Caterpillar C4.4 (Mech) Industrial Engine. Operation and Maintenance Manual (2007)

i01658146

Important Safety Information

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

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

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

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

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

could result in injury or death.

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

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

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

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

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

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

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

presented.

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

this publication.

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

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

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

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

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

repair procedures that you choose.

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

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

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

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

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

When replacement parts are required for this

product Caterpillar recommends using 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.

SEBU8327

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 at the

manual should be stored in or near the engine area

appropriate intervals as indicated in the Maintenance

in a literature holder or literature storage area. Read,

Interval Schedule. The actual operating environment

study and keep it with the literature and engine

of the engine also governs the Maintenance Interval

information.

Schedule. Therefore, under extremely severe,

dusty, wet or freezing cold operating conditions,

English is the primary language for all Caterpillar

more frequent lubrication and maintenance than is

publications. The English used facilitates translation

specified in the Maintenance Interval Schedule may

and consistency in electronic media delivery.

be necessary.

Some photographs or illustrations in this manual

The maintenance schedule items are organized for

show details or attachments that may be different

a preventive maintenance management program. If

from your engine. Guards and covers may have

the preventive maintenance program is followed, a

been removed for illustrative purposes. Continuing

periodic tune-up is not required. The implementation

improvement and advancement of product design

of a preventive maintenance management program

may have caused changes to your engine which are

should minimize operating costs through cost

not included in this manual. Whenever a question

avoidances resulting from reductions in unscheduled

arises regarding your engine, or this manual, please

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 individual

This safety section lists basic safety precautions.

items in each level should be shifted ahead or back

In addition, this section identifies hazardous,

depending upon your specific maintenance practices,

warning situations. Read and understand the basic

operation and application. We recommend that

precautions listed in the safety section before

the maintenance schedules be reproduced and

operating or performing lubrication, maintenance and

displayed near the engine as a convenient reminder.

repair on this product.

We also recommend that a maintenance record be

maintained as part of the engine’s permanent record.

Operation

See the section in the Operation and Maintenance

Operating techniques outlined in this manual are

Manual, “Maintenance Records” for information

basic. They assist with developing the skills and

regarding documents that are generally accepted

techniques required to operate the engine more

as proof of maintenance or repair. Your authorized

efficiently and economically. Skill and techniques

Caterpillar dealer can assist you in adjusting your

develop as the operator gains knowledge of the

maintenance schedule to meet the needs of your

engine and its capabilities.

operating environment.

The operation section is a reference for operators.

Overhaul

Photographs and illustrations guide the operator

through procedures of inspecting, starting, operating

Major engine overhaul details are not covered in the

and stopping the engine. This section also includes a

Operation and Maintenance Manual except for the

discussion of electronic diagnostic 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 care.

programs. If you experience a major engine failure,

The illustrated, step-by-step instructions are grouped

there are also numerous after failure overhaul options

by fuel consumption, service hours and/or calendar

available from your Caterpillar dealer. Consult with

time maintenance intervals. Items in the maintenance

your dealer for information regarding these options.

schedule are referenced to detailed instructions that

follow.

SEBU8327

Safety Section

Safety Messages

The Universal Warning label (2) is located on the

Safety Section

rear end of the valve mechanism cover. Refer to

illustration 2.

i02690461

Safety Messages

SMCS Code: 1000; 7405

There may be several specific warning signs on your

engine. The exact location and a description of the

warning signs are reviewed in this section. Please

become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean

the warning signs or replace the warning signs if

the words cannot be read or if the illustrations are

not visible. Use a cloth, water, and soap to clean

the warning signs. Do not use solvents, gasoline, or

other harsh chemicals. Solvents, gasoline, or harsh

chemicals could loosen the adhesive that secures the

warning signs. The warning signs that are loosened

could drop off of the engine.

Replace any warning sign that is damaged or

missing. If a warning sign is attached to a part of the

engine that is replaced, install a new warning sign on

the replacement part. Your Caterpillar dealer or your

distributor can provide new warning signs.

(1) Universal Warning

Do not operate or work on this equipment unless

you have read and understand the instructions

and warnings in the Operation and Maintenance

Manuals. Failure to follow the instructions or

heed the warnings could result in serious injury

or death.

g01154807

Illustration 1

Typical example

SEBU8327

Safety Section

General Hazard Information

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 start the

the maintenance under the following conditions:

engine and operate the engine in a well ventilated

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

• The engine is stopped. Ensure that the engine

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 understood.

•

• Grease fittings

Use the proper tools. Replace any equipment that

is damaged or repair the equipment.

• Pressure taps

Pressurized Air and Water

• Breathers

Pressurized air and/or water can cause debris

• Drain plugs

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

personal injury.

Use caution when cover plates are removed.

Gradually loosen, but do not remove the last two

When pressurized air and/or pressurized water is

bolts or nuts that are located at opposite ends of

used for cleaning, wear protective clothing, protective

the cover plate or the device. Before removing the

shoes, and eye protection. Eye protection includes

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

goggles or a protective face shield.

relieve any spring pressure or other pressure.

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).

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long

after the engine has been stopped. The pressure can

cause hydraulic fluid or items such as pipe plugs to

escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts

until pressure has been relieved or personal injury

g00702020

Illustration 5

may occur. Do not disassemble any hydraulic

components or parts until pressure has been relieved

• Wear a hard hat, protective glasses, and other

or personal injury may occur. Refer to the OEM

protective equipment, as required.

information for any procedures that are required to

relieve the hydraulic pressure.

• When work is performed around an engine that is

operating, wear protective devices for ears in order

to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

• Ensure that all protective guards and all covers are

secured in place on the engine.

• Never put maintenance fluids into glass containers.

Glass containers can break.

SEBU8327

Safety Section

General Hazard Information

Asbestos Information

g00687600

Illustration 6

g00702022

Illustration 7

Always use a board or cardboard when you check

for a leak. Leaking fluid that is under pressure can

Caterpillar equipment and replacement parts that are

penetrate body tissue. Fluid penetration can cause

shipped from Caterpillar are asbestos free. Caterpillar

serious injury and possible death. A pin hole leak can

recommends the use of only genuine Caterpillar

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

replacement parts. Use the following guidelines

you must get treatment immediately. Seek treatment

when you handle any replacement parts that contain

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

asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be

Containing Fluid Spillage

generated when you handle components that contain

asbestos fibers. Inhaling this dust can be hazardous

Care must be taken in order to ensure that fluids

to your health. The components that may contain

are contained during performance of inspection,

asbestos fibers are brake pads, brake bands, lining

maintenance, testing, adjusting and repair of the

material, clutch plates, and some gaskets. The

engine. Prepare to collect the fluid with suitable

asbestos that is used in these components is usually

containers before opening any compartment or

bound in a resin or sealed in some way. Normal

disassembling any component that contains fluids.

handling is not hazardous unless airborne dust that

contains asbestos is generated.

Refer to Special Publication, NENG2500, “Dealer

Service Tool Catalog” for the following items:

If dust that may contain asbestos is present, there

are several guidelines that should be followed:

• Tools that are suitable for collecting fluids and

equipment that is suitable for collecting fluids

• Never use compressed air for cleaning.

• Tools that are suitable for containing fluids and

• Avoid brushing materials that contain asbestos.

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.

SEBU8327

Safety Section

Burn Prevention

• Comply with applicable rules and regulations

Any contact with hot coolant or with steam can cause

for the work place. In the United States, use

severe burns. Allow cooling system components to

Occupational Safety and Health Administration

cool before the cooling system is drained.

(OSHA) requirements. These OSHA requirements

can be found in “29 CFR 1910.1001”.

Check the coolant level after the engine has stopped

and the engine has been allowed to cool.

• Obey environmental regulations for the disposal

of asbestos.

Ensure that the filler cap is cool before removing the

filler cap. The filler cap must be cool enough to touch

• Stay away from areas that might have asbestos

with a bare hand. Remove the filler cap slowly in

particles in the air.

order to relieve pressure.

Cooling system conditioner contains alkali. Alkali can

Dispose of Waste Properly

cause personal injury. Do not allow alkali to contact

the skin, the eyes, or the mouth.

Oils

Hot oil and hot lubricating components can cause

personal injury. Do not allow hot oil to contact the

skin. Also, do not allow hot components to contact

the skin.

Batteries

Electrolyte is an acid. Electrolyte can cause personal

injury. Do not allow electrolyte to contact the skin or

g00706404

the eyes. Always wear protective glasses for servicing

Illustration 8

batteries. Wash hands after touching the batteries

and connectors. Use of gloves is recommended.

Improperly disposing of waste can threaten the

environment. Potentially harmful fluids should be

disposed of according to local regulations.

i01372254

Always use leakproof containers when you drain

Fire Prevention and Explosion

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

Prevention

drain, or into any source of water.

SMCS Code: 1000; 7405

i01480768

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

All fuels, most lubricants, and some coolant mixtures

engine coolant is hot. The coolant is also under

are flammable.

pressure. The radiator and all lines to the heaters or

to the engine contain hot coolant.

SEBU8327

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

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

Use caution when you are refueling an engine. Do

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

not smoke while you are refueling an engine. Do not

installed correctly.

refuel an engine near open flames or sparks. Always

stop the engine before refueling.

Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines or tanks that contain

flammable fluid. Clean any such lines or tanks

thoroughly with a nonflammable solvent prior to

welding or flame cutting.

Wiring must be kept in good condition. All electrical

wires must be properly routed and securely attached.

Check all electrical wires daily. Repair any wires

that are loose or frayed before you operate the

engine. Clean all electrical connections and tighten

all electrical connections.

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than

the recommended gauge. Do not bypass any fuses

and/or circuit breakers.

Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and properly

maintained battery cables will help to prevent arcing

or sparking.

g00704135

Illustration 11

SEBU8327

Safety Section

Crushing Prevention and Cutting Prevention

Gases from a battery can explode. Keep any open

Check lines, tubes and hoses carefully. Do not use

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

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

not smoke in battery charging areas.

cardboard to check for leaks. Tighten all connections

to the recommended torque.

Never check the battery charge by placing a metal

object across the terminal posts. Use a voltmeter or

Replace the parts if any of the following conditions

a hydrometer.

are present:

Improper jumper cable connections can cause

• End fittings are damaged or leaking.

an explosion that can result in injury. Refer to

the Operation Section of this manual for specific

• Outer coverings are chafed or cut.

instructions.

• Wires are exposed.

Do not charge a frozen battery. This may cause an

explosion.

• Outer coverings are ballooning.

The batteries must be kept clean. The covers

• Flexible part of the hoses are kinked.

(if equipped) must be kept on the cells. Use the

recommended cables, connections, and battery box

• Outer covers have embedded armoring.

covers when the engine is operated.

• End fittings are displaced.

Fire Extinguisher

Make sure that all clamps, guards, and heat shields

are installed correctly. During engine operation, this

Make sure that a fire extinguisher is available. Be

will help to prevent vibration, rubbing against other

familiar with the operation of the fire extinguisher.

parts, and excessive heat.

Inspect the fire extinguisher and service the fire

extinguisher regularly. Obey the recommendations

on the instruction plate.

i01359666

Crushing Prevention and

Ether

Cutting Prevention

Ether is flammable and poisonous.

SMCS Code: 1000; 7405

Use ether in well ventilated areas. Do not smoke

while you are replacing an ether cylinder or while you

Support the component properly when work beneath

are using an ether spray.

the component is performed.

Do not store ether cylinders in living areas or in the

Unless other maintenance instructions are provided,

engine compartment. Do not store ether cylinders

never attempt adjustments while the engine is

in direct sunlight or in temperatures above 49 °C

running.

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

flames or sparks.

Stay clear of all rotating parts and of all moving

parts. Leave the guards in place until maintenance

Dispose of used ether cylinders properly. Do not

is performed. After the maintenance is performed,

puncture an ether cylinder. Keep ether cylinders

reinstall the guards.

away from unauthorized personnel.

Keep objects away from moving fan blades. The fan

Do not spray ether into an engine if the engine is

blades will throw objects or cut objects.

equipped with a thermal starting aid for cold weather

starting.

When objects are struck, wear protective glasses in

order to avoid injury to the eyes.

Lines, Tubes and Hoses

Chips or other debris may fly off objects when objects

are struck. Before objects are struck, ensure that no

Do not bend high pressure lines. Do not strike high

one will be injured by flying debris.

pressure lines. Do not install any lines that are bent

or damaged.

Repair any lines that are loose or damaged. Leaks

can cause fires. Consult your Caterpillar dealer for

repair or for replacement parts.

SEBU8327

Safety Section

Mounting and Dismounting

i01372247

All protective guards and all protective covers must

be installed if the engine must be started in order

Mounting and Dismounting

to perform service procedures. To help prevent an

accident that is caused by parts in rotation, work

SMCS Code: 1000; 7405

around the parts carefully.

Inspect the steps, the handholds, and the work area

Do not bypass the automatic shutoff circuits. Do not

before mounting the engine. Keep these items clean

disable the automatic shutoff circuits. The circuits are

and keep these items in good repair.

provided in order to help prevent personal injury. The

circuits are also provided in order to help prevent

Mount the engine and dismount the engine only at

engine damage.

locations that have steps and/or handholds. Do not

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

See the Service Manual for repairs and for

adjustments.

Face the engine in order to mount the engine or

dismount the engine. Maintain a three-point contact

with the steps and handholds. Use two feet and one

i02707603

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

Engine Starting

controls as handholds.

SMCS Code: 1000

Do not stand on components which cannot support

your weight. Use an adequate ladder or use a work

platform. Secure the climbing equipment so that the

equipment will not move.

Do not use aerosol types of starting aids such as

Do not carry tools or supplies when you mount the

ether. Such use could result in an explosion and

engine or when you dismount the engine. Use a hand

personal injury.

line to raise and lower tools or supplies.

If a warning tag is attached to the engine start switch

i02704618

or to the controls DO NOT start the engine or move

the controls. Consult with the person that attached

Before Starting Engine

the warning tag before the engine is started.

SMCS Code: 1000

All protective guards and all protective covers must

be installed if the engine must be started in order

NOTICE

to perform service procedures. To help prevent an

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

accident that is caused by parts in rotation, work

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

around the parts carefully.

provision to shut the engine off should an overspeed

occur. This may be accomplished by shutting off the

Start the engine from the operator’s compartment or

air and/or fuel supply to the engine.

from the engine start switch.

Always start the engine according to the procedure

Overspeed shutdown should occur automatically.

that is described in the Operation and Maintenance

If automatic shutdown does not occur, press the

Manual, “Engine Starting” topic in the Operation

emergency stop button in order to cut the fuel and/or

Section. Knowing the correct procedure will help to

air to the engine.

prevent major damage to the engine components.

Knowing the procedure will also help to prevent

Inspect the engine for potential hazards.

personal injury.

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

To ensure that the jacket water heater (if equipped)

underneath, or close to the engine. Ensure that the

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

area is free of personnel.

correctly, check the water temperature gauge

and/or the oil temperature gauge during the heater

If equipped, ensure that the lighting system for the

operation.

engine is suitable for the conditions. Ensure that all

lights work properly, if equipped.

Engine exhaust contains products of combustion

which can be harmful to your health. Always start the

engine and operate the engine in a well ventilated

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

vent the engine exhaust to the outside.

SEBU8327

Safety Section

Engine Stopping

Note: The engine is equipped with a device for cold

Grounding Practices

starting. If the engine will be operated in very cold

conditions, then an extra cold starting aid may be

Correct grounding for the engine electrical system

required. Normally, the engine will be equipped with

is necessary for optimum engine performance

the correct type of starting aid for your region of

and reliability. Incorrect grounding will result in

operation.

uncontrolled electrical circuit paths and in unreliable

electrical circuit paths.

These engines are equipped with a glow plug starting

aid in each individual cylinder that heats the intake

Uncontrolled electrical circuit paths can result in

air in order to improve starting.

damage to main bearings, to crankshaft bearing

journal surfaces, and to aluminum components.

i02707233

Engines that are installed without engine-to-frame

ground straps can be damaged by electrical

Engine Stopping

discharge.

SMCS Code: 1000

To ensure that the engine and the engine electrical

systems function correctly, an engine-to-frame

Stop the engine according to the procedure in

ground strap with a direct path to the battery must be

the Operation and Maintenance Manual, “Engine

used. This path may be provided by way of a direct

Stopping (Operation Section)” in order to avoid

engine ground to the frame.

overheating of the engine and accelerated wear of

the engine components.

All grounds should be tight and free of corrosion. The

engine alternator must be grounded to the negative

Use the Emergency Stop Button (if equipped) ONLY

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

in an emergency situation. Do not use the Emergency

handle the full charging current of the alternator.

Stop Button for normal engine stopping. After an

emergency stop, DO NOT start the engine until the

problem that caused the emergency stop has been

corrected.

Stop the engine if an overspeed condition occurs

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

that has been overhauled. This may be accomplished

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

shutting off the air supply to the engine.

i02176668

Electrical System

SMCS Code: 1000; 1400

Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit

is operating. A spark can cause the combustible

gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible

gases that are produced by some batteries, the

negative “-” jump start cable should be connected

last from the external power source to the negative

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

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

the jump start cable to the engine block.

Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires

before the engine is started. Repair all frayed

electrical wires before the engine is started. See

the Operation and Maintenance Manual for specific

starting instructions.

SEBU8327

Product Information Section

Model Views

Engine Specifications

The engine lubricating oil is supplied by a gear

type pump. The engine lubricating oil is cooled and

Note: The front end of the engine is opposite the

the engine lubricating oil is filtered. Bypass valves

flywheel end of the engine. The left and the right

provide unrestricted flow of lubrication oil to the

sides of the engine are determined from the flywheel

engine parts when oil viscosity is high. Bypass valves

end. The number 1 cylinder is the front cylinder.

can also provide unrestricted flow of lubrication oil

to the engine parts if the oil cooler should become

plugged or if the oil filter element should become

plugged.

Engine efficiency, efficiency of emission controls, and

engine performance depend on adherence to proper

operation and maintenance recommendations.

Engine performance and efficiency also depend on

the use of recommended fuels, lubrication oils, and

coolants. Refer to the Operation and Maintenance

Manual, “Maintenance Interval Schedule” for more

information on maintenance items.

Engine Service Life

g00984281

Illustration 14

Engine efficiency and maximum utilization of engine

A typical example of the layout of the valves

performance depend on the adherence to proper

(A) Inlet valves

operation and maintenance recommendations. In

(B) Exhaust valves

addition, use recommended fuels, coolants and

lubricants. Use the Operation and Maintenance

Table 1

Manual as a guide for required engine maintenance.

C-4.4 Industrial Engine Specifications

Expected engine life is generally predicted by the

Number of Cylinders

4 In-Line

average power that is demanded. The average power

Bore

105 mm (4.134 inch)

that is demanded is based on fuel consumption of

the engine over a period of time. Reduced hours of

Stroke

127 mm (5.0 inch)

operation at full throttle and/or operating at reduced

Aspiration

Naturally aspirated

throttle settings result in a lower average power

Turbocharged

demand. Reduced hours of operation will increase

Turbocharged aftercooled

the length of operating time before an engine

overhaul is required.

Compression Ratio

NA 19.3:1

T, TA 18.2:1

Displacement

4.4 L (268 in³)

Firing Order

1342

Rotation (flywheel end)

Counterclockwise

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

Valve Lash Setting

0.45 mm (0.018 inch)

(Exhaust)

Engine Cooling and Lubrication

The cooling system consists of the following

components:

• Gear-driven centrifugal water pump

• Water temperature regulator which regulates the

engine coolant temperature

• Gear-driven oil pump (gear type)

• Oil cooler

SEBU8327

Product Information Section

Product Identification Information

Product Identification

Information

i02711140

Plate Locations and Film

Locations

SMCS Code: 1000

g01258789

Illustration 16

Serial number plate

i02708605

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 in the appropriate space.

Make a copy of this list for a record. Keep the

information for future reference.

