(ISO)

detailed explanation of the Emissions Warranty

1, rue de Varembé

that is applicable to Certified engines is found in

Case postale 56

Supplement, SEBU6981, “Federal Emissions Control

CH-1211 Genève 20

Warranty Information”. The Engine is Certified if

Switzerland

the engine has a special label that states that the

Telephone: +41 22 749 01 11

engine is certified. A Caterpillar dealer can also

Facsimile: +41 22 733 34 30

inform you if the engine is Certified.

E-mail: central@iso.ch

Web site: http://www.iso.ch

i01109461

European classifications are established by the

Additional Reference Material

Counseil International Des Machines a Combustion

(CIMAC) (International Council on Combustion

SMCS Code: 1000

Engines).

The “EMA Lubricating Oils Data Book” can

CIMAC Central Secretariat

be obtained from the following locations: local

Lyoner Strasse 18

technological society, local library, and local college.

60528 Frankfurt

If necessary, consult EMA at the following address:

Germany

Telephone: +49 69 6603 1567

Engine Manufacturers Associaton

Facsimile: +49 69 6603 1566

401 N. Michigan Ave.

Chicago, IL, USA 60611

i00912149

Telephone: (312) 644-6610 ext. 3626

Maintenance Records

The “Society of Automotive Engineers (SAE)

Specifications” can be found in your SAE handbook.

SMCS Code: 1000

This publication can also be obtained from the

following locations: local technological society, local

Caterpillar Inc. recommends the retention

library, and local college. If necessary, consult SAE

of accurate maintenance records. Accurate

at the following address:

maintenance records can be used for the following

purposes:

SAE International

400 Commonwealth Drive

• Determine operating costs.

Warrendale, PA, USA 15096-0001

Telephone: (724) 776-4841

• Establish maintenance schedules for other

engines that are operated in the same

environment.

Reference Information Section

Reference Materials

• Show compliance with the required maintenance

practices and maintenance intervals.

Maintenance records can be used for a variety of

other business decisions that are related to engine

maintenance.

Maintenance records are a key element of a

maintenance program that is well managed.

Accurate maintenance records can help your

Caterpillar dealer to fine tune the recommended

maintenance intervals in order to meet the specific

operating situation. This should result in a lower

engine operating cost.

Records should be kept for the following items:

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’s repair costs

• Owner’s receipts

• Maintenance log

Index Section

Index

Cooling System Coolant (ELC) - Change

Drain

Additional Reference Material

Fill

After Starting Engine

Flush

After Stopping Engine

Cooling System Coolant Extender (ELC) - Add

Aftercooler Core - Clean/Test (Air-To-Air

Cooling System Coolant Level - Check

Aftercooler)

Cooling System Specifications

Aftermarket Oil Additives

Cooling System Supplemental Coolant Additive

Air Compressor - Inspect

(SCA) - Test/Add

Air Starting

Add the SCA, If Necessary

Air Starting Motor Lubricator Oil Level - Check (If

S·O·S Coolant Analysis

Equipped)

Test for SCA Concentration

Oiler Feed Adjustment

Cooling System Water Temperature Regulator -

Air Tank Moisture and Sediment - Drain (If

Replace

Equipped)

Crankshaft Vibration Damper - Inspect

Alternator - Inspect

Rubber Damper

Alternator Belt - Inspect/Adjust/Replace

Visconic Damper

Adjustment

Crushing Prevention and Cutting Prevention

Inspection

Customer Assistance

Replacement

Outside of the USA and of Canada

USA and Canada

Customer Service

Battery - Replace

Battery Charger - Check

Checking After Stopping

Diesel Engine Antifreeze/Coolant (DEAC)

