SEBU7655-04 (en-us)

July 2018

Operation and
Maintenance
Manual
3054C Industrial Engine
334 1-UP (Engine)
330 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.
SEBU7655-04 3
Table of Contents

Table of Contents Maintenance Interval Schedule....................... 53

Foreword ........................................................... 4 Reference Information Section

Engine Ratings ................................................ 88

Safety Section
Customer Service............................................ 90
Safety Messages............................................... 6
Reference Materials ........................................ 92
General Hazard Information.............................. 8

Burn Prevention................................................11 Index Section

Fire Prevention and Explosion Prevention...... 12 Index................................................................ 96

Crushing Prevention and Cutting Prevention.. 14

Mounting and Dismounting ............................. 14

Before Starting Engine .................................... 14

Engine Starting................................................ 15

Engine Stopping .............................................. 15

Electrical System............................................. 15

Product Information Section

Model Views .................................................... 17

Product Identification Information ................... 20

Operation Section

Lifting and Storage .......................................... 23

Gauges and Indicators .................................... 24

Features and Controls..................................... 25

Engine Starting................................................ 26

Engine Operation ............................................ 29

Engine Stopping .............................................. 32

Cold Weather Operation ................................. 34

Maintenance Section

Refill Capacities............................................... 36
4 SEBU7655-04
Foreword

Foreword Some photographs or illustrations in this manual

show details or attachments that may be different
from your engine. Guards and covers may have been
California Proposition 65 Warning removed for illustrative purposes. Continuing
improvement and advancement of product design
Diesel engine exhaust and some of its may have caused changes to your engine which are
not included in this manual Whenever a question
constituents are known to the State of arises regarding your engine, or this manual, please
California to cause cancer, birth defects, consult with your Cat dealer for the latest available
and other reproductive harm. information.

WARNING – This product can Safety

expose you to chemicals
including ethylene glycol, which This safety section lists basic safety precautions. In
is known to the State of California to addition, this section identifies hazardous, warning
cause birth defects or other reproductive situations. Read and understand the basic
harm. For more information go to: precautions listed in the safety section before
operating or performing lubrication, maintenance,
and repair on this product.
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands Operation
after handling to avoid incidental Operating techniques outlined in this manual are
ingestion. basic. They assist with developing the skills and
techniques required to operate the engine more
WARNING – This product can efficiently and economically. Skill and techniques
expose you to chemicals develop as the operator gains knowledge of the
including lead and lead engine and its capabilities.
compounds, which are known to the
The operation section is a reference for operators.
State of California to cause cancer, birth Photographs and illustrations guide the operator
defects, or other reproductive harm. For through procedures of inspecting, starting, operating,
more information go to: and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
www.P65Warnings.ca.gov
Maintenance
Wash hands after handling components
that may contain lead. The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
Literature Information by fuel consumption, service hours and/or calendar
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that
This manual contains safety, operation instructions, follow.
lubrication, and maintenance information. This
manual should be stored in or near the engine area in Use fuel consumption or service hours to determine
a literature holder or literature storage area. Read, intervals. Calendar intervals shown (daily, annually,
study, and keep it with the literature and engine etc.) may be used instead of service meter intervals if
information. they provide more convenient schedules and
approximate the indicated service meter reading.
English is the primary language for all Cat
publications. The English used facilitates translation Recommended service should be performed at the
and consistency in electronic media delivery. appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
freezing cold operating conditions, more frequent
lubrication, and maintenance than is specified in the
Maintenance Interval Schedule may be necessary.
SEBU7655-04 5
Foreword

The maintenance schedule items are organized for a

preventive maintenance management program. If the
preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.

Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. We recommend that the
maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engine's permanent record.
See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information
regarding documents that are accepted as proof of
maintenance or repair. Your authorized Cat dealer
can assist you in adjusting your maintenance
schedule to meet the needs of your operating
environment.

Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
authorized Cat dealer. Your Cat dealer offers various
options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available
from your Cat dealer. Consult with your dealer for
information regarding these options.
6 SEBU7655-04
Safety Section
Safety Messages

Safety Section
i03698546

Safety Messages
SMCS Code: 1000; 7405
There may be several specific warning signs 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 Illustration 1 g01154807
words cannot be read or if the pictures are not visible.
Typical example
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. The Universal Warning label (2) is located on the rear
Solvents, gasoline, or harsh chemicals could loosen end of the valve mechanism cover. Refer to
illustration 2 .
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.
Proper care is your responsibility. Failure to follow the
instructions or failure to heed the warnings could
result in injury or in death.

(1) Universal Warning

Do not operate or work on this equipment unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.
SEBU7655-04 7
Safety Section
Safety Messages

Illustration 2 g01353108
Typical example
(1) Ether Warning Label (2) Universal warning

(2) Ether The ether warning label (1) is located on the inlet
manifold cover. Refer to illustration 2 .

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

Illustration 4 g00107406
Typical example

Illustration 3 g01154809 The warning label for the clutch is located on the
Typical example clutch housing (if equipped).
8 SEBU7655-04
Safety Section
General Hazard Information

• Grease fittings
• Pressure taps

• Breathers
• Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of the
cover plate or the device. Before removing the last
two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.

Illustration 5 g00107407
Typical example

Rotating gears can cause entanglement of fingers or

entanglement of hands. Do not service this
component without first reading the operator manual.

i06300340

General Hazard Information

SMCS Code: 1000; 7405

Illustration 7 g00702020

• Wear a hard hat, protective glasses, and other

protective equipment, as required.