Record for Reference

g01360892

Illustration 15

Engine Model

_______________________________________________

Location of the serial number plate

Engine Serial number

_____________________________________

Serial Number Plate (1)

Engine Low Idle rpm

______________________________________

The engine serial number plate is located on the left

Engine Full Load rpm

_____________________________________

side of the cylinder block to the rear of the engine.

Primary Fuel Filter

_________________________________________

Caterpiller dealers need all of these numbers in order

to determine the components that were included with

Water Separator Element

________________________________

the engine. This permits accurate identification of

replacement part numbers.

Secondary Fuel Filter Element

__________________________

Lubrication Oil Filter Element

___________________________

Auxiliary Oil Filter Element

_______________________________

Total Lubrication System Capacity

_____________________

Total Cooling System Capacity

_________________________

Air Cleaner Element

_______________________________________

Fan Drive Belt

______________________________________________

Alternator Belt ______________________________________________

SEBU8327

Operation Section

Lifting and Storage

i02068367

Operation Section

Product Storage

SMCS Code: 1000; 1404; 7002

Lifting and Storage

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

i02708018

lubricating oil will drain from the cylinder walls and

from the piston rings. Rust can form on the cylinder

Product Lifting

liner surface. Rust on the cylinder liner surface will

cause increased engine wear and a reduction in

SMCS Code: 1000; 1404; 7002

engine service life.

To help prevent excessive engine wear, use the

following guidelines:

• Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance

Manual, “Maintenance Interval Schedule”

(Maintenance Section).

• If freezing temperatures are expected, check the

cooling system for adequate protection against

freezing. See this Operation and Maintenance

Manual, “Refill Capacities and Recommendations”

(Maintenance Section).

g00103219

Illustration 19

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

is not planned, special precautions should be made.

NOTICE

If the engine will be stored for more than one month,

Never bend the eyebolts and the brackets. Only load

a complete protection procedure is recommended.

the eyebolts and the brackets under tension. Remem-

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

For more detailed information on engine storage, see

between the supporting members and the object be-

Special Instruction, SEHS9031, “Storage Procedure

comes less than 90 degrees.

For Caterpillar Products”.

When it is necessary to remove a component at an

Your Caterpillar dealer can assist in preparing the

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

engine for extended storage periods.

the weight.

Use a hoist to remove heavy components. Use

an adjustable lifting beam to lift the engine. All

supporting members (chains and cables) should be

parallel to each other. The chains and cables should

be perpendicular to the top of the object that is being

lifted.

Some removals require lifting the fixtures in order to

obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that

are on the engine.

Lifting eyes are designed and installed for the specific

engine arrangement. Alterations to the lifting eyes

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

fixtures obsolete. If alterations are made, ensure

that proper lifting devices are provided. Consult your

Caterpillar dealer for information regarding fixtures

for proper engine lifting.

SEBU8327

Operation Section

Gauges and Indicators

1. Reduce the load and the engine rpm.

Gauges and Indicators

2. Inspect the cooling system for leaks.

i02704606

3. Determine if the engine must be shut down

Gauges and Indicators

immediately or if the engine can be cooled by

reducing the load.

SMCS Code: 1900; 7450

Tachometer - This gauge indicates engine

Your engine may not have the same gauges or all of

speed (rpm). When the throttle control lever

the gauges that are described. For more information

is moved to the full throttle position without

about the gauge package, see the OEM information.

load, the engine is running at high idle. The engine is

running at the full load rpm when the throttle control

Gauges provide indications of engine performance.

lever is at the full throttle position with maximum

Ensure that the gauges are in good working order.

rated load.

Determine the normal operating range by observing

the gauges over a period of time.

NOTICE

Noticeable changes in gauge readings indicate

To help prevent engine damage, never exceed the

potential gauge or engine problems. Problems may

high idle rpm. Overspeeding can result in serious

also be indicated by gauge readings that change

damage to the engine. The engine can be operated

even if the readings are within specifications.

at high idle without damage, but should never be

Determine and correct the cause of any significant

allowed to exceed high idle rpm.

change in the readings. Consult your Caterpillar

dealer for assistance.

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

stamped on the Information Plate.

NOTICE

If no oil pressure is indicated, STOP the engine. If

Ammeter - This gauge indicates the

maximum coolant temperature is exceeded, STOP

amount of charge or discharge in the

the engine. Engine damage can result.

battery charging circuit. Operation of the

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

Engine Oil Pressure - The oil pressure

should be greatest after a cold engine is

Fuel Level - This gauge indicates the

started. The typical engine oil pressure with

fuel level in the fuel tank. The electrically

SAE10W30 is 207 to 413 kPa (30 to 60 psi) at rated

operated fuel level gauge only operates

rpm.

when the “START/STOP” switch is “ON”.

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

Service Hour Meter - This gauge

is stable and the gauge reading changes, perform

indicates operating time of the engine.

the following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

Jacket Water Coolant Temperature -

Typical temperature range is 71 to 96°C

(160 to 205°F). The maximum allowable

temperature with the pressurized cooling system at

48 kPa (7 psi) is 103°C (217°F). Higher temperatures

may occur under certain conditions. The water

temperature reading may vary according to load. The

reading should never exceed the boiling point for the

pressurized system that is being used.

If the engine is operating above the normal range

and steam becomes apparent, perform the following

procedure:

SEBU8327

Operation Section

Features and Controls

Engines may be equipped with alarms in order

Features and Controls

to alert the operator when undesirable operating

conditions occur.

i02704608

NOTICE

Engine Shutoffs and Engine

When an alarm is activated, corrective measures must

Alarms

be taken before the situation becomes an emergency

in order to avoid possible engine damage.

SMCS Code: 1900; 7400; 7418

If corrective measures are not taken within a

Shutoffs

reasonable time, engine damage could result. The

alarm will continue until the condition is corrected.

Shutoffs and alarms are electrically operated or

The alarm may need to be reset.

mechanically operated. The operation of all electric

shutoffs and alarms utilize components which actuate

A switch may be installed in the alarm while the

switches in a sensing unit.

engine is stopped for repairs. Before the engine is

started, ensure that the switch is moved to the ON

Shutoffs are set at critical levels for the following

position and that the warning lights are flashing. The

items: operating temperature, operating pressure,

engine will not be protected if the switch is left in the

operating level, and operating rpm. The particular

OFF position.

shutoff may need to be reset before the engine will

start.

Testing the Shutoff and Alarm

NOTICE

System

Always determine the cause of the engine shutdown.

Make necessary repairs before attempting to restart

Most control panels are equipped with a lamp test

the engine.

switch. Turn the switch to the ON position in order

to check the indicator lights for proper operation.

Replace worn bulbs immediately.

Be familiar with the following items:

NOTICE

• Types and locations of shutoff

During testing, abnormal operating conditions must be

simulated. Perform the tests correctly in order to help

• Conditions which cause each shutoff to function

prevent possible engine damage.

• The resetting procedure that is required to restart

the engine

Refer to the Service Manual for more information on

testing procedures or consult your Caterpillar dealer.

Alarms

i02704607

Alarms consist of a switch and a contactor. The

switches are wired to the contactors. The contactors

Fuel Shutoff

activate alarm circuits in an annunciator panel. Your

engine may be equipped with the following switches:

SMCS Code: 1259; 1704

Engine oil pressure - The engine oil pressure

The fuel shutoff solenoid is located on the fuel

switch indicates when oil pressure drops below rated

injection pump.

system pressure.

When the fuel shutoff solenoid is activated, the

Coolant level - The low coolant level switch

solenoid moves to the “Open” position.

indicates when the coolant level is low.

When the fuel shutoff solenoid is deactivated, the

Coolant temperature - The coolant temperature

solenoid moves to the “Closed” position.

switch indicates high jacket water coolant

temperature.

Note: The sensing element of the coolant

temperature switch must be submerged in coolant

in order to operate.

SEBU8327

Operation Section

Engine Starting

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

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

similar warning tag attached to the start switch or

i02704617

to the controls.

Before Starting Engine

• Ensure that the areas around the rotating parts are

clear.

SMCS Code: 1000; 1400; 1450

•

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

Perform the required daily maintenance and other

damaged guards or for missing guards. Repair

periodic maintenance before the engine is started.

any damaged guards. Replace damaged guards

Inspect the engine compartment. This inspection can

and/or missing guards.

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

Operation and Maintenance Manual, “Maintenance

• Disconnect any battery chargers that are not

Interval Schedule” for more information.

protected against the high current drain that

is created when the electric starting motor (if

• For the maximum service life of the engine, make

equipped) is engaged. Check electrical cables

a thorough inspection before the engine is started.

and check the battery for poor connections and

Look for the following items: oil leaks, coolant

for corrosion.

leaks, loose bolts, and trash buildup. Remove trash

buildup and arrange for repairs, as needed.

• Reset all of the shutoffs or alarm components (if

equipped).

• Inspect the cooling system hoses for cracks and

for loose clamps.

• Check the engine lubrication oil level. Maintain the

oil level between the “MIN” mark and the “MAX”

• Inspect the alternator and accessory drive belts for

mark on the oil level gauge.

cracks, breaks, and other damage.

•

Check the coolant level. Observe the coolant level

• Inspect the wiring for loose connections and for

in the coolant recovery tank (if equipped). Maintain

worn wires or frayed wires.

the coolant level to the “FULL” mark on the coolant

recovery tank.

• Check the fuel supply. Drain water from the water

separator (if equipped). Open the fuel supply valve

• If the engine is not equipped with a coolant

(if equipped).

recovery tank maintain the coolant level within

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

the engine is equipped with a sight glass, maintain

NOTICE

the coolant level in the sight glass.

All valves in the fuel return line must be open before

and during engine operation to help prevent high fuel

pressure. High fuel pressure may cause filter housing

• Observe the air cleaner service indicator (if

equipped). Service the air cleaner when the yellow

failure or other damage.

diaphragm enters the red zone, or when the red

piston locks in the visible position.

If the engine has not been started for several weeks,

fuel may have drained from the fuel system. Air

• Ensure that any driven equipment has been

may have entered the filter housing. Also, when fuel

disengaged. Minimize electrical loads or remove

filters have been changed, some air pockets will be

any electrical loads.

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.

SEBU8327

Operation Section

Engine Starting

i02710653

When Group 2 diesel fuel is used, the following items

provide a means of minimizing starting problems

Starting the Engine

and fuel problems in cold weather: engine oil pan

heaters, jacket water heaters, fuel heaters, and fuel

SMCS Code: 1000; 1450

line insulation.

Use the procedure that follows for cold weather

starting.

Do not use aerosol types of starting aids such as

1. If equipped, move the throttle lever to the full

ether. Such use could result in an explosion and

throttle position before you start the engine.

personal injury.

2. If equipped, turn the engine start switch to the

Refer to the OMM for your type of controls. Use the

HEAT position. Hold the engine start switch in the

following procedure to start the engine.

HEAT position for 6 seconds until the glow plug

indicator light illuminates. This will activate the

1. If equipped, move the throttle lever to the full

glow plugs and aid in the starting of the engine.

throttle position before you start the engine.

NOTICE

Do not crank the engine for more than 30 seconds.

Allow the electric starting motor to cool for two minutes

before cranking the engine again.

3. While the glow plug indicator light is illuminated,

2. Turn the engine start switch to the START position.

turn the engine start switch to the START position

Hold the engine start switch in the START position

and crank the engine.

Note: If the glow plug indicator light illuminates

3. When the engine starts, release the engine start

rapidly for 2 to 3 seconds, or if the glow plug indicator

switch.

light fails to illuminate, a malfunction exists in the cold

start system. Do not use ether or other starting fluids

4. If equipped, slowly move the throttle lever to the

to start the engine.

low idle position and allow the engine to idle. Refer

to the Operation and Maintenance Manual, “After

4. When the engine starts, release the engine start

Starting Engine” topic.

switch key.

5. If the engine does not start, release the engine

start switch and allow the electric starting motor to

start switch and allow the starting motor to cool.

cool. Then, repeat steps 2 through step 4.

Then, repeat steps 2 through step 4.

6. Turn the engine start switch to the OFF position in

6. If the engine is equipped with a throttle allow the

order to stop the engine.

engine to idle for three to five minutes, or allow the

engine to idle until the water temperature indicator

begins to rise. The engine should run at low idle

i02710719

smoothly until speed is gradually increased to high

Cold Weather Starting

idle. Allow the white smoke to disperse before

proceeding with normal operation.

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

7. Operate the engine at low load until all systems

reach operating temperature. Check the gauges

during the warm-up period.

Do not use aerosol types of starting aids such as

8. Turn the engine start switch to the OFF position in

ether. Such use could result in an explosion and

order to stop the engine.

personal injury.

Startability will be improved at temperatures below

-18 °C (0 °F) from the use of a jacket water heater

or extra battery capacity.

SEBU8327

Operation Section

Engine Starting

i02344933

2. Connect one positive end of the jump start cable

to the positive cable terminal of the discharged

Starting with Jump Start

battery. Connect the other positive end of the jump

start cable to the positive cable terminal of the

Cables

electrical source.

SMCS Code: 1000; 1401; 1402; 1900

3. Connect one negative end of the jump start cable

to the negative cable terminal of the electrical

source. Connect the other negative end of the

jump start cable to the engine block or to the

Improper jump start cable connections can cause

chassis ground. This procedure helps to prevent

an explosion resulting in personal injury.

potential sparks from igniting the combustible

gases that are produced by some batteries.

Prevent sparks near the batteries. Sparks could

cause vapors to explode. Do not allow jump start

4. Start the engine.

cable ends to contact each other or the engine.

5. Immediately after the engine is started, disconnect

the jump start cables in reverse order.

If the installation is not equipped with a backup

battery system, it may be necessary to start the

After jump starting, the alternator may not be able to

engine from an external electrical source.

fully recharge batteries that are severely discharged.

The batteries must be replaced or charged to the

For information on troubleshooting the charging

proper voltage with a battery charger after the engine

system, refer to Special Instruction, REHS0354,

is stopped. Many batteries which are considered

“Charging System Troubleshooting”.

unusable are still rechargeable. Refer to Operation

and Maintenance Manual, “Battery - Replace” and

Many batteries which are considered unusable are

Testing and Adjusting Manual, “Battery - Test”.

still rechargeable. After jump starting, the alternator

may not be able to fully recharge batteries that

Refer to the Electrical Schematic for your engine.

are severely discharged. The batteries must be

Consult your Caterpillar dealer for more information.

charged to the proper voltage with a battery charger.

For information on testing and charging, refer to

the Special Instruction, SEHS7633, “Battery Test

i02710753

Procedure”.

After Starting Engine

NOTICE

SMCS Code: 1000

Using a battery source with the same voltage as the

electric starting motor. Use ONLY equal voltage for

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

jump starting. The use of higher voltage will damage

the warm-up time is approximately three minutes. In

the electrical system.

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

time may be required.

Do not reverse the battery cables. The alternator can

be damaged. Attach ground cable last and remove

When the engine idles during warm-up, observe the

first.

following conditions:

When using an external electrical source to start the

engine, turn the generator set control switch to the

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

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

“OFF” position. Turn all electrical accessories OFF be-

before operating the engine under load. This is not

fore attaching the jump start cables.

possible in some applications.

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

tion before attaching the jump start cables to the en-

• Operate the engine at low idle until all systems

achieve operating temperatures. Check all gauges

gine being started.

during the warm-up period.

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

Note: Gauge readings should be observed and

OFF position. Turn off all the engine’s accessories.

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.

SEBU8327

Operation Section

Engine Operation

i01646335

Engine Operation

Engaging the Driven

i02708025

Equipment

Engine Operation

SMCS Code: 1000

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

when possible.

Proper operation and maintenance are key factors

in obtaining the maximum life and economy of

Engage the driven equipment without a load on

the engine. If the directions in the Operation and

the equipment, when possible.

Maintenance Manual are followed, costs can be

minimized and engine service life can be maximized.

Interrupted starts put excessive stress on the drive

train. Interrupted starts also waste fuel. To get the

The time that is needed for the engine to reach

driven equipment in motion, engage the clutch

normal operating temperature can be less than the

smoothly with no load on the equipment. This

time taken for a walk-around inspection of the engine.

method should produce a start that is smooth and

easy. The engine rpm should not increase and the

The engine can be operated at the rated rpm after

clutch should not slip.

the engine is started and after the engine reaches

operating temperature. The engine will reach normal

Ensure that the ranges of the gauges are normal

operating temperature sooner during a low engine

when the engine is operating at one-half of

speed (rpm) and during a low power demand. This

the rated rpm. Ensure that all gauges operate

procedure is more effective than idling the engine

properly.

at no load. The engine should reach operating

temperature in a few minutes.

Increase the engine rpm to the rated rpm. Always

increase the engine rpm to the rated rpm before

Gauge readings should be observed and the data

the load is applied.

should be recorded frequently while the engine

is operating. Comparing the data over time will

Apply the load. Begin operating the engine at low

help to determine normal readings for each gauge.

load. Check the gauges and equipment for proper

Comparing data over time will also help detect

operation. After normal oil pressure is reached

abnormal operating developments. Significant

and the temperature gauge begins to move,

changes in the readings should be investigated.

the engine may be operated at full load. Check

the gauges and equipment frequently when the

i02707215

engine is operated under load.

Engine Warm-up

Extended operation at low idle or at reduced load

may cause increased oil consumption and carbon

SMCS Code: 1000

buildup in the cylinders. This carbon buildup

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

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

or run the engine at low idle until the jacket water

coolant temperature starts to rise.

More time may be necessary when the

temperature is below -18°C (0°F).

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

period.

3. Perform a walk-around inspection. Check the

engine for fluid leaks and air leaks.

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

fluid leaks and air leaks. The engine may be

operated at full rated rpm and at full load when

the temperature of the water jacket reaches 60°C

(140°F).

SEBU8327

Operation Section

Engine Operation

i02707216

Fuel Conservation Practices

SMCS Code: 1000; 1250

The efficiency of the engine can affect the fuel

economy. Caterpillar’s design and technology in

manufacturing provides maximum fuel efficiency in

all applications. Follow the recommended procedures

in order to attain optimum performance for the life

of the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel

may overflow from the fuel tank. Inspect fuel lines for

leaks. Repair the fuel lines, as needed.

• Be aware of the properties of the different fuels.

Use only the recommended fuels. Refer to the

Operations and Maintenance Manual, “Fuel

Recommendations”for further information.

• Avoid unnecessary idling.

Shut off the engine rather than idle for long periods of

time.

• Observe the service indicator frequently. Keep the

air cleaner elements clean.

• Ensure that the turbocharger is operating correctly

so that the proper air/fuel ratio is maintained. Clean

exhaust indicates proper functioning.

• Maintain a good electrical system.

One faulty battery cell will overwork the alternator.

This will consume excess power and excess fuel.

• Ensure that the belts are properly adjusted. The

belts should be in good condition. Refer to the

Specifications manual for further information.

• Ensure that all of the connections of the hoses are

tight. The connections should not leak.

• Ensure that the driven equipment is in good

working order.

• Cold engines consume excess fuel. Utilize heat

from the jacket water system and the exhaust

system, when possible. Keep cooling system

components clean and keep cooling system

components in good repair. Never operate the

engine without water temperature regulators.

All of these items will help maintain operating

temperatures.

SEBU8327

Operation Section

Engine Stopping

i02704619

Engine Stopping

After Stopping Engine

i02710650

SMCS Code: 1000

Stopping the Engine

Note: Before you check the engine oil, do not operate

SMCS Code: 1000; 7000

the engine for at least 10 minutes in order to allow

the engine oil to return to the oil pan.

NOTICE

• Check the crankcase oil level. Maintain the oil level

Stopping the engine immediately after it has been

between the “MIN” mark and the “MAX” mark on

working under load can result in overheating and ac-

the oil level dipstick.

celerated wear of the engine components.

• If necessary, perform minor adjustments. Repair

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

any leaks and tighten any loose bolts.

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

to reduce and stabilize internal engine temperature

• Note the required service interval. Perform

before stopping the engine.

the maintenance that is in the Operation and

Maintenance Manual, “Maintenance Interval

Avoiding hot engine shutdowns will maximize tur-

Schedule”.

bocharger shaft and bearing life.

