Sebu7766 07 00 All PDF

SEBU7766-07
April 2010
Operation and
Maintenance
Manual
C7 On-highway Engine
NPH1-Up (Engine)
KAL1-Up (Engine)
LBM1-Up (Engine)
SAP1-Up (Engine)
WAX1-Up (Engine)
SAFETY.CAT.COM
i03684547
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 identied by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identied by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without rst
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specic rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specically 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 become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specications, 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 rec-
ommends using Caterpillar replacement parts or parts with equivalent
specications including, but not limited to, physical dimensions, type,
strength and material.
Failure to heed this warning can lead to premature failures, product
damage, personal injury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7766-07 3
Table of Contents
Table of Contents
Foreword .................................................................................................. 5
Safety Section
Safety Messages ..................................................................................... 8
General Hazard Information .................................................................. 10
Burn Prevention ..................................................................................... 16
Fire Prevention and Explosion Prevention ............................................. 17
Crushing Prevention and Cutting Prevention ......................................... 22
Mounting and Dismounting .................................................................... 23
Before Starting Engine ........................................................................... 23
Engine Starting ...................................................................................... 24
Engine Stopping .................................................................................... 25
Electrical System ................................................................................... 26
Engine Electronics ................................................................................. 29
Product Information Section

General Information ............................................................................... 31
Model Views .......................................................................................... 35
Product Identication Information ......................................................... 41
Operation Section
Lifting and Storage ................................................................................. 51
Gauges and Indicators ........................................................................... 53
Features and Controls ........................................................................... 56

4 SEBU7766-07
Table of Contents
Engine Diagnostics ................................................................................ 59
Engine Starting ...................................................................................... 72
Engine Operation ................................................................................... 81
Engine Stopping .................................................................................... 98
Cold Weather Operation ...................................................................... 100
Maintenance Section
Rell Capacities ................................................................................... 104
Maintenance Interval Schedule (Engines with a Shallow Oil Sump) ... 120
Maintenance Interval Schedule (Engines with a Deep Oil Sump) ....... 123
Warranty Section
Warranty Information ........................................................................... 201
Reference Information Section

Customer Service ................................................................................ 212
Reference Materials ............................................................................. 216
Index Section
Index .................................................................................................... 223
SEBU7766-07 5
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions, lubrication and
maintenance information. This manual should be stored in or near the
engine area in a literature holder or literature storage area. Read, study
and keep it with the literature and engine information.
English is the primary language for all Caterpillar publications. The English
used facilitates translation and consistency in electronic media delivery.
Some photographs or illustrations in this manual show details or

attachments that may be different from your engine. Guards and
covers may have been removed for illustrative purposes. Continuing
improvement and advancement of product design may have caused
changes to your engine which are not included in this manual. Whenever
a question arises regarding your engine, or this manual, please consult
with your Caterpillar dealer for the latest available information.
Safety
This safety section lists basic safety precautions. In addition, this section
identies hazardous, warning situations. Read and understand the basic
precautions listed in the safety section before operating or performing
lubrication, maintenance and repair on this product.
Operation
Operating techniques outlined in this manual are basic. They assist with
developing the skills and techniques required to operate the engine more
efciently and economically. Skill and techniques develop as the operator
gains knowledge of the engine and its capabilities.
The operation section is a reference for operators. Photographs and

illustrations guide the operator through procedures of inspecting, starting,
operating and stopping the engine. This section also includes a discussion
of electronic diagnostic information.
6 SEBU7766-07
Foreword
Maintenance
The maintenance section is a guide to engine care. The illustrated,
step-by-step instructions are grouped by fuel consumption, service hours
and/or calendar time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that follow.
Use fuel consumption or service hours to determine intervals. Calendar

intervals shown (daily, annually, etc.) may be used instead of service
meter intervals if they provide more convenient schedules and
approximate the indicated service meter reading.
Recommended service should be performed at the appropriate intervals

as indicated in the Maintenance Interval Schedule. The actual operating
environment of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty, wet or freezing cold
operating conditions, more frequent lubrication and maintenance than is
specied in the Maintenance Interval Schedule may be necessary.
The maintenance schedule items are organized for a preventive

maintenance management program. If the preventive maintenance
program is followed, a periodic tune-up is not required. The
implementation of a preventive maintenance management program
should minimize operating costs through cost avoidances resulting from
reductions in unscheduled downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the original requirement.
Each level and/or individual items in each level should be shifted ahead
or back depending upon your specic maintenance practices, operation
and application. We recommend that the maintenance schedules be
reproduced and displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be maintained as part
of the engine's permanent record.
See the section in the Operation and Maintenance Manual, “Maintenance

Records” for information regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized Caterpillar dealer can
assist you in adjusting your maintenance schedule to meet the needs of
your operating environment.
SEBU7766-07 7
Foreword
Overhaul
Major engine overhaul details are not covered in the Operation and
Maintenance Manual except for the interval and the maintenance items
in that interval. Major repairs are best left to trained personnel or an
authorized Caterpillar dealer. Your Caterpillar dealer offers a variety of
options regarding overhaul programs. If you experience a major engine
failure, there are also numerous after failure overhaul options available
from your Caterpillar dealer. Consult with your dealer for information
regarding these options.
California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State
of California to cause cancer, birth defects, and other reproductive harm.
Battery posts, terminals and related accessories contain lead and lead
compounds. Wash hands after handling.
8 SEBU7766-07
Safety Section
Safety Messages
Safety Section
i03203384
Safety Messages
SMCS Code: 1000; 7405
There may be several specic safety messages on your engine. The

exact location and a description of the safety messages are reviewed in
this section. Please become familiar with all safety messages.
Ensure that all of the safety messages are legible. Clean the safety
messages or replace the safety messages if the words cannot be read or
if the illustrations are not visible. Use a cloth, water, and soap to clean
the safety messages. Do not use solvents, gasoline, or other harsh
chemicals. Solvents, gasoline, or harsh chemicals could loosen the
adhesive that secures the safety messages. The safety messages that
are loosened could drop off of the engine.
Replace any safety message that is damaged or missing. If a safety

message is attached to a part of the engine that is replaced, install a
new safety message on the replacement part. Your Caterpillar dealer
can provide new safety messages.
SEBU7766-07 9
Safety Section
Safety Messages
g00986753
Illustration 1
(1) Universal warning label
(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
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement manu-
als. Proper care is your responsibility.
10 SEBU7766-07
Safety Section
General Hazard Information
g00934493
Illustration 2
The Universal warning label is typically located on each side of the valve
cover base.
i02966200

SMCS Code: 1000; 7405
Attach a “Do Not Operate” warning tag or a similar warning tag to the
start switch or to the controls before the engine is serviced or before the
engine is repaired. These warning tags (Special Instruction, SEHS7332)
are available from your Caterpillar dealer. Attach the warning tags to
the engine and to each operator control station. When it is appropriate,
disconnect the starting controls.
SEBU7766-07 11
Safety Section
g00104545
Illustration 3
Do not allow unauthorized personnel on the engine or around the

engine when the engine is serviced.
• Tampering with the engine installation or tampering with the OEM

supplied wiring can be dangerous. Personal injury, death and/or engine
damage could result.
• Vent the engine exhaust to the outside when the engine is operated
in an enclosed area.
• If the engine is not running, do not release the secondary brake or

the parking brake systems unless the vehicle is blocked or unless the
vehicle is restrained.
• Wear a hard hat, protective glasses, and other protective equipment,

as required.
• When work is performed around an engine that is operating, wear

protective devices for ears in order to help prevent damage to hearing.
• 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 uids into glass containers. Glass containers

can break.
12 SEBU7766-07
Safety Section
• Use all cleaning solutions with care.

• Report all necessary repairs.
Unless other instructions are provided, perform the maintenance under
the following conditions:
• The engine is stopped. Ensure that the engine can not be started.
• The protective locks or the controls are in the applied position.
• Engage the secondary brakes or parking brakes.
• Block the vehicle or restrain the vehicle before maintenance or repairs
are performed.
• Disconnect the batteries when maintenance is performed or when the

electrical system is serviced. Disconnect the battery ground leads. Tape
the leads in order to help prevent sparks.
• Disconnect the connector for the unit injector that is located on the
valve cover base. This will help prevent personal injury from the high
voltage to the unit injectors. Do not come in contact with the unit injector
terminals while the engine is operating.
• Do not attempt any repairs or any adjustments to the engine while the
engine is operating.
• Do not attempt any repairs that are not understood. Use the proper
tools. Replace any equipment that is damaged or repair the equipment.
• For initial start-up of a new engine or for starting an engine that has
been serviced, make provisions to stop the engine if an overspeed
occurs. This may be accomplished by shutting off the fuel supply and/or
the air supply to the engine.
• Start the engine from the operator's station (cab). Never short across
the starting motor terminals or the batteries. This could bypass the
engine neutral start system and/or the electrical system could be
damaged.
Cautiously remove the following parts:
Note: To help prevent spraying or splashing of pressurized uids, hold a

rag over the part that is being removed.
SEBU7766-07 13
Safety Section
• Filler caps
• Grease ttings
• Pressure taps
• Breathers
• Drain plugs
Use caution when cover plates are removed. Gradually loosen but do not
remove the last two bolts or nuts that are located at opposite ends of the
cover plate or the device. Before removing the last two bolts or nuts, pry
the cover loose in order to relieve any spring pressure or other pressure.
Pressure Air and Water

Pressurized air and/or water can cause debris and/or hot water to be
blown out. This could result in personal injury. When pressure air is
used for cleaning, wear a protective face shield, protective clothing, and
protective shoes. The maximum air pressure for cleaning purposes must
be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded and
used with effective chip guarding (if applicable) and personal protective
equipment. The maximum water pressure for cleaning purposes must
be below 275 kPa (40 psi). Always wear eye protection for cleaning the
cooling system.
Fluid Penetration
Always use a board or cardboard when the engine components are
checked for leaks. Leaking uid that is under pressure can cause serious
injury or possible death. This includes leaks that are the size of a pin
hole. If uid is injected into the skin, seek treatment immediately. Seek
treatment from a doctor that is familiar with this type of injury.
14 SEBU7766-07
Safety Section
Fluid Spillage
NOTICE
Care must be taken to ensure that uids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the uid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing uids.
Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” or refer to Special Pub-
lication, PECJ0003, “Caterpillar Shop Supplies and
Tools Catalog” for tools and supplies suitable to col-
lect and contain uids on Caterpillar products.
Dispose of all uids according to local regulations and

mandates.
Asbestos Information
g00702022
Illustration 4
Caterpillar equipment and replacement parts that are shipped from

Caterpillar are asbestos free. Caterpillar recommends the use of only
genuine Caterpillar replacement parts. Use the following guidelines when
you handle any replacement parts that contain asbestos or when you
handle asbestos debris.
SEBU7766-07 15
Safety Section
Use caution. Avoid inhaling dust that might be generated when you
handle components that contain asbestos bers. Inhaling this dust can
be hazardous to your health. The components that may contain asbestos
bers are brake pads, brake bands, lining material, clutch plates, and
some gaskets. The asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal handling is not hazardous
unless airborne dust that contains asbestos is generated.
If dust that may contain asbestos is present, there are several guidelines
that should be followed:
• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos materials.
• A vacuum cleaner that is equipped with a high efciency particulate
air lter (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.
• Comply with applicable rules and regulations for the work place. In
the United States, use Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements can be found in
“29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of asbestos.

• Stay away from areas that might have asbestos particles in the air.
Lines, Tubes, and Hoses

Do not bend or strike high pressure lines. Do not install lines, tubes, or
hoses that are damaged.
Repair any fuel lines, oil lines, tubes, or hoses that are loose or damaged.
Leaks can cause res.
16 SEBU7766-07
Safety Section
Burn Prevention
Inspect all lines, tubes and hoses carefully. Do not use bare hands to
check for leaks. Always use a board or cardboard for checking engine
components for leaks. Tighten all connections to the recommended
torque.
Check for the following conditions:
• End ttings that are damaged or leaking

• Outer covering that is chafed or cut
• Wire that is exposed in reinforced hose
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
Ensure that all of the clamps, the guards, and the heat shields are
installed correctly. This will help to prevent these effects: vibration, rubbing
against other parts, and excessive heat during operation.
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, ttings or related
items are disconnected.
Coolant
When the engine is at operating temperature, the engine coolant is hot.
The coolant is also under pressure. The radiator and all lines to the
heaters or to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause severe burns. Allow
cooling system components to cool before the cooling system is drained.
SEBU7766-07 17
Safety Section
Fire Prevention and Explosion Prevention
Check the coolant level after the engine has stopped and the engine
has been allowed to cool.
Ensure that the ller cap is cool before removing the ller cap. The ller
cap must be cool enough to touch with a bare hand. Remove the ller cap
slowly in order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can cause personal

injury. Do not allow alkali to contact the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause personal injury. Do
not allow hot oil to contact the skin. Also, do not allow hot components
to contact the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause personal injury. Do not
allow electrolyte to contact the skin or the eyes. Always wear protective
glasses for servicing batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
i01806909

SMCS Code: 1000; 7405
g00704000
Illustration 5
18 SEBU7766-07
Safety Section
All fuels, most lubricants, and some coolant mixtures are ammable.
Flammable uids that are leaking or spilled onto hot surfaces or onto
electrical components can cause a re. Fire may cause personal injury
and property damage.
A ash re may result if the covers for the engine crankcase are removed
within fteen minutes after an emergency shutdown.
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 ammable materials such as fuel, oil, and debris from the
engine. Do not allow any ammable materials to accumulate on the
engine.
Store fuels and lubricants in properly marked containers away from

unauthorized persons. Store oily rags and any ammable materials in
protective containers. Do not smoke in areas that are used for storing
ammable materials.
Do not expose the engine to any ame.
Exhaust shields (if equipped) protect hot exhaust components from oil
or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields
must be installed correctly.
Do not weld on lines or tanks that contain ammable uids. Do not ame
cut lines or tanks that contain ammable uid. Clean any such lines or
tanks thoroughly with a nonammable solvent prior to welding or ame
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.
SEBU7766-07 19
Safety Section
Arcing or sparking could cause a re. Secure connections, recommended

wiring, and properly maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for deterioration. The hoses must
be properly routed. The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the recommended torque.
Leaks can cause res.
Oil lters and fuel lters must be properly installed. The lter housings
must be tightened to the proper torque.
g00704059
Illustration 6
Use caution when you are refueling an engine. Do not smoke while you
are refueling an engine. Do not refuel an engine near open ames or
sparks. Always stop the engine before refueling.
20 SEBU7766-07
Safety Section
g00704135
Illustration 7
Gases from a battery can explode. Keep any open ames or sparks away
from the top of a battery. Do not smoke in battery charging areas.
Never check the battery charge by placing a metal object across the
terminal posts. Use a voltmeter or a hydrometer.
Improper jumper cable connections can cause an explosion that can

result in injury. Refer to the Operation Section of this manual for specic
instructions.
Do not charge a frozen battery. This may cause an explosion.
The batteries must be kept clean. The covers (if equipped) must be kept
on the cells. Use the recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a re extinguisher is available. Be familiar with the
operation of the re extinguisher. Inspect the re extinguisher and
service the re extinguisher regularly. Obey the recommendations on
the instruction plate.
SEBU7766-07 21
Safety Section
Ether (If Equipped)

Ether is ammable and poisonous.
Use ether in well ventilated areas. Do not smoke while you are replacing
an ether cylinder or while you are using an ether spray.
Do not store ether cylinders in living areas or in the engine compartment.

Do not store ether cylinders in direct sunlight or in temperatures above
49 °C (120 °F). Keep ether cylinders away from open ames or sparks.
Dispose of used ether cylinders properly. Do not puncture an ether

cylinder. Keep ether cylinders away from unauthorized personnel.
DO NOT USE ETHER (starting uids) unless

specically instructed to do so. If the engine is
equipped with an Air Inlet Heater (electrically or
fuel ignited manifold heater), DO NOT use ether
(starting uids) at any time. The use could result
in engine damage and/or personal injury.
Do not spray ether into an engine if the engine is equipped with a thermal
starting aid for cold weather starting.
Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high pressure lines. Do not
install any lines that are bent or damaged.
Repair any lines that are loose or damaged. Leaks can cause res.
Consult your Caterpillar dealer for repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not use your bare hand to
check for leaks. Use a board or cardboard to check for leaks. Tighten all
connections to the recommended torque.
Replace the parts if any of the following conditions are present:
• End ttings are damaged or leaking.

• Outer coverings are chafed or cut.
22 SEBU7766-07
Safety Section
Crushing Prevention and Cutting Prevention
• Wires are exposed.

• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End ttings are displaced.
Make sure that all clamps, guards, and heat shields are installed correctly.
During engine operation, this will help to prevent vibration, rubbing against
other parts, and excessive heat.
i01359666
Crushing Prevention and Cutting

Prevention
SMCS Code: 1000; 7405
Support the component properly when work beneath the component is

performed.
Unless other maintenance instructions are provided, never attempt

adjustments while the engine is running.
Stay clear of all rotating parts and of all moving parts. Leave the guards in
place until maintenance is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan blades will throw
objects or cut objects.
When objects are struck, wear protective glasses in order to avoid injury
to the eyes.
Chips or other debris may y off objects when objects are struck. Before
objects are struck, ensure that no one will be injured by ying debris.
SEBU7766-07 23
Safety Section
Mounting and Dismounting
i01372247
Mounting and Dismounting

SMCS Code: 1000; 7405
Inspect the steps, the handholds, and the work area before mounting the
engine. Keep these items clean and keep these items in good repair.
Mount the engine and dismount the engine only at locations that have
steps and/or handholds. Do not climb on the engine, and do not jump
off the engine.
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 hand or use one foot and two hands. Do not use any controls as
handholds.
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 carry tools or supplies when you mount the engine or when you
dismount the engine. Use a hand line to raise and lower tools or supplies.
i03560601
Before Starting Engine

SMCS Code: 1000
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
24 SEBU7766-07
Safety Section
Engine Starting
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.
Inspect the engine for potential hazards.
Do not start the engine or move any of the controls if there is a “DO NOT
OPERATE” warning tag or similar warning tag attached to the start switch
or to the controls.
Before starting the engine, ensure that no one is on, underneath, or close
to the engine. Ensure that the area is free of personnel.
If equipped, ensure that the lighting system for the engine is suitable for
the conditions. Ensure that all lights work properly, if equipped.
All protective guards and all protective covers must be installed if the
engine must be started in order to perform service procedures. To help
prevent an accident that is caused by parts in rotation, work around the
parts carefully.
Do not bypass the automatic shutoff circuits. Do not disable the automatic
shutoff circuits. The circuits are provided in order to help prevent personal
injury. The circuits are also provided in order to help prevent engine
damage.
See the Service Manual for repairs and for adjustments.
i01185283
Engine Starting
SMCS Code: 1000
Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.
SEBU7766-07 25
Safety Section
Engine Stopping
If a warning tag is attached to the engine start switch or to the controls,

DO NOT start the engine or move the controls. Consult with the person
that attached the warning tag before the engine is started.
All protective guards and all protective covers must be installed if the
engine must be started in order to perform service procedures. To help
prevent an accident that is caused by parts in rotation, work around the
parts carefully.
Start the engine from the operator's compartment or from the engine
start switch.
Always start the engine according to the procedure that is described in

the Operation and Maintenance Manual, “Engine Starting” topic in the
Operation Section. Knowing the correct procedure will help to prevent
major damage to the engine components. Knowing the procedure will
also help to prevent personal injury.
To ensure that the jacket water heater (if equipped) and/or the lube oil
heater (if equipped) is working properly, check the water temperature
gauge and the oil temperature gauge during the heater operation.
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.
i01462046
Engine Stopping
SMCS Code: 1000
Stop the engine according to the procedure in the Operation and

Maintenance Manual, “Engine Stopping (Operation Section)” in order
to avoid overheating of the engine and accelerated wear of the engine
components.
Use the Emergency Stop Button (if equipped) ONLY in an emergency

situation. Do not use the Emergency Stop Button for normal engine
stopping. After an emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been corrected.
26 SEBU7766-07
Safety Section
Electrical System
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.
To stop an electronically controlled engine, cut the power to the engine.
i02434598
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 this Operation and
Maintenance Manual, “Engine Starting” for specic starting instructions.
SEBU7766-07 27
Safety Section
Electrical System
Grounding Practices
g01075589
Illustration 8
Typical example
(1) Recommended connections
(2) Alternate connections
28 SEBU7766-07
Safety Section
Electrical System
g01075601
Illustration 9
Typical example
(1) Recommended connection
(2) Alternate connection
Proper grounding for the engine electrical system is necessary for

optimum engine performance and reliability. Improper grounding will
result in uncontrolled electrical circuit paths and in unreliable electrical
circuit paths.
Uncontrolled electrical circuit paths can result in damage to main bearings,

to crankshaft bearing journal surfaces, and to aluminum components.
Engines that are installed without engine-to-frame ground straps can be

damaged by electrical discharge.
SEBU7766-07 29
Safety Section
Engine Electronics
To ensure that the engine and the engine electrical systems function
properly, an engine-to-frame ground strap with a direct path to the battery
must be used. This path may be provided by way of a starting motor
ground, a starting motor ground to the frame, or a direct engine ground
to the frame.
All grounds should be tight and free of corrosion. The engine alternator
must be grounded to the negative “-” battery terminal with a wire that is
adequate to handle the full charging current of the alternator.
i02451352
Engine Electronics
SMCS Code: 1000; 1400; 1900
Electrical Shock Hazard. The unit injector system

uses 90 - 120 volts. The ECM sends this signal to
the unit injectors. Do not come in contact with the
unit injector harness connector while the engine is
operating. Failure to follow this instruction could
resulting in personal injury or death.
This engine has a comprehensive, programmable Engine Monitoring

System. The Engine Control Module (ECM) has the ability to monitor
the engine operating conditions. If any of the engine parameters extend
outside an allowable range, the ECM will initiate an immediate action.
The following actions are available for engine monitoring control:

WARNING, DERATE, and SHUTDOWN. These engine monitoring modes
have the ability to limit engine speed and/or the engine power.
Many of the parameters that are monitored by the ECM can be

programmed for the engine monitoring functions. The following
parameters can be monitored as a part of the Engine Monitoring System:
• Operating Altitude
• Engine Coolant Level
• Engine Coolant Temperature
30 SEBU7766-07
Safety Section
Engine Electronics
• Engine Oil Pressure

• Engine Speed
• Intake Manifold Air Temperature
• System Voltage
The Engine Monitoring package can vary for different engine models and
different engine applications. However, the monitoring system and the
engine monitoring control will be similar for all engines.
Note: Many of the engine control systems and display modules that
are available for Caterpillar Engines will work in unison with the Engine
Monitoring System. Together, the two controls will provide the engine
monitoring function for the specic engine application. Refer to the
Troubleshooting Guide in the Service Manual for more information.
SEBU7766-07 31
General Information
General Information
i02668476
Welding on Engines with Electronic

Controls
SMCS Code: 1000
NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
Proper welding procedures are necessary in order to avoid damage to

the engine's ECM, sensors, and associated components. When possible,
remove the component from the unit and then weld the component. If
removal of the component is not possible, the following procedure must
be followed when you weld on a unit that is equipped with a Caterpillar
Electronic Engine. The following procedure is considered to be the safest
procedure to weld on a component. This procedure should provide a
minimum risk of damage to electronic components.
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other com-
ponents.
Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.
1. Stop the engine. Turn the switched power to the OFF position.
32 SEBU7766-07
General Information
2. Disconnect the negative battery cable from the battery. If a battery

disconnect switch is provided, open the switch.
3. Disconnect the J1/P1 and J2/P2 connectors from the ECM. Move the
harness to a position that will not allow the harness to accidentally
move back and make contact with any of the ECM pins.
SEBU7766-07 33
General Information
g01075639
Illustration 10
Use the example above. The current ow from the welder to
the ground clamp of the welder will not cause damage to any
associated components.
(1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Minimum distance between the component that is being welded
and any electrical/electronic component
(9) The component that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
34 SEBU7766-07
General Information
4. Connect the welding ground cable directly to the part that will be
welded. Place the ground cable as close as possible to the weld in
order to reduce the possibility of welding current damage to bearings,
hydraulic components, electrical components, and ground straps.
Note: If electrical/electronic components are used as a ground for the

welder, or electrical/electronic components are located between the
welder ground and the weld, current ow from the welder could severely
damage the component.
5. Protect the wiring harness from welding debris and spatter.
6. Use standard welding practices to weld the materials.

SEBU7766-07 35
Model Views
Model Views
i02112288
Model View Illustrations

SMCS Code: 1000
g01075652
Illustration 11
Left side view
(1) Belt tensioner
(2) Lifting eyes
(3) Engine oil level gauge
(4) Air inlet heater relay
(5) Engine control module (ECM)
(6) Engine oil ller
(7) Fuel priming pump
(8) Fuel lter
(9) Unit injector hydraulic pump
(10) Air compressor
(11) Crankcase breather
36 SEBU7766-07
Model Views
g01075656
Illustration 12
Right side view
(12) Exhaust manifold
(13) Turbocharger
(14) Engine oil lter
(15) Alternator
i02524988
Engine Description
SMCS Code: 1000
The Caterpillar C7 engines are designed primarily for on-highway

trucks with medium-duty applications. The engines have the following
characteristics: air-to-air aftercooled, direct fuel injection, four stroke
cycle, and in-line 6 cylinder.
Engine Specications
Note: The front end of the engine is opposite the ywheel end of the
engine. The left and the right sides of the engine are determined from the
ywheel end. The number 1 cylinder is the front cylinder.
SEBU7766-07 37
Model Views
g01075672
Illustration 13
Cylinder and valve location
(A) Exhaust valve
(B) Inlet valve
Table 1
C7 Engine Specications
Arrangement and
In-Line 6 cylinder
Cylinders
Bore 110 mm (4.3 inch)
Stroke 127 mm (5.0 inch)
Aspiration ATAAC(1)
Displacement 7.2 L (440 in3)
Firing Order 1-5-3-6-2-4
Rotation (ywheel end) Counterclockwise
(1) Air-to-air aftercooled
Electronic Engine Features

The Caterpillar C7 engines are designed for electronic controls. The
integral on board computer controls the operation of the engine. Current
operating conditions are monitored. The Engine Control Module (ECM)
controls the response of the engine to these conditions and to the
demands of the operator. These conditions and operator demands
determine the precise control of fuel injection by the ECM. The electronic
engine control system provides the following features:
38 SEBU7766-07
Model Views
• Engine speed governor

• Automatic air/fuel ratio control
• Torque rise shaping
• Injection timing control
• System diagnostics
The following programmable features are included in the electronic
control:
• Cruise control
• Governing of PTO
• Vehicle speed limiter
• Idle shutdown
• Compression brake operation control
For more information on electronic engine features, refer to the Operation
and Maintenance Manual, “Engine Features and Controls” topic
(Operation Section).
Additional Features
The following additional features provide increased engine fuel economy
and serviceability:
• Cold starting capability

• Tampering detection
• Diagnostics
• American Trucking Association (ATA) data link (“SAE J1587”)
Hydraulic Electronic Unit Injectors
Hydraulically Actuated Electronic Unit Injectors (HEUI) perform the
following functions: pumping of fuel, fuel metering, and fuel timing.
SEBU7766-07 39
Model Views
The unit injectors are controlled by the ECM which uses the camshaft
position and the engine speed signals from the engine speed/timing
sensors and the inlet air pressure sensors. The engine's rated rpm is
identied on the Information Plate.
Engine Diagnostics
The engine has built-in diagnostics in order to ensure that all of the
components are functioning properly. In the event of a deviation from
the programmed limits, the operator will be alerted to the condition by a
“DIAGNOSTIC” lamp that is mounted on the dashboard. Under certain
conditions, the engine horsepower and the vehicle speed may be limited.
A Caterpillar electronic service tool or the vehicle's cruise control switches
(if equipped) may be used to display the diagnostic code.
There are three types of diagnostic codes: active, logged, and event.
Most of the diagnostic codes are logged and stored in the ECM. For
additional information, refer to the Operation and Maintenance Manual,
“Engine Diagnostics” topic (Operation Section).
The ECM provides an electronic governor that controls the injector

output in order to maintain the desired engine rpm. The functionality of
electronic governor is similar to the Caterpillar mechanical governor, but
the electronic governor includes additional features.
Engine Cooling and Lubrication

The cooling system consists of the following components:
• Centrifugal pump that is driven by belts

• Water temperature regulator which regulates the engine coolant
temperature
• Oil cooler and radiator which incorporates a shunt system

The engine lubricating oil that is supplied is cooled. The engine lubricating
oil is also ltered. Bypass valves provide unrestricted ow of lubrication oil
to the engine components during the following conditions:
• High oil viscosity

• Plugged oil cooler or plugged oil lter elements (paper cartridge)
40 SEBU7766-07
Model Views
Engine Service Life

Engine efciency and maximum utilization of engine performance
depend on the adherence to proper operation and maintenance
recommendations. In addition, use recommended fuels, coolants and
lubricants. Use the Operation and Maintenance Manual as a guide for
required engine maintenance.
Expected engine life is generally predicted by the average power that

is demanded. The average power that is demanded is based on fuel
consumption of the engine over a period of time. Reduced hours of
operation at full throttle and/or operating at reduced throttle settings
result in a lower average power demand. Reduced hours of operation
will increase the length of operating time before an engine overhaul is
required. For more information, refer to the Operation and Maintenance
Manual, “Overhaul Considerations” topic (Maintenance Section).
Aftermarket Products and CaterpillarEngines

NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel,
a two micron absolute high efciency fuel lter is re-
quired for all Caterpillar Hydraulic Electronic Unit In-
jectors. Caterpillar High Efciency Fuel Filters meet
these requirements. Consult your Caterpillar dealer
for the proper part numbers.
When auxiliary devices, accessories, or consumables (lters, additives,

catalysts, etc) which are made by other manufacturers are used on
Caterpillar products, the Caterpillar warranty is not affected simply
because of such use.
However, failures that result from the installation or use of other

manufacturers' devices, accessories, or consumables are NOT
Caterpillar defects. Therefore, the defects are NOT covered under
the Caterpillar warranty.
SEBU7766-07 41
Product Identication Information

i01028428
Engine Identication
SMCS Code: 1000
Caterpillar engines are identied with serial numbers, with performance

specication numbers, and with arrangement numbers. In some of the
cases, modication numbers are used. These numbers are shown on
the Serial Number Plate and the Information Plate that are mounted on
the engine.
Caterpillar dealers need these numbers in order to determine the

components that were included with the engine. This permits accurate
identication of replacement part numbers.
i01461841
Serial Number Plate

SMCS Code: 1000
g00764267
Illustration 14
The Serial Number Plate is located on the right side of the cylinder block
near the rear of the engine.
The following information is stamped on the Serial Number Plate: engine

serial number, engine model, and arrangement number.
42 SEBU7766-07
i02117355
Information Plate
SMCS Code: 1000
g00764335
Illustration 15
Typical example
The Information Plate is on the front cover. The following information is

on the Information Plate: engine serial number, engine model, engine
arrangement number, maximum altitude of the engine that is possible
to achieve the rated power, horsepower, high idle, full load rpm, fuel
settings, and other information.
i00836358
Reference Numbers
SMCS Code: 1000
Information for the following items may be needed to order parts. Locate
the information for your engine. Record the information on the appropriate
space. Make a copy of this list for a record. Retain the information for
future reference.
Record for Reference

Chassis Serial No. ___________________________________________________________________
Engine Model _________________________________________________________________________

SEBU7766-07 43
Engine Serial No. ____________________________________________________________________
Engine Arrangement No. ___________________________________________________________
Modication No. ______________________________________________________________________
Engine Low Idle rpm ________________________________________________________________
Engine Full Load rpm _______________________________________________________________
Performance Specication No. ____________________________________________________
Engine hp ______________________________________________________________________________
Primary Fuel Filter No. ______________________________________________________________
Water Separator Element No. _____________________________________________________
Secondary Fuel Filter Element No. ______________________________________________
Lubrication Oil Filter Element No. ________________________________________________
Auxiliary Oil Filter Element No. ___________________________________________________
Supplemental Coolant Additive Maintenance Element No. (Optional)

____________________________________________________________________________________________
Total Lubrication System Capacity _______________________________________________
Total Cooling System Capacity ___________________________________________________
Air Cleaner Element No. ____________________________________________________________
Fan Drive Belt No. ___________________________________________________________________
Alternator Belt No. ___________________________________________________________________

44 SEBU7766-07
i00844066
Emissions Certication Film

SMCS Code: 1000; 7405
g00284658
Illustration 16
EPA Emissions Certication Film
g00415538
Illustration 17
European Emissions Certication Film
The EPA Emissions Certication Film (if equipped) and/or the European
Emissions Certication Film (if equipped) is located on the side of the
engine.
i01937608
Customer Specied Parameters

SMCS Code: 1000
To record programmed specications, use the following blanks.