• When work is performed around an engine that is

operating, wear protective devices for ears in
order to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can

snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers

are secured in place on the engine.
• Never put maintenance fluids into glass
Illustration 6 g03838041
containers. Glass containers can break.
Attach a “Do Not Operate” warning tag to the start
switch or controls before the engine is serviced or • Use all cleaning solutions with care.
repaired. These warning tags (Special Instruction, • Report all necessary repairs.
SEHS7332) are available from your Cat dealer.
Attach the warning tags to the engine and to each Unless other instructions are provided, perform
operator control station. When appropriate, the maintenance under the following conditions:
disconnect the starting controls.
• The engine is stopped. Ensure that the engine
Do not allow unauthorized personnel on the engine,
cannot be started.
or around the engine when the engine is being
serviced. • The protective locks or the controls are in the
Cautiously remove the following parts. To help applied position.
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed. • Disconnect the batteries when maintenance is
performed or when the electrical system is
• Filler caps serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
SEBU7655-04 9
Safety Section
General Hazard Information

• When starting a new engine, make provisions to Avoid direct spraying of water on electrical
stop the engine if an overspeed occurs. If an connectors, connections, and components. When
engine has not been started since service has using air for cleaning, allow the machine to cool to
been performed, make provisions to stop the reduce the possibility of fine debris igniting when
engine if an overspeed occurs. Shutting down the redeposited on hot surfaces.
engine may be accomplished by shutting off the
fuel supply and/or the air supply to the engine. Fluid Penetration
• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.
• 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.
Illustration 8 g00687600
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air Always use a board or cardboard when you check for
nozzle is deadheaded and used with effective chip a leak. Leaking fluid that is under pressure can
guarding (if applicable) and personal protective penetrate body tissue. Fluid penetration can cause
equipment. The maximum water pressure for serious injury and possible death. A pin hole leak can
cleaning purposes must be below 275 kPa (40 psi). cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
When pressurized air and/or pressurized water is from a doctor that is familiar with this type of injury.
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes Containing Fluid Spillage
goggles or a protective face shield. Always wear eye
protection for cleaning the cooling system.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
10 SEBU7655-04
Safety Section
General Hazard Information

Static Electricity Hazard when Ensure that all of the clamps, the guards, and the
heat shields are installed correctly. Correct
Fueling with Ultra-low Sulfur Diesel installation of these components will help to prevent
Fuel these effects: vibration, rubbing against other parts
and excessive heat during operation.
The removal of sulfur and other compounds in ultra-
low sulfur diesel fuel (ULSD fuel) decreases the Inhalation
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.

Illustration 9 g02159053
Avoid static electricity risk when fueling. Ultra-
low sulfur diesel fuel (ULSD fuel) poses a greater Exhaust
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death Use caution. Exhaust fumes can be hazardous to
or serious injury from fire or explosion. Consult your health. If you operate the equipment in an
with your fuel or fuel system supplier to ensure enclosed area, adequate ventilation is necessary.
the delivery system is in compliance with fueling
standards for proper grounding and bonding Asbestos Information
practices.
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free.
Lines, Tubes, and Hoses Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
Do not bend or strike high-pressure lines. Do not you handle any replacement parts that contain
install lines, tubes, or hoses that are damaged. asbestos or when you handle asbestos debris.

Repair any fuel lines, oil lines, tubes, or hoses that Use caution. Avoid inhaling dust that might be
are loose or damaged. Leaks can cause fires. generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
Inspect all lines, tubes, and hoses carefully. Do not to your health. The components that may contain
use bare hands to check for leaks. Always use a asbestos fibers are brake pads, brake bands, lining
board or cardboard for checking engine components material, clutch plates, and some gaskets. The
for leaks. Tighten all connections to the asbestos that is used in these components is bound
recommended torque. in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
Check for the following conditions: asbestos is generated.

• End fittings that are damaged or leaking If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Outer covering that is chafed or cut
• Never use compressed air for cleaning.
• Wire that is exposed in reinforced hose
• Avoid brushing materials that contain asbestos.
• Outer covering that is ballooning locally
• Avoid grinding materials that contain asbestos.
• Flexible part of the hose that is kinked or crushed
• Use a wet method in order to clean up asbestos
• Armoring that is embedded in the outer covering materials.
SEBU7655-04 11
Safety Section
Burn Prevention

• A vacuum cleaner that is equipped with a high Reference: The applicable material safety data
efficiency particulate air filter (HEPA) can also be sheets can be found at the following web site by
used. searching using part number or the name:

• Use exhaust ventilation on permanent machining https://catmsds.cat.com/MSDSSearch/servlet/

jobs. cat.cis.ecs.
msdsSearch.controller.
• Wear an approved respirator if there is no other UserIdentificationDisplayServlet
way to control the dust.
• Comply with applicable rules and regulations for Dispose of Waste Properly
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
approved by the National Institute of Occupational
Safety and Health (NIOSH). Wear appropriate Illustration 10 g00706404
protective clothing in order to minimize direct contact.
Use good hygiene practices and wash hands Improperly disposing of waste can threaten the
thoroughly after handling Softwrap material. Do not environment. Potentially harmful fluids should be
smoke until washing hands thoroughly after handling disposed of according to local regulations.
Softwrap material. Clean up debris with a vacuum or
by wet sweeping. Do not use pressurized air to clean Always use leakproof containers when you drain
up debris. 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.