•

Fill the fuel tank in order to help prevent

Prior to stopping an engine that is being operated

accumulation of moisture in the fuel. Do not overfill

at low loads, operate the engine at low idle for 30

the fuel tank.

seconds before stopping. If the engine has been

operating at highway speeds and/or at high loads,

NOTICE

operate the engine at low idle for at least three

Only use antifreeze/coolant mixtures recommended in

minutes. This procedure will cause the internal

the Refill Capacities and Recommendations topic that

engine temperature to be reduced and stabilized.

is in this Operation and Maintenance Manual. Failure

to do so can cause engine damage.

Ensure that the engine stopping procedure is

understood. Stop the engine according to the shutoff

system on the engine or refer to the instructions that

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

are provided by the OEM.

If freezing temperatures are expected, check the

•

coolant for the correct antifreeze protection. The

• To stop the engine, turn the keyswitch to the OFF

cooling system must be protected against freezing

position.

to the lowest expected outside temperature. Add

the correct coolant/water mixture, if necessary.

i01903586

• Perform all required periodic maintenance on all

Emergency Stopping

driven equipment. This maintenance is outlined in

the instructions from the OEM.

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.

The OEM may have equipped the application with

an emergency stop button. For more information

about the emergency stop button, refer to the OEM

information.

Ensure that any components for the external system

that support the engine operation are secured after

the engine is stopped.

SEBU8327

Operation Section

Cold Weather Operation

• Special Fuels

Caterpillar prefer only Group 1 and Group 2 fuels for

i02708046

use in this series of engines.

Radiator Restrictions

Group 1 fuels are the preferred Group of Fuels for

general use by Caterpillar. Group 1 fuels maximize

SMCS Code: 1353; 1396

engine life and engine performance. Group 1 fuels

are usually less available than Group 2 fuels.

Caterpillar discourages the use of air flow restriction

Frequently, Group 1 fuels are not available in colder

devices that are mounted in front of radiators. Air flow

climates during the winter.

restriction can cause the following conditions:

Note: Group 2 fuels must have a maximum wear

• High exhaust temperatures

scar of 650 micrometers (HFRR to ISO 12156-1).

• Power loss

Group 2 fuels are considered acceptable for issues

of warranty. This group of fuels may reduce the life

• Excessive fan usage

of the engine, the engine’s maximum power, and the

engine’s fuel efficiency.

• Reduction in fuel economy

When Group 2 diesel fuels are used the following

If an air flow restriction device must be used, the

components provide a means of minimizing problems

device should have a permanent opening directly

in cold weather:

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

minimum opening dimension of at least 770 cm²

• Glow plugs (if equipped)

(120 in²).

•

Engine coolant heaters, which may be an OEM

A centered opening that is directly in line with the fan

option

hub is specified in order to prevent an interrupted air

flow on the fan blades. Interrupted air flow on the fan

• Fuel heaters, which may be an OEM option

blades could cause a fan failure.

• Fuel line insulation, which may be an OEM option

Caterpillar recommends a warning device for the

inlet manifold temperature and/or the installation of

There are three major differences between Group

an inlet air temperature gauge. The warning device

1 fuels and Group 2 fuels. Group 1 fuels have the

for the inlet manifold temperature should be set at

following different characteristics to Group 2 fuels.

75 °C (167 °F). The inlet manifold air temperature

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

• A lower cloud point

exceed this limit can cause power loss and potential

engine damage.

• A lower pour point

A higher energy per unit volume of fuel

•

i02704604

Fuel and the Effect from Cold

Note: Group 3 fuels reduce the life of the engine. The

use of Group 3 fuels is not covered by the Caterpillar

Weather

warranty.

SMCS Code: 1000; 1250

Group 3 fuels include Low Temperature Fuels and

Aviation Kerosene Fuels.

Note: Only use grades of fuel that are recommended

by Caterpillar. Refer to this Operation and

Special fuels include Biofuel.

Maintenance Manual, “Fluid Recommendations”.

The cloud point is a temperature that allows wax

The following fuels can be used in this series of

crystals to form in the fuel. These crystals can cause

engine.

the fuel filters to plug.

• Group 1

The pour point is the temperature when diesel fuel

ken. The diesel fuel becomes more resistant

will thic

• Group 2

to flow through fuel lines, fuel filters,and fuel pumps.

• Group 3

SEBU8327

Operation Section

Cold Weather Operation

Be aware of these facts when diesel fuel is

The micron rating and the location of a primary fuel

purchased. Consider the average ambient air

filter is important in cold weather operation. The

temperature for the engine’s application. Engines

primary fuel filter and the fuel supply line are the most

that are fueled in one climate may not operate well if

common components that are affected by cold fuel.

the engines are moved to another climate. Problems

can result due to changes in temperature.

Fuel Heaters

Before troubleshooting for low power or for poor

Fuel heaters help to prevent fuel filters from plugging

performance in the winter, check the fuel for waxing.

in cold weather due to waxing. A fuel heater should

be installed in the fuel system before the primary

Low temperature fuels may be available for engine

fuel filter.

operation at temperatures below 0 °C (32 °F). These

fuels limit the formation of wax in the fuel at low

The following fuel heaters are recommended for

temperatures.

Caterpillar engines:

For more information on cold weather operation, refer

• 7C-3557 Fuel Heater Group

to the Operation and Maintenance Manual, “Cold

Weather Operation and Fuel Related Components in

• 7C-3558 Heater Kit

Cold Weather”.

For further information on fuel heaters, consult your

i02705983

Caterpillar dealer.

Fuel Related Components in

Disconnect the fuel heater in warm weather.

Cold Weather

Note: Fuel heaters that are controlled by the water

temperature regulator or self-regulating fuel heaters

SMCS Code: 1000; 1250

should be used with this engine. Fuel heaters that

are not controlled by the water temperature regulator

Fuel Tanks

can heat the fuel in excess of 65°C (149°F). A loss of

engine power can occur if the fuel supply temperature

Condensation can form in partially filled fuel tanks.

exceeds 37°C (100°F).

Top off the fuel tanks after you operate the engine.

Note: Heat exchanger type fuel heaters should have

Fuel tanks should contain some provision for draining

a bypass provision in order to prevent overheating of

water and sediment from the bottom of the tanks.

the fuel in warm weather operation.

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.

Drain the water and sediment from any fuel storage

tank at the following intervals: weekly, oil changes,

and refueling of the fuel tank. This will help prevent

water and/or sediment from being pumped from the

fuel storage tank and into the engine fuel tank.

Fuel Filters

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.

SEBU8327

Maintenance Section

Refill Capacities

Table 2

Maintenance Section

API Classifications

Current

Obsolete

Refill Capacities

CH-4⁽¹⁾

CE, CC, CD

CI-4

i02501519

CD-2⁽²⁾

⁽¹⁾ API CH-4 and CI-4 oils are acceptable if the requirements

Refill Capacities and

of Caterpillar’s ECF-1 (Engine Crankcase Fluid

specification-1) are met. CH-4 and CI-4 oils that have not

Recommendations

met the requirements of Caterpillar’s ECF-1 Specification

may cause reduced engine life.

SMCS Code: 1348; 1395; 7560

⁽²⁾ The oil CD-2 is for a two-cycle diesel engine. Caterpillar does

not sell engines that utilize CD-2 oil.

Engine Oil

Note: When oil meets more than one API

classification, the applicable footnote is determined

NOTICE

by the highest API classification that is met.

These recommendations are subject to change with-

out notice. Contact your local Caterpillar dealer for the

Example - An oil meets both the API CH-4 and the

most up to date recommendations.

API CF oil classifications. In this case, the API CH-4

applies.

API Oils

Cat DEO (Diesel Engine Oil)

The Engine Oil Licensing and Certification System by

Caterpillar Oils have been developed and tested in

the American Petroleum Institute (API) is recognized

order to provide the full performance and service

by Caterpillar. For detailed information about this

life that has been designed and built into Caterpillar

system, see the latest edition of the “API publication

Engines. Caterpillar Oils are currently used to fill

No. 1509”. Engine oils that bear the API symbol are

diesel engines at the factory. These oils are offered

authorized by API.

by Caterpillar dealers for continued use when the

engine oil is changed. Consult your Caterpillar dealer

for more information on these oils.

Due to significant variations in the quality and in

the performance of commercially available oils,

Caterpillar makes the following recommendations:

• Cat DEO (Diesel Engine Oil) (10W-30)

• Cat DEO (Diesel Engine Oil) (15W-40)

Caterpillar multigrade DEO is formulated with the

correct amounts of detergents, dispersants, and

alkalinity in order to provide superior performance in

g00546535

Caterpillar Diesel Engines.

Illustration 20

Typical API symbol

Caterpillar multigrade DEO is available in various

viscosity grades that include SAE 10W-30 and SAE

Diesel engine oils CC, CD, CD-2, and CE have not

15W-40. To choose the correct viscosity grade for

been API authorized classifications since 1 January

the ambient temperature, see Table 3. Multigrade

1996.

oils provide the correct viscosity for a broad range of

operating temperatures.

Multigrade oils are effective in maintaining low oil

consumption and low levels of piston deposits.

SEBU8327

Maintenance Section

Refill Capacities

Caterpillar multigrade DEO can be used in other

diesel engines and in gasoline engines. See the

NOTICE

engine manufacturer’s guide for the recommended

In selecting oil for any engine application, both the oil

specifications. Compare the specifications to the

viscosity and oil performance classification/specifica-

specifications of Caterpillar multigrade DEO. The

tion as specified by the engine manufacturer must be

current industry standards for Caterpillar DEO are

defined and satisfied. Using only one of these param-

listed on the product label and on the data sheets

eters will not sufficiently define oil for an engine appli-

for the product.

cation.

Consult your Caterpillar dealer for part numbers and

In order to make the proper choice of a commercial

for available sizes of containers.

oil, refer to the following explanations:

Note: Caterpillar SAE 15W-40 multigrade DEO

API CI-4 - API CI-4 oils were developed in order

exceeds the performance requirements for the

to meet the requirements of high performance

following API classifications: CI-4, CH-4, CG-4, CF-4,

diesel engines that use cooled Exhaust Gas

and CF. The Caterpillar multigrade DEO exceeds the

Recirculation (EGR). API CI-4 oils are acceptable

requirements of the Caterpillar specification that is

if the requirements of Caterpillar’s ECF-1 (Engine

ECF-1 (Engine Crankcase Fluid-1). The Caterpillar

Crankcase Fluid specification-1) are met.

SAE 15W-40 multigrade DEO passes the following

proprietary tests: sticking of the piston ring, oil control

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

tests, wear tests, and soot tests. Proprietary tests

to protect low emissions diesel engines that use a

help ensure that Caterpillar multigrade oil provides

0.05 percent level of fuel sulfur. However, API CH-4

superior performance in Caterpillar Diesel Engines.

oils may be used with higher sulfur fuels. API CH-4

In addition, Caterpillar multigrade oil exceeds

oils are acceptable if the requirements of Caterpillar’s

many of the performance requirements of other

ECF-1 (Engine Crankcase Fluid specification-1) are

manufacturers of diesel engines. Therefore, this oil is

met.

an excellent choice for many mixed fleets. True high

performance oil is produced with a combination

Note: CH-4 oils and CI-4 oils that have not met the

of the following factors: industry standard tests,

requirements of Caterpillar’s ECF-1 Specification

proprietary tests, field tests, and prior experience

may cause reduced engine life.

with similar formulations. The design and the

development of Caterpillar lubricants that are

both high performance and high quality are

NOTICE

based on these factors.

Failure to follow these oil recommendations can cause

shortened engine service life due to deposits and/or

Note: Non-Caterpillar commercial oils are second

excessive wear.

choice oils.

Note: Refer to Special Publication, SEBU6251,

Commercial Oils

“Caterpillar Commercial Diesel Engine Fluids

Recommendations” for additional information that

Note: If Caterpillar Multigrade DEO is not used,

relates to lubrication for your engine.

use only commercial oils that meet the following

classifications.

Lubricant Viscosity Recommendations

• API CH-4 multigrade oils and API CI-4 multigrade

The proper SAE viscosity grade of oil is determined

oils are acceptable if the requirements of

by the minimum ambient temperature during

Caterpillar’s ECF-1 (Engine Crankcase Fluid

cold engine start-up, and the maximum ambient

specification-1) are met. CH-4 oils and CI-4 oils

temperature during engine operation.

that have not met the requirements of Caterpillar’s

ECF-1 Specification may cause reduced engine

Refer to Table 3 (minimum temperature) in order to

life.

determine the required oil viscosity for starting a cold

engine.

• API CF-4 multigrade oils are not recommended for

this series of diesel engines. For all other smaller

Refer to Table 3 (maximum temperature) in order to

commercial diesel engines, the oil drain interval

select the oil viscosity for engine operation at the

should not exceed 50 percent of the standard oil

highest ambient temperature that is anticipated.

drain interval for your engine.

Note: Generally, use the highest oil viscosity that is

available to meet the requirement for the temperature

at start-up.

SEBU8327

Maintenance Section

Refill Capacities

If ambient temperature conditions at engine start-up

Refill Capacities for the Lubrication

require the use of multigrade SAE 0W oil, SAE

System

0W-40 viscosity grade is preferred over SAE 0W-20

or SAE 0W-30.

The refill capacities for the engine crankcase reflect

the approximate capacity of the crankcase or sump

Table 3

plus standard oil filters. Auxiliary oil filter systems will

Engine Oil Viscosities for Ambient Temperatures

require additional oil. Refer to the OEM specifications

for the capacity of the auxiliary oil filter.

Ambient Temperature

Viscosity Grade

Minimum

Maximum

Table 4

SAE 0W-20

-40 °C (-40 °F)

10 °C (50 °F)

Engine

Refill Capacities

SAE 0W-30

-40 °C (-40 °F)

30 °C (86 °F)

Compartment or System

Minimum

Maximum

SAE 0W-40

-40 °C (-40 °F)

40 °C (104 °F)

7 L

5 L

SAE 5W-30

-30 °C (-22 °F)

30 °C (86 °F)

Crankcase Oil Sump⁽¹⁾

(7.3968

(5.2834 qt)

qt)

SAE 5W-40

-30 °C (-22 °F)

50 °C (122 °F)

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

SAE 10W-30

-18 °C (0 °F)

40 °C (104 °F)

oil sump (aluminum) which includes the standard factory

installed oil filters. Engines with auxiliary oil filters will require

SAE 10W-40

-18 °C (0 °F)

50 °C (122 °F)

additional oil. Refer to the OEM specifications for the capacity

of the auxiliary oil filter.

SAE 15W-40

-9.5 °C (15 °F)

50 °C (122 °F)

Lubricating Grease

Note: Supplemental heat is recommended below the

minimum recommended ambient temperature.

Caterpillar provides a range of moderate greases

to extremely high performance greases in order to

S·O·S Oil Analysis

service the entire line of Caterpillar products that

operate throughout the wide variety of climates.

Caterpillar has developed a tool for maintenance

From this variety of Caterpillar grease products, you

management that evaluates oil degradation and the

will find at least one of the Caterpillar greases that

tool also detects the early signs of wear on internal

will satisfy the performance requirements for any

components. The Caterpillar tool for oil analysis is

machine or equipment application.

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

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

Before selecting a grease for any application, the

oil analysis into three categories:

performance requirements must be determined.

Consult the grease recommendations that are made

• Wear Analysis

by the OEM for the equipment when the equipment is

operated in the expected conditions. Then, consult

• Oil condition

with your Caterpillar dealer for a list of greases and

the following related characteristics.

• Additional tests

Performance specifications

•

The wear analysis monitors metal particles, some oil

additives, and some contaminants.

• Available sizes of containers

Oil condition uses infrared (IR) analysis to evaluate

• Part numbers

the chemistry of the oil. Infrared analysis is also used

to detect certain types of contamination.

Always choose a grease that satisfies the

recommendations that are specified by the

Additional tests are used to measure contamination

equipment manufacturer for the application.

levels from water, fuel, or coolant. Oil viscosity and

corrosion protection can be evaluated, as needed.

Note: If it is necessary to choose a single grease

to use for all of the equipment at one site, always

Refer to Special Publication, SEBU6251, “Caterpillar

choose a grease that satisfies the requirements

Commercial Diesel Engine Fluids Recommendations”

of the most demanding application.

or contact your local Caterpillar dealer for additional

information concerning the S·O·S Oil Analysis

Do not use the cost per pound as the only factor

program.

when you choose a grease. Use the grease that

yields the lowest total cost of operation. The cost

analysis should include the following factors:

SEBU8327

Maintenance Section

Refill Capacities

• Parts

General Coolant Information

• Labor

NOTICE

These recommendations are subject to change with-

• Downtime

out notice. Contact your local Caterpillar dealer for the

most up to date fluids recommendations.

• Cost of the grease

Greases that barely meet the minimum performance

NOTICE

requirements can be expected to barely produce the

Never add coolant to an overheated engine. Engine

minimum life of the parts.

damage could result. Allow the engine to cool first.

Note: Take care when you change the type of grease.

Take care when you change to a different supplier of

NOTICE

grease. Some greases are not chemically compatible.

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

Some brands of grease can not be interchanged. If

with below freezing temperatures, the cooling system

you are in doubt about the compatibility of the

must be either protected to the lowest outside temper-

old grease and the new grease, purge all of the

ature or drained completely to prevent damage.

old grease from the joint. Consult your supplier in

order to determine if the greases are compatible.

NOTICE

Frequently check the specific gravity of the coolant for

Note: All Caterpillar brand of greases are

proper freeze protection or for anti-boil protection.

compatible with each other.

Note: Refer to Special Publication, SEBU6251,

Clean the cooling system for the following reasons:

“Caterpillar Commercial Diesel Engine Fluids

Recommendations” for additional information that

• Contamination of the cooling system

relates to lubrication for your engine.

• Overheating of the engine

General Fuel Information

• Foaming of the coolant

Diesel fuels that meet the Caterpillar Specification

for Distillate Diesel Fuel are recommended. These

Note: Air pockets can form in the cooling system if

fuels will help to provide maximum engine service life

the cooling system is filled at a rate that is greater

and performance. In North America, diesel fuel that

than 5 L (1.3 US gal) per minute.

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

generally meet the specifications. Diesel fuels from

After you drain the cooling system and after you refill

other sources could exhibit detrimental properties

the cooling system, operate the engine. Operate the

that are not defined or controlled by this specification.

engine without the filler cap until the coolant reaches

normal operating temperature and the coolant level

stabilizes. Ensure that the coolant is maintained to

NOTICE

the proper level.

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

ommendations can cause the following effects: start-

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

NOTICE

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

Never operate an engine without water temperature

posits in the combustion chamber, and reduced ser-

regulators in the cooling system. Water temperature

vice life of the engine.

regulators help to maintain the engine coolant at the

proper operating temperature. Cooling system prob-

lems can develop without water temperature regula-

Note: Refer to Special Publication, SEBU6251,

tors.

“Caterpillar Commercial Diesel Engine Fluids

Recommendations” for the Caterpillar Specification

Refer to Special Instruction, SEBD0518, “Know

for distillate fuel and for additional information that

Your Cooling System” and Special Instruction,

relates to fuel for your engine.

SEBD0970, “Coolant and Your Engine” for more

detailed information.

Refill Capacities for the Fuel System

Refer to the Operation and Maintenance Manual that

is provided by the OEM for capacities of the fuel

system.

SEBU8327

Maintenance Section

Refill Capacities

Many engine failures are related to the cooling

• Agricultural agent

system. The following problems are related to cooling

system failures: overheating, leakage of the water

• Independent laboratory

pump, plugged radiators or heat exchangers, and

pitting of the cylinder liners.

Additives

These failures can be avoided with proper cooling

Additives help to protect the metal surfaces of

system maintenance. Cooling system maintenance is

the cooling system. A lack of coolant additives or

as important as maintenance of the fuel system and

insufficient amounts of additives enable the following

the lubrication system. Quality of the coolant is as

conditions to occur:

important as the quality of the fuel and the lubricating

oil.

• Corrosion

Coolant is normally composed of three elements:

• Formation of mineral deposits

water, additives, and glycol.