SEBU7766-07 45
Customer Passwords
• “First Password” ___________________________________________________________________

• “Second Password” _______________________________________________________________
Selected Engine Rating ___________________________________________________________
• “Rating Number” __________________________________________________________________

ECM Identication Parameters
• “Vehicle ID” _________________________________________________________________________

Truck Manufacturer Parameters
• “Truck Manufacturer” _____________________________________________________________

Vehicle Speed Parameters
• “Vehicle Speed Calibration” __________ pulses per km or pulses per mile

• “Vehicle Speed Cal (J1939-Trans)” ___________ km per hr or miles per hr
• “Vehicle Speed Cal (J1939-ABS)” ____________ km per hr or miles per hr
• “Vehicle Speed Limit” ____________________________ km per hr or miles per hr
• “VSL Protection” ___________________________________________________________________
• “Tachometer Calibration” _____________________________ pulses per revolution
• “Soft Vehicle Speed Limit” _______________________________________________________
• “Low Speed Range Axle Ratio” ________________________________________________
• “High Speed Range Axle Ratio” _______________________________________________
Cruise Control Parameters
• “Low Cruise Control Speed Set Limit” ___________________________________ km

per hr or miles per hr
• “High Cruise Control Speed Set Limit” ___________________________________ km

46 SEBU7766-07
• “Engine Brake MODE” ___________________________________________________________

• “Cruise/Idle/PTO Switch Conguration” ______________________________________
• “Soft Cruise Control” _____________________________________________________________
• “Auto Retarder in Cruise” ________________________________________________________
Idle Parameters
• “Idle Vehicle Speed Limit” _______________________ km per hr or miles per hr

• “Idle RPM Limit” ___________________________________________________________________
• “Idle/PTO RPM Ramp Rate” _________________________________________ rpm/sec
• “Idle/PTO Bump RPM” ___________________________________________________________
• “Fast Idle RPM #1” ________________________________________________________________
• “Fast Idle RPM #2” ________________________________________________________________
• “Warm Up Mode Idle Speed” ___________________________________________________
Dedicated PTO Parameters
• “PTO Conguration” ______________________________________________________________

• “PTO Top Engine Limit” __________________________________________________________
• “PTO Engine RPM Set Speed” _________________________________________________
• “PTO to Set Speed” ______________________________________________________________
• “PTO Cab Throttle RPM Limit” _________________________________________________
• “PTO Kickout Vehicle Speed Limit” ___________________________________________
• “Torque Limit” _______________________________________________________ N·m or lb ft
• “PTO Shutdown Time” ___________________________________________________________
• “PTO Activation of Cooling Fan (If Equipped)” ______________________________
• “PTO Engine RPM Set Speed A” ______________________________________________
SEBU7766-07 47
• “PTO Engine RPM Set Speed B” ______________________________________________

• “Maximum PTO Enable Speed” ________________________________________________
• “Maximum PTO Vehicle Speed” _______________________________________________
Exhaust Brake Options
• “Exhaust Brake/Warm Up Enable” ____________________________________________

“Engine/Gear Parameters”
• “Lower Gears Engine RPM Limit” _____________________________________________

• “Lower Gears Turn Off Speed” _________________ km per hr or miles per hr
• “Intermediate Gears Engine RPM Limit” _____________________________________
• “Intermediate Gears Turn Off Speed” __________ km per hr or miles per hr
• “Gear Down Protection RPM Limit” ___________________________________________
• “Gear Down Protection Turn On Speed” ________________________________ km
• “Top Engine Limit” _________________________________________________________________

• “Low Idle Engine RPM” __________________________________________________________
• “AT/MT/HT Part Throttle Shift Speed” ________________________________________
• “Transmission Style” ______________________________________________________________
• “Starting Aid Output Mode” _____________________________________________________
• “Governor Type” ___________________________________________________________________
Smart Idle Parameters
• “Battery Monitor and Engine Control Voltage” ______________________________

• “Battery Monitor and Low Idle Engine Speed” ______________________________
Timer Parameters
• “Idle Shutdown Time” ____________________________________________________________

48 SEBU7766-07
• “ Allow Idle Shutdown Override” _______________________________________________

• “A/C Switch Fan On - Time” ____________________________________________________
• “Fan with Engine Brake On” ____________________________________________________
Engine Monitoring Parameters
• “Engine Monitoring Mode” _______________________________________________________

• “Engine Monitoring Lamps” _____________________________________________________
• “Warning/Derate/Shutdown” ____________________________________________________
• “Coolant Level Sensor” __________________________________________________________
• “Engine Oil Pressure Sensor” __________________________________________________
• “Engine Oil Level Switch” (Not available for every OEM) _________________
Maintenance Parameters
• “Maintenance Indicator Mode” _________________________________________________

• “PM1 Interval” ______________________________________________________________________
• “Engine Oil Capacity” _____________________________________________________________
Trip Parameters
• “Dash-Customer Parameters” __________________________________________________

• “Dash-PM1 Reset” ________________________________________________________________
• “Theft Deterrent System Control” ______________________________________________
• “Theft Deterrent Password” _____________________________________________________
• “Quick Stop Rate” _________________________________________________________________
Input Selections
• “Fan override Switch” ____________________________________________________________

• “Transmission Neutral Switch” _________________________________________________
SEBU7766-07 49
• “Exhaust Brake Switch” __________________________________________________________

• “Ignore Brake/Clutch Switch” ___________________________________________________
• “Two Speed Axle Switch” ________________________________________________________
• “Vehicle Speed Input” ____________________________________________________________
• “PTO Engine Shutdown Switch” _______________________________________________
• “Torque Limit Switch” _____________________________________________________________
• “PTO Engine RPM Set Speed Input A” _______________________________________
• “PTO Engine RPM Set Speed Input B” _______________________________________
• “Diagnostic Enable Switch” _____________________________________________________
• “Cruise Control ON/Off Switch” ________________________________________________
• “Cruise Control Set/Resume/Accel/Decel Switch” _________________________
• “Cruise Control Pause Switch” _________________________________________________
• “Clutch Pedal Position Switch” _________________________________________________
• “Service Brake Pedal Position Switch #1” ___________________________________
• “Accelerator Pedal Position” ____________________________________________________
• “A/C Fan Request ” (Not Available for every OEM) ________________________
Output Selections
• “Fan Control Type” ________________________________________________________________

• “PTO Active Output” ______________________________________________________________
• “PTO Switch ON Lamp” _________________________________________________________
• “Fast Idle Enabled Lamp” _______________________________________________________
• “Engine Running Output” (Not Available for every OEM) _________________
• “Change Oil Lamp” _______________________________________________________________
50 SEBU7766-07
Fuel Tank Parameters
• “Primary Fuel Tank Capacity” (Not Available for every OEM) ___________
• “Secondary Fuel Tank Capacity” (Not Available for every OEM)
_________________________________________________________________________________________
Data Link Parameters
• “Powertrain Data Link” ___________________________________________________________

SEBU7766-07 51
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage

i02123539
Product Lifting
SMCS Code: 1000; 1404; 7002
g00103219
Illustration 18
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
When it is necessary to remove a component at an

angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use an adjustable lifting beam

to lift the engine. All supporting members (chains and cables) should be
parallel to each other. The chains and cables should be perpendicular to
the top of the object that is being lifted.
52 SEBU7766-07
Operation Section
Lifting and Storage
Some removals require lifting the xtures in order to obtain proper balance
and safety.
To remove the engine ONLY, use the lifting eyes that are on the engine.
If the lifting eyes are missing, refer to the Parts Manual for the proper
lifting eyes and bolts.
Lifting eyes are designed for the specic engine arrangement. These
lifting eyes are installed when the engine is manufactured. Alterations
to the lifting eyes and/or the engine make the lifting eyes and the lifting
xtures obsolete. If alterations are made, ensure that proper lifting devices
are provided. Consult your Caterpillar dealer for information regarding
xtures for proper engine lifting.
i02068367
Product Storage
SMCS Code: 1000; 1404; 7002
If the engine will not be started for several weeks, the lubricating oil will
drain from the cylinder walls and from the piston rings. Rust can form on
the cylinder liner surface. Rust on the cylinder liner surface will cause
increased engine wear and a reduction in 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, “Rell Capacities and Recommendations”
(Maintenance Section).
If an engine is out of operation and if use of the engine is not planned,

special precautions should be made. If the engine will be stored for more
than one month, a complete protection procedure is recommended.
For more detailed information on engine storage, see Special Instruction,

SEHS9031, “Storage Procedure For Caterpillar Products”.
Your Caterpillar dealer can assist in preparing the engine for extended
storage periods.
SEBU7766-07 53
Operation Section
Gauges and Indicators

i02154799

SMCS Code: 1900; 7450
Your engine may not have the same gauges or all of the gauges that
are described. For more information about the gauge package, see the
literature that is provided by the OEM.
Gauges provide indications of engine performance. Ensure that the

gauges are in good working order. Determine the normal operating range
by observing the gauges over a period of time.
Noticeable changes in gauge readings indicate potential gauge or engine

problems. Problems may also be indicated by gauge readings that
change even if the readings are within specications. Determine the
cause of any signicant change in the readings. Then, correct any cause
of any signicant change in the readings. Consult your Caterpillar dealer
for assistance.
Caterpillar requires one lamp in addition to the gauge package that

is normally provided. The “Diagnostic” lamp is yellow or amber. The
“Diagnostic” lamp will communicate the status of the engine's electronic
system. The optional red “Warning” lamp is also available. This red
“Warning” lamp warns the operator of engine problems.
The following conditions are some examples of the engine problems:
• Low oil pressure

• High coolant temperature
• Low coolant level
• High inlet air temperature
Engine Oil Pressure – Typical oil pressure for an engine
at rated speed with SAE 10W30 or with SAE 15W40 is
235 to 395 kPa (30 to 60 psi).
54 SEBU7766-07
Operation Section
A lower oil pressure is normal at low idle. If the load is stable and the
gauge reading changes, perform the following procedure:
1. Remove the load.
2. Reduce engine speed to low idle.
3. Check the oil level. Maintain the oil level at the proper amount.
The diagnostic lamp will turn on if the oil pressure drops below 35 kPa
(5 psi) at low idle rpm. The diagnostic code will be logged in the Engine
Control Module (ECM).
Engine Oil Temperature – This gauge indicates the engine

oil temperature. An oil temperature that is higher than normal
indicates a heat problem in the lubrication system and/or the
cooling system. This problem can damage the cylinder heads, the cylinder
liners, the pistons, and the crankshaft bearings.
Jacket Water Coolant Temperature – Typical temperature

range is 88 to 102 °C (190 to 215 °F). The maximum allowable
temperature with the pressurized cooling system is 105 °C
(220 °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:
1. Reduce the load and the engine rpm.
2. Inspect the cooling system for leaks.
3. Determine if the engine must be shut down immediately or if the engine

can be cooled by reducing the load.
Tachometer – This gauge indicates engine speed. When the

throttle control lever is moved to the full throttle position without
load, the engine is running at high idle. The engine is running
at the full load rpm when the throttle control lever is at the full throttle
position with maximum rated load.
Note: The high idle rpm and the full load rpm are stamped on the
Information Plate.
SEBU7766-07 55
Operation Section
Ammeter – This gauge indicates the amount of a charge or

of discharge in the battery charging circuit. Operation of the
indicator should be to the right side of “0”(zero).
Service Hour Meter – This gauge indicates the number of

clock hours of engine operation. The hours of operation are
logged in the ECM. A service tool is needed to retrieve the hours
from the ECM. A Service Hour Meter may be installed on the engine.
Fuel Pressure – This gauge indicates fuel pressure to the

electronic unit injectors from the fuel lter. The indicator should
indicate the “NORMAL” range. A decrease in fuel pressure
usually indicates a plugged fuel lter.
Fuel Level – This gauge indicates the level of fuel in the fuel
tank. The fuel level gauge registers the fuel level only when the
ignition switch is in the ON position.
56 SEBU7766-07
Operation Section
Features and Controls

i00838698
Emergency Vehicle Engine Features

SMCS Code: 1000
Note: The emergency vehicle engine features refer to re truck and
ambulance engines that are equipped with an automatic transmission and
have power ratings of 205 kW (275 hp) or 246 kW (330 hp).
The emergency vehicle engine features have the following modications:

Top Tank Design Temperature (maximum allowable
temperature) ............................................................... 110° C (230° F)
High Coolant Temperature Warning ........................... 113° C (235° F)
Very High Coolant Temperature Warning ................... 115° C (240° F)
Very High Coolant Temperature Shutdown (OEM installation) .. 115° C
(240° F)
If the emergency vehicle engine is programmed to derate, reduced power

will begin when the fault code for the High Coolant Temperature Warning
ashes. The engine will continue to derate until the coolant temperature
reaches 115° C (240° F).
i02463681
Monitoring System
SMCS Code: 1900; 7400; 7402; 7450; 7451
NOTICE
The Engine Monitoring System is not a guarantee
against catastrophic failures. Programmed delays
and derate schedules are designed to minimize false
alarms and provide time for the operator to stop the
engine.
SEBU7766-07 57
Operation Section
Programmable Options and Systems Operation

Caterpillar provides a factory installed engine monitoring system. The
system monitors engine oil pressure, coolant temperature, inlet manifold
air temperature, and coolant level (optional device). Optional devices are
installed by the vehicle Original Equipment Manufacturer (OEM).
The monitoring system can be programmed to three different modes.

These three modes of programming are the following modes: “Warning”,
“Derate”, and “Shutdown”. The coolant temperature sensor, the oil
pressure sensor and the coolant level sensor (optional device) will operate
in the engine monitoring mode that is selected.
For example, if “Derate” was selected, the engine will derate engine
power and vehicle speed. Sensors are used to detect the conditions that
exceed acceptable limits.
An excessive inlet manifold air temperature will not derate the engine.
Also, an excessive inlet manifold air temperature will not shut down the
engine.
“Warning”
The “DIAGNOSTIC” lamp and the warning signal (red lamp or buzzer)
turn “ON” and the warning signal is activated continuously in order to
alert the operator that one or more of the engine parameters is not within
normal operating range.
“Warning/Derate”
The “DIAGNOSTIC” lamp turns “ON” and the warning signal (red lamp
or buzzer) is activated. After the warning, the engine will derate rpm and
power. The warning lamp will begin to ash when the derating occurs.
When the engine is fully derated, the engine power is limited to 90 kW

(120 hp). The vehicle speed is limited to 72 km/h (45 mph).
“Warning/Derate/Shutdown”
The “DIAGNOSTIC” lamp turns “ON” and the warning signal (red lamp
or buzzer) is activated. After the warning, the engine will derate rpm and
power. The engine will continue to derate rpm until a shutdown of the
engine occurs. The engine can be restarted after a shutdown for use in
an emergency.
58 SEBU7766-07
Operation Section
A shutdown of the engine may occur in as little as 20 seconds. The engine

can be restarted after a shutdown for use in an emergency. However, the
cause of the initial shutdown may still exist. The engine may shut down
again in as little as 20 seconds.
If there is a signal for coolant loss, there will be a 10 second delay in

order to verify the condition. The system will derate the engine rpm for
40 seconds before the engine will shut down if the engine has been
programmed to shut down.
If there is a signal for low oil pressure or for coolant temperature, there
will be a two second delay in order to verify the condition. The system will
derate the engine rpm for 30 seconds before the engine will shut down if
the engine has been programmed to shutdown.
If the Shutdown mode has been selected and the

warning indicator activates, engine shutdown
may take as little as 20 seconds from the time
the warning indicator is activated. Depending on
the application, special precautions should be
taken to avoid personal injury. The engine can
be restarted following shutdown for emergency
maneuvers, if necessary.
The Customer Specied Parameters may be secured by customer

passwords. The engine may have all of the parameters that are
programmed or any combination of the parameters that are programmed.
Refer to the Service Manual, SENR9517, “Troubleshooting Guide”

for more information about the engine monitoring system. For further
assistance, consult your Caterpillar dealer.
SEBU7766-07 59
Operation Section
Engine Diagnostics
Engine Diagnostics
i01563934
Self-Diagnostics
SMCS Code: 1000; 1900; 1901; 1902
Caterpillar Electronic Engines have the capability to perform a

self-diagnostics test. When the system detects an active problem,
the “DIAGNOSTIC” lamp is activated. Diagnostic codes will be stored
in permanent memory in the Electronic Control Module (ECM). The
diagnostic codes can be retrieved by using the following components:
• Caterpillar electronic service tools

• “DIAGNOSTIC” lamp
Note: The “DIAGNOSTIC” lamp must be installed by the OEM or by the
customer.
Some installations have electronic displays that provide direct readouts of

the engine diagnostic codes. Refer to the manual that is provided by the
OEM for more information on retrieving engine diagnostic codes.
Active codes represent problems that currently exist. These problems

should be investigated rst. If a code is active, the “DIAGNOSTIC” lamp
will ash the ash code at ve second intervals.
Logged codes represent the following items:
• Intermittent problems
• Recorded events
• Performance history
The problems may have been repaired since the logging of the code.
These codes do not indicate that a repair is needed. The codes are
guides or signals when a situation exists. Codes may be helpful to
troubleshoot problems.
When the problems have been corrected, the corresponding logged fault
codes should be cleared.
60 SEBU7766-07
Operation Section
Engine Diagnostics
i01563946
Diagnostic Lamp
SMCS Code: 1000; 1900; 1901; 1902; 7451
The “DIAGNOSTIC” lamp is used to indicate the existence of a fault by

ashing codes. The “DIAGNOSTIC” lamp that is on the dashboard is
usually “YELLOW”.
When the ignition switch is rst turned on, the “DIAGNOSTIC” lamp will
go through the following procedure:
• The “DIAGNOSTIC” lamp will illuminate for ve seconds.

• The “DIAGNOSTIC” lamp will turn off.
Whenever the Engine Control Module (ECM) detects an active fault or
condition the lamp will ash at ve second intervals. If the lamp turns on
and if the lamp stays on after initial start-up, the ECM has detected a
system problem.
The “DIAGNOSTIC” lamp is also used for the Idle Shutdown Timer. The
lamp will start to ash at a rapid rate 90 seconds before the programmed
idle time expires. The engine will shut down after the 90 second interval.
To disable the Idle Shutdown Timer, the “ALLOW IDLE SHUTDOWN
OVERRIDE” must be programmed to “YES”. The clutch pedal or the
service brake pedal must be depressed during the nal 90 seconds while
the “YELLOW” lamp is ashing. A diagnostic “EVENT” code or Override
of the Idle Shutdown Timer will be logged in the ECM.
i02668582
Diagnostic Flash Code Retrieval

SMCS Code: 1000; 1900; 1901; 1902
Diagnostic Lamp
Use the diagnostic Lamp or a Caterpillar electronic service tool to
determine the diagnostic ash code.
Use the following procedure to retrieve the ash codes if the engine is
equipped with a diagnostic lamp:
SEBU7766-07 61
Operation Section
Engine Diagnostics
1. Turn the ignition key to the ON position.
2. Turn the ignition keyswitch to the OFF position.
3. Turn the cruise control ON/OFF switch to the OFF position.
4. Move the SET/RESUME switch to either position. Hold that position

until the yellow lamp begins to ash.
The yellow lamp will ash in order to indicate a two digit ash code and
the SET/RESUME switch may be released. The sequence of ashes
represents the system diagnostic message. Count the rst sequence of
ashes in order to determine the rst digit of the ash code. After a two
second pause, the second sequence of ashes will identify the second
digit of the ash code.
Any additional ash codes will follow after a pause. These codes will be
displayed in the same manner. Flash Code 55 indicates that No Detected
Faults have occurred since the ignition keyswitch has been turned to
the ON position.
For further information, assistance for repairs, or troubleshooting, refer to

the Service Manual or consult an authorized Caterpillar dealer.
Some codes record events. Also, some codes may also indicate that a
mechanical system needs attention. Troubleshooting is not required for
codes 35, 41, 47 and 55. Code 01 will not display a ash code. Some
codes will limit the operation or the performance of the engine.
Table 2 indicates the potential effect on the engine performance with

active ash codes and table 2 forms a list of electronic diagnostic codes
and descriptions.
Table 2 also indicates the suggested operator action for each active
ash code.
Table 2
Flash Codes for C7 and C9 On-Highway Engines
(continued)
62 SEBU7766-07
Operation Section
Engine Diagnostics
(Table 2, contd)
An “X” indicates that
An “X” indicates the
the effect on engine
suggested operator action
performance may occur if
Diagnostic if the code is active.
the code is active.
Flash Code
Loss Schedule
Low Shut Stop Service
Misre of Engine
Power Down Engine Engine
(1) (2)
RPM Service(3)
Coolant
Level Sensor
12 X
Circuit Fault
(4)(5)
An Injection
Actuation
15 Pressure X X X
Sensor
Circuit Fault
Injection
Actuation
17 Pressure X X X X
Sensor Out
of Range
Driver Fault
for the
Injection
18 Actuation X X X
Pressure
Control
Valve
Sensor
Supply
21 X X
Voltage Fault
(6)
Oil Pressure
24 Sensor fault X X
(5)
An Inlet Air
Pressure
25 X X
Sensor
Circuit Fault
(continued)
SEBU7766-07 63
Operation Section
Engine Diagnostics
(Table 2, contd)

the code is active.
Flash Code
Loss Schedule
Misre of Engine
(1) (2)
RPM Service(3)
Atmospheric
Pressure
26 X
Sensor Fault
(5)(6)
Coolant
Temperature
27 X
Sensor
Fault(4)(6)
Check
Throttle
28 X X
Sensor
Adjustment
Check PTO
Throttle
29 X X
Sensor
Adjustment(5)
Loss of
Vehicle
31 X X
Speed
Signal
Throttle
32 Position X X
Sensor Fault
Turbo
Wastegate
33 X X X
Solenoid
Circuit Fault
Engine RPM
34 X X X X
Signal Fault
Engine
35 Overspeed X
Warning
(continued)
64 SEBU7766-07
Operation Section
Engine Diagnostics
(Table 2, contd)

the code is active.
Flash Code
Loss Schedule
Misre of Engine
(1) (2)
RPM Service(3)
Vehicle
36 Speed X X
Signal Fault
An Inlet Air
Temperature
38 X X
Sensor Fault
(6)
Injection
Actuation
39 X X X X
Pressure
System Fault
Vehicle
41 Overspeed X X
Warning
Check
Timing
42 X X
Sensor
Calibrations
Fuel Level
Sensor
44 X
Circuit Fault
(5)
Very Low Oil

46 X X X X X X
Pressure (5)
Shutdown
47 X
Occurrence
Inlet Air
49 Heater X
Circuit Fault
(continued)
SEBU7766-07 65
Operation Section
Engine Diagnostics
(Table 2, contd)

the code is active.
Flash Code
Loss Schedule
Misre of Engine
(1) (2)
RPM Service(3)
Intermittent X X X X
Battery
51
Power to
ECM
No Detected
55
Faults
Check
Customer
56 Parameters X X X
or System
Parameters
Transmission
Datalink
57 X
Engine
Derate
A Powertrain
58 Data Link X
Fault
Incorrect
59 Engine X
Software
High Coolant
61 Temperature X X X X
Warning
Low Coolant
62 Level X X X X
Warning
Very High
Intake
64 Manifold Air X X X X
Temperature
Warning
(continued)
66 SEBU7766-07
Operation Section
Engine Diagnostics
(Table 2, contd)

the code is active.
Flash Code
Loss Schedule
Misre of Engine
(1) (2)
RPM Service(3)
Ignition
71 Keyswitch X X X X
Circuit Fault
Cylinder
1 Fault or
72 X X X
Cylinder 2
Fault
Cylinder
3 Fault or
73 X X X
Cylinder 4
Fault
Cylinder
5 Fault or
74 X X X
Cylinder 6
Fault
(1) Stop the Engine: Operate the engine cautiously. Get immediate service. Severe engine
damage may result.
(2) The operator should go to the nearest location that has a qualied service program.
(3) Schedule Service: The problem should be investigated when the operator has access
to a qualied service program.
(4) These Flash Codes reduce the effectiveness of the Engine Monitoring feature when
the codes are active.
(5) The code will ash if the sensor is used for this application.
(6) These Flash Codes may affect the system under specic environmental conditions such
as engine start-up at cold temperature and cold weather operation at high altitudes.
For further information or assistance for repairs, consult an authorized

Caterpillar dealer.
SEBU7766-07 67
Operation Section
Engine Diagnostics
i01174828
ECM Snapshot
SMCS Code: 1901
The ECM can record a snapshot of the engine parameters and vehicle
parameters. The snapshot records the parameters for a period of 13
seconds that surrounds the event, 9 seconds before the trigger and 4
seconds after the trigger. A technician can use a service tool in order
to view this snapshot information.
Triggering Snapshot Information

An operator can aid in the troubleshooting of intermittent problems by
taking a “snapshot” when the problem is experienced. A snapshot can
be triggered by using the Cruise Control Set/Resume Switch. Use the
following procedure in order to perform this function:
g00627693
Illustration 19
(1) OFF position
(2) SET position
(3) RESUME position
1. Toggle the switch quickly from the OFF position (1) to the SET position
(2).
2. Toggle the switch quickly from the SET position (2) to the RESUME
position (3).
3. Toggle the switch quickly from the RESUME position (3) back to the
OFF position (1).
68 SEBU7766-07
Operation Section
Engine Diagnostics
Note: The switch must be toggled within a one second time period in
order to take a snapshot of the engine parameters. The procedure can
also be performed in the reverse order.
Storage of Snapshots In the ECM

The ECM can store a maximum of four snapshots that are triggered
manually. The newest snapshot will replace the oldest snapshot if a fth
snapshot that is triggered manually is taken.
Snapshots are automatically cleared by the ECM after 100 hours of

operation. Also, the snapshots can be cleared manually by using an
Electronic Service Tool.
i01833390
Fault Logging
SMCS Code: 1000; 1900; 1901; 1902
The system provides the capability of Fault Logging. When the Engine
Control Module (ECM) generates an active diagnostic code, the code will
be logged in the memory of the ECM. The codes that have been logged
in the memory of the ECM can be retrieved with Caterpillar electronic
service tools. The codes that have been logged can be cleared with
Caterpillar electronic service tools. The codes that have been logged in
the memory of the ECM will be automatically cleared from the memory
after 100 hours. A factory password must be used in order to clear the
following faults from the memory of the ECM: overspeed, low engine oil
pressure, high engine coolant temperature, and low coolant level.
SEBU7766-07 69
Operation Section
Engine Diagnostics
i02784364
Engine Operation with Active Diagnostic

Codes
SMCS Code: 1000; 1900; 1901; 1902
If the diagnostic lamp starts to ash codes during normal engine

operation, the system has identied a situation that is not within the
specication. Use Caterpillar electronic service tools to check the active
diagnostic codes.
Note: If the customer has selected “DERATE” and if there is a low oil
pressure condition, the Electronic Control Module (ECM) will limit the
engine power until the problem is corrected. If the oil pressure is within
the normal range, the engine may be operated at the rated speed and
load. However, maintenance should be performed as soon as possible.
Refer to Operation and Maintenance Manual, “Diagnostic Flash Code
Retrieval” for more information on ash codes.
The active diagnostic code should be investigated. The cause of the

problem should be corrected as soon as possible. Operation of the
engine and performance of the engine can be limited as a result of
the active diagnostic code that is generated. If the cause of the active
diagnostic code is repaired and there is only one active diagnostic code,
the diagnostic lamp will turn off.
70 SEBU7766-07
Operation Section
Engine Diagnostics
i01456915
Engine Operation with Intermittent

Diagnostic Codes
SMCS Code: 1000; 1900; 1901; 1902
If the diagnostic lamp starts to ash codes during normal engine operation
and the diagnostic lamp shuts off, an intermittent fault may have occurred.
If a fault has occurred, the fault will be logged into the memory of the
Electronic Control Module (ECM).
In most cases, it is not necessary to stop the engine because of an

intermittent code. However, the operator should retrieve the logged fault
codes and the operator should reference the appropriate information in
order to identify the nature of the event. The operator should log any
observation that could have caused the lamp to light.
• Low power
• Limits of the engine speed
• Excessive smoke, etc
This information can be useful to help troubleshoot the situation. The
information can also be used for future reference. For more information
on diagnostic codes, refer to the Troubleshooting Guide for this engine.
SEBU7766-07 71
Operation Section
Engine Diagnostics
i01563987
Customer Specied Parameters

SMCS Code: 1000; 1900; 1901; 1902
Customer specied parameters that will enhance the fuel efciency

and the operator's convenience can be programmed into the Electronic
Control Module (ECM). Some parameters may affect engine operation.
This may lead to complaints from the operator about power or about
performance. Certain engine parameters may be programmed by the
customer by using Caterpillar electronic service tools in order to inuence
the operation of the engine:
The customer specied parameters can be changed as often as needed.

