Manual de Operacion y Mantnimiento PDF

SEBU8312-03 (en-us)
February 2016
Operation and
Maintenance
Manual
C0.5 , C0.7, C1.1 , C1.5 , C1.6 and C2.2
Industrial Engines
C6F 1-UP (Engine)
C6H 1-UP (Engine)
C7H 1-UP (Engine)
C7J 1-UP (Engine)
C6J 1-UP (Engine)
C6K 1-UP (Engine)
G8N 1-UP (Engine)
C6L 1-UP (Engine)
C7Y 1-UP (Engine)
G7P 1-UP (Engine)
C6N 1-UP (Engine)
C8W 1-UP (Engine)
G7L 1-UP (Engine)
C6M 1-UP (Engine)
C8Y 1-UP (Engine)
C8Z 1-UP (Engine)
SAFETY.CAT.COM
i06558969
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU8312-03 3
Table of Contents
Table of Contents Maintenance Recommendations .................... 51
Maintenance Interval Schedule....................... 53

Foreword ........................................................... 4
Safety Section Warranty Section
Warranty Information....................................... 92
Safety Messages............................................... 5
General Hazard Information.............................. 8 Reference Information Section
Burn Prevention............................................... 12 Engine Ratings ................................................ 93
Fire Prevention and Explosion Prevention...... 12 Customer Service............................................ 95
Crushing Prevention and Cutting Prevention.. 14 Reference Materials ........................................ 97
Mounting and Dismounting ............................. 15 Index Section
Before Starting Engine .................................... 15 Index.............................................................. 101
Engine Starting................................................ 15
Engine Stopping .............................................. 16
Electrical System............................................. 16
Product Information Section
Model Views .................................................... 18
Product Identification Information ................... 27
Operation Section
Lifting and Storage .......................................... 29
Gauges and Indicators .................................... 30
Features and Controls..................................... 31
Engine Starting................................................ 33
Engine Operation ............................................ 36
Engine Stopping .............................................. 38
Cold Weather Operation ................................. 40
Maintenance Section
Refill Capacities............................................... 42
4 SEBU8312-03
Foreword
Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
This manual contains safety, operation instructions, wet or freezing cold operating conditions, more
lubrication and maintenance information. This frequent lubrication and maintenance than is
manual should be stored in or near the engine area in specified in the Maintenance Interval Schedule may
a literature holder or literature storage area. Read, be necessary.
study and keep it with the literature and engine
information. The maintenance schedule items are organized for a
preventive maintenance management program. If the
English is the primary language for all Cat preventive maintenance program is followed, a
publications. The English used facilitates translation periodic tune-up is not required. The implementation
and consistency in electronic media delivery. of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures.
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design Maintenance Intervals
may have caused changes to your engine which are
not included in this manual. Whenever a question Perform maintenance on items at multiples of the
arises regarding your engine, or this manual, please original requirement. Each level and/or individual
consult with your Cat dealer for the latest available items in each level should be shifted ahead or back
information. depending upon your specific maintenance practices,
operation and application. We recommend that the
maintenance schedules be reproduced and
Safety displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
This safety section lists basic safety precautions. In maintained as part of the engine's permanent record.
addition, this section identifies hazardous, warning
situations. Read and understand the basic See the section in the Operation and Maintenance
precautions listed in the safety section before Manual, “Maintenance Records” for information
operating or performing lubrication, maintenance and regarding documents that are generally accepted as
repair on this product. proof of maintenance or repair. Your authorized Cat
dealer can assist you in adjusting your maintenance
schedule to meet the needs of your operating
Operation environment.
Operating techniques outlined in this manual are
basic. They assist with developing the skills and Overhaul
techniques required to operate the engine more
efficiently and economically. Skill and techniques Major engine overhaul details are not covered in the
develop as the operator gains knowledge of the Operation and Maintenance Manual except for the
engine and its capabilities. interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
The operation section is a reference for operators. authorized Cat dealer. Your Cat dealer offers a
variety of options regarding overhaul programs. If you
Photographs and illustrations guide the operator experience a major engine failure, there are also
through procedures of inspecting, starting, operating numerous after failure overhaul options available
and stopping the engine. This section also includes a from your Cat dealer. Consult with your dealer for
discussion of electronic diagnostic information. information regarding these options.
Maintenance California Proposition 65 Warning

The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped Diesel engine exhaust and some of its constituents
by fuel consumption, service hours and/or calendar are known to the State of California to cause cancer,
time maintenance intervals. Items in the maintenance birth defects, and other reproductive harm.
schedule are referenced to detailed instructions that
follow. Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
Use fuel consumption or service hours to determine after handling.
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals if
they provide more convenient schedules and
approximate the indicated service meter reading.
SEBU8312-03 5
Safety Section
Safety Messages
Safety Section
i02639935
Safety Messages
SMCS Code: 1000; 7405
There may be several specific safety messages on
an engine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Please become familiar with all warning
signs.
Ensure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if the
words cannot be read or if the pictures are not visible.
When the warning signs are cleaned, use a cloth,
water, and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the warning signs.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the warning signs. The
warning signs that are loosened could drop off of the
engine.
Replace any damaged warning signs or missing
warning signs. If a warning sign is attached to a part
of the engine that is replaced, install a new warning
sign on the replacement part. Any Caterpillar dealer
can provide new warning signs.
Do not work on the engine and do not operate the
engine unless the instructions and warnings in the
Operation and Maintenance Manual are understood.
Correct care is your responsibility. Failure to follow
the instructions or failure to heed the warnings could
result in injury or in death.
The warning labels that may be found on the engine
are illustrated.
6 SEBU8312-03
Safety Section
Safety Messages
Illustration 1 g01324126
(A) Location of the warning labels (3) C1.1 (6) C2.2

(1) C0.5 (4) C1.5
(2) C0.7 (5) C1.6
SEBU8312-03 7
Safety Section
Safety Messages
(B) Location of ether warning labels (3) C1.1 (6) C2.2

(1) C0.5 (4) C1.5
(2) C0.7 (5) C1.6
8 SEBU8312-03
Safety Section
General Hazard Information
Universal Warning (A)

Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
i06300340

SMCS Code: 1000; 7405
Warning label (A) is installed in different locations.

The location will change according to the physical
size of the engine. Refer to illustration 1 for the
location of the warning labels.
Do not operate or work on this equipment unless

you have read and understand the instructions
and warnings in the Operation and Maintenance Illustration 5 g03838041
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury Attach a “Do Not Operate” warning tag to the start
or death. switch or controls before the engine is serviced or
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Cat dealer.
No Ether (B) Attach the warning tags to the engine and to each
operator control station. When appropriate,
disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps
• Grease fittings
• Pressure taps
• Breathers
• Drain plugs
Warning label (B) is installed in different locations.
The location will change according to the physical Use caution when cover plates are removed.
size of the engine. Refer to illustration 2 for the Gradually loosen, but do not remove the last two
location of the warning labels. 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.
SEBU8312-03 9
Safety Section
• Start the engine with the operator controls. Never

short across the starting motor terminals or the
batteries. This method of starting the engine could
bypass the engine neutral start system and/or the
electrical system could be damaged.
Pressurized Air and Water

Pressurized air and/or water can cause debris and/or
hot water to be blown out which could result in
personal injury.
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).
• Wear a hard hat, protective glasses, and other
protective equipment, as required. When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
• When work is performed around an engine that is shoes, and eye protection. Eye protection includes
operating, wear protective devices for ears in goggles or a protective face shield. Always wear eye
order to help prevent damage to hearing. protection for cleaning the cooling system.
• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.
• Ensure that all protective guards and all covers

are secured in place on the engine.
• Never put maintenance fluids into glass

containers. Glass containers can break.
• 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
cannot be started.
• The protective locks or the controls are in the

applied position.
• Disconnect the batteries when maintenance is

performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• When starting a new engine, make provisions to
stop the engine if an overspeed occurs. If an
engine has not been started since service has
been performed, make provisions to stop the
engine if an overspeed occurs. Shutting down the
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine.
• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.
10 SEBU8312-03
Safety Section
Avoid direct spraying of water on electrical Static Electricity Hazard when

connectors, connections, and components. When
using air for cleaning, allow the machine to cool to Fueling with Ultra-low Sulfur Diesel
reduce the possibility of fine debris igniting when Fuel
redeposited on hot surfaces.
The removal of sulfur and other compounds in ultra-
Fluid Penetration low sulfur diesel fuel (ULSD fuel) decreases the
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.
Avoid static electricity risk when fueling. Ultra-
Always use a board or cardboard when you check for low sulfur diesel fuel (ULSD fuel) poses a greater
a leak. Leaking fluid that is under pressure can static ignition hazard than earlier diesel formula-
penetrate body tissue. Fluid penetration can cause tions with a higher sulfur contents. Avoid death
serious injury and possible death. A pin hole leak can or serious injury from fire or explosion. Consult
cause severe injury. If fluid is injected into your skin, with your fuel or fuel system supplier to ensure
you must get treatment immediately. Seek treatment the delivery system is in compliance with fueling
from a doctor that is familiar with this type of injury. standards for proper grounding and bonding
practices.
Containing Fluid Spillage
NOTICE Lines, Tubes, and Hoses
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Do not bend or strike high-pressure lines. Do not
nance, testing, adjusting, and repair of the product. install lines, tubes, or hoses that are damaged.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Repair any fuel lines, oil lines, tubes, or hoses that
bling any component containing fluids. are loose or damaged. Leaks can cause fires.
Refer to Special Publication, NENG2500, “Cat Dealer Inspect all lines, tubes, and hoses carefully. Do not
Service Tool Catalog” or refer to Special Publication, use bare hands to check for leaks. Always use a
PECJ0003, “Cat Shop Supplies and Tools Catalog” board or cardboard for checking engine components
for tools and supplies suitable to collect and contain for leaks. Tighten all connections to the
fluids on Cat products. recommended torque.
Dispose of all fluids according to local regulations Check for the following conditions:
and mandates.
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering
SEBU8312-03 11
Safety Section
Ensure that all of the clamps, the guards, and the • A vacuum cleaner that is equipped with a high
heat shields are installed correctly. Correct efficiency particulate air filter (HEPA) can also be
installation of these components will help to prevent used.
these effects: vibration, rubbing against other parts
and excessive heat during operation. • Use exhaust ventilation on permanent machining
jobs.
Inhalation • 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.
Softwrap
Keep the engine room ventilation operating at full
capacity. Wear a particulate respirator that has been
Exhaust approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate
Use caution. Exhaust fumes can be hazardous to protective clothing in order to minimize direct contact.
your health. If you operate the equipment in an Use good hygiene practices and wash hands
enclosed area, adequate ventilation is necessary. thoroughly after handling Softwrap material. Do not
smoke until washing hands thoroughly after handling
Asbestos Information Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean
Cat equipment and replacement parts that are up debris.
shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is 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.
12 SEBU8312-03
Safety Section
Burn Prevention
Reference: The applicable material safety data Ensure that the filler cap is cool before removing the
sheets can be found at the following web site by filler cap. The filler cap must be cool enough to touch
searching using part number or the name: with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
https://catmsds.cat.com/MSDSSearch/servlet/
cat.cis.ecs. Cooling system conditioner contains alkali. Alkali can
msdsSearch.controller. cause personal injury. Do not allow alkali to contact
UserIdentificationDisplayServlet the skin, the eyes, or the mouth.
Dispose of Waste Properly 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.
i05626649
Illustration 9 g00706404 Fire Prevention and Explosion

Improperly disposing of waste can threaten the Prevention
environment. Potentially harmful fluids should be
disposed of according to local regulations. SMCS Code: 1000; 7405
Always use leakproof containers when you drain

fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01480768
Burn Prevention
SMCS Code: 1000; 7405
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the hydraulic system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings or related items are
disconnected.
Use of personal protection equipment (PPE) may be
Coolant needed.
When the engine is at operating temperature, the All fuels, most lubricants, and some coolant mixtures
engine coolant is hot. The coolant is also under are flammable.
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
Any contact with hot coolant or with steam can cause product when a fire hazard exists. Contact your Cat
severe burns. Allow cooling system components to dealer for service.
cool before the cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
SEBU8312-03 13
Safety Section
Fire Prevention and Explosion Prevention
Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause a deterioration. Properly route all hoses. The lines and
fire. Fire may cause personal injury and property hoses must have adequate support and secure
damage. clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an Properly install all oil filters and fuel filters. The filter
emergency shutdown. housings must be tightened to the proper torque.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of
combustible gases, consult your Cat dealer for
additional information about suitable protection
devices.
Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
All fluids that are captured in the fluid spill
containment basin should be cleaned up
immediately. Failure to clean up spilled fluids can
cause a fire. Fire may cause personal injury and
property damage.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective Illustration 11 g00704059
containers. Do not smoke in areas that are used for
storing flammable materials. Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not
Do not expose the engine to any flame. refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in a line, a tube, or Avoid static electricity risk when fueling. Ultra Low
a seal failure. Exhaust shields must be installed Sulfur Diesel (ULSD) poses a greater static ignition
correctly. hazard than earlier diesel formulations with a higher
Sulfur content. Avoid death or serious injury from fire
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain or explosion. Consult with your fuel or fuel system
flammable fluid. Clean any such lines or tanks supplier to ensure that the delivery system is in
thoroughly with a nonflammable solvent prior to compliance with fueling standards for proper
welding or flame cutting. grounding and bonding practices.
Wiring must be kept in good condition. Properly route

and attach all electrical wires. Check all electrical
wires daily. Repair any wires that are loose or frayed
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
14 SEBU8312-03
Safety Section
Crushing Prevention and Cutting Prevention
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
flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
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 fires. Consult your Cat dealer for repair or
for replacement parts.
Check lines, tubes, and hoses carefully. Do not use
Gases from a battery can explode. Keep any open your bare hand to check for leaks. Use a board or
flames or sparks away from the top of a battery. Do cardboard to check for leaks. Tighten all connections
not smoke in battery charging areas. to the recommended torque.
Never check the battery charge by placing a metal Replace the parts if any of the following conditions
object across the terminal posts. Use a voltmeter or a are present:
hydrometer.
• End fittings are damaged or leaking.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to the • Outer coverings are chafed or cut.
Operation Section of this manual for specific
instructions. • Wires are exposed.
Do not charge a frozen battery. Charging a frozen • Outer coverings are ballooning.
battery may result in an explosion.
• Flexible parts of the hoses are kinked.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the • Outer covers have embedded armoring.
recommended cables, connections, and battery box
covers when the engine is operated. • End fittings are displaced.
Fire Extinguisher Make sure that all clamps, guards, and heat shields
are installed correctly in order to prevent vibration,
Make sure that a fire extinguisher is available. Be rubbing against other parts, and excessive heat.
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire i01359666
extinguisher regularly. Obey the recommendations
on the instruction plate. Crushing Prevention and
Ether Cutting Prevention
SMCS Code: 1000; 7405
Ether is flammable and poisonous.
Support the component properly when work beneath
Use ether in ventilated areas. Do not smoke while the component is performed.
you are replacing an ether cylinder or while you are
using an ether spray. Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
SEBU8312-03 15
Safety Section
Mounting and Dismounting
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, Engine exhaust contains products of combustion
reinstall the guards.
which may be harmful to your health. Always
Keep objects away from moving fan blades. The fan start and operate the engine in a well ventilated
blades will throw objects or cut objects. area and, if in an enclosed area, vent the exhaust
to the outside.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes. Inspect the engine for potential hazards.
Chips or other debris may fly off objects when objects Do not start the engine or move any of the controls if
are struck. Before objects are struck, ensure that no there is a “DO NOT OPERATE” warning tag or similar
one will be injured by flying debris. warning tag attached to the start switch or to the
controls.
i01372247 Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
Mounting and Dismounting area is free of personnel.
SMCS Code: 1000; 7405 If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
Inspect the steps, the handholds, and the work area lights work properly, if equipped.
before mounting the engine. Keep these items clean
and keep these items in good repair. All protective guards and all protective covers must
be installed if the engine must be started in order to
Mount the engine and dismount the engine only at perform service procedures. To help prevent an
locations that have steps and/or handholds. Do not accident that is caused by parts in rotation, work
climb on the engine, and do not jump off the engine. around the parts carefully.
Face the engine in order to mount the engine or Do not bypass the automatic shutoff circuits. Do not
dismount the engine. Maintain a three-point contact disable the automatic shutoff circuits. The circuits are
with the steps and handholds. Use two feet and one provided in order to help prevent personal injury. The
hand or use one foot and two hands. Do not use any circuits are also provided in order to help prevent
controls as handholds. engine damage.
Do not stand on components which cannot support See the Service Manual for repairs and for
your weight. Use an adequate ladder or use a work adjustments.
platform. Secure the climbing equipment so that the
equipment will not move. i01185283
Do not carry tools or supplies when you mount the

engine or when you dismount the engine. Use a hand Engine Starting
line to raise and lower tools or supplies.
SMCS Code: 1000
i03560601
Before Starting Engine Do not use aerosol types of starting aids such as
SMCS Code: 1000 ether. Such use could result in an explosion and
personal injury.
NOTICE If a warning tag is attached to the engine start switch
For initial start-up of a new or rebuilt engine, and for or to the controls, DO NOT start the engine or move
start-up of an engine that has been serviced, make the controls. Consult with the person that attached
provision to shut the engine off should an overspeed the warning tag before the engine is started.
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine. 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.
16 SEBU8312-03
Safety Section
Engine Stopping
Always start the engine according to the procedure Check the electrical wires daily for wires that are
that is described in the Operation and Maintenance loose or frayed. Tighten all loose electrical wires
Manual, “Engine Starting” topic in the Operation before the engine is started. Repair all frayed
Section. Knowing the correct procedure will help to electrical wires before the engine is started. See this
prevent major damage to the engine components. Operation and Maintenance Manual for specific
Knowing the procedure will also help to prevent starting instructions.
personal injury.
To ensure that the jacket water heater (if equipped) Grounding Practices
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.
i01032808
Engine Stopping
SMCS Code: 1000
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to this Operation and Maintenance
Manual, “Engine Stopping” topic (Operation Section).
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 Illustration 13 g01308335
until the problem that caused the emergency stop Typical example
has been corrected. Ground to battery
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop the
engine if an overspeed condition occurs. This may be
accomplished by shutting off the fuel supply and/or
the air supply to the engine.
i02613441
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.
Typical example
Alternate Ground to frame
SEBU8312-03 17
Safety Section
Electrical System
Correct grounding for the engine electrical system is

necessary for optimum engine performance and
reliability. Incorrect 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.
To ensure that the engine and the engine electrical
systems function correctly, 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, or a starting motor 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.
18 SEBU8312-03
Model Views
Product Information
Section
Model Views
i02613456
Model View Illustrations

SMCS Code: 1000
The following model views show typical features of
the C0.5, C0.7, C1.1, C1.5, C1.6 and C2.2 Engines.
Due to individual applications, your engine may
appear different from the illustrations.
Note: Individual components are detailed on the
C2.2 turbocharged engine only.
Typical view of the C0.5 Engine
SEBU8312-03 19
Typical view of the C1.5 turbocharged engine
20 SEBU8312-03
Right side view of the C2.2 turbocharged engine
(1) Fuel shutoff solenoid (5) Throttle lever (9) Engine oil filter
(2) Number one fuel injector (6) Cover plate for the accessory drive (10) Fuel injection pump
(3) Water pump (7) Engine oil level gauge (11) Transfer pump
(4) Lower engine oil filler cap (8) Engine oil cooler (12) Fuel filter
SEBU8312-03 21
Engine Description
Left side view of the C2.2 Engine
(13) Top engine oil filler cap (19) Water temperature regulator housing (25) Fan drive belt
(14) Crankcase breather (20) Starting motor solenoid (26) Crankshaft pulley
(15) Rear Lifting eye (21) Electric starting motor (27) Coolant temperature switch
(16) Air inlet elbow (22) Alternator (28) Cooling fan
(17) Valve mechanism cover (23) Engine oil pan
(18) Turbocharger (24) Engine oil drain plug
i02613886 The pistons have two compression rings and an oil

control ring. It is important to ensure the correct
Engine Description piston height so that the piston does not contact the
cylinder head. The correct piston height also ensures
SMCS Code: 1000 efficient combustion of fuel that is necessary in order
to conform to requirements for emissions.
The C0.5, C0.7, C1.1, C1.5, C1.6 and C2.2 engines
are direct injection engines. The engines are The crankshaft for a two cylinder engine has two
controlled with a mechanically actuated fuel injection main bearing journals. The crankshaft for a three
pump. The engine cylinders are arranged in-line. cylinder engine has four main bearing journals. The
crankshaft for a four cylinder engine has five main
The cylinder head assembly has one inlet valve and bearing journals. End play is controlled by the thrust
one exhaust valve for each cylinder. Each cylinder washers that are located on the rear main bearing.
valve has a single valve spring.
22 SEBU8312-03
Engine Description
The timing gears are stamped with timing marks in C0.5 Engine
order to ensure the correct assembly of the gears.
When the No. 1 piston is at top center compression
stroke, the teeth that are stamped on the crankshaft
gear and the camshaft gear will be in alignment with
the idler gear.
The crankshaft gear turns the idler gear which then
turns the camshaft gear and the gear for the engine
oil pump.
The fuel injection pump is mounted in the cylinder
block. The fuel injection pump is operated by lobes
on the camshaft. The fuel transfer pump is located on
the right hand side of the cylinder block. The fuel
transfer pump is also operated by lobes on the
camshaft.
The fuel injection pump conforms to requirements for
emissions. If any adjustments to the fuel injection
pump timing and high idle are required you must refer (A) Exhaust valves
to your Caterpillar dealer. Some fuel injection pumps (B) Inlet valves
have mechanical governors that control the engine
rpm. Some fuel injection pumps have a governor that Table 1
is electrically controlled. C0.5 Engine Specifications
A gerotor oil pump is located in the center of the idler Maximum Operating Speed
3600 rpm
gear. The engine oil pump sends lubricating oil to the (rpm)
main oil gallery through a pressure relief valve and an
Cylinders and Arrangement In-Line two cylinder
engine oil filter. The rocker arms receive pressurized
oil through an externally located oil line that runs from Bore 67 mm (2.64 inch)
the main oil gallery to the cylinder head.
Stroke 72 mm (2.83 inch)
Coolant from the bottom of the radiator passes
through the belt driven centrifugal water pump. The Displacement 0.507 L (30.9390 in3)
coolant is cooled by the radiator and the temperature Aspiration NA(1)
is regulated by a water temperature regulator.
Compression Ratio 23.5:1
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to proper Firing Order 1-2
operation and maintenance recommendations.
Engine performance and efficiency also depend on Rotation that is viewed from the
Counterclockwise
the use of recommended fuels, lubrication oils, and flywheel
coolants. Refer to this Operation and Maintenance Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Manual, “Maintenance Interval Schedule” for more
information on maintenance items. Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch)
Injection
Engine Specifications Indirect
(1) Naturally Aspirated
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
The No. 1 cylinder is the front cylinder.
SEBU8312-03 23
Engine Description
C0.7 Engine C1.1 Engine
Illustration 20 g00852304 Illustration 21 g00852304

(A) Exhaust valves (A) Exhaust valves
(B) Inlet valves (B) Inlet valves
Table 2 Table 3
C0.7 Engine Specifications C1.1 Engine Specifications
Maximum Operating Speed Maximum Operating Speed