• Rust

Water

• Scale

NOTICE

Never use water alone without Supplemental Coolant

• Pitting and erosion from cavitation of the cylinder

liner

Additives (SCA) or without inhibited coolant. Water

alone is corrosive at engine operating temperatures.

Water alone does not provide adequate protection

• Foaming of the coolant

against boiling or freezing.

Many additives are depleted during engine operation.

These additives must be replaced periodically.

Water is used in the cooling system in order to

This can be done by adding Supplemental Coolant

transfer heat.

Additives (SCA) to Diesel Engine Antifreeze/Coolant

(DEAC) or by adding ELC Extender to Extended Life

Distilled water or deionized water is

Coolant (ELC).

recommended for use in engine cooling systems.

Additives must be added at the proper concentration.

DO NOT use the following types of water in cooling

Overconcentration of additives can cause the

systems: hard water, softened water that has been

inhibitors to drop out-of-solution. The deposits can

conditioned with salt, and sea water.

enable the following problems to occur:

If distilled water or deionized water is not available,

• Formation of gel compounds

use water with the properties that are listed in Table 5.

• Reduction of heat transfer

Table 5

Caterpillar Minimum Acceptable Water Requirements

• Leakage of the water pump seal

Property

Maximum Limit

ASTM Test

• Plugging of radiators, coolers, and small passages

40 mg/L

“D512”,

Chloride (Cl)

(2.4 grains/US gal)

“D4327”

Glycol

100 mg/L

Sulfate (SO4)

“D516”

(5.9 grains/US gal)

Glycol in the coolant helps to provide protection

against the following conditions:

170 mg/L

Total Hardness

“D1126”

(10 grains/US gal)

• Boiling

340 mg/L

Total Solids

“D1888”

(20 grain/US gal)

• Freezing

Acidity

pH of 5.5 to 9.0

“D1293”

• Cavitation of the water pump and the cylinder liner

For a water analysis, consult one of the following

For optimum performance, Caterpillar recommends a

sources:

1:1 mixture of a water/glycol solution.

• Caterpillar dealer

Note: Use a mixture that will provide protection

against the lowest ambient temperature.

• Local water utility company

SEBU8327

Maintenance Section

Refill Capacities

Note: 100 percent pure glycol will freeze at a

Caterpillar recommends a 1:1 mixture of water and

temperature of -23 °C (-9 °F).

glycol. This mixture of water and glycol will provide

optimum heavy-duty performance as a antifreeze.

Most conventional heavy-duty antifreezes use

ethylene glycol. Propylene glycol may also be used.

Note: Caterpillar DEAC does not require a treatment

In a 1:1 mixture with water, ethylene and propylene

with an SCA at the initial fill. A commercial heavy-duty

glycol provide similar protection against freezing and

antifreeze that meets “ASTM D4985” or “ASTM

boiling. See Tables 6 and 7.

D6210” specifications MAY require a treatment with

an SCA at the initial fill. These coolants WILL require

Table 6

a treatment with an SCA on a maintenance basis.

Ethylene Glycol

Refer to Special Publication, SEBU6251, “Caterpillar

Freeze

Boil

Concentration

Commercial Diesel Engine Fluids Recommendations”

Protection

for additional information that relates to coolant.

50 Percent

-36 °C (-33 °F)

106 °C (223 °F)

60 Percent

-51 °C (-60 °F)

111 °C (232 °F)

S·O·S Coolant Analysis

Table 8

NOTICE

Recommended Interval

Do not use propylene glycol in concentrations that ex-

ceed 50 percent glycol because of propylene glycol’s

Type of Coolant

Level 1

Level 2

reduced heat transfer capability. Use ethylene glycol

DEAC

Every 250 Hours

Yearly⁽¹⁾

in conditions that require additional protection against

boiling or freezing.

ELC

Not Required

Yearly

⁽¹⁾ The Level 2 Coolant Analysis should be performed sooner if a

problem is identified by a Level 1 Coolant Analysis.

Table 7

Propylene Glycol

S·O·S Coolant Analysis (Level 1)

Freeze

Anti-Boil

Concentration

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

Protection

of the coolant.

50 Percent

-29 °C (-20 °F)

106 °C (223 °F)

The following properties of the coolant are tested:

To check the concentration of glycol, use the

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

• Glycol concentration for freeze protection and boil

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

protection

Fahrenheit). The testers give readings that are

immediate and accurate. The testers can be used

• Ability to protect from erosion and corrosion

with ethylene or propylene glycol.

• pH

Coolant Recommendations

• Conductivity

NOTICE

• Visual analysis

Do not use a commercial coolant/antifreeze that on-

ly meets the ASTM D3306 specification. This type of

• Odor analysis

coolant/antifreeze is made for light duty automotive

applications.

The results are reported, and appropriate

recommendations are made.

The following two coolants are used in Caterpillar

Refer to the Maintenance Interval Schedule in

diesel engines:

this Operation and Maintenance Manual, “Cooling

System Coolant Sample (Level 1) - Obtain” for a

Preferred - Caterpillar Extended Life Coolant (ELC)

sampling location and the maintenance interval for

or a commercial extended life coolant that meets the

collecting the coolant samples.

Caterpillar EC-1 specification

S·O·S Coolant Analysis (Level 2)

Acceptable - Caterpillar Diesel Engine Antifreeze

(DEAC) or a commercial heavy-duty antifreeze

that meets “ASTM D4985”, or “ASTM D6210”

specifications

SEBU8327

Maintenance Section

Refill Capacities

A coolant analysis (Level 2) is a comprehensive

Table 9

chemical evaluation of the coolant. This analysis is

Engine

also a check of the overall condition of the inside of

Refill Capacities

the cooling system.

Compartment or System

Liters

The S·O·S Coolant Analysis has the following

Engine Only

7 L (7.3968 qt)

features:

External System Per OEM⁽¹⁾

• Full coolant analysis (Level 1)

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

tank with the following components: heat exchanger and

piping. Refer to the OEM specifications. Enter the value for the

• Identification of the source of metal corrosion and

capacity of the External System in this row.

of contaminants

• Water hardness

• Identification of buildup of the impurities that cause

corrosion

• Identification of buildup of the impurities that cause

scaling

The results are reported, and appropriate

recommendations are made.

Refer to the Maintenance Interval Schedule in

this Operation and Maintenance Manual, “Cooling

System Coolant Sample (Level 2) - Obtain” for a

sampling location and the maintenance interval for

collecting the coolant samples.

Testing the engine coolant is important to ensure that

the engine is protected from internal cavitation and

from corrosion. The analysis also tests the ability of

the coolant to protect the engine from boiling and

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

done at your Caterpillar dealer. Caterpillar S·O·S

Coolant Analysis is the best way to monitor the

condition of your coolant and your cooling system.

S·O·S Coolant Analysis is a program that is based

on periodic samples.

Refer to Special Publication, SEBU6251, “Caterpillar

Commercial Diesel Engine Fluids Recommendations”

for additional information.

Refill Capacity of the 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 antifreeze that is required for the Total Cooling

System.

SEBU8327

Maintenance Section

Maintenance Interval Schedule

i02711636

Every 1000 Service Hours

Maintenance Interval Schedule

Engine Valve Lash - Inspect/Adjust

SMCS Code: 1000; 7500

Every 2000 Service Hours

Alternator - Inspect

When Required

Starting Motor - Inspect

Battery - Replace

Turbocharger - Inspect

Battery or Battery Cable - Disconnect

Water Pump - Inspect

Engine - Clean

Engine Air Cleaner Element (Dual Element) -

Every 2000 Service Hours or 1 Year

Clean/Replace

Engine Air Cleaner Element (Single Element) -

Engine Mounts - Inspect

Inspect/Replace

Fuel System - Prime

Every Year

Severe Service Application - Check

Cooling System Coolant Sample (Level 2) -

Obtain

Daily

Alternator Belt - Inspect/Adjust/Replace

Every 3000 Service Hours

Cooling System Coolant Level - Check

Alternator Belt - Inspect/Adjust/Replace

Driven Equipment - Check

Fuel Injection Nozzles - Test/Exchange

Engine Air Cleaner Service Indicator - Inspect

Engine Air Precleaner - Check/Clean

Every 3000 Service Hours or 2 Years

Engine Oil Level - Check

Fuel System Primary Filter/Water Separator -

Cooling System Coolant (DEAC) - Change

Drain

Cooling System Water Temperature Regulator -

V-Belts - Inspect/Adjust/Replace

Replace

Walk-Around Inspection

Every 12 000 Service Hours or 6 Years

Every 50 Service Hours or Weekly

Cooling System Coolant (ELC) - Change

Fuel Tank Water and Sediment - Drain

Overhaul

Every 250 Service Hours

Overhaul Considerations

Cooling System Coolant Sample (Level 1) -

Obtain

Engine Oil Sample - Obtain

Every 500 Service Hours

V-Belts - Inspect/Adjust/Replace

Every 500 Service Hours or 6 Months

Engine Protective Devices - Check

Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check

Cooling System Supplemental Coolant Additive

(SCA) - Test/Add

Crankcase Breather (Canister) - Replace

Engine Air Cleaner Element (Dual Element) -

Clean/Replace

Engine Oil and Filter - Change

Fuel System Secondary Filter - Replace

Hoses and Clamps - Inspect/Replace

Radiator - Clean

SEBU8327

Maintenance Section

Alternator - Inspect

i02704667

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.

Check the alternator and the battery charger for

proper operation. If the batteries are properly

charged, the ammeter reading should be very near

zero. All batteries should be kept charged. The

batteries should be kept warm because temperature

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

the battery will not crank the engine. The battery will

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

g01251375

Illustration 21

When the engine is not run for long periods of time

Typical example

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

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

freeze more easily than a battery with a full charge.

Adjustment

This type of belt has an automatic belt tensioner.

i02491869

Alternator Belt -

Replace

Inspect/Adjust/Replace

Refer to Disassembly and Assembly manual,

(Poly V-Belt)

“Alternator Belt - Remove and Install”.

SMCS Code: 1357-036; 1357-510

i02322315

Inspection

Battery - Replace

To maximize the engine performance, inspect the belt

SMCS Code: 1401-510

(1) for wear and for cracking. Replace the belt if the

belt is worn or damaged.

• If the belt (1) has more than four cracks per

Batteries give off combustible gases which can

25.4000 mm (1 inch) the belt must be replaced.

explode. A spark can cause the combustible gas-

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

• Check the belt of cracks, splits, glazing, grease,

jury or death.

and splitting.

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

near batteries. Do not smoke when batteries are

serviced.

SEBU8327

Maintenance Section

Battery Electrolyte Level - Check

The battery cables or the batteries should not be

All lead-acid batteries contain sulfuric acid which

removed with the battery cover in place. The bat-

can burn the skin and clothing. Always wear a face

tery cover should be removed before any servic-

shield and protective clothing when working on or

ing is attempted.

near batteries.

Removing the battery cables or the batteries with

1. Remove the filler caps. Maintain the electrolyte

the cover in place may cause a battery explosion

level to the “FULL” mark on the battery.

resulting in personal injury.

If the addition of water is necessary, use distilled

1. Switch the engine to the OFF position. Remove

water. If distilled water is not available use clean

all electrical loads.

water that is low in minerals. Do not use artificially

softened water.

2. Turn off any battery chargers. Disconnect any

battery chargers.

2. Check the condition of the electrolyte with the

245-5829 Coolant Battery Tester Refractometer.

3. The NEGATIVE “-” cable connects the NEGATIVE

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

3. Keep the batteries clean.

on the starting motor. 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 POSITIVE “+” terminal

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

on the starting motor. Disconnect the cable from

1 L (1 qt) of clean water

the POSITIVE “+” battery terminal.

•

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

Note: Always recycle a battery. Never discard a

(1 qt) of clean water

battery. Dispose of used batteries to an appropriate

recycling facility.

Thoroughly rinse the battery case with clean water.

5. Remove the used battery.

Use a fine grade of sandpaper to clean the

terminals and the cable clamps. Clean the items

6. Install the new battery.

until the surfaces are bright or shiny. DO NOT

remove material excessively. Excessive removal

Note: Before the cables are connected, ensure that

of material can cause the clamps to not fit properly.

the engine start switch is OFF.

Coat the clamps and the terminals with 5N-5561

Silicone Lubricant, petroleum jelly or MPGM.

7. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.

i02323088

8. Connect the NEGATIVE “-” cable to the NEGATIVE

Battery or Battery Cable -

“-” battery terminal.

Disconnect

i02710765

SMCS Code: 1402-029

Battery Electrolyte Level -

Check

The battery cables or the batteries should not be

SMCS Code: 1401-535

removed with the battery cover in place. The bat-

tery cover should be removed before any servic-

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

ing is attempted.

when the engine is run for short periods, the batteries

may not fully recharge. Ensure a full charge in order

Removing the battery cables or the batteries with

to help prevent the battery from freezing. If batteries

the cover in place may cause a battery explosion

are properly charged, ammeter reading should be

resulting in personal injury.

very near zero, when the engine is in operation.

SEBU8327

Maintenance Section

Cooling System Coolant (DEAC) - Change

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

Note: Inspect the water pump and the water

ignition switch (if equipped) to the OFF position

temperature regulator after the cooling system has

and remove the key and all electrical loads.

been drained. This is a good opportunity to replace

the water pump, the water temperature regulator and

2. Disconnect the negative battery terminal. Ensure

the hoses, if necessary.

that the cable cannot contact the terminal. When

four 12 volt batteries are involved, two negative

Drain

connection must be disconnected.

3. Remove the positive connection.

4. Clean all disconnected connection and battery

Pressurized System: Hot coolant can cause seri-

terminals.

ous burns. To open the cooling system filler cap,

stop the engine and wait until the cooling system

5. Use a fine grade of sandpaper to clean the

components are cool. Loosen the cooling system

terminals and the cable clamps. Clean the items

pressure cap slowly in order to relieve the pres-

until the surfaces are bright or shiny. DO NOT

sure.

remove material excessively. Excessive removal

of material can cause the clamps to not fit

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

correctly. Coat the clamps and the terminals with

Loosen the cooling system filler cap slowly in

a suitable silicone lubricant or petroleum jelly.

order to relieve any pressure. Remove the cooling

system filler cap.

6. Tape the cable connections in order to help

prevent accidental starting.

7. Proceed with necessary system repairs.

8. In order to connect the battery, connect the

positive connection before the negative connector.

i02710742

Cooling System Coolant

(DEAC) - Change

SMCS Code: 1350-070; 1395-044

g01003928

Illustration 22

Clean the cooling system and flush the cooling

system before the recommended maintenance

2. Open the cooling system drain valve (if equipped).

interval if the following conditions exist:

If the cooling system is not equipped with a drain

valve, remove the drain plug (1).

• The engine overheats frequently.

Allow the coolant to drain.

• Foaming is observed.

NOTICE

• The oil has entered the cooling system and the

Dispose of used engine coolant properly or recycle.

coolant is contaminated.

Various methods have been proposed to reclaim used

coolant for reuse in engine cooling systems. The full

• The fuel has entered the cooling system and the

distillation procedure is the only method acceptable by

coolant is contaminated.

Caterpillar to reclaim the used coolant.

NOTICE

Use of commercially available cooling system clean-

For information regarding the disposal and the

ers may cause damage to cooling system compo-

recycling of used coolant, consult your Caterpillar

nents. Use only cooling system cleaners that are ap-

dealer or consult Dealer Service Tools Group:

proved for Caterpillar engines.

Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL

Canada: 1-800-523-TOOL

SEBU8327

Maintenance Section

Cooling System Coolant (DEAC) - Change

Flush

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

plug (1). Install the drain plug. Refer to Torque

1. Flush the cooling system with clean water in order

Specifications, SENR3130 for more information

to remove any debris.

on the correct torques.

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

NOTICE

plug (1). Install the drain plug. Refer to Torque

Do not fill the cooling system faster than 5 L

Specifications, SENR3130 for more information

(1.3 US gal) per minute to avoid air locks.

on the correct torques.

Cooling system air locks may result in engine damage.

NOTICE

Do not fill the cooling system faster than 5 L

3. Fill the cooling system with a mixture of clean

(1.3 US gal) per minute to avoid air locks.

water and Caterpillar Fast Acting Cooling System

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

Cooling system air locks may result in engine damage.

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

capacity. Install the cooling system filler cap.

3. Fill the cooling system with a mixture of clean

water and Caterpillar Fast Acting Cooling System

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

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

of 90 minutes. The coolant temperature should be

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

at least 82 °C (180 °F).

the cooling system filler cap.

NOTICE

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

Improper or incomplete rinsing of the cooling system

of 30 minutes. The coolant temperature should be

can result in damage to copper and other metal com-

at least 82 °C (180 °F).

ponents.

NOTICE

To avoid damage to the cooling system, make sure

Improper or incomplete rinsing of the cooling system

to completely flush the cooling system with clear wa-

can result in damage to copper and other metal com-

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

ponents.

cleaning agent are gone.

To avoid damage to the cooling system, make sure

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

to completely flush the cooling system with clear wa-

Loosen the cooling system filler cap slowly

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

in order to relieve any pressure. Remove the

cleaning agent are gone.

cooling system filler cap. Open the drain valve

(if equipped) or remove the cooling system drain

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

plug (1). Allow the water to drain. Flush the cooling

Loosen the cooling system filler cap slowly

system with clean water. Close the drain valve (if

in order to relieve any pressure. Remove the

equipped). Clean the drain plug. Install the drain

cooling system filler cap. Open the drain valve

plug. Refer to Torque Specifications, SENR3130

(if equipped) or remove the cooling system drain

for more information on the correct torques.

plug (1). Allow the water to drain. Flush the cooling

system with clean water. Close the drain valve (if

Fill

equipped). Clean the drain plug. Install the drain

plug. Refer to Torque Specifications, SENR3130

NOTICE

for more information on the correct torques.

Do not fill the cooling system faster than 5 L

(1.3 US gal) per minute to avoid air locks.

Cooling Systems with Heavy

Cooling system air locks may result in engine damage.

Deposits or Plugging

Note: For the following procedure to be effective,

1. Fill the cooling system with coolant or antifreeze.

there must be some active flow through the cooling

Refer to this Operation and Maintenance Manual,

system components.

“Refill Capacities and Recommendations” topic

(Maintenance Section) for more information on

1. Flush the cooling system with clean water in order

cooling system specifications. Do not install the

to remove any debris.

cooling system filler cap.

SEBU8327

Maintenance Section

Cooling System Coolant (ELC) - Change

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

Drain

engine rpm to 1500 rpm. Run the engine at high

idle for one minute in order to purge the air from

the cavities of the engine block. Stop the engine.

Pressurized System: Hot coolant can cause seri-

3. Check the coolant level. Maintain the coolant level

ous burns. To open the cooling system filler cap,

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

stop the engine and wait until the cooling system

pipe for filling. Maintain the coolant level within

components are cool. Loosen the cooling system

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

pressure cap slowly in order to relieve the pres-

glass (if equipped).

sure.

4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If

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

the gasket that is on the cooling system filler cap

Loosen the cooling system filler cap slowly in

is damaged, discard the old cooling system filler

order to relieve any pressure. Remove the cooling

cap and install a new cooling system filler cap.

system filler cap.

If the gasket that is on the cooling system filler

cap is not damaged, perform a pressure test. A

2. Open the cooling system drain valve (if equipped).

9S-8140 Pressurizing Pump is used to perform

If the cooling system is not equipped with a drain

the pressure test. The correct pressure for the

valve, remove the cooling system drain plugs.

cooling system filler cap is stamped on the face of

the cooling system filler cap. If the cooling system

Allow the coolant to drain.

filler cap does not retain the correct pressure,

obtain a new cooling system filler cap. Install the

NOTICE

cooling system filler cap.

Dispose of used engine coolant properly or recycle.