Password protection is provided so that the customer can change the
parameters. The customer can authorize someone else to change
the parameters. Ensure that a record of the parameters is kept in the
Operation and Maintenance Manual, “Customer Specied Parameters”
(Product Information Section). For detailed instructions on programming
the engine for optimum performance and for optimum fuel economy,
consult your Caterpillar dealer.
72 SEBU7766-07
Operation Section
Engine Starting
Engine Starting
i02112415
Starting the Engine

SMCS Code: 1000; 1450
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.
Under-the-Hood Inspection
Perform the required daily maintenance and other periodic maintenance
before you start the engine. Inspect the engine compartment. This
inspection can help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, “Walk-Around Inspection” topic
(Maintenance Section) for more information.
• For the maximum service life of the engine, make a thorough inspection
before you start the engine. Look for the following items: oil leaks,
coolant leaks, loose bolts, and trash buildup. Remove trash buildup and
arrange for repairs, as needed.
• Inspect the cooling system hoses for cracks and for loose clamps.
• Inspect the alternator and accessory drive belts for cracks, breaks,
and other damage.
• Inspect the wiring for loose connections and for worn wires or frayed
wires.
• Check the fuel supply. Drain water from the water separator (if
equipped). Open the fuel supply valve.
SEBU7766-07 73
Operation Section
Engine Starting
NOTICE
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 lter housing
failure or other damage.
• Do not start the engine or do not move any of the controls if there is a
“DO NOT OPERATE” warning tag or similar warning tag attached to
the start switch or to the controls.
• Ensure that the areas around the rotating parts are clear.
• All of the guards must be put in place. Check for damaged guards or
for missing guards. Repair any damaged guards. Replace damaged
guards and/or missing guards.
• Disconnect any battery chargers that are not protected against the
high current drain that is created when the electric starting motor (if
equipped) is engaged. Check electrical cables and check the battery
for poor connections and for corrosion.
• Reset all of the shutoffs or alarm components.

• Check the engine lubrication oil level. Maintain the oil level between the
“ADD” mark and the “FULL” mark on the oil level gauge.
• Check the coolant level. Observe the coolant level in the coolant
recovery tank (if equipped). Maintain the coolant level to the “FULL”
mark on the coolant recovery tank.
• If the engine is not equipped with a coolant recovery tank maintain the
coolant level within 13 mm (.5 inch) of the bottom of the ller pipe. If
the engine is equipped with a sight glass, maintain the coolant level in
the sight glass.
• Observe the air cleaner service indicator (if equipped). Service the air
cleaner when the yellow diaphragm enters the red zone, or when the
red piston locks in the visible position.
• Ensure that any driven equipment has been disengaged. Remove any
electrical loads.
74 SEBU7766-07
Operation Section
Engine Starting
Cold Weather Starting

Starting the engine and operation in cold weather is dependent on the
type of fuel that is used, the oil viscosity, and other optional starting aids.
For more information, refer to the Operation and Maintenance Manual,
“Cold Weather Operation” topic (Operation Section).
Air Inlet Heater
DO NOT USE ETHER (starting uids) unless

specically instructed to do so. If the engine is
equipped with an Air Inlet Heater (electrically or
fuel ignited manifold heater), DO NOT use ether
(starting uids) at any time. The use could result
in engine damage and/or personal injury.
Note: There will be an indicator lamp on the dashboard of the vehicle that
is marked “AIR INLET HEATER”.
For detailed information on the operation of the Air Inlet Heater, refer to
System Operation, “Air Inlet and Exhaust”.
Use the following procedure in order to start the engine:
1. Engage the parking brake. Place the transmission in NEUTRAL. If

the vehicle is equipped with a manual transmission, depress the
clutch pedal in order to disengage the ywheel clutch. This reduces
transmission drag and this prevents movement of the vehicle.
Depressing the clutch helps to reduce the battery drain. In cold
weather, this can mean the difference between starting the engine
and not starting the engine.
The “CHECK ENGINE/DIAGNOSTIC” lamp will ash while the engine

is cranking. The lamp should turn off after proper engine oil pressure is
achieved. If the lamp fails to ash, notify your authorized Caterpillar
dealer. If the lamp continues to ash, the ECM has detected a problem
in the system. Refer to the Operation and Maintenance Manual,
“Engine Diagnostics” topic (Operation Section).
2. Turn the keyswitch to the ON position. The air inlet heater can preheat
the system in order to improve cold weather starting.
SEBU7766-07 75
Operation Section
Engine Starting
Note: The “AIR INLET HEATER” indicator lamp will ash for a minimum
of two seconds regardless of the coolant temperature. If the “AIR INLET
HEATER” indicator lamp ashes for more than two seconds, wait until
the indicator lamp stops ashing (approximately 30 seconds) before
attempting to start the engine. If the indicator lamp continues to ash,
the ECM will control the air inlet heater during a restart of the engine.
Restarting the engine at this point can cause excessive white smoke.
Note: A buzz may be heard while the air inlet heater is engaged. This is
the sound of the fuel injectors that are being exercised in preparation
for starting.
NOTICE
Do not engage the starting motor when ywheel is
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release

the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.
3. Turn the keyswitch to the START position in order to crank the engine.
The air inlet heater will turn ON if the sum of the coolant temperature
and the inlet air temperature is less than 25 °C (77 °F). Do not push
the throttle or do not hold the throttle downward while the engine is
cranked. The system will automatically provide the correct amount
of fuel in order to start the engine. If the engine does not start after
15 to 20 seconds of cranking, release the keyswitch. If the sum of
the coolant temperature and the inlet air temperature is less than
25 °C (77 °F), the preheat for the air inlet heater will restart. Turn the
keyswitch to the OFF position. Allow the starting motor to cool for two
minutes. Repeat Steps 2 and 3.
NOTICE
Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine speed until the
oil pressure gauge indicates normal. If oil pressure
is not indicated on the gauge within 15 seconds, DO
NOT operate the engine. STOP the engine, investi-
gate and correct the cause.
76 SEBU7766-07
Operation Section
Engine Starting
4. Release the keyswitch to the ON or RUN position immediately after

the engine starts. After the engine starts, check in order to ensure
that the transmission is still in the NEUTRAL position and release the
clutch pedal (manual transmission). Once a normal engine oil pressure
and air pressure are reached, the vehicle may be operated at a light
load and speed.
After the engine has started, the air inlet heater may continue to
operate in a “Continuous” mode and/or in an “Intermittent” mode. The
air inlet heater will turn OFF when the sum of the coolant temperature
and the air inlet temperature exceeds 35 °C (95 °F).
If the engine is operated with a low load, the engine will reach normal
operating temperature sooner than idling the engine with no load.
When the engine is idled in cold weather, increase the engine rpm to
approximately 1000 to 1200 rpm. This will warm up the engine more
quickly. Do not exceed the recommended rpm in order to increase the
speed of the warm-up. Limit unnecessary idle time to ten minutes.
Starting Problems
An occasional starting problem may be caused by one of the following
items:
• Low battery charge

• Lack of fuel
• Problem with the wiring harness
If the engine fuel system has been run dry, ll the fuel tank and prime
the fuel system. Refer to the Operation and Maintenance Manual, “Fuel
System - Prime” topic (Maintenance Section).
If the other problems are suspected, perform the appropriate procedure

in order to start the engine.
SEBU7766-07 77
Operation Section
Engine Starting
Problems with the Wiring Harness
g01075737
Illustration 20
(1) Engine harness
(2) Connection for the chassis harness (vehicle OEM)
Locate the ECM. Two harness connectors are attached to the ECM. One
connector is engine harness (1) and the other connector is the chassis
harness. Check the connectors in order to ensure that the connectors are
secure. Lightly pull each of the wires in the chassis harness.
1. Pull each wire with approximately 4.5 kg (10 lb) of force. The wire
should remain in the connector.
2. If a wire is loose, push the wire back into the connector. Pull the wire
again in order to ensure that the wire is secure.
3. Start the engine. If the engine does not start, consult the nearest
Caterpillar dealer for assistance.
78 SEBU7766-07
Operation Section
Engine Starting
i03640789
Starting with Jump Start Cables

SMCS Code: 1000; 1401; 1402; 1900
Improper jump start cable connections can cause

an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could

cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
If the installation is not equipped with a backup battery system, it may be

necessary to start the engine from an external electrical source.
For information on troubleshooting the charging system, refer to Special

Instruction, REHS0354, “Charging System Troubleshooting”.
Many batteries which are considered unusable are still rechargeable. After
jump starting, the alternator may not be able to fully recharge batteries
that are severely discharged. The batteries must be charged to the proper
voltage with a battery charger. For information on testing and charging,
refer to the Special Instruction, SEHS7633, “Battery Test Procedure”.
SEBU7766-07 79
Operation Section
Engine Starting
NOTICE
Use a battery that is sourced with the same voltage as
the electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
Do not reverse the battery cables. The alternator can

be damaged. Attach the negative battery cable last
and remove the negative battery cable rst.
When an external electrical source is used to start the

engine, turn the control switch on the generator set to
the “OFF” position. Turn all electrical accessories OFF
before attaching the jump start cables.
Ensure that the main power switch is in the OFF po-

sition before jump start cables are attached to the en-
gine that is being started.
1. Turn the start switch on the stalled engine to the OFF position. Turn
off all accessories.
2. Connect one positive end of the jump start cable to the positive cable
terminal of the discharged battery. Connect the other positive end of
the jump start cable to the positive cable terminal of the charging or
starting source.
3. Connect one negative end of the jump start cable to the negative cable
terminal of the charging or starting source. Connect the other negative
end of the jump start cable to the stalled engine block or to the chassis
ground. This procedure helps to prevent potential sparks from igniting
combustible gases that are produced by some batteries.
4. Charge the batteries. The engine will not continue to run after starting
if the batteries have not been charged.
5. Start the engine.
6. Immediately after the stalled engine is started, disconnect the jump

start cables in reverse order.
Refer to the Electrical Schematic for your engine. Consult your Caterpillar
dealer for more information.
80 SEBU7766-07
Operation Section
Engine Starting
i01646248
After Starting Engine

SMCS Code: 1000
Note: In temperatures from 0 to 60°C (32 to 140°F), the warm-up time

is approximately three minutes. In temperatures below 0°C (32°F),
additional warm-up time may be required.
Note: Ensure that the self test for the monitoring system (if equipped) is
completed before operating the engine under load.
When the engine idles during warm-up, observe the following conditions:
• Check for any uid or for any air leaks at idle rpm and at one-half full
rpm (no load on the engine) before operating the engine under load.
This is not possible in some applications.
• Operate the engine at low idle until all systems achieve operating
temperatures. Check all gauges during the warm-up period.
Note: Gauge readings should be observed and the data should be

recorded frequently while the engine is operating. Comparing the
data over time will help to determine normal readings for each gauge.
Comparing data over time will also help detect abnormal operating
developments. Signicant changes in the readings should be investigated.
SEBU7766-07 81
Operation Section
Engine Operation
Engine Operation
i03134068
Engine Operation
SMCS Code: 1000
Proper operation, driving techniques and maintenance are key factors in

obtaining the maximum service life and economy of Caterpillar engines.
The recommendations in this Operation and Maintenance Manual will
help to lower operating costs. For more information, refer to Special
Publication, LEDT2254, “Cat Answers Your Questions About Truck
Performance” or consult your Caterpillar dealer.
If the engine is operated at low idle or at low load for 24 or more

consecutive hours, the engine should be run at rated conditions for ve
to fteen minutes. Running the engine at rated conditions should clean
out the catalytic converter/mufer.
Idling
Idle speed is adjustable on Caterpillar electronic engines. Consult your
Caterpillar dealer for information. The idle rpm is preset between 700
and 750 rpm.
Avoid excess idling. If the vehicle is parked for more than ve minutes,
stop the engine. An engine can burn from 2.8 L (0.7 US gal) to 5.7 L
(1.5 US gal) of fuel per hour while the engine is idling. Excessive idling
can cause carbon buildup and/or excessive idling can cause the engine to
slobber. This is harmful to the engine.
If extended idle time is required, control the engine rpm to 1000 rpm or
above 1000 rpm. Ensure that the coolant temperature exceeds 82° C
(180° F). Consult your Caterpillar dealer for assistance.
The engine may be programmed in order to provide an elevated idle

speed when the battery voltage drops below a level that is predetermined.
The engine rpm will increase to the preprogrammed amount for a time
of 5 minutes. At the end of that 5 minute period, the engine will return
to low idle. The engine will return to the elevated idle speed that is
programmed for another 5 minutes if the battery is still below the low limit
that is programmed. This cycle will continue until one of the following
occurrences takes place.
82 SEBU7766-07
Operation Section
Engine Operation
• The battery has recharged sufciently.

• The operator has depressed the clutch.
• The operator has depressed the brake.
• The engine has been put into PTO mode.
• The transmission has been put into gear.
Fast idle can be programmed within the range of 700 rpm to the top
engine limit. Fast idle requires an “ON/OFF” switch on the dashboard.
Consult your Caterpillar dealer for assistance.
Idle Shutdown Timer

The idle shutdown timer can be programmed in order to shut down
the engine after a specic time period of idling. The idle time can be
programmed from three minutes to 1440 minutes (24 hours). If the idle
shutdown timer is set to 0 minutes, the idle shutdown feature is disabled.
If the setting of the timer is unknown, allow the engine to idle. Observe the
time that elapses before the engine shuts down. The following conditions
must be met in order to activate the idle shutdown timer:
• The idle shutdown feature is selected.

• No vehicle speed is detected by the Engine Control Module (ECM).
• The engine is not under load.
• The engine is at operating temperature. The engine is not in Cold Mode.
After the vehicle is stationary, the idle shutdown timer begins. The engine
can be operating at low idle or at an idle rpm that is selected by the idle
governor. The “CHECK ENGINE/DIAGNOSTIC” lamp will ash rapidly for
90 seconds prior to shutdown. Movement of the vehicle automatically
resets the idle shutdown timer to the programmed setting.
The following conditions must be met in order to override the idle

shutdown timer:
1. Program the “ALLOW IDLE SHUTDOWN OVERRIDE” to “YES”.

SEBU7766-07 83
Operation Section
Engine Operation
2. The “CHECK ENGINE/DIAGNOSTIC”lamp will ash rapidly

for 90 seconds prior to shutdown. Depress the service brake
or the clutch pedal during the 90 seconds when the “CHECK
ENGINE/DIAGNOSTIC” lamp ashes.
After an idle shutdown, the engine can be restarted without turning the
ignition keyswitch to the OFF position.
The override function is disabled if the “ALLOW IDLE SHUTDOWN

OVERRIDE” is programmed to “NO”.
Cold Mode Operation

Cold mode is initiated if the sum of the coolant temperature and the inlet
air temperature is below 18 °C (64 °F). In cold mode, the low idle is
increased to 1000 rpm and the engine power is limited. The strategy for
cold mode provides reduced smoke emission and faster warm-up time.
Cold mode is deactivated when the temperature condition is met, or when

the engine has been operating for 12 minutes.
After the cold mode is completed, the engine should be operated at low
rpm and low load until normal operating temperature is reached. The
engine will reach normal operating temperature faster when the engine is
operated at low rpm and low power demand. This method is faster than
trying to reach operating temperature by idling with no load.
NOTICE
It is not recommended that the vehicle be moved until
the engine is out of cold mode. Power may be notice-
ably reduced if the vehicle is operated while the engine
is in cold mode. At a speed above 8 km/h (5 mph),
the low idle speed will be reduced to the customer
programmed low idle speed. The power will still be
reduced.
Cold mode is disabled if the throttle, the service brake, or the clutch (if
equipped) is depressed. The rpm for cold mode operation drops to the
programmed low idle speed in order to allow the transmission to be put
into gear.
84 SEBU7766-07
Operation Section
Engine Operation
Mufer and Converter (If Equipped)
The mufer and converter will become extrem-

ly hot during engine operation. A hot mufer
and converter can cause serious burns. Allow
adaquate cooling time before working on or near
the mufer and converter.
Proper operation, driving techniques and maintenance are key factors in

obtaining the maximum service life of the mufer and converter. Some
precautions should be taken if the engine is equipped with a mufer and
converter.
Avoid excess idling. Excessive idling can cause the mufer and converter
to plug. A plugged mufer and converter will lead to an increase in
exhaust back pressure. Operating the engine in extremely cold conditions
can cause the mufer and converter to plug sooner. Use the procedure
below to clean out the mufer and converter if extended idle periods or
extended low load periods are required.
If the engine is operated at low idle or at low load for 24 or more

consecutive hours, the engine should be run at rated conditions for ve
to fteen minutes. Running the engine at rated conditions should clean
out the mufer and converter. If the engine has low power or the engine
does not respond properly, refer to the Service Manual or an authorized
Caterpillar Service Center.
Diesel Particulate Filter (If Equipped)

The diesel particulate lter (DPF) may become restricted. The restriction
is caused by ash and soot from the exhaust. A restricted exhaust will
increase the exhaust back pressure. The amber colored warning light
will turn on when the exhaust back pressure reaches a level that is
unacceptable. The lter should be cleaned immediately. The red colored
warning light will ash when the engine has exceeded the safe level of
exhaust back pressure. This will cause the engine to go into the derate
mode. The power of the engine will be limited. The lter needs to be
cleaned immediately.
Note: The diagnostic module for the DPF will need to be reset if the red
warning light turns on. The engine derate will reset with the diagnostic
module for the DPF.
SEBU7766-07 85
Operation Section
Engine Operation
Getting Started
Caterpillar electronic engines do not require long warm-up periods that
needlessly waste fuel. Typically, the engine should be at normal operating
temperature in a few minutes. Begin operating the engine at low load.
After normal oil pressure is reached and the temperature gauges begin
to rise, the engine may be operated at full load.
To get the vehicle in motion, use a gear that will result in a smooth start.
Move the load without increasing the engine rpm above low idle or without
slipping the clutch. Engage the clutch smoothly. Slipping the clutch and
engaging the clutch can cause stress to occur on the drive train. This
can also cause fuel to be wasted.
Use progressive shifting techniques. Progressive shifting is using only the

rpm that is required in order to upshift into the next gear. Progressive
shifting improves fuel economy.
• Keep the engine rpm to a minimum. Use an rpm that is from 1400 to
2000 rpm.
• Use only enough rpm to pick up the next gear.

Progressive shifting also reduces the acceleration rate. Top gear is
reached sooner because less time is needed to synchronize the gears
during shifting. In addition, the engine is operating at the highest range of
torque.
The amount of rpm that is required to upshift increases as the vehicle

speed increases, unless upshifts are made on upgrades. Experience
with the vehicle will show the amount of rpm that is required to upshift
under various conditions.
Note: These engines may be programmed to encourage progressive

shifting. The acceleration rate may slow down at certain rpm in lower
gears. If this occurs, progressive shift parameters may have been
programmed into the ECM. Progressive shift parameters will limit the
rpm when the vehicle is driven in higher gears. These parameters are
protected by customer passwords. If the vehicle can be operated in a
higher gear at a vehicle speed that is desired, select the highest gear that
is available to pull the load. This recommendation will help to obtain fuel
economy. The engine will be operating at the lowest rpm that is required
to pull the load.
86 SEBU7766-07
Operation Section
Engine Operation
Vehicle Efciency
An efcient vehicle performs the desired amount of work while the power
demand on the engine is minimized. The following factors are major
contributors to power demand:
• Aerodynamic drag (wind resistance)

• Rolling resistance of the tires
• Gross weight of the vehicle
• Losses in the drive train and the load from the engine driven accessories
For more information about vehicle efciency, refer to Special Publication,
LEDT2254, “CAT Answers Your Questions About Truck Performance”.
Fuel Economy
Fuel is the largest single operating cost of today's on-highway vehicle
engines. Improved fuel economy can have a substantial impact on
operating prot. The following items are the most signicant factors that
inuence vehicle fuel economy:
• Driver techniques
• Vehicle efciency
• Operating conditions
• Engine efciency
A No. 1 grade of fuel contains less energy per volume and increases
fuel consumption. A greater volume of fuel must be injected in order to
yield the same amount of work as a No. 2 fuel. The difference in the fuel
economy between the two grades of fuel can be as great as 0.2 km/L
(0.5 mpg) to 0.3 km/L (0.7 mpg).
For more information about fuel economy, refer to Special Publication,

LEDT2254, “Cat Answers Your Questions About Truck Performance”.
SEBU7766-07 87
Operation Section
Engine Operation
Rolling hills provide a great opportunity to reduce fuel consumption. Avoid

downshifting on small hills. The vehicle should not be downshifted even if
the engine must be lugged down to an rpm that is below the peak torque
rpm. When the vehicle is going down a hill, use gravity instead of the
engine's power to regain vehicle speed.
On grades that require more than one downshift, allow the engine to lug
to peak torque rpm. If the rpm stabilizes with the engine running at peak
torque rpm or above peak torque rpm remain in that gear.
Long steep down grades should be anticipated. Vehicle speed should be

reduced before cresting the top of a hill and proceeding down a long steep
grade. Minimize the amount of braking that is used in order to maintain a
safe speed for maximizing fuel efciency.
The engine's ability to hold the vehicle back increases with engine rpm.
Select a gear that runs the engine near the high engine rpm limit for long
steep hills when braking is required.
Speed reductions and future stops should be anticipated. Downshifts

should be avoided. The amount of braking should be minimized in order
to improve fuel consumption. By coasting to a stop, a vehicle can travel a
considerable distance without consuming any fuel.
Cruising
Vehicles that are driven faster consume more fuel. Increasing the cruising
speed from 88 km/h (55 mph) to 104 km/h (65 mph) will increase the
fuel consumption of a typical Class 8 vehicle by approximately 0.4 km/L
(1 mpg). When a vehicle is driven fast in order to allow more time for
stops, the stops become very expensive. Cruising allows the engine to
operate in the most efcient rpm range (1400 to 2000 rpm).
Cruise Control
The functionality of the cruise control can vary depending on the vehicle
manufacturer. The Cruise Control switch may be programmed to operate
in one of two modes:
• The SET position may operate as the SET/ACCEL SWITCH position

or the RESUME/DECEL position.
• The RESUME position may operate as the SET/DECEL position or the

RESUME/ACCEL position.
88 SEBU7766-07
Operation Section
Engine Operation
Refer to the markings on the Cruise Control switch or refer to your “Truck
Service Manual”.
Perform the following steps in order to set the Cruise Control:
1. After accelerating to the desired speed, turn the “ON/OFF” switch to

the ON position.
2. Press the “SET/RESUME” switch to the SET position.
The ECM will control the vehicle speed until the clutch pedal or the service
brake is depressed or the “ON/OFF” switch is turned to the OFF position.
Note: The vehicle can also be accelerated to the desired speed and the
cruise control speed can be set by pressing the “SET/RESUME” switch to
the ACCEL position.
Perform the following step in order to reset the Cruise Control:
1. Press “RESUME” and the vehicle will return to the set speed.
Momentarily pressing or bumping the “SET/RESUME” switch to the

ACCEL position will increase vehicle speed by one mph. Press the
switch to the DECEL position in order to decrease the speed by one
mph. The operating range of the cruise control has been programmed
into the ECM.
Soft Cruise Control

The Cruise Control can be programmed to operate in one of two modes,
“Soft Cruise = YES” or “Soft Cruise = NO”.
Soft Cruise Control provides an operating range of 8 km/h (5 mph) around

the setting for the cruise control. Engines that are shipped from Caterpillar
are programmed to operate in the “Soft Cruise = YES” mode. Soft Cruise
Control allows the vehicle to accelerate slightly while the engine is under
power. The vehicle can proceed down a hill while momentum is gained for
the next hill. Improved fuel economy can be gained in this mode.
When “Soft Cruise = NO” is programmed, the “SET” speed is maintained.

Consult your Caterpillar dealer for more information.
SEBU7766-07 89
Operation Section
Engine Operation
Idle Mode
The cruise control function of the electronic engine works as an engine
speed governor when the vehicle is stationary or when the vehicle is
operated at a vehicle speed below the idle vehicle speed limit. The
engine speed governor is activated and deactivated in the same way
as the cruise control.
The engine speed governor will operate at any engine rpm from low idle
to the maximum idle rpm limit. The maximum idle rpm limit is actually
less than the rated engine rpm. The maximum idle governor speed is
a Customer Specied Parameter.
Perform the following procedure in order to activate idle mode:
1. Set the “ON/OFF” switch to the ON position. The throttle can then be
used to determine the desired engine rpm.
2. When the desired engine rpm is reached, place the “SET/RESUME”

switch to the SET position and release the switch. The engine rpm
will be maintained at this speed.
Note: If the “SET/RESUME” switch is held for more than one second
in the ACCEL position, the ECM will increase the engine rpm until the
“SET/RESUME” switch is released. If the parameter is programmed, the
ECM will increase the engine rpm up to the idle engine rpm limit, or to
the top engine limit (TEL).
Perform one of the following procedures in order to disengage the idle

mode:
• Move the “Cruise/Idle ON/OFF” switch to the OFF position.

• Depress the clutch pedal.
• Depress the service brake pedal.
Perform the following procedure in order to resume the idle mode:
1. Ensure that the “Cruise/Idle ON/OFF” switch is in the ON position.
2. Move the “SET/RESUME” switch momentarily to the RESUME

position.
90 SEBU7766-07
Operation Section
Engine Operation
Note: If the “SET/RESUME” switch is held for more than one second in
the DECEL position, the ECM will decrease the engine rpm until the switch
is released. A new set rpm is established when the switch is released.
Uphill Operation
For optimum performance, allow the engine to lug downward to peak
torque rpm (1440 to 1550 rpm) before downshifting. Continue to downshift
in this manner until a gear that maintains the desired speed is reached.
Continue to operate at a low rpm (1440 to 1550 rpm) if the vehicle will
proceed to the top without a downshift. Begin upshifting as the grade of
the hill decreases and the engine begins to accelerate above 2000 rpm.
Driving this way will provide optimum fuel economy and performance.
Note: Allowing the engine to lug below peak torque is permissible if the
vehicle is cresting the top of a hill. However, extended operation at an
engine rpm that is below peak torque (1400 rpm) will raise the exhaust
temperature and the cylinder pressure. This can lead to reduced engine
service life.
Downhill Operation
NOTICE
DO NOT allow the engine rpm to exceed 2900 rpm,
engine damage can result.
On a downgrade, do not allow the vehicle to coast while the clutch pedal
is depressed or while the transmission is in the NEUTRAL position. If a
power loss is not desired, disengage the Cruise Control.
Select the correct gear that does not allow the engine rpm to exceed 2900
rpm. Use the service brakes to control the speed of the vehicle. As a basic
rule, select the same gear that would be required to go up the grade.
Refer to the rated rpm (full load) that is on the engine Information Plate.
SEBU7766-07 91
Operation Section
Engine Operation
i01637441
Exhaust Brake
SMCS Code: 1093
If your vehicle is equipped with an auxiliary brake,

follow the instructions provided in the auxiliary
brake owner's manual. Failure to follow the in-
structions during wet or slippery conditions could
reduce vehicle control and result in personal in-
jury or death.
NOTICE
Auxiliary brakes should not be used as a primary or
service brake. The vehicle's service brake must be
used in order to bring the vehicle to a complete stop.
Certain exhaust brakes are approved for use on these engines. Refer to
the Truck Engine Application and Installation Guide or see your Caterpillar
dealer for more information. For information on the specic exhaust brake
that is installed on your vehicle, refer to the information that is provided
by the OEM of the vehicle.
The anti-lock brake system (ABS) of this vehicle may interrupt the
operation of the auxiliary engine brake during the actuation of the ABS.
Compression brakes and exhaust brakes are typical examples of auxiliary
engine brakes. For information on the operation of the ABS, refer to the
literature that is provided by the OEM of the vehicle.
The exhaust brake may be used as a warm up device for the engine
in order to add parasitic load to the engine. This parasitic load will help
maintain normal engine operating temperatures. The engine will ramp to
the programmed Warm Up Mode Idle Speed and the exhaust brake will
be engaged when the engine is programmed to either “Warm Up Only” or
“Exhaust Brake & Warm Up”. Also, the switch for the exhaust brake must
be in the ON position if this switch has been installed.
Warm Up Mode will be disengaged when one of the following conditions

occurs.
• The engine is warmed up.