3600 rpm 3600 rpm
(rpm) (rpm)
Cylinders and Arrangement In-Line three cylinder Cylinders and Arrangement In-Line three cylinder
Bore 67 mm (2.64 inch) Bore 77 mm (3.03 inch)
Stroke 72 mm (2.83 inch) Stroke 81 mm (3.19 inch)
Displacement 0.762 L (46.5001 in3) Displacement 1.131 L (69.0178 in3)
Aspiration NA(1) Aspiration NA(1)
Compression Ratio 23.5:1 Compression Ratio 23:1
Firing Order 1-2-3 Firing Order 1-2-3
Rotation that is viewed from the Rotation that is viewed from the
Counterclockwise Counterclockwise
flywheel flywheel
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch) Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch)
Injection Indirect Injection Indirect

(1) Naturally Aspirated (1) Naturally Aspirated
24 SEBU8312-03
Engine Description
C1.5 Engine C1.5 Turbocharged Engine

Table 4 Table 5
C1.5 Engine Specifications C1.5 Turbocharged Engine Specifications

3000 rpm 3000 rpm
(rpm) (rpm)
Cylinders and Arrangement In-Line three cylinder Cylinders and Arrangement In-Line three cylinder
Bore 84 mm (3.31 inch) Bore 84 mm (3.31 inch)
Stroke 90 mm (3.54 inch) Stroke 90 mm (3.54 inch)
Displacement 1.496 L (91.2915 in3) Displacement 1.496 L (91.2915 in3)
Aspiration NA(1) Aspiration T(1)
Compression Ratio 22.5:1 Compression Ratio 22.5:1
Firing Order 1-2-3 Firing Order 1-2-3
flywheel flywheel

(1) Naturally Aspirated (1) Turbocharged
SEBU8312-03 25
Engine Description
C1.6 Engine C2.2 Engine

Table 6 Table 7
C1.6 Engine Specifications C2.2 Engine Specifications

3000 rpm 3000 rpm
(rpm) (rpm)
Cylinders and Arrangement In-Line four cylinder Cylinders and Arrangement In-Line four cylinder
Bore 77 mm (3.03 inch) Bore 84.0 mm (3.31 inch)
Stroke 81 mm (3.19 inch) Stroke 100.0 mm (3.94 inch)
Displacement 1.508 L (92.0238 in3) Displacement 2.216 cc (0.1352 in3)
Aspiration NA(1) Aspiration NA(1)
Firing Order 1-3-4-2 Firing Order 1-3-4-2
flywheel flywheel

(1) Naturally Aspirated (1) Naturally Aspirated
26 SEBU8312-03
Engine Description
C2.2 Turbocharged Engine C2.2 Turbocharged Aftercooled Engine

Table 8 Table 9
C2.2 Turbocharged Engine Specifications C2.2 Turbocharged Aftercooled Engine Specifications

3000 rpm 2800 rpm
(rpm) (rpm)
Cylinders and Arrangement In-Line four cylinder Cylinders and Arrangement In-Line four cylinder
Bore 84.0 mm (3.31 inch) Bore 84.0 mm (3.31 inch)
Stroke 100.0 mm (3.94 inch) Stroke 100.0 mm (3.94 inch)
Displacement 2.216 cc (0.1352 in3) Displacement 2.216 cc (0.1352 in3)
Aspiration T(1) Aspiration TA(1)
Firing Order 1-3-4-2 Firing Order 1-3-4-2
flywheel flywheel

(1) Turbocharged (1) Turbocharged aftercooled
SEBU8312-03 27
Product Identification Information
Product Identification
Information
i02656316
Plate Locations and Film

Locations Illustration 29 g01131696
SMCS Code: 1000 Serial number plate
i00610276
Reference Numbers
SMCS Code: 1000
Information for the following items may be needed to
order parts. Locate the information for your engine.
Record the information on the appropriate space.
Make a copy of this list for a record. Retain the
information for future reference.
Record for Reference

Engine Model
Engine Serial No.
Engine Arrangement No.
Modification No.
Engine Low Idle rpm
Engine Full Load rpm
Typical example
Performance Specification No.
Caterpillar engines are identified by serial numbers
and by arrangement numbers. These numbers are Primary Fuel Filter No.
shown on the engine serial number plate. Caterpillar
dealers need these numbers in order to determine Water Separator Element No.
the components that were included with the engine.
This permits accurate identification of replacement Secondary Fuel Filter Element No.
part numbers.
Lubrication Oil Filter Element No.
Serial Number Plate (1) Auxiliary Oil Filter Element No.
The engine serial number plate is located on the Supplemental Coolant Additive Maintenance
upper right side of the engine block above the fuel Element No. (Optional)
injection pump for all engine models in the series.
Total Lubrication System Capacity
Total Cooling System Capacity
Air Cleaner Element No.
Fan Drive Belt No.
28 SEBU8312-03
Emissions Certification Film
Alternator Belt No.
i06602168
Emissions Certification Film

SMCS Code: 1000; 7405
Note: This information is pertinent in the United

States and in Canada.
Typical example
Typical example
Refer to illustration 31 . The equipment manufacturer

must install the label to the equipment. This
procedure is recommended by Caterpillar. The label
must be attached to the equipment near the fuel inlet
to comply with the EPA regulations. The equipment
manufacturer may install another fuel label.
SEBU8312-03 29
Operation Section
Lifting and Storage
Operation Section i05111635
Product Storage
Lifting and Storage SMCS Code: 1000; 1404; 7002
If the engine will not be started for several weeks, the
i04342729 lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
Product Lifting liner surface. Rust on the cylinder liner surface will
cause increased engine wear and a reduction in
SMCS Code: 1000; 1404; 7002 engine service life.
To help prevent excessive engine wear, use the
following guidelines:
• Complete all of the lubrication recommendations
that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).
• If freezing temperatures are expected, check the

cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
(Maintenance Section).
If an engine is out of operation and if use of the
engine is not planned, special precautions should be
Illustration 32 g00103219 made. If the engine will be stored for more than 1
month, a complete protection procedure is
NOTICE recommended.
Never bend the eyebolts and the brackets. Only load For more detailed information on engine storage, see
the eyebolts and the brackets under tension. Re- Special Instruction, SEHS9031, “Storage Procedure
member that the capacity of an eyebolt is less as the For Caterpillar Products”.
angle between the supporting members and the ob-
ject becomes less than 90 degrees. Your Cat dealer can assist in preparing the engine for
extended storage periods.
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.
Some removals require lifting the fixtures in order to
obtain proper balance and safety.
To remove the engine only, use the lifting eyes that
are on the engine.
Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting
eyes and/or the engine make the lifting eyes and the
lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Cat dealer for information regarding
fixtures for proper engine lifting.
30 SEBU8312-03
Operation Section
Gauges and Indicators
Gauges and Indicators 3. Determine if the engine must be shut down

immediately or if the engine can be cooled by
reducing the load.
i01139916
Tachometer – This gauge indicates
Gauges and Indicators engine speed (rpm). When the throttle
SMCS Code: 1900; 7450 control lever is moved to the full throttle
position without load, the engine is running at
Your engine may not have the same gauges or all of high idle. The engine is running at the full load
the gauges that are described. For more information rpm when the throttle control lever is at the full
about the gauge package, see the OEM information. throttle position with maximum rated load.
Gauges provide indications of engine performance.

Ensure that the gauges are in good working order. NOTICE
To help prevent engine damage, never exceed the
Determine the normal operating range by observing high idle rpm. Overspeeding can result in serious
the gauges over a period of time. damage to the engine. The engine can be operated
Noticeable changes in gauge readings indicate at high idle without damage, but should never be al-
potential gauge or engine problems. Problems may lowed to exceed high idle rpm.
also be indicated by gauge readings that change
even if the readings are within specifications.
Determine and correct the cause of any significant Note: The high idle rpm and the full load rpm are
change in the readings. Consult your Caterpillar stamped on the Information Plate.
dealer for assistance.
Ammeter – This gauge indicates the
amount of charge or discharge in the
NOTICE battery charging circuit. Operation of
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP the indicator should be to the right side of “ 0””
the engine. Engine damage can result. (zero).
Fuel Level – This gauge indicates the

Engine Oil Pressure – The oil pressure fuel level in the fuel tank. The electrically
should be greatest after a cold engine is operated fuel level gauge only registers
started. The typical engine oil pressure when the “ START/STOP”” switch is “ ON”” .
with SAE10W30 is 207 to 413 kPa (30 to 60 psi) at
rated rpm. Service Hour Meter – This gauge
indicates the total number of clock
A lower oil pressure is normal at low idle. If the load is hours that the engine has operated.
stable and the gauge reading changes, perform the
following procedure:
1. Remove the load.
2. Reduce engine speed to low idle.
3. Check and maintain the oil level.
Jacket Water Coolant Temperature –

Typical temperature range is 71 to 96°C
(160 to 205°F). The maximum allowable
temperature with the pressurized cooling system
at 48 kPa (7 psi) is 103°C (217°F). Higher
temperatures may occur under certain
conditions. The water temperature reading may
vary according to load. The reading should never
exceed the boiling point for the pressurized
system that is being used.
If the engine is operating above the normal range
and steam becomes apparent, perform the following
procedure:
1. Reduce the load and the engine rpm.
2. Inspect the cooling system for leaks.
SEBU8312-03 31
Operation Section
Features and Controls
Features and Controls NOTICE

When an alarm is activated, corrective measures
i01007515
must be taken before the situation becomes an emer-
gency in order to avoid possible engine damage.
Engine Shutoffs and Engine
If corrective measures are not taken within a
Alarms reasonable time, engine damage could result. The
SMCS Code: 1900; 7400; 7418 alarm will continue until the condition is corrected.
The alarm may need to be reset.
Shutoffs A switch may be installed in the alarm while the

engine is stopped for repairs. Before the engine is
Shutoffs and alarms are electrically operated or started, ensure that the switch is moved to the ON
mechanically operated. The operation of all electric position and that the warning lights are flashing. The
shutoffs and alarms utilize components which engine will not be protected if the switch is left in the
actuate switches in a sensing unit. OFF position.
Shutoffs are set at critical levels for the following Testing the Shutoff and Alarm
items: operating temperature, operating pressure,
operating level and operating rpm. The particular System
shutoff may need to be reset before the engine will
start. Most control panels are equipped with a lamp test
switch. Turn the switch to the ON position in order to
NOTICE check the indicator lights for proper operation.
Always determine the cause of the engine shutdown. Replace defective bulbs immediately.
Make necessary repairs before attempting to restart
the engine. NOTICE
During testing, abnormal operating conditions must
be simulated. Perform the tests correctly in order to
Be familiar with the following items: help prevent possible engine damage.
• Types and locations of shutoff
Refer to the Service Manual for more information on
• Conditions which cause each shutoff to function testing procedures or consult your Caterpillar dealer.
• The resetting procedure that is required to restart i02613889
the engine
Fuel Shutoff
Alarms
SMCS Code: 1259; 1704
Alarms consist of a switch and a contactor. The
switches are wired to the contactors. The contactors The fuel shutoff solenoid is located on the fuel
activate alarm circuits in an annunciator panel. Your injection pump. When the fuel shutoff solenoid is
engine may be equipped with the following switches: activated, the solenoid moves the fuel rack to the
“OFF” position.
Engine oil pressure – The engine oil pressure
switch indicates when oil pressure drops below rated
system pressure.
Coolant level – The low coolant level switch
indicates when the coolant level is low.
Coolant temperature – The coolant temperature
switch indicates high jacket water coolant
temperature.
Note: The sensing element of the coolant

temperature switch must be submerged in coolant in
order to operate.
Engines may be equipped with alarms in order to
alert the operator when undesirable operating Illustration 33 g01305771
conditions occur. Typical example
(1) Fuel shutoff solenoid
32 SEBU8312-03
Operation Section
Fuel Shutoff
If an electronically controlled governor has been

installed the governor operates the fuel rack in order
to stop the engine.
SEBU8312-03 33
Operation Section
Engine Starting
Engine Starting • Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
i01486758 to the controls.
Before Starting Engine • Ensure that the areas around the rotating parts are
clear.
SMCS Code: 1000; 1400; 1450
• All of the guards must be put in place. Check for
Perform the required daily maintenance and other
damaged guards or for missing guards. Repair
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can any damaged guards. Replace damaged guards
help prevent major repairs at a later date. Refer to and/or missing guards.
the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for more • Disconnect any battery chargers that are not
information. protected against the high current drain that is
created when the electric starting motor (if
• For the maximum service life of the engine, make equipped) is engaged. Check electrical cables and
a thorough inspection before the engine is started. check the battery for poor connections and for
Look for the following items: oil leaks, coolant corrosion.
leaks, loose bolts and trash buildup. Remove trash
buildup and arrange for repairs, as needed. • Reset all of the shutoffs or alarm components.
• Inspect the cooling system hoses for cracks and • Check the engine lubrication oil level. Maintain the
for loose clamps. oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage. • Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
• Inspect the wiring for loose connections and for the coolant level to the “FULL” mark on the coolant
worn wires or frayed wires. recovery tank.
• Check the fuel supply. Drain water from the water • If the engine is not equipped with a coolant
separator (if equipped). Open the fuel supply recovery tank maintain the coolant level within
valve. 13 mm (0.5 inch) of the bottom of the filler pipe. If
the engine is equipped with a sight glass, maintain
NOTICE the coolant level in the sight glass.
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel • Observe the air cleaner service indicator (if
pressure. High fuel pressure may cause filter housing equipped). Service the air cleaner when the yellow
failure or other damage. diaphragm enters the red zone, or when the red
piston locks in the visible position.
If the engine has not been started for several weeks, • Ensure that any driven equipment has been
fuel may have drained from the fuel system. Air may disengaged. Minimize electrical loads or remove
have entered the filter housing. Also, when fuel filters any electrical loads.
have been changed, some air pockets will be trapped
in the engine. In these instances, prime the fuel i06602184
system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system. Starting the Engine
SMCS Code: 1000; 1450
Engine exhaust contains products of combustion

which may be harmful to your health. Always Do not use aerosol types of starting aids such as
start and operate the engine in a well ventilated ether. Such use could result in an explosion and
area and, if in an enclosed area, vent the exhaust personal injury.
to the outside.
Refer to the Service Manual for your type of controls.
Use the following procedure to start the engine.
1. Move the throttle lever to the low idle position
before you start the engine.
34 SEBU8312-03
Operation Section
Cold Weather Starting
Note: If necessary, increase the throttle position so Note: If the glow plug indicator light flashes for 2 to 3
that the engine will start in cold conditions. The seconds or fails to illuminate, a malfunction exists in
engine speed should not exceed 1500 rev/min until the cold start system. Do not use ether or other
the oil pressure has increased. starting fluids to start the engine.
6. If the engine does not start, release the engine

NOTICE
Do not operate the glow plugs for more than 60 sec- start switch and allow the electric starting motor to
onds at one time. Damage to the glow plugs could cool. Then, repeat steps 2 through step 5.
occur.
7. Turn the engine start switch to the OFF position to
stop the engine.
i05287569
Cold Weather Starting

SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.
Startability will be improved at temperatures below

−18 °C (0 °F) from the use of a jacket water heater or
extra battery capacity.
When No. 2 diesel fuel is used, the following items
provide a means of minimizing starting problems and
fuel problems in cold weather: engine oil pan heaters,
jacket water heaters, fuel heaters and fuel line
insulation.
Use the procedure that follows for cold weather
starting.
2. Turn the engine start switch to the HEAT position.
Hold the engine start switch in the HEAT position 1. The governor control needs to be in the LOW IDLE
for time shown in illustration 34 . This action will position if the temperature is below 0 °C (32 °F).
activate the glow plugs and aid in the starting of
the engine. NOTICE
Do not operate the glow plugs for more than 60 sec-
onds at one time. Damage to the glow plugs could
NOTICE occur.
Do not crank the engine for more than 30 seconds.
Allow the electric starting motor to cool for two mi-
nutes before cranking the engine again. 2. Turn the keyswitch to the HEAT position until the
glow plug indicator lamp illuminates.
3. When the glow plug indicator light is illuminated,
turn the engine start switch to the START position NOTICE
Do not crank the engine for more than 30 seconds.
and crank the engine. Allow the electric starting motor to cool for two mi-
4. When the engine starts, release the engine start nutes before cranking the engine again.
switch.
3. Turn the keyswitch to the START position.
5. Slowly move the throttle lever to the low idle
position and allow the engine to idle. Refer to the 4. When the engine starts, release the keyswitch.
Operation and Maintenance Manual, “After
5. If the engine does not start, release the keyswitch
Starting Engine” topic.
and allow the starter motor to cool. Then, repeat
steps 2 through step 4.
SEBU8312-03 35
Operation Section
Starting with Jump Start Cables
6. Allow the engine to idle for 3 to 5 minutes, or allow 1. Turn the start switch on the stalled engine to the
the engine to idle until the water temperature OFF position. Turn off all accessories.
indicator begins to rise. The engine should run at
2. Connect one positive end of the jump start cable to
low idle smoothly until speed is gradually
the positive cable terminal of the discharged
increased to high idle. Allow the white smoke to
battery. Connect the other positive end of the jump
disperse before proceeding with normal operation.
start cable to the positive cable terminal of the
7. Operate the engine at low load until all systems electrical source.
reach operating temperature. Check the gauges
3. Connect one negative end of the jump start cable
during the warm-up period.
to the negative cable terminal of the electrical
source. Connect the other negative end of the
i02242604
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
Starting with Jump Start potential sparks from igniting combustible gases
Cables that are produced by some batteries.
SMCS Code: 1000; 1401; 1402; 1900 4. Charge the batteries. The engine will not continue
to run after starting if the batteries have not been
charged.
Improper jump start cable connections can cause 5. Start the engine.
an explosion resulting in personal injury. 6. Immediately after the stalled engine is started,
Prevent sparks near the batteries. Sparks could disconnect the jump start cables in reverse order.
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine. i01646248
If the installation is not equipped with a backup

battery system, it may be necessary to start the
After Starting Engine
engine from an external electrical source. SMCS Code: 1000
First, determine the reason that it is necessary to Note: In temperatures from 0 to 60°C (32 to 140°F),
start with power from an external source. the warm-up time is approximately three minutes. In
temperatures below 0°C (32°F), additional warm-up
Many batteries which are considered unusable are
still rechargeable. After jump starting, the alternator time may be required.
may not be able to fully recharge batteries that are
Note: Ensure that the self test for the monitoring
severely discharged. The batteries must be charged
to the proper voltage with a battery charger. For system (if equipped) is completed before operating
information on testing and charging, refer to the the engine under load.
Special Instruction, SEHS7633, “Battery Test When the engine idles during warm-up, observe the
Procedure”.
following conditions:
NOTICE • Check for any fluid or for any air leaks at idle rpm
Using a battery source with the same voltage as the and at one-half full rpm (no load on the engine)
electric starting motor. Use ONLY equal voltage for before operating the engine under load. This is not
jump starting. The use of higher voltage will damage
possible in some applications.
the electrical system.
Do not reverse the battery cables. The alternator can • Operate the engine at low idle until all systems
be damaged. Attach ground cable last and remove achieve operating temperatures. Check all gauges
first. during the warm-up period.
When using an external electrical source to start the Note: Gauge readings should be observed and the
engine, turn the generator set control switch to the data should be recorded frequently while the engine
“OFF” position. Turn all electrical accessories OFF is operating. Comparing the data over time will help
before attaching the jump start cables. to determine normal readings for each gauge.
Comparing data over time will also help detect
Ensure that the main power switch is in the OFF posi- abnormal operating developments. Significant
tion before attaching the jump start cables to the en- changes in the readings should be investigated.
gine being started.
36 SEBU8312-03
Operation Section
Engine Operation
Engine Operation 3. Perform another walk-around inspection. Check

the engine for fluid leaks and air leaks.
i06545704 4. Increase the rpm to the rated rpm. Check for fluid
leaks and air leaks. The engine may be operated
Engine Operation at full rated rpm and at full load when the jacket
SMCS Code: 1000 water temperature reaches 60°C (140°F).
Proper operation and maintenance are key factors in i01646335

obtaining the maximum life and economy of the
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be
Engaging the Driven
minimized and engine service life can be maximized. Equipment
The time that is needed for the engine to reach SMCS Code: 1000
normal operating temperature can be less than the
time needed for a walk-around inspection of the 1. Operate the engine at one-half of the rated rpm,
engine. when possible.
After the engine is started and after the engine 2. Engage the driven equipment without a load on the
reaches normal operating temperature, the engine equipment, when possible.
can be operated at the rated rpm. The engine will
reach normal operating temperature faster when the Interrupted starts put excessive stress on the drive
engine is at rated speed. The engine will reach train. Interrupted starts also waste fuel. To get the
normal operating temperature faster when the engine driven equipment in motion, engage the clutch
is at low-power demand. This procedure is more smoothly with no load on the equipment. This
effective than idling the engine at no load. The engine method should produce a start that is smooth and
should reach operating temperature in a few minutes. easy. The engine rpm should not increase and the
clutch should not slip.
Gauge readings should be observed and the data
should be recorded frequently while the engine is 3. Ensure that the ranges of the gauges are normal
operating. Comparing the data over time will help to when the engine is operating at one-half of the
determine normal readings for each gauge. rated rpm. Ensure that all gauges operate
Comparing data over time will also help detect properly.
abnormal operating developments. Significant
changes in the readings should be investigated. 4. Increase the engine rpm to the rated rpm. Always
increase the engine rpm to the rated rpm before
Engines rated for constant speed use are allowed to the load is applied.
complete a starting sequence, an operation at a
single constant speed, and a shutdown sequence. 5. Apply the load. Begin operating the engine at low
Every time the engine is run, each of these load. Check the gauges and equipment for proper
operations should occur only once. The starting
sequence and shutdown sequence can include a operation. After normal oil pressure is reached and
short period of operation at the low idle speed for the temperature gauge begins to move, the engine
purposes of warming up and cooling down the engine may be operated at full load. Check the gauges
or driven equipment. The emissions type approval is and equipment frequently when the engine is
not valid for operation of a constant speed engine in operated under load.
a manner different from that described above.
Extended operation at low idle or at reduced load
i00613522 may cause increased oil consumption and carbon
buildup in the cylinders. This carbon buildup
Engine Warm-up results in a loss of power and/or poor
performance.
SMCS Code: 1000
1. Run the engine at low idle for three to five minutes,

or run the engine at low idle until the jacket water
temperature starts to rise.
More time may be necessary when the
temperature is below −18°C (0°F).
2. Check all of the gauges during the warm-up
period.
SEBU8312-03 37
Operation Section
Fuel Conservation Practices
i01432412
Fuel Conservation Practices

SMCS Code: 1000; 1250
The efficiency of the engine can affect the fuel
economy. Caterpillar's design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
in order to attain optimum performance for the life of
the engine.
• Avoid spilling fuel.
Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
• Be aware of the properties of the different fuels.
Use only the recommended fuels.
• Avoid unnecessary idling.