Various methods have been proposed to reclaim used

5. Start the engine. Inspect the cooling system for

coolant for reuse in engine cooling systems. The full

leaks and for the correct operating temperature.

distillation procedure is the only method acceptable by

Caterpillar to reclaim the used coolant.

i02242512

For information regarding the disposal and the

Cooling System Coolant (ELC)

recycling of used coolant, consult your Caterpillar

- Change

dealer or consult Dealer Service Tools:

SMCS Code: 1350-070; 1395-044

Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL

Clean the cooling system and flush the cooling

Canada: 1-800-523-TOOL

system before the recommended maintenance

interval if the following conditions exist:

Flush

• The engine overheats frequently.

1. Flush the cooling system with clean water in order

to remove any debris.

• Foaming is observed.

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

• The oil has entered the cooling system and the

drain plugs. Install the drain plugs. Refer to Torque

coolant is contaminated.

Specifications, SENR3130 for more information

on the correct torques.

• The fuel has entered the cooling system and the

coolant is contaminated.

NOTICE

Note: When the cooling system is cleaned, only

Do not fill the cooling system faster than 5 L

clean water is needed when the ELC is drained and

(1.3 US gal) per minute to avoid air locks.

replaced.

Cooling system air locks may result in engine damage.

Note: Inspect the water pump and the water

temperature regulator after the cooling system has

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

been drained. This is a good opportunity to replace

cooling system filler cap.

the water pump, the water temperature regulator and

the hoses, if necessary.

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

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

SEBU8327

Maintenance Section

Cooling System Coolant Level - Check

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

i02480380

Loosen the cooling system filler cap slowly

Cooling System Coolant Level

in order to relieve any pressure. Remove the

cooling system filler cap. Open the drain valve

- Check

(if equipped) or remove the cooling system drain

plugs. Allow the water to drain. Flush the cooling

SMCS Code: 1395-082

system with clean water. Close the drain valve (if

equipped). Clean the drain plugs. Install the drain

Engines With a Coolant Recovery

plugs. Refer to Torque Specifications, SENR3130

for more information on the correct torques.

Tank

Note: The cooling system may not have been

Fill

provided by Caterpillar. The procedure that follows

is for typical cooling systems. Refer to the OEM

NOTICE

information for the correct procedures.

Do not fill the cooling system faster than 5 L

(1.3 US gal) per minute to avoid air locks.

Check the coolant level when the engine is stopped

and cool.

Cooling system air locks may result in engine damage.

1. Observe the coolant level in the coolant recovery

Fill the cooling system with Extended Life Coolant

tank. Maintain the coolant level to “COLD FULL”

(ELC). Refer to this Operation and Maintenance

mark on the coolant recovery tank.

Manual, “Refill Capacities and Recommendations”

topic (Maintenance Section) for more information

on cooling system specifications. Do not install the

cooling system filler cap.

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,

Start and run the engine at low idle. Increase the

stop the engine and wait until the cooling system

engine rpm to high idle. Run the engine at high

components are cool. Loosen the cooling system

idle for one minute in order to purge the air from

pressure cap slowly in order to relieve the pres-

the cavities of the engine block. Stop the engine.

sure.

Check the coolant level. Maintain the coolant level

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

2. Loosen filler cap slowly in order to relieve any

pipe for filling. Maintain the coolant level within

pressure. Remove the filler cap.

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

glass (if equipped).

3. Pour the correct coolant mixture into the tank.

Refer to the Operation and Maintenance Manual,

Clean the cooling system filler cap. Inspect the

“Refill Capacities and Recommendations” for

gasket that is on the cooling system filler cap. If

information on the correct mixture and type of

the gasket that is on the cooling system filler cap

coolant. Refer to the Operation and Maintenance

is damaged, discard the old cooling system filler

Manual, “Refill Capacities and Recommendations”

cap and install a new cooling system filler cap. If

for the cooling system capacity. Do not fill the

the gasket that is on the cooling system filler cap is

coolant recovery tank above “COLD FULL” mark.

not damaged, use a 9S-8140 Pressurizing Pump

in order to pressure test the cooling system filler

cap. The correct pressure for the cooling system

filler cap is stamped on the face of the cooling

system filler cap. If the cooling system filler cap

does not retain the correct pressure, install a new

cooling system filler cap.

Start the engine. Inspect the cooling system for

leaks and for proper operating temperature.

g00103639

Illustration 23

SEBU8327

Maintenance Section

Cooling System Coolant Sample (Level 1) - Obtain

4. Clean filler cap and the receptacle. Reinstall the

i02603581

filler cap and inspect the cooling system for leaks.

Cooling System Coolant

Note: The coolant will expand as the coolant heats

Sample (Level 1) - Obtain

up during normal engine operation. The additional

volume will be forced into the coolant recovery tank

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

during engine operation. When the engine is stopped

and cool, the coolant will return to the engine.

Note: Obtaining a Coolant Sample (Level 1) is

optional if the cooling system is filled with Cat

Engines Without a Coolant

ELC (Extended Life Coolant). Cooling systems that

are filled with Cat ELC should have a Coolant Sample

Recovery Tank

(Level 2) that is obtained at the recommended interval

that is stated in the Maintenance Interval Schedule.

Check the coolant level when the engine is stopped

and cool.

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

cooling system is filled with any other coolant

instead of Cat ELC. This includes the following

types of coolants:

• Commercial long life coolants that meet the

Caterpillar Engine Coolant Specification -1

(Caterpillar EC-1)

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze

Table 10

Recommended Interval

g00285520

Illustration 24

Type of Coolant

Level 1

Level 2

Cooling system filler cap

Every 250

Cat DEAC

Yearly⁽¹⁾⁽²⁾

Hours⁽¹⁾

Cat ELC

Optional⁽²⁾

Yearly⁽²⁾

Pressurized System: Hot coolant can cause seri-

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

conventional heavy-duty coolant/antifreeze. This is also the

ous burns. To open the cooling system filler cap,

recommended interval for coolant samples of commercial

stop the engine and wait until the cooling system

coolants that meet the Cat EC-1 specification for engine

components are cool. Loosen the cooling system

coolant.

pressure cap slowly in order to relieve the pres-

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

sure.

problem is suspected or identified.

NOTICE

1. Remove the cooling system filler cap slowly in

Always use a designated pump for oil sampling, and

order to relieve pressure.

use a separate designated pump for coolant sampling.

Using the same pump for both types of samples may

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

contaminate the samples that are being drawn. This

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

contaminate may cause a false analysis and an incor-

equipped with a sight glass, maintain the coolant

rect interpretation that could lead to concerns by both

level to the correct level in the sight glass.

dealers and customers.

3. Clean the cooling system filler cap and inspect the

gasket. If the gasket is damaged, discard the old

Note: Level 1 results may indicate a need for

filler cap and install a new filler cap. If the gasket

Level 2 Analysis.

is not damaged, use a suitable pressurizing pump

in order to pressure test the filler cap. The correct

pressure is stamped on the face of the filler cap. If

the filler cap does not retain the correct pressure,

install a new filler cap.

4. Inspect the cooling system for leaks.

SEBU8327

Maintenance Section

Cooling System Coolant Sample (Level 2) - Obtain

Obtain the sample of the coolant as close as possible

Submit the sample for Level 2 analysis.

to the recommended sampling interval. In order

to receive the full effect of S·O·S analysis, you

For additional information about coolant

must establish a consistent trend of data. In order

analysis, see Special Publication, SEBU6251,

to establish a pertinent history of data, perform

“Caterpillar Commercial Diesel Engines Fluids

consistent samplings that are evenly spaced.

Recommendations” or consult your Caterpillar dealer.

Supplies for collecting samples can be obtained from

your Caterpillar dealer.

i02456600

Use the following guidelines for proper sampling of

Cooling System Supplemental

the coolant:

Coolant Additive (SCA) -

• Complete the information on the label for the

Test/Add

sampling bottle before you begin to take the

samples.

SMCS Code: 1352-045; 1395-081

• Keep the unused sampling bottles stored in plastic

bags.

• Obtain coolant samples directly from the coolant

Cooling system coolant additive contains alkali.

sample port. You should not obtain the samples

To help prevent personal injury, avoid contact with

from any other location.

the skin and the eyes. Do not drink cooling system

coolant additive.

• Keep the lids on empty sampling bottles until you

are ready to collect the sample.

Note: Test the concentration of the Supplemental

Coolant Additive (SCA) or test the SCA concentration

• Place the sample in the mailing tube immediately

as part of an S·O·S Coolant Analysis.

after obtaining the sample in order to avoid

contamination.

Test for SCA Concentration

• Never collect samples from expansion bottles.

Coolant and SCA

• Never collect samples from the drain for a system.

NOTICE

Submit the sample for Level 1 analysis.

Do not exceed the recommended six percent supple-

mental coolant additive concentration.

For additional information about coolant analysis,

see Special Publication, SEBU6251, “Caterpillar

Commercial Diesel Engine Fluids Recommendations”

Use the 8T-5296 Coolant Conditioner Test Kit

or consult your Caterpillar dealer.

or use the 4C-9301 Coolant Conditioner Test Kit

in order to check the concentration of the SCA.

Refer to this Operation and Maintenance Manual,

i01987714

“Refill Capacities and Recommendations” for more

information.

Cooling System Coolant

Sample (Level 2) - Obtain

Water and SCA

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

NOTICE

Do not exceed the recommended eight percent sup-

NOTICE

plemental coolant additive concentration.

Always use a designated pump for oil sampling, and

use a separate designated pump for coolant sampling.

Using the same pump for both types of samples may

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

contaminate the samples that are being drawn. This

Coolant Conditioner Test Kit. Refer to the Special

contaminate may cause a false analysis and an incor-

Publication, SEBU6251, “Caterpillar Commercial

rect interpretation that could lead to concerns by both

Diesel Engine Fluids Recommendations” for more

dealers and customers.

information.

Refer to Operation and Maintenance Manual,

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

for the guidelines for proper sampling of the coolant.

SEBU8327

Maintenance Section

Cooling System Water Temperature Regulator - Replace

S·O·S Coolant Analysis

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

Pressurized System: Hot coolant can cause seri-

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

ous burns. To open the cooling system filler cap,

program that is based on periodic samples.

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

Level 1

pressure cap slowly in order to relieve the pres-

sure.

Level 1 is a basic analysis of the coolant. The

following items are tested:

1. Slowly loosen the cooling system filler cap in

order to relieve the pressure. Remove the cooling

• Glycol Concentration

system filler cap.

• Concentration of SCA

Note: Always discard drained fluids according to

local regulations.

• pH

2. If necessary, drain some coolant from the cooling

• Conductivity

system into a suitable container in order to allow

The results are reported, and recommendations

space for the extra SCA.

are made according to the results. Consult your

Caterpillar dealer for information on the benefits of

3. Add the proper amount of SCA. Refer

managing your equipment with an S·O·S Coolant

to the Special Publication, SEBU6251,

Analysis.

“Caterpillar Commercial Diesel Engines Fluids

Recommendations” for more information on SCA

requirements.

Level 2

4. Clean the cooling system filler cap. Inspect the

This level coolant analysis is recommended when the

gaskets of the cooling system filler cap. If the

engine is overhauled. Refer to this Operations and

gaskets are damaged, replace the old cooling

Maintenance Manual, “Overhaul Considerations” for

system filler cap with a new cooling system filler

further information.

cap. Install the cooling system filler cap.

Add the SCA, If Necessary

i02623972

NOTICE

Cooling System Water

Do not exceed the recommended amount of sup-

Temperature Regulator -

plemental coolant additive concentration. Excessive

supplemental coolant additive concentration can form

Replace

deposits on the higher temperature surfaces of the

cooling system, reducing the engine’s heat transfer

SMCS Code: 1355-510

characteristics. Reduced heat transfer could cause

cracking of the cylinder head and other high temper-

Replace the water temperature regulator before

ature components. Excessive supplemental coolant

the water temperature regulator fails. This is a

additive concentration could also result in radiator

recommended preventive maintenance practice.

tube blockage, overheating, and/or accelerated water

Replacing the water temperature regulator reduces

pump seal wear. Never use both liquid supplemental

the chances for unscheduled downtime.

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

at the same time. The use of those additives together

A water temperature regulator that fails in a

could result in supplemental coolant additive concen-

partially opened position can cause overheating or

tration exceeding the recommended maximum.

overcooling of the engine.

A water temperature regulator that fails in the closed

position can cause excessive overheating. Excessive

overheating could result in cracking of the cylinder

head or piston seizure problems.

SEBU8327

Maintenance Section

Crankcase Breather (Canister) - Replace

A water temperature regulator that fails in the open

position will cause the engine operating temperature

to be too low during partial load operation. Low

engine operating temperatures during partial loads

could cause an excessive carbon buildup inside the

cylinders. This excessive carbon buildup could result

in an accelerated wear of the piston rings and wear

of the cylinder liner.

NOTICE

Failure to replace your water temperature regulator

on a regularly scheduled basis could cause severe

engine damage.

Caterpillar engines incorporate a shunt design cooling

g01350307

Illustration 25

system and require operating the engine with a water

Typical example

temperature regulator installed.

1. Place a container under the canister (1).

If the water temperature regulator is installed incor-

rectly, the engine may overheat, causing cylinder head

2. Clean the outside of the canister. Remove the

damage. Ensure that the new water temperature reg-

canister with a 1U-8760 Chain Wrench.

ulator is installed in the original position. Ensure that

the water temperature regulator vent hole is open.

3. Lubricate the O ring seal (2) on the new canister

(3) with clean engine lubricating oil. Install the new

Do not use liquid gasket material on the gasket or

canister. Tighten the canister to 12 N·m (8 lb ft).

cylinder head surface.

Do not overtighten the canister.

Refer to two articles in the Disassembly and

4. Remove the container. Dispose of the old canister

Assembly Manual, “Water Temperature Regulators

and any split oil in a safe place.

- Remove and Water Temperature Regulators -

Install” for the replacement procedure of the water

i00174798

temperature regulator, or consult your Caterpillar

dealer.

Driven Equipment - Check

Note: If only the water temperature regulators are

SMCS Code: 3279-535

replaced, drain the coolant from the cooling system to

a level that is below the water temperature regulator

Refer to the OEM specifications for more information

housing.

on the following maintenance recommendations for

the driven equipment:

i02711635

• Inspection

Crankcase Breather (Canister)

• Adjustment

- Replace

•

Lubrication

SMCS Code: 1317-510

• Other maintenance recommendations

NOTICE

Ensure that the engine is stopped before any servicing

Perform any maintenance for the driven equipment

or repair is performed.

which is recommended by the OEM.

Note: This breather assembly is not installed on all

engines.

SEBU8327

Maintenance Section

Engine - Clean

i02708606

i02708051

Engine - Clean

Engine Air Cleaner Element

(Dual Element) - Clean/Replace

SMCS Code: 1000-070

SMCS Code: 1054-037; 1054-510

NOTICE

Personal injury or death can result from high volt-

Never run the engine without an air cleaner element

age.

installed. Never run the engine with a damaged air

cleaner element. Do not use air cleaner elements with

Moisture can create paths of electrical conductiv-

damaged pleats, gaskets or seals. Dirt entering the

ity.

engine causes premature wear and damage to engine

components. Air cleaner elements help to prevent air-

Make sure that the electrical system is OFF. Lock

borne debris from entering the air inlet.

out the starting controls and tag the controls “DO

NOT OPERATE”.

NOTICE

Never service the air cleaner element with the engine

NOTICE

running since this will allow dirt to enter the engine.

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

Servicing the Air Cleaner Elements

the engine.

Note: The air filter system may not have been

NOTICE

provided by Catapillar. The procedure that follows

Failure to protect some engine components from

is for a typical air filter system. Refer to the OEM

washing may make your engine warranty invalid.

information for the correct procedure.

Allow the engine to cool for one hour before washing

the engine.

If the air cleaner element becomes plugged, the air

can split the material of the air cleaner element.

Unfiltered air will drastically accelerate internal

Periodic cleaning of the engine is recommended.

engine wear. Refer to the OEM information for the

Steam cleaning the engine will remove accumulated

correct air cleaner elements for your application.

oil and grease. A clean engine provides the following

benefits:

• Check the precleaner (if equipped) and the dust

bowl daily for accumulation of dirt and debris.

• Easy detection of fluid leaks

Remove any dirt and debris, as needed.

• Maximum heat transfer characteristics

• Operating in dirty conditions may require more

frequent service of the air cleaner element.

• Ease of maintenance

•

The air cleaner element should be replaced at least

Note: Caution must be used in order to prevent

one time per year. This replacement should be

electrical components from being damaged by

performed regardless of the number of cleanings.

excessive water when the engine is cleaned. When a

pressure washer or steam cleaner is used to clean

Replace the dirty air cleaner elements with clean air

the engine, a minimum distance of 300 mm (12 inch)

cleaner elements. Before installation, the air cleaner

must be maintained between the components of the

elements should be thoroughly checked for tears

engine and the jet nozzle of the pressure washer

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

or steam cleaner. Pressure washers and steam

or the seal of the air cleaner element for damage.

cleaners should not be directed at any electrical

Maintain a supply of suitable air cleaner elements

connectors or the junction of cables into the rear of

for replacement purposes.

the connectors. Avoid electrical components such as

the alternator and the starter. Protect the fuel injection

Dual Element Air Cleaners

pump from fluids in order to wash the engine.

The dual element air cleaner contains a primary air

cleaner element and a secondary air cleaner element.

SEBU8327

Maintenance Section

Engine Air Cleaner Element (Dual Element) - Clean/Replace

The primary air cleaner element can be used up

Cleaning the Primary Air Cleaner

to six times if the element is properly cleaned and

Elements

properly inspected. The primary air cleaner element

should be replaced at least one time per year. This

NOTICE

replacement should be performed regardless of the

Caterpillar recommends certified air filter cleaning ser-

number of cleanings.

vices that are available at Caterpillar dealers. The

Caterpillar cleaning process uses proven procedures

The secondary air cleaner element is not serviceable.

to assure consistent quality and sufficient filter life.

Refer to the OEM information for instructions in order

to replace the secondary air cleaner element.

Observe the following guidelines if you attempt to

clean the filter element:

When the engine is operating in environments that

are dusty or dirty, air cleaner elements may require

Do not tap or strike the filter element in order to re-

more frequent replacement.

move dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not

exceed 207 kPa (30 psi). Direct the air flow up the

pleats and down the pleats from the inside of the filter

element. Take extreme care in order to avoid damage

to the pleats.

Do not use air filters with damaged pleats, gaskets, or

seals. Dirt entering the engine will cause damage to

engine components.

g00736431

Illustration 26

The primary air cleaner element can be used up to six

(1) Cover

times if the element is properly cleaned and properly

(2) Primary air cleaner element

inspected. When the primary air cleaner element is

(3) Secondary air cleaner element

(4) Air inlet

cleaned, check for rips or tears in the filter material.

The primary air cleaner element should be replaced

1. Remove the cover. Remove the primary air

at least one time per year. This replacement should

cleaner element.

be performed regardless of the number of cleanings.

2. The secondary air cleaner element should be

Use clean primary air cleaner elements while dirty

removed and discarded for every three cleanings

elements are being cleaned.

of the primary air cleaner element.

NOTICE

Note: Refer to “Cleaning the Primary Air Cleaner

Do not clean the air cleaner elements by bumping or

Elements”.

tapping. This could damage the seals. Do not use el-

ements with damaged pleats, gaskets or seals. Dam-

3. Cover the air inlet with tape in order to keep dirt

aged elements will allow dirt to pass through. Engine

out.

damage could result.

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

with a clean, dry cloth.

Visually inspect the primary air cleaner elements

before cleaning. Inspect the air cleaner elements for

5. Remove the tape for the air inlet. Install the

damage to the seal, the gaskets, and the outer cover.

secondary air cleaner element. Install a primary

Discard any damaged air cleaner elements.

air cleaner element that is new or cleaned.

There are two common methods that are used to

6. Install the air cleaner cover.

clean primary air cleaner elements:

7. Reset the air cleaner service indicator.

• Pressurized air

• Vacuum cleaning

SEBU8327

Maintenance Section

Engine Air Cleaner Element (Dual Element) - Clean/Replace

Pressurized Air

Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.

Inspecting the Primary Air Cleaner

Personal injury can result from air pressure.