92 SEBU7766-07
Operation Section
Engine Operation
• The service brake is depressed.

• The clutch pedal is depressed. (Dependent on transmission style)
• The switch for the exhaust retarder (Optional) is turned to the Off
position.
• The vehicle is in gear. (Optional neutral switch)

• The throttle is depressed.
• The vehicle speed is more than 1 km/h (1 mph).
• The ECM detects excessive engine load.
• The engine rpm is less than 500 rpm or more than 1450 rpm.
The exhaust brake provides additional braking in order to slow the vehicle
on grades and curves. The exhaust brake also helps to control the speed.
The exhaust brake is useful when a reduction of speed is necessary,
but a long application of the service brake is not desired. Controlling the
slowing or downhill speed of a vehicle by using the exhaust brake results
in reduced wear on brake linings and brake drums. A reduced wear
on these components helps to save the service brakes for emergency
stopping requirements.
An exhaust brake generates the maximum retarding effect at the engine's

maximum rated rpm. As the engine rpm decreases, the performance of
the exhaust brake also decreases. For maximum available retarding, the
operator should select a gear which will provide the desired road speed at
the highest allowable engine rpm.
To maximize the benet of the exhaust brake, the exhaust brake should be
used whenever the operator wants to slow the vehicle. The exhaust brake
should be kept in the ON position during all normal operating conditions.
The operation of any vehicle under slippery conditions requires caution.

This is also true when a vehicle with an exhaust brake is operated. As
a general rule, start with the exhaust brake in the OFF position and
ensure that the vehicle maintains control through natural retardation.
Then activate the exhaust brake at the lowest power setting. Increase the
power setting as conditions improve.
SEBU7766-07 93
Operation Section
Engine Operation
Operating the Exhaust Brake

The exhaust brake is controlled by a switch on the dashboard. Before
starting the engine, ensure that the switch is in the OFF position.
After the engine is started, turn the switch to the ON position. The switch
may stay in the ON position during engine operation. The exhaust brake
will only activate when no fuel is supplied to the engine. The exhaust
brake will help to slow the vehicle when no pressure is applied to the
throttle pedal or to the clutch pedal.
The exhaust brake may be programmed to one of three modes:
• “COAST”
• “LATCH”
• “MANUAL”
The “COAST” mode and the “LATCH” mode require the Cruise Control
switch to be in the ON position. The “COAST” mode and the “LATCH”
mode do not require the Cruise Control to be active. In the “COAST” mode
or the “LATCH” mode, the exhaust brake is activated by the service brake.
Using the service brake will deactivate the Cruise Control. However, the
service brake does not turn the Cruise Control to the OFF position.
In the “MANUAL” mode, it is not necessary to depress the service brake

in order to activate the exhaust brake.
If the “Cruise Control ON/OFF” switch is in the OFF position, the exhaust
brake will activate regardless of the service brake.
“COAST” Mode
If the exhaust brake is programmed to “COAST” and the Cruise Control
switch is in the ON position, the exhaust brake will activate when the
service brake is depressed. In the “COAST” mode, the braking power is
provided by both the service brake and the exhaust brake.
The exhaust brake will deactivate when the service brake is released.
94 SEBU7766-07
Operation Section
Engine Operation
“LATCH” Mode
If the exhaust brake is programmed to “LATCH” and the Cruise Control
switch is in the ON position, the exhaust brake will activate when the
service brake is depressed.
The exhaust brake remains active when the service brake is released.
The exhaust brake remains active until the throttle pedal or the clutch
pedal is depressed, or the engine speed drops below 900 rpm.
“MANUAL” Mode
If the exhaust brake is programmed to “MANUAL”, the exhaust brake
will activate regardless of the service brake or the position of the Cruise
Control switch.
The exhaust brake will turn off once the engine exceeds 900 rpm during
acceleration. Once you remove your foot from the accelerator pedal, the
exhaust brake should turn on again within 0.25 seconds. The exhaust
brake will only activate when no fuel is supplied to the engine. The
exhaust brake will activate when no pressure is applied to the throttle
pedal or to the clutch pedal.
SEBU7766-07 95
Operation Section
Engine Operation
i01885870
Caterpillar Driver Information Display

(Messenger)
SMCS Code: 7490
g00916428
Illustration 21
Messenger display
This display is intended to allow the driver to monitor the vehicle and
engine information while the vehicle is being operated. The display may
also display stored trip information. When possible, the driver should
select the proper display screen before operating the vehicle.
Diagnostic Data
Engine diagnostic codes may be displayed for the driver. The Messenger
display will automatically display potentially serious engine problems.
When one of these codes appears, the driver should bring the vehicle to a
safe stop. After the display of a serious diagnostic code, the engine may
shut down within 20 seconds. Refer to the Operation and Maintenance
Manual, “Diagnostic Flash Code Retrieval” for additional information.
96 SEBU7766-07
Operation Section
Engine Operation
Engine Operating Information

The Messenger display provides information on cruise control set speed,
PTO engine rpm set speed, fuel temperature to the engine, boost and oil
pressure, coolant temperature, and intake manifold temperature.
Vehicle Trip Information

The Messenger display provides information concerning the quantity of
fuel that has been used, the fuel economy, the average vehicle speed,
idle time, PTO time, percent idle hour, idle fuel, and PTO fuel. These
parameters may relate to trip segments or to the engine history. A Driver
and a Fleet Trip Segment is available. For the Driver Trip Segment, the
driver determines the start and stop points. For the Fleet Trip Segment,
the vehicle owner determines the start and stop points. The vehicle may
be operated in separate states. The Fleet Trip Segment may be tied to
each of these states. The Fleet Trip Segment may be split between two
drivers and two id codes.
Maintenance Information
The system has an oil and lter change indicator which allows the display
to indicate when the next maintenance is due.
Theft Deterrent
Messenger provides the capability to allow the engine to start or the
capability to prevent the engine from starting. The Messenger display can
shut down the engine after entering a password with four characters into
the display when the engine is at idle.
Fuel Correction Adjustment

Messenger provides the capability to adjust the Fuel Correction Factor
of the ECM.
Conguration of the Display

Messenger can provide information in either English, French, or Spanish.
Units of measure can be displayed in English (miles per hour, US gallons,
psi, and °F), English (miles per hour, Imperial gallons, psi, and °F), or
Metric units (kilometer per hour, liters, kPa, and °C). The French or
Spanish manuals may be ordered by contacting a Caterpillar dealer.
SEBU7766-07 97
Operation Section
Engine Operation
Driver ID Entry
The Messenger display provides the capability to enter the id of multiple
drivers. This allows the ECM to log information for multiple drivers. This is
useful in driving applications that involve several drivers.
State Crossing
Messenger allows the driver to enter the current state.
Access to Parameters
The availability of parameters is determined by the engine manufacturer,
the model year of the engine, and the ECM settings for the Customer
Programmable Parameters.
98 SEBU7766-07
Operation Section
Engine Stopping
Engine Stopping
i00948324
Stopping the Engine

SMCS Code: 1000; 7000
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of the engine components.
If the engine has been operating at high rpm and/or

high loads, run at low idle for at least three minutes
to reduce and stabilize internal engine temperature
before stopping the engine.
Avoiding hot engine shutdowns will maximize tur-

bocharger shaft and bearing life.
Prior to stopping an engine that is being operated at low loads, operate

the engine at low idle for 30 seconds before stopping. If the engine has
been operating at highway speeds and/or at high loads, operate the
engine at low idle for at least three minutes. This procedure will cause the
internal engine temperature to be reduced and stabilized.
Ensure that the engine stopping procedure is understood. Stop the engine
according to the shutoff system on the vehicle or refer to the instructions
that are provided by the OEM of the vehicle.
• To stop the engine, turn the ignition key switch to the OFF position.
After Stopping the Engine

• Check the crankcase oil level. Maintain the oil level between the “ADD”
mark and the “FULL” mark on the oil level gauge.
• If necessary, perform minor adjustments. Repair any leaks and tighten

any loose bolts.
SEBU7766-07 99
Operation Section
Engine Stopping
• Note the service hour meter reading. Perform the maintenance that
is in the Operation and Maintenance Manual, “Maintenance Interval
Schedule”.
• Fill the fuel tank in order to help prevent accumulation of moisture in the
fuel. Do not overll the fuel tank.
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Coolant Specications that are in the Operation
and Maintenance Manual. Failure to do so can cause
engine damage.
• Allow the engine to cool. Check the coolant level. Maintain the cooling
system at 13 mm (.5 inch) from the bottom of the pipe for lling.
• If freezing temperatures are expected, check the coolant for proper

antifreeze protection. The cooling system must be protected against
freezing to the lowest expected outside temperature. Add the proper
coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all driven equipment. This

maintenance is outlined in the instructions from the OEM.
100 SEBU7766-07
Operation Section
Cold Weather Operation

i01502338
Radiator Restrictions
SMCS Code: 1353; 1396
Caterpillar discourages the use of airow restriction devices that are

mounted in front of radiators. Airow restriction can cause the following
conditions:
• High exhaust temperatures

• Power loss
• Excessive fan usage
• Reduction in fuel economy
Shutters can be properly used for parking overnight, very cold
temperatures, and high winds. In those particular cases, the coolant
temperature and the inlet manifold temperature must be carefully
monitored and controlled.
NOTICE
Failure to open the winter fronts in the morning could
cause engine damage and/or loss of fuel economy.
i02118561
Fuel and the Effect from Cold Weather

SMCS Code: 1000; 1250
The following fuels are the grades that are available for Caterpillar
engines:
• No.1
• No.2
• Blend of No.1 and No.2
SEBU7766-07 101
Operation Section
No.2 diesel fuel is the most commonly used fuel. Either No.1 diesel fuel or
a blend of No.1 and No.2 is best suited for cold weather operation.
Note: Engines that are equipped with a Diesel Particulate Filter (DPF)
are required to use Ultra Low Sulfur Diesel (ULSD) diesel fuel. ULSD fuel
contains less than 15 ppm sulfur using ASTM D 2622 or DIN 51400. The
use of higher sulfur diesel fuel in an engine with a DPF will cause the
engine to produce emissions that are not in compliance with emissions
standards and deactivation of the catalyst within the DPF. The use of a
blend of No.1 and No.2 fuel is allowed in an engine that is equipped with
a DPF, if both of the base fuels meet the ULSD standard.
Quantities of No.1 diesel fuel are limited. No.1 diesel fuels are usually
available during the months of the winter in the colder climates. During
cold weather operation, if No.1 diesel fuel is not available, use No.2 diesel
fuel, if necessary.
There are three major differences between No.1 and No.2 diesel fuel.
No.1 diesel fuel has the following properties:
• Lower cloud point

• Lower pour point
• Lower rating of BTU per unit volume of fuel
When No.1 diesel fuel is used, a decrease in power and in fuel efciency
may be noticed. Other operating effects should not be experienced.
The cloud point is the temperature when a cloud of wax crystals begins
to form in the fuel. These crystals can cause the fuel lters to plug. The
pour point is the temperature when diesel fuel will thicken. The diesel fuel
becomes more resistant to ow through fuel pumps and through fuel lines.
Be aware of these values when diesel fuel is purchased. Anticipate the

average ambient temperature of the location of the engine's area of
operation. Engines that are fueled in one climate may not operate well
if the engines are moved to another climate. Problems can result due
to changes in temperature.
Before troubleshooting for low power or for poor performance in the

winter, check the type of fuel that is being used.
When No.2 diesel fuel is used the following components provide a means
of minimizing problems in cold weather:
102 SEBU7766-07
Operation Section
• Starting aids
• Engine oil pan heaters
• Engine coolant heaters
• Fuel heaters
• Fuel line insulation
For more information about fuel, refer to Special Publication, SEBU6385,
“Caterpillar On-highway Diesel Truck Engine Fluids Recommendations”.
i01502354
Fuel Related Components in Cold Weather

SMCS Code: 1000; 1250
Fuel Tanks
Condensation can form in partially lled fuel tanks. Top off the fuel tanks
after operating the engine.
Fuel tanks should contain some provision for draining water and sediment
from the bottom of the tanks. 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 lter is important.
Drain the water and sediment from any fuel storage tank at the following
intervals:
• Weekly
• Oil changes
• 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.
SEBU7766-07 103
Operation Section
Fuel Filters
A primary fuel lter and/or a water separator is installed between the fuel
tank and the engine mounted fuel lter. The location of the primary fuel
lter is important in cold weather operation. The primary fuel lter and the
fuel supply line are commonly affected by cold fuel. The best location for
the primary fuel lter is in the engine compartment. Here, the primary fuel
lter will benet from the radiant heat of the engine. A primary fuel lter
that is mounted outside the frame rails or in any location that is exposed
to wind can be a persistent problem in cold weather.
Fuel Heaters
Fuel heaters help to prevent fuel lters from plugging in cold weather due
to waxing. A fuel heater should be installed so that the fuel is heated
before the fuel enters the primary fuel lter.
Select a fuel heater that is mechanically simple, yet adequate for the
application. The fuel heater should also help to prevent overheating of
the fuel. High fuel temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater with a large heating
surface. The fuel heater should be practical in size. Small heaters can be
too hot due to the limited surface area.
Disconnect the fuel heater in warm weather.
Note: Fuel heaters that are controlled by the water temperature regulator
or self-regulating fuel heaters should be used with this engine. Fuel
heaters that are not controlled by the water temperature regulator can
heat the fuel in excess of 65 °C (149 °F). A loss of engine power can
occur if the fuel supply temperature exceeds 37 °C (100 °F).
Note: Heat exchanger type fuel heaters should have a bypass provision
in order to prevent overheating of the fuel in warm weather operation.
The following fuel heaters are recommended for use with Caterpillar
engines:
• 7C-3557 Fuel Heater Group

• 7C-3558 Heater Kit
For further information on fuel heaters, consult your Caterpillar dealer.
104 SEBU7766-07
Maintenance Section
Rell Capacities
Maintenance Section
Rell Capacities
i03903590
Rell Capacities and Recommendations

SMCS Code: 1348; 1395; 7560
NOTICE
Every attempt is made to provide accurate, up to date
information. By use of this document, you agree that
Caterpillar Inc. is not responsible for errors or omis-
sions.
NOTICE
These recommendations are subject to change with-
out prior notice. Contact your Caterpillar dealer for the
most up to date recommendations.
Note: Note: Refer to the latest edition of Special Publication, SEBU6385,

“Caterpillar On-highway Diesel Engine Fluids Recommendations” for
additional information. Contact your Caterpillar dealer in order to conrm
that you have the newest recommendations for uids.
Note: Instructions for the installation of the lter are printed on the side of
each Caterpillar spin-on lter. For lters that are not Caterpillar lters, refer
to the installation instructions that are provided by the supplier of the lter.
Engine Oil
Cat DEO (Diesel Engine Oil)
Cat oils have been developed and tested in order to provide the full
performance and service life that has been designed and built into Cat
engines.
Due to signicant variations in the quality and in the performance

of commercially available oils, Caterpillar makes the following
recommendations:
SEBU7766-07 105
Maintenance Section
Rell Capacities
• Cat DEO (Diesel Engine Oil) (10W-30)

• Cat DEO (Diesel Engine Oil) (15W-40)
• Cat DEO-ULS (Diesel Engine Oil - Ultralow Sulfur) (15W-40) (SAE
10W-30 is only available in bulk quantities)
Note: Cat DEO-ULS and Cat DEO multigrade oils are the preferred oils
for use in all Cat on-highway engines.
Note: For optimum engine system performance of DPF equipped Cat

diesel engines, the use of Cat DEO-ULS is strongly recommended.
For optimum engine system performance of DPF equipped Cat diesel
engines, the use of ultralow sulfur diesel fuel (ULSD) is required.
Commercial Oils
NOTICE
Caterpillar does not warrant the quality or perfor-
mance of non-Caterpillar uids.
Note: Non-Caterpillar commercial oils are, as a group, second choice

oils. Within this grouping of second choice oils there are tiered levels
of performance.
Caterpillar developed the Engine Crankcase Fluid (ECF) specications

to ensure the availability of high performance commercial diesel engine
oils in order to provide satisfactory life and performance in Cat diesel
engines where recommended for use.
There are three current Cat ECF specications: Cat ECF-1-a, Cat ECF-2,
and Cat ECF-3. Each higher Cat ECF specication provides increased
performance over lower Cat ECF specications. For example, Cat ECF-3
provides higher performance than Cat ECF-2 and Cat ECF-3 provides
much higher performance than Cat ECF-1-a.
After Cat DEO-ULS and Cat DEO, commercial oils that meet the Cat
ECF-3 specication are preferred oils for use in Cat On-highway Engines.
Oils that meet the API CJ-4 oil category requirements are compliant with
the Cat ECF-3 specication.
106 SEBU7766-07
Maintenance Section
Rell Capacities
Commercial oils that meet the requirements of the Cat ECF-1-a

specication and commercial oils that meet the requirements of the Cat
ECF-2 specication are acceptable for use in theCaterpillar On-highway
Engines that are covered by this publication. API category oils that have
not met the requirements of at least one Cat ECF specication may cause
reduced engine life.
Use of oil that does not meet the Cat ECF-3 specication and the API
CJ-4 oil category may require more frequent DPF cleaning cycles and
may contribute to DPF plugging. When the recommended and preferred
Cat DEO-ULS is not used, it is strongly recommended that DPF equipped
engines use oil that meets the Cat ECF-3 specication and the API CJ-4
oil category.
In selecting oil for any engine application, both the oil viscosity and
oil performance category/specication as specied by the engine
manufacturer must be dened and satised. Using only one of these
parameters will not sufciently dene oil for an engine application.
Lubricant Viscosity Recommendations
The proper SAE viscosity grade of oil is determined by the minimum

ambient temperature during cold engine start-up, and the maximum
ambient temperature during engine operation.
Refer to Table 3 (minimum temperature) in order to determine the required

oil viscosity for starting a cold engine.
Refer to Table 3 (maximum temperature) in order to select the oil viscosity

for engine operation at the highest ambient temperature that is anticipated.
NOTICE
In selecting oil for any engine application, both the
oil viscosity and oil performance category/specica-
tion as specied by the engine manufacturer must be
dened and satised. Using only one of these param-
eters will not sufciently dene oil for an engine appli-
cation.
SEBU7766-07 107
Maintenance Section
Rell Capacities
Table 3
Engine Oil Viscosities for Ambient Temperatures
Ambient Temperature
Viscosity Grade Minimum Maximum
SAE 0W-30 40 °C (40 °F) 30 °C (86 °F)
SAE 0W-40 40 °C (40 °F) 40 °C (104 °F)
SAE 5W-30 30 °C (22 °F) 30 °C (86 °F)
SAE 5W-40 30 °C (22 °F) 50 °C (122 °F)
SAE 10W-30 18 °C (0 °F) 40 °C (104 °F)
SAE 10W-40 18 °C (0 °F) 50 °C (122 °F)
SAE 15W-40 9.5 °C (15 °F) 50 °C (122 °F)
Note: Supplemental heat is recommended below the minimum

recommended ambient temperature.
S·O·S Oil Analysis

Caterpillar has developed a maintenance tool that evaluates oil
degradation. The maintenance management also detects the early signs
of wear on internal components. The Caterpillar tool for oil analysis
is called S·O·S oil analysis and the tool is part of the S·O·S Services
program. S·O·S oil analysis divides oil analysis into four categories:
• Component wear rate

• Oil condition
• Oil contamination
• Identication of oil
These four types of analysis are used to monitor the condition of your
equipment. The four types of analysis will also help you identify potential
problems. A properly administered S·O·S oil analysis program will reduce
repair costs and the program will lessen the impact of downtime.
108 SEBU7766-07
Maintenance Section
Rell Capacities
The S·O·S oil analysis program uses a wide range of tests to determine
the condition of the oil and the condition of the lubricated compartment.
Guidelines that are based on experience and a correlation to failures
have been established for these tests. Exceeding one or more of
these guidelines could indicate serious uid degradation or a pending
component failure. A trained person at your Caterpillar dealership should
make the nal analysis.
NOTICE
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
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Refer to this Operation and Maintenance Manual, “Engine Oil Sample

- Obtain” in order to ascertain the correct interval for obtaining an oil
sample.
Refer to Special Publication, SEBU6385, “Caterpillar On-highway Diesel

Engine Fluids Recommendations” in order to obtain additional information
about S·O·S Services oil analysis. You can also contact your local
Caterpillar dealer in order to obtain additional information about the S·O·S
Services oil analysis program.
Rell Capacities (Engine Oil)

The rell capacities for the engine crankcase reect the approximate
capacity of the crankcase or sump plus standard oil lters. Auxiliary oil
lter systems will require additional oil. Refer to the OEM specications
for the capacity of the auxiliary oil lter.
SEBU7766-07 109
Maintenance Section
Rell Capacities
g01142908
Illustration 22
(1) Shallow oil sump (2) Deep oil sump
Table 4
Approximate Rell Capacities
(continued)
110 SEBU7766-07
Maintenance Section
Rell Capacities
(Table 4, contd)
Rell with Rell without

Compartment or System(1) lter change lter change
(L) (Qts) (L) (Qts)
Oil Sump Capacity (Shallow Sump) 18 (L) 16 (L)

180 mm (7.1 inch) deep 19 (Qts) 17 (Qts)
(continued)
SEBU7766-07 111
Maintenance Section
Rell Capacities
(Table 4, contd)
Oil Sump Capacity (Deep Sump) (1) 25.5 (L) 23.7 (L)
245 mm (9.6 inch) deep 27 (Qts) 25(Qts)
(1) These values are the approximate capacities for the crankcase oil sump which include
the standard oil lters that are installed at the factory. Engines with auxiliary oil lters will
require additional oil. Refer to the OEM specications for the capacity of the auxiliary oil
lter.
Fuel
Caterpillar is not in the position to continuously evaluate and monitor all of
the many worldwide distillate diesel fuel specications and the ongoing
revisions that are published by governments and technological societies.
NOTICE
Caterpillar recommends the ltration of distillate fuel
through a fuel lter with a rating of four microns(c)
absolute or less as the fuel is dispensed to the fuel
tank for the engine.
Note: Caterpillar requires the ltration of all fuel through a primary fuel
lter with a rating of ten microns(c) absolute to 15 microns(c) absolute.
112 SEBU7766-07
Maintenance Section
Rell Capacities
NOTICE
In order to meet expected fuel system component
life, 4 micron(c) absolute or less secondary fuel l-
tration is required for all Caterpillar Diesel Engines
that are equipped with unit injected fuel systems. Note
that all current Caterpillar Diesel Engines are factory
equipped with Caterpillar Advanced Efciency 4 mi-
cron(c) absolute fuel lters.
Caterpillar does not warrant the quality or perfor-

mance of non-Caterpillar uids and lters.
All fuel must meet the Caterpillar specications for distillate diesel fuel
found in Special Publication, SEBU6385, “Caterpillar On-highway Diesel
Engine Fluids Recommendations”, “Distillate Diesel Fuels”.
NOTICE
In the United States (U.S.), burning fuel with greater
than 500 ppm sulfur in model year 2006 and older
on-highway diesel engines is illegal and punishable
with civil penalties.
Note: The owner and the operator of the engine has the responsibility
of using the correct fuel that is recommended by the manufacturer and
allowed by the US EPA and, as appropriate, other regulatory agencies.
The preferred fuels provide maximum engine service life and

performance. The preferred fuels are distillate fuels. These fuels are
commonly called diesel fuel, furnace oil, gas oil, or kerosene.
Note: Fuel with 15 ppm sulfur or fuel with less than 15 ppm sulfur is
required for use in every Caterpillar On-highway Engine that is equipped
with a DPF.
The permissible fuels include some biodiesel fuels. Use of

permissable fuels can result in higher maintenance costs and reduced
engine service life.
SEBU7766-07 113
Maintenance Section
Rell Capacities
Biodiesel
Biodiesel that meets the requirements that are listed in the Caterpillar
specication for biodiesel, ASTM D6751, or EN 14214 are acceptable for
use in any Cat On-highway Engine that is covered by this publication. The
biodiesel blend must meet the Caterpillar specications for distillate diesel
fuel found in Special Publication, SEBU6385, “Caterpillar On-highway
Diesel Engine Fluids Recommendations”, “Distillate Diesel Fuels”.
Biodiesel may be blended in amounts up to a maximum of 30 percent with

an acceptable diesel fuel.
Note: The user of the engine has the responsibility of using the correct
fuel that is recommended by the manufacturer and allowed by the U.S.
EPA and other appropriate regulatory agencies.
Note: Refer to Special Publication, SEBU6385, “Caterpillar On-highway

Diesel Engine Fluids Recommendations”, “Fuel Specications” for specic
information about types of biodiesel that are recommended for use in
Caterpillar On-highway Engines.
Note: A complete Caterpillar S·O·S Services oil analysis program is

strongly recommended when using biodiesel blends above 5 percent.
Aftermarket Fuel Additives

Note: Caterpillar strongly recommends that a fuel additive with 15 ppm
sulfur or greater NOT be used with an engine that is equipped with a DPF.
There are many different types of fuel additives that are available to use.
Caterpillar does not generally recommend the use of fuel additives.
In special circumstances, Caterpillar recognizes the need for fuel

additives. Fuel additives need to be used with caution. Some additives
may damage emission control systems. Some additives may raise fuel
sulfur levels above the maximum allowed by the US Environmental
Protection Agency (EPA) or, as appropriate, other regulatory agencies.
Contact your fuel supplier for those circumstances when fuel additives are
required. Your fuel supplier can make recommendations for additives to
use and for the proper level of treatment.
Note: The U.S. EPA bans the use of metallic fuel additives in on-highway
applications.
114 SEBU7766-07
Maintenance Section
Rell Capacities
Note: For best results, your fuel supplier should treat the fuel when
additives are needed.
Cat Diesel Fuel Conditioner
Cat Diesel Fuel Conditioner is the only fuel conditioner/additive that is

tested and approved by Caterpillar for use in Caterpillar diesel engines.
Cat Diesel Fuel Conditioner is a proven high performance, multipurpose

diesel fuel conditioner that is designed to improve:
• Fuel economy (through cleanup of the fuel system)

• Lubricity
• Oxidative stability
• Detergency/dispersancy
• Dispersancy of moisture
• Corrosion protection
• Cetane
Note: When used as directed, Cat Diesel Fuel Conditioner will not raise
fuel sulfur levels measurably in the nal fuel/additive blend. In the U.S.
the current formulation of Cat Diesel Fuel Conditioner must be blended in
at the recommended treat-rate at the fuel supplier/distributor level for use
in on-highway or other applications where use of ULSD fuel is mandated
(15 ppm or less fuel sulfur). Follow all applicable national, regional, and
local laws, mandates, and regulations concerning the use of diesel fuel
conditioners/additives.
Lubricating Grease
Caterpillar provides various greases that vary in performance from a
moderate performance to an extremely high performance. These greases
service the entire line of Caterpillar products in the wide variety of climates
throughout the world. From this variety of Caterpillar grease products, you
can nd a Caterpillar grease that will meet or exceed the performance
requirements of most on-highway trucks.
SEBU7766-07 115
Maintenance Section
Rell Capacities
The performance requirements of your engine must be determined before

you select any Caterpillar grease. Consult the recommendations for
greases that are made by the OEM for the equipment. Then, consult with
your Caterpillar dealer for a list of greases that have the performance
specications and the available sizes of containers.
Note: Always choose grease that meets or exceeds the recommendations

that are specied by the equipment manufacturer for the application.
If it is necessary to choose a single grease to use for all of the equipment

at one site, always choose a grease that meets or exceeds the
requirements of the most demanding application. Remember that the
products which barely meet the minimum performance requirements can
be expected to barely produce the minimum lives of your parts. False
economy is being used if a grease is purchased with the lowest cost as
the only consideration. Instead, use the grease that yields the lowest total
operating cost. This cost should be based on an analysis that includes
the costs of parts, labor, downtime, and the cost of the amount of grease
that is required.
Some greases are not chemically compatible with other greases. Consult
your supplier in order to determine if the greases are compatible. Purge
all of the old grease from a joint in the following circumstances:
• Before you change from one type of grease to another type of grease
• Before you change from one brand of grease to another brand of grease
All Caterpillar greases are chemically compatable but may be formulated
for different levels of performance. Mixing Caterpillar greases can affect
the performance of the greases. Do not mix Caterpillar greases.
If you are not certain that the old grease is compatible with the new
grease, purge the old grease from the system before applying the new
grease.
Coolant
NOTICE
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool rst.
116 SEBU7766-07
Maintenance Section
Rell Capacities
NOTICE
If the truck is to be stored in, or shipped to an area with
below freezing temperatures, the cooling system must
be either protected to the lowest outside temperature
or drained completely to prevent damage caused by
freezing coolant.
NOTICE
Frequently check the specic gravity of the coolant for
proper freeze protection or for anti-boil protection.
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
lems can develop without water temperature regula-
tors.
The following two coolants are used in Caterpillar diesel engines:
Preferred – Cat ELC (Extended Life Coolant) or a commercial extended

life coolant that meets the Caterpillar EC-1 specication
Acceptable – Cat DEAC (Diesel Engine Antifreeze/Coolant) or a

commercial heavy-duty coolant that meets “ASTM D4985”, or “ASTM
D6210” specications
Note: Cat DEAC does not require a treatment with an Supplemental