Shut off the engine rather than idle for long periods of
time.
• Observe the service indicator frequently. Keep the
air cleaner elements clean.
• Maintain a good electrical system.
One bad battery cell will overwork the alternator. This
will consume excess power and excess fuel.
• Ensure that the belts are properly adjusted. The

belts should be in good condition.
• Ensure that all of the connections of the hoses are
tight. The connections should not leak.
• Ensure that the driven equipment is in good
working order.
• Cold engines consume excess fuel. Utilize heat
from the jacket water system and the exhaust
system, when possible. Keep cooling system
components clean and keep cooling system
components in good repair. Never operate the
engine without water temperature regulators. All of
these items will help maintain operating
temperatures.
• Settings for the fuel system and the limits for the
operating altitude are stamped on the Engine
Information Plate. If an engine is moved to a
higher altitude, the settings must be changed by a
Caterpillar dealer. Changing the settings will help
to provide the maximum efficiency for the engine.
Engines can be operated safely at higher
altitudes, but the engines will deliver less
horsepower. The fuel settings should be changed
by a Caterpillar dealer in order to obtain the rated
horsepower.
38 SEBU8312-03
Operation Section
Engine Stopping
Engine Stopping Emergency Stop Button
i01433818
Stopping the Engine

SMCS Code: 1000; 7000
Note: Individual applications will have different

control systems. Ensure that the shutoff procedures
are understood. Use the following general guidelines
in order to stop the engine.
1. Reduce the engine rpm to low idle.

2. Remove the load from the engine.
3. If the engine has been operated at low loads, run Illustration 35 g00104303
the engine at low idle for 30 seconds before you
Typical emergency stop button
stop the engine.
4. If the engine has been operated at high load, The emergency stop button is in the OUT position for
increase engine rpm to no more than 1/2 rated normal engine operation. Push the emergency stop
button. The engine will not start when the button is
rpm for three to five minutes. locked. Turn the button clockwise in order to reset.
This reduces coolant temperatures and oil
temperatures. A reduction in these temperatures NOTICE
stabilizes internal engine coolant and oil Stopping the engine immediately after it has been
temperatures. working under load can result in overheating and ac-
celerated wear of the engine components.
5. Reduce the engine rpm to low idle before stopping
the engine. If the engine has been operating at high rpm and/or
high loads, run the engine at low idle for at least three
6. After the cool down period, turn the start switch to minutes to reduce and stabilize the internal engine
the OFF position. temperature before stopping the engine.
i01171573
i02242518
Emergency Stopping After Stopping Engine

SMCS Code: 1000; 7418
SMCS Code: 1000
NOTICE Note: Before you check the engine oil, do not
Emergency shutoff controls are for EMERGENCY operate the engine for at least 10 minutes in order to
use ONLY. DO NOT use emergency shutoff devices allow the engine oil to return to the oil pan.
or controls for normal stopping procedure.
• Check the crankcase oil level. Maintain the oil
Ensure that any components for the external system level between the “ADD” mark and the “FULL”
that support the engine operation are secured after
the engine is stopped. mark on the oil level gauge.
• If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.
• Note the service hour meter reading. Perform the
maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
• Fill the fuel tank in order to help prevent
accumulation of moisture in the fuel. Do not overfill
the fuel tank.
SEBU8312-03 39
Operation Section
After Stopping Engine
NOTICE
Only use antifreeze/coolant mixtures that are recom-
mended in this Operation and Maintenance Manual,
“Refill Capacities and Recommendations”.
• Allow the engine to cool. Check the coolant level.

Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling.
• If freezing temperatures are expected, check the
coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in
the instructions from the OEM.
40 SEBU8312-03
Operation Section
Cold Weather Operation
Cold Weather Operation There are three major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
i01457051
• Lower cloud point
Radiator Restrictions • Lower pour point
SMCS Code: 1353; 1396
• Lower rating of kJ (BTU) per unit volume of fuel
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow When No. 1 diesel fuel is used, a decrease in power
restriction can cause the following conditions: and in fuel efficiency may be noticed. Other operating
effects should not be experienced.
• High exhaust temperatures
The cloud point is the temperature when a cloud of
• Power loss wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is the
• Excessive fan usage temperature when diesel fuel will thicken. The diesel
fuel becomes more resistant to flow through fuel
• Reduction in fuel economy pumps and through fuel lines.
If an airflow restriction device must be used, the Be aware of these values when diesel fuel is
device should have a permanent opening directly in purchased. Anticipate the average ambient
line with the fan hub. The device must have a temperature of the area. Engines that are fueled in
minimum opening dimension of at least 770 cm2 one climate may not operate well if the engines are
(120 in2). moved to another climate. Problems can result due to
changes in temperature.
A centered opening that is directly in line with the fan
hub is specified in order to prevent an interrupted Before troubleshooting for low power or for poor
airflow on the fan blades. Interrupted airflow on the performance in the winter, check the type of fuel that
fan blades could cause a fan failure. is being used.
Caterpillar recommends a warning device for the inlet When No. 2 diesel fuel is used the following
manifold temperature and/or the installation of an components provide a means of minimizing problems
inlet air temperature gauge. The warning device for in cold weather:
the inlet manifold temperature should be set at 75 °C
(167 °F). The inlet manifold air temperature should • Starting aids
not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential • Engine oil pan heaters
engine damage.
• Engine coolant heaters
i05264084
• Fuel heaters
Fuel and the Effect from Cold • Fuel line insulation
Weather For more information on cold-weather operation, see
SMCS Code: 1000; 1250 Special Publication, SEBU5898, “Cold Weather
Recommendations”.
The following fuels are the grades that are available
for Cat engines: i01250450
• No. 1
Fuel Related Components in
• No. 2 Cold Weather
• Blend of No. 1 and No. 2 SMCS Code: 1000; 1250
No. 2 diesel fuel is the most commonly used fuel.
Either No. 1 diesel fuel or a blend of No. 1 and No. 2 Fuel Tanks
is best suited for cold-weather operation.
Condensation can form in partially filled fuel tanks.
Quantities of No. 1 diesel fuel are limited. No. 1 Top off the fuel tanks after you operate the engine.
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.
SEBU8312-03 41
Operation Section
Fuel Related Components in Cold Weather
Fuel tanks should contain some provision for draining Note: Fuel heaters that are controlled by the water
water and sediment from the bottom of the tanks. temperature regulator or self-regulating fuel heaters
Some fuel tanks use supply pipes that allow water should be used with this engine. Fuel heaters that are
and sediment to settle below the end of the fuel not controlled by the water temperature regulator can
supply pipe.
heat the fuel in excess of 65°C (149°F). A loss of
Some fuel tanks use supply lines that take fuel engine power can occur if the fuel supply
directly from the bottom of the tank. If the engine is temperature exceeds 37°C (100°F).
equipped with this system, regular maintenance of
the fuel system filter is important. Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
Drain the water and sediment from any fuel storage the fuel in warm weather operation.
tank at the following intervals: weekly, oil changes
and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.
Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual in the Maintenance Section for more
information on priming the fuel system.
The micron rating and the location of a primary fuel
filter is important in cold weather operation. The
primary fuel filter and the fuel supply line are the most
common components that are affected by cold fuel.
NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a
two micron absolute high efficiency fuel filter is re-
quired for all Caterpillar Electronic Unit Injectors. Cat-
erpillar High Efficiency Fuel Filters meet these
requirements. Consult your Caterpillar dealer for the
proper part numbers.
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in the fuel system before the primary fuel
filter.
The following fuel heaters are recommended for
Caterpillar engines:
• 7C-3557 Fuel Heater Group
• 7C-3558 Heater Kit

For further information on fuel heaters, consult your
Caterpillar dealer.
Disconnect the fuel heater in warm weather.
42 SEBU8312-03
Maintenance Section
Refill Capacities
Maintenance Section (Table 10, contd)

CF(4) CC, CD
CF-2(5) CD-2(5)
Refill Capacities (1) API CH-4 and CI-4 oils are acceptable if the requirements
of Caterpillar's ECF-1 (Engine Crankcase Fluid specifica-
i04040209
tion-1) are met. CH-4 and CI-4 oils that have not met the re-
quirements of Caterpillar's ECF-1 Specification may cause
reduced engine life.
Refill Capacities and (2) API CG-4 oils are acceptable for all Caterpillar diesel engines.
When the API CG-4 oils are used, the oil drain interval should
Recommendations not exceed the standard oil drain interval for your engine.
(3) API CF-4 oils are not recommended for this series of Caterpillar
SMCS Code: 1348; 1395; 7560 diesel engines. For all other commercial diesel engines, the oil
drain interval should not exceed 50 percent of the standard oil
drain interval for your engine with a maximum of 125 hours.
Engine Oil (4) API CF oils are not recommended for this series of Caterpillar
engines and smaller Direct Injection (DI) diesel engines.
(5) API CF-2 and CD-2 oils are classifications for two-cycle diesel
NOTICE engines. Caterpillar does not sell engines that utilize the CD-2
These recommendations are subject to change with- and the API CF-2 oils.
out notice. Contact your local Caterpillar dealer for
the most up-to-date recommendations. Note: When oil meets more than one API
classification, the applicable footnote is determined
by the highest API classification that is met.
API Oils
Example – An oil meets both the API CH-4 and the
The Engine Oil Licensing and Certification System by API CF oil classifications. In this case, the API CH-4
the American Petroleum Institute (API) is recognized applies.
by Caterpillar. For detailed information about this
system, see the latest edition of the “API publication
No. 1509”. Engine oils that bear the API symbol are Cat DEO (Diesel Engine Oil)
authorized by API.
Caterpillar Oils have been developed and tested in
order to provide the full performance and service life
that has been designed and built into Caterpillar
Engines. Caterpillar Oils are currently used to fill
diesel engines at the factory. These oils are offered
by Caterpillar dealers for continued use when the
engine oil is changed. Consult your Caterpillar dealer
for more information on these oils.
Due to significant variations in the quality and in the
performance of commercially available oils,
Caterpillar makes the following recommendations:
• Cat DEO (Diesel Engine Oil) (10W-30)
• Cat DEO (Diesel Engine Oil) (15W-40)
Caterpillar multigrade DEO is formulated with the
Typical API symbol correct amounts of detergents, dispersants, and
alkalinity in order to provide superior performance in
Diesel engine oils CC, CD, CD-2, and CE have not Caterpillar Diesel Engines.
been API authorized classifications since January 1,
1996. Table 10 summarizes the status of the Caterpillar multigrade DEO is available in various
classifications. viscosity grades that include SAE 10W-30 and SAE
Table 10 15W-40. To choose the correct viscosity grade for the
API Classifications ambient temperature, see Table 11 . Multigrade oils
provide the correct viscosity for a broad range of
Current Obsolete operating temperatures.
CI-4(1). CH-4(1) . CG-4(2). CF-4(3) CE
Multigrade oils are effective in maintaining low oil
consumption and low levels of piston deposits.
(continued)
SEBU8312-03 43
Maintenance Section
Refill Capacities and Recommendations
Caterpillar multigrade DEO can be used in other • API CF-4 multigrade oils are not recommended for
diesel engines and in gasoline engines. See the this series of diesel engines. For all other smaller
engine manufacturers guide for the recommended commercial diesel engines, the oil drain interval
specifications. Compare the specifications to the should not exceed 50 percent of the standard oil
specifications of Caterpillar multigrade DEO. The drain interval for your engine.
current industry standards for Caterpillar DEO are
listed on the product label and on the data sheets for
the product. NOTICE
In selecting oil for any engine application, both the oil
Consult your Caterpillar dealer for part numbers and viscosity and oil performance classification/specifica-
for available sizes of containers. tion as specified by the engine manufacturer must be
defined and satisfied. Using only one of these param-
Note: Caterpillar SAE 15W-40 multigrade DEO eters will not sufficiently define oil for an engine
exceeds the performance requirements for the application.
following API classifications: CI-4, CH-4, CG-4, CF-4
and CF. The Caterpillar multigrade DEO exceeds the In order to make the proper choice of a commercial
requirements of the Caterpillar specification that is oil, refer to the following explanations:
ECF-1 (Engine Crankcase Fluid-1). The Caterpillar API CI-4 – API CI-4 oils were developed in order to
SAE 15W-40 multigrade DEO passes the following meet the requirements of high performance diesel
proprietary tests: sticking of the piston ring, oil control engines that use cooled Exhaust Gas Recirculation
tests, wear tests and soot tests. Proprietary tests (EGR). API CI-4 oils are acceptable if the
help ensure that Caterpillar multigrade oil provides requirements of Caterpillar's ECF-1 (Engine
superior performance in Caterpillar Diesel Engines. Crankcase Fluid specification-1) are met.
In addition, Caterpillar multigrade oil exceeds many
of the performance requirements of other
API CH-4 – API CH-4 oils were developed in order to
manufacturers of diesel engines. Therefore, this oil is protect low emissions diesel engines that use a 0.05
an excellent choice for many mixed fleets. True high percent level of fuel sulfur. However, API CH-4 oils
performance oil is produced with a combination may be used with higher sulfur fuels. API CH-4 oils
of the following factors: industry standard tests, are acceptable if the requirements of Caterpillar's
proprietary tests, field tests and prior experience ECF-1 (Engine Crankcase Fluid specification-1) are
with similar formulations. The design and the met.
development of Caterpillar lubricants that are
both high performance and high quality are
based on these factors. Note: CH-4 oils and CI-4 oils that have not met the
requirements of Caterpillar's ECF-1 Specification
Note: Non-Caterpillar commercial oils are second may cause reduced engine life.
choice oils.
NOTICE
Commercial Oils Failure to follow these oil recommendations can
cause shortened engine service life due to deposits
Note: If Caterpillar Multigrade DEO is not used, use and/or excessive wear.
only commercial oils that meet the following
classifications.
Note: Refer to Special Publication, SEBU6251,
• API CH-4 multigrade oils and API CI-4 multigrade “Caterpillar Commercial Diesel Engine Fluids
oils are acceptable if the requirements of Recommendations” for additional information that
Caterpillar's ECF-1 (Engine Crankcase Fluid relates to lubrication for your engine.
specification-1) are met. CH-4 oils and CI-4 oils
that have not met the requirements of Caterpillar's Lubricant Viscosity Recommendations
ECF-1 Specification may cause reduced engine
life. The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during cold
• API CG-4 multigrade oils are acceptable for all engine start-up, and the maximum ambient
Caterpillar diesel engines. When the API CG-4 temperature during engine operation.
oils are used, the oil drain interval should not
exceed the standard oil drain interval for your Refer to Table 11 (minimum temperature) in order to
determine the required oil viscosity for starting a cold
engine. engine.
Refer to Table 11 (maximum temperature) in order to
select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
44 SEBU8312-03
Maintenance Section
Note: Generally, use the highest oil viscosity that is Refill Capacities for the Lubrication
available to meet the requirement for the temperature System
at start-up.
The refill capacities for the engine crankcase reflect
If ambient temperature conditions at engine start-up the approximate capacity of the crankcase or sump
require the use of multigrade SAE 0W oil, SAE 0W- plus standard oil filters. Auxiliary oil filter systems will
40 viscosity grade is preferred over SAE 0W-20 or require additional oil. Refer to the OEM specifications
SAE 0W-30. for the capacity of the auxiliary oil filter.
Table 11
Table 12
Engine Oil Viscosities for Ambient Temperatures
C0.5 Engine
Ambient Temperature Approximate Refill Capacities
Viscosity Grade Minimum Maximum Compartment or System Min Max
SAE 0W-20 −40 °C (−40 °F) 10 °C (50 °F) Crankcase Oil Sump (Standard)(1) 1.6 L 2.01 L
(1.7 qt) (2.1 qt)
SAE 0W-30 −40 °C (−40 °F) 30 °C (86 °F)
External System (OEM)(2)
SAE 0W-40 −40 °C (−40 °F) 40 °C (104 °F)
Total Lubrication System(3)
SAE 5W-30 −30 °C (−22 °F) 30 °C (86 °F)
(1) These values are the approximate capacities for the crankcase
SAE 5W-40 −30 °C (−22 °F) 50 °C (122 °F) oil sump which include the standard oil filters that are installed
at the factory.
SAE 10W-30 −18 °C (0 °F) 40 °C (104 °F) (2) Enter the capacity for the External System in this row. Refer to
either Caterpillar specifications or OEM specifications for fur-
SAE 10W-40 −18 °C (0 °F) 50 °C (122 °F) ther information. Engines with auxiliary oil filters will require ad-
ditional oil. Refer to the OEM specifications for the capacity of
SAE 15W-40 −9.5 °C (15 °F) 50 °C (122 °F) the auxiliary oil filter.
(3) The Total Lubrication System includes the capacity for the
Crankcase Oil Sump plus the capacity for the External System.
Note: Supplemental heat is recommended below the Enter the total in this row.
minimum recommended ambient temperature.
Table 13
S·O·S Oil Analysis C0.7 Engine
Approximate Refill Capacities
Caterpillar has developed a tool for maintenance
management that evaluates oil degradation and the Compartment or System Min Max
tool also detects the early signs of wear on internal Crankcase Oil Sump (Standard)(1) 2.35 L 3.05 L
components. The Caterpillar tool for oil analysis is (2.5 qt) (3.2 qt)
called S·O·S Oil Analysis and the tool is part of the
S·O·S Services program. S·O·S Oil Analysis divides External System (OEM)(2)
oil analysis into three categories:
• Wear Analysis (1) These values are the approximate capacities for the crankcase
oil sump which include the standard oil filters that are installed
• Oil condition at the factory.
(2) Enter the capacity for the External System in this row. Refer to
• Additional tests either Caterpillar specifications or OEM specifications for fur-
ther information. Engines with auxiliary oil filters will require ad-
The wear analysis monitors metal particles, some oil ditional oil. Refer to the OEM specifications for the capacity of
additives, and some contaminants. the auxiliary oil filter.
Oil condition uses infrared (IR) analysis to evaluate Crankcase Oil Sump plus the capacity for the External System.
Enter the total in this row.
the chemistry of the oil. Infrared analysis is also used
to detect certain types of contamination. Table 14
Additional tests are used to measure contamination C1.1 Engine
levels from water, fuel, or coolant. Oil viscosity and Approximate Refill Capacities
corrosion protection can be evaluated, as needed.
Compartment or System Min Max
Refer to Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids Crankcase Oil Sump (Standard)(1) 3.4 L 4.4 L
Recommendations” or contact your local Caterpillar (3.6 qt) (4.6 qt)
dealer for additional information concerning the
S·O·S Oil Analysis program.
(continued)
SEBU8312-03 45
Maintenance Section
(Table 14, contd) Table 17

C1.1 Engine C2.2 Turbocharged Engines and Naturally Aspirated
Approximate Refill Capacities Engines
Crankcase Oil Sump (Standard)(1) 8.9 L 10.6 L
Total Lubrication System(3) (9.4 qt) (11.2 qt)
(1) These values are the approximate capacities for the crankcase
oil sump which include the standard oil filters that are installed
at the factory. Total Lubrication System(3)
(2) Enter the capacity for the External System in this row. Refer to
either Caterpillar specifications or OEM specifications for fur- (1) These values are the approximate capacities for the crankcase
ther information. Engines with auxiliary oil filters will require ad- oil sump which include the standard oil filters that are installed
ditional oil. Refer to the OEM specifications for the capacity of at the factory.
the auxiliary oil filter. (2) Enter the capacity for the External System in this row. Refer to
(3) The Total Lubrication System includes the capacity for the either Caterpillar specifications or OEM specifications for fur-
Crankcase Oil Sump plus the capacity for the External System. ther information. Engines with auxiliary oil filters will require ad-
Enter the total in this row. ditional oil. Refer to the OEM specifications for the capacity of
the auxiliary oil filter.
Table 15 (3) The Total Lubrication System includes the capacity for the
Crankcase Oil Sump plus the capacity for the External System.
C1.5 Turbocharged Engines and Naturally Aspirated Enter the total in this row.
Engines
Lubricating Grease
Crankcase Oil Sump (Standard)(1) 4.5 L 6L Caterpillar provides a range of moderate greases to
(4.8 qt) (6.3 qt) extremely high performance greases in order to
service the entire line of Caterpillar products that
External System (OEM)(2) operate throughout the wide variety of climates. From
this variety of Caterpillar grease products, you will
Total Lubrication System(3) find at least one of the Caterpillar greases that will
(1) These values are the approximate capacities for the crankcase satisfy the performance requirements for any
oil sump which include the standard oil filters that are installed machine or equipment application.
at the factory.
(2) Enter the capacity for the External System in this row. Refer to Before selecting a grease for any application, the
either Caterpillar specifications or OEM specifications for fur- performance requirements must be determined.
ther information. Engines with auxiliary oil filters will require ad- Consult the grease recommendations that are made
ditional oil. Refer to the OEM specifications for the capacity of
the auxiliary oil filter. by the OEM for the equipment when the equipment is
(3) The Total Lubrication System includes the capacity for the operated in the expected conditions. Then, consult
Crankcase Oil Sump plus the capacity for the External System. with your Caterpillar dealer for a list of greases and
Enter the total in this row. the following related characteristics.
Table 16 • Performance specifications
C1.6 Engine
Approximate Refill Capacities • Available sizes of containers
Compartment or System Min Max • Part numbers
Crankcase Oil Sump (Standard)(1) 3.9 L 5.6 L Always choose a grease that satisfies the
(4.1 qt) (6 qt) recommendations that are specified by the
equipment manufacturer for the application.
Note: If it is necessary to choose a single grease
to use for all of the equipment at one site, always
(1) These values are the approximate capacities for the crankcase choose a grease that satisfies the requirements
oil sump which include the standard oil filters that are installed of the most demanding application.
at the factory.
(2) Enter the capacity for the External System in this row. Refer to Do not use the cost per pound as the only factor
either Caterpillar specifications or OEM specifications for fur-
ther information. Engines with auxiliary oil filters will require ad- when you choose a grease. Use the grease that
ditional oil. Refer to the OEM specifications for the capacity of yields the lowest total cost of operation. The cost
the auxiliary oil filter. analysis should include the following factors:
Crankcase Oil Sump plus the capacity for the External System. • Parts
Enter the total in this row.
46 SEBU8312-03
Maintenance Section
• Labor Table 18
• Downtime Territory Fuel Requirements from 2007
EPA Low Sulfur (500 ppm) maximum

• Cost of the grease
Sulfur/Power Low sulfur (300 Sulphur (1000
Greases that barely meet the minimum performance ppm) maximum ppm) maximum
requirements can be expected to barely produce the for less than or for greater than
minimum life of the parts. equal to 19 kW 19 kW
EC Models C0.5 and C1.1, C1.5NA,
Note: Take care when you change the type of
grease. Take care when you change to a different C0.7 C1.5T, C1.6,
supplier of grease. Some greases are not chemically C2.2NA, C2.2T
and
compatible. Some brands of grease cannot be
C2.2TA(1)
interchanged. If you are in doubt about the
compatibility of the old grease and the new Non-Regulated Sulfur limit of less than 4000 ppm
grease, purge all of the old grease from the joint. Territories
Consult your supplier in order to determine if the (1) NA is Naturally Aspirated. T is Turbocharged. TA is Turbo-
greases are compatible. charged Aftercooled.
Note: All Caterpillar brand of greases are Table 19

compatible with each other. Territory Fuel Requirements from 2010
Note: Refer to Special Publication, SEBU6251, EPA Ultra Low Sulfur (15 ppm) maximum
“Caterpillar Commercial Diesel Engine Fluids
Recommendations” for additional information that Sulfur/Power Ultra Low sul- Low sulphur
relates to lubrication for your engine. phur (10 ppm) (300 ppm)
maximum for maximum for
less than or greater than 37
General Fuel Information EC equal to 37 kW kW
Diesel fuels that meet the Caterpillar Specification for Models C0.5, C0.7, C2.2NA, C2.2T
Distillate Diesel Fuel are recommended. These fuels C1.1, C1.5NA, and
will help to provide maximum engine service life and C1.5T, C1.6 C2.2TA(1)
performance. In North America, diesel fuel that is
identified as No. 1-D or No. 2-D in “ASTM D975” Non Regulated Sulfur limit of less than 4000 ppm
generally meet the specifications. Diesel fuels from Territories
other sources could exhibit detrimental properties (1) NA is Naturally Aspirated. T is Turbocharged. TA is Turbo-
that are not defined or controlled by this specification. charged Aftercooled.
NOTICE Note: Refer to Special Publication, SEBU6251,