Elements

Personal injury can result without following prop-

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

tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Pressurized air can be used to clean primary air

cleaner elements that have not been cleaned more

than three times. Use filtered, dry air with a maximum

pressure of 207 kPa (30 psi). Pressurized air will not

remove deposits of carbon and oil.

g00281693

Illustration 28

Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a similar

facility. Place the blue light in the primary air cleaner

element. Rotate the primary air cleaner element.

Inspect the primary air cleaner element for tears

and/or holes. Inspect the primary air cleaner element

for light that may show through the filter material. If it

is necessary in order to confirm the result, compare

the primary air cleaner element to a new primary air

cleaner element that has the same part number.

Do not use a primary air cleaner element that has

g00281692

Illustration 27

any tears and/or holes in the filter material. Do not

use a primary air cleaner element with damaged

Note: When the primary air cleaner elements are

pleats, gaskets or seals. Discard damaged primary

cleaned, always begin with the clean side (inside)

air cleaner elements.

in order to force dirt particles toward the dirty side

(outside).

Storing Primary Air Cleaner Elements

Aim the air hose so that air flows along the length of

If a primary air cleaner element that passes inspection

the filter. Follow the direction of the paper pleats in

will not be used, the primary air cleaner element can

order to prevent damage to the pleats. Do not aim

be stored for future use.

the air directly at the face of the paper pleats.

Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.

Vacuum Cleaning

Vacuum cleaning is a good method for removing

accumulated dirt from the dirty side (outside) of a

primary air cleaner element. Vacuum cleaning is

especially useful for cleaning primary air cleaner

elements which require daily cleaning because of a

dry, dusty environment.

Cleaning from the clean side (inside) with pressurized

air is recommended prior to vacuum cleaning the

Illustration 29

g00281694

dirty side (outside) of a primary air cleaner element.

SEBU8327

Maintenance Section

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

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

Some engines are equipped with a differential gauge

protective covering for storage. An air flow restriction

for inlet air pressure. The differential gauge for inlet

may result. To protect against dirt and damage, wrap

air pressure displays the difference in the pressure

the primary air cleaner elements in Volatile Corrosion

that is measured before the air cleaner element and

Inhibited (VCI) paper.

the pressure that is measured after the air cleaner

element. As the air cleaner element becomes dirty,

Place the primary air cleaner element into a box

the pressure differential rises. If your engine is

for storage. For identification, mark the outside of

equipped with a different type of service indicator,

the box and mark the primary air cleaner element.

follow the OEM recommendations in order to service

Include the following information:

the air cleaner service indicator.

• Date of cleaning

The service indicator may be mounted on the air

cleaner element or in a remote location.

• Number of cleanings

Store the box in a dry location.

i02708042

Engine Air Cleaner

Element (Single Element) -

Inspect/Replace

SMCS Code: 1054-040; 1054-510

Refer to Operation and Maintenance Manual, “Engine

Air Cleaner Service Indicator-Inspect”.

g00103777

Illustration 30

Typical service indicator

NOTICE

Never run the engine without an air cleaner element

Observe the service indicator. The air cleaner

installed. Never run the engine with a damaged air

element should be cleaned or the air cleaner element

cleaner element. Do not use air cleaner elements with

should be replaced when one of the following

damaged pleats, gaskets or seals. Dirt entering the

conditions occur:

engine causes premature wear and damage to engine

components. Air cleaner elements help to prevent air-

• The yellow diaphragm enters the red zone.

borne debris from entering the air inlet.

• The red piston locks in the visible position.

NOTICE

Test the Service Indicator

Never service the air cleaner element with the engine

running since this will allow dirt to enter the engine.

Service indicators are important instruments.

A wide variety of air cleaners may be installed for use

• Check for ease of resetting. The service indicator

with this engine. Consult the OEM information for the

should reset in less than three pushes.

correct procedure to replace the air cleaner.

• Check the movement of the yellow core when

the engine is accelerated to the engine rated

i02708041

speed. The yellow core should latch at the greatest

vacuum that is attained.

Engine Air Cleaner Service

Indicator - Inspect

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

yellow core does not latch at the greatest vacuum,

SMCS Code: 7452-040

the service indicator should be replaced. If the new

service indicator will not reset, the hole for the service

Some engines may be equipped with a different

indicator may be restricted.

service indicator.

The service indicator may need to be replaced

frequently in environments that are severely dusty.

SEBU8327

Maintenance Section

Engine Air Precleaner - Check/Clean

i02708039

i02708019

Engine Air Precleaner -

Engine Oil Level - Check

Check/Clean

SMCS Code: 1348-535-FLV

SMCS Code: 1055-070; 1055-535

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to

contact the skin.

g00287039

Illustration 31

Typical precleaner

(1) Wing nut

(2) Cover

(3) Body

g01165836

Illustration 32

Remove wing nut (1) and cover (2). Check for an

(Y) “Min” mark. (X) “Max” mark.

accumulation of dirt and debris in body (3). Clean the

body, if necessary.

NOTICE

After cleaning the precleaner, install cover (2) and

Perform this maintenance with the engine stopped.

wing nut (1).

Note: Ensure that the engine is either level or that

Note: When the engine is operated in dusty

the engine is in the normal operating position in order

applications, more frequent cleaning is required.

to obtain a true level indication.

i02456872

Note: After the engine has been switched OFF, wait

for ten minutes in order to allow the engine oil to drain

Engine Mounts - Inspect

to the oil pan before checking the oil level.

SMCS Code: 1152-040

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

and the “MAX” mark (X) on the engine oil dipstick.

Inspect the engine mounts for deterioration and for

Do not fill the crankcase above the “MAX” mark

proper bolt torque. Engine vibration can be caused

(X).

by the following conditions:

NOTICE

• Improper mounting of the engine

Operating your engine when the oil level is above the

“FULL” mark could cause your crankshaft to dip into

• Deterioration of the engine mounts

the oil. The air bubbles created from the crankshaft

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

Any engine mount that shows deterioration should be

acteristics and could result in the loss of power.

replaced. Refer to Special Publication, SENR3130,

“Torque Specifications” for the recommended

torques. Refer to the OEM recommendations for

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

more information.

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

SEBU8327

Maintenance Section

Engine Oil Sample - Obtain

i01935337

NOTICE

Engine Oil Sample - Obtain

Always use a designated pump for oil sampling, and

use a separate designated pump for coolant sampling.

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

Using the same pump for both types of samples may

7542-554-OC, SM

contaminate the samples that are being drawn. This

contaminate may cause a false analysis and an incor-

In addition to a good preventive maintenance

rect interpretation that could lead to concerns by both

program, Caterpillar recommends using S·O·S oil

dealers and customers.

analysis at regularly scheduled intervals in order

to monitor the condition of the engine and the

maintenance requirements of the engine. S·O·S oil

If the engine is not equipped with a sampling valve,

analysis provides infrared analysis, which is required

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

for determining nitration and oxidation levels.

designed to accept sampling bottles. Disposable

tubing must be attached to the pump for insertion

into the sump.

Obtain the Sample and the Analysis

For instructions, see Special Publication, PEHP6001,

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

Caterpillar dealer for complete information and

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

Hot oil and hot components can cause personal

engine.

injury. Do not allow hot oil or hot components to

contact the skin.

i02712378

Before you take the oil sample, complete the Label,

Engine Oil and Filter - Change

PEEP5031 for identification of the sample. In order

to help obtain the most accurate analysis, provide

SMCS Code: 1318-510; 1348-044

the following information:

• Engine model

• Service hours on the engine

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to

• The number of hours that have accumulated since

contact the skin.

the last oil change

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

• The amount of oil that has been added since the

cools, suspended waste particles settle on the bottom

last oil change

of the oil pan. The waste particles are not removed

with the draining cold oil. Drain the crankcase with

To ensure that the sample is representative of the

the engine stopped. Drain the crankcase with the

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

oil warm. This draining method allows the waste

sample.

particles that are suspended in the oil to be drained

properly.

To avoid contamination of the oil samples, the tools

and the supplies that are used for obtaining oil

Failure to follow this recommended procedure will

samples must be clean.

cause the waste particles to be recirculated through

the engine lubrication system with the new oil.

Caterpillar recommends using the sampling valve

in order to obtain oil samples. The quality and the

consistency of the samples are better when the

sampling valve is used. The location of the sampling

valve allows oil that is flowing under pressure to be

obtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle is

recommended for use with the sampling valve. The

fluid sampling bottle includes the parts that are

needed for obtaining oil samples. Instructions are

also provided.

SEBU8327

Maintenance Section

Engine Oil and Filter - Change

Drain the Engine Oil

1. Remove the oil filter with a 1U-8760 Chain

Wrench.

Note: The following actions can be carried out as

part of the preventive maintenance program.

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

Cutter Gp. Break apart the pleats and inspect the

oil filter for metal debris. An excessive amount

of metal debris in the oil filter may indicate early

wear or a pending failure.

Use a magnet to differentiate between the ferrous

metals and the nonferrous metals that are found in

the oil filter element. Ferrous metals may indicate

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

Nonferrous metals may indicate wear on the

aluminum parts, brass parts or bronze parts of

the engine. Parts that may be affected include

the following items: main bearings, rod bearings,

turbocharger bearings, and cylinder heads.

g01356033

Illustration 33

Due to normal wear and friction, it is not

Oil drain plug

uncommon to find small amounts of debris in the

oil filter. Consult your Caterpillar dealer in order

After the engine has been run at the normal operating

to arrange for a further analysis if an excessive

temperature, stop the engine. Use one of the

amount of debris is found in the oil filter.

following methods to drain the engine crankcase oil:

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

drain valve knob counterclockwise in order to drain

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

knob clockwise in order to close the drain valve.

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

remove the oil drain plug (1) in order to allow the

oil to drain. If the engine is equipped with a shallow

sump, remove the bottom oil drain plugs from both

ends of the oil pan.

After the oil has drained, the oil drain plugs should

be cleaned and installed. If necessary, renew the O

ring seal on the drain plug.

Some types of oil pans have oil drain plugs that are

on both sides of the oil pan, because of the shape of

the pan. This type of oil pan requires the engine oil to

be drained from both plugs.

g01356034

Illustration 34

Replace the Spin-on Oil Filter

(2) Filter head

(3) O ring seal

(4) Union

NOTICE

Caterpillar oil filters are built to Caterpillar speci-

3. Clean the sealing surface of the oil filter head

fications. Use of an oil filter not recommended by

(2). Ensure that the union (4) in the filter head is

Caterpillar could result in severe engine damage to

secure.

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

the larger waste particles from unfiltered oil entering

4. Clean the sealing surface of the oil filter head

the engine lubricating system. Only use oil filters

(2). Ensure that the union (4) in the filter head is

recommended by Caterpillar.

secure.

SEBU8327

Maintenance Section

Engine Protective Devices - Check

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

NOTICE

IDLE” for two minutes. Perform this procedure in

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

order to ensure that the lubrication system has

This oil would not be filtered and could be contaminat-

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

ed. Contaminated oil can cause accelerated wear to

filter for oil leaks.

engine components.

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

the sump for a minimum of ten minutes.

5. Install the oil filter. Tighten the oil filter by hand

according to the instructions that are shown on

the oil filter. Do not overtighten the oil filter.

Note: Some oil filters may be installed vertically.

Refer to illustration 35. Start at step (1) in order to

remove the oil filter and install the oil filter.

g01165836

Illustration 36

(Y) “MIN” mark. (X) “MAX” mark.

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

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

and “MAX” marks on the oil level gauge.

i00626013

Engine Protective Devices -

Check

g01356074

Illustration 35

SMCS Code: 7400-535

Typical example

Alarms and shutoffs must function properly. Alarms

provide timely warning to the operator. Shutoffs help

Fill the Engine Crankcase

to prevent damage to the engine. It is impossible

to determine if the engine protective devices are

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

in good working order during normal operation.

and Maintenance Manual for more information on

Malfunctions must be simulated in order to test the

lubricant specifications. Fill the crankcase with the

engine protective devices.

proper amount of oil. Refer to the Operation and

Maintenance Manual for more information on refill

A calibration check of the engine protective devices

capacities.

will ensure that the alarms and shutoffs activate

at the setpoints. Ensure that the engine protective

NOTICE

devices are functioning properly.

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

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

NOTICE

facturer’s recommendations. Under filling or overfilling

During testing, abnormal operating conditions must be

the crankcase with oil can cause engine damage.

simulated.

The tests must be performed correctly in order to pre-

NOTICE

vent possible damage to the engine.

To prevent crankshaft bearing damage, crank the en-

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

starting the engine. Do not crank the engine for more

than 30 seconds.

SEBU8327

Maintenance Section

Engine Valve Lash - Inspect/Adjust

To prevent damage to the engine, only authorized

i02707243

service personnel or your Caterpillar dealer should

Fuel Injection Nozzles -

perform the tests.

Test/Exchange

Visual Inspection

SMCS Code: 1254-013; 1254-081

Visually check the condition of all gauges, sensors

and wiring. Look for wiring and components that

are loose, broken, or damaged. Damaged wiring

or components should be repaired or replaced

Fuel leaked or spilled onto hot surfaces or electri-

immediately.

cal components can cause a fire.

i02707257

NOTICE

Engine Valve Lash -

Do not allow dirt to enter the fuel system. Thoroughly

clean the area around a fuel system component that

Inspect/Adjust

will be disconnected. Fit a suitable cover over discon-

nected fuel system component.

SMCS Code: 1102-025

This maintenance is recommended by Caterpillar

Fuel injection nozzles are subject to tip wear. Tip

as part of a lubrication and preventive maintenance

wear is a result of fuel contamination. Tip wear can

schedule in order to help provide maximum engine

cause the following problems:

life.

• Increased fuel consumption

NOTICE

• Black smoke

Only qualified service personnel should perform this

maintenance. Refer to the Systems Operation/Testing

• Misfire

and Adjusting Manual, “Valve Lash and Valve Bridge

Adjustment”article or consult your Caterpillar dealer

• Rough running

for the complete valve lash adjustment procedure.

Fuel Injection nozzles should be cleaned, inspected,

Operation of Caterpillar engines with improper valve

tested, and replaced, if necessary. Refer to Special

adjustments can reduce engine efficiency. This re-

Instruction, SEHS7292 for using the 8S-2245

duced efficiency could result in excessive fuel usage

Injector Cleaning Tool Gp. Consult your Caterpillar

and/or shortened engine component life.

dealer about cleaning the fuel injection nozzle and

testing the fuel injection nozzle.

NOTICE

Ensure that the engine can not be started while

Never wire brush or scrape a fuel injection nozzle.

this maintenance is being performed. To help pre-

Wire brushing or scraping a fuel injection nozzle will

vent possible injury, do not use the starting motor

damage the finely machine orifice. Proper tools for

to turn the flywheel.

cleaning and testing the fuel injection nozzles can be

obtained from Caterpillar dealers.

Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-

The following items are symptoms of a malfunction of

suring/adjusting valve lash clearance.

the fuel injection nozzle:

Ensure that the engine is stopped before measuring

• Abnormal engine operation

the valve lash. To obtain an accurate measurement,

allow the valves to cool before this maintenance is

• Smoke emission

performed.

• Engine knock

Refer to the Service Manual for more information.

Each fuel injection nozzle must be isolated one at

a time in order to determine the malfunctioning fuel

injection nozzle.

1. Start the engine.

SEBU8327

Maintenance Section

Fuel System - Prime

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

3. Turn the ignition key to the OFF position.

injection pump. A cloth or similar material must be

used in order to prevent fuel from spraying on the

hot exhaust components. Tighten each nut before

loosening the next nut.

3. Worn fuel injection nozzles or faulty fuel injection

nozzles may be identified when a fuel line nut is

loosened and the following conditions are present:

• The exhaust smoke is partially eliminated or the

exhaust smoke is completely eliminated.

• Engine performance is not affected.

A fuel injection nozzle that is suspected of being

g01003929

worn and/or faulty should be removed. A new fuel

Illustration 37

injection nozzle should be installed in the cylinder

Injector nuts

in order to determine if the removed fuel injection

nozzle is worn and/or faulty.

Note: Damage to the fuel injection pump, to the

battery, and to the starting motor can occur if the

starting motor is used excessively to purge the air

Removal and Installation of the

from the fuel system.

Fuel Injection Nozzles

4. Loosen the flare nuts (1) for the high pressure fuel

For the removal and the installation of fuel injection

lines on all of the fuel injectors.

nozzles, special tooling is required. Refer to the

Service Manual for more information. Consult your

NOTICE

Caterpillar dealer for assistance.

Do not crank the engine continuously for more than

30 seconds. Allow the starting motor to cool for two

i02677377

minutes before cranking the engine again.

Fuel System - Prime

5. Observe the connection at the flare nut. Operate

SMCS Code: 1258-548

the starting motor and crank the engine until the

fuel is free of air.

If air enters the fuel system, the air must be purged

from the fuel system before the engine can be

6. Tighten the flare nuts (1) to a torque of 30 N·m

started. Air can enter the fuel system when the

(22 lb ft).

following events occur:

7. The engine is now ready to start. Operate the

• The fuel tank is empty or the fuel tank has been

engine at low idle for a minimum of five minutes

partially drained.

immediately after air has been removed from the

fuel system.

• The low pressure fuel lines are disconnected.

Note: Running the engine for this period of time will

help ensure that the pump is completely free of air.

• A leak exists in the low pressure fuel system.

• The fuel filter is replaced.

• A new injection pump is installed.

Use the following procedure in order to remove air

from the fuel system:

1. Remove the cover for the fuel injectors. Refer to

the Disassembly and Assembly Manual.

2. Turn the ignition key to the RUN position. Leave

the ignition key in the RUN position for three

minutes.

SEBU8327

Maintenance Section

Fuel System Primary Filter/Water Separator - Drain

i02699081

Fuel System Primary

Filter/Water Separator - Drain

SMCS Code: 1260-543; 1263-543

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-

vent possible injury, turn the start switch off when

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

NOTICE

The water separator is not a filter. The water separa-

tor separates water from the fuel. The engine should

never be allowed to run with the water separator more

than half full. Engine damage may result.

NOTICE

The water separator is under suction during normal

engine operation. Ensure that the drain valve is tight-

ened securely to help prevent air from entering the fuel

system.

g01353878

Illustration 38

(1) Screw

(2) Element

(3) Bowl

(4) Bottom cover

(5) Drain

(6) Sensor connection

1. Place a suitable container below the water

separator.

2. Open the drain (5). Allow the fluid to drain into

the container.

3. When clean fuel drains from the water separator

close the drain (5). Tighten the drain by hand

pressure only. Dispose of the drained fluid

correctly.

i02699073

Fuel System Secondary Filter -

Replace

SMCS Code: 1261-510-SE

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-

vent possible injury, turn the start switch off when

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

SEBU8327

Maintenance Section

Fuel System Secondary Filter - Replace

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly

clean the area around a fuel system component that

will be disconnected. Fit a suitable cover over discon-

nected fuel system component.

Element filter

Turn the valves for the fuel lines (if equipped) to the

OFF position before performing this maintenance.

Place a tray under the fuel filter in order to catch

any fuel that might spill. Clean up any spilled fuel

immediately.

g01353857

Illustration 40

(3) Filter head

(4) Element

(5) O ring seal

3. Remove the filter bowl (1) from the filter head

(3). Press on the element (4). Rotate the element

counterclockwise in order to release the element

for the filter bowl and remove the element from the

bowl. Discard the used element.

4. Remove the O ring (5) from the filter bowl and

clean the filter bowl. Check that the threads of the

filter bowl are not damaged.

5. Install a new O ring seal (5) to the filter bowl (1).

g01353856

Illustration 39

(1) Filter bowl

6. Locate a new filter element (4) into the filter bowl

(2) Drain

(1). Press on the element and rotate the element

clockwise in order to lock the element into the

1. Close the valves for the fuel lines (if equipped).

filter bowl.

2. Clean the outside of the fuel filter assembly. Open

7. Install the filter bowl (1) into the top of the filter

the fuel drain (2) and drain the fuel into a suitable

head (3).

container.

8. Tighten the filter bowl by hand until the filter bowl

contacts the filter head. Rotate the filter bowl

through 90 degrees.