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
12 SEBU7655-04
Safety Section
Fire Prevention and Explosion Prevention

Ensure that the filler cap is cool before removing the Flammable fluids that are leaking or spilled onto hot
filler cap. The filler cap must be cool enough to touch surfaces or onto electrical components can cause a
with a bare hand. Remove the filler cap slowly in fire. Fire may cause personal injury and property
order to relieve pressure. damage.
Cooling system conditioner contains alkali. Alkali can A flash fire may result if the covers for the engine
cause personal injury. Do not allow alkali to contact crankcase are removed within 15 minutes after an
the skin, the eyes, or the mouth. emergency shutdown.
Determine whether the engine will be operated in an
Oils environment that allows combustible gases to be
drawn into the air inlet system. These gases could
Hot oil and hot lubricating components can cause cause the engine to overspeed. Personal injury,
personal injury. Do not allow hot oil to contact the property damage, or engine damage could result.
skin. Also, do not allow hot components to contact
the skin. If the application involves the presence of
combustible gases, consult your Cat dealer for
Batteries additional information about suitable protection
devices.
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
the eyes. Always wear protective glasses for
materials to accumulate on the engine.
servicing batteries. Wash hands after touching the
batteries and connectors. Use of gloves is All fluids that are captured in the fluid spill
recommended. containment basin should be cleaned up
immediately. Failure to clean up spilled fluids can
i07254650 cause a fire. Fire may cause personal injury and
property damage.
Fire Prevention and Explosion
Store fuels and lubricants in properly marked
Prevention containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
SMCS Code: 1000; 7405
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in a line, a tube, or
a seal failure. Exhaust shields must be installed
correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not use flame to cut lines or tanks that
contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Properly route
and attach all electrical wires. Check all electrical
wires daily. Repair any wires that are loose or frayed
Illustration 11 g00704000
before you operate the engine. Clean all electrical
connections and tighten all electrical connections.
Use of personal protection equipment (PPE) may be
needed. Eliminate all wiring that is unattached or
All fuels, most lubricants, and some coolant mixtures unnecessary. Do not use any wires or cables that are
are flammable. smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a Arcing or sparking could cause a fire. Secure
product when a fire hazard exists. Contact your Cat connections, recommended wiring, and properly
dealer for service. maintained battery cables will help to prevent arcing
or sparking.
SEBU7655-04 13
Safety Section
Fire Prevention and Explosion Prevention

Inspect all lines and hoses for wear or for

deterioration. Properly route all hoses. The lines and
hoses must have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Leaks can cause fires.
Properly install all oil filters and fuel filters. The filter
housings must be tightened to the proper torque.

Illustration 13 g02298225

Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a
Illustration 12 g00704059 hydrometer.

Use caution when you are refueling an engine. Do Improper jumper cable connections can cause an
not smoke while you are refueling an engine. Do not explosion that can result in injury. Refer to the
refuel an engine near open flames or sparks. Always Operation Section of this manual for specific
stop the engine before refueling. instructions.

Avoid static electricity risk when fueling. Ultra Low Do not charge a frozen battery. Charging a frozen
Sulfur Diesel (ULSD) poses a greater static ignition battery may result in an explosion.
hazard than earlier diesel formulations with a higher The batteries must be kept clean. The covers (if
Sulfur content. Avoid death or serious injury from fire equipped) must be kept on the cells. Use the
or explosion. Consult with your fuel or fuel system recommended cables, connections, and battery box
supplier to ensure that the delivery system is in covers when the engine is operated.
compliance with fueling standards for proper
grounding and bonding practices.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

Ether
Ether is flammable and poisonous.
Use ether in ventilated areas. Do not smoke while
you are replacing an ether cylinder or while you are
using an ether spray.
14 SEBU7655-04
Safety Section
Crushing Prevention and Cutting Prevention

Do not store ether cylinders in living areas or in the Stay clear of all rotating parts and of all moving parts.
engine compartment. Do not store ether cylinders in Leave the guards in place until maintenance is
direct sunlight or in temperatures above 49 °C performed. After the maintenance is performed,
(120 °F). Keep ether cylinders away from open reinstall the guards.
flames or sparks.
Keep objects away from moving fan blades. The fan
Dispose of used ether cylinders properly. Do not blades will throw objects or cut objects.
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel. When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Do not spray ether into an engine if the engine is
equipped with a thermal starting aid for cold weather Chips or other debris may fly off objects when objects
starting. are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
Lines, Tubes, and Hoses
i01372247
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent Mounting and Dismounting
or damaged.
SMCS Code: 1000; 7405
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Cat dealer for repair or Inspect the steps, the handholds, and the work area
for replacement parts. before mounting the engine. Keep these items clean
and keep these items in good repair.
Check lines, tubes, and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or Mount the engine and dismount the engine only at
cardboard to check for leaks. Tighten all connections locations that have steps and/or handholds. Do not
to the recommended torque. climb on the engine, and do not jump off the engine.

Replace the parts if any of the following conditions Face the engine in order to mount the engine or
are present: dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
• End fittings are damaged or leaking. hand or use one foot and two hands. Do not use any
controls as handholds.
• Outer coverings are chafed or cut. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
• Wires are exposed. platform. Secure the climbing equipment so that the
equipment will not move.
• Outer coverings are ballooning.
Do not carry tools or supplies when you mount the
• Flexible parts of the hoses are kinked. engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
• Outer covers have embedded armoring.
• End fittings are displaced. i03560601

Make sure that all clamps, guards, and heat shields

are installed correctly to prevent vibration, rubbing
Before Starting Engine
against other parts, and excessive heat. SMCS Code: 1000

i01359666 NOTICE
For initial start-up of a new or rebuilt engine, and for
Crushing Prevention and start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
Cutting Prevention occur. This may be accomplished by shutting off the
SMCS Code: 1000; 7405 air and/or fuel supply to the engine.