Coolant Additive (SCA) at the initial ll. However, a commercial heavy-duty
coolant that only meets the “ASTM D4985” specication WILL require a
treatment with an SCA at the initial ll. A commercial heavy-duty coolant
that meets the “ASTM D6210” specication will NOT require a treatment
with an SCA at the initial ll. Read the label or the instructions that are
provided by the manufacturer of the commercial heavy-duty coolant.
Note: Coolants that meet only the “ASTM D4985” specication

WILL require a treatment with a supplemental coolant additive on
a maintenance basis. Coolants that meet only the “ASTM D6210”
specication WILL require a treatment with a supplemental coolant
additive on a maintenance basis.
SEBU7766-07 117
Maintenance Section
Rell Capacities
Table 5
Service Life Before Flushing and Before Relling
Coolant Service Life(1)(2)(3)
Cat ELC 965,606 kilometers
(600,000 miles), 12,000
hours, or 6 years(4)
Commercial coolant that 482,803 kilometers
meets the Caterpillar EC-1 (300,000 miles), 6000
specication hours, or 6 years(5)
Cat DEAC 321,869 kilometers
(200,000 miles), 3000
hours, or 3 years(6)
Commercial Heavy-Duty 241,402 kilometers
Coolant that meets “ASTM (150,000 miles), 3000
D4985”(7) or “ASTM D6210” hours, or 1 year(6)
(1) Use the interval that occurs rst.
(2) Refer to this Operation and Maintenance Manual,
“Maintenance Interval Schedule” for the interval for servicing
the water temperature regulator.
(3) Caterpillar On-highway Engines that have excessive idle time
must reduce the coolant change intervals to one-half of the
kilometers (miles) that are allowed or Caterpillar On-highway
Engines that have excessive idle time must base the coolant
service life on the hours that are stated. Engine hours of
operation are reported in the ECM (Electronic Control Module).
(4) Cat ELC Extender must be added at 6000 service hours or
one half of the service life of the Cat ELC.
(5) An extender must be added at 3000 service hours or one half
of the service life of the coolant.
(6) Requires treatment with a supplemental coolant additive on
a maintenance basis.
(7) Requires pre-charge of a supplemental coolant additive.
Note: These coolant change intervals are only possible with annual S·O·S
Services Level 2 coolant sampling and analysis.
S·O·S Services Coolant Analysis

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 Services Coolant Analysis can be performed 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.
118 SEBU7766-07
Maintenance Section
Rell Capacities
NOTICE
Do not use the same vacuum sampling pump for ex-
tracting oil samples that is used for extracting coolant
samples.
A small residue of either type sample may remain in

the pump and may cause a false positive analysis for
the sample being taken.
Always use a pump that is designated only for oil sam-

pling and a pump that is designated only for coolant
sampling.
Failure to do so may cause a false analysis which

could lead to customer and dealer concerns.
Recommended Interval for S·O·S Services Coolant Sample
Table 6
Recommended Interval
Type of Coolant Level 1 Level 2
Every
Cat DEAC 24140 kilometers Yearly(2)(3)
(15000 miles)(1)(2)
Cat ELC Optional(3) Yearly(3)
(1) This is also the recommended sampling interval for all
commercial coolants that meet Cat EC-1 (Engine Coolant
specication - 1)
(2) The recommended sampling interval for all other
conventional heavy-duty coolant/antifreeze is 20120 kilometers
(12500 miles).
(3) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identied.
Note: Check the SCA (Supplemental Coolant Additive) of the conventional

coolant at every oil change or at every 250 hours. Perform this check at
the interval that occurs rst.
New Systems, Relled Systems, and Converted Systems
Perform an S·O·S coolant analysis (Level 2) at the following maintenance

intervals.
SEBU7766-07 119
Maintenance Section
Rell Capacities
• Every Year
• Initial 500 service hours
Perform this analysis at the interval that occurs rst for new systems, for
relled systems, or for converted systems that use Cat ELC (Extended
Life Coolant) or use Cat DEAC (Diesel Engine Antifreeze/Coolant). This
500 hour check will also check for any residual cleaner that may have
contaminated the system.
Rell Capacity (Coolant System)

The total cooling system capacity will vary depending on the radiator that
is provided by the vehicle manufacturer. The table for the capacity of the
cooling system is blank. The customer should ll in the table.
Table 7
Approximate Capacity of the Cooling System
Compartment
Liters Quarts
or System
Total Cooling
System(1)
(1) The total cooling system capacity includes the following
components:the engine block, the radiator, and all coolant
hoses and lines.
Note: Refer to Special Publication, SEBU6385, “Caterpillar On-highway

Diesel Truck Engine Fluids Recommendations” for additional information
that relates to coolant for your engine.
120 SEBU7766-07
Maintenance Section
Maintenance Interval Schedule
i03914676

(Engines with a Shallow Oil Sump)
SMCS Code: 1000; 7500
Ensure that all safety information, warnings, and instructions are read
and understood before any operation or any maintenance procedures
are performed.
The user is responsible for the performance of maintenance, including

all adjustments, the use of proper lubricants, uids, lters, and the
replacement of components due to normal wear and aging. Failure to
adhere to proper maintenance intervals and procedures may result
in diminished performance of the product and/or accelerated wear of
components.
Use mileage, fuel consumption, service hours, or calendar time, WHICH

EVER OCCURS FIRST, in order to determine the maintenance intervals.
Products that operate in severe operating conditions may require more
frequent maintenance.
Note: Before each consecutive interval is performed, all maintenance

from the previous interval must be performed.
When Required
Air Dryer - Check ................................................................................. 128
Battery - Replace ................................................................................. 129
Battery or Battery Cable - Disconnect ................................................. 132
Engine - Clean ..................................................................................... 157
Engine Air Cleaner Element - Clean/Replace ...................................... 158
Engine Oil Level Gauge - Calibrate ..................................................... 165
Engine Storage Procedure - Check ..................................................... 176
Fuel System - Prime ............................................................................ 179
Severe Service Application - Check .................................................... 194
Daily
Cooling System Coolant Level - Check ............................................... 146
Engine Air Cleaner Service Indicator - Inspect .................................... 158
Engine Oil Level - Check ..................................................................... 162
Fuel System Water Separator - Drain .................................................. 182
Walk-Around Inspection ....................................................................... 198
SEBU7766-07 121
Maintenance Section
Initial 17 700 km (11 000 miles) or 4150 L (1100 US gal) of Fuel

or 250 Service Hours or 6 Months
Engine Valve Lash - Inspect/Adjust ..................................................... 177
PM Level 1 - Every 17 700 km (11 000 miles) or 4150 L

(1100 US gal) of Fuel or 250 Service Hours or 6 Months
Aftercooler Core - Clean/Test .............................................................. 126
Air Compressor Filter - Clean/Replace ................................................ 127
Battery Electrolyte Level - Check ......................................................... 131
Belt - Inspect ........................................................................................ 132
Cooling System Coolant Sample (Level 1) - Obtain ............................ 147
Cooling System Supplemental Coolant Additive (SCA) - Test/Add ..... 150
Cylinder Head Grounding Stud - Inspect/Clean/Tighten ...................... 156
Engine Crankcase Breather - Clean .................................................... 161
Engine Oil Sample - Obtain ................................................................. 167
Engine Oil and Filter - Change ............................................................ 169
Fan Drive Bearing - Lubricate .............................................................. 178
Fuel System Primary Filter - Clean/Replace ........................................ 182
Fuel Tank Water and Sediment - Drain ................................................ 184
Hoses and Clamps - Inspect/Replace ................................................. 185
Radiator - Clean ................................................................................... 193
PM Level 2 - Every 161 000 km (100 000 miles) or 56 850 L

(15 000 US gal) of Fuel or 2000 Service Hours or 2 Years
Air Compressor - Inspect ..................................................................... 126
Alternator - Inspect .............................................................................. 128
Belt Tensioner - Inspect ....................................................................... 136
Cooling System Water Temperature Regulator - Replace ................... 153
Crankshaft Vibration Damper - Inspect ................................................ 155
Engine Mounts - Inspect ...................................................................... 162
Starting Motor - Inspect ....................................................................... 195
Turbocharger - Inspect ......................................................................... 195
Water Pump - Inspect .......................................................................... 200
Every 3 Years or 322 000 km (200 000 miles)

Cooling System Coolant (DEAC) - Change ......................................... 136
Every 483 000 km (300 000 miles)

Cooling System Coolant Extender (ELC) - Add ................................... 144
122 SEBU7766-07
Maintenance Section

Cooling System Coolant (ELC) - Change ............................................ 141
Every 114 000 L (30 000 US gal) of Fuel

Overhaul Considerations ..................................................................... 192
SEBU7766-07 123
Maintenance Section
i03914720

(Engines with a Deep Oil Sump)
SMCS Code: 1000; 7500
Ensure that all safety information, warnings, and instructions are read
and understood before any operation or any maintenance procedures
are performed.
The user is responsible for the performance of maintenance, including

all adjustments, the use of proper lubricants, uids, lters, and the
replacement of components due to normal wear and aging. Failure to
adhere to proper maintenance intervals and procedures may result
in diminished performance of the product and/or accelerated wear of
components.
Use mileage, fuel consumption, service hours, or calendar time, WHICH

EVER OCCURS FIRST, in order to determine the maintenance intervals.
Products that operate in severe operating conditions may require more
frequent maintenance.
Note: Before each consecutive interval is performed, all maintenance

from the previous interval must be performed.
When Required
Air Dryer - Check ................................................................................. 128
Battery - Replace ................................................................................. 129
Battery or Battery Cable - Disconnect ................................................. 132
Engine - Clean ..................................................................................... 157
Engine Oil Level Gauge - Calibrate ..................................................... 165
Engine Storage Procedure - Check ..................................................... 176
Fuel System - Prime ............................................................................ 179
Severe Service Application - Check .................................................... 194
Daily
Cooling System Coolant Level - Check ............................................... 146
Engine Air Cleaner Service Indicator - Inspect .................................... 158
Engine Oil Level - Check ..................................................................... 162
124 SEBU7766-07
Maintenance Section
Initial 24 000 km (15 000 miles) or 5700 L (1500 US gal) of Fuel

or 400 Service Hours or 6 Months
PM Level 1 - Every 24 000 km (15 000 miles) or 5700 L

(1500 US gal) of Fuel or 400 Service Hours or 6 Months
Aftercooler Core - Clean/Test .............................................................. 126
Air Compressor Filter - Clean/Replace ................................................ 127
Belt - Inspect ........................................................................................ 132
Cooling System Supplemental Coolant Additive (SCA) - Test/Add ..... 150
Engine Crankcase Breather - Clean .................................................... 161
Engine Oil Sample - Obtain ................................................................. 167
Engine Oil and Filter - Change ............................................................ 169
Fan Drive Bearing - Lubricate .............................................................. 178
Hoses and Clamps - Inspect/Replace ................................................. 185
Radiator - Clean ................................................................................... 193
PM Level 2 - Every 161 000 km (100 000 miles) or 56 850 L

(15 000 US gal) of Fuel or 2000 Service Hours or 2 Years
Air Compressor - Inspect ..................................................................... 126
Alternator - Inspect .............................................................................. 128
Belt Tensioner - Inspect ....................................................................... 136
Cooling System Water Temperature Regulator - Replace ................... 153
Engine Mounts - Inspect ...................................................................... 162
Starting Motor - Inspect ....................................................................... 195
Water Pump - Inspect .......................................................................... 200

Cooling System Coolant (DEAC) - Change ......................................... 136
Every 483 000 km (300 000 miles)

Cooling System Coolant Extender (ELC) - Add ................................... 144
SEBU7766-07 125
Maintenance Section

Cooling System Coolant (ELC) - Change ............................................ 141
Every 114 000 L (30 000 US gal) of Fuel

Overhaul Considerations ..................................................................... 192
126 SEBU7766-07
Maintenance Section
Aftercooler Core - Clean/Test
i01807350
Aftercooler Core - Clean/Test

(Air-To-Air Aftercooler)
SMCS Code: 1064-070; 1064-081
The air-to-air aftercooler is OEM installed in many applications. Please

refer to the OEM specications for information that is related to the
aftercooler.
i02113479
Air Compressor - Inspect

SMCS Code: 1803-040
Do not disconnect the air line from the air com-

pressor governor without purging the air brake
and the auxiliary air systems. Failure to purge the
air brake and the auxiliary air systems before re-
moving the air compressor and/or the air lines
could cause personal injury.
g01076630
Illustration 23
(1) Pressure relief valve
SEBU7766-07 127
Maintenance Section
Air Compressor Filter - Clean/Replace
If the air compressor pressure relief valve that is

mounted in the air compressor cylinder head is
bypassing compressed air, there is a malfunction
in the air system, possibly ice blockage. Under
these conditions, your engine may have insuf-
cient air for normal brake operation.
Do not operate the engine until the reason for the

air bypass is identied and corrected. Failure to
heed this warning could lead to property damage,
personal injury, or death to the operator or by-
standers.
The function of the pressure relief valve is to bypass air when there is a
malfunction in the air compressor system.
The pressure relief valve releases air at 1723 kPa (250 psi). Do not stand
near the pressure relief valve. Compressed air may be released without
warning. All personnel should also stay clear of the air compressor when
the engine is operating and the air compressor is exposed.
Refer to the Service Manual or refer to the OEM specications in order to

nd information concerning the air compressor. Consult your Caterpillar
dealer for assistance.
i01491325
Air Compressor Filter - Clean/Replace

SMCS Code: 1803-070-FQ; 1803-510-FQ
One of the single most important aspects of preventive maintenance for

the air compressor is the induction of clean air. The type of maintenance
that is required for the air compressor and the maintenance interval
depends on the type of air induction system that is used. Operating
conditions (dust, dirt and debris) may require more frequent service.
Refer to the Service Manual for the type of air compressor that is installed
on the engine. Follow the maintenance recommendations that are
provided by the OEM of the air compressor. Some engines use boost air
pressure so the engine air cleaner will require servicing.
128 SEBU7766-07
Maintenance Section
Air Dryer - Check
i00863920
Air Dryer - Check

SMCS Code: 4285-535
Follow the maintenance recommendations that are provided by the OEM

or consult your Caterpillar dealer for assistance.
i02676048
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. When the engine is not run for
long periods of time 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.
SEBU7766-07 129
Maintenance Section
Battery - Replace
i02153996
Battery - Replace
SMCS Code: 1401-510
Batteries give off combustible gases which can

explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.
Ensure proper ventilation for batteries that are 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.
The battery cables or the batteries should not be

removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with

the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the key start switch to the OFF position. Remove the key and
all electrical loads.
2. Turn OFF the battery charger. Disconnect the charger.
3. The NEGATIVE “-” cable connects the NEGATIVE “-” battery terminal
to the ground plane. Disconnect the cable from the NEGATIVE “-”
battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE “+” battery terminal
to the starting motor. Disconnect the cable from the POSITIVE “+”
battery terminal.
130 SEBU7766-07
Maintenance Section
Battery - Replace
Note: Always recycle a battery. Never discard a battery. Return used

batteries to an appropriate recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that the key start switch
is OFF.
7. Connect the cable from the starting motor to the POSITIVE “+” battery
terminal.
8. Connect the cable from the ground plane to the NEGATIVE “-” battery
terminal.
SEBU7766-07 131
Maintenance Section
Battery Electrolyte Level - Check
i02601752
Battery Electrolyte Level - Check

SMCS Code: 1401-535
When the engine is not run for long periods of time or when the engine is
run for short periods, the batteries may not fully recharge. Ensure a full
charge in order to help prevent the battery from freezing.
All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the ller caps. Maintain the electrolyte level to the “FULL”
mark on the battery.
If the addition of water is necessary, use distilled water. If distilled

water is not available use clean water that is low in minerals. Do not
use articially softened water.
2. Check the condition of the electrolyte with the 245-5829 Coolant

Battery Tester Refractometer.
3. Keep the batteries clean.
Clean the battery case with one of the following cleaning solutions:
• A mixture of 0.1 kg (0.2 lb) of baking soda and 1 L (1 qt) of clean

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

Thoroughly rinse the battery case with clean water.
Use a ne grade of sandpaper to clean the terminals and the cable
clamps. Clean the items until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal of material can cause
the clamps to not t properly. Coat the clamps and the terminals with
5N-5561 Silicone Lubricant, petroleum jelly or MPGM.
132 SEBU7766-07
Maintenance Section
Battery or Battery Cable - Disconnect
i01492654
Battery or Battery Cable - Disconnect

SMCS Code: 1402-029
The battery cables or the batteries should not be

removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with

the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the ignition switch (if
equipped) to the OFF position and remove the key and all electrical
loads.
2. Disconnect the negative battery terminal at the battery that goes to the
start switch. Ensure that the cable cannot contact the terminal. When
four 12 volt batteries are involved, the negative side of two batteries
must be disconnected.
3. Tape the leads in order to help prevent accidental starting.
4. Proceed with necessary system repairs. Reverse the steps in order to

reconnect all of the cables.
i02149963
Belt - Inspect
SMCS Code: 1357-040; 1357; 1397-040; 1397
Inspection
Belt tension should be checked initially between the rst 20 to 40
hours of engine operation.
SEBU7766-07 133
Maintenance Section
Belt - Inspect
Check the belt tension. Refer to the Operation and Maintenance Manual,
“Maintenance Interval Schedule” topic (Maintenance Section) for the
proper intervals.
To check the belt tension, apply 110 N (25 lb ft) of force midway between
the pulleys. A correctly adjusted belt will deect 9 mm (0.35 inch) to
15 mm (0.59 inch).
To maximize the engine performance, inspect the belts for wear and for
cracking. Replace belts that are worn or damaged.
For applications that require multiple drive belts, replace the belts in
matched sets. Replacing only one belt of a matched set will cause the
new belt to carry more load because the older belt is stretched. The
additional load on the new belt could cause the new belt to break.
If the belts are too loose, vibration causes unnecessary wear on the belts
and pulleys. Loose belts may slip enough to cause overheating.
If the belts are too tight, unnecessary stresses are placed on the pulley
bearings and on the belts. This may shorten the service life of the
components.
Remove the belt guard. Inspect the condition and adjustment of the
alternator belts and accessory drive belts (if equipped).
If the belt does not require replacement or adjustment, install the belt
guard. If the belt requires adjustment or replacement, perform the
following procedure to adjust the belt tension.
• If the engine is equipped with a refrigerant compressor (air conditioner),

the belt for the fan drive, the alternator, and the accessories will have
an automatic belt tensioner.
• If the engine is not equipped with a refrigerant compressor, the

alternator is used to adjust the belt tension.
134 SEBU7766-07
Maintenance Section
Belt - Inspect
Adjustment
Alternator Belt
g01075759
Illustration 24
(1) Adjusting bolt
(2) Mounting bolts
1. Slightly loosen mounting bolts (2) and adjusting bolt (1).
2. Move the pulley in order to adjust the belt tension.
3. Tighten adjusting bolt (1) and mounting bolts (2). For the proper torque,
refer to the Specications Manual, SENR3130, “Torque Specications”.
4. Install the belt guard.
If new belts are installed, check the belt tension again after 30 minutes of
engine operation at the rated rpm.
SEBU7766-07 135
Maintenance Section
Belt - Inspect
Water Pump Belt
g01075753
Illustration 25
Exploded view of the drive assembly for a water pump belt
(1) Mounting bolt
(2) Square hole
(3) Adjusting bolt
1. Slightly loosen mounting bolts (1) and adjusting bolt (3).
2. Adjust the belt tension with a square drive in square hole (2).
3. Tighten adjusting bolt (3) and mounting bolt (1). For the proper torque,
4. Install the belt guard.
If new belts are installed, check the belt tension after 30 minutes of engine
operation at the rated rpm.
136 SEBU7766-07
Maintenance Section
Belt Tensioner - Inspect
i01555583
Belt Tensioner - Inspect

(If Equipped)
SMCS Code: 1358-040
g00426964
Illustration 26
Belt tensioner
Inspect the belt tensioner for unusual noise, excessive looseness and/or
shaking of the bearings.
If the belt tensioner should require disassembly, refer to the Service

Manual for the procedure.
i02139869
Cooling System Coolant (DEAC) - Change

SMCS Code: 1350-070; 1395-044
Clean the cooling system and ush the cooling system before the
recommended maintenance interval if the following conditions exist:
• The engine overheats frequently.

• Foaming is observed.
• The oil has entered the cooling system and the coolant is contaminated.
SEBU7766-07 137
Maintenance Section
• The fuel has entered the cooling system and the coolant is
contaminated.
NOTICE
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
Note: Inspect the water pump and the water temperature regulator after
the cooling system has been drained. This is a good opportunity to
replace the water pump, the water temperature regulator and the hoses, if
necessary.
Drain
Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system ller cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Stop the engine and allow the engine to cool. Loosen the cooling
system ller cap slowly in order to relieve any pressure. Remove the
cooling system ller cap.
2. Open the cooling system drain valve (if equipped). If the cooling system
is not equipped with a drain valve, remove one of the drain plugs.
Note: If equipped, be sure to drain the heater and any related supply
and return lines.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
138 SEBU7766-07
Maintenance Section
For information regarding the disposal and the recycling of used coolant,
consult your Caterpillar dealer or consult Caterpillar Dealer Service Tool
Group:
Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
1. Flush the cooling system with clean water in order to remove any
debris.
2. Close the drain valve (if equipped). Clean the drain plugs. Install the
drain plugs. Refer to the Specications Manual, SENR3130, “Torque
Specications” for more information on the proper torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean water and Caterpillar
Fast Acting Cooling System Cleaner. Add 0.5 L (1 pint) of cleaner
per 15 L (4 US gal) of the cooling system capacity. Install the cooling
system ller cap.
4. Start and run the engine at low idle for a minimum of 30 minutes. The
coolant temperature should be at least 82 °C (180 °F).
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure

to completely ush the cooling system with clear wa-
ter. Continue to ush the system until all signs of the
cleaning agent are gone.
SEBU7766-07 139
Maintenance Section
cooling system ller cap. Open the drain valve (if equipped) or remove
the cooling system drain plugs. Allow the water to drain. Flush the
cooling system with clean water. If equipped, be sure to ush the
heater and any related supply and return lines. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain plugs. Refer to the
Specications Manual, SENR3130, “Torque Specications” for more
information on the proper torques.
Cooling Systems with Heavy Deposits or

Plugging
Note: For the following procedure to be effective, there must be some
active ow through the cooling system components.
debris.
Note: If equipped, be sure to ush the heater and any related supply
and return lines.
drain plugs. Refer to the Specications Manual, SENR3130, “Torque
Specications” for more information on the proper torques.
NOTICE
3. Fill the cooling system with a mixture of clean water and Caterpillar
Fast Acting Cooling System Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system capacity. Install the
4. Start and run the engine at low idle for a minimum of 90 minutes. The
coolant temperature should be at least 82 °C (180 °F).
140 SEBU7766-07
Maintenance Section
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure

to completely ush the cooling system with clear wa-
ter. Continue to ush the system until all signs of the
cleaning agent are gone.
system ller cap slowly in order to relieve any pressure. Remove
the cooling system ller cap. Open the drain valve (if equipped) or
remove the cooling system drain plugs. Allow the water to drain.
Flush the cooling system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain plugs. Refer to the
Specications Manual, SENR3130, “Torque Specications” for more
information on the proper torques.
Fill
NOTICE
1. Fill the cooling system with coolant/antifreeze. Refer to the Operation

and Maintenance Manual, “Rell Capacitites and Recommendations”
topic (Maintenance Section) for more information on cooling system
specications. Do not install the cooling system ller cap.
2. Start and run the engine at low idle. Increase the 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.
3. Check the coolant level. Maintain the coolant level within 13 mm

(0.5 inch) below the bottom of the pipe for lling. Maintain the coolant
level within 13 mm (0.5 inch) to the proper level on the sight glass (if
equipped).
SEBU7766-07 141
Maintenance Section
Cooling System Coolant (ELC) - Change
4. Clean the cooling system ller cap. Inspect the gasket that is on the
cooling system ller cap. If the gasket that is on the cooling system ller
cap is damaged, discard the old cooling system ller cap and install
a new cooling system ller cap. If the gasket that is on the cooling
system ller cap is not damaged, perform a pressure test. A 9S-8140
Pressurizing Pump is used to perform the pressure test. The correct
pressure for the cooling system ller cap is stamped on the face of the
cooling system ller cap. If the cooling system ller cap does not retain
the correct pressure, install a new cooling system ller cap.
5. Start the engine. Inspect the cooling system for leaks and for proper
operating temperature.
i03292691

SMCS Code: 1350-070; 1395-044
Clean the cooling system and ush the cooling system before the
recommended maintenance interval if the following conditions exist:
• The engine overheats frequently.

• Foaming is observed.
• The oil has entered the cooling system and the coolant is contaminated.
• The fuel has entered the cooling system and the coolant is
contaminated.
Note: When the cooling system is cleaned, only clean water is needed
when the ELC is drained and replaced.
Note: Inspect the water pump and the water temperature regulator after
the cooling system has been drained. This is a good opportunity to
replace the water pump, the water temperature regulator and the hoses, if
necessary.
142 SEBU7766-07
Maintenance Section
Drain

sure.
2. Open the cooling system drain valve (if equipped). If the cooling
system is not equipped with a drain valve, remove the cooling system
drain plugs.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the recycling of used coolant,
consult your Caterpillar dealer or consult Caterpillar Dealer Service Tool
Group:
Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
debris.
Note: If equipped, be sure to ush the heater and any related supply
and return lines.
SEBU7766-07 143
Maintenance Section
drain plugs. For the proper torque, refer to the Specications Manual,
SENR3130, “Torque Specications”.
NOTICE
3. Fill the cooling system with clean water. Install the cooling system
ller cap.
4. Start and run the engine at low idle until the temperature reaches
49 to 66 °C (120 to 150 °F).
cooling system ller cap. Open the drain valve (if equipped) or remove
the cooling system drain plugs. Allow the water to drain. Flush the
cooling system with clean water. Close the drain valve (if equipped).
Clean the drain plugs. Install the drain plugs. For the proper torque,
Fill
NOTICE
1. Fill the cooling system with Extended Life Coolant (ELC). See Special
Publication, SEBU6385, “Caterpillar On-highway Diesel Truck Engine
Fluids Recommendations” for more information on cooling system
specications. Do not install the cooling system ller cap.
2. Start and run the engine at low idle for 5 minutes. Then, increase the
engine rpm to high idle. Run the engine at high idle for one minute in
order to purge the air from the cavities of the engine block.
3. Check the coolant level. Maintain the coolant level within 13 mm

(0.5 inch) below the bottom of the pipe for lling. Maintain the coolant
level within 13 mm (0.5 inch) to the proper level on the sight glass (if
equipped).
144 SEBU7766-07
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
4. Clean the cooling system ller cap. Inspect the gasket that is on the
cooling system ller cap. If the gasket that is on the cooling system ller
cap is damaged, discard the old cooling system ller cap and install
a new cooling system ller cap. If the gasket that is on the cooling
system ller cap is not damaged, use a 9S-8140 Pressurizing Pump
in order to pressure test the cooling system ller cap. The correct
pressure for the cooling system ller cap is stamped on the face of the
cooling system ller cap. If the cooling system ller cap does not retain
the correct pressure, install a new cooling system ller cap.
5. Start the engine. Inspect the cooling system for leaks and for proper
operating temperature.
i02482066
Cooling System Coolant Extender (ELC) -

Add
SMCS Code: 1352-045; 1395-081
Cat ELC (Extended Life Coolant) does not require the frequent additions
of any supplemental cooling additives which are associated with the
present conventional coolants. The Cat ELC Extender only needs to be
added once.
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender
with Cat ELC.
Do NOT use conventional supplemental coolant addi-

tive (SCA) with Cat ELC. Mixing Cat ELC with conven-
tional coolants and/or conventional SCA reduces the
Cat ELC service life.
Check the cooling system only when the engine is stopped and cool.
SEBU7766-07 145
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.
NOTICE

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain uids on Caterpillar
products.

mandates.
1. Loosen the cooling system ller cap slowly in order to relieve pressure.
Remove the cooling system ller cap.
2. It may be necessary to drain enough coolant from the cooling system

in order to add the Cat ELC Extender.
146 SEBU7766-07
Maintenance Section
Cooling System Coolant Level - Check
3. Add Cat ELC Extender according to the requirements for your engine's
cooling system capacity. Refer to the Operation and Maintenance
Manual, “Rell Capacities and Recommendations” article for more
information.
4. Clean the cooling system ller cap. Inspect the gaskets on the cooling
system ller cap. Replace the cooling system ller cap if the gaskets
are damaged. Install the cooling system ller cap.
i01197583
Cooling System Coolant Level - Check

SMCS Code: 1395-082
Check the coolant level when the engine is stopped and cool.
g00285520
Illustration 27
Cooling system ller cap

sure.
1. Remove the cooling system ller cap slowly in order to relieve pressure.
SEBU7766-07 147
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
2. Maintain the coolant level within 13 mm (0.5 inch) of the bottom of the
ller pipe. If the engine is equipped with a sight glass, maintain the
coolant level to the proper level in the sight glass.
g00103639
Illustration 28
Typical ller cap gaskets
3. Clean the cooling system ller cap and check the condition of the ller
cap gaskets. Replace the cooling system ller cap if the ller cap
gaskets are damaged. Reinstall the cooling system ller cap.
4. Inspect the cooling system for leaks.
i02837191
Cooling System Coolant Sample (Level 1) -

Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
Note: Obtaining a Coolant Sample (Level 1) is optional if the cooling

system is lled with Cat ELC (Extended Life Coolant). Cooling
systems that are lled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended interval that is stated in
the Maintenance Interval Schedule.
Note: Obtain a Coolant Sample (Level 1) if the cooling system is

lled with any other coolant instead of Cat ELC. This includes the
following types of coolants:
148 SEBU7766-07
Maintenance Section
• Commercial long life coolants that meet the Caterpillar Engine Coolant
Specication -1 (Caterpillar EC-1)
• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze
Table 8
Recommended Interval
Type of Coolant Level 1 Level 2
Every 250
Cat DEAC Yearly(1)(2)
Hours(1)
Cat ELC Optional(2) Yearly(2)
(1) This is the recommended interval for coolant samples for all
conventional heavy-duty coolant/antifreeze. This is also the
recommended interval for coolant samples of commercial
coolants that meet the Cat EC-1 specication for engine
coolant.
(2) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identied.
NOTICE
Note: Level 1 results may indicate a need for Level 2 Analysis.
Obtain the sample of the coolant as close as possible to the recommended

sampling interval. In order to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order to establish a pertinent
history of data, perform consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from your Caterpillar
dealer.
Use the following guidelines for proper sampling of the coolant:
• Complete the information on the label for the sampling bottle before you
begin to take the samples.
SEBU7766-07 149
Maintenance Section
• Keep the unused sampling bottles stored in plastic bags.