Note: Do not use a tool to tighten the filter bowl.

9. Open the valves for the fuel lines (if equipped).

Spin-on filter

Turn the valves for the fuel lines (if equipped) to the

OFF position before performing this maintenance.

Place a tray under the fuel filter in order to catch

any fuel that might spill. Clean up any spilled fuel

immediately.

SEBU8327

Maintenance Section

Fuel Tank Water and Sediment - Drain

g01353860

Illustration 42

(4) O ring seal

4. Lubricate the sealing ring (4) with clean fuel oil.

5. Install the spin-on filter (2) into the top of the filter

g01353858

head (1).

Illustration 41

(1) Filter Head

6. Tighten the spin-on filter by hand until the sealing

(2) Spin-on filter

(3) Drain

ring contacts the filter head. Rotate the spin-on

filter through 90 degrees.

1. Clean the outside of the fuel filter assembly. Open

the fuel drain (3) and drain the fuel into a suitable

7. Prime the fuel system. Refer to Operation and

container.

Maintenance Manual, “Fuel System - Prime”.

2. Use a suitable tool in order to remove the spin-on

i02702048

filter (2) from the filter head (1).

Fuel Tank Water and Sediment

3. Ensure that the fuel drain (3) on the new spin-on

- Drain

filter is closed.

SMCS Code: 1273-543-M&S

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

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

to collect the fluid with suitable containers before

opening any compartment or disassembling any com-

ponent containing fluids.

Dispose of all fluids according to local regulations and

mandates.

Fuel Tank

Fuel quality is critical to the performance and to the

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

excessive wear to the fuel system.

SEBU8327

Maintenance Section

Hoses and Clamps - Inspect/Replace

Water can be introduced into the fuel tank when the

i02705980

fuel tank is being filled.

Hoses and Clamps -

Condensation occurs during the heating and cooling

Inspect/Replace

of fuel. The condensation occurs as the fuel passes

through the fuel system and the fuel returns to the

SMCS Code: 7554-040; 7554-510

fuel tank. This causes water to accumulate in fuel

tanks. Draining the fuel tank regularly and obtaining

Inspect all hoses for leaks that are caused by the

fuel from reliable sources can help to eliminate water

following conditions:

in the fuel.

• Cracking

Drain the Water and the Sediment

• Softness

Fuel tanks should contain some provision for draining

water and draining sediment from the bottom of the

• Loose clamps

fuel tanks.

Replace hoses that are cracked or soft. Tighten any

Open the drain valve on the bottom of the fuel tank

loose clamps.

in order to drain the water and the sediment. Close

the drain valve.

NOTICE

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

Check the fuel daily. Allow five minutes after the

stall bent or damaged lines, tubes or hoses. Repair

fuel tank has been filled before draining water and

any loose or damaged fuel and oil lines, tubes and

sediment from the fuel tank.

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

and hoses carefully. Tighten all connections to the rec-

Fill the fuel tank after operating the engine in

ommended torque.

order to drive out moist air. This will help prevent

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

fuel expands as the fuel gets warm. The tank may

Check for the following conditions:

overflow.

• End fittings that are damaged or leaking

Some fuel tanks use supply pipes that allow water

and sediment to settle below the end of the fuel

• Outer covering that is chafed or cut

supply pipe. Some fuel tanks use supply lines that

take fuel directly from the bottom of the tank. If

• Exposed wire that is used for reinforcement

the engine is equipped with this system, regular

maintenance of the fuel system filter is important.

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

Fuel Storage Tanks

• Armoring that is embedded in the outer covering

Drain the water and the sediment from the fuel

storage tank at the following intervals:

A constant torque hose clamp can be used in place

of any standard hose clamp. Ensure that the constant

• Weekly

torque hose clamp is the same size as the standard

clamp.

• Service intervals

Due to extreme temperature changes, the hose will

• Refill of the tank

heat set. Heat setting causes hose clamps to loosen.

This can result in leaks. A constant torque hose

This will help prevent water or sediment from being

clamp will help to prevent loose hose clamps.

pumped from the storage tank into the engine fuel

tank.

Each installation application can be different. The

differences depend on the following factors:

If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to

• Type of hose

settle before filling the engine fuel tank. Internal

baffles in the bulk storage tank will also help trap

• Type of fitting material

sediment. Filtering fuel that is pumped from the

storage tank helps to ensure the quality of the fuel.

• Anticipated expansion and contraction of the hose

When possible, water separators should be used.

SEBU8327

Maintenance Section

Overhaul Considerations

• Anticipated expansion and contraction of the

The need for an overhaul is generally indicated by

fittings

increased fuel consumption and by reduced power.

The following factors are important when a decision

Replace the Hoses and the Clamps

is being made on the proper time for an engine

overhaul:

• The need for preventive maintenance

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,

• The quality of the fuel that is being used

stop the engine and wait until the cooling system

components are cool. Loosen the cooling system

• The operating conditions

pressure cap slowly in order to relieve the pres-

sure.

• The results of the S·O·S analysis

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

Oil Consumption as an Overhaul

Indicator

2. Loosen the cooling system filler cap slowly in

order to relieve any pressure. Remove the cooling

Oil consumption, fuel consumption, and maintenance

system filler cap.

information can be used to estimate the total

operating cost for your Caterpillar engine. Oil

Note: Drain the coolant into a suitable, clean

consumption can also be used to estimate the

container. The coolant can be reused.

required capacity of a makeup oil tank that is suitable

for the maintenance intervals.

3. Drain the coolant from the cooling system to a

level that is below the hose that is being replaced.

Oil consumption is in proportion to the percentage

of the rated engine load. As the percentage of the

4. Remove the hose clamps.

engine load is increased, the amount of oil that is

consumed per hour also increases.

5. Disconnect the old hose.

The oil consumption rate (brake specific oil

6. Replace the old hose with a new hose.

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

bhp). The brake specific oil consumption (BSOC)

7. Install the hose clamps with a torque wrench.

depends on the engine load. Consult your Caterpillar

dealer for assistance in determining the typical oil

Note: Refer to the Specifications, SENR3130,

consumption rate for your engine.

“Torque Specifications” in order to locate the proper

torques.

When an engine’s oil consumption has risen to three

times the original oil consumption rate due to normal

8. Refill the cooling system.

wear, an engine overhaul should be scheduled.

There may be a corresponding increase in blowby

9. Clean the cooling system filler cap. Inspect the

and a slight increase in fuel consumption.

cooling system filler cap’s gaskets. Replace

the cooling system filler cap if the gaskets are

Overhaul Options

damaged. Install the cooling system filler cap.

Before Failure Overhaul

10. Start the engine. Inspect the cooling system for

leaks.

A planned overhaul before failure may be the best

value for the following reasons:

i02708037

• Costly unplanned downtime can be avoided.

Overhaul Considerations

Many original parts can be reused according to the

•

SMCS Code: 7595-043

standards for reusable parts.

Reduced hours of operation at full load will result in a

• The engine’s service life can be extended without

lower average power demand. A decreased average

the risk of a major catastrophe due to engine

power demand should increase both the engine

failure.

service life and the overhaul interval.

SEBU8327

Maintenance Section

Overhaul Considerations

• The best cost/value relationship per hour of

• Salvaging

extended life can be attained.

• Repairing

After Failure Overhaul

• Replacing

If a major engine failure occurs and the engine

must be removed, many options are available. An

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

overhaul should be performed if the engine block or

problems:

the crankshaft needs to be repaired.

• Unscheduled downtime

If the engine block is repairable and/or the crankshaft

is repairable, the overhaul cost should be between 40

• Costly repairs

percent and 50 percent of the cost of a new engine

with a similar exchange core.

• Damage to other engine parts

This lower cost can be attributed to three aspects:

• Reduced engine efficiency

• Specially designed Caterpillar engine features

• Increased fuel consumption

• Caterpillar dealer exchange components

Reduced engine efficiency and increased fuel

consumption translates into higher operating costs.

• Caterpillar Inc. remanufactured exchange

Therefore, Caterpillar Inc. recommends repairing

components

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

Overhaul Recommendation

Inspection and/or Replacement

To minimize downtime, Caterpillar Inc. recommends

Crankshaft Bearings and Crankshaft Seals

a scheduled engine overhaul by your Caterpillar

dealer before the engine fails. This will provide you

The following components may not last until the

with the best cost/value relationship.

second overhaul.

Note: Overhaul programs vary according to the

• Thrust bearings

engine application and according to the dealer that

performs the overhaul. Consult your Caterpillar

• Main bearings

dealer for specific information about the available

overhaul programs and about overhaul services for

• Rod bearings

extending the engine life.

• Crankshaft seals

If an overhaul is performed without overhaul service

from your Caterpillar dealer, be aware of the following

Caterpillar Inc. recommends the installation of new

maintenance recommendations.

parts at each overhaul period.

Inspect these parts while the engine is disassembled

Rebuild or Exchange

for an overhaul.

Cylinder Head Assembly, Oil Pump, and Fuel

Inspect the crankshaft for any of the following

Transfer Pump

conditions:

These components should be inspected according to

• Deflection

the instructions that are found in various Caterpillar

reusability publications. The Special Publication,

• Damage to the journals

SEBF8029 lists the reusability publications that are

needed for inspecting the engine parts.

• Bearing material that has seized to the journals

If the parts comply with the established inspection

Check the journal taper and the profile of the

specifications that are expressed in the reusable

crankshaft journals. Check these components by

parts guideline, the parts should be reused.

interpreting the wear patterns on the following

components:

Parts that are not within the established inspection

specifications should be dealt with in one of the

• Rod bearing

following manners:

SEBU8327

Maintenance Section

Overhaul Considerations

• Main bearings

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

removes any remaining residue from the cleaner.

Inspect the camshaft for damage to the journals and

Flush the fins of the oil cooler core. Remove any

to the lobes.

other trapped debris.

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

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

the magnetic particle inspection process to check for

Rinse the oil cooler core thoroughly with clean

cracks in the camshaft.

water.

Inspect the following components for signs of wear or

for signs of scuffing:

Personal injury can result from air pressure.

• Camshaft bearings

Personal injury can result without following prop-

• Lifters

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

tective face shield and protective clothing.

Caterpillar Inc. recommends replacing the crankshaft

vibration damper.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Oil Cooler Core

During an overhaul, Caterpillar Inc. recommends the

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

removal of the oil cooler core. Clean the oil cooler

the air in the reverse direction of the normal flow.

core. Then, pressure test the oil cooler core.

7. Inspect the components in order to ensure

cleanliness. The oil cooler core should be

NOTICE

pressure tested. Repair the oil cooler core, if

Do not use caustic cleaners to clean the core.

necessary. Install the oil cooler core.

Caustic cleaners can attack the internal metals of the

For more information about cleaning the cores,

core and cause leakage.

consult your Caterpillar dealer.

Note: Use this cleaning procedure to clean the oil

Obtain Coolant Analysis

cooler core.

The concentration of supplemental coolant additive

1. Remove the oil cooler core.

(SCA) should be checked regularly with test kits

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

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

coolant analysis is recommended when the engine

remove debris from the oil cooler core, turn the oil

is overhauled.

cooler core onto one end.

For example, considerable deposits are found in the

3. Flush the oil cooler core internally with cleaner in

water jacket areas on the external cooling system, but

order to loosen foreign substances. This will also

the concentrations of coolant additives were carefully

help to remove oil from the oil cooler core.

maintained. The coolant water probably contained

minerals that were deposited on the engine over time.

Note: Caterpillar Inc. recommends the use of

Hydrosolv Liquid Cleaners. Table 11 lists the

A coolant analysis can be conducted in order to verify

Hydrosolv Liquid Cleaners that are available from

the condition of the water that is being used in the

your Caterpillar dealer.

cooling system. A full water analysis can be obtained

by consulting your local water utility company or

Table 11

an agricultural agent. Private laboratories are also

Hydrosolv Liquid Cleaners

available for water analysis.

Part

Description

Size

Caterpillar Inc. recommends an S·O·S Coolant

Number

Analysis (Level 2).

1U-5490

Hydrosolv4165

19 L (5 US gal)

1U-5492

Hydrosolv100

19 L (5 US gallon)

SEBU8327

Maintenance Section

Radiator - Clean

S·O·S Coolant Analysis (Level 2)

Pressurized air is the preferred method for removing

loose debris. Direct the air in the opposite direction

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

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

comprehensive coolant analysis which completely

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

analyzes the coolant and the effects on the cooling

air nozzle in a direction that is parallel with the tubes.

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

This will remove debris that is between the tubes.

the following information:

Pressurized water may also be used for cleaning.

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

The maximum water pressure for cleaning purposes

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

• Visual inspection of properties

water in order to soften mud. Clean the core from

both sides.

• Identification of metal corrosion

Use a degreaser and steam for removal of oil and

• Identification of contaminants

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

with detergent and hot water. Thoroughly rinse the

• Identification of built up impurities (corrosion and

core with clean water.

scale)

After cleaning, start the engine and accelerate the

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

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

the results of both the analysis and the maintenance

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

recommendations.

Use a light bulb behind the core in order to inspect

the core for cleanliness. Repeat the cleaning, if

For more information about coolant analysis, see

necessary.

your Caterpillar dealer.

Inspect the fins for damage. Bent fins may be opened

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

i02708040

welds, mounting brackets, air lines, connections,

clamps, and seals. Make repairs, if necessary.

Radiator - Clean

For more detailed information on cleaning and

SMCS Code: 1353-070

inspection, refer to Special Publication, SEBD0518,

“Know Your Cooling System”.

The radiator is not usually supplied by Caterpillar. The

following text describes a typical cleaning procedure

for the radiator. Refer to OEM information for further

i00151038

information on cleaning the radiator.

Severe Service Application -

Note: Adjust the frequency of cleaning according to

Check

the effects of the operating environment.

SMCS Code: 1000-535

Inspect the radiator for these items: damaged fins,

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

Severe service is an application of an engine that

debris. Clean the radiator, if necessary.

exceeds current published standards for that engine.

Caterpillar maintains standards for the following

engine parameters:

Personal injury can result from air pressure.

• Performance (power range, speed range, and fuel

consumption)

Personal injury can result without following prop-

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

• Fuel quality

tective face shield and protective clothing.

• Altitude range

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

• Maintenance intervals

• Oil selection and maintenance

• Coolant selection and maintenance

• Environmental qualities

SEBU8327

Maintenance Section

Starting Motor - Inspect

• Installation

Improper Maintenance Procedures

Refer to the standards for the engine or consult with

• Extending the maintenance intervals

your Caterpillar dealer in order to determine if the

engine is operating within the defined parameters.

• Failure to use recommended fuel, lubricants and

coolant/antifreeze

Severe service operation can accelerate component

wear. Engines that operate under severe conditions

i02348493

may need more frequent maintenance intervals in

order to ensure maximum reliability and retention of

Starting Motor - Inspect

full service life.

SMCS Code: 1451-040; 1453-040

Due to individual applications, it is not possible to

identify all of the factors which can contribute to

Caterpillar recommends a scheduled inspection of

severe service operation. Consult your Caterpillar

the starting motor. If the starting motor fails, the

dealer for the unique maintenance that is necessary

engine may not start in an emergency situation.

for the engine.

Check the starting motor for correct operation. Check

The operating environment, improper operating

the electrical connections and clean the electrical

procedures and improper maintenance procedures

connections. Refer to the Systems Operation, Testing

can be factors which contribute to severe service

and Adjusting Manual, “Electric Starting System -

conditions.

Test” for more information on the checking procedure

and for specifications or consult your Caterpillar

Environmental Factors

dealer for assistance.

Ambient temperatures - The engine may be

i02710646

exposed to extended operation in extremely

cold environments or hot environments. Valve

Turbocharger - Inspect

components can be damaged by carbon buildup if

the engine is frequently started and stopped in very

SMCS Code: 1052-040; 1052

cold temperatures. Extremely hot inlet air reduces

engine performance.

A regular visual inspection of the turbocharger is

recommended. Any fumes from the crankcase are

Air Quality - The engine may be exposed to

filtered through the air inlet system. Therefore,

extended operation in an environment that is dirty

by-products from oil and from combustion can collect

or dusty, unless the equipment is cleaned regularly.

in the turbocharger compressor housing. Over time,

Mud, dirt and dust can encase components.

this buildup can contribute to loss of engine power,

Maintenance can be very difficult. The buildup can

increased black smoke and overall loss of engine

contain corrosive chemicals.

efficiency.

Buildup - Compounds, elements, corrosive

If the turbocharger fails during engine operation,

chemicals and salt can damage some components.

damage to the turbocharger compressor wheel

and/or to the engine may occur. Damage to the

Altitude - Problems can arise when the engine is

turbocharger compressor wheel can cause additional

operated at altitudes that are higher than the intended

damage to the pistons, the valves, and the cylinder

settings for that application. Necessary adjustments

head.

should be made.

Improper Operating Procedures

• Extended operation at low idle

• Frequent hot shutdowns

• Operating at excessive loads

• Operating at excessive speeds

• Operating outside the intended application

SEBU8327

Maintenance Section

V-Belts - Inspect/Adjust/Replace

The presence of oil may be the result of extended

NOTICE

engine operation at low idle. The presence of oil

Turbocharger bearing failures can cause large quanti-

may also be the result of a restriction of the line

ties of oil to enter the air intake and exhaust systems.

for the intake air (clogged air filters), which causes

Loss of engine lubricant can result in serious engine

the turbocharger to slobber.

damage.

3. Inspect the bore of the housing of the turbine

Minor leakage of oil into a turbocharger under extend-

outlet for corrosion.

ed low idle operation should not cause problems as

long as a turbocharger bearing failure has not oc-

4. Fasten the air intake pipe and the exhaust outlet

cured.

pipe to the turbocharger housing.

When a turbocharger bearing failure is accompanied

i02517672

by a significant engine performance loss (exhaust

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

V-Belts - Inspect/Adjust/

engine operation until the turbocharger is renewed.

Replace

A visual inspection of the turbocharger can minimize

SMCS Code: 1357-025; 1357-040; 1357-510

unscheduled downtime. A visual inspection of the

turbocharger can also reduce the chance for potential

Inspection

damage to other engine parts.

Removal and Installation

Note: The turbochargers that are supplied are

nonserviceable.

For options regarding the removal, installation, and

replacement, consult your Carerpillar dealer or your

Carerpillar distributor. Refer to the Disassembly and

Assembly Manual, “Turbocharger - Remove and

Turbocharger - Install” for further information.

Inspecting

NOTICE

The compressor housing for the turbocharger must

not be removed from the turbocharger for cleaning.

The actuator linkage is connected to the compressor

housing. If the actuator linkage is moved or disturbed

g01249073

Illustration 43

the engine may not comply with emmissions legisla-

tion.

Arrangement for the V-belts

To maximize the engine performance, inspect the

1. Remove the pipe from the turbocharger exhaust

belts for wear and for cracking. Replace belts that are

outlet and remove the air intake pipe to the

worn or damaged.

turbocharger. Visually inspect the piping for the

presence of oil. Clean the interior of the pipes

For applications that require multiple drive belts,

in order to prevent dirt from entering during

replace the belts in matched sets. Replacing only

reassembly.

one belt of a matched set will cause the new belt to

carry more load because the older belt is stretched.

2. Check for the presence of oil. If oil is leaking from

The additional load on the new belt could cause the

the back side of the compressor wheel, there is a

new belt to break.

possibility of a failed turbocharger oil seal.

If the belts are too loose, vibration causes

unnecessary wear on the belts and pulleys. Loose

belts may slip enough to cause overheating.

SEBU8327

Maintenance Section

Walk-Around Inspection

To accurately check the belt tension, install

i02457734

144-0235 Belt Tension Gauge.

Walk-Around Inspection

SMCS Code: 1000-040

Inspect the Engine for Leaks and

for Loose Connections

A walk-around inspection should only take a few

minutes. When the time is taken to perform these

checks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thorough

inspection of the engine compartment before starting

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

g01003936

leaks, loose bolts, worn belts, loose connections and

Illustration 44

trash buildup. Make repairs, as needed:

Typical example

(1) Gauge

• The guards must be in the correct place. Repair

damaged guards or replace missing guards.