Operating with fuels that do not meet Caterpillar's “Caterpillar Commercial Diesel Engine Fluids
recommendations can cause the following effects: Recommendations” for the Caterpillar Specification
starting difficulty, poor combustion, deposits in the for distillate fuel and for additional information that
fuel injectors, reduced service life of the fuel system, relates to fuel for your engine.
deposits in the combustion chamber and reduced
service life of the engine.
Refill Capacities for the Fuel System
Refer to the Operation and Maintenance Manual that
is provided by the OEM for capacities of the fuel
system.
General Coolant Information

NOTICE
These recommendations are subject to change with-
out notice. Contact your local Caterpillar dealer for
the most up-to-date fluids recommendations.
SEBU8312-03 47
Maintenance Section
NOTICE
Water
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first. NOTICE
Never use water alone without Supplemental Coolant
Additives (SCA) or without inhibited coolant. Water
NOTICE alone is corrosive at engine operating temperatures.
If the engine is to be stored in, or shipped to an area Water alone does not provide adequate protection
with below freezing temperatures, the cooling system against boiling or freezing.
must be either protected to the lowest outside tem-
perature or drained completely to prevent damage. Water is used in the cooling system in order to
transfer heat.
Distilled water or deionized water is
NOTICE recommended for use in engine cooling systems.
Frequently check the specific gravity of the coolant
for proper freeze protection or for anti-boil protection. DO NOT use the following types of water in cooling
systems: hard water, softened water that has been
Clean the cooling system for the following reasons: conditioned with salt and sea water.
• Contamination of the cooling system If distilled water or deionized water is not available,
use water with the properties that are listed in Table
• Overheating of the engine 20 .
Table 20
• Foaming of the coolant
Caterpillar Minimum Acceptable Water Requirements
Note: Air pockets can form in the cooling system if
Property Maximum Limit ASTM Test
the cooling system is filled at a rate that is greater
than 5 L (1.3 US gal) per minute. 40 mg/L “D512”,
Chloride (Cl)
(2.4 grains/US gal) “D4327”
After you drain the cooling system and after you refill
the cooling system, operate the engine. Operate the 100 mg/L
Sulfate (SO4) “D516”
engine without the filler cap until the coolant reaches (5.9 grains/US gal)
normal operating temperature and the coolant level 170 mg/L
stabilizes. Ensure that the coolant is maintained to Total Hardness (10 grains/US gal) “D1126”
the proper level.
Total Solids 340 mg/L (20 grain/US gal) “D1888”
NOTICE
Never operate an engine without water temperature Acidity pH of 5.5 to 9.0 “D1293”
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the For a water analysis, consult one of the following
proper operating temperature. Cooling system prob- sources:
lems can develop without water temperature
regulators. • Caterpillar dealer
• Local water utility company

Refer to Special Instruction, SEBD0518, “Know Your
Cooling System” and Special Instruction, SEBD0970, • Agricultural agent
“Coolant and Your Engine” for more detailed
information. • Independent laboratory
Many engine failures are related to the cooling
system. The following problems are related to cooling Additives
system failures: overheating, leakage of the water
pump, plugged radiators or heat exchangers and Additives help to protect the metal surfaces of the
pitting of the cylinder liners. cooling system. A lack of coolant additives or
insufficient amounts of additives enable the following
These failures can be avoided with proper cooling conditions to occur:
system maintenance. Cooling system maintenance is
as important as maintenance of the fuel system and • Corrosion
the lubrication system. Quality of the coolant is as
important as the quality of the fuel and the lubricating • Formation of mineral deposits
oil.
• Rust
Coolant is normally composed of three elements:
water, additives and glycol. • Scale
48 SEBU8312-03
Maintenance Section
• Pitting and erosion from cavitation of the cylinder

NOTICE
liner Do not use propylene glycol in concentrations that
exceed 50 percent glycol because of the reduced
• Foaming of the coolant heat transfer capability of propylene glycol. Use ethyl-
Many additives are depleted during engine operation. ene glycol in conditions that require additional protec-
These additives must be replaced periodically. This tion against boiling or freezing.
can be done by adding Supplemental Coolant
Additives (SCA) to Diesel Engine Antifreeze/Coolant Table 22
(DEAC) or by adding ELC Extender to Extended Life Propylene Glycol
Coolant (ELC).
Freeze Anti-Boil
Additives must be added at the proper concentration. Concentration
Protection Protection
Overconcentration of additives can cause the
inhibitors to drop out-of-solution. The deposits can 50 Percent −29 °C (−20 °F) 106 °C (223 °F)
enable the following problems to occur:
To check the concentration of glycol, use the
• Formation of gel compounds 1U-7298 Coolant/Battery Tester (Degrees Celsius)
• Reduction of heat transfer or use the 1U-7297 Coolant/Battery Tester
(Degrees Fahrenheit). The testers give readings that
• Leakage of the water pump seal are immediate and accurate. The testers can be used
with ethylene or propylene glycol.
• Plugging of radiators, coolers, and small passages
Coolant Recommendations
Glycol
NOTICE
Glycol in the coolant helps to provide protection Do not use a commercial coolant/antifreeze that only
against the following conditions: meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light duty automotive
• Boiling applications.
• Freezing The following two coolants are used in Caterpillar
diesel engines:
• Cavitation of the water pump and the cylinder liner
Preferred – Caterpillar Extended Life Coolant (ELC)
For optimum performance, Caterpillar recommends a or a commercial extended life coolant that meets the
1:1 mixture of a water/glycol solution. Caterpillar EC-1 specification
Note: Use a mixture that will provide protection
against the lowest ambient temperature. Acceptable – Caterpillar Diesel Engine Antifreeze
(DEAC) or a commercial heavy-duty coolant that
Note: 100 percent pure glycol will freeze at a meets “ASTM D4985”, or “ASTM D6210”
temperature of −23 °C (−9 °F). specifications
Most conventional heavy-duty Coolants use ethylene Caterpillar recommends a 1:1 mixture of water and
glycol. Propylene glycol may also be used. In a 1:1 glycol. This mixture of water and glycol will provide
mixture with water, ethylene and propylene glycol optimum heavy-duty performance as a coolant.
provide similar protection against freezing and
boiling. See Tables 21 and 22 . Note: Caterpillar DEAC does not require a treatment
Table 21 with an SCA at the initial fill. A commercial heavy-
Ethylene Glycol duty coolant that meets “ASTM D4985” or “ASTM
D6210” specifications MAY require a treatment with
Concentration
Freeze
Boil Protection
an SCA at the initial fill. These coolants WILL require
Protection a treatment with an SCA on a maintenance basis.
50 Percent −36 °C (−33 °F) 106 °C (223 °F)
60 Percent −51 °C (−60 °F) 111 °C (232 °F)

SEBU8312-03 49
Maintenance Section
Refer to Special Publication, SEBU6251, “Caterpillar • Identification of buildup of the impurities that
Commercial Diesel Engine Fluids cause corrosion
Recommendations” for additional information that
relates to coolant. • Identification of buildup of the impurities that
cause scaling
S·O·S Coolant Analysis The results are reported, and appropriate
Table 23
recommendations are made.
Refer to the Maintenance Interval Schedule in this
Recommended Interval Operation and Maintenance Manual, “Cooling
System Coolant Sample (Level 2) - Obtain” for a
Type of Level 1 Level 2 sampling location and the maintenance interval for
Coolant collecting the coolant samples.
DEAC Every 250 Hours Yearly(1) Testing the engine coolant is important to ensure that
ELC Not Required Yearly the engine is protected from internal cavitation and
from corrosion. The analysis also tests the ability of
(1) The Level 2 Coolant Analysis should be performed sooner if a the coolant to protect the engine from boiling and
problem is identified by a Level 1 Coolant Analysis. from freezing. The S·O·S Coolant Analysis can be
done at your Caterpillar dealer. Caterpillar S·O·S
S·O·S Coolant Analysis (Level 1) Coolant Analysis is the best way to monitor the
condition of your coolant and your cooling system.
A coolant analysis (Level 1) is a test of the properties S·O·S Coolant Analysis is a program that is based on
of the coolant. periodic samples.
The following properties of the coolant are tested:
Refer to Special Publication, SEBU6251, “Caterpillar
• Glycol concentration for freeze protection and boil Commercial Diesel Engine Fluids
protection Recommendations” for additional information.
• Ability to protect from erosion and corrosion Refill Capacity of the Cooling
• pH System
• Conductivity To maintain the cooling system, the Total Cooling
System capacity must be known. The approximate
• Visual analysis capacity for the “Engine Only” cooling system is
listed. External System capacities will vary among
• Odor analysis applications. Refer to the OEM specifications for the
External System capacity. This capacity information
The results are reported, and appropriate will be needed in order to determine the amount of
recommendations are made. coolant that is required for the Total Cooling System.
Refer to the Maintenance Interval Schedule in this Table 24
Operation and Maintenance Manual, “Cooling C0.5 Engine
System Coolant Sample (Level 1) - Obtain” for a Approximate Refill Capacities
sampling location and the maintenance interval for
collecting the coolant samples. Compartment or System Liters Quarts
S·O·S Coolant Analysis (Level 2) Engine Only 1.1 1.2
A coolant analysis (Level 2) is a comprehensive External System (OEM)(1)

chemical evaluation of the coolant. This analysis is Total Cooling System(2)
also a check of the overall condition of the inside of
the cooling system. (1) The External System includes a radiator or an expansion tank
with the following components: heat exchanger, aftercooler and
The S·O·S Coolant Analysis has the following piping. Enter the capacity for the External System in this row.
features: Refer to either Caterpillar specifications or OEM specifications
for further information.
(2) The Total Cooling System includes the capacity for the “Engine
• Full coolant analysis (Level 1) Only” plus the capacity for the External System. Enter the total
in this row.
• Identification of the source of metal corrosion and
of contaminants
• Water hardness
50 SEBU8312-03
Maintenance Section
Table 25
C0.7 Engine Table 28
C1.6 Engine
Compartment or System Liters Quarts Approximate Refill Capacities
Engine Only 1.2 1.3 Compartment or System Liters Quarts

External System (OEM)(1) Engine Only 2.4 2.5
Total Cooling System(2) External System (OEM)(1)

(1) The External System includes a radiator or an expansion tank Total Cooling System(2)
piping. Enter the capacity for the External System in this row. (1) The External System includes a radiator or an expansion tank
Refer to either Caterpillar specifications or OEM specifications with the following components: heat exchanger, aftercooler and
for further information. piping. Enter the capacity for the External System in this row.
(2) The Total Cooling System includes the capacity for the “Engine Refer to either Caterpillar specifications or OEM specifications
Only” plus the capacity for the External System. Enter the total for further information.
in this row. (2) The Total Cooling System includes the capacity for the “Engine
Only” plus the capacity for the External System. Enter the total
Table 26 in this row.
C1.1 Engine Table 29

C2.2 Turbocharged engines and Naturally Aspirated
Compartment or System Liters Quarts Engines
Engine Only 1.9 2.0
Compartment or System Liters Quarts
Engine Only 3.6 3.8
Total Cooling System(2)
(1)
The External System includes a radiator or an expansion tank
with the following components: heat exchanger, aftercooler and Total Cooling System(2)
piping. Enter the capacity for the External System in this row.
Refer to either Caterpillar specifications or OEM specifications (1) The External System includes a radiator or an expansion tank
for further information. with the following components: heat exchanger, aftercooler and
(2) The Total Cooling System includes the capacity for the “Engine piping. Enter the capacity for the External System in this row.
Only” plus the capacity for the External System. Enter the total Refer to either Caterpillar specifications or OEM specifications
in this row. for further information.
Table 27 Only” plus the capacity for the External System. Enter the total
in this row.
C1.5 Turbocharged Engines and Naturally Aspirated
Engines
Compartment or System Liters Quarts

Engine Only 2.6 2.7
Total Cooling System(2)

(1) The External System includes a radiator or an expansion tank
piping. Enter the capacity for the External System in this row.
Refer to either Caterpillar specifications or OEM specifications
for further information.
Only” plus the capacity for the External System. Enter the total
in this row.
SEBU8312-03 51
Maintenance Section
Maintenance Recommendations
Maintenance Do not loosen the high pressure fuel lines in order to

remove air pressure from the fuel system.
Recommendations
Engine Oil
i02909163
To relieve pressure from the lubricating system, turn
System Pressure Release off the engine.
SMCS Code: 1250; 1300; 1350; 5050 i05909227
Coolant System Welding on Engines with

Electronic Controls
SMCS Code: 1000
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra- NOTICE
diator is cool. Then loosen cap slowly to relieve Because the strength of the frame may decrease,
the pressure. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Cat dealer regarding welding on a chas-
off the engine. Allow the cooling system pressure cap sis frame or rail.
to cool. Remove the cooling system pressure cap
slowly in order to relieve pressure. Proper welding procedures are necessary in order to
avoid damage to the engine ECM, sensors, and
Fuel System associated components. When possible, remove the
component from the unit and then weld the
component. If removal of the component is not
To relieve the pressure from the fuel system, turn off
possible, the correct procedure must be followed.
the engine.
When welding on a unit that is equipped with a Cat
Electronic Engine, the following is considered to be
High Pressure Fuel Lines (If Equipped) the safest procedure:
NOTICE
Do not ground the welder to electrical components
Contact with high pressure fuel may cause fluid such as the ECM or sensors. Improper grounding
penetration and burn hazards. High pressure fuel can cause damage to the drive train, the bearings,
hydraulic components, electrical components, and
spray may cause a fire hazard. Failure to follow
other components.
these inspection, maintenance and service in-
structions may cause personal injury or death. Do not ground the welder across the centerline of the
package. Improper grounding could cause damage
The high pressure fuel lines are the fuel lines that are to the bearings, the crankshaft, the rotor shaft, and
between the high pressure fuel pump and the high other components.
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These Clamp the ground cable from the welder to the com-
fuel lines are different from fuel lines on other fuel ponent that will be welded. Place the clamp as close
systems. as possible to the weld. This will help reduce the pos-
This is because of the following differences: sibility of damage.
• The high pressure fuel lines are constantly

charged with high pressure. Note: Perform the welding in areas that are free from
explosive hazards.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system. 1. Stop the engine. Turn the switched power to the
OFF position.
Before any service or repair is performed on the
engine fuel lines, perform the following tasks: 2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
1. Stop the engine. open the switch.
2. Wait for ten minutes.
52 SEBU8312-03
Maintenance Section
Welding on Engines with Electronic Controls
3. Disconnect the J1/P1 and J2/P2 connectors from 5. Connect the welding ground cable directly to the
the ECM. Move the harness to a position that will part that will be welded. Place the ground cable as
not allow the harness to move back accidentally, close as possible to the weld. This location will
and contact any of the ECM pins. reduce the possibility of welding current damage
to bearings, hydraulic components, electrical
4. Disconnect any component with a microprocessor
components, and ground straps.
from the engine harness, such as:
Note: If electrical/electronic components are used as
• Engine ECM a ground for the welder, current flow from the welder
could severely damage the component. Current flow
• Product Link
from the welder could also severely damage
electrical/electronic components that are located
• Cell/Sat Radio
between the welder ground and the weld.
• DOC Identity Modules
6. Protect the wiring harness from welding debris and
spatter.
7. Use standard welding practices to weld the
materials.
Use the example above. The current flow from the
welder to the ground clamp of the welder will not
damage 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
SEBU8312-03 53
Maintenance Section
Maintenance Interval Schedule
i03659171 “ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . . .
Maintenance Interval Schedule Every 250 Service Hours or 1 Year

SMCS Code: 1000; 7500
“ Cooling System Supplemental Coolant Additive
(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . 64
When Required
“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
“ Battery or Battery Cable - Disconnect” . . . . . . . . 58
Systems)
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“Cooling System Coolant Sample (Level 2) - Obtain”
“ Engine Air Cleaner Element (Dual Element) - Clean/ ...........................................
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“ Engine Air Cleaner Element (Single Element) - Every 500 Service Hours
Inspect/Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
“ Fuel System Secondary Filter - Replace” . . . . . . 81
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 77
“ Severe Service Application - Check” . . . . . . . . . . 88
Every 500 Service Hours or 1 Year
“ Battery Electrolyte Level - Check” . . . . . . . . . . . . . .
Daily
“ Cooling System Supplemental Coolant Additive
“ Cooling System Coolant Level - Check” . . . . . . . 62 (SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . 64
“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . 66 “ Engine Air Cleaner Element (Dual Element) - Clean/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“ Engine Air Cleaner Service Indicator - Inspect” . . .
“ Engine Oil and Filter - Change” . . . . . . . . . . . . . . 73
“ Engine Air Precleaner - Check/Clean” . . . . . . . . . 71
“ Engine Protective Devices - Check” . . . . . . . . . . . .
“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 72
“ Hoses and Clamps - Inspect/Replace” . . . . . . . . . .
“ Fuel System Primary Filter/Water Separator - Drain”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 “ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 90 Every 1000 Service Hours

Every 50 Service Hours or Weekly “ Alternator and Fan Belts - Replace” . . . . . . . . . . 57
“ Fuel Tank Water and Sediment - Drain” . . . . . . . . . “ Engine Valve Lash - Inspect/Adjust” . . . . . . . . . . 76
“ Turbocharger - Inspect” . . . . . . . . . . . . . . . . . . . . 89
Every 250 Service Hours
“Cooling System Coolant Sample (Level 1) - Obtain” Every 2000 Service Hours
...........................................
“ Aftercooler Core - Inspect” . . . . . . . . . . . . . . . . . . 55
Every 250 Service Hours or 6 “ Alternator - Inspect” . . . . . . . . . . . . . . . . . . . . . . . 55
Months
“ Engine Crankcase Breather - Replace” . . . . . . . . 71
“ Alternator and Fan Belts - Inspect/Adjust” . . . . . . 56
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 72
54 SEBU8312-03
Maintenance Section
Maintenance Interval Schedule
“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 89
Every Year
...........................................

“ Fuel Injector - Test/Change” . . . . . . . . . . . . . . . . . 76
“ Water Pump - Inspect” . . . . . . . . . . . . . . . . . . . . . 91
Every 3000 Service Hours or 2

Years
“ Cooling System Coolant (DEAC) - Change” . . . . 58
“ Cooling System Water Temperature Regulator -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

“ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . . 55
Every 6000 Service Hours or 3

Years
“ Cooling System Coolant Extender (ELC) - Add”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Every 12 000 Service Hours or 6

Years
“ Cooling System Coolant (ELC) - Change” . . . . . 60
Overhaul
“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . 87
SEBU8312-03 55
Maintenance Section
Aftercooler Core - Clean/Test
i03632427 Pressurized water may also be used for cleaning.

The maximum water pressure for cleaning purposes
Aftercooler Core - Clean/Test must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
(Air-To-Air Aftercooler) both sides.
SMCS Code: 1064-070; 1064-081 Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
S/N: G7L1–Up with detergent and hot water. Thoroughly rinse the
core with clean water.
S/N: C6M1–Up
After cleaning, start the engine and accelerate the
S/N: C8Y1–Up engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine. Use
S/N: C8Z1–Up a light bulb behind the core in order to inspect the
The air-to-air aftercooler is OEM installed in many core for cleanliness. Repeat the cleaning, if
applications. Please refer to the OEM specifications necessary.
for information that is related to the aftercooler.
Inspect the fins for damage. Bent fins may be opened
with a “comb”.
i03632432
Note: If parts of the aftercooler system are repaired
Aftercooler Core - Inspect or replaced, a leak test is highly recommended. The
SMCS Code: 1064-040 FT1984 Aftercooler Testing Group is used to
perform leak tests on the aftercooler. Refer to the
S/N: G7L1–Up Systems Operation/Testing and Adjusting,
“Aftercooler - Test” and the Special Instruction,
S/N: C6M1–Up SEHS8622 for the proper testing procedure.
S/N: G8N1–Up Inspect these items for good condition: welds,
mounting brackets, air lines, connections, clamps
S/N: C8Y1–Up and seals. Make repairs, if necessary.
S/N: C8Z1–Up
For more detailed information on cleaning and
Note: Adjust the frequency of cleaning according to inspection, see Special Publication, SEBD0518,
the effects of the operating environment. “Know Your Cooling System”.
Inspect the aftercooler for these items: damaged fins, i02676048

corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the aftercooler, if necessary. Alternator - Inspect
For air-to-air aftercoolers, use the same methods that SMCS Code: 1405-040
are used for cleaning radiators.
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
Personal injury can result from air pressure. order to ensure proper battery performance and/or
proper performance of the electrical system. Make
Personal injury can result without following prop- repairs, as required.
er procedure. When using pressure air, wear a
protective face shield and protective clothing. Check the alternator and the battery charger for
proper operation. If the batteries are properly
Maximum air pressure at the nozzle must be less charged, the ammeter reading should be very near
than 205 kPa (30 psi) for cleaning purposes. zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
Pressurized air is the preferred method for removing affects the cranking power. If the battery is too cold,
loose debris. Direct the air in the opposite direction of the battery will not crank the engine. The battery will
the fan's air flow. Hold the nozzle approximately not crank the engine, even if the engine is warm.
6 mm (.25 inch) away from the fins. Slowly move the When the engine is not run for long periods of time or
air nozzle in a direction that is parallel with the tubes. if the engine is run for short periods, the batteries
This will remove debris that is between the tubes. may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
56 SEBU8312-03
Maintenance Section
Alternator and Fan Belts - Inspect/Adjust
i02226340 If twin belts are installed, check and adjust the

tension on both belts.
Alternator and Fan Belts -
Inspect/Adjust Adjustment
SMCS Code: 1357-025; 1357-040
Inspection
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.
To accurately check the belt tension, Gauge
144-0235 Belt Tension Gauge should be used.
Typical example
(1) Adjusting bolt
(2) Mounting bolts
1. Loosen the mounting bolts (2) and the adjusting

bolt (1).
2. Move the alternator in order to increase or
decrease the belt tension.
Typical example
(1) 144-0235 Belt Tension Gauge
Install the gauge (1) at the center of the belt between

the alternator and the crankshaft pulley and check
the belt tension. The correct tension for a new belt is
400 N (90 lb) to 489 N (110 lb). The correct tension
for a used belt that has been in operation for 30
minutes or more at the rated speed is 267 N (60 lb)
to 356 N (80 lb).
SEBU8312-03 57
Maintenance Section
Alternator and Fan Belts - Replace
3. Tighten the adjusting bolt (1). Tighten the mounting i06103470

bolts (2). Refer to the Specifications Manual for
the correct torque settings. Battery - Replace
SMCS Code: 1401-510
i02226343
Alternator and Fan Belts -