• Obtain coolant samples directly from the coolant sample port. You
should not obtain the samples from any other location.
• Keep the lids on empty sampling bottles until you are ready to collect
the sample.
• Place the sample in the mailing tube immediately after obtaining the
sample in order to avoid contamination.
• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see this Operation

and Maintenance Manual, “Rell Capacities and Recommendations” or
consult your Caterpillar dealer.
150 SEBU7766-07
Maintenance Section
i01987714
Cooling System Coolant Sample (Level 2) -

Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Refer to Operation and Maintenance Manual, “Cooling System Coolant

Sample (Level 1) - Obtain” for the guidelines for proper sampling of the
coolant.
Submit the sample for Level 2 analysis.
For additional information about coolant analysis, see Special

Publication, SEBU6251, “Caterpillar Commercial Diesel Engines Fluids
Recommendations” or consult your Caterpillar dealer.
i02440893
Cooling System Supplemental Coolant

Additive (SCA) - Test/Add
SMCS Code: 1352-045; 1395-081
NOTICE
Cooling system coolant additive contains alkali. To
help prevent personal injury, avoid contact with the
skin and the eyes. Do not drink cooling system coolant
additive.
Note: Test the Supplemental Coolant Additive (SCA) or test the SCA
concentration as part of an S·O·S Coolant Analysis.
SEBU7766-07 151
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
Test the SCA Concentration

Coolant and SCA
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact with
the skin and the eyes. Do not drink cooling system
coolant additive.
Use the 8T-5296 Coolant Conditioner Test Kit or use the 4C-9301
Coolant Conditioner Test Kit in order to check the concentration of the
SCA. See Special Publication, SEBU6385, “Caterpillar On-highway Diesel
Truck Engine Fluids Recommendations” for more information.
S·O·S Coolant Analysis

S·O·S coolant samples can be analyzed at your Caterpillar dealer. S·O·S
Coolant Analysis is a program that is based on periodic samples.
Level I
Level I is a basic analysis of the coolant. The following items are tested:
• Glycol Concentration
• Concentration of SCA
• pH
• Conductivity
The results are reported, and recommendations are made according to
the results. Consult your Caterpillar dealer for information on the benets
of managing your equipment with an S·O·S Coolant Analysis.
152 SEBU7766-07
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
Add the SCA, If Necessary

NOTICE
Do not exceed the recommended amount of sup-
plemental coolant additive concentration. Excessive
supplemental coolant additive concentration can form
deposits on the higher temperature surfaces of the
cooling system, reducing the engine's heat transfer
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high temper-
ature components. Excessive supplemental coolant
additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated water
pump seal wear. Never use both liquid supplemental
coolant additive and the spin-on element (if equipped)
at the same time. The use of those additives together
could result in supplemental coolant additive concen-
tration exceeding the recommended maximum.

sure.
1. Slowly loosen the cooling system ller cap in order to relieve the
pressure. Remove the cooling system ller cap.
Note: Always discard drained uids according to local regulations.
2. If necessary, drain some coolant from the cooling system into a

suitable container in order to allow space for the extra SCA.
3. Add the proper amount of SCA. Refer to Operation and Maintenance

Manual, SEBU6385, “Caterpillar On-highway Diesel Truck Engines
Fluids Recommendations” for more information on SCA requirements.
4. Clean the cooling system ller cap. Inspect the gaskets of the cooling
system ller cap. If the gaskets are damaged, replace the old cooling
system ller cap with a new cooling system ller cap. Install the cooling
system ller cap.
SEBU7766-07 153
Maintenance Section
Cooling System Water Temperature Regulator - Replace
i03645060
Cooling System Water Temperature

Regulator - Replace
SMCS Code: 1355-510
Replace the water temperature regulator before the water temperature

regulator fails. This is a recommended preventive maintenance practice.
Replacing the water temperature regulator reduces the chances for
unscheduled downtime. Refer to this Operation and Maintenance Manual,
“Maintenance Interval Schedule” for the proper maintenance interval.
A water temperature regulator that fails in a partially opened position can

cause overheating or overcooling of the engine.
A water temperature regulator that fails in the closed position can cause
excessive overheating. Excessive overheating could result in cracking of
the cylinder head or piston seizure problems.
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

system and require operating the engine with a water
temperature regulator installed.
If the water temperature regulator is installed incor-

rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or

cylinder head surface.
154 SEBU7766-07
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Refer to two articles in the Disassembly and Assembly Manual, “Water

Temperature Regulators - Remove and Water Temperature Regulators -
Install” for the replacement procedure of the water temperature regulator,
or consult your Caterpillar dealer.
Note: If only the water temperature regulators are replaced, drain the
coolant from the cooling system to a level that is below the water
temperature regulator housing.
SEBU7766-07 155
Maintenance Section
Crankshaft Vibration Damper - Inspect
i02933380
Crankshaft Vibration Damper - Inspect

SMCS Code: 1205-040
Damage to the crankshaft vibration damper or failure of the crankshaft

vibration damper can increase torsional vibrations. This can result in
damage to the crankshaft and to other engine components. A damper
that is damaged can cause excessive gear train noise at variable points
in the speed range.
The damper is mounted to the crankshaft which is located behind the belt
guard on the front of the engine.
Visconic Damper
The visconic damper has a weight that is located inside a uid lled case.
The weight moves in the case in order to limit torsional vibration.
Inspect the damper for evidence of uid leaks. If a uid leak is found,
determine the type of uid. The uid in the damper is silicone. Silicone has
the following characteristics: transparent, viscous, smooth, and adhering.
If the uid leak is oil, inspect the crankshaft seals for leaks. If a leak is
observed, replace the crankshaft seals.
Inspect the damper and repair or replace the damper for any of the
following reasons:
• The damper is dented, cracked, or leaking.

• The paint on the damper is discolored from heat.
• The engine has had a failure because of a broken crankshaft.
• Analysis of the oil has revealed that the front main bearing is badly worn.
• There is a large amount of gear train wear that is not caused by a
lack of oil.
Refer to the Disassembly and Assembly Manual, “Vibration Damper

and Pulley - Remove and Install” or consult your Caterpillar dealer for
information about damper replacement.
156 SEBU7766-07
Maintenance Section
Cylinder Head Grounding Stud - Inspect/Clean/Tighten
i00856194
Cylinder Head Grounding Stud -

Inspect/Clean/Tighten
SMCS Code: 7423-040; 7423-070; 7423-079
g00427181
Illustration 29
Cylinder head grounding stud
Inspect the OEM harness for good connections and condition.
The cylinder head grounding stud must have a wire ground to the battery.
Tighten the cylinder head grounding stud at every oil change. Ground
wires and straps should be combined at engine grounds. All grounds
should be tight and free of corrosion.
• Clean the cylinder head grounding stud and the terminals for the
cylinder head ground strap with a clean cloth.
• If the connections are corroded, clean the connections with a solution

of baking soda and water.
• Keep the cylinder head grounding stud and the strap clean and coated
with MPGM grease or petroleum jelly.
SEBU7766-07 157
Maintenance Section
Engine - Clean
i01646701
Engine - Clean
SMCS Code: 1000-070
Personal injury or death can result from high volt-

age.
Moisture can create paths of electrical conductiv-

ity.
Make sure that the electrical system is OFF. Lock

out the starting controls and tag the controls “DO
NOT OPERATE”.
NOTICE
Accumulated grease and oil on an engine is a re haz-
ard. Keep the engine clean. Remove debris and uid
spills whenever a signicant quantity accumulates on
the engine.
Periodic cleaning of the engine is recommended. Steam cleaning the

engine will remove accumulated oil and grease. A clean engine provides
the following benets:
• Easy detection of uid leaks

• Maximum heat transfer characteristics
• Ease of maintenance
Note: Caution must be used in order to prevent electrical components
from being damaged by excessive water when you clean the engine.
Avoid electrical components such as the alternator, the starter, and the
ECM.
158 SEBU7766-07
Maintenance Section
Engine Air Cleaner Element - Clean/Replace
i00857000
Engine Air Cleaner Element -

Clean/Replace
SMCS Code: 1054-070; 1054-510
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
If the air cleaner element becomes plugged, the air can split the material
of the air cleaner element. Unltered air will drastically accelerate internal
engine wear.
• Operating conditions (dust, dirt and debris) may require more frequent
service of the air cleaner element.
• The air cleaner element should be replaced at least one time per year.
This replacement should be performed regardless of the number of
cleanings.
Replace the dirty paper air cleaner elements with clean air cleaner
elements. Before installation, the air cleaner elements should be
thoroughly checked for tears and/or holes in the lter material. Inspect
the gasket or the seal of the air cleaner element for damage. Maintain a
supply of suitable air cleaner elements for replacement purposes.
Your Caterpillar dealer has the proper air cleaner elements for your
application. Consult your Caterpillar dealer for the correct air cleaner
element or follow the instructions that are provided by the OEM.
i01900118
Engine Air Cleaner Service Indicator -

Inspect
(If Equipped)
SMCS Code: 7452-040
Some engines may be equipped with a different service indicator.

SEBU7766-07 159
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Some engines are equipped with a differential gauge for inlet air pressure.
The differential gauge for inlet air pressure displays the difference in
the pressure that is measured before the air cleaner element and the
pressure that is measured after the air cleaner element. As the air cleaner
element becomes dirty, the pressure differential rises. If your engine
is equipped with a different type of service indicator, follow the OEM
recommendations in order to service the air cleaner service indicator.
The service indicator may be mounted on the air cleaner housing or in a

remote location.
g00103777
Illustration 30
Typical service indicator
Observe the service indicator. The air cleaner element should be cleaned
or the air cleaner element should be replaced when one of the following
conditions occur:
• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.
Test the Service Indicator

Service indicators are important instruments.
• Check for ease of resetting. The service indicator should reset in less
than three pushes.
160 SEBU7766-07
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
• Check the movement of the yellow core when the engine is accelerated
to the engine rated speed. The yellow core should latch approximately
at the greatest vacuum that is attained.
If the service indicator does not reset easily, or if the yellow core does not
latch at the greatest vacuum, the service indicator should be replaced. If
the new service indicator will not reset, the hole for the service indicator
may be plugged.
The service indicator may need to be replaced frequently in environments

that are severely dusty, if necessary. Replace the service indicator
annually regardless of the operating conditions. Replace the service
indicator when the engine is overhauled, and whenever major engine
components are replaced.
Note: When a new service indicator is installed, excessive force may

crack the top of the service indicator. Tighten the service indicator to a
torque of 2 N·m (18 lb in).
SEBU7766-07 161
Maintenance Section
Engine Crankcase Breather - Clean
i02112507
Engine Crankcase Breather - Clean

SMCS Code: 1317-070
g01075811
Illustration 31
1. Remove bolt (2) and the washer. Remove the breather assembly (1)
and the seal.
2. Wash the breather element in solvent that is clean and nonammable.

Allow the breather element to dry before installation.
3. Install a breather element that is clean and dry. Install breather

assembly (1) and the seal.
4. Install bolt (2) and the washer. For the proper torque, refer to the
Specications Manual, RENR7571, “C7 On-highway Engine”.
162 SEBU7766-07
Maintenance Section
Engine Mounts - Inspect
i02139969
Engine Mounts - Inspect

SMCS Code: 1152-040
Inspect the engine mounts for deterioration and for proper bolt torque.
Engine vibration can be caused by the following conditions:
• Improper mounting of the engine

• Deterioration of the engine mounts
Any engine mount that shows deterioration should be replaced. Refer to
the Specications Manual, SENR3130, “Torque Specications”. Refer to
your Caterpillar dealer for more information.
i02113104
Engine Oil Level - Check

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

injury. Do not allow hot oil or hot components to
contact the skin.
SEBU7766-07 163
Maintenance Section
g01076429
Illustration 32
(1) Oil ller cap
(2) Oil level gauge
g00110310
Illustration 33
(Y) “ADD” mark
(X) “FULL” mark
NOTICE
Perform this maintenance with the engine stopped.
Note: Before you perform this maintenance, do not operate the engine for
at least 10 minutes in order to allow the engine oil to return to the oil pan.
1. Maintain the oil level between “ADD” mark (Y) and “FULL” mark (X) on
oil level gauge (1). Do not ll the crankcase above “FULL” mark (X).
164 SEBU7766-07
Maintenance Section
NOTICE
Engine damage can occur if the crankcase is lled
above the “FULL” mark on the oil level gauge (dip-
stick).
An overfull crankcase can enable the crankshaft to

dip into the oil. This will reduce the power that is de-
veloped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil's ability to lubricate, reduction of oil
pressure, inadequate cooling of the pistons, oil blow-
ing out of the crankcase breathers, and excessive oil
consumption.
Excessive oil consumption will enable deposits to form

on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately.
2. Remove oil ller cap (2) and add oil, if necessary. For the correct oil to
use, refer to Special Publication, SEBU6251, “Caterpillar Commercial
Diesel Engine Fluids Recommendations”. Do not ll the crankcase
above “FULL” mark (X) on the oil level gauge. Clean the oil ller cap.
Install the oil ller cap.
3. Record the amount of oil that is added. For the next oil sample and
analysis, include the total amount of oil that has been added since
the previous sample. This will help to provide the most accurate oil
analysis.
SEBU7766-07 165
Maintenance Section
Engine Oil Level Gauge - Calibrate
i03916858

SMCS Code: 1326-524
Check Calibration at the First Oil Change

The engine oil level will vary depending on the angle and the slant of
the engine installation. The angle is the front to back tilt. The slant is
the sideways tilt.
The oil level gauge markings must be veried in order to ensure that
the markings are correct. Verify the oil level gauge markings at the rst
oil change.
Verify the “ADD” mark and verify the “FULL” mark that is on the oil level
gauge. Use the following procedure.
NOTICE
The vehicle must be parked on a level surface in order
to perform this maintenance procedure.
NOTICE


mandates.
1. Operate the engine until normal operating temperature is achieved.

Stop the engine. Remove the crankcase oil drain plugs. The oil drain
plug from the deep portion of the oil pan should be removed. Drain the
oil from the crankcase for 20 minutes.
166 SEBU7766-07
Maintenance Section
2. Remove the used oil lter(s). Install the new oil lter(s). Install the oil
drain plugs and tighten to 70 ± 15 N·m (50 ± 11 lb ft).
Note: Your engine may be equipped with auxiliary oil lters. The auxiliary
oil lters require a different volume of oil. Refer to the OEM specications
for the auxiliary oil lter.
3. Refer to this Operation and Maintenance Manual, “Rell Capacities

and Recommendations” for information about choosing the correct
oil for your engine.
Table 9
Quantity of Oil Shallow Sump Standard (Deep)

Sump
A 13.2 L (14 qt) 20.8 L (22 qt)
B 2.8 L (3 qt) 2.8 L (3 qt)
C 1.9 L (2 qt) 1.9 L (2 qt)
D
Total Capacity of
the Lubrication
System for
Engine Oil
4. Refer to the table that is correct for your engine and oil pan below.
Pour quantity “A” of engine oil into the crankcase.
5. Allow enough time for the oil to drain into the crankcase. Approximately
20 minutes should be allowed. Check the oil level. Wait for several
minutes and check the oil level again. Proceed after the oil level stops
changing.
6. Check the oil level on the oil level gauge. The oil level should be at the
“ADD” mark. If the oil level is not at the existing “ADD” mark, grind off
the “ADD” mark and engrave the new “ADD” level. Use an engraving
pen in order to engrave the new “ADD” mark.
7. Pour quantity “B” of oil into the crankcase. Allow enough time for the
oil to drain into the crankcase.
8. Check the oil level on the oil level gauge. The oil level should be at the
“FULL” mark. If the oil level is not at the existing “FULL” mark, grind
off the “FULL” mark. Use an engraving pen in order to engrave the
new “FULL” mark.
SEBU7766-07 167
Maintenance Section
Engine Oil Sample - Obtain
9. Pour quantity “C” of oil into the crankcase in order to allow oil to ll
the oil lter.
NOTICE
Do not crank the engine for more than 30 seconds.
Allow the starting motor to cool for two minutes before
cranking again.
10. Start the engine and run the engine enough to ensure that the
lubrication system is lled. Inspect the engine for oil leaks.
11. Stop the engine and allow enough time for the oil to drain into the
crankcase.
12. Check the oil level on the oil level gauge. If the oil level is not at the
calibrated “FULL” mark, ll the crankcase to the calibrated “FULL”
mark. Record the amount of oil that was added as quantity D. Record
the oil capacity of the lubrication system for future oil changes.
i03542996

SMCS Code: 1000-008; 1348-554-SM; 7542-554-OC, SM
In addition to a good preventive maintenance program, Caterpillar

recommends using S·O·S oil 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 analysis provides infrared analysis,
which is required for determining nitration and oxidation levels.
Obtain the Sample and the Analysis

contact the skin.
Before you take the oil sample, complete the Label, PEEP5031 for
identication of the sample. In order to help obtain the most accurate
analysis, provide the following information:
168 SEBU7766-07
Maintenance Section
• Engine model
• Service hours on the engine
• The number of hours that have accumulated since the last oil change
• The amount of oil that has been added since the last oil change
To ensure that the sample is representative of the oil in the crankcase,
obtain a warm, well mixed oil sample.
To avoid contamination of the oil samples, the tools and the supplies that
are used for obtaining oil samples must be clean.
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 owing under pressure to be obtained during normal engine
operation.
The 169-8373 Fluid Sampling Bottle is recommended for use with the
sampling valve. The uid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are also provided.
NOTICE
If the engine is not equipped with a sampling valve, use the 1U-5718
Vacuum Pump. The pump is designed to accept sampling bottles.
Disposable tubing must be attached to the pump for insertion into the
sump.
For instructions, see Special Publication, PEgj0047, “How To Take A

Good S·O·S Oil Sample”. Consult your Caterpillar dealer for complete
information and assistance in establishing an S·O·S program for your
engine.
SEBU7766-07 169
Maintenance Section
Engine Oil and Filter - Change
i01947041

SMCS Code: 1318-510; 1348-044

contact the skin.
NOTICE
The vehicle must be parked on a level surface for this
maintenance procedure.
Do not drain the oil when the engine is cold. As the oil cools, suspended
waste particles settle on the bottom of the oil pan. The waste particles
are not removed with the draining cold oil. Drain the crankcase with the
engine stopped. Drain the crankcase while the oil is warm. This draining
method will allow the waste particles that are suspended in the oil to be
properly drained.
Failure to follow this recommended procedure will cause the waste

particles to be recirculated through the engine lubrication system with
the new oil.
Drain the Engine Oil

After the engine has been run at the normal operating temperature, stop
the engine. Attach a “DO NOT OPERATE” or a similar warning tag to the
ignition key switch before the engine is serviced. Catch the oil in a suitable
container. Recycle the used oil, or dispose of the used oil properly.
1. Remove the oil drain plug in order to allow the oil to drain.
2. After the oil has drained, the oil drain plug should be cleaned and
installed.
Tighten the oil drain plug to the following torque: .............. 70 ± 15 N·m
(50 ± 11 lb ft)
170 SEBU7766-07
Maintenance Section
Replace the Oil Filter

NOTICE
Caterpillar oil lters are built to Caterpillar speci-
cations. Use of an oil lter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unltered oil entering
the engine lubricating system. Only use oil lters
recommended by Caterpillar.
1. Remove the oil lter with a 185-3630 Chain Wrench.
g00588944
Illustration 34
Element with debris
2. Cut the oil lter open with a 175-7546 Oil Filter Cutter. Break apart the
pleats and inspect the oil lter for metal debris. An excessive amount of
metal debris in the oil lter 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 lter 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.
SEBU7766-07 171
Maintenance Section
Due to normal wear and friction, it is not uncommon to nd small

amounts of debris in the oil lter. Consult your Caterpillar dealer in
order to arrange for a further analysis if an excessive amount of debris
is found in the oil lter.
g00103713
Illustration 35
Typical lter mounting base and lter gasket
3. Clean the sealing surface of the lter mounting base. Ensure that all of
the old oil lter gasket is removed.
4. Apply clean engine oil to the new oil lter gasket.
NOTICE
Do not ll the oil lters with oil before installing them.
This oil would not be ltered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to
engine components.
5. Install the oil lter. Tighten the oil lter until the oil lter gasket contacts
the base. Tighten the oil lter by hand according to the instructions that
are shown on the oil lter. Do not overtighten the oil lter.
Fill the Engine Crankcase

1. Remove the oil ller cap. Refer to the Operation and Maintenance
Manual, “Rell Capacities and Recommendations” topic (Maintenance
Section) for more information. Fill the crankcase with the proper
amount of oil.
172 SEBU7766-07
Maintenance Section
NOTICE
If equipped with an auxiliary oil lter or system, extra
oil must be added when lling the crankcase. Follow
the OEM or lter manufacturer's recommendations. If
the extra oil is not added, the engine may starve for
oil.
NOTICE
To help prevent crankshaft or bearing damage, crank
engine to ll all lters before starting. Do not crank
engine for more than 30 seconds.
2. Start the engine and run the engine at “LOW IDLE” for two minutes.
Perform this procedure in order to ensure that the lubrication system
has oil and that the oil lters are lled. Inspect the oil lter for oil leaks.
3. Stop the engine and allow the oil to drain back to the sump for a
minimum of ten minutes.
4. Remove the oil level gauge in order to check the oil level. Maintain
the oil level between the “ADD” and “FULL” marks on the “ENGINE
STOPPED” side of the oil level gauge.
Oil Change Interval Adjustments

There are many circumstances under certain conditions that may allow an
adjustment to the normal oil change interval. Many conditions that can
affect the selection of the best oil change interval exist. The decision is
based on the fundamental requirement that lubrication oil should be in
an acceptable condition that provides continuous engine protection. The
quality of the oil and amount of the oil that is available is balanced against
the oil's ability to absorb by-products that are caused by combustion.
Due to the manufacturing tolerances, the engine application, and the

maintenance variations, all engines do not consume fuel and oil at the
same rate. The amount of fuel that is consumed is in direct relation to the
maximum oil change interval that is selected. It is essential to include
an S·O·S oil analysis before an adjustment of the oil change interval is
considered. For more information on extending oil change intervals,
contact your local Caterpillar dealer. S·O·S oil analysis should be used to
verify the oil change interval adjustments. Table 10 can be used in order
to determine the oil change interval adjustments.
SEBU7766-07 173
Maintenance Section
S·O·S oil analysis should be used to verify the oil change interval
adjustments. Table 10 can be used in order to determine your oil change
interval adjustments.
Table for the Oil Change Interval Adjustments

Note: Metric units are listed before English units.
Note: Use of table 10 assumes the use of a recommended oil type.
Table 10
Permissible Oil Change Interval
Oil Vehicle Applications
Capacity
of the Light Medium Heavy Severe
Engine Duty(1) Duty(2) Duty(3) Service(4)
in Liters KM (Miles) to Next Oil Change
(quarts)
18 (20) 19,320 16,000 12,890 9,670
(12,000) (10,000) (8,000) (6,000)
21 (22)(5) 21,260 17,710 14,170 10,960
(13,200) (11,000) (8,800) (6,800)(6)
23 (24) 23,190 19,320 15,460 12,230
(14,400) (12,000) (9,600) (7,600)
25 (26) 25,110 20,930 16,750 13,530
(15,600) (13,000) (10,400) (8,400)
27 (28) 27,040 22,540 18,040 14,810
(16,800) (14,000) (11,200) (9,200)
28 (30)(7) 28,980 24,000 19,320 16,100
(18,000) (15,000) (12,000) (10,000)(6)
30 (32) 30,900 25,760 20,510 17,380
(19,200) (16,000) (12,800) (10,800)
32 (34) 32,850 27,370 21,900 18,670
(20,400) (17,000) (13,600) (11,600)
34 (36) 34,770 28,980 23,190 19,970
(21,600) (18,000) (14,400) (12,400)
36 (38) 36,700 30,590 24,470 21,260
(22,800) (19,000) (15,200) (13,200)
(continued)
174 SEBU7766-07
Maintenance Section
(Table 10, contd)
38 (40) 38,640 32,200 25,760 22,540

(24,000) (20,000) (16,000) (14,000)
40 (42) 40,580 33,810 27,050 23,830
(25,200) (21,000) (16,800) (14,800)
(1) Typical applications are Recreational Vehicles and intercity
delivery (average that is greater than 10 mpg).
(2) Typical applications are intracity driving (average 8 to 10 mpg).
(3) Typical applications are bus services and pickup and/or
delivery services (less than 8 mpg).
(4) Less than 6 mpg refer to the Operation and Maintenance
Manual, “Severe Service Application - Check” for the
requirements.
(5) The capacity of the shallow oil sump is 21 L (22 qt).
(6) It is important to understand the operation of your vehicle.
Use the fuel consumption, service hours, or calendar time,
whichever occurs rst, in order to determine the maintenance
intervals. Engines which operate in severe operating conditions
may require more frequent maintenance.
(7) The capacity of the deep oil sump is 28 L (30 qt).
There are many applications of medium duty truck engines. It is important

to understand the operation of your vehicle. Use the fuel consumption,
service hours, or calendar time, whichever occurs rst, in order to
determine the maintenance intervals. Engines which operate in severe
operating conditions may require more frequent maintenance.
Instructions for the Table

1. Determine your type of vehicle application. Locate the column which
lists your type of vehicle application.
2. Determine your available oil in liters or quarts. The oil quantity equals
the sum of the capacities of the oil sump and the oil lter. Locate the
row which lists your available oil.
3. The intersection of the column and the row lists the maximum
permissible number of kilometers or miles between oil change intervals.
SEBU7766-07 175
Maintenance Section
Example
You determined that the vehicle application is light duty commercial. The
oil capacity of the engine is 21 L (22 qt) and the oil capacity of the auxiliary
oil lter is 10 L (10 qt). With S·O·S Oil Analysis verication, the maximum
permissible oil change interval is 30900 kilometers (19200 miles).
For more information on optimizing oil change intervals, see your

Caterpillar dealer.
176 SEBU7766-07
Maintenance Section
Engine Storage Procedure - Check
i01458399
Engine Storage Procedure - Check

SMCS Code: 1000-535
The oil change interval may be extended to 12 months for a vehicle that
is operated seasonally and placed in storage for the remainder of the
year by using the required storage procedures and the required start-up
procedures. This extension is permitted if the following categories for oil
change intervals in the Operation and Maintenance Manual, “Maintenance
Interval Schedule” have not been reached:
• Mileage
• Operating hours
• Fuel consumption
If an engine is out of operation and if use of the engine is not planned,
special precautions should be made. If the engine will be stored for more
than three months, a complete protection procedure is recommended.
For more detailed information on engine storage, see Special Instruction,
SEHS9031, “Storage Procedure For Caterpillar Products”.
If the engine will not be started for several weeks, the lubricating oil will
drain from the cylinder walls and from the piston rings. Rust can form on
the cylinder liner surface. Rust on the cylinder liner surface will cause
increased engine wear and a reduction in engine service life. Caterpillar
recommends the use of volatile corrosion inhibitor (VCI) oil in order to
prevent internal engine damage due to moisture during storage. These
inhibitors in the VCI oil act by evaporating inside the engine. The inhibitors
then condense over the inside surfaces of the engine. The evaporation
process and the condensing process offers full protection to surfaces
that cannot be reached with preservatives. 0.9 L (1.0 qt) of 4C-6792
VCI oil will treat 28.4 L (30.0 qt) of engine oil. This will give a 3 percent
concentration of VCI oil. The engine must be completely sealed when
the engine is stored in order for the VCI oil to function properly. The VCI
oil is easily cleaned from the engine when you remove the engine from
storage. The volatile vapors are removed by simply running the engine to
operating temperature. A mineral oil base is left behind after the volatile
vapors are removed.
SEBU7766-07 177
Maintenance Section
Engine Valve Lash - Inspect/Adjust
i03840829
Engine Valve Lash - Inspect/Adjust

SMCS Code: 1102-025
The initial valve lash adjustment on new engines, rebuilt engines, or

remanufactured engines is recommended at the rst scheduled oil
change. The adjustment is necessary due to the initial wear of the valve
train components and to the seating of the valve train components.
This maintenance is recommended by Caterpillar as part of a lubrication

and preventive maintenance schedule in order to help provide maximum
engine life.
NOTICE
Only qualied service personnel should perform this
maintenance. Refer to the Systems Operation/Testing
and Adjusting Manual, “Valve Lash and Valve Bridge
Adjustment” article or consult your Caterpillar dealer
for the complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve

adjustments can reduce engine efciency. This re-
duced efciency could result in excessive fuel usage
and/or shortened engine component life.
Ensure that the engine cannot be started while this

maintenance is being performed. To help prevent
possible injury, do not use the starting motor to
turn the ywheel.
Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.
Ensure that the engine is stopped before measuring the valve lash. To
obtain an accurate measurement, allow the valves to cool before this
maintenance is performed.
Refer to the Service Manual for more information.