Support the component properly when work beneath

the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
SEBU7655-04 15
Safety Section
Engine Starting

Always start the engine according to the procedure

that is described in the Operation and Maintenance
Engine exhaust contains products of combustion Manual, “Engine Starting” topic in the Operation
which may be harmful to your health. Always Section. Knowing the correct procedure will help to
start and operate the engine in a well ventilated prevent major damage to the engine components.
area and, if in an enclosed area, vent the exhaust Knowing the procedure will also help to prevent
to the outside. personal injury.

Inspect the engine for potential hazards. To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Do not start the engine or move any of the controls if properly, check the water temperature and the oil
there is a “DO NOT OPERATE” warning tag or similar temperature during heater operation.
warning tag attached to the start switch or to the
controls. Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
Before starting the engine, ensure that no one is on, engine and operate the engine in a well ventilated
underneath, or close to the engine. Ensure that the area. If the engine is started in an enclosed area,
area is free of personnel. vent the engine exhaust to the outside.

If equipped, ensure that the lighting system for the i03698544

engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
Engine Stopping
All protective guards and all protective covers must SMCS Code: 1000
be installed if the engine must be started in order to
perform service procedures. To help prevent an Stop the engine according to the procedure in the
accident that is caused by parts in rotation, work Operation and Maintenance Manual, “Engine
around the parts carefully. Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
Do not bypass the automatic shutoff circuits. Do not the engine components.
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The Use the Emergency Stop Button (if equipped) ONLY
circuits are also provided in order to help prevent in an emergency situation. Do not use the
engine damage. Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
See the Service Manual for repairs and for until the problem that caused the emergency stop
adjustments. has been corrected.
i02136012 Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
Engine Starting engine that has been overhauled. This may be
accomplished by shutting off the fuel supply to the
SMCS Code: 1000 engine and/or shutting off the air supply to the
engine.
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move i02469632
the controls. Consult with the person that attached
the warning tag before the engine is started.
Electrical System
All protective guards and all protective covers must
SMCS Code: 1000; 1400
be installed if the engine must be started in order to
perform service procedures. To help prevent an Never disconnect any charging unit circuit or battery
accident that is caused by parts in rotation, work circuit cable from the battery when the charging unit
around the parts carefully. is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
If there is a possibility that unburned gas remains in
the exhaust system, refer to the purge procedure in To help prevent sparks from igniting combustible
this Operation and Maintenance Manual, “Engine gases that are produced by some batteries, the
Starting” topic in the Operation Section. negative “−” jump start cable should be connected
last from the external power source to the negative
Start the engine from the operator's compartment or “−” terminal of the starting motor. If the starting motor
from the engine start switch. is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
16 SEBU7655-04
Safety Section
Electrical System

Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. Refer to
the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.

Grounding Practices

Illustration 15 g00771487
Typical example
Alternate Grounding Stud To Battery Ground

Proper grounding for the engine electrical system is

necessary for optimum engine performance and
reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Illustration 14 g00771448
Typical example Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
Grounding Stud To Battery Ground 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 properly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a starting
motor ground, a starting motor ground to the frame,
or a direct engine ground to the frame.
All grounds should be tight and free of corrosion. The
engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.
SEBU7655-04 17
Product Information Section
Model Views

Product Information
Section

Model Views
i03699149

Model View Illustrations

SMCS Code: 1000

Engine Model Views

Illustration 16 g01012280
Typical example
(1) Valve mechanism cover (2) Crankcase breather (3) Fuel filter
18 SEBU7655-04
Product Information Section
Engine Description

(4) Fuel injection pump (6) Crankshaft pulley (8) Fan pulley
(5) Engine oil filter (7) Water pump (9) Water temperature regulator housing

Illustration 17 g01990073
Typical example
(10) Oil filler cap (13) Turbocharger (16) Flywheel
(11) Exhaust manifold (14) Starting motor (17) Air intake
(12) Alternator (15) Flywheel housing

i03699300 • Turbocharged aftercooled

Engine Description • Turbocharged

SMCS Code: 1000 • Naturally aspirated
The 3054C Industrial Engines are designed for the
following applications: machine and industrial mobile
equipment. The engines are available in the following
types of aspiration:
SEBU7655-04 19
Product Information Section
Engine Description

Engine Specifications • Oil cooler

Note: The front end of the engine is opposite the The engine lubricating oil is supplied by a oil pump
flywheel end of the engine. The left and the right that is a gear type. The engine lubricating oil is
cooled and the engine lubricating oil is filtered.
sides of the engine are determined from the flywheel Bypass valves provide unrestricted flow of lubrication
end. The number 1 cylinder is the front cylinder. oil to the engine parts when oil viscosity is high.
Bypass valves can also provide unrestricted flow of
lubrication oil to the engine parts if the oil cooler
should become plugged or if the oil filter element
should become plugged.
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to proper
operation and maintenance recommendations.
Engine performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and
coolants. Refer to Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
information on maintenance items.