Replace Batteries give off combustible gases which can
explode. A spark can cause the combustible
SMCS Code: 1357-510 gases to ignite. This can result in severe personal
injury 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.
Note: Always recycle a battery. Never discard a

battery. Return used batteries to an appropriate
recycling facility.
Typical example 1. Turn the key start switch to the OFF position.
(1) Adjusting bolt Remove the key and all electrical loads.
(2) Mounting bolts
2. Turn OFF the battery charger. Disconnect the
For applications that require multiple drive belts, charger.
replace the belts in matched sets. Replacing only one
belt of a matched set will cause the new belt to carry 3. The NEGATIVE “-” cable connects the NEGATIVE
more load because the older belt is stretched. The “-” battery terminal to the ground plane.
additional load on the new belt could cause the new Disconnect the cable from the NEGATIVE “-”
belt to break.
battery terminal.
Note: When new belts are installed, check the belt 4. The POSITIVE “+” cable connects the POSITIVE
tension again after 20 hours of engine operation.
“+” battery terminal to the starting motor.
Refer to the Disassembly and Assembly Manual for Disconnect the cable from the POSITIVE “+”
the installation procedure and the removal procedure battery terminal.
for the belt.
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.
58 SEBU8312-03
Maintenance Section
Battery Electrolyte Level - Check
i06064262 i01492654
Battery Electrolyte Level - Battery or Battery Cable -

Check Disconnect
SMCS Code: 1401-535 SMCS Code: 1402-029
When the engine has not run for long or short periods
of time, the batteries may not fully recharge. Ensure a
full charge in order to help prevent the battery from
freezing. 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.
All lead-acid batteries contain sulfuric acid which Removing the battery cables or the batteries with
can burn the skin and clothing. Always wear a the cover in place may cause a battery explosion
face shield and protective clothing when working resulting in personal injury.
on or near batteries.
1. Turn the start switch to the OFF position. Turn the
1. Remove the filler caps. Maintain the electrolyte ignition switch (if equipped) to the OFF position
level to the “FULL” mark on the battery. and remove the key and all electrical loads.
If the addition of water is necessary, use distilled 2. Disconnect the negative battery terminal at the
water. If distilled water is not available use clean battery that goes to the start switch. Ensure that
water that is low in minerals. Do not use artificially
the cable cannot contact the terminal. When four
softened water.
12 volt batteries are involved, the negative side of
2. Check the condition of the electrolyte with the two batteries must be disconnected.
245-5829 Coolant Battery Tester Refractometer.
3. Tape the leads in order to help prevent accidental
3. Keep the batteries clean. starting.
Clean the battery case with one of the following 4. Proceed with necessary system repairs. Reverse
cleaning solutions: the steps in order to reconnect all of the cables.
• A mixture of 0.1 kg (0.2 lb) of baking soda and i02789695
1 L (1 qt) of clean water
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L

Cooling System Coolant
(1 qt) of clean water (DEAC) - Change
Thoroughly rinse the battery case with clean SMCS Code: 1350-070; 1395-044
water.
Clean the cooling system and flush the cooling
Use the 1U-9921 Battery Service Tool to clean system before the recommended maintenance
the battery terminals. Use a wire brush to clean interval if the following conditions exist:
the cable clamps. Clean the items until the
surfaces are bright or shiny. DO NOT remove • The engine overheats frequently.
material excessively. Excessive removal of
material can cause the clamps to fit improperly. • Foaming is observed.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM. • The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.
NOTICE
Use of commercially available cooling system
cleaners may cause damage to cooling system com-
ponents. Use only cooling system cleaners that are
approved for Caterpillar engines.
SEBU8312-03 59
Maintenance Section
Cooling System Coolant (DEAC) - Change
Note: Inspect the water pump and the water 3. Fill the cooling system with a mixture of clean
temperature regulator after the cooling system has water and Caterpillar Fast Acting Cooling System
been drained. This is a good opportunity to replace Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
the water pump, the water temperature regulator and (4 US gal) of the cooling system capacity. Install
the hoses, if necessary. the cooling system filler cap.
Drain 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).
Pressurized System: Hot coolant can cause seri- NOTICE

ous burns. To open the cooling system filler cap, Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal
stop the engine and wait until the cooling system
components.
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the To avoid damage to the cooling system, make sure to
pressure.
completely flush the cooling system with clear water.
Continue to flush the system until all signs of the
1. Stop the engine and allow the engine to cool. cleaning agent are gone.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling 5. Stop the engine and allow the engine to cool.
system filler cap. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
Note: Refer to Operation and Maintenance Manual,
system filler cap. Open the drain valve (if
“General Hazard Information” for information on
Containing Fluid Spillage. equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
2. Open the cooling system drain valve (if equipped). system with clean water. Close the drain valve (if
If the cooling system is not equipped with a drain equipped). Clean the drain plugs. Install the drain
valve, remove one of the drain plugs. plugs. Refer to Torque Specifications, SENR3130
for more information on the correct torques.
Allow the coolant to drain into a suitable container.
3. Properly dispose of the drained material. Obey Cooling Systems with Heavy
local regulations for the disposal of the material. Deposits or Plugging
NOTICE Note: For the following procedure to be effective,
Dispose of used engine coolant properly or recycle. there must be some active flow through the cooling
Various methods have been proposed to reclaim system components.
used coolant for reuse in engine cooling systems.
The full distillation procedure is the only method ac- 1. Flush the cooling system with clean water in order
ceptable by Caterpillar to reclaim the used coolant.
to remove any debris.
2. Close the drain valve (if equipped). Clean the drain
Flush plugs. Install the drain plugs. Refer to Torque
Specifications, SENR3130 for more information on
1. Flush the cooling system with clean water in order the correct torques.
to remove any debris.
NOTICE
2. Close the drain valve (if equipped). Clean the drain Do not fill the cooling system faster than 5 L
plugs. Install the drain plugs. Refer to Torque (1.3 US gal) per minute to avoid air locks.
Specifications, SENR3130 for more information on
the correct torques. Cooling system air locks may result in engine
damage.
NOTICE
Do not fill the cooling system faster than 5 L 3. Fill the cooling system with a mixture of clean
(1.3 US gal) per minute to avoid air locks.
water and Caterpillar Fast Acting Cooling System
Cooling system air locks may result in engine Cleaner. Add 0.5 L (1 pint) of cleaner per
damage. 3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the cooling system filler cap.
60 SEBU8312-03
Maintenance Section
Cooling System Coolant (ELC) - Change
4. Start and run the engine at low idle for a minimum 4. Clean the cooling system filler cap. Inspect the
of 90 minutes. The coolant temperature should be gasket that is on the cooling system filler cap. If
at least 82 °C (180 °F). the gasket that is on the cooling system filler cap is
damaged, discard the old cooling system filler cap
NOTICE and install a new cooling system filler cap. If the
Improper or incomplete rinsing of the cooling system gasket that is on the cooling system filler cap is not
can result in damage to copper and other metal
components. damaged, perform a pressure test. A 9S-8140
Pressurizing Pump is used to perform the
To avoid damage to the cooling system, make sure to pressure test. The correct pressure for the cooling
completely flush the cooling system with clear water. system filler cap is stamped on the face of the
Continue to flush the system until all signs of the cooling system filler cap. If the cooling system filler
cleaning agent are gone.
cap does not retain the correct pressure, install a
new cooling system filler cap.
5. Stop the engine and allow the engine to cool.
5. Start the engine. Inspect the cooling system for
Loosen the cooling system filler cap slowly in
leaks and for the correct operating temperature.
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain valve (if
i02822203
equipped) or remove the cooling system drain
system with clean water. Close the drain valve (if
Cooling System Coolant (ELC)
equipped). Clean the drain plugs. Install the drain - Change
plugs. Refer to Torque Specifications, SENR3130 SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
Fill system before the recommended maintenance
interval if the following conditions exist:
NOTICE • The engine overheats frequently.

Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks. • Foaming is observed.
Cooling system air locks may result in engine • The oil has entered the cooling system and the
damage. coolant is contaminated.
• The fuel has entered the cooling system and the
1. Fill the cooling system with the coolant/antifreeze. coolant is contaminated.
Refer to this Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic Note: When the cooling system is cleaned, only
(Maintenance Section) for more information on clean water is needed when the ELC is drained and
cooling system specifications. Do not install the replaced.
cooling system filler cap. Note: Inspect the water pump and the water
2. Start and run the engine at low idle. Increase the temperature regulator after the cooling system has
engine rpm to 1500 rpm. Run the engine at high been drained. This is a good opportunity to replace
idle for one minute in order to purge the air from the water pump, the water temperature regulator and
the hoses, if necessary.
the cavities of the engine block. Stop the engine.
3. Check the coolant level. Maintain the coolant level Drain
within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped). Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
pressure cap slowly in order to relieve the
pressure.
SEBU8312-03 61
Maintenance Section
Cooling System Coolant (ELC) - Change
1. Stop the engine and allow the engine to cool. 5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling order to relieve any pressure. Remove the cooling
system filler cap. system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
system with clean water. Close the drain valve (if
valve, remove the cooling system drain plugs.
equipped). Clean the drain plugs. Install the drain
Allow the coolant to drain. plugs. Refer to Torque Specifications, SENR3130
NOTICE
Dispose of used engine coolant properly or recycle. Fill
Various methods have been proposed to reclaim
used coolant for reuse in engine cooling systems.
The full distillation procedure is the only method ac- NOTICE
ceptable by Caterpillar to reclaim the used coolant. Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar Cooling system air locks may result in engine
dealer or consult Dealer Service Tools. damage.
Flush 1. Fill the cooling system with Extended Life Coolant

(ELC). Refer to this Operation and Maintenance
1. Flush the cooling system with clean water in order Manual, “Refill Capacities and Recommendations”
to remove any debris. topic (Maintenance Section) for more information
2. Close the drain valve (if equipped). Clean the drain on cooling system specifications. Do not install the
plugs. Install the drain plugs. Refer to Torque cooling system filler cap.
Specifications, SENR3130 for more information on 2. Start and run the engine at low idle. Increase the
the correct torques. engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
NOTICE the cavities of the engine block. Stop the engine.
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks. 3. Check the coolant level. Maintain the coolant level
Cooling system air locks may result in engine within 13 mm (0.5 inch) below the bottom of the
damage. pipe for filling. Maintain the coolant level within
13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
3. Fill the cooling system with clean water. Install the
cooling system filler cap. 4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
4. Start and run the engine at low idle until the the gasket that is on the cooling system filler cap is
temperature reaches 49 to 66 °C (120 to 150 °F). damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the
gasket that is on the cooling system filler cap is not
damaged, use a 9S-8140 Pressurizing Pump in
order to pressure test the cooling system filler cap.
The correct pressure for the cooling system filler
cap is stamped on the face of the cooling system
filler cap. If the cooling system filler cap does not
retain the correct pressure, install a new cooling
system filler cap.
62 SEBU8312-03
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
5. Start the engine. Inspect the cooling system for

NOTICE
leaks and for proper operating temperature. Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
i02482066 nance, testing, adjusting and repair of the product.
Cooling System Coolant ers before opening any compartment or disassem-
bling any component containing fluids.
Extender (ELC) - Add
Refer to Special Publication, NENG2500, “Caterpillar
SMCS Code: 1352-045; 1395-081 Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
Cat ELC (Extended Life Coolant) does not require products.
the frequent additions of any supplemental cooling
additives which are associated with the present Dispose of all fluids according to local regulations
conventional coolants. The Cat ELC Extender only and mandates.
needs to be added once.
NOTICE 1. Loosen the cooling system filler cap slowly in order

Use only Cat Extended Life Coolant (ELC) Extender to relieve pressure. Remove the cooling system
with Cat ELC. filler cap.
Do NOT use conventional supplemental coolant addi- 2. It may be necessary to drain enough coolant from
tive (SCA) with Cat ELC. Mixing Cat ELC with con- the cooling system in order to add the Cat ELC
ventional coolants and/or conventional SCA reduces
the Cat ELC service life. Extender.
3. Add Cat ELC Extender according to the
Check the cooling system only when the engine is requirements for your engine's cooling system
stopped and cool. capacity. Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
article for more information.
4. Clean the cooling system filler cap. Inspect the
Personal injury can result from hot coolant,
steam and alkali. gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
At operating temperature, engine coolant is hot damaged. Install the cooling system filler cap.
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
i01197583
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to Cooling System Coolant Level
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to - Check
touch with your bare hand. SMCS Code: 1395-082
Do not attempt to tighten hose connections when Check the coolant level when the engine is stopped
the coolant is hot, the hose can come off causing and cool.
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
Cooling system filler cap
SEBU8312-03 63
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
Note: Obtain a Coolant Sample (Level 1) if the

cooling system is filled with any other coolant
Pressurized System: Hot coolant can cause seri- instead of Cat ELC including the following
ous burns. To open the cooling system filler cap, coolants:
components are cool. Loosen the cooling system • Commercial long life coolants that meet the
pressure cap slowly in order to relieve the Caterpillar Engine Coolant Specification -1
pressure. (Caterpillar EC-1)
• Cat DEAC (Diesel Engine Antifreeze/Coolant)
1. Remove the cooling system filler cap slowly in
order to relieve pressure. • Commercial heavy-duty coolant/antifreeze
2. Maintain the coolant level within 13 mm (0.5 inch) Table 30
of the bottom of the filler pipe. If the engine is Recommended Interval
equipped with a sight glass, maintain the coolant
Type of Coolant Level 1 Level 2
level to the proper level in the sight glass.
Cat DEAC
Conventional heavy
duty-coolant
Every 250 service
Commercial coolant Every year(1)
hours
that meets the re-
quirements of the
Caterpillar EC-1
standard
Cat ELC or conven-
Optional Every year(1)
tional EC-1 coolant
(1) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
Typical filler cap gaskets pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
3. Clean the cooling system filler cap and check the drawn. This contaminate may cause a false analysis
condition of the filler cap gaskets. Replace the and an incorrect interpretation that could lead to con-
cooling system filler cap if the filler cap gaskets are cerns by both dealers and customers.
damaged. Reinstall the cooling system filler cap.
4. Inspect the cooling system for leaks. Note: Level 1 results may indicate a need for
Level 2 Analysis.
i04035949
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order to
Cooling System Coolant receive the full effect of S·O·S analysis, establish a
Sample (Level 1) - Obtain consistent trend of data. In order to establish a
pertinent history of data, perform consistent
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your
Note: Obtaining a Coolant Sample (Level 1) is Caterpillar dealer.
optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems Use the following guidelines for proper sampling of
the coolant:
filled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended • Complete the information on the label for the
interval as stated in the maintenance interval sampling bottle before you begin to take the
schedule. samples.
• Keep the unused sampling bottles stored in plastic

bags.
64 SEBU8312-03
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
• Obtain coolant samples directly from the coolant For additional information about coolant analysis, see
sample port. You should not obtain the samples Special Publication, SEBU6251, “Caterpillar
from any other location. Commercial Diesel Engines Fluids
Recommendations” or consult your Caterpillar dealer.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample. i02456600
• Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
Cooling System Supplemental
contamination. Coolant Additive (SCA) - Test/
• Never collect samples from expansion bottles. Add
SMCS Code: 1352-045; 1395-081
• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see Cooling system coolant additive contains alkali.
this Operation and Maintenance Manual, “Refill To help prevent personal injury, avoid contact
Capacities and Recommendations” or consult your with the skin and the eyes. Do not drink cooling
Caterpillar dealer. system coolant additive.
i04051750
Note: Test the concentration of the Supplemental
Cooling System Coolant Coolant Additive (SCA) or test the SCA concentration
as part of an S·O·S Coolant Analysis.
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542 Test for SCA Concentration
NOTICE Coolant and SCA
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam- NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con- Use the 8T-5296 Coolant Conditioner Test Kit or
cerns by both dealers and customers. use the 4C-9301 Coolant Conditioner Test Kit in
order to check the concentration of the SCA. Refer to
this Operation and Maintenance Manual, “Refill
NOTICE Capacities and Recommendations” for more
Care must be taken to ensure that fluids are con- information.
nance, testing, adjusting, and repair of the product. Water and SCA
ers before opening any compartment or disassem-
bling any component containing fluids. NOTICE
Do not exceed the recommended eight percent sup-
Refer to Special Publication, NENG2500, “Cat Dealer plemental coolant additive concentration.
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” Test the concentration of the SCA with the 8T-5296
for tools and supplies suitable to collect and contain Coolant Conditioner Test Kit. Refer to the Special
fluids on Cat products. Publication, SEBU6251, “Caterpillar Commercial
Diesel Engine Fluids Recommendations” for more
Dispose of all fluids according to local regulations information.
and mandates.
Refer to Operation and Maintenance Manual,
S·O·S Coolant Analysis
S·O·S coolant samples can be analyzed at your
for the guidelines for proper sampling of the coolant.
Caterpillar dealer. S·O·S Coolant Analysis is a
Submit the sample for Level 2 analysis. program that is based on periodic samples.
SEBU8312-03 65
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Level 1 2. If necessary, drain some coolant from the cooling

system into a suitable container in order to allow
Level 1 is a basic analysis of the coolant. The space for the extra SCA.
following items are tested:
3. Add the proper amount of SCA. Refer to the
• Glycol Concentration Special Publication, SEBU6251, “Caterpillar
• Concentration of SCA Commercial Diesel Engines Fluids
Recommendations” for more information on SCA
• pH requirements.
• Conductivity 4. Clean the cooling system filler cap. Inspect the

gaskets of the cooling system filler cap. If the
The results are reported, and recommendations are gaskets are damaged, replace the old cooling
made according to the results. Consult your system filler cap with a new cooling system filler
Caterpillar dealer for information on the benefits of
managing your equipment with an S·O·S Coolant cap. Install the cooling system filler cap.
Analysis.
i02625506
Level 2
Cooling System Water
This level coolant analysis is recommended when the
engine is overhauled. Refer to this Operations and Temperature Regulator -
Maintenance Manual, “Overhaul Considerations” for
further information.
Replace
SMCS Code: 1355-510
Add the SCA, If Necessary Replace the water temperature regulator before the
water temperature regulator fails. This is a
NOTICE recommended preventive maintenance practice.
Do not exceed the recommended amount of supple- Replacing the water temperature regulator reduces
mental coolant additive concentration. Excessive the chances for unscheduled downtime.
supplemental coolant additive concentration can form
deposits on the higher temperature surfaces of the A water temperature regulator that fails in a partially
cooling system, reducing the engine's heat transfer opened position can cause overheating or
characteristics. Reduced heat transfer could cause overcooling of the engine.
cracking of the cylinder head and other high tempera-
ture components. Excessive supplemental coolant A water temperature regulator that fails in the closed
additive concentration could also result in radiator position can cause excessive overheating. Excessive
tube blockage, overheating, and/or accelerated water overheating could result in cracking of the cylinder
pump seal wear. Never use both liquid supplemental head or piston seizure problems.
coolant additive and the spin-on element (if
equipped) at the same time. The use of those addi- A water temperature regulator that fails in the open
tives together could result in supplemental coolant position will cause the engine operating temperature
additive concentration exceeding the recommended to be too low during partial load operation. Low
maximum. engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear of
the cylinder liner.
Pressurized System: Hot coolant can cause seri-
pressure cap slowly in order to relieve the
pressure.
1. Slowly loosen the cooling system filler cap in order

to relieve the pressure. Remove the cooling
system filler cap.
Note: Always discard drained fluids according to

local regulations.
66 SEBU8312-03
Maintenance Section
Driven Equipment - Check
i06103535
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe Engine - Clean
engine damage. SMCS Code: 1000-070
Caterpillar engines incorporate a shunt design cool-
ing system and require operating the engine with a
water temperature regulator installed.
Personal injury or death can result from high
If the water temperature regulator is installed incor- voltage.
rectly, the engine may overheat, causing cylinder
head damage. Ensure that the new water tempera- Moisture can create paths of electrical
ture regulator is installed in the original position. En- conductivity.
sure that the water temperature regulator vent hole is
open. Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “ DO
Do not use liquid gasket material on the gasket or cyl- NOT OPERATE”” .
inder head surface.
Refer to Disassembly and Assembly, “Water NOTICE

Temperature Regulator - Remove and Install”. Accumulated grease and oil on an engine is a fire
Consult your Caterpillar dealer for more information. hazard. Keep the engine clean. Remove debris and
fluid spills whenever a significant quantity accumu-
Note: If only the water temperature regulators are lates on the engine.
replaced, drain the coolant from the cooling system
Periodic cleaning of the engine is recommended.
to a level that is below the water temperature Steam cleaning the engine will remove accumulated
regulator housing. oil and grease. A clean engine provides the following
benefits:
i00174798
• Easy detection of fluid leaks
Driven Equipment - Check • Maximum heat transfer characteristics
SMCS Code: 3279-535
• Ease of maintenance
Refer to the OEM specifications for more information
on the following maintenance recommendations for Note: Caution must be used in order to prevent
the driven equipment: electrical components from being damaged by
excessive water when you clean the engine. Avoid
• Inspection electrical components such as the alternator, the
starter, and the ECM.
• Adjustment
• Lubrication i04404720
• Other maintenance recommendations Engine Air Cleaner Element

Perform any maintenance for the driven equipment (Dual Element) - Clean/Replace
which is recommended by the OEM.
SMCS Code: 1054-510; 1054-037
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements
with damaged pleats, gaskets or seals. Dirt entering
the engine causes premature wear and damage to
engine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
SEBU8312-03 67
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
engine wear. Your Caterpillar dealer has the proper
air cleaner elements for your application. Consult
your Caterpillar dealer for the correct air cleaner
element.
• Check the precleaner (if equipped) daily for

accumulation of dirt and debris. Remove any dirt
and debris, as needed.
• Operating conditions (dust, dirt, and debris) may
require more frequent service of the air cleaner
element.
(1) Cover
• The air cleaner element may be cleaned up to six (2) Primary air cleaner element
(3) Secondary air cleaner element
times if the element is properly cleaned and (4) Turbocharger air inlet
inspected.
• The air cleaner element should be replaced at 1. Remove the cover. Remove the primary air cleaner
least one time per year. This replacement should element.
be performed regardless of the number of 2. The secondary air cleaner element should be
cleanings.
removed and discarded for every three cleanings
Replace the dirty paper air cleaner elements with of the primary air cleaner element.
clean air cleaner elements. Before installation, the air
cleaner elements should be thoroughly checked for Note: Refer to “Cleaning the Primary Air Cleaner
tears and/or holes in the filter material. Inspect the Elements”.
gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner 3. Cover the turbocharger air inlet with tape in order
elements for replacement purposes. to keep out dirt.
Dual Element Air Cleaners 4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner 5. Remove the tape for the turbocharger air inlet.
element. The primary air cleaner element can be Install the secondary air cleaner element. Install a
used up to six times if the element is properly primary air cleaner element that is new or cleaned.
cleaned and inspected. The primary air cleaner
element should be replaced at least one time per 6. Install the air cleaner cover.
year. This replacement should be performed
regardless of the number of cleanings.
The secondary air cleaner element is not serviceable
or washable. The secondary air cleaner element
should be removed and discarded for every three
cleanings of the primary air cleaner element. When
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more
frequent replacement.
68 SEBU8312-03
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
7. Reset the air cleaner service indicator. Pressurized Air