178 SEBU7766-07
Maintenance Section
Fan Drive Bearing - Lubricate
i01771215
Fan Drive Bearing - Lubricate

SMCS Code: 1359-086-BD
g00746166
Illustration 36
Typical location of the grease tting that is for the fan drive bearing
The belt guards have been removed in this illustration.
Note: In some applications, the fan drives are supplied by the OEM. Refer
to the OEM specications if the fan drive is not supplied by Caterpillar.
Lubricate the grease tting that is on the fan drive bearing with Bearing
Lubricant or the equivalent.
Inspect the fan drive pulley assembly for wear or for damage. If the shaft
is loose, an inspection of the internal components should be performed.
Refer to the Service Manual for additional information.
SEBU7766-07 179
Maintenance Section
Fuel System - Prime
i02113137
Fuel System - Prime

SMCS Code: 1258-548
Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a re. To help pre-
vent possible injury, turn the start switch off when
changing fuel lters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
Prime the fuel system in order to ll the fuel lter. Prime the fuel system in
order to purge trapped air. The fuel system should be primed under the
following conditions:
• Running out of fuel

• Storage
• Replacement of the fuel lter
Engines that are Equipped with a Fuel Priming

Pump
NOTICE
Do not loosen the fuel lines at the fuel manifold. The
ttings may be damaged and/or a loss of priming pres-
sure may occur when the fuel lines are loosened.
1. Open the fuel priming pump and operate the fuel priming pump until
a strong pressure is felt. This procedure will require considerable
strokes. Lock the fuel priming pump.
180 SEBU7766-07
Maintenance Section
Fuel System - Prime
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
2. Promptly start the engine. If the engine runs rough, continue to operate
the engine at low idle. Do not raise the engine rpm above an idle, until
the engine operates smoothly.
3. If the engine does not start, open the fuel priming pump and repeat
Steps 1 and 2 in order to start the engine.
Engines that are Not Equipped with a Fuel

Priming Pump
If the engine is not equipped with a fuel priming pump, you can use the
following procedures to prime the fuel system. These procedures will
allow only ltered fuel to enter the fuel system.
Fuel Filter Bases that are Equipped with a Plug
NOTICE
SEBU7766-07 181
Maintenance Section
Fuel System - Prime
g01076450
Illustration 37
(1) Plug
(2) Fuel lter
1. Remove plug (1) in order to ll fuel lter (2). Ensure that air is able to
vent from the tting of the plug while the fuel lter is being lled. Clean
up any spilled fuel immediately. Clean plug (1). Install plug (1).
NOTICE
2. Start the engine and operate the engine at low idle. Do not raise the
engine speed above an idle, until the engine operates smoothly.
Fuel Filter Bases that are Not Equipped with a Plug
NOTICE
1. Operate the starting motor. This will ll the fuel lter and the fuel lines
with fuel.
2. Once the engine starts, operate the engine at low idle. Do not raise the
engine speed above an idle, until the engine operates smoothly.
182 SEBU7766-07
Maintenance Section
Fuel System Primary Filter - Clean/Replace
i00861167
Fuel System Primary Filter - Clean/Replace

SMCS Code: 1260-070; 1260-510

NOTICE
For more information on the maintenance of the primary fuel lter, refer to
the literature that is provided by the OEM of the vehicle, or refer to the
literature that is provided by the OEM of the primary fuel lter.
i02112513
Fuel System Water Separator - Drain

SMCS Code: 1263-543

SEBU7766-07 183
Maintenance Section
Fuel System Water Separator - Drain
NOTICE
The water separator is not a lter. It separates water
from the fuel.
The engine should never be allowed to run with the

water level in the separator more than 1/2 full or en-
gine damage may result.
A water separator is recommended. The water separator should be

installed between the fuel tank and the engine fuel inlet. Drain the water
and sediment from the water separator on a daily basis.
g01076474
Illustration 38
(1) Drain
1. Open drain (1). Catch the draining water in a suitable container.

Dispose of the water properly.
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.
2. Close drain (1).

184 SEBU7766-07
Maintenance Section
Fuel Tank Water and Sediment - Drain
i03645042
Fuel Tank Water and Sediment - Drain

SMCS Code: 1273-543-M&S
NOTICE


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. Condensation occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the fuel system and the
fuel returns to the fuel tank. This causes water to accumulate in fuel tanks.
Draining the fuel tank regularly and obtaining fuel from reliable sources
can help to eliminate water in the fuel.
Drain the Water and the Sediment

Fuel tanks should contain some provision for draining water and draining
sediment from the bottom of the fuel tanks.
Open the drain valve on the bottom of the fuel tank in order to drain the
water and the sediment. Close the drain valve.
Note: Failure to properly close the drain can allow air into the system,
which could have detrimental results to performance.
SEBU7766-07 185
Maintenance Section
Hoses and Clamps - Inspect/Replace
Check the fuel daily. Drain the water and sediment from the fuel tank
after operating the engine or drain the water and sediment from the fuel
tank after the fuel tank has been lled. Allow ve to ten minutes before
performing this procedure.
Fill the fuel tank after operating the engine in order to drive out moist air.
This will help prevent condensation. Do not ll the tank to the top. The fuel
expands as the fuel gets warm. The tank may overow.
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 lter is important.
Fuel Storage Tanks

Drain the water and the sediment from the fuel storage tank during the
following conditions:
• Weekly
• Oil change
• Rell of the tank
This will help prevent water or sediment from being pumped from the
storage tank into the engine fuel tank. A four micron(c) absolute lter for
the breather vent on the fuel tank is also recommended. Refer to Special
Publication, SENR9620, “Improving Fuel System Durablity”.
If a bulk storage tank has been relled or moved recently, allow adequate
time for the sediment to settle before lling the engine fuel tank. Internal
bafes in the bulk storage tank will also help trap sediment. Filtering fuel
that is pumped from the storage tank helps to ensure the quality of the
fuel. When possible, water separators should be used.
i03847809

SMCS Code: 7554-040; 7554-510
Hoses and clamps must be inspected periodically in order to ensure safe

operation and continuous operation of the engine. Take proper safety
precautions before inspecting or replacing hoses and clamps.
186 SEBU7766-07
Maintenance Section
Note: Always use a board or cardboard when the engine components

are checked for leaks. Leaking uid that is under pressure can cause
serious injury or possible death. This includes leaks that are the size of a
pin hole. Refer to Operation and Maintenance Manual, “General Hazard
Information” for more information.
Inspect the Hoses and the Clamps

Inspect all hoses for leaks that are caused by the following conditions.
Replace any hose which exhibits any of the following conditions. Failure
to replace a hose which exhibits any of the following conditions may result
in a hazardous situation.
• Hoses which are cracked

• Hoses which are soft
• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
• Hoses which exhibit signs of leakage which are not the result of loose
couplings or clamps
Inspect all clamps for the following conditions. Replace any clamp which
exhibits signs of any of the following conditions.
• Cracking
• Looseness
• Damage
Inspect all couplings for leaks. Replace any coupling which exhibits signs
of leaks.
Each installation application can be different. The differences depend on

the following factors:
SEBU7766-07 187
Maintenance Section
• Type of hose
• Type of tting material
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the ttings
Due to extreme temperature changes, the hose will heat set. Heat setting
causes hose clamps to loosen. This can result in leaks. A constant torque
hose clamp will help to prevent loose hose clamps.
Replace hoses that are cracked or soft. Replace hoses that show signs
of leakage. Replace hoses that show signs of damage. Replace hose
clamps that are cracked or damaged. Tighten or replace hose clamps
which are loose.
Replace the Hoses and the Clamps

NOTICE


mandates.
188 SEBU7766-07
Maintenance Section
Cooling System

sure.
Personal injury can result from removing hoses or

ttings in a pressure system.
Failure to relieve pressure can cause personal in-

jury.
Do not disconnect or remove hoses or ttings un-

til all pressure in the system has been relieved.
1. Stop the engine.
2. Allow the engine to cool.
3. Before servicing a coolant hose, slowly loosen the ller cap for the
cooling system in order to relieve any pressure.
4. Remove the ller cap for the cooling system.
5. Drain the coolant from the cooling system to a level that is below the
hose that is being replaced. Drain the coolant into a suitable clean
container. The coolant can be reused.
6. Remove the hose clamps.
7. Disconnect the old hose.
8. Replace the old hose with a new hose.

SEBU7766-07 189
Maintenance Section
9. Install hose clamps which have been inspected or install new hose
clamps. Refer to Specications, SENR3130, “Torque Specications”,
“Hose Clamps” for information about selecting and installing the proper
hose clamps.
10. Rell the cooling system.
11. Clean the ller cap for the cooling system. Inspect the gaskets on the
ller cap. Replace the ller cap if the gaskets are damaged. Install
the ller cap.
12. Start the engine. Inspect the cooling system for leaks.
Fuel System
Personal injury can result from removing hoses or

ttings in a pressure system.
Failure to relieve pressure can cause personal in-

jury.
Do not disconnect or remove hoses or ttings un-

til all pressure in the system has been relieved.
Contact with high pressure fuel may cause uid

penetration and burn hazards. High pressure fu-
el spray may cause a re hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause res. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
ommended torque.
190 SEBU7766-07
Maintenance Section
NOTICE
Note: High pressure fuel lines may be installed between the high pressure
fuel pump and the fuel injectors. High pressure fuel lines are constantly
charged with high pressure. Do not check the high pressure fuel lines with
the engine or the starting motor in operation. Wait for 10 minutes after the
engine stops before you perform any service or repair on high pressure
fuel lines in order to allow pressure to be purged.
1. Drain the fuel from the fuel system to a level that is below the hose
that is being replaced.
hose clamps.
6. Carefully inspect the engine for any spilled fuel. Make sure that no fuel
remains on or close to the engine.
Note: Fuel must be added to the fuel system ahead of the fuel lter.
7. Rell the fuel system. Refer to this Operation and Maintenance

Manual, “Fuel System - Prime” for information about priming the
engine with fuel.
8. Start the engine. Inspect the fuel system for leaks.

SEBU7766-07 191
Maintenance Section
Lubrication System

contact the skin.
1. Drain the oil from the lubrication system to a level that is below the
hose that is being replaced.
hose clamps.
6. Rell the lubrication system. Refer to this Operation and Maintenance

Manual, “Engine Oil Level - Check” in order to ensure that the
lubrication system is lled with the proper amount of engine oil.
7. Start the engine. Inspect the lubrication system for leaks.
Air System
hose clamps.
5. Start the engine. Inspect the air lines for leaks.

192 SEBU7766-07
Maintenance Section
Overhaul Considerations
i02394984
Overhaul Considerations
SMCS Code: 7595-043
Refer to the Operation and Maintenance Manual, “Maintenance Interval

Schedule” topic (Maintenance Section) for the proper intervals in order to
perform an overhaul of the engine.
Several factors are important when an overhaul of the engine is

considered. The following factors are included:
• The performance of preventive maintenance

• The ratio of oil consumption to fuel consumption
• Fuel consumption
• The quality of the fuel that has been consumed
• The mileage of the vehicle
• The operating conditions of the vehicle
• The results of the S·O·S oil analysis
• The loss of engine power
An overhaul is a regular maintenance interval when the engine is
inspected and worn components are replaced with rebuilt parts or new
parts.
A top end overhaul is generally indicated by increased fuel consumption

and reduced power. This interval consists of completely reconditioning
the cylinder head. Normally, it is not necessary to repair the cylinder
components at this time.
A major overhaul is an interval when the items that have major wear in
the engine should be replaced. Items that can have major wear include
the following items: piston rings, main bearings, rods, and valves.
SEBU7766-07 193
Maintenance Section
Radiator - Clean
Overhaul Options
Caterpillar Dealer – Consult your Caterpillar dealer in order to schedule
a before failure overhaul.
i02559063
Radiator - Clean
SMCS Code: 1353-070
Note: Adjust the frequency of cleaning according to the effects of the

operating environment.
Inspect the radiator for these items: damaged ns, corrosion, dirt, grease,
insects, leaves, oil, and other debris. Clean the radiator, if necessary.
Personal injury can result from air pressure.
Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
The maximum air pressure for cleaning purposes

must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
Pressurized air is the preferred method for removing loose debris. Direct
the air in the opposite direction of the fan's air ow. Hold the nozzle
approximately 6 mm (0.25 inch) away from the ns. Slowly move the
air nozzle in a direction that is parallel with the tubes. This will remove
debris that is between the tubes.
Pressurized water may also be used for cleaning. The maximum water
pressure for cleaning purposes must be less than 275 kPa (40 psi). Use
pressurized water in order to soften mud. Clean the core from both sides.
Use a degreaser and steam for removal of oil and grease. Clean both
sides of the core. Wash the core with detergent and hot water. Thoroughly
rinse the core with clean water.
194 SEBU7766-07
Maintenance Section
Severe Service Application - Check
After cleaning, start the engine and accelerate the engine to high idle
rpm. This will help in the removal of debris and drying of the core. Stop
the engine. Use a light bulb behind the core in order to inspect the core
for cleanliness. Repeat the cleaning, if necessary.
Inspect the ns for damage. Bent ns may be opened with a “comb”.
Inspect these items for good condition: welds, mounting brackets, air
lines, connections, clamps, and seals. Make repairs, if necessary.
For more detailed information on cleaning and inspection, refer to Special

Publication, SEBD0518, “Know Your Cooling System”.
i02385785
Severe Service Application - Check

SMCS Code: 1000-535
Operation and maintenance practices affect the service life of the

component when the engine is operated in certain applications that
require severe service.
The level of maintenance is crucial to the service life of the engine. Other
major factors that affect service life are operating speed and loads.
Reduce the maintenance intervals for engines that operate under

conditions that are severe.
• Frequent operation with more than 22700 kg (50000 lb) of gross vehicle
weight
• Frequent low speed operation (less than 20 Miles per Hour)

• Use of API CF-4 oil
• Use of fuel with more than 0.05% sulfur
• No water separator
• Frequent operation in dusty conditions or off-highway operation
• High load factor operation (less than 6 miles per gallon or off-highway
operation)
• Frequent high altitude operation above 1525 m (5000 ft)

SEBU7766-07 195
Maintenance Section
Starting Motor - Inspect
• Frequent operation at low idle (more than 20%)

• Frequent cold starts at temperatures below 18 °C (0 °F)
• Frequent dry starting (starting after more than 3 days of shutdown)
• Frequent hot shutdowns (minimum three minute cool down periods
after high load factor operation)
• If the engine is stored over 3 months, see Special Instruction,

SEHS9031, “Storage Procedure for Caterpillar Products”.
i00651416
Starting Motor - Inspect

SMCS Code: 1451-040; 1453-040
Caterpillar Inc. recommends a scheduled inspection of the starting motor.

If the starting motor fails, the engine may not start in an emergency
situation.
Check the starting motor for proper operation. Check the electrical
connections and clean the electrical connections. Refer to the Service
Manual for more information on the checking procedure and for
specications or consult your Caterpillar dealer for assistance.
i01539769
Turbocharger - Inspect
SMCS Code: 1052-040; 1052
Periodic inspection and cleaning is recommended for the turbocharger

compressor housing (inlet side). Any fumes from the crankcase are
ltered through the air inlet system. Therefore, by-products from oil and
from combustion can collect in the turbocharger compressor housing.
Over time, this buildup can contribute to loss of engine power, increased
black smoke and overall loss of engine efciency.
If the turbocharger fails during engine operation, damage to the

turbocharger compressor wheel and/or to the engine may occur. Damage
to the turbocharger compressor wheel can cause additional damage to
the pistons, the valves, and the cylinder head.
196 SEBU7766-07
Maintenance Section
NOTICE
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
Minor leakage of a turbocharger housing under ex-

tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc-
curred.
When a turbocharger bearing failure is accompanied

by a signicant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize unscheduled downtime.

An inspection of the turbocharger can also reduce the chance for potential
damage to other engine parts.
Note: Turbocharger components require precision clearances. The

turbocharger cartridge must be balanced due to high rpm. Severe
Service Applications can accelerate component wear. Severe Service
Applications require more frequent inspections of the cartridge.
Removal and Installation

For options regarding the removal, installation, repair and replacement,
consult your Caterpillar dealer. Refer to the Service Manual for this engine
for the procedure and specications.
Cleaning and Inspecting

1. Remove the exhaust outlet piping and remove the air inlet piping from
the turbocharger. Visually inspect the piping for the presence of oil.
Clean the interior of the pipes in order to prevent dirt from entering
during reassembly.
SEBU7766-07 197
Maintenance Section
2. Turn the compressor wheel and the turbine wheel by hand. The
assembly should turn freely. Inspect the compressor wheel and
the turbine wheel for contact with the turbocharger housing. There
should not be any visible signs of contact between the turbine wheel
or compressor wheel and the turbocharger housing. If there is any
indication of contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing, the turbocharger
must be reconditioned.
3. Check the compressor wheel for cleanliness. If only the blade side
of the wheel is dirty, dirt and/or moisture is passing through the air
ltering system. If oil is found only on the back side of the wheel, there
is a possibility of a failed turbocharger oil seal.
The presence of oil may be the result of extended engine operation

at low idle. The presence of oil may also be the result of a restriction
of the line for the inlet air (plugged air lters), which causes the
turbocharger to slobber.
4. Use a dial indicator to check the end clearance on the shaft. If the
measured end play is greater than the Service Manual specications,
the turbocharger should be repaired or replaced. An end play
measurement that is less than the minimum Service Manual
specications could indicate carbon buildup on the turbine wheel. The
turbocharger should be disassembled for cleaning and for inspection
if the measured end play is less than the minimum Service Manual
specications.
5. Inspect the bore of the turbine housing for corrosion.
6. Clean the turbocharger housing with standard shop solvents and a

soft bristle brush.
7. Fasten the air inlet piping and the exhaust outlet piping to the
turbocharger housing.
198 SEBU7766-07
Maintenance Section
Walk-Around Inspection
i01185304
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 leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
• The guards must be in the proper place. Repair damaged guards or

replace missing guards.
• Wipe all caps and plugs before the engine is serviced in order to reduce
the chance of system contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
uid. If leaking is observed, nd the source and correct
the leak. If leaking is suspected, check the uid levels
more often than recommended until the leak is found
or xed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a re hazard. Remove this debris with steam cleaning
or high pressure water.
• Ensure that the cooling lines are properly clamped and that the cooling
lines are tight. Check for leaks. Check the condition of all pipes.
• Inspect the water pumps for coolant leaks.

SEBU7766-07 199
Maintenance Section
Note: The water pump seal is lubricated by coolant in the cooling system.
It is normal for a small amount of leakage to occur as the engine cools
down and the parts contract.
Excessive coolant leakage may indicate the need to replace the water
pump seal. For the removal of water pumps and the installation of water
pumps and/or seals, refer to the Service Manual for the engine or consult
your Caterpillar dealer.
• Inspect the lubrication system for leaks at the front crankshaft seal, the
rear crankshaft seal, the oil pan, the oil lters and the valve cover.
• Inspect the fuel system for leaks. Look for loose fuel line clamps or for
loose fuel line tie-wraps.
• Inspect the piping for the air inlet system and the elbows for cracks and
for loose clamps. Ensure that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
• Inspect the alternator belt and the accessory drive belts for cracks,
breaks or other damage.
Belts for multiple groove pulleys must be replaced as matched sets. If

only one belt is replaced, the belt will carry more load than the belts that
are not replaced. The older belts are stretched. The additional load on the
new belt could cause the belt to break.
• Drain the water and the sediment from fuel tanks 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.
• Inspect the ECM to the cylinder head 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.
200 SEBU7766-07
Maintenance Section
Water Pump - Inspect
i00864339
Water Pump - Inspect

SMCS Code: 1361-040; 1361
Overconcentration of coolant additive (conditioner), mineral deposits from

hard water, or cooling system contamination can accelerate the wear on
the water pump seal.
Replace the Water Pump Seal, If Necessary

Inspect the water pump for leaks. The water pump seal is lubricated by
coolant in the cooling system. It is normal for a small amount of leakage
to occur as the engine cools down and the parts contract.
Removal and Installation

Refer to the Service Manual for more information on the removal and
installation of the water pump, or consult your Caterpillar dealer for
assistance.
Inspect the Bearing for the Water Pump Pulley

Inspect the water pump pulley for unusual noise, excessive looseness
and/or vibration of the bearings.
Refer to the Service Manual for more information on the removal and
installation of the water pump pulley, or consult your Caterpillar dealer
for assistance.
SEBU7766-07 201
Warranty Section
Warranty Information
Warranty Section
i01902123
Federal Emission Control Warranty

SMCS Code: 1000
Emissions Warranty
New 3126 and C7 Engines Powering On-highway Vehicles.
Caterpillar Inc. warrants new 3126 and C7 engines to the initial owner
and to the subsequent owner of a diesel engine (powering an on-highway
truck) that such an engine is:
1. Designed, built and equipped so as to conform, at the time of sale, with

all applicable regulations adopted by the United States Environmental
Protection Agency (EPA).
2. Free from defects in materials and workmanship in specic emission

related parts for the following periods:
• For new engines powering on-highway vehicles, other than

those powering school buses, recreational vehicles, re trucks,
emergency service vehicles, ambulances and specialty trucks
(as dened below), the standard warranty period is 36 months
or 241,402 kilometers (150,000 miles) or 3600 operating hours,
whichever occurs rst, after date of delivery to the rst user.
• For new engines powering school buses, recreational vehicles, re

trucks, emergency service vehicles, ambulances, the standard
warranty period is 60 months or 6000 operating hours, whichever
occurs rst, after date of delivery to the rst user.
• For new engines powering specialty trucks (i.e., trucks equipped for
pulling trailers or fth-wheel-type trailers) the standard warranty
period is 60 months or 241,402 kilometers (150,000 miles) or 3600
operating hours, whichever occurs rst, after date of delivery to the
rst user.
202 SEBU7766-07
Warranty Section
Note: This warranty only applies to specialty trucks that are used solely for
personal purposes and are not used for commercial (revenue producing)
purposes. Pulling recreational trailers or trailers for recreational or hobby
activities, such as boats, horses, race cars, etc., is considered personal
use.
Following the standard warranty periods specied above, the emission

warranty of 60 months, 161,000 kilometers (100,000 miles) or 3000
service hours of operation, whichever occurs rst, after the date of
delivery to the initial owner would be effective.
If an emission related part fails during the warranty period, the part will be
repaired or replaced. Any such part repaired or replaced under warranty
is warranted for the remainder of the warranty period.
During the term of this warranty, Caterpillar Inc. will provide through
a Caterpillar dealer or other establishment authorized by it, repair or
replacement of any warranted part at no charge to the truck engine owner.
In an emergency, repairs may be performed at any service establishment,

or by the owner, using any replacement part. It is recommended that
emission related parts be replaced with genuine Caterpillar Inc. parts.
Caterpillar Inc. will reimburse the owner for their expenses, including
diagnostic charges for such an emergency repair. These expenses shall
not exceed the Caterpillar Inc. suggested retail price for all warranted
parts replaced, and labor charges based on Caterpillar Inc. recommended
time allowance for the warranty repair and the geographically appropriate
hourly labor rate.
As a condition of reimbursement, replaced parts and receipted invoices

must be presented at a place of business of a Caterpillar dealer or other
establishment authorized by Caterpillar Inc.
Limitations and Responsibilities

The warranty is subject to the following:
Caterpillar Inc. Responsibilities
During the emission warranty period, if a defect in material or workmanship

of an emission related part or component is found, Caterpillar Inc. will
provide:
SEBU7766-07 203
Warranty Section
• New, Remanufactured or repaired parts and/or components, approved

pursuant to EPA Regulations, required to correct the defect.
Note: Items replaced under this warranty become the property of

Caterpillar Inc.
• Reasonable and customary labor, during normal working hours that is

required to make the warranty repair. This includes labor in order to
remove and install the engine, if necessary.
Owner Responsibilities
During the emission warranty period, the owner is responsible for:
• Premium or overtime labor costs, unless essential to prevent loss to

perishable goods.
• Costs to investigate complaints which are not caused by a defect in

Caterpillar Inc. material or workmanship.
• Providing timely notice of a warrantable failure and promptly making the

product available for repair
Limitations
Caterpillar Inc. is not responsible for resultant damages to an emission

related part or component resulting from:
• Any application or installation Caterpillar Inc. deems improper.

• Attachments, accessory items or parts not sold nor approved by
Caterpillar Inc.
• Improper truck engine maintenance, repair or abuse

• Owner's unreasonable delay in making the product available after being
notied of a potential product problem
This warranty is in addition to Caterpillar Inc. standard warranty, applicable

to the truck engine product involved.
Remedies under this warranty are limited to the provision of material

and services as specied herein. Caterpillar Inc. is not responsible for
incidental or consequential damages.
204 SEBU7766-07
Warranty Section
i01902268
California Emission Control Warranty

Statement
SMCS Code: 1000
Owner Warranty Rights and Obligations

The California Air Resources Board (CARB) and Caterpillar Inc. are
pleased to explain the emission control system warranty on your 2003
or later truck engine.
In California, new motor vehicle engines must be designed, built and

equipped to meet the state's stringent anti-smog standards. Caterpillar
Inc. must warrant the emission control system on your truck engine for
the duration of time listed below provided there has not been any abuse,
neglect or improper maintenance of your truck engine.
Your emission control system may include parts such as the fuel injection
system and engine computer, if equipped. Also included may be hoses,
connectors, clamps and other emission related components.
Where a warrantable condition exists, Caterpillar Inc. will repair the truck
engine at no cost to the owner including diagnosis, parts and labor.
Manufacturer's Warranty Coverage

• For new engines powering on-highway vehicles, other than those
powering school buses, recreational vehicles, re trucks, emergency
service vehicles, ambulances and specialty trucks (as dened below),
the standard warranty period is 36 months or 241,402 kilometers
(150,000 miles) or 3600 operating hours, whichever occurs rst, after
date of delivery to the rst user.
• For new engines powering school buses, recreational vehicles, re

trucks, emergency service vehicles, ambulances, the standard
warranty period is 60 months or 6000 operating hours, whichever
occurs rst, after date of delivery to the rst user.
• For new engines powering specialty trucks (i.e., trucks equipped for
pulling trailers or fth-wheel-type trailers) the standard warranty
period is 60 months or 241,402 kilometers (150,000 miles) or 3600
operating hours, whichever occurs rst, after date of delivery to the
rst user.
SEBU7766-07 205
Warranty Section
Note: This warranty only applies to specialty trucks that are used solely for
personal purposes and are not used for commercial (revenue producing)
purposes. Pulling recreational trailers or trailers for recreational or hobby
activities, such as boats, horses, race cars, etc., is considered personal
use.
Following the standard warranty periods specied above, the emission

warranty of 60 months, 161,000 kilometers (100,000 miles) or 3000
service hours of operation, whichever occurs rst, after the date of
delivery to the initial owner would be effective.
If an emission related part or component on your truck engine is defective,

the part or component will be repaired or replaced by Caterpillar Inc. This
is your emission control system WARRANTY.
Owner's Warranty Responsibilities

• As the truck engine owner, you are responsible for the performance of
the required maintenance listed in the truck engine owner's manual
(Operation and Maintenance Manual). Caterpillar Inc. recommends
that you retain all receipts and records covering the maintenance on
your truck engine, but cannot deny warranty solely for the lack of
receipts and records or for your failure to ensure the performance of all
scheduled maintenance.
• You are responsible for presenting your truck engine to a Caterpillar

Inc. dealer as soon as a truck engine problem exists. The warranty
repairs should be completed in a reasonable amount of time, not to
exceed 30 days.
• As the truck engine owner, you should also be aware that Caterpillar
Inc. may deny you warranty coverage if your truck engine or an
emission component or part has failed due to abuse, neglect, improper
maintenance or unapproved modications.
If you have questions regarding your warranty rights and responsibilities,

contact:
Caterpillar Inc.
Manager, Truck Engine Business
P.O. Box 0600
Mossville, IL 61552
Phone 800-447-4986
OR
206 SEBU7766-07
Warranty Section
California Air Resources Board (CARB)

9528 Telstar Ave.
El Monte, CA 91731
Emissions Warranty
Caterpillar Inc. warrants to the initial owner and subsequent owner of a
diesel engine (powering an on-highway truck), that such an engine is:
1. Designed, built and equipped so as to conform, at the time of sale,

with all applicable regulations adopted by the California Air Resources
Board (CARB).
2. Free from defects in materials and workmanship in specic emission

related parts for a period of 60 months, 161 000 km (100 000 miles)
or 3000 service hours of operation, whichever occurs rst, after the
date of delivery to the initial owner.
If an emission related part fails during the warranty period, it will be

repaired or replaced. Any such part repaired or replaced under warranty
is warranted for the remainder of the warranty period.
During the term of this warranty, Caterpillar Inc. will provide through
a Caterpillar dealer or other establishment authorized by it, repair or
replacement of any warranted part at no charge to the truck engine owner.
In an emergency, where an authorized dealer is not reasonably available,

repairs may be performed at any available service establishment, or by
the owner, using any replacement part. It is recommended that emission
related parts be replaced with genuine Caterpillar Inc. parts.
The manufacturer shall reimburse the owner for expenses, including

diagnosis not to exceed the manufacturer's suggested retail price
for all warranted parts replaced and labor charges based on the
manufacturer's recommended time allowance for the warranty repair and
the geographically appropriate hourly labor rate.
A part not being available within 30 days or a repair not being complete
within 30 days constitutes an emergency.
As a condition of reimbursement, replaced parts and receipted invoices

must be presented at a place of business of a Caterpillar dealer or other
establishment authorized by Caterpillar Inc.
SEBU7766-07 207
Warranty Section
This warranty covers the following emission related parts and

components.
• Exhaust Aftertreatment System (If Equipped)

• Fuel Injection System
• Inlet Manifold
• Turbocharger System
• Electronic Engine Control System
• Miscellaneous hoses, clamps, connectors and sealing devices used in
the above systems.
Any replacement part may be used for maintenance or repairs. The owner
should ensure that such parts are equivalent in design and durability to
genuine Caterpillar parts. Use of non-genuine Caterpillar parts does not
invalidate the warranty. However, Caterpillar Inc. is not liable for parts
which are not genuine Caterpillar parts.
Limitations and Responsibilities

These warranties are subject to the following:
Caterpillar Inc. Responsibilities
During the emission warranty period, if a defect in material or workmanship

of a warranted part or component is found, Caterpillar Inc. will provide:
• New, Remanufactured or repaired parts and/or components required

to correct the defect.
Note: Items replaced under this warranty become the property of

Caterpillar Inc.
• Reasonable and customary labor, during normal working hours that is

required to make the warranty repair. This includes diagnosis and labor
to remove and install the engine, if necessary.
Owner Responsibilities
During the emission warranty period, the owner is responsible for:

208 SEBU7766-07
Warranty Section
• The performance of all required maintenance. A warranty claim will not

be denied because the scheduled maintenance was not performed.
However, if the lack of required maintenance was the reason for the
repair, then the claim will be denied.
• Premium or overtime labor costs, unless essential to prevent loss to

perishable goods.
• Costs to investigate complaints which are not caused by a defect in

Caterpillar Inc. material or workmanship.
• Providing timely notice of a warrantable failure and promptly making

the product available for repair.
Limitations
Caterpillar Inc. is not responsible for resultant damages to an emission

related part or component resulting from:
• Any application or installation Caterpillar Inc. deems improper as

explained in the Operation and Maintenance Manual.
• Attachments, accessory items or parts not authorized for use by

Caterpillar Inc.
• Improper truck engine maintenance, repair or abuse.