Checking Before Start-Up

Driven Equipment - Check

Battery Electrolyte Level - Check

Battery or Battery Cable - Disconnect

Before Starting Engine

12, 24

Burn Prevention

Batteries

Emergency Stopping

Coolant

Emergency Stop Button

Oils

Emissions Certification Film

Engaging the Driven Equipment

Engine - Clean

Engine Air Cleaner Element (Single Element) -

Inspect/Replace

Cold Weather Lubricants

Engine Air Cleaner Service Indicator - Inspect

Cold Weather Operation

Test the Service Indicator

Cold Weather Starting

Engine Crankcase Breather - Clean

Commercial Heavy-Duty Coolant/Antifreeze and

Engine Description

SCA

Engine Cooling and Lubrication

Conventional Coolant/Antifreeze Cooling System

Engine Information

Maintenance

Engine Specifications

Cleaning the System of Heavy-Duty

Engine Features and Controls

Coolant/Antifreeze

Engine Identification

Cooling Systems with Larger Capacities

Engine Lifting

Coolant Recommendations

Engine Lifting with a Fuel Tank

Cooling System Coolant (DEAC) - Change

Engine Lifting and Storage

Cooling Systems with Heavy Deposits or

Engine Mounts - Inspect

Plugging

Engine Oil

Drain

Caterpillar Diesel Engine Oil

Fill

Commercial Oils

Flush

Total Base Number (TBN) and Fuel Sulfur Levels

for Direct Injection (DI) Diesel Engines

Index Section

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

Engine Oil Level - Check

Engine Oil Sample - Obtain

Obtain the Sample and the Analysis

Engine Operation

Engine Protective Devices - Check

Gauges and Indicators

Visual Inspection

General Coolant Information

Engine Shutoffs and Engine Alarms

Additives

Alarms

Glycol

Shutoffs

Water

Testing the Shutoff and Alarm System

General Hazard Information

Engine Starting

13, 24

Asbestos Information

Ether

Containing Fluid Spillage

Engine Stopping

13, 30

Dispose of Waste Properly

Engine Storage

Fluid Penetration

Engine Valve Lash - Inspect/Adjust

Pressure Air and Water

Engine Valve Rotators - Inspect

General Torque Information

Engine Warm-up

Extended Life Coolant (ELC)

Extended Life Coolant (ELC) Cooling System

Maintenance

Caterpillar ELC Extender

Hoses and Clamps - Inspect/Replace

Changing to Caterpillar ELC

Replace the Hoses and the Clamps

Commercial ELC

ELC Cooling System Cleaning

ELC Cooling System Contamination

Proper additions to the Extended Life Coolant .. 50

Important Safety Information

Information Plate

Fan Drive Bearing - Lubricate

Fire Prevention and Explosion Prevention

Ether

Lubricant Information

Fire Extinguisher

API Oils

Foreword

Engine Manufacturers Association (EMA) Oils .. 37

California Proposition 65 Warning

General Information

Literature Information

Lubricant Specifications

Maintenance

Lubricating Grease

Maintenance Intervals

Caterpillar Premium Grease (CPG)

Operation

Multipurpose Greases

Overhaul

Special Purpose Grease (SPG)

Safety

Fuel and the Effect from Cold Weather

Fuel Conservation Practices

Fuel Control Linkage - Check/Lubricate

Fuel Injection Nozzles - Test/Exchange

Maintenance Interval Schedule

Removal and Installation of the Fuel Injection

Maintenance Log

Nozzles

Maintenance Records

Fuel Ratio Control - Inspect/Adjust

Maintenance Section

Fuel Recommendations

Manual Stop Procedure

Fuel Related Components in Cold Weather

Model View Illustrations

Fuel Filters

Model Views

Fuel Heaters

Mounting and Dismounting

Fuel Tanks

Fuel Specifications

Fuel System - Prime

Fuel System Primary Filter - Clean/Replace

Index Section

Operation Section

Table of Contents

Ordering Replacement Parts

Torque Specifications

Overhaul Considerations

Turbocharger - Inspect

Oil Consumption as an Overhaul Indicator

Cleaning and Inspecting

Overhaul Recommendation

Removal and Installation

Power Take-Off Clutch - Check/Adjust/Lubricate...

Walk-Around Inspection

Product Identification Information

Inspect the Engine for Leaks and for Loose

Product Information Section

Connections

Water Pump - Inspect

Water/Supplemental Coolant Additive (SCA)

Cooling Systems with Larger Capacities

Radiator - Clean

Radiator Restrictions

Re-refined Base Stock Oils

Reference Information Section

Reference Material

Coolants

Emissions Warranty

Fuels

Lubricants

Miscellaneous

Reference Materials

Reference Numbers

Record for Reference

Refill Capacities

Cooling System

Lubrication System

S·O·S Coolant Analysis

New Systems, Refilled Systems, and Converted

Systems

Recommended Interval for S·O·S Coolant

Sample

S·O·S Coolant Analysis (Level 1)

S·O·S Coolant Analysis (Level 2)

S·O·S Oil Analysis

Safety Section

Safety Signs and Labels

Serial Number Plate

Standard Torque for Constant Torque Hose

Clamps

Standard Torque for Inch Fasteners

Standard Torque for Metric Fasteners

Standard Torque for Worm Drive Band Hose

Clamps

Starting Motor - Inspect

Starting the Engine

Starting with Jump Start Cables

Supplemental Coolant Additive (SCA)

Synthetic Base Stock Oils