Pressurized air can be used to clean primary air
Cleaning the Primary Air Cleaner cleaner elements that have not been cleaned more
Elements than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).
NOTICE
Caterpillar recommends certified air filter cleaning
services that are available at Cat dealers. The Cat
cleaning process uses proven procedures to assure
consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to re-
move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter Illustration 44 g00281692
element. Take extreme care in order to avoid damage
to the pleats. Note: When the primary air cleaner elements are
cleaned, always begin with the clean side (inside) in
Do not use air filters with damaged pleats, gaskets,
or seals. Dirt entering the engine will cause damage order to force dirt particles toward the dirty side
to engine components. (outside).
The primary air cleaner element can be used up to Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
six times if the element is properly cleaned and damage to the paper pleats. Do not aim the stream of
inspected. When the primary air cleaner element is air directly at the primary air cleaner element. Dirt
cleaned, check for rips or tears in the filter material. could be forced further into the pleats.
The primary air cleaner element should be replaced
at least one time per year. This replacement should Note: Refer to “Inspecting the Primary Air Cleaner
be performed regardless of the number of cleanings.
Elements”.
Use clean primary air cleaner elements while dirty
elements are being cleaned. Vacuum Cleaning
NOTICE Vacuum cleaning is a good method for cleaning

Do not clean the air cleaner elements by bumping or primary air cleaner elements which require daily
tapping. This could damage the seals. Do not use el- cleaning because of a dry, dusty environment.
ements with damaged pleats, gaskets or seals. Dam- Cleaning with pressurized air is recommended prior
aged elements will allow dirt to pass through. Engine to vacuum cleaning. Vacuum cleaning will not
damage could result. remove deposits of carbon and oil.
Note: Refer to “Inspecting the Primary Air Cleaner
Visually inspect the primary air cleaner elements Elements”.
before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
There are two common methods that are used to
clean primary air cleaner elements:
• Pressurized air
• Vacuum cleaning
SEBU8312-03 69
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Replace
Inspecting the Primary Air Cleaner

Elements
Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a similar Illustration 46 g02595738
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element. Typical example
Inspect the primary air cleaner element for tears and/
or holes. Inspect the primary air cleaner element for Do not use paint, a waterproof cover, or plastic as a
light that may show through the filter material. If it is protective covering for storage. An airflow restriction
necessary in order to confirm the result, compare the may result. To protect against dirt and damage, wrap
primary air cleaner element to a new primary air the primary air cleaner elements in Volatile Corrosion
cleaner element that has the same part number. Inhibited (VCI) paper.
Do not use a primary air cleaner element that has Place the primary air cleaner element into a box for
any tears and/or holes in the filter material. Do not storage. For identification, mark the outside of the
use a primary air cleaner element with damaged box and mark the primary air cleaner element.
pleats, gaskets, or seals. Discard damaged primary Include the following information:
air cleaner elements.
• Date of cleaning
Storing Primary Air Cleaner Elements • Number of cleanings
If a primary air cleaner element that passes Store the box in a dry location.
inspection will not be used, the primary air cleaner
element can be stored for future use.
i01432811
Engine Air Cleaner Element

(Single Element) - Inspect/
Replace
SMCS Code: 1054-040; 1054-510
S/N: C6F1–Up
S/N: C7H1–Up
S/N: C6J1–Up
S/N: C6L1–Up
S/N: G7L1–Up
S/N: C6M1–Up
S/N: C6N1–Up
70 SEBU8312-03
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
S/N: G8N1–Up 5. Remove the seal from the opening of the air inlet.
S/N: G7P1–Up 6. Install a clean, undamaged air filter element (2).
S/N: C8W1–Up 7. Install air cleaner cover (1).
S/N: C7Y1–Up 8. Reset the air cleaner service indicator.
S/N: C8Y1–Up
i06103548
S/N: C8Z1–Up
Perform the Operation and Maintenance Manual,
Engine Air Cleaner Service
“Engine Air Cleaner Service Indicator-Inspect” Indicator - Inspect
procedure and perform the Operation and
Maintenance Manual, “Engine Air Precleaner Check/ (If Equipped)
Clean” procedure (if equipped) before performing the SMCS Code: 7452-040
following procedure.
S/N: C6F1–Up
NOTICE
Never run the engine without an air cleaner element S/N: C7H1–Up
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements S/N: C6J1–Up
with damaged pleats, gaskets or seals. Dirt entering
the engine causes premature wear and damage to S/N: C6L1–Up
engine components. Air cleaner elements help to pre- S/N: G7L1–Up
vent airborne debris from entering the air inlet.
S/N: C6M1–Up
NOTICE S/N: C6N1–Up

Never service the air cleaner element with the engine S/N: G8N1–Up
running since this will allow dirt to enter the engine.
S/N: G7P1–Up
S/N: C8W1–Up
S/N: C7Y1–Up
S/N: C8Y1–Up
S/N: C8Z1–Up
Some engines may be equipped with a different
service indicator.
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 and after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
Illustration 47 g00310664 equipped with a different type of service indicator,
(1) Air cleaner cover
follow the OEM recommendations in order to service
(2) Air filter element
the air cleaner service indicator.
(3) Air inlet
The service indicator may be mounted on the clean
side of the air cleaner housing or in a remote
1. Remove air cleaner cover (1) and remove air filter location.
element (2).
2. Cover air inlet (3) with tape or a clean cloth so that
debris cannot enter the air inlet.
3. Clean the inside of air cleaner cover (1). Clean the
body that holds the air cleaner element.
4. Inspect the replacement element for the following
items:damage, dirt and debris.
SEBU8312-03 71
Maintenance Section
Engine Air Precleaner - Check/Clean
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).
i02927289
Engine Air Precleaner - Check/

Clean
SMCS Code: 1055-070; 1055-535
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. Typical engine air precleaner
(1) Wing nut
• Check for ease of resetting. The service indicator (2) Cover
should reset in less than three pushes. (3) Body
• Check the movement of the service indicator core Remove wing nut (1) and cover (2). Check for an
when the engine is run at full load speed. The core accumulation of dirt and debris in body (3). Clean the
should latch approximately at the greatest vacuum body, if necessary.
that is attained.
After cleaning the precleaner, install cover (2) and
If the service indicator does not reset easily, or if the wing nut (1).
core does not latch at the greatest vacuum, the
service indicator should be replaced. If the new Note: When the engine is operated in dusty
service indicator will not reset, the hole for the service applications, more frequent cleaning is required.
indicator may be plugged.
If necessary, replace the service indicator more i02657607
frequently in environments that are severely dusty.
Replace the service indicator annually regardless of Engine Crankcase Breather -
the operating conditions. Replace the service
indicator when the engine is overhauled, and Replace
whenever major engine components are replaced. SMCS Code: 1317-510
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
72 SEBU8312-03
Maintenance Section
Engine Mounts - Inspect
6. Install a new diaphragm and plate (4) for the

breather assembly into the cavity (7) of the valve
mechanism cover or the spacer (5) for
turbocharged engines.
7. Install a new spring (3).
8. Install the breather cover (2) and the four screws
(1). Tighten the screws.
i02456872
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 Special Publication, SENR3130,
“Torque Specifications” for the recommended
torques. Refer to the OEM recommendations for
more information.
Illustration 50 g01335247 i00623423

Typical example
(1) Screws for the breather cover Engine Oil Level - Check
(2) Breather cover
(3) Spring SMCS Code: 1348-535-FLV
(4) Diaphragm and plate
(5) Spacer for turbocharged engines only
(6) Joint for turbocharged engines only
(7) Cavity
(8) Vent hole Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
1. Loosen the screws (1) and remove the breather contact the skin.
cover (2) from the valve mechanism cover.
2. Remove the spring (3). Remove the diaphragm
and plate (4).
3. For turbocharged engines, remove the spacer (5)
and the joint (6).
4. Clean the vent hole (8) and the cavity (7) in the
valve mechanism cover.
NOTICE (Y) “ADD” mark. (X) “FULL” mark.

Make sure that the components of the breather as-
sembly are installed correctly. Engine damage may
occur if the breather assembly is not working NOTICE
Perform this maintenance with the engine stopped.
correctly.
1. Maintain the oil level between “ADD” mark (Y) and

5. For turbocharged engines, install a new joint (6)
“FULL” mark (X) on oil level gauge (1). Do not fill
and the spacer (5).
the crankcase above “FULL” mark (X).
SEBU8312-03 73
Maintenance Section
Engine Oil Sample - Obtain
The 169-8373 Fluid Sampling Bottle is

NOTICE recommended for use with the sampling valve. The
Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into fluid sampling bottle includes the parts that are
the oil. The air bubbles created from the crankshaft needed for obtaining oil samples. Instructions are
dipping into the oil reduces the oil's lubricating char- also provided.
acteristics and could result in the loss of power.
NOTICE
2. Remove the oil filler cap and add oil, if necessary. use a separate designated pump for coolant sam-
Clean the oil filler cap. Install the oil filler cap. pling. Using the same pump for both types of sam-
drawn. This contaminate may cause a false analysis
i04237495
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
Engine Oil Sample - Obtain
SMCS Code: 1000-008; 1348-554-SM; 7542-554- If the engine is not equipped with a sampling valve,
SM; 7542-554-OC use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
In addition to a good preventive maintenance tubing must be attached to the pump for insertion into
program, Caterpillar recommends using S·O·S oil the sump.
analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required For instructions, see Special Publication, PEGJ0047,
for determining nitration and oxidation levels. “How To Take A Good S·O·S Oil Sample”. Consult
your Cat dealer for complete information and
Obtain the Sample and the assistance in establishing an S·O·S program for your
engine.
Analysis
i02625985
Engine Oil and Filter - Change

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to SMCS Code: 1318-510; 1348-044
contact the skin.
Before you take the oil sample, complete the Label,

PEEP5031 for identification of the sample. In order to Hot oil and hot components can cause personal
help obtain the most accurate analysis, provide the injury. Do not allow hot oil or hot components to
following information: contact the skin.
• Engine model
• Service hours on the engine NOTICE

• The number of hours that have accumulated since tained during performance of inspection, mainte-
the last oil change nance, testing, adjusting and repair of the product.
• The amount of oil that has been added since the ers before opening any compartment or disassem-
last oil change bling any component containing fluids.
To ensure that the sample is representative of the oil Dispose of all fluids according to local regulations
in the crankcase, obtain a warm, mixed oil sample. and mandates.
To avoid contamination of the oil samples, the tools

and the supplies that are used for obtaining oil NOTICE
samples must be clean. Keep all parts clean from contaminants.
Caterpillar recommends using the sampling valve in Contaminants may cause rapid wear and shortened
order to obtain oil samples. The quality and the component life.
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
74 SEBU8312-03
Maintenance Section
Engine Oil and Filter - Change
Do not drain the oil when the engine is cold. As the oil Nonferrous metals may indicate wear on the
cools, suspended waste particles settle on the aluminum parts, brass parts or bronze parts of the
bottom of the oil pan. The waste particles are not engine. Parts that may be affected include the
removed with the draining cold oil. Drain the following items: main bearings, rod bearings,
crankcase with the engine stopped. Drain the turbocharger bearings and cylinder heads.
crankcase with the oil warm. This draining method
allows the waste particles that are suspended in the Due to normal wear and friction, it is not
oil to be drained correctly. uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order to
Failure to follow this recommended procedure will arrange for a further analysis if an excessive
cause the waste particles to be recirculated through amount of debris is found in the oil filter.
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. Use one of
the following methods to drain the engine crankcase
oil:
• If the engine is equipped with a drain valve, turn
the drain valve knob counterclockwise in order to
drain the oil. After the oil has drained, turn the
drain valve knob clockwise in order to close the
drain valve.
• If the engine is not equipped with a drain valve,

remove the oil drain plug in order to allow the oil to
drain. After the oil has drained, the oil drain plug
should be cleaned and installed.
Replace the Oil Filter

NOTICE Illustration 52 g01334593
Caterpillar oil filters are built to Caterpillar specifica- (1) Oil cooler
tions. Use of an oil filter not recommended by Cater- (2) Adapter
pillar could result in severe engine damage to the (3) Oil filter
engine bearings, crankshaft, etc., as a result of the
larger waste particles from unfiltered oil entering the Note: Oil cooler (1) and adapter (2) are not installed
engine lubricating system. Only use oil filters recom- on all engines.
mended by Caterpillar.
3. Clean the sealing surface of the cylinder block or
the oil cooler (1).
1. Remove the oil filter with a 1U-8760 Chain
Wrench. 4. Apply clean engine oil to the new oil filter seal (3).
Note: The following actions can be carried out as NOTICE

part of the preventive maintenance program. Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
2. Cut the oil filter open with a 175-7546 Oil Filter nated. Contaminated oil can cause accelerated wear
Cutter Gp. Break apart the pleats and inspect the to engine components.
oil filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early wear
or a pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.
SEBU8312-03 75
Maintenance Section
Engine Protective Devices - Check
5. Install the oil filter. Tighten the oil filter until the oil
filter seal contacts the cylinder block or the oil
cooler. Tighten the oil filter by hand according to
the instructions that are shown on the oil filter. Do
not overtighten the oil filter.
Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to this Operation Illustration 53 g00110310
and Maintenance Manual , “Refill Capacities and
Recommendations” for more information on 4. Remove the oil level gauge in order to check the oil
lubricant specifications. Fill the crankcase with the level. Maintain the oil level between the “ADD” and
correct amount of oil. Refer to this Operation and “FULL” marks on the oil level gauge.
Maintenance Manual , “Refill Capacities” for more
information on refill capacities. i05264151
NOTICE Engine Protective Devices -

If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
Check
facturer's recommendations. Under filling or SMCS Code: 7400-535
overfilling the crankcase with oil can cause engine
damage. Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. Determining if the
NOTICE engine protective devices are in good working order
To prevent crankshaft bearing damage, crank the en- during normal operation is impossible. Malfunctions
gine with the fuel OFF. This will fill the oil filters before must be simulated in order to test the engine
starting the engine. Do not crank the engine for more protective devices.
than 30 seconds.
A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate at
2. Start the engine and run the engine at “LOW IDLE” the setpoints. Ensure that the engine protective
for two minutes. Perform this procedure in order to devices are functioning properly.
ensure that the lubrication system has oil and that
NOTICE
the oil filters are filled. Inspect the oil filter for oil During testing, abnormal operating conditions must
leaks. be simulated.
3. Stop the engine and allow the oil to drain back to The tests must be performed correctly in order to pre-
the sump for a minimum of ten minutes. vent possible damage to the engine.
To prevent damage to the engine, only authorized

service personnel or your Cat dealer should perform
the tests.
76 SEBU8312-03
Maintenance Section
Engine Valve Lash - Inspect/Adjust
Visual Inspection i02625315
Visually check the condition of all gauges, sensors, Fuel Injector - Test/Change
and wiring. Look for wiring and components that are
loose, broken, or damaged. Damaged wiring or SMCS Code: 1290-510; 1290-081
components should be repaired or replaced
immediately.
i02676796 Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.
Engine Valve Lash - Inspect/
Adjust NOTICE
SMCS Code: 1102-025 Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
This maintenance is recommended by Caterpillar as will be disconnected. Fit a suitable cover over discon-
part of a lubrication and preventive maintenance nected fuel system component.
schedule in order to help provide maximum engine
life. The maintenance for the valve lash is important Fuel injectors are subject to tip wear. Tip wear is a
in order to keep the engine compliant. result of fuel contamination. Tip wear can cause the
following problems:
This maintenance is recommended by Caterpillar as
part of a lubrication and preventive maintenance • Increased fuel consumption
schedule in order to help provide maximum engine
life. • Black smoke
• Misfire
NOTICE
Only qualified service personnel should perform this • Rough running
maintenance. Refer to the Systems Operation/Test-
ing and Adjusting Manual, “Valve Lash and Valve Fuel injectors should be cleaned, inspected, tested,
Bridge Adjustment”article or consult your Caterpillar and replaced, if necessary. Refer to Special
dealer for the complete valve lash adjustment Instruction, SEHS7292 for using the 8S-2245
procedure. Injector Cleaning Tool Gp. Consult your Caterpillar
dealer about cleaning the fuel injectors and testing
Operation of Caterpillar engines with improper valve the fuel injectors.
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life. NOTICE
Never wire brush or scrape a fuel injection nozzle.
Wire brushing or scraping a fuel injection nozzle will
damage the finely machine orifice. Proper tools for
cleaning and testing the fuel injection nozzles can be
obtained from Caterpillar dealers.
Ensure that the engine can not be started while
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor The following items are symptoms of a malfunction of
to turn the flywheel. the fuel injectors:
Hot engine components can cause burns. Allow • Abnormal engine operation
additional time for the engine to cool before
measuring/adjusting valve lash clearance. • Smoke emission
• Engine knock
Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement, Each fuel injector must be isolated one at a time in
allow the valves to cool before this maintenance is order to determine the malfunctioning fuel injector.
performed.
1. Start the engine.
Refer to the Service Manual for more information.
2. Loosen each fuel line nut one at a time at the fuel
injection pump. A cloth or similar material must be
used in order to prevent fuel from spraying on the
hot exhaust components. Tighten each nut before
loosening the next nut.
SEBU8312-03 77
Maintenance Section
Fuel System - Prime
3. A faulty fuel injector may be identified when a fuel

NOTICE
line nut is loosened and the following conditions Care must be taken to ensure that fluids are con-
are present: tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
• The exhaust smoke is partially eliminated or Be prepared to collect the fluid with suitable contain-
the exhaust smoke is completely eliminated. ers before opening any compartment or disassem-
• Engine performance is not affected.
Dispose of all fluids according to local regulations
A fuel injector that is suspected of being faulty and mandates.
should be removed. A new fuel injector should be
installed in the cylinder in order to determine if the
removed fuel injector is faulty. Primary filter
Removal and Installation of the Ensure that the air is removed from the primary filter
before you prime the fuel filters. Refer to illustration
Fuel Injection Nozzles 54 .
For the removal and the installation of fuel injectors,
special tooling is required. Refer to the Service
Manual for more information. Consult your Caterpillar
dealer for assistance.
i02596360
Fuel System - Prime

SMCS Code: 1258-548
NOTICE
and mandates.
Use the following procedure in order to prime the fuel Illustration 54 g01316878
system: This filter may not be installed on the engine.
If air enters the fuel system, the air must be purged (1) Vent screws
from the fuel system before the engine can be
started. Air can enter the fuel system when the Fuel filters
following events occur:
There are three types of fuel filter that may be
• The fuel tank is empty or the fuel tank has been installed on the engine.
partially drained.
• Element
• The low pressure fuel lines are disconnected.
• Canister
• A leak exists in the low pressure fuel system.
• Spin-on filter with fuel priming pump
• The fuel filter is replaced.
78 SEBU8312-03
Maintenance Section
Fuel System - Prime

Element Spin-on filter with fuel priming pump
(2) Fuel valve (5) Vent screw
(3) Vent screw
Vent screw (3) is installed on the filter that has an
element. Vent screw (4) is installed on the fuel filter
that has a canister. Vent screw (5) is installed on the
spin-on filter.
Priming the system

Ensure that the air is removed from the primary filter.
Loosen vent screws (1). Refer to illustration 54 .
Operate the priming pump. When fuel free from air
flows from the vent screw tighten the vent screw.
Note: Some fuel system will use gravity in order to

prime the primary fuel filter. If gravity is used ensure
that the fuel tank is full and that all stop valves in the
fuel line are open.
There is four different types of systems that can be
installed on the engine in order to prime the fuel
system. Refer to illustration 58 .
• Hand priming pump

• In-line hand priming pump
Canister • Electrical priming pump
(4) Vent screw
• Transfer pump that is operated by the starting
motor
SEBU8312-03 79
Maintenance Section
Fuel System - Prime
(6) Hand priming pump (8) Electrical priming pump

(7) In-line priming pump (9) Fuel transfer pump
(10) Connector bolt (11) Fuel return line (12) Connector bolt
Hand Priming Pump 6 1. Ensure that fuel valve (2) for the fuel filter that has
an element is in the ON position. Refer to
In order to identify the hand priming pump, refer to illustration 55 .
illustration 58 .
80 SEBU8312-03
Maintenance Section
Fuel System - Prime
2. Loosen vent screw (3 4 or 5) on the fuel filter. 1. Ensure that fuel valve (2) for the fuel filter that has
3. Operate hand priming pump (6). When fuel free
illustration 55 .
from air flows from the vent screw tighten the vent
screw. 2. Loosen vent screw (3 4 or 5) on the fuel filter.
4. Loosen connection (10 or 12) at the fuel injection 3. Operate electrical priming pump (8). When fuel
pump. Refer to illustration 59 . free from air flows from the vent screw tighten the
vent screw. Switch off the electrical priming pump.
Note: Fuel return line (11) may need to be removed
in order to prime the fuel system. 4. Loosen connection (10 or 12) at the fuel injection
pump. Refer to illustration 59 .
5. Operate the hand priming pump. When fuel free
from air flows from the connections tighten the Note: Fuel return line (11) may need to be removed
connecting bolt. in order to prime the fuel system.
6. The engine should now be able to start. Operate 5. Operate the in-line priming pump. When fuel free
the starting motor in order to start the engine. from air flows from the connections tighten the
connecting bolt.
Note: Do not operate the starting motor for more than
15 seconds. If the engine does not start after 15 6. The engine should now be able to start. Operate
seconds, stop and wait for 30 seconds before trying the starting motor in order to start the engine.
again.
In-line Priming Pump 7 15 seconds. If the engine does not start after 15
seconds, stop and wait for 30 seconds before trying
In order to identify the in-line priming pump, refer to again.
illustration 58 .
Fuel Transfer Pump 9
1. Ensure that fuel valve (2) for the fuel filter that has
an element is in the ON position. Refer to In order to identify the fuel transfer pump, refer to
illustration 55 . illustration 58 .
2. Loosen vent screw (3 4 or 5) on the fuel filter. Note: In order to use the transfer pump, you must
operate the starting motor. Do not operate the
3. Operate in-line priming pump (7). When fuel free
starting motor for more than 15 seconds. After 15
from air flows from the vent screw tighten the vent seconds, stop and wait for 30 seconds before
screw. operating the starting motor.
4. Loosen connection (10 or 12) at the fuel injection
1. Ensure that fuel valve (2) for the fuel filter that has
pump. Refer to illustration 59 .
Note: Fuel return line (11) may need to be removed illustration 55 .
in order to prime the fuel system.
2. Loosen vent screw (3 4 or 5) on the fuel filter.
5. Operate the in-line priming pump. When fuel free 3. Operate fuel transfer pump (9). When fuel free
from air flows from the connections tighten the from air flows from the vent screw tighten the vent
connecting bolt. screw. Stop the fuel transfer pump.
6. The engine should now be able to start. Operate 4. Loosen connection (10 or 12) at the fuel injection
the starting motor in order to start the engine. pump. Refer to illustration 59 .
Note: Do not operate the starting motor for more than Note: Fuel return line (11) may need to be removed
15 seconds. If the engine does not start after 15 in order to prime the fuel system.
seconds, stop and wait for 30 seconds before trying
again. 5. Operate the fuel transfer pump. When fuel free
from air flows from the connections tighten the
Electrical Priming Pump 8 connecting bolt. Stop the transfer pump.
In order to identify the electrical priming pump, refer 6. The engine should now be able to start. Operate
to illustration 58 . the starting motor in order to start the engine.
SEBU8312-03 81
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

NOTICE
15 seconds. If the engine does not start after 15 The water separator is under suction during normal
seconds, stop and wait for 30 seconds before trying engine operation. Ensure that the drain valve is tight-
again. ened securely to help prevent air from entering the
fuel system.
i02627223
Fuel System Primary Filter/ i02627769
Water Separator - Drain Fuel System Secondary Filter -

SMCS Code: 1260-543; 1263-543
Replace
SMCS Code: 1261-510-SE
Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when Fuel leaked or spilled onto hot surfaces or electri-
changing fuel filters or water separator elements. cal components can cause a fire. To help prevent
Clean up fuel spills immediately. possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
The water separator is not a filter. The water separa-
tor separates water from the fuel. The engine should NOTICE
never be allowed to run with the water separator Do not allow dirt to enter the fuel system. Thoroughly
more than half full. Engine damage may result. clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
NOTICE
and mandates.
Fuel Filter with Canister

1. Close the fuel supply valve.
Typical example
1. Open drain (1). Catch the draining fluid in a

suitable container. Dispose of the drained fluid
correctly.
2. Close drain (1).
82 SEBU8312-03
Maintenance Section
Fuel System Secondary Filter - Replace
6. Fasten the assembly to the fuel filter base with

setscrew (2).
The fuel system will need to be primed after the new
filter is installed. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime”.
Fuel Filter with Element

1. Close the fuel supply valve (1).
Typical example
2. Clean the outside of the fuel filter assembly (1).

3. Remove setscrew (2).
4. Remove the canister (3). Ensure that any fluid is
drained into a suitable container.
Typical example
2. Clean the outside of the fuel filter assembly.