Engine Service Life

Illustration 18 g00577193 Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
3054C operation and maintenance recommendations. In
(A) Exhaust valves addition, use recommended fuels, coolants and
(B) Inlet valves lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
Table 1
3054C Industrial Engine Specifications Expected engine life is generally predicted by the
average power that is demanded. The average
Number of Cylinders 4 In-Line power that is demanded is based on fuel
consumption of the engine over a period of time.
Bore 105 mm (4.134 inch) Reduced hours of operation at full throttle and/or
Stroke 127 mm (5.0 inch)
operating at reduced throttle settings result in a lower
average power demand. Reduced hours of operation
Aspiration Turbocharged aftercooled will increase the length of operating time before an
Turbocharged engine overhaul is required. For more information,
Naturally aspirated refer to Operation and Maintenance Manual,
“Overhaul Considerations”.
Compression Ratio 19.25:1 NA
18.23:1 T and TA
Aftermarket Products and
Displacement 4.4 L (268 in 3)
Caterpillar Engines
Firing Order 1342
When auxiliary devices, accessories, or
Rotation (flywheel end) Counterclockwise
consumables (filters, additives, catalysts, etc) which
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) are made by other manufacturers are used on
Caterpillar products, the Caterpillar warranty is not
Valve Lash Setting (Exhaust) 0.45 mm (0.018 inch) affected simply because of such use.
However, failures that result from the installation
Engine Cooling and Lubrication or use of other manufacturers' devices,
accessories, or consumables are NOT Caterpillar
defects. Therefore, the defects are NOT covered
The cooling system consists of the following under the Caterpillar warranty.
components:
• Gear-driven centrifugal water pump

• Water temperature regulators which regulate the

engine coolant temperature

• Gear-driven oil pump (gear type)

20 SEBU7655-04
Product Information Section
Product Identification Information

Product Identification
Information
i03699303

Engine Identification
SMCS Code: 1000
Caterpillar engines are identified with model
numbers, and serial numbers, with performance
specification numbers, and with arrangement
numbers. These numbers are shown on the serial
number plate that is mounted on the engine.
Caterpillar dealers need these numbers in order to Illustration 20 g01258789
determine the components that were included with Typical example of the serial number plate
the engine. This permits accurate identification of
replacement part numbers. The following information is stamped on the Serial
Number Plate: engine serial number, model and
i03699324 arrangement number.

Serial Number Plate i01484593

SMCS Code: 1000 Information Plate

SMCS Code: 1000

Illustration 21 g00764335

The Information Plate is on the valve cover. The

following information is on the Information Plate:
engine serial number, engine model, engine
Illustration 19 g01360892 arrangement number, maximum altitude of the
Typical example of the location of the serial number engine that is necessary to achieve the rated power,
plate horsepower, high idle, full load rpm, fuel settings and
other information.
The Serial Number Plate is located on the left side of
the cylinder block near the rear of the engine.
SEBU7655-04 21
Product Information Section
Reference Numbers

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
Performance Specification No.
Primary Fuel Filter No.
Water Separator Element No.
Secondary Fuel Filter Element No.
Lubrication Oil Filter Element No.
Auxiliary Oil Filter Element No.
Supplemental Coolant Additive Maintenance
Element No. (Optional)
Total Lubrication System Capacity
Total Cooling System Capacity
Air Cleaner Element No.
Fan Drive Belt No.
22 SEBU7655-04
Product Information Section
Emissions Certification Film

Alternator Belt No.

i03699340

Emissions Certification Film

SMCS Code: 1000; 7405

Illustration 22 g01990175
Typical example
SEBU7655-04 23
Operation Section
Lifting and Storage

Operation Section 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,
Lifting and Storage ensure that proper lifting devices are provided.
Consult your Cat dealer for information regarding
fixtures for proper engine lifting.
i07435001

Product Lifting i04342749

SMCS Code: 1000; 1404; 7002 Product Storage

SMCS Code: 1000; 1404; 7002
If the engine will not be started for several weeks, the
lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface. Rust on the cylinder liner surface will
cause increased engine wear and a reduction in
engine service life.
To help prevent excessive engine wear, use the
following guidelines:
• Complete all of the lubrication recommendations
that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).
Illustration 23 g00103219
• If freezing temperatures are expected, check the
cooling system for adequate protection against
NOTICE freezing. See this Operation and Maintenance
Never bend the eyebolts and the brackets. Only load Manual, “Refill Capacities and Recommendations”
the eyebolts and the brackets under tension. Re- (Maintenance Section).
member that the capacity of an eyebolt is less as the
angle between the supporting members and the ob- If an engine is out of operation and if use of the
ject becomes less than 90 degrees. engine is not planned, special precautions should be
made. If the engine will be stored for more than one
When it is necessary to remove a component at an month, a complete protection procedure is
angle, only use a link bracket that is properly rated for recommended.
the weight.
For more detailed information on engine storage, see
Special Instruction, SEHS9031, “Storage Procedure
NOTICE For Caterpillar Products”.
Always inspect lifting eyebolts and all other lifting
equipment for damage before performing any lifting. Your Cat dealer can assist in preparing the engine for
Never Bend the eyebolts and the brackets. Never extended storage periods.
perform product lifting if the components are
damaged.
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 to obtain
proper balance and safety.
To remove the engine only, use the lifting eyes that
are on the engine.
24 SEBU7655-04
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.
SEBU7655-04 25
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
the engine

Alarms
Alarms consist of a switch and a contactor. The
switches are wired to the contactors. The contactors
activate alarm circuits in an annunciator panel. Your
engine may be equipped with the following switches:
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
conditions occur.
26 SEBU7655-04
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 i03699360
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. If equipped, move the throttle lever to the full
throttle position before you start the engine.
SEBU7655-04 27
Operation Section
Cold Weather Starting

NOTICE NOTICE
Do not crank the engine for more than 30 seconds. Do not crank the engine for more than 30 seconds.
Allow the electric starting motor to cool for two mi- Allow the electric starting motor to cool for two mi-
nutes before cranking the engine again. nutes before cranking the engine again.

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

NOTICE
Hold the engine start switch in the START position Do not operate the glow plugs for more than 30 sec-
and crank the engine. onds at one time. Damage to the glow plugs could
occur.
3. When the engine starts, release the engine start
switch.
3. While the glow plug indicator light is illuminated,
4. If equipped, slowly move the throttle lever to the turn the engine start switch to the START position
low idle position and allow the engine to idle. Refer and crank the engine.
to Operation and Maintenance Manual, “After
Starting Engine”. Note: If the glow plug indicator light illuminates
rapidly for 2 to 3 seconds, or if the glow plug indicator
5. If the engine does not start, release the engine light fails to illuminate, a malfunction exists in the
start switch and allow the electric starting motor to system for the cold start. Do not use ether or other
cool. Then, repeat steps 2 through step 4. starting fluids to start the engine.
6. Turn the engine start switch to the OFF position in 4. When the engine starts, release the engine start
order to stop the engine. switch key.

i03699380 5. If the engine does not start, release the engine

start switch and allow the starting motor to cool.
Cold Weather Starting Then, repeat steps 8 through step 4.
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900 6. If the engine is equipped with a throttle allow the
engine to idle for three to five minutes, or allow the
engine to idle until the water temperature indicator
begins to rise. The engine should run at low idle
Do not use aerosol types of starting aids such as smoothly until speed is gradually increased to high
ether. Such use could result in an explosion and idle. Allow the white smoke to disperse before
personal injury. proceeding with normal operation.
Startability will be improved at temperatures below 7. Operate the engine at low load until all systems
−18 °C (0 °F) from the use of a jacket water heater or reach operating temperature. Check the gauges
extra battery capacity. during the warm-up period.
When No. 2 diesel fuel is used, the following items 8. Turn the engine start switch to the OFF position in
provide a means of minimizing starting problems and order to stop the engine.
fuel problems in cold weather: engine oil pan heaters,
jacket water heaters, fuel heaters and fuel line
insulation. i03640789

Use the procedure that follows for cold weather

starting.
Starting with Jump Start
Cables
1. If equipped, move the throttle lever to the full
throttle position before you start the engine. SMCS Code: 1000; 1401; 1402; 1900

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

HEAT position. Hold the engine start switch in the
HEAT position for 6 seconds until the glow plug Improper jump start cable connections can cause
indicator light illuminates. This will activate the an explosion resulting in personal injury.
glow plugs and aid in the starting of the engine.
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
28 SEBU7655-04
Operation Section
After Starting Engine

If the installation is not equipped with a backup i01646248

battery system, it may be necessary to start the
engine from an external electrical source. After Starting Engine
For information on troubleshooting the charging SMCS Code: 1000
system, refer to Special Instruction, REHS0354,
“Charging System Troubleshooting”. Note: In temperatures from 0 to 60°C (32 to 140°F),
the warm-up time is approximately three minutes. In
Many batteries which are considered unusable are temperatures below 0°C (32°F), additional warm-up
still rechargeable. After jump starting, the alternator time may be required.
may not be able to fully recharge batteries that are
severely discharged. The batteries must be charged Note: Ensure that the self test for the monitoring
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
Procedure”. When the engine idles during warm-up, observe the
following conditions:
NOTICE
Use a battery that is sourced with the same voltage • Check for any fluid or for any air leaks at idle rpm
as the electric starting motor. Use ONLY equal volt- and at one-half full rpm (no load on the engine)
age for jump starting. The use of higher voltage will before operating the engine under load. This is not
damage the electrical system. possible in some applications.
Do not reverse the battery cables. The alternator can • Operate the engine at low idle until all systems
be damaged. Attach the negative battery cable last achieve operating temperatures. Check all gauges
and remove the negative battery cable first.
during the warm-up period.
When an external electrical source is used to start
the engine, turn the control switch on the generator Note: Gauge readings should be observed and the
set to the “OFF” position. Turn all electrical accesso- data should be recorded frequently while the engine
ries OFF before attaching the jump start cables. is operating. Comparing the data over time will help
to determine normal readings for each gauge.
Ensure that the main power switch is in the OFF posi- Comparing data over time will also help detect
tion before jump start cables are attached to the en- abnormal operating developments. Significant
gine that is being started. changes in the readings should be investigated.

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

OFF position. Turn off all accessories.
2. Connect one positive end of the jump start cable to
the positive cable terminal of the discharged
battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the
charging or starting source.
3. Connect one negative end of the jump start cable
to the negative cable terminal of the charging or
starting source. Connect the other negative end of
the jump start cable to the stalled engine block or
to the chassis ground. This procedure helps to
prevent potential sparks from igniting combustible
gases that are produced by some batteries.
4. Charge the batteries. The engine will not continue
to run after starting if the batteries have not been
charged.
5. Start the engine.
6. Immediately after the stalled engine is started,
disconnect the jump start cables in reverse order.
Refer to the Electrical Schematic for your engine.
Consult your Caterpillar dealer for more information.
SEBU7655-04 29
Operation Section
Engine Operation

Engine Operation Cylinder Cutout Strategy

The cylinder cutout starts at 1000 rpm. The
i01646252 hydrocarbon mitigation monitors the exhaust and
intake target temperatures and increases speed if
Engine Operation temperatures are not achieved in intervals. The
intervals are 20 minutes and with 200 rpm
(Hydrocarbon Mitigation) increments. The speed range for the strategy is 1000
rpm to 1800 rpm with a minimum run time of 100
SMCS Code: 1000 minutes.
Proper operation and maintenance are key factors in
obtaining the maximum life and economy of the Note: This strategy only runs in non-work mode.
engine. If the directions in the Operation and The strategy success criteria is based on the
Maintenance Manual are followed, costs can be following:
minimized and engine service life can be maximized.
The time that is needed for the engine to reach • Intake air manifold temperature over 10° C (50° F)
normal operating temperature can be less than the
time taken for a walk-around inspection of the • Exhaust manifold temperature over 325° C
engine. (617° F)

The engine can be operated at the rated rpm after If successful, the machine will continue to run
indefinitely at the current rpm until taken out of non-
the engine is started and after the engine reaches work mode.
operating temperature. The engine will reach normal
operating temperature sooner during a low engine
speed (rpm) and during a low-power demand. This Exhaust Temperature Low Code Actions
procedure is more effective than idling the engine at
no load. The engine should reach operating Once the 173-18 Engine Exhaust Manifold #1
temperature in a few minutes. Temperature #1: Low - Moderate Severity (2)
warning message is shown, there are two actions the
Gauge readings should be observed and the data can be taken to remove them:
should be recorded frequently while the engine is
operating. Comparing the data over time will help to Non-Work Mode
determine normal readings for each gauge.
Comparing data over time will also help detect Put the machine in Non-Work mode.
abnormal operating developments. Significant
changes in the readings should be investigated. • This will allow Hydrocarbon Mitigation to start
automatically and attempt to achieve the target
temperatures for the intake and exhaust.
Hydrocarbon Mitigation
• If the strategy does not achieve target
The hydrocarbon mitigation is a feature to protect the temperatures, the engine will return to low idle for
DOC against temperatures below 325° C (617° F). 60 minutes and then Hydrocarbon Mitigation
Temperatures below this range can damage the begins.
aftertreatment of the machine. The initial occurrence
displays as a warning and then if temperatures do not • If the strategy continues to fail, the next action will
increase by the operator or strategy, the machine will
go into shutdown. Messages appear sequentially as need to be taken to clear the codes.
follows: Non-Work Mode Failure
• First : Key cycle to warning If the machine is being used at the time of the
• Secondary : Warning to shut down warning message and cannot be put into Non-Work
mode, then raise the intake and exhaust temperature
If the warning messages are not acknowledged, then for their time thresholds.
the shutdown counter begins. Once the engine has
shutdown for low exhaust temperatures, the 173-18 • Intake air manifold temperature is greater than
Engine Exhaust Manifold #1 Temperature #1: Low - 10° C (50° F) for 10 minutes continuously
Moderate Severity (2) will return until the engine has
successfully reached target temperatures. • Exhaust manifold temperature is greater than
325° C (617° F) for 30 minutes continuously
Once exhaust temperatures below 325° C (617° F)
are observed for an hour, the Hydrocarbon Mitigation • Blender - Ideal time to perform this is during the 60
feature begins and the following conditions below minute low time after a Hydrocarbon Mitigation
become active. failure.
30 SEBU7655-04
Operation Section
Engine Warm-up

Note: Hydrocarbon Mitigation will always start 5. Apply the load. Begin operating the engine at low
mitigation. load. Check the gauges and equipment for proper
operation. After normal oil pressure is reached and
i00613522 the temperature gauge begins to move, the engine
may be operated at full load. Check the gauges
Engine Warm-up and equipment frequently when the engine is
SMCS Code: 1000 operated under load.
Extended operation at low idle or at reduced load
1. Run the engine at low idle for three to five minutes, may cause increased oil consumption and carbon
or run the engine at low idle until the jacket water buildup in the cylinders. This carbon buildup
temperature starts to rise. results in a loss of power and/or poor
performance.
More time may be necessary when the
temperature is below −18°C (0°F).
i03698887
2. Check all of the gauges during the warm-up
period. Fuel Conservation Practices
3. Perform another walk-around inspection. Check SMCS Code: 1000; 1250
the engine for fluid leaks and air leaks. The efficiency of the engine can affect the fuel
4. Increase the rpm to the rated rpm. Check for fluid economy. Caterpillar's design and technology in
leaks and air leaks. The engine may be operated manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
at full rated rpm and at full load when the jacket in order to attain optimum performance for the life of
water temperature reaches 60°C (140°F). the engine.

i01646335 • Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel
Engaging the Driven may overflow from the fuel tank. Inspect fuel lines for
Equipment leaks. Repair the fuel lines, as needed.
SMCS Code: 1000 • Be aware of the properties of the different fuels.
Use only the recommended fuels.
1. Operate the engine at one-half of the rated rpm,
when possible. • Avoid unnecessary idling.

2. Engage the driven equipment without a load on the Shut off the engine rather than idle for long periods of
equipment, when possible. time.

Interrupted starts put excessive stress on the drive • Observe the service indicator frequently. Keep the
train. Interrupted starts also waste fuel. To get the air cleaner elements clean.
driven equipment in motion, engage the clutch
smoothly with no load on the equipment. This • Maintain a good electrical system.
method should produce a start that is smooth and
easy. The engine rpm should not increase and the One bad battery cell will overwork the alternator. This
clutch should not slip. will consume excess power and excess fuel.

3. Ensure that the ranges of the gauges are normal • Ensure that the belts are properly adjusted. The
when the engine is operating at one-half of the belts should be in good condition.
rated rpm. Ensure that all gauges operate
• Ensure that all of the connections of the hoses are
properly.
tight. The connections should not leak.
4. Increase the engine rpm to the rated rpm. Always
increase the engine rpm to the rated rpm before • Ensure that the driven equipment is in good
working order.
the load is applied.
SEBU7655-04 31
Operation Section
Fuel Conservation Practices

• 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.
32 SEBU7655-04
Operation Section
Engine Stopping

Engine Stopping Emergency Stop Button

i01428739

Stopping the Engine

SMCS Code: 1000; 7000

NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of the engine components.
If the engine has been operating at high rpm and/or
high loads, run at low idle for at least three minutes to
reduce and stabilize internal engine temperature be-
fore stopping the engine.
Illustration 24 g00104303
Avoiding hot engine shutdowns will maximize turbo- Typical emergency stop button
charger shaft and bearing life.
The emergency stop button is in the OUT position for
Prior to stopping an engine that is being operated at normal engine operation. Push the emergency stop
low loads, operate the engine at low idle for 30 button. The engine will not start when the button is
seconds before stopping. If the engine has been locked. Turn the button clockwise in order to reset.
operating at highway speeds and/or at high loads,
operate the engine at low idle for at least three
minutes. This procedure will cause the internal NOTICE
Stopping the engine immediately after it has been
engine temperature to be reduced and stabilized. working under load can result in overheating and ac-
Ensure that the engine stopping procedure is celerated wear of the engine components.
understood. Stop the engine according to the shutoff If the engine has been operating at high rpm and/or
system on the engine or refer to the instructions that high loads, run the engine at low idle for at least three
are provided by the OEM. minutes to reduce and stabilize the internal engine
temperature before stopping the engine.
• To stop the engine, turn the ignition key switch to
the OFF position.
i04315380
i01171573

Emergency Stopping Manual Stop Procedure

SMCS Code: 1000
SMCS Code: 1000; 7418

NOTICE
NOTICE Stopping the engine immediately after it has been
Emergency shutoff controls are for EMERGENCY working under load can result in overheating and ac-
use ONLY. DO NOT use emergency shutoff devices celerated wear of the engine components.
or controls for normal stopping procedure.
If the engine has been operating at high rpm and/or
Ensure that any components for the external system high loads, run at low idle for at least three minutes to
that support the engine operation are secured after reduce and stabilize internal engine temperature be-
the engine is stopped. fore stopping the engine.
Avoiding hot engine shutdowns will maximize turbo-
charger shaft and bearing life.

Note: Individual applications have different control

systems. Ensure that the shutoff procedures are
understood. Use the following general guidelines in
order to stop the engine.
SEBU7655-04 33
Operation Section
After Stopping Engine

1. Remove the load from the engine so that the

engine has no more than 30% power.
2. Run the engine at the programmed low idle speed
for at least 3 minutes.
3. After the cool down period, turn the start switch to
the OFF position.

i01465494

After Stopping Engine

SMCS Code: 1000

Note: Before you check the engine oil, do not

operate the engine for at least 10 minutes in order to
allow the engine oil to return to the oil pan.
• Check the crankcase oil level. Maintain the oil
level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.
• Note the service hour meter reading. Perform the
maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
• Fill the fuel tank in order to help prevent
accumulation of moisture in the fuel. Do not overfill
the fuel tank.

NOTICE
Only use antifreeze/coolant mixtures recommended
in the Coolant Specifications that are in the Operation
and Maintenance Manual. Failure to do so can cause
engine damage.

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

• 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.
34 SEBU7655-04
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: i01821501

• 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.
SEBU7655-04 35
Operation Section
Fuel Related Components in Cold Weather

Fuel tanks should contain some provision for draining

water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.
Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.
Drain the water and sediment from any fuel storage
tank at the following intervals: weekly, oil changes
and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.

Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual in the Maintenance Section for more
information on priming the fuel system.
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.

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.
Note: Fuel heaters that are controlled by the water
temperature regulator or self-regulating fuel heaters
should be used with this engine. Fuel heaters that are
not controlled by the water temperature regulator can
heat the fuel in excess of 65°C (149°F). A loss of
engine power can occur if the fuel supply
temperature exceeds 37°C (100°F).
Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
the fuel in warm weather operation.
36 SEBU7655-04
Maintenance Section
Refill Capacities

Maintenance Section 3054C Industrial Engine

Table 3

Refill Capacities 3054C Industrial Naturally Aspirated Engine

Compartment or System Liters Quarts

i03698892
Engine Only 10.4 11

Refill Capacities External cooling system capacity

(OEM recommendation) (1)
SMCS Code: 1348; 1395; 7560
Total Cooling System(2)

Lubrication System (1) The external cooling system includes a radiator or an expan-
sion tank with the following components: heat exchanger, after-
cooler and piping. Refer to the Caterpillar specifications and/or
The refill capacities for the engine crankcase reflect the OEM specifications. Enter the value for the external system
the approximate capacity of the crankcase or sump capacity in this row.
plus standard oil filters. Auxiliary oil filter systems will (2) The Total Cooling System includes the capacity for the engine
require additional oil. Refer to the OEM specifications cooling system plus the capacity for the external cooling sys-
for the capacity of the auxiliary oil filter. Refer to tem. Enter the total in this row.
Operation and Maintenance Manual, “Maintenance
Table 4
Section” for more information on Lubricant
Specifications. 3054C Industrial Turbocharged Engine

3054C Industrial Engine Compartment or System Liters Quarts

Engine Only 11.4 12
Table 2
3054C Industrial Engine External cooling System capacity
(OEM recommendation)(1)
Compartment or System Liters Quarts
Total Cooling System(2)
Standard Oil Sump for the Engine Crank- (1) The external cooling system includes a radiator or an expan-
6.5 7
case(1) sion tank with the following components: heat exchanger, after-
(1) These values are the approximate capacities for the crankcase cooler and piping. Refer to Caterpillar specifications and/or the
oil sump which include the standard factory installed oil filters. OEM specifications. Enter the value for the external cooling
Engines with auxiliary oil filters will require additional oil. Refer system capacity in this row.
(2) The Total Cooling System includes the capacity for the engine
to the OEM specifications for the capacity of the auxiliary oil
filter. cooling system plus the capacity for the external cooling sys-
tem. Enter the total in this row.

Cooling System i03