Fit the gauge (1) at the center of the longest free

length and check the tension. The correct tension is

• Wipe all caps and plugs before the engine is

400 N (90 lb). If the tension of the belt is below 250 N

serviced in order to reduce the chance of system

(56 lb) adjust the belt to 400 N (90 lb).

contamination.

If twin belts are installed, check and adjust the

NOTICE

tension on both belts.

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

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

Adjustment

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

more often than recommended until the leak is found

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

unwarranted.

NOTICE

Accumulated grease and/or oil on an engine is a fire

hazard. Remove the accumulated grease and oil. Re-

fer to this Operation and Maintenance Manual, “En-

gine - Clean” for more information.

• Ensure that the cooling system hoses are correctly

clamped and that the cooling system hoses are

tight. Check for leaks. Check the condition of all

pipes.

g01003939

Illustration 45

• Inspect the water pump for coolant leaks.

1. Loosen The alternator pivot bolt (2) and the bolt

(3).

Note: The water pump seal is lubricated by the

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

2. Move the alternator in order to increase or

amount of leakage to occur as the engine cools down

decrease the belt tension. Tighten the alternator

and the parts contract.

pivot bolt and the link bolt to 22 N·m (16 lb ft).(1).

Excessive coolant leakage may indicate the need

Replace

to replace the water pump seal. For the removal of

the water pump and the installation of water pump

Refer to Disassembly and Assembly manual for more

and/or seal, refer to the Disassembly and Assembly

information.

Manual, “Water Pump - Remove and Install” for more

information or consult your Caterpillar dealer.

SEBU8327

Maintenance Section

Water Pump - Inspect

• Inspect the lubrication system for leaks at the front

Note: The water pump seal is lubricated by the

crankshaft seal, the rear crankshaft seal, the oil

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

pan, the oil filters and the rocker cover.

amount of leakage to occur as the engine cools down

and parts contract.

• Inspect the fuel system for leaks. Look for loose

fuel line clamps and/or tie-wraps.

Visually inspect the water pump for leaks. Renew

the water pump seal or the water pump if there

• Inspect the piping for the air intake system and the

is an excessive leakage of coolant. Refer to

elbows for cracks and for loose clamps. Ensure

Disassembly and Assembly, “Water Pump - Remove”

that hoses and tubes are not contacting other

for the disassembly procedure and then refer to

hoses, tubes, wiring harnesses, etc.

Disassembly and Assembly, “Water Pump - Install”

for the assembly procedure.

• Inspect the alternator belts and any accessory

drive belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced as

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

carry more load than the belts that are not replaced.

The older belts are stretched. The additional load on

the new belt could cause the belt to break.

• Drain the water and the sediment from the fuel

tank on a daily basis in order to ensure that only

clean fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed

wires.

• Inspect the ground strap for a good connection and

for good condition.

• 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 that are cracked. Replace any gauge that

can not be calibrated.

i02457735

Water Pump - Inspect

SMCS Code: 1361-040; 1361

A failed water pump may 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

SEBU8327

Reference Information Section

Engine Ratings

i00819749

Reference Information

Engine Rating Definitions

Section

SMCS Code: 1000

Engine Ratings

It is important to know the use of the engine so

that the rating will match the operating profile. The

proper rating selection is also important so that the

i00727327

customer’s perception of price and value is realized.

Engine Rating Conditions

In selecting a rating for a specific application, the

most important consideration is the time that is spent

SMCS Code: 1000

at full throttle. These rating definitions identify the

percent of time at full throttle. The definitions also

All engine ratings are in compliance with the following

identify the corresponding times below rated rpm.

standard ambient air conditions of “SAE J1349”:

Note: The examples of the applications are only

• 99 kPa (29.3 inches of Hg)

for reference. For an exact determination of the

appropriate rating, follow the OEM specifications or

• 30 percent relative humidity

consult your Caterpillar dealer.

• A temperature of 25 °C (77 °F)

A Rating - This rating is used for heavy-duty

applications that are operated at rated load and at

Ratings relate to the standard conditions of

rated rpm up to 100 percent. This rating is used for

“ISO8665”, of “ISO3046/1”, of “DIN6271”, and of

engines that operate without interruption of load

“BS5514”.

cycling. Typical applications include the following

examples: pipeline pumping and ventilation.

The engine ratings are based on the following fuel

specifications:

B Rating - This rating is used when power and/or

rpm are cyclic. The engine should be run at full load.

• Low heat value (LHV) of the fuel of 42 780 kJ/kg

The engine should not exceed 80 percent of the

(18,390 Btu/lb) at 29 °C (84 °F)

duty cycle. Typical applications include the following

examples: irrigation, operation where normal pump

• Gravity (API) of 35 degrees at 15 °C (60 °F)

demand is 85 percent of the engine rating, oil

pumping/drilling, field mechanical pumping/drilling,

• Specific gravity of .849 at 15 °C (60 °F)

and stationary/plant air compressors.

• Density of 850 kg/m³ (7.085 lb/US gal)

C Rating - This rating is used when power and/or

rpm are cyclic. The horsepower and the rpm of the

The engine ratings are gross output ratings.

engine can be utilized continuously for one hour. This

is followed by one hour of operation at the A rating

Gross Output Ratings - The total output capability

or below the A rating. The engine should be run at

of the engine that is equipped with standard

full load. The engine should not exceed 50 percent

accessories.

of the duty cycle. Typical applications include the

following examples: agricultural tractors, harvesters

Standard accessories include the following

and combines, off-highway trucks, fire pumps, blast

components:

hole drills, rock curshers, wood chippers with high

torque rise, and oil field hoisting.

• Oil pumps

D Rating - This rating is used when rated power

• Fuel pumps

is required for periodic overloads. The maximum

horsepower and the rpm of the engine can be utilized

• Water pumps

continuously for a maximum of 30 minutes. This is

followed by one hour of operation at the C rating. The

Subtract the power that is required to drive auxiliary

engine should be run at full load. The engine should

components from the gross output. This will produce

not exceed 10 percent of the duty cycle. Typical

the net power that is available for the external load

applications include the following examples: offshore

(flywheel).

cranes, runway snow blowers, water well drills,

portable air compressors, and fire pump certification

power.

SEBU8327

Reference Information Section

Customer Service

Latin America, Mexico, Carribean

Customer Service

Caterpillar Americas Co.

701 Waterford Way, Suite 200

i02097871

Miami, FL 33126-4670

USA

Customer Assistance

Phone: 305-476-6800

Fax: 305-476-6801

SMCS Code: 1000

Europe, Africa, and Middle East

USA and Canada

Caterpillar Overseas S.A.

76 Route de Frontenex

When a problem arises concerning the operation of

P.O. Box 6000

an engine or concerning the service of an engine,

CH-1211 Geneva 6

the problem will normally be managed by the dealer

Switzerland

in your area.

Phone: 22-849-4444

Fax: 22-849-4544

Your satisfaction is a primary concern to Caterpillar

and to Caterpillar dealers. If you have a problem that

Far East

has not been handled to your complete satisfaction,

Caterpillar Asia Pte. Ltd.

follow these steps:

7 Tractor Road

Jurong, Singapore 627968

1. Discuss your problem with a manager from the

Republic of Singapore

dealership.

Phone: 65-662-8333

Fax: 65-662-8302

2. If your problem cannot be resolved at the dealer

level without additional assistance, use the phone

China

number that is listed below to talk with a Field

Caterpillar China Ltd.

Service Coordinator:

37/F., The Lee Gardens

33 Hysan Avenue

1-800-447-4986

Causeway Bay

G.P.O. Box 3069

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

Hong Kong

through Friday Central Standard Time.

Phone: 852-2848-0333

Fax: 852-2848-0440

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

matter in writing to the following address:

Japan

Shin Caterpillar Mitsubishi Ltd.

Caterpillar Inc.

SBS Tower

Manager, Customer Service, Engine Division

10-1, Yoga 4-Chome

Mossville Bldg AC

Setagaya-Ku, Tokyo 158-8530

P.O. Box 610

Japan

Mossville, Illinois 61552-0610

Phone: 81-3-5717-1150

Fax: 81-3-5717-1177

Please keep in mind: probably, your problem will

ultimately be solved at the dealership, using the

Japan

dealership’s facilities, equipment, and personnel.

Caterpillar Power Systems, Inc.

Therefore, follow the steps in sequence when a

SBS Tower (14th floor)

problem is experienced.

4-10-1, Yoga

Setagaya-Ku, Tokyo 158-0097

Phone: 81-3-5797-4300

Outside of the USA and of Canada

Fax: 81-3-5797-4359

If a problem arises outside the USA and outside

Australia and New Zealand

Canada, and if the problem cannot be resolved at the

Caterpillar of Australia Ltd.

dealer level, consult the appropriate Caterpillar office.

1 Caterpillar Drive

Private Mail Bag 4

Tullamarine, Victoria 3043

Australia

Phone: 03-9953-9333

Fax: 03-9335-3366

SEBU8327

Reference Information Section

Customer Service

i01028392

Ordering Replacement Parts

SMCS Code: 7567

When replacement parts are required for this

product Caterpillar recommends using Caterpillar

replacement parts or parts with equivalent spec-

ifications including, but not limited to, physical

dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.

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

The parts stocks include all of the parts that are

normally needed to protect your Caterpillar engine

investment.

When you order parts, please specify the following

information:

• Part number

• Part name

• Quantity

If there is a question concerning the part number,

please provide your dealer with a complete

description of the needed item.

When a Caterpillar engine requires maintenance

and/or repair, provide the dealer with all the

information that is stamped on the Information Plate.

This information is described in this Operation and

Maintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform the

dealer about the conditions of the problem and the

nature of the problem. Inform the dealer about when

the problem occurs. This will help the dealer in

troubleshooting the problem and solving the problem

faster.

SEBU8327

Reference Information Section

Reference Materials

• Special Publication, SEBD0970, “Coolant and Your

Engine”

i02708607

• Label, PEEP5027, “Extended Life Coolant/

Antifreeze”

Reference Material

SMCS Code: 1000

Miscellaneous

The following literature can be obtained through any

• Service Manual, REG1139F, “Service Manual

Caterpillar dealer.

Contents Microfiche”

• Service Manual, KENR6217, “C4.4 Industrial

Lubricants

Engines”

• Special Publication, PEHP8038, “Data Sheet -

• Systems Operation, Testing and Adjusting,

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

RENR9965, “C4.4 Industrial Engines”

America)”

• Specifications, RENR9961, “C4.4 Industrial

• Special Publication, PEHP9536, “Data Sheet

Engines.”

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

(International only)”

• Disassembly and Assembly, KENR6216, “C4.4

Industrial Engines”

• Special Publication, NEDG6022, “Cat Lubricating

Grease”

• Specifications, SENR3130, “Torque Specifications”

• Special Publication, PEHP0002, “Data Sheet -

• Special Publication, PECP9067, “One Safe

Molybdenum (MPGM) Grease”

Source” English language for use in NACD

• Special Publication, NEHP6015, “Data Sheet -

• Special Publication, LEDM5615, “Caterpillar

Caterpillar Special Purpose Grease (SPG)”

Marine Parts and Service Locations Directory”

• Special Publication, SEBD0640, “Oil and Your

• Special Publication, SEBF8029, “Index to

Engine”

Guidelines for Reusable Parts and Salvage

Operations”

• Operation and Maintenance Manual, SEBU5898,

“Cold Weather Recommendations”

• Special Publication, SEBF8062, “Procedure to

Inspect and Clean Air Filters”

• Operation and Maintenance Manual, SEBU6251,

“Caterpillar Commercial Diesel Engine Fluids

• Special Instruction, SEHS9031, “Storage

Recomendations”

Procedure for Caterpillar Products”

• Special Publication, PEHP6001, “How To Take A

• Special Publication, NEHS0526, “Service

Good Oil Sample”

Technician Application Guide”

Fuels

• Special Publication, SEBU6251, “Caterpillar

Commercial Diesel Engine Fluids Recomendations”

• Special Publication, SEBD0717, “Diesel Fuels and

Your Engine”

• Special Instruction, SEHS7633, “Battery Test

Procedure”

Coolants

• Label, SEHS7332, “Danger Do Not Operate”

• Special Publication, PEHP4036, “Data Sheet -

Extended Life Coolant”

• Special Publication, PEHP7057, “Data Sheet -

S·O·S Coolant Analysis”

• Special Publication, SEBD0518, “Know Your

Cooling System”

SEBU8327

Reference Information Section

Reference Materials

Emissions Warranty

International Organization for Standardization

(ISO)

This engine may be Certified and this engine

1, rue de Varembé

may be covered by an Emissions Warranty. A

Case postale 56

detailed explanation of the Emissions Warranty

CH-1211 Genève 20

that is applicable to Certified engines is found

Switzerland

in Supplement, SMBU6981, “Emissions Control

Telephone: +41 22 749 01 11

Warranty Information”. The engine is Certified if

Facsimile: +41 22 733 34 30

the engine has a special label that verifies the

E-mail: central@iso.ch

certification. A Caterpillar dealer can also inform you

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

if the engine is certified.

European classifications are established by the

Counseil International Des Machines a Combustion

i01775229

(CIMAC) (International Council on Combustion

Engines).

Additional Reference Material

CIMAC Central Secretariat

SMCS Code: 1000

Lyoner Strasse 18

60528 Frankfurt

The “Engine Fluids Data Book” can be obtained from

Germany

the following locations: local technological society,

Telephone: +49 69 6603 1567

local library, and local college. If necessary, consult

Facsimile: +49 69 6603 1566

EMA at the following address:

Engine Manufacturers Association

i02707212

Two North LaSalle Street, Suite 2200

Chicago, Illinois, USA 60602

Maintenance Records

E-mail: ema@enginemanufacturers.org

(312) 827-8700

SMCS Code: 1000

Facsimile: (312) 827-8737

Caterpillar Inc. recommends the retention of accurate

The “Society of Automotive Engineers (SAE)

maintenance records. Accurate maintenance records

Specifications” can be found in your SAE handbook.

can be used for the following purposes:

This publication can also be obtained from the

following locations: local technological society, local

• Determine operating costs.

library, and local college. If necessary, consult SAE

at the following address:

• Establish maintenance schedules for other engines

that are operated in the same environment.

SAE International

400 Commonwealth Drive

• Show compliance with the required maintenance

Warrendale, PA, USA 15096-0001

practices and maintenance intervals.

Telephone: (724) 776-4841

Maintenance records can be used for a variety of

The “American Petroleum Institute Publication No.

other business decisions that are related to engine

1509” can be obtained from the following locations:

maintenance.

local technological society, local library, and local

college. If necessary, consult API at the following

Maintenance records are a key element of a

address:

maintenance program that is well managed. Accurate

maintenance records can help your Caterpillar dealer

American Petroleum Institute

to fine tune the recommended maintenance intervals

1220 L St. N.W.

in order to meet the specific operating situation. This

Washington, DC, USA 20005

should result in a lower engine operating cost.

Telephone: (202) 682-8000

Records should be kept for the following items:

The International Organization for Standardization

(ISO) offers information and customer service

Fuel Consumption - A record of fuel consumption

regarding international standards and standardizing

is essential in order to determine when the load

activities. ISO can also supply information on the

sensitive components should be inspected or

following subjects that are not controlled by ISO:

repaired. Fuel consumption also determines overhaul

national standards, regional standards, regulations,

intervals.

certification, and related activities. Consult the

member of ISO in your country.

SEBU8327

Index Section

Index

Customer Service

Additional Reference Material

After Starting Engine

After Stopping Engine

Alternator - Inspect

Driven Equipment - Check

Alternator Belt - Inspect/Adjust/Replace (Poly

V-Belt)

Adjustment

Inspection

Replace

Electrical System

Grounding Practices

Emergency Stopping

Emissions Certification Film

Emissions Warranty Information

Battery - Replace

Engaging the Driven Equipment

Battery Electrolyte Level - Check

Engine - Clean

Battery or Battery Cable - Disconnect

Engine Air Cleaner Element (Dual Element) -

Before Starting Engine

13, 25

Clean/Replace

Burn Prevention

Cleaning the Primary Air Cleaner Elements

Batteries

Servicing the Air Cleaner Elements

Coolant

Engine Air Cleaner Element (Single Element) -

Oils

Inspect/Replace

Engine Air Cleaner Service Indicator - Inspect

Test the Service Indicator

Engine Air Precleaner - Check/Clean

Engine Description

Cold Weather Operation

Engine Cooling and Lubrication

Cold Weather Starting

Engine Service Life

Cooling System Coolant (DEAC) - Change

Engine Specifications

Cooling Systems with Heavy Deposits or

Engine Mounts - Inspect

Plugging

Engine Oil and Filter - Change

Drain

Drain the Engine Oil

Fill

Fill the Engine Crankcase

Flush

Replace the Spin-on Oil Filter

Cooling System Coolant (ELC) - Change

Engine Oil Level - Check

Drain

Engine Oil Sample - Obtain

Fill

Obtain the Sample and the Analysis

Flush

Engine Operation

Cooling System Coolant Level - Check

Engine Protective Devices - Check

Engines With a Coolant Recovery Tank

Visual Inspection

Engines Without a Coolant Recovery Tank

Engine Rating Conditions

Cooling System Coolant Sample (Level 1) -

Engine Rating Definitions

Obtain

Engine Ratings

Cooling System Coolant Sample (Level 2) -

Engine Shutoffs and Engine Alarms

Obtain

Alarms

Cooling System Supplemental Coolant Additive

Shutoffs

(SCA) - Test/Add

Testing the Shutoff and Alarm System

Add the SCA, If Necessary

Engine Starting

13, 25

S·O·S Coolant Analysis

Engine Stopping

14, 30

Test for SCA Concentration

Engine Valve Lash - Inspect/Adjust

Cooling System Water Temperature Regulator -

Engine Warm-up

Replace

Crankcase Breather (Canister) - Replace

Crushing Prevention and Cutting Prevention

Customer Assistance

Outside of the USA and of Canada

Features and Controls

USA and Canada

SEBU8327

Index Section

Fire Prevention and Explosion Prevention

Ether

Fire Extinguisher

Maintenance Interval Schedule

Lines, Tubes and Hoses

Maintenance Log

Foreword

Maintenance Records

California Proposition 65 Warning

Maintenance Section

Literature Information

Model View Illustrations

Maintenance

Engine Model Views

Maintenance Intervals

Model Views

Operation

Mounting and Dismounting

Overhaul

Safety

Fuel and the Effect from Cold Weather

Fuel Conservation Practices

Fuel Injection Nozzles - Test/Exchange

Operation Section

Removal and Installation of the Fuel Injection

Ordering Replacement Parts

Nozzles

Overhaul Considerations

Fuel Related Components in Cold Weather

Oil Consumption as an Overhaul Indicator

Fuel Filters

Overhaul Recommendation

Fuel Heaters

Fuel Tanks

Fuel Shutoff

Fuel System - Prime

Fuel System Primary Filter/Water Separator -

Plate Locations and Film Locations

Drain

Serial Number Plate (1)

Fuel System Secondary Filter - Replace

Product Identification Information

Element filter

Product Information Section

Spin-on filter

Product Lifting

Fuel Tank Water and Sediment - Drain

Product Storage

Drain the Water and the Sediment

Fuel Storage Tanks

Fuel Tank

Radiator - Clean

Radiator Restrictions

Reference Information Section

Gauges and Indicators

Reference Material

General Hazard Information

Coolants

Asbestos Information

Emissions Warranty

Containing Fluid Spillage

Fuels

Dispose of Waste Properly

Lubricants

Fluid Penetration

Miscellaneous

Pressurized Air and Water

Reference Materials

Reference Numbers

Record for Reference

Refill Capacities

Refill Capacities and Recommendations

Hoses and Clamps - Inspect/Replace

Coolant Recommendations

Replace the Hoses and the Clamps

Engine Oil

General Coolant Information

General Fuel Information

Lubricating Grease

Refill Capacity of the Cooling System

Important Safety Information

S·O·S Coolant Analysis

Lifting and Storage

Safety Messages

(1) Universal Warning

(2) Ether