3. Loosen locking ring (2).
4. Remove the casing for the filter (3) and the
element. Ensure that any fluid is drained into a
suitable container.
Typical example
5. Assemble the following items: seals (8), seal (7),

canister (3) and bowl (10). Place washer (5) and
seal (6) on setscrew (2).
SEBU8312-03 83
Maintenance Section
Fuel System Secondary Filter - Replace
Typical example
3. Remove spin-on filter (1). Use a 1U-8760 Chain

Wrench in order to remove the filter. Ensure that
any fluid is drained into a suitable container.
Note: Do not fill the fuel filter with fuel. This fuel will
not be filtered and the fuel could be contaminated.
Contaminated fuel can damage the fuel system.
4. Install the new spin-on filter. Tighten the spin-on

filter by hand.
Typical example
5. Assemble the following items: seal (5), filter

element (6) and casing (3).
Note: Do not fill the fuel filter with fuel. This fuel will
not be filtered and the fuel could be contaminated.
Contaminated fuel can damage the fuel system.
6. Install the assembled items to the filter base (4).

7. Install the locking ring (2) to the filter base. Rotate
the locking ring in order to lock the assembly.
The fuel system will need to be primed after the new
filter is installed. Refer to this Operation and
Maintenance Manual, “Fuel System - Prime”.
Fuel filter with priming pump

1. Close the fuel supply valve.
2. Clean the outside of the fuel filter assembly.
84 SEBU8312-03
Maintenance Section
Fuel Tank Water and Sediment - Drain
The fuel system will need to be primed after the new Check the fuel daily. Drain the water and sediment
filter is installed. Refer to this Operation and from the fuel tank after operating the engine. Drain
Maintenance Manual, “Fuel System - Prime”. the water and sediment from the fuel tank after the
fuel tank has been filled. Allow 5 to 10 minutes before
performing this procedure.
i06104305
Fill the fuel tank after operating the engine in order to
Fuel Tank Water and Sediment drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel
- Drain expands as the fuel gets warm. The tank may
SMCS Code: 1273-543-M&S overflow.
Some fuel tanks use stand pipes that allow water and
NOTICE sediment to settle below the end of the fuel stand
Care must be taken to ensure that fluids are con- pipe. Some fuel tanks use supply lines that take fuel
tained during performance of inspection, mainte- directly from the bottom of the tank. If the engine is
nance, testing, adjusting, and repair of the product. equipped with this system, regular maintenance of
Be prepared to collect the fluid with suitable contain- the fuel system filter is important.
bling any component containing fluids. Fuel Storage Tanks
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication, Drain the water and the sediment from the fuel
PECJ0003, “Cat Shop Supplies and Tools Catalog” storage tank during the following conditions:
for tools and supplies suitable to collect and contain
fluids on Cat products. • Weekly
Dispose of all fluids according to local regulations • Refill of the tank

and mandates. This procedure will help prevent water or sediment
from being pumped from the storage tank into the
engine fuel tank. A four micron(c) absolute filter for
Fuel Tank the breather vent on the fuel tank is also
recommended.
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause If a bulk storage tank has been refilled or moved
excessive wear to the fuel system. Condensation recently, allow adequate time for the sediment to
occurs during the heating and cooling of fuel. The settle before filling the engine fuel tank. Internal
condensation occurs as the fuel passes through the baffles in the bulk storage tank will also help trap
fuel system and the fuel returns to the fuel tank. This sediment. Filtering fuel that is pumped from the
causes water to accumulate in fuel tanks. Draining storage tank helps to ensure the quality of the fuel.
the fuel tank regularly and obtaining fuel from reliable When possible, water separators should be used.
sources can help to eliminate water in the fuel. The
fuel tank utilizes a fuel tank vent to prevent an air lock i06104329
or vacuum. Ensure that the vent is free of debris and
not damaged. Hoses and Clamps - Inspect/
Drain the Water and the Sediment Replace
SMCS Code: 7554-040; 7554-510
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the Hoses and clamps must be inspected periodically
fuel tanks. and replaced at the recommended interval to ensure
safe and continuous operation of the engine. Failure
Prepare to catch water and sediment in an to replace a fuel hose at the recommended change
appropriate container. Connect a hose (if necessary) interval may result in a hazardous situation. Take
to the valve prior to opening the valve. proper safety precautions before inspecting or
replacing hoses and clamps.
Open the drain valve on the bottom of the fuel tank in
order to drain the water and the sediment. Close the Note: Always use a board or cardboard when the
drain valve.
engine components are checked for leaks. Leaking
Note: Failure to close the drain properly could result fluid that is under pressure can cause serious injury
in fuel leakage, which could have detrimental results or possible death. Leaks that are the size of a pin
to performance. hole are included. Refer to Operation and
Maintenance Manual, “General Hazard Information”
for more information.
SEBU8312-03 85
Maintenance Section
Hoses and Clamps - Inspect/Replace
Note: Ensure that the hose is compatible with the Replace hoses that are cracked or soft. Replace
application. hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace
Inspect the Hoses and the Clamps hose clamps which are loose.
Inspect all hoses for leaks that are caused by the
following conditions. Replace any hose which Replace the Hoses and the Clamps
exhibits any of the following conditions. Failure to
replace a hose which exhibits any of the following
NOTICE
conditions may result in a hazardous situation. Care must be taken to ensure that fluids are con-
• Hoses which are cracked nance, testing, adjusting, and repair of the product.
• Hoses which are soft ers before opening any compartment or disassem-
• Outer covering that is chafed or cut
Refer to Special Publication, NENG2500, “Cat Dealer
• Exposed wire that is used for reinforcement Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
• Outer covering that is ballooning locally for tools and supplies suitable to collect and contain
fluids on Cat products.
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering and mandates.
• Hoses which exhibit signs of leakage which are
not the result of loose couplings or clamps
Cooling System
Inspect all clamps for the following conditions.
Replace any clamp which exhibits signs of any of the
following conditions.
• Cracking Pressurized System: Hot coolant can cause seri-

• Looseness stop the engine and wait until the cooling system
• Damage pressure cap slowly in order to relieve the
pressure.
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: Personal injury can result from removing hoses
or fittings in a pressure system.
• Type of hose
Failure to relieve pressure can cause personal
• Type of fitting material injury.
• Anticipated expansion and contraction of the hose Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
• Anticipated expansion and contraction of the
fittings
1. Stop the engine.
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen 2. Allow the engine to cool.
which can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps. 3. Before servicing a coolant hose, slowly loosen the
filler cap for the cooling system in order to relieve
any pressure.
4. Remove the filler cap for the cooling system.
86 SEBU8312-03
Maintenance Section
Hoses and Clamps - Inspect/Replace
5. Drain the coolant from the cooling system to a

NOTICE
level that is below the hose that is being replaced. Do not allow dirt to enter the fuel system. Thoroughly
Drain the coolant into a suitable clean container. clean the area around a fuel system component that
The coolant can be reused. will be disconnected. Fit a suitable cover over any
disconnected fuel system components.
6. Remove the hose clamps.
7. Disconnect the old hose.
Note: High-pressure fuel lines may be installed
8. Replace the old hose with a new hose. between the high-pressure fuel pump and the fuel
injectors. High-pressure fuel lines are constantly
9. Install hose clamps which have been inspected or charged with high pressure. Do not check the high-
install new hose clamps. Refer to Specifications, pressure fuel lines with the engine or the starting
SENR3130, “Torque Specifications” “Hose motor in operation. Wait for 10 minutes after the
Clamps” for information about selecting and engine stops before you perform any service or
installing the proper hose clamps. repair on high-pressure fuel lines. Waiting for 10
minutes will to allow the pressure to be purged.
10. Refill the cooling system.
1. Drain the fuel from the fuel system to a level that is
11. Clean the coolant filler cap. Inspect the gaskets
below the hose that is being replaced.
on the filler cap. Inspect the gasket seat. Inspect
the vacuum valve and seat for debris or damage. 2. Remove the hose clamps.
Replace the filler cap if the gaskets are damaged.
3. Disconnect the old hose.
Install the filler cap.
12. Start the engine. Inspect the cooling system for Note: When servicing fuel system, use cap/s or
leaks. cover/s as required to protect the system and
maintain fuel system cleanliness.
Fuel System 4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications,
Personal injury can result from removing hoses SENR3130, “Torque Specifications” “Hose
or fittings in a pressure system. Clamps” for information about selecting and
installing the proper hose clamps.
Failure to relieve pressure can cause personal
injury. 6. Carefully inspect the engine for any spilled fuel.
Make sure that no fuel remains on or close to the
Do not disconnect or remove hoses or fittings un- engine.
til all pressure in the system has been relieved.
Note: Fuel must be added to the fuel system ahead
of the fuel filter.
7. Refill the fuel system. Refer to this Operation and

Contact with high pressure fuel may cause fluid Maintenance Manual, “Fuel System - Prime” for
penetration and burn hazards. High pressure fuel information about priming the engine with fuel.
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in- 8. Start the engine. Inspect the fuel system for leaks.
structions may cause personal injury or death.
Lubrication System
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 Hot oil and hot components can cause personal
hoses. Leaks can cause fires. Inspect all lines, tubes injury. Do not allow hot oil or hot components to
and hoses carefully. Tighten all connections to the contact the skin.
recommended torque.
1. Drain the oil from the lubrication system to a level
that is below the hose that is being replaced.
2. Remove the hose clamps.
SEBU8312-03 87
Maintenance Section
Overhaul Considerations
3. Disconnect the old hose. Oil Consumption as an Overhaul

4. Replace the old hose with a new hose. Indicator
5. Install hose clamps which have been inspected or Oil consumption, fuel consumption, and maintenance
install new hose clamps. Refer to Specifications, information can be used to estimate the total
SENR3130, “Torque Specifications” “Hose operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
Clamps” for information about selecting and required capacity of a makeup oil tank that is suitable
installing the proper hose clamps. for the maintenance intervals.
6. Refill the lubrication system. Refer to this Oil consumption is in proportion to the percentage of
Operation and Maintenance Manual, “Engine Oil the rated engine load. As the percentage of the
Level - Check” in order to ensure that the engine load is increased, the amount of oil that is
lubrication system is filled with the proper amount consumed per hour also increases.
of engine oil. The oil consumption rate (brake specific oil
7. Start the engine. Inspect the lubrication system for consumption) is measured in grams per kW/h (lb per
leaks. bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
Air System consumption rate for your engine.
1. Remove the hose clamps. When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal
2. Disconnect the old hose. wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
3. Replace the old hose with a new hose.
and a slight increase in fuel consumption.
4. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications, Overhaul Recommendation
SENR3130, “Torque Specifications” “Hose
Clamps” for information about selecting and Caterpillar recommends replacement of the engine.
For more information about replacement of the
installing the proper hose clamps. engine, see your Caterpillar dealer. Engine
components are available in a standard size only.
Note: The bellows and the V-clamps that are used on
the exhaust bellows should never be reused.
Cleaning
5. Start the engine. Inspect the air lines for leaks.
Caterpillar recommends the use of Hydrosolv Liquid
Cleaners. Table 31 lists the Hydrosolv Liquid
i02677504
Cleaners that are available from your Caterpillar
dealer.
Overhaul Considerations Table 31
SMCS Code: 7595-043 HydrosolvLiquid Cleaners
Reduced hours of operation at full load will result in a Part Number Description Size
lower average power demand. A decreased average
power demand should increase both the engine
service life and the overhaul interval. 1U-8812 4 L (1 US gallon)
The need for an overhaul is generally indicated by Hydrosolv4165
increased fuel consumption and by reduced power.
1U-5490 19 L (5 US gallon)
The following factors are important when a decision
is being made on the proper time for an engine 8T-7570 208 L (55 US gallon)
overhaul:
1U-8804 4 L (1 US gallon)
• The need for preventive maintenance
Hydrosolv100
1U-5492 19 L (5 US gallon)
• The quality of the fuel that is being used
8T-5571 208 L (55 US gallon)
• The operating conditions
• The results of the S·O·S analysis

88 SEBU8312-03
Maintenance Section
Radiator - Clean
Obtain Coolant Analysis

The concentration of supplemental coolant additive Personal injury can result from air pressure.
(SCA) should be checked regularly with test kits or
with S·O·S Coolant Analysis (Level I). Personal injury can result without following prop-
er procedure. When using pressure air, wear a
A coolant analysis can be conducted in order to verify protective face shield and protective clothing.
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained The maximum air pressure for cleaning purposes
by consulting your local water utility company or an must be reduced to 205 kPa (30 psi) when the air
agricultural agent. Private laboratories are also nozzle is deadheaded.
available for water analysis.
Caterpillar Inc. recommends an S·O·S Coolant Pressurized air is the preferred method for removing
Analysis (Level II). loose debris. Direct the air in the opposite direction of
the air flow. Hold the nozzle approximately 6 mm
S·O·S Coolant Analysis (Level II) (0.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes.
An S·O·S Coolant Analysis (Level II) is a This movement will remove debris that is between
comprehensive coolant analysis which completely the tubes.
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level II) Pressurized water may also be used for cleaning.
provides the following information: The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
• Complete S·O·S Coolant Analysis (Level I) water in order to soften mud. Clean the core from
both sides.
• Visual inspection of properties
Use a degreaser and steam for removal of oil and
• Identification of metal corrosion grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
• Identification of contaminants core with clean water.
After cleaning, start the engine and accelerate the
• Identification of built up impurities (corrosion and engine to high idle rpm. This procedure will help in
scale) the removal of debris and drying of the core. Stop the
engine. Use a light bulb behind the core in order to
S·O·S Coolant Analysis (Level II) provides a report of inspect the core for cleanliness. Repeat the cleaning,
the results of both the analysis and the maintenance if necessary.
recommendations.
For more information about coolant analysis, see Inspect the fins for damage. Bent fins may be opened
your Caterpillar dealer. with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps and seals. Make repairs, if necessary.
i04020194
Radiator - Clean i00151038
SMCS Code: 1353-070 Severe Service Application -

Note: Adjust the frequency of cleaning according to Check
the effects of the operating environment. SMCS Code: 1000-535
Inspect the radiator for these items: damaged fins, Severe service is an application of an engine that
corrosion, dirt, grease, insects, leaves, oil and other exceeds current published standards for that engine.
debris. Clean the radiator, if necessary. Caterpillar maintains standards for the following
engine parameters:
• Performance (power range, speed range and fuel

consumption)
• Fuel quality
• Altitude range
• Maintenance intervals
SEBU8312-03 89
Maintenance Section
Starting Motor - Inspect
• Oil selection and maintenance • Operating outside the intended application

• Coolant selection and maintenance
Improper Maintenance Procedures
• Environmental qualities
• Extending the maintenance intervals
• Installation
• Failure to use recommended fuel, lubricants and
Refer to the standards for the engine or consult with coolant/antifreeze
your Caterpillar dealer in order to determine if the
engine is operating within the defined parameters. i00651416
Severe service operation can accelerate component

wear. Engines that operate under severe conditions Starting Motor - Inspect
may need more frequent maintenance intervals in SMCS Code: 1451-040; 1453-040
order to ensure maximum reliability and retention of
full service life. Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
Due to individual applications, it is not possible to engine may not start in an emergency situation.
identify all of the factors which can contribute to
severe service operation. Consult your Caterpillar Check the starting motor for proper operation. Check
dealer for the unique maintenance that is necessary the electrical connections and clean the electrical
for the engine. connections. Refer to the Service Manual for more
information on the checking procedure and for
The operating environment, improper operating specifications or consult your Caterpillar dealer for
procedures and improper maintenance procedures assistance.
can be factors which contribute to severe service
conditions. i02226957
Environmental Factors Turbocharger - Inspect

Ambient temperatures – The engine may be (If Equipped)
exposed to extended operation in extremely cold
environments or hot environments. Valve SMCS Code: 1052; 1052-040
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very A regular visual inspection of the turbocharger is
cold temperatures. Extremely hot inlet air reduces recommended. Any fumes from the crankcase are
engine performance. filtered through the air inlet system. Therefore, by-
products from oil and from combustion can collect in
Air Quality – The engine may be exposed to the turbocharger compressor housing. Over time, this
extended operation in an environment that is dirty or buildup can contribute to loss of engine power,
dusty, unless the equipment is cleaned regularly. increased black smoke and overall loss of engine
Mud, dirt and dust can encase components. efficiency.
Maintenance can be very difficult. The buildup can
contain corrosive chemicals. If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel and/
Buildup – Compounds, elements, corrosive or to the engine may occur. Damage to the
chemicals and salt can damage some components. turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder
Altitude – Problems can arise when the engine is head.
operated at altitudes that are higher than the
intended settings for that application. Necessary
adjustments should be made.
Improper Operating Procedures

• Extended operation at low idle
• Frequent hot shutdowns
• Operating at excessive loads

• Operating at excessive speeds
90 SEBU8312-03
Maintenance Section
Walk-Around Inspection
4. Fasten the air intake pipe and the exhaust outlet

NOTICE
Turbocharger bearing failures can cause large quan- pipe to the turbocharger housing.
tities of oil to enter the air intake and exhaust sys-
tems. Loss of engine lubricant can result in serious i00632301
engine damage.
Minor leakage of oil into a turbocharger under ex-
Walk-Around Inspection
tended low idle operation should not cause problems SMCS Code: 1000-040
as long as a turbocharger bearing failure has not
occured.
Inspect the Engine for Leaks and
When a turbocharger bearing failure is accompanied for Loose Connections
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue A walk-around inspection should only take a few
engine operation until the turbocharger is renewed. minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
A visual inspection of the turbocharger can minimize For maximum engine service life, make a thorough
unscheduled downtime. A visual inspection of the inspection of the engine compartment before starting
turbocharger can also reduce the chance for potential the engine. Look for items such as oil leaks or
damage to other engine parts. coolant leaks, loose bolts, worn belts, loose
connections and trash buildup. Make repairs, as
Removal and Installation needed:
Note: The turbochargers that are supplied are • The guards must be in the proper place. Repair
nonserviceable. damaged guards or replace missing guards.
For options regarding the removal, installation, repair • Wipe all caps and plugs before the engine is
and replacement, consult your Caterpillar dealer. serviced in order to reduce the chance of system
Refer to the Service Manual for this engine for the contamination.
procedure and specifications.
NOTICE
Inspecting For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and
correct the leak. If leaking is suspected, check the flu-
NOTICE id levels more often than recommended until the leak
The compressor housing for the turbocharger must is found or fixed, or until the suspicion of a leak is
not be removed from the turbocharger for cleaning. proved to be unwarranted.
The actuator linkage is connected to the compressor
housing. If the actuator linkage is moved or disturbed
the engine may not comply with emmissions NOTICE
Accumulated grease and/or oil on an engine or deck
legislation.
is a fire hazard. Remove this debris with steam clean-
ing or high pressure water.
1. Remove the pipe from the turbocharger exhaust
outlet and remove the air intake pipe to the • Ensure that cooling lines are properly clamped
turbocharger. Visually inspect the piping for the and tight. Check for leaks. Check the condition of
presence of oil. Clean the interior of the pipes in all pipes.
order to prevent dirt from entering during
reassembly. • Inspect the water pump for coolant leaks.
2. Check for the presence of oil. If oil is leaking from Note: The water pump seal is lubricated by coolant in
the back side of the compressor wheel, there is a the cooling system. It is normal for a small amount of
possibility of a failed turbocharger oil seal. leakage to occur as the engine cools down and the
parts contract.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil Excessive coolant leakage may indicate the need to
may also be the result of a restriction of the line for replace the water pump seal. For the removal of
the intake air (clogged air filters), which causes the water pump and the installation of water pump and/or
turbocharger to slobber. seals, refer to the Service Manual for the engine or
consult your Caterpillar dealer.
3. Inspect the bore of the housing of the turbine outlet
for corrosion.
SEBU8312-03 91
Maintenance Section
Water Pump - Inspect
• Inspect the lubrication system for leaks at the front Visually inspect the water pump for leaks. Renew the
crankshaft seal, the rear crankshaft seal, the oil water pump seal or the water pump if there is an
pan, the oil filters and the valve cover. excessive leakage of coolant. Refer to the
Disassembly and Assembly Manual, “Water Pump -
• Inspect the fuel system for leaks. Look for loose Remove and Install” for the disassembly and
fuel line clamps. assembly procedure.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
• 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 engine-to-frame ground strap for a
good connection and for good condition.
• Disconnect any battery chargers that are not

protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.
• Check the condition of the gauges. Replace any
gauges which are cracked or can not be
calibrated.
i02226958
Water Pump - Inspect

SMCS Code: 1361-040; 1361
A failed water pump may cause severe engine
overheating problems that could result in the
following conditions:
• Cracks in the cylinder head
• A piston seizure
• Other potential damage to the engine
Note: The water pump seal is lubricated by the

coolant in the cooling system. It is normal for a small
amount of leakage to occur as the engine cools down
and parts contract.
92 SEBU8312-03
Warranty Section
Warranty Information
Warranty Section The aftertreatment system can be expected to

function properly for the lifetime of the engine
(emissions durability period) subject to prescribed
maintenance requirements being followed.
Warranty Information
A detailed explanation of the Emission Control
Warranty that is applicable to new non-road and
i05549472 stationary diesel engines, including the components
covered and the warranty period, is found in a
Emissions Warranty supplemental Special Publication. Consult your
authorized Cat dealer to determine if your engine is
Information subject to an Emission Control Warranty and to
SMCS Code: 1000 obtain a copy of the applicable Special Publication.
The certifying engine manufacturer warrants to the

ultimate purchaser and each subsequent purchaser
that:
1. New non-road diesel engines and stationary diesel
engines less than 10 liters per cylinder (including
Tier 1 and Tier 2 marine engines < 37 kW, but
excluding locomotive and other marine engines)
operated and serviced in the United States and
Canada, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to
conform, at the time of sale, with applicable
emission standards prescribed by the United
States Environmental Protection Agency
(EPA) by way of regulation.
b. Free from defects in materials and

workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.
2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to
conform, at the time of sale, to all applicable
regulations adopted by the California Air
Resources Board (ARB).
b. Free from defects in materials and

workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the engine manufacturer's
application for certification for the warranty
period.
SEBU8312-03 93
Reference Information Section
Engine Ratings
Reference Information i00819749
Section Engine Rating Definitions