• Owner's unreasonable delay in making the product available after being
notied of a potential product problem.
This warranty is in addition to Caterpillar Inc. standard warranty, applicable

to the truck engine product involved.
Remedies under this warranty are limited to the provision of material

and services as specied herein. Caterpillar Inc. is not responsible for
incidental or consequential damages such as downtime or loss-of-use
of truck.
SEBU7766-07 209
Warranty Section
i02118591
Emissions Warranty Information

SMCS Code: 1000
Maintenance Recommendations
Caterpillar Inc. truck engines are certied by the United States
Environmental Protection Agency (EPA) in order to comply with exhaust
emission standards and gaseous emission standards that are prescribed
by Federal laws at the time of manufacture.
Efciency of the emission control and the engine performance depends

on adherence to proper operation and maintenance recommendations
and use of recommended fuels and lubricating oils. According to
recommendations, major adjustments and repairs should be made by
your authorized Caterpillar dealer.
Various chemical fuel additives which claim to reduce visible smoke are
available commercially. Although additives have been used to solve some
isolated smoke problems in the eld, additives are not recommended for
general use. The engines should be certied without smoke depressants
according to federal smoke regulations.
Take corrective steps immediately after worn parts which may affect
emission levels are discovered in order to ensure the proper operation
of the emission control systems. The use of genuine Caterpillar parts is
recommended. Suppliers of non-Caterpillar parts must ensure the owner
that the use of such parts will not adversely affect emission levels.
Regular maintenance intervals with a special emphasis on the following

items are necessary in order to keep exhaust emissions within acceptable
limits for the useful life of the engine. Refer to the Operation and
Maintenance Manual, “Severe Service Application - Check” topic
(Maintenance Section). If the engine is operating under severe conditions,
adjust the maintenance schedule accordingly. See your authorized
Caterpillar dealer in order to help analyze your specic application,
operating environment and maintenance schedule adjustments.
The following information is an explanation of maintenance items for

emission related components. See the Operation and Maintenance
Manual, “Maintenance Interval Schedule” (Maintenance Section) for the
specic interval for the following items.
210 SEBU7766-07
Warranty Section
EXHAUST AFTERTREATMENT SYSTEM – Aftertreatment devices

are sensitive to the type of fuel used and the operating schedule. Poor
quality fuel may cause increases in exhaust back pressure or clogging
resulting in loss of power. An authorized Caterpillar truck engine dealer
can determine if the aftertreatment device needs service.
UNIT INJECTORS – Unit injectors are subject to tip wear as a result of

fuel contamination. This damage can cause the following conditions: an
increase in fuel consumption, black smoke, misre, and rough running
engine. The unit injector should be inspected, tested and replaced, if
necessary. Unit injectors can be tested by an authorized Caterpillar truck
engine dealer.
TURBOCHARGER – Check for any unusual sound or vibration in the

turbocharger. Inspect the inlet piping and connections and inspect the
exhaust piping and connections. Check the condition of the bearing.
Perform the maintenance that is described in the Operation and
Maintenance Manual, “Maintenance Interval Schedule” (Maintenance
Section).
ELECTRONIC ENGINE CONTROL – This component is a device that

is designed to control engine operation with respect to the amount of
fuel injected, the injection timing as well as controlling the black smoke
emission of the engine during the engine's operation when low inlet
manifold pressure exists.
Any erratic engine behavior may indicate a need for replacement or repair.
Your Caterpillar dealer is equipped with the necessary tools, personnel
and procedures in order to perform this service.
The owner is encouraged to keep adequate maintenance records.

However, the absence of such records will not invalidate the warranty.
Refer to the Operation and Maintenance Manual, “Maintenance Log”
(Reference Materials Section).
The vehicle owner may perform routine maintenance, repairs and other
work that is outside of the warranty. The work may be done at any repair
facility. Such work does not need to be performed at a designated station
that is determined by the warranty in order for the warranty to remain
in force.
SEBU7766-07 211
Warranty Section
Customer Assistance (Emission Control

Systems Warranty)
Caterpillar Inc. intends to ensure that the Emission Control Systems
Warranty is properly administered. If you do not receive adequate
warranty service under the Emission Control Systems Warranty, call or
write to the following address:
Caterpillar Inc.
Manager, Truck Engine Business
P.O. Box 0600 Mossville, IL 61552
Authorized dealers are recommended for major maintenance and for

repair work. Authorized dealers are staffed with trained personnel and
proper tools. Authorized dealers are aware of the latest maintenance
methods and procedures. If owners or other persons desire to perform
the work, a Service Manual should be purchased and current service
information should be obtained from a Caterpillar dealer.
Refer to the TEPS Directory for information regarding an authorized

dealer or call the following toll free number:
1-800-447-4986
212 SEBU7766-07
Customer Service
Customer Service
i03910306
Customer Assistance
SMCS Code: 1000
USA and Canada

When a problem arises concerning the operation or the service of an
engine, the problem will normally be managed by the dealer in your area.
Your satisfaction is a primary concern to Caterpillar and to Caterpillar

dealers. If you have a problem that has not been handled to your complete
satisfaction, follow these steps:
1. Discuss your problem with a manager from the dealership.
2. If your problem cannot be resolved at the dealer level, use the phone
number that is listed below to talk with a Field Service Coordinator:
1-800-447-4986
The normal hours are from 8:00 to 4:30 Monday through Friday Central
Standard Time.
3. If your needs have not been met still, submit the matter in writing to the
following address:
Caterpillar Inc.
Manager, Customer Service, Engine Division
Mossville Bldg AC
P.O. Box 610
Mossville, Illinois 61552-0610
Please keep in mind: probably, your problem will ultimately be solved

at the dealership, using the dealership facilities, equipment, and
personnel. Therefore, follow the steps in sequence when a problem
is experienced.
SEBU7766-07 213
Customer Service
Outside of the USA and of Canada

If a problem arises outside the USA and outside Canada, and if the
problem cannot be resolved at the dealer level, consult the appropriate
Caterpillar ofce.
Latin America, Mexico, Carribean

Caterpillar Americas Co.
701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Fax: 305-476-6801
Europe, Africa, and Middle East

Caterpillar Overseas S.A.
76 Route de Frontenex
P.O. Box 6000
CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
Fax: 22-849-4544
Far East
Caterpillar Asia Pte. Ltd.
7 Tractor Road
Jurong, Singapore 627968
Republic of Singapore
Phone: 65-662-8333
Fax: 65-662-8302
China
Caterpillar China Ltd.
37/F., The Lee Gardens
33 Hysan Avenue
Causeway Bay
G.P.O. Box 3069
Hong Kong
Phone: 852-2848-0333
Fax: 852-2848-0440
214 SEBU7766-07
Customer Service
Japan
Shin Caterpillar Mitsubishi Ltd.
SBS Tower
10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
Japan
Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Japan
Caterpillar Power Systems, Inc.
SBS Tower (14th oor)
4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Phone: 81-3-5797-4300
Fax: 81-3-5797-4359
Australia and New Zealand

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

SMCS Code: 7567
When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ications 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.
SEBU7766-07 215
Customer Service
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.
216 SEBU7766-07
Reference Materials
Reference Materials
i02282930
Reference Material
SMCS Code: 1000
The following literature can be obtained through any Caterpillar dealer.
Lubricants
• Data Sheet, PEHP0002, “Cat MPGM (Multi-Purpose Grease with
Molybdenum)”
• Data Sheet, NEHP6015, “Cat SPG (Special Purpose Grease)”

• Special Publication, NEHP5621, “How To Select the Right Grease for
Any Job”
• Special Publication, PEHP6001, “How To Take A Good Oil Sample”

• Special Publication, SEBD0640, “Oil and Your Engine”
• Special Publication, PEDP7036, “SOS Fluids Analysis Cornerstone”
Fuels
• Special Publication, SEBD0717, “Diesel Fuels and Your Engine”
• Special Publication, SENR9620, “Improving Fuel System Durability”
Coolants
• Special Publication, SEBD0970, “Coolant and Your Engine”
• Data Sheet, PEHJ0067, “Cat ELC (Extended Life Coolant)”
• Special Publication, SEBD0518, “Know Your Cooling System”
• Data Sheet, PEHP7057, “S·O·S Coolant Analysis”
• Data Sheet, PEHP9554, “Cat DEAC (Diesel Engine Antifreeze/Coolant)”
SEBU7766-07 217
Reference Materials
Miscellaneous
• Service Manual, RENR7575, “C7 On-highway Engine”
• Special Publication, SEBU6385, “Caterpillar On-Highway Diesel Truck
Engine Fluids Recommendations”
• Special Publication, PECP9067, “One Safe Source”

• Special Instruction, REHS0184, “Removal and Installation for the
3126B and 3126E HEUI Injector”
• Special Instruction, SMHS7001, “Assembly of Fan Drive Pulley

Assemblies”
• Special Instruction, SEHS7633, “Battery Test Procedure”

• Special Instruction, LEDT2254, “Cat Answers Your Questions About
Truck Performance”
• Special Publication, SEBF8062, “Guideline for Reusable Parts -

Procedure to Inspect and Clean Air Filters”
• Special Publication, SEBF8029, “Index to Guidelines for Reusable

Parts and Salvage Operations”
• Special Publication, LEXT0023, “Programming Caterpillar Electronic

Truck Engines”
• Special Publication, NEHS0526, “Service Technology Application

Guide”
• Special Instruction, SEHS9031, “Storage Procedure for Caterpillar

Products”
• Specications, SENR3130, “Torque Specications Module”

• Special Instruction, SEHS8742, “Using the 8T-8697 Electronic Control
Analyzer Programmer (ECAP)”
• Special Instruction, SEHS7332, “Warning Tag - Danger Do Not Operate”

• Special Publication, “Truck Engine Application and Installation Guide”
(See your Caterpillar dealer.)
218 SEBU7766-07
Reference Materials
Additional Reference Material

The “Engine Fluids Data Book” can be obtained from the following
locations: local technological society, local library, and local college. If
necessary, consult EMA at the following address:
Engine Manufacturers Associaton

Two North LaSalle Street, Suite 2200
Chicago, IL, USA 60602
E-mail: [email protected]
(312) 827-8737
The “Society of Automotive Engineers (SAE) Specications” can be found

in your SAE handbook. This publication can also be obtained from the
following locations: local technological society, local library, and local
college. If necessary, consult SAE at the following address:
SAE International
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
E-mail: www.sae.org
(724) 776-4841
The “American Petroleum Institute Publication No. 1509” can be obtained

from the following locations: local technological society, local library, and
local college. If necessary, consult API at the following address:
American Petroleum Institute

1220 L St. N.W.
Washington, DC, USA 20005
E-mail: www.api.org
(202) 682-8000
For information regarding “Technology and Maintenance Council (TMC)

Specications”, refer to the following address:
Technology and Maintenance Council

American Trucking Association
2200 Mill Road
Alexandria, VA, USA 22314
E-mail: www.trucking.org/cc/councils/tmc
(703) 838-1763
SEBU7766-07 219
Reference Materials
i00866435
Engine Protection Plans

SMCS Code: 1000
Extended Warranties and Service Contracts

A wide variety of protection plans are available for Caterpillar On-Highway
Truck Engines. Consult your authorized Caterpillar Truck Engine dealer
for information on the following plans which is best suited for your needs.
• ESC (Extended Service Coverage)

• OPT (Overhaul Protection for Trucks)
• Remanufactured Extended Coverage
• TOPP (Truck Owner Protection Plan)
Consult your authorized Caterpillar Truck Engine dealer for more detailed
information on specic programs and coverage that is available. Ask for
the Engine Protection Plan Sales Manager.
i00912149
Maintenance Records
SMCS Code: 1000
Caterpillar Inc. recommends the retention of accurate maintenance

records. Accurate maintenance records can be used for the following
purposes:
• Determine operating costs.

• Establish maintenance schedules for other engines that are operated
in the same environment.
• Show compliance with the required maintenance practices and

maintenance intervals.
Maintenance records can be used for a variety of other business decisions

that are related to engine maintenance.
220 SEBU7766-07
Reference Materials
Maintenance records are a key element of a maintenance program that is

well managed. Accurate maintenance records can help your Caterpillar
dealer to ne tune the recommended maintenance intervals in order to
meet the specic operating situation. This should result in a lower engine
operating cost.
Records should be kept for the following items:
Fuel Consumption – A record of fuel consumption is essential in order

to determine when the load sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul intervals.
Service Hours – A record of service hours is essential to determine

when the speed sensitive components should be inspected or repaired.
Documents – These items should be easy to obtain, and these items

should be kept in the engine history le. All of the documents should show
this information: date, service hours, fuel consumption, unit number, and
engine serial number. The following types of documents should be kept
as proof of maintenance or repair for warranty:
Keep the following types of documents as proof of maintenance for

warranty. Also, keep these types of documents as proof of repair for
warranty:
• Dealer work orders and itemized bills

• Owner's repair costs
• Owner's receipts
• Maintenance log
SEBU7766-07 221
Reference Materials
i00920302
Maintenance Log
SMCS Code: 1000
Table 11
Engine Model Customer Identier
Serial Number Arrangement Number
Table 12
Service Quantity
Item Serviced Date Authorization
Hours of Fuel
(continued)
222 SEBU7766-07
Reference Materials
(Table 12, contd)
Service Quantity
Item Serviced Date Authorization
Hours of Fuel
SEBU7766-07 223
Index Section
Index
A
After Starting Engine .............................................................................. 80

Aftercooler Core - Clean/Test (Air-To-Air Aftercooler) .......................... 126
Air Compressor - Inspect...................................................................... 126
Air Compressor Filter - Clean/Replace................................................. 127
Air Dryer - Check .................................................................................. 128
Alternator - Inspect ............................................................................... 128
Battery - Replace.................................................................................. 129

Battery or Battery Cable - Disconnect .................................................. 132
Before Starting Engine ........................................................................... 23
Belt - Inspect......................................................................................... 132
Adjustment ........................................................................................ 134
Inspection.......................................................................................... 132
Belt Tensioner - Inspect (If Equipped) .................................................. 136
Burn Prevention...................................................................................... 16
Batteries.............................................................................................. 17
Coolant................................................................................................ 16
Oils...................................................................................................... 17
California Emission Control Warranty Statement ................................. 204

Emissions Warranty .......................................................................... 206
Owner Warranty Rights and Obligations........................................... 204
Caterpillar Driver Information Display (Messenger)................................ 95
Access to Parameters......................................................................... 97
Conguration of the Display................................................................ 96
Diagnostic Data................................................................................... 95
Driver ID Entry .................................................................................... 97
Engine Operating Information ............................................................. 96
Fuel Correction Adjustment ................................................................ 96
Maintenance Information .................................................................... 96
State Crossing .................................................................................... 97
Theft Deterrent.................................................................................... 96
Vehicle Trip Information ...................................................................... 96
224 SEBU7766-07
Index Section
Cold Weather Operation....................................................................... 100

Cooling System Coolant (DEAC) - Change.......................................... 136
Cooling Systems with Heavy Deposits or Plugging .......................... 139
Drain ................................................................................................. 137
Fill ..................................................................................................... 140
Flush ................................................................................................. 138
Cooling System Coolant (ELC) - Change............................................. 141
Drain ................................................................................................. 142
Fill ..................................................................................................... 143
Flush ................................................................................................. 142
Cooling System Coolant Extender (ELC) - Add.................................... 144
Cooling System Coolant Level - Check ................................................ 146
Cooling System Coolant Sample (Level 1) - Obtain ............................. 147
Cooling System Coolant Sample (Level 2) - Obtain ............................. 150
Cooling System Supplemental Coolant Additive (SCA) - Test/Add ...... 150
Add the SCA, If Necessary ............................................................... 152
S·O·S Coolant Analysis..................................................................... 151
Test the SCA Concentration.............................................................. 151
Cooling System Water Temperature Regulator - Replace.................... 153
Visconic Damper............................................................................... 155
Crushing Prevention and Cutting Prevention ......................................... 22
Customer Assistance............................................................................ 212
Outside of the USA and of Canada................................................... 213
USA and Canada .............................................................................. 212
Customer Service ................................................................................. 212
Customer Specied Parameters....................................................... 44, 71
Diagnostic Flash Code Retrieval ............................................................ 60

Diagnostic Lamp ................................................................................. 60
Diagnostic Lamp..................................................................................... 60
ECM Snapshot ....................................................................................... 67

Storage of Snapshots In the ECM ...................................................... 68
Triggering Snapshot Information......................................................... 67
Electrical System .................................................................................... 26
Grounding Practices ........................................................................... 27
Emergency Vehicle Engine Features ..................................................... 56
Emissions Certication Film ................................................................... 44
SEBU7766-07 225
Index Section
Emissions Warranty Information........................................................... 209

Customer Assistance (Emission Control Systems Warranty) ........... 211
Maintenance Recommendations ...................................................... 209
Engine - Clean...................................................................................... 157
Engine Air Cleaner Service Indicator - Inspect (If Equipped) ............... 158
Test the Service Indicator.................................................................. 159
Engine Crankcase Breather - Clean..................................................... 161
Engine Description ................................................................................. 36
Aftermarket Products and CaterpillarEngines..................................... 40
Electronic Engine Features................................................................. 37
Engine Cooling and Lubrication .......................................................... 39
Engine Service Life ............................................................................. 40
Engine Specications.......................................................................... 36
Engine Diagnostics................................................................................. 59
Engine Electronics.................................................................................. 29
Engine Identication ............................................................................... 41
Engine Mounts - Inspect....................................................................... 162
Engine Oil and Filter - Change ............................................................. 169
Drain the Engine Oil.......................................................................... 169
Fill the Engine Crankcase ................................................................. 171
Oil Change Interval Adjustments ...................................................... 172
Replace the Oil Filter ........................................................................ 170
Engine Oil Level - Check ...................................................................... 162
Engine Oil Level Gauge - Calibrate ...................................................... 165
Check Calibration at the First Oil Change......................................... 165
Engine Oil Sample - Obtain .................................................................. 167
Obtain the Sample and the Analysis................................................. 167
Engine Operation.................................................................................... 81
Cold Mode Operation.......................................................................... 83
Cruise Control ..................................................................................... 87
Cruising............................................................................................... 87
Diesel Particulate Filter (If Equipped) ................................................. 84
Downhill Operation.............................................................................. 90
Fuel Economy ..................................................................................... 86
Getting Started.................................................................................... 85
Idle Mode ............................................................................................ 89
Idling ................................................................................................... 81
Mufer and Converter (If Equipped).................................................... 84
Uphill Operation .................................................................................. 90
Vehicle Efciency ................................................................................ 86
Engine Operation with Active Diagnostic Codes .................................... 69
Engine Operation with Intermittent Diagnostic Codes ............................ 70
Engine Protection Plans ....................................................................... 219
Extended Warranties and Service Contracts .................................... 219
Engine Starting ................................................................................. 24, 72
226 SEBU7766-07
Index Section
Engine Stopping ............................................................................... 25, 98

Engine Storage Procedure - Check...................................................... 176
Engine Valve Lash - Inspect/Adjust ...................................................... 177
Exhaust Brake ........................................................................................ 91
Operating the Exhaust Brake.............................................................. 93
Fan Drive Bearing - Lubricate............................................................... 178

Fault Logging.......................................................................................... 68
Features and Controls ............................................................................ 56
Federal Emission Control Warranty...................................................... 201
Emissions Warranty .......................................................................... 201
Fire Prevention and Explosion Prevention ............................................. 17
Ether (If Equipped).............................................................................. 21
Fire Extinguisher ................................................................................. 20
Lines, Tubes and Hoses ..................................................................... 21
Foreword .................................................................................................. 7
California Proposition 65 Warning ........................................................ 7
Literature Information............................................................................ 5
Maintenance ......................................................................................... 6
Maintenance Intervals........................................................................... 6
Operation .............................................................................................. 5
Overhaul ............................................................................................... 7
Safety.................................................................................................... 5
Fuel and the Effect from Cold Weather ................................................ 100
Fuel Related Components in Cold Weather ......................................... 102
Fuel Filters ........................................................................................ 103
Fuel Heaters ..................................................................................... 103
Fuel Tanks......................................................................................... 102
Fuel System - Prime ............................................................................. 179
Engines that are Equipped with a Fuel Priming Pump...................... 179
Engines that are Not Equipped with a Fuel Priming Pump ............... 180
Drain the Water and the Sediment.................................................... 184
Fuel Storage Tanks ........................................................................... 185
Fuel Tank .......................................................................................... 184
Gauges and Indicators ........................................................................... 53

SEBU7766-07 227
Index Section
General Hazard Information ................................................................... 10

Asbestos Information .......................................................................... 14
Fluid Penetration................................................................................. 13
Fluid Spillage ...................................................................................... 14
Lines, Tubes, and Hoses .................................................................... 15
Pressure Air and Water....................................................................... 13
General Information................................................................................ 31
Hoses and Clamps - Inspect/Replace .................................................. 185

Inspect the Hoses and the Clamps ................................................... 186
Replace the Hoses and the Clamps ................................................. 187
Important Safety Information .................................................................... 2

Information Plate .................................................................................... 42
Lifting and Storage ................................................................................. 51
Maintenance Interval Schedule (Engines with a Deep Oil Sump) ........ 123
Maintenance Interval Schedule (Engines with a Shallow Oil Sump) .... 120
Maintenance Log .................................................................................. 221
Maintenance Records........................................................................... 219
Maintenance Section ............................................................................ 104
Model View Illustrations.......................................................................... 35
Model Views ........................................................................................... 35
Monitoring System.................................................................................. 56
Programmable Options and Systems Operation ................................ 57
Mounting and Dismounting..................................................................... 23
Operation Section................................................................................... 51
Ordering Replacement Parts ................................................................ 214
228 SEBU7766-07
Index Section
Overhaul Considerations ...................................................................... 192

Overhaul Options .............................................................................. 193
Product Identication Information ........................................................... 41

Product Information Section ................................................................... 31
Product Lifting......................................................................................... 51
Product Storage...................................................................................... 52
Radiator - Clean ................................................................................... 193

Radiator Restrictions ............................................................................ 100
Reference Information Section ............................................................. 212
Reference Material ............................................................................... 216
Additional Reference Material........................................................... 218
Coolants............................................................................................ 216
Fuels ................................................................................................. 216
Lubricants ......................................................................................... 216
Miscellaneous ................................................................................... 217
Reference Materials ............................................................................. 216
Reference Numbers ............................................................................... 42
Record for Reference.......................................................................... 42
Rell Capacities.................................................................................... 104
Rell Capacities and Recommendations.............................................. 104
Coolant.............................................................................................. 115
Engine Oil ......................................................................................... 104
Fuel ................................................................................................... 111
Lubricating Grease............................................................................ 114
Safety Messages ...................................................................................... 8

(1) Universal Warning ........................................................................... 9
Safety Section .......................................................................................... 8
Self-Diagnostics...................................................................................... 59
Serial Number Plate ............................................................................... 41
Severe Service Application - Check ..................................................... 194
Starting Motor - Inspect ........................................................................ 195
SEBU7766-07 229
Index Section
Starting the Engine ................................................................................. 72

Air Inlet Heater .................................................................................... 74
Cold Weather Starting......................................................................... 74
Problems with the Wiring Harness...................................................... 77
Starting Problems ............................................................................... 76
Under-the-Hood Inspection................................................................. 72
Starting with Jump Start Cables ............................................................. 78
Stopping the Engine ............................................................................... 98
After Stopping the Engine ................................................................... 98
Table of Contents...................................................................................... 3
Cleaning and Inspecting ................................................................... 196
Removal and Installation................................................................... 196

Inspect the Engine for Leaks and for Loose Connections ................ 198
Warranty Information ............................................................................ 201
Warranty Section .................................................................................. 201
Water Pump - Inspect ........................................................................... 200
Inspect the Bearing for the Water Pump Pulley ................................ 200
Replace the Water Pump Seal, If Necessary.................................... 200
Welding on Engines with Electronic Controls ......................................... 31
230 SEBU7766-07
Index Section
Product and Dealer Information
Note: For product identication plate locations, see the section “Product Identication
Information” in the Operation and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identication Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
©2010 Caterpillar Cat, Caterpillar, their respective logos, Printed in
All Rights “Caterpillar Yellow” and the Power edge trade U.S.A.
Reserved dress, as well as corporate and product identity
used herein, are trademarks of Caterpillar and
may not be used without permission.

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SEBU7766-07

Important Safety Information

The meaning of this safety alert symbol is as follows:

General Hazard Information .................................................................. 10

Burn Prevention ..................................................................................... 16

Fire Prevention and Explosion Prevention ............................................. 17

Crushing Prevention and Cutting Prevention ......................................... 22

Mounting and Dismounting .................................................................... 23

Before Starting Engine ........................................................................... 23

Engine Starting ...................................................................................... 24

Engine Stopping .................................................................................... 25

Electrical System ................................................................................... 26

Engine Electronics ................................................................................. 29

Product Information Section

Model Views .......................................................................................... 35

Product Identication Information ......................................................... 41

Gauges and Indicators ........................................................................... 53

Features and Controls ........................................................................... 56

Engine Diagnostics ................................................................................ 59

Engine Starting ...................................................................................... 72

Engine Operation ................................................................................... 81

Engine Stopping .................................................................................... 98

Cold Weather Operation ...................................................................... 100

Reference Information Section

Reference Materials ............................................................................. 216

Some photographs or illustrations in this manual show details or

The operation section is a reference for operators. Photographs and

Use fuel consumption or service hours to determine intervals. Calendar

Recommended service should be performed at the appropriate intervals

The maintenance schedule items are organized for a preventive

See the section in the Operation and Maintenance Manual, “Maintenance

California Proposition 65 Warning

There may be several specic safety messages on your engine. The

Replace any safety message that is damaged or missing. If a safety

(1) Universal Warning

Do not operate or work on this equipment unless

General Hazard Information

Do not allow unauthorized personnel on the engine or around the

• Tampering with the engine installation or tampering with the OEM

• If the engine is not running, do not release the secondary brake or

• Wear a hard hat, protective glasses, and other protective equipment,

• When work is performed around an engine that is operating, wear

• Do not wear loose clothing or jewelry that can snag on controls or on

• Never put maintenance uids into glass containers. Glass containers

• Use all cleaning solutions with care.

• Disconnect the batteries when maintenance is performed or when the

Cautiously remove the following parts:

Note: To help prevent spraying or splashing of pressurized uids, hold a

Pressure Air and Water

Refer to Special Publication, NENG2500, “Caterpillar

Dispose of all uids according to local regulations and

Caterpillar equipment and replacement parts that are shipped from

• Never use compressed air for cleaning.

• Use exhaust ventilation on permanent machining jobs.

• Obey environmental regulations for the disposal of asbestos.

Lines, Tubes, and Hoses

Check for the following conditions:

• End ttings that are damaged or leaking

Cooling system conditioner contains alkali. Alkali can cause personal