SMCS Code: 1000
Engine Ratings It is important to know the use of the engine so that

the rating will match the operating profile. The proper
rating selection is also important so that the
i00727327 customer's perception of price and value is realized.
Engine Rating Conditions In selecting a rating for a specific application, the

most important consideration is the time that is spent
SMCS Code: 1000 at full throttle. These rating definitions identify the
percent of time at full throttle. The definitions also
All engine ratings are in compliance with the following identify the corresponding times below rated rpm.
standard ambient air conditions of “SAE J1349”:
Note: The examples of the applications are only for
• 99 kPa (29.3 inches of Hg) reference. For an exact determination of the
appropriate rating, follow the OEM specifications or
• 30 percent relative humidity
consult your Caterpillar dealer.
• A temperature of 25 °C (77 °F) A Rating – This rating is used for heavy-duty
Ratings relate to the standard conditions of applications that are operated at rated load and at
“ISO8665”, of “ISO3046/1”, of “DIN6271”, and of rated rpm up to 100 percent. This rating is used for
“BS5514”. engines that operate without interruption of load
cycling. Typical applications include the following
The engine ratings are based on the following fuel examples: pipeline pumping and ventilation.
specifications:
B Rating – This rating is used when power and/or
• Low heat value (LHV) of the fuel of 42 780 kJ/kg rpm are cyclic. The engine should be run at full load.
(18,390 Btu/lb) at 29 °C (84 °F) The engine should not exceed 80 percent of the duty
cycle. Typical applications include the following
• Gravity (API) of 35 degrees at 15 °C (60 °F) examples: irrigation, operation where normal pump
demand is 85 percent of the engine rating, oil
• Specific gravity of .849 at 15 °C (60 °F) pumping/drilling, field mechanical pumping/drilling
and stationary/plant air compressors.
• Density of 850 kg/m3 (7.085 lb/US gal)
C Rating – This rating is used when power and/or
The engine ratings are gross output ratings. rpm are cyclic. The horsepower and the rpm of the
engine can be utilized continuously for one hour. This
Gross Output Ratings – The total output capability is followed by one hour of operation at the A rating or
of the engine that is equipped with standard below the A rating. The engine should be run at full
accessories. load. The engine should not exceed 50 percent of the
duty cycle. Typical applications include the following
examples: agricultural tractors, harvesters and
Standard accessories include the following combines, off-highway trucks, fire pumps, blast hole
components: drills, rock curshers, wood chippers with high torque
rise and oil field hoisting.
• Oil pumps
D Rating – This rating is used when rated power is
• Fuel pumps required for periodic overloads. The maximum
horsepower and the rpm of the engine can be utilized
• Water pumps continuously for a maximum of 30 minutes. This is
followed by one hour of operation at the C rating. The
Subtract the power that is required to drive auxiliary engine should be run at full load. The engine should
components from the gross output. This will produce not exceed 10 percent of the duty cycle. Typical
the net power that is available for the external load applications include the following examples: offshore
(flywheel). cranes, runway snow blowers, water well drills,
portable air compressors and fire pump certification
power.
E Rating – This rating is used when rated power is
required for a short time for initial starting or for
sudden overload. The rating is also used for
emergency service when standard power is not
94 SEBU8312-03
Engine Rating Definitions
available. The horsepower and the rpm of the engine

can be utilized continuously for a maximum of 15
minutes. This is followed by one hour of operation at
the C rating or by the duration of the emergency. The
engine should be run at full load. The engine should
not exceed 5 percent of the duty cycle. Typical
applications include the following examples: standby
centrifugal water pumps, oil field well servicing, crash
trucks, portable air compressors and gas turbine
starting motors.
NOTICE
Operating engines above the rating definitions can
result in shorter service life before overhaul.
SEBU8312-03 95
Customer Service
Customer Service Europe, Africa, and Middle East

Caterpillar Overseas S.A.
76 Route de Frontenex
i03910306
P.O. Box 6000
CH-1211 Geneva 6
Customer Assistance Switzerland
SMCS Code: 1000 Phone: 22-849-4444
Fax: 22-849-4544
USA and Canada Far East
Caterpillar Asia Pte. Ltd.
When a problem arises concerning the operation or 7 Tractor Road
the service of an engine, the problem will normally be
managed by the dealer in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level, use the phone number that is listed below to Hong Kong
talk with a Field Service Coordinator: Phone: 852-2848-0333
Fax: 852-2848-0440
1-800-447-4986
The normal hours are from 8:00 to 4:30 Monday Japan
through Friday Central Standard Time. Shin Caterpillar Mitsubishi Ltd.
SBS Tower
3. If your needs have not been met still, submit the 10-1, Yoga 4-Chome
matter in writing to the following address: Setagaya-Ku, Tokyo 158-8530
Japan
Caterpillar Inc. Phone: 81-3-5717-1150
Manager, Customer Service, Engine Division Fax: 81-3-5717-1177
Mossville Bldg AC
P.O. Box 610 Japan
Mossville, Illinois 61552-0610 Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
Please keep in mind: probably, your problem will 4-10-1, Yoga
ultimately be solved at the dealership, using the Setagaya-Ku, Tokyo 158-0097
dealership facilities, equipment, and personnel. Phone: 81-3-5797-4300
Therefore, follow the steps in sequence when a
problem is experienced. Fax: 81-3-5797-4359
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 office.
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
96 SEBU8312-03
Ordering Replacement Parts
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 speci-
fications including, but not limited to, physical di-
mensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available
from Caterpillar dealers throughout the world.
Caterpillar dealers' parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following
information:
• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance
and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the
dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
SEBU8312-03 97
Reference Materials
Reference Materials • Label, PEEP5027, “Extended Life Coolant/

Antifreeze”
i02627762
Miscellaneous
Reference Material • Service Manual, REG1139F, “Service Manual
SMCS Code: 1000 Contents Microfiche”
The following literature can be obtained through any • Service Manual, KENR6925, “C0.5, C0.7, C1.1,
Caterpillar dealer. C1.5, C1.6 and C2.2 Industrial Engines”
Lubricants • Systems Operation, Testing and Adjusting,

KENR6228, “C0.5, C0.7, C1.1, C1.5, C1.6 and
• Special Publication, PEHP8038, “Data Sheet - C2.2 Industrial Engines”
Caterpillar Diesel Engine Oils (DEO) (CH-4)
(North America)” • Specifications, KENR6227, “C0.5, C0.7, C1.1,
C1.5, C1.6 and C2.2 Industrial Engines.”
• Special Publication, PEHP9536, “Data Sheet -
Caterpillar Diesel Engine Oil (DEO) (CF-4) • Disassembly and Assembly, KENR6229, “C0.5,
(International only)” C0.7, C1.1, C1.5, C1.6 and C2.2 Industrial
Engines”
• Special Publication, NEDG6022, “Cat Lubricating
Grease” • Specifications, SENR3130, “Torque
Specifications”
Molybdenum (MPGM) Grease” • Special Publication, PECP9067, “One Safe
Source” English language for use in NACD
• Special Publication, NEHP6015, “Data Sheet -
Caterpillar Special Purpose Grease (SPG)” • Special Publication, LEDM5615, “Caterpillar
Marine Parts and Service Locations Directory”
• Special Publication, SEBD0640, “Oil and Your
Engine” • Special Publication, SEBF8029, “Index to
Guidelines for Reusable Parts and Salvage
• Operation and Maintenance Manual, SEBU5898, Operations”
“Cold Weather Recommendations”
• Special Publication, SEBF8062, “Procedure to
• Operation and Maintenance Manual, SEBU6251, Inspect and Clean Air Filters”
“Caterpillar Commercial Diesel Engine Fluids
Recomendations” • Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”
• Special Publication, PEHP6001, “How To Take A
Good Oil Sample” • Special Publication, NEHS0526, “Service
Technician Application Guide”
Fuels • Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids
• Special Publication, SEBD0717, “Diesel Fuels and Recomendations”
Your Engine”
• Special Instruction, SEHS7633, “Battery Test
Coolants Procedure”

Extended Life Coolant”
S·O·S Coolant Analysis”
• Special Publication, SEBD0518, “Know Your

Cooling System”
• Special Publication, SEBD0970, “Coolant and

Your Engine”
98 SEBU8312-03
Additional Reference Material
• Label, SEHS7332, “Danger Do Not Operate” European classifications are established by the
Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Emissions Warranty Engines).
This engine may be Certified and this engine may be CIMAC Central Secretariat
covered by an Emissions Warranty. A detailed Lyoner Strasse 18
explanation of the Emissions Warranty that is 60528 Frankfurt
applicable to Certified engines is found in Germany
Supplement, SMBU6981, “Emissions Control
Telephone +49 69 6603 1567
Warranty Information”. The engine is Certified if the
engine has a special label that verifies the Facsimile +49 69 6603 1566
certification. A Caterpillar dealer can also inform you
if the engine is certified. i05264255
i02780825 Maintenance Records

SMCS Code: 1000
Additional Reference Material
Caterpillar Inc. recommends the retention of accurate
SMCS Code: 1000 maintenance records. Accurate maintenance records
can be used for the following purposes:
The “Society of Automotive Engineers (SAE)
Specifications” can be found in your SAE handbook. • Determine operating costs.
This publication can also be obtained from the
following locations: local technological society, local • Establish maintenance schedules for other
library and local college. If necessary, consult SAE at engines that are operated in the same
the following address: environment.
SAE International • Show compliance with the required maintenance
400 Commonwealth Drive practices and maintenance intervals.
Warrendale, PA, USA 15096-0001
Telephone (724) 776-4841 Maintenance records can be used for various other
business decisions that are related to engine
The “American Petroleum Institute Publication No. maintenance.
1509” can be obtained from the following locations:
local technological society, local library and local Maintenance records are a key element of a
college. If necessary, consult API at the following maintenance program that is managed. Accurate
address: maintenance records can help your Cat dealer to
fine-tune the recommended maintenance intervals in
American Petroleum Institute order to meet the specific operating situation. This
1220 L St. N.W. should result in a lower engine operating cost.
Washington, DC, USA 20005
Records should be kept for the following items:
Telephone (202) 682-8000
Fuel Consumption – A record of fuel consumption is
The International Organization for Standardization essential in order to determine when the load
(ISO) offers information and customer service sensitive components should be inspected or
regarding international standards and standardizing repaired. Fuel consumption also determines overhaul
activities. ISO can also supply information on the intervals.
following subjects that are not controlled by ISO:
national standards, regional standards, regulations, Service Hours – A record of service hours is
certification and related activities. Consult the essential to determine when the speed sensitive
member of ISO in your country. components should be inspected or repaired.
International Organization for Standardization Documents – These items should be easy to obtain,
(ISO) and these items should be kept in the engine history
1, rue de Varembé file. All of the documents should show this
information: date, service hours, fuel consumption,
Case postale 56
unit number and engine serial number. The following
CH-1211 Genève 20 types of documents should be kept as proof of
Switzerland maintenance or repair for warranty:
Telephone +41 22 749 01 11
Facsimile +41 22 733 34 30
E-mail [email protected] Keep the following types of documents as proof of
Web site http://www.iso.ch maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
SEBU8312-03 99
Maintenance Log
• Dealer work orders and itemized bills

• Owner repair costs
• Owner receipts
• Maintenance log
i01176304
Maintenance Log
SMCS Code: 1000
Table 32
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity Of
Service Item Date Authorization
Hours Fuel
(continued)
100 SEBU8312-03
Maintenance Log
(Table 32, contd)

SEBU8312-03 101
Index Section
Index
A Test for SCA Concentration ......................... 64
Cooling System Water Temperature
Additional Reference Material ......................... 98
Regulator - Replace....................................... 65
After Starting Engine ....................................... 35
Crushing Prevention and Cutting Prevention.. 14
After Stopping Engine ..................................... 38
Customer Assistance ...................................... 95
Aftercooler Core - Clean/Test (Air-To-Air
Outside of the USA and of Canada ............. 95
Aftercooler) .................................................... 55
USA and Canada......................................... 95
Aftercooler Core - Inspect ............................... 55
Customer Service............................................ 95
Alternator - Inspect .......................................... 55
Alternator and Fan Belts - Inspect/Adjust ....... 56
Adjustment................................................... 56 D
Inspection .................................................... 56 Driven Equipment - Check .............................. 66
Alternator and Fan Belts - Replace ................. 57
E
B
Electrical System............................................. 16
Battery - Replace............................................. 57 Grounding Practices .................................... 16
Battery Electrolyte Level - Check .................... 58 Emergency Stopping....................................... 38
Battery or Battery Cable - Disconnect............. 58 Emergency Stop Button............................... 38
Before Starting Engine .............................. 15, 33 Emissions Certification Film ............................ 28
Burn Prevention............................................... 12 Emissions Warranty Information ..................... 92
Batteries....................................................... 12 Engaging the Driven Equipment ..................... 36
Coolant ........................................................ 12 Engine - Clean................................................. 66
Oils............................................................... 12 Engine Air Cleaner Element (Dual Element)
- Clean/Replace............................................. 66
C Cleaning the Primary Air Cleaner
Elements .................................................... 68
Cold Weather Operation ................................. 40
Servicing the Air Cleaner Elements............. 67
Cold Weather Starting ..................................... 34
Engine Air Cleaner Element (Single
Cooling System Coolant (DEAC) - Change .... 58
Element) - Inspect/Replace ........................... 69
Cooling Systems with Heavy Deposits or
Engine Air Cleaner Service Indicator -
Plugging ..................................................... 59
Inspect (If Equipped) ..................................... 70
Drain ............................................................ 59
Test the Service Indicator ............................ 71
Fill ................................................................ 60
Engine Air Precleaner - Check/Clean ............. 71
Flush ............................................................ 59
Engine Crankcase Breather - Replace ........... 71
Cooling System Coolant (ELC) - Change ....... 60
Engine Description .......................................... 21
Drain ............................................................ 60
Engine Specifications .................................. 22
Fill ................................................................ 61
Engine Mounts - Inspect.................................. 72
Flush ............................................................ 61
Engine Oil and Filter - Change ........................ 73
Cooling System Coolant Extender (ELC) -
Drain the Engine Oil..................................... 74
Add ................................................................ 62
Fill the Engine Crankcase............................ 75
Cooling System Coolant Level - Check........... 62
Replace the Oil Filter ................................... 74
Cooling System Coolant Sample (Level 1) -
Engine Oil Level - Check................................. 72
Obtain ............................................................ 63
Engine Oil Sample - Obtain............................. 73
Cooling System Coolant Sample (Level 2) -
Obtain the Sample and the Analysis ........... 73
Obtain ............................................................ 64
Engine Operation ............................................ 36
Cooling System Supplemental Coolant
Engine Protective Devices - Check................. 75
Additive (SCA) - Test/Add.............................. 64
Visual Inspection.......................................... 76
Add the SCA, If Necessary .......................... 65
Engine Rating Conditions................................ 93
S·O·S Coolant Analysis............................... 64
102 SEBU8312-03
Index Section
Engine Rating Definitions................................ 93 G

Engine Ratings ................................................ 93
Gauges and Indicators .................................... 30
Engine Shutoffs and Engine Alarms ............... 31
General Hazard Information.............................. 8
Alarms.......................................................... 31
Containing Fluid Spillage............................. 10
Shutoffs........................................................ 31
Dispose of Waste Properly .......................... 12
Testing the Shutoff and Alarm System ........ 31
Fluid Penetration ......................................... 10
Engine Starting.......................................... 15, 33
Inhalation ......................................................11
Engine Stopping ........................................ 16, 38
Lines, Tubes, and Hoses ............................. 10
Engine Valve Lash - Inspect/Adjust................. 76
Pressurized Air and Water............................. 9
Engine Warm-up ............................................. 36
Softwrap........................................................11
Static Electricity Hazard when Fueling with
F Ultra-low Sulfur Diesel Fuel ....................... 10
Features and Controls..................................... 31
Fire Prevention and Explosion Prevention...... 12 H
Ether ............................................................ 14
Hoses and Clamps - Inspect/Replace............. 84
Fire Extinguisher.......................................... 14
Inspect the Hoses and the Clamps.............. 85
Lines, Tubes, and Hoses ............................. 14
Replace the Hoses and the Clamps ............ 85
Foreword ........................................................... 4
California Proposition 65 Warning ................. 4
Literature Information .................................... 4 I
Maintenance .................................................. 4 Important Safety Information............................. 2
Maintenance Intervals ................................... 4
Operation ....................................................... 4
L
Overhaul ........................................................ 4
Safety............................................................. 4 Lifting and Storage .......................................... 29
Fuel and the Effect from Cold Weather ........... 40
Fuel Conservation Practices ........................... 37 M
Fuel Injector - Test/Change ............................. 76
Removal and Installation of the Fuel Injection Maintenance Interval Schedule....................... 53
Nozzles ...................................................... 77 Daily ............................................................. 53
Fuel Related Components in Cold Weather ... 40 Every 1000 Service Hours........................... 53
Fuel Filters ................................................... 41 Every 12 000 Service Hours or 6 Years....... 54
Fuel Heaters ................................................ 41 Every 2000 Service Hours........................... 53
Fuel Tanks ................................................... 40 Every 250 Service Hours ............................. 53
Fuel Shutoff ..................................................... 31 Every 250 Service Hours or 1 Year ............. 53
Fuel System - Prime ........................................ 77 Every 250 Service Hours or 6 Months......... 53
Fuel filters .................................................... 77 Every 3000 Service Hours........................... 54
Primary filter................................................. 77 Every 3000 Service Hours or 2 Years ......... 54
Priming the system ...................................... 78 Every 4000 Service Hours........................... 54
Fuel System Primary Filter/Water Every 50 Service Hours or Weekly.............. 53
Separator - Drain ........................................... 81 Every 500 Service Hours ............................. 53
Fuel System Secondary Filter - Replace ........ 81 Every 500 Service Hours or 1 Year ............. 53
Fuel Filter with Canister ............................... 81 Every 6000 Service Hours or 3 Years ......... 54
Fuel Filter with Element ............................... 82 Every Year ................................................... 54
Fuel filter with priming pump........................ 83 Initial 500 Hours (for New Systems, Refilled
Fuel Tank Water and Sediment - Drain ........... 84 Systems, and Converted Systems) ........... 53
Drain the Water and the Sediment .............. 84 Overhaul ...................................................... 54
Fuel Storage Tanks...................................... 84 When Required............................................ 53
Fuel Tank ..................................................... 84 Maintenance Log............................................. 99
Maintenance Recommendations .................... 51
Maintenance Records ..................................... 98
SEBU8312-03 103
Index Section
Maintenance Section....................................... 42 Severe Service Application - Check................ 88

Model View Illustrations .................................. 18 Environmental Factors................................. 89
Model Views .................................................... 18 Improper Maintenance Procedures ............. 89
Mounting and Dismounting ............................. 15 Improper Operating Procedures.................. 89
Starting Motor - Inspect ................................... 89
O Starting the Engine.......................................... 33
Starting with Jump Start Cables...................... 35
Operation Section............................................ 29 Stopping the Engine ........................................ 38
Ordering Replacement Parts........................... 96 System Pressure Release............................... 51
Overhaul Considerations................................. 87 Coolant System ........................................... 51
Oil Consumption as an Overhaul Indicator.. 87 Engine Oil .................................................... 51
Overhaul Recommendation......................... 87 Fuel System................................................. 51
P T
Plate Locations and Film Locations ................ 27 Table of Contents .............................................. 3
Serial Number Plate (1) ............................... 27 Turbocharger - Inspect (If Equipped) .............. 89
Product Identification Information ................... 27 Inspecting .................................................... 90
Product Information Section............................ 18 Removal and Installation ............................. 90
Product Lifting ................................................. 29
Product Storage .............................................. 29
W
R Walk-Around Inspection .................................. 90

Inspect the Engine for Leaks and for Loose
Radiator - Clean .............................................. 88 Connections ............................................... 90
Radiator Restrictions....................................... 40 Warranty Information....................................... 92
Reference Information Section ....................... 93 Warranty Section ............................................. 92
Reference Material .......................................... 97 Water Pump - Inspect...................................... 91
Coolants....................................................... 97 Welding on Engines with Electronic
Emissions Warranty..................................... 98 Controls ......................................................... 51
Fuels ............................................................ 97
Lubricants .................................................... 97
Miscellaneous .............................................. 97
Reference Materials ........................................ 97
Reference Numbers ........................................ 27
Record for Reference .................................. 27
Refill Capacities............................................... 42
Refill Capacities and Recommendations ........ 42
Coolant Recommendations ......................... 48
Engine Oil .................................................... 42
General Coolant Information ....................... 46
General Fuel Information............................. 46
Lubricating Grease ...................................... 45
Refill Capacity of the Cooling System ......... 49
S·O·S Coolant Analysis............................... 49
S
Safety Messages............................................... 5
No Ether (B) ................................................... 8
Universal Warning (A).................................... 8
Safety Section ................................................... 5
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification 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:
SEBU8312 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2016 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.
106 February 2016

Manual de Operacion y Mantnimiento PDF

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SEBU8312-03 (en-us)

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Maintenance Recommendations .................... 51

Maintenance Interval Schedule....................... 53

Safety Section Warranty Section

General Hazard Information.............................. 8 Reference Information Section

Burn Prevention............................................... 12 Engine Ratings ................................................ 93

Fire Prevention and Explosion Prevention...... 12 Customer Service............................................ 95

Crushing Prevention and Cutting Prevention.. 14 Reference Materials ........................................ 97

Mounting and Dismounting ............................. 15 Index Section

Before Starting Engine .................................... 15 Index.............................................................. 101

Engine Stopping .............................................. 16

Product Information Section

Model Views .................................................... 18

Product Identification Information ................... 27

Lifting and Storage .......................................... 29

Gauges and Indicators .................................... 30

Features and Controls..................................... 31

Engine Operation ............................................ 36

Engine Stopping .............................................. 38

Cold Weather Operation ................................. 40

Foreword Recommended service should be performed at the

Maintenance California Proposition 65 Warning

(A) Location of the warning labels (3) C1.1 (6) C2.2

(B) Location of ether warning labels (3) C1.1 (6) C2.2

Universal Warning (A)

General Hazard Information

Warning label (A) is installed in different locations.

Do not operate or work on this equipment unless

• Start the engine with the operator controls. Never

Pressurized Air and Water

• Ensure that all protective guards and all covers

• Never put maintenance fluids into glass

• Report all necessary repairs.

• The protective locks or the controls are in the

• Disconnect the batteries when maintenance is

Avoid direct spraying of water on electrical Static Electricity Hazard when

• Wire that is exposed in reinforced hose

• Flexible part of the hose that is kinked or crushed

• Stay away from areas that might have asbestos

• Never use compressed air for cleaning.

• Avoid grinding materials that contain asbestos.

Dispose of Waste Properly Oils

Illustration 9 g00706404 Fire Prevention and Explosion

Always use leakproof containers when you drain

Wiring must be kept in good condition. Properly route

Do not store ether cylinders in living areas or in the

Lines, Tubes, and Hoses

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

Do not carry tools or supplies when you mount the

Correct grounding for the engine electrical system is

Model View Illustrations

i02613886 The pistons have two compression rings and an oil

C0.7 Engine C1.1 Engine

Illustration 20 g00852304 Illustration 21 g00852304

Maximum Operating Speed Maximum Operating Speed

Bore 67 mm (2.64 inch) Bore 77 mm (3.03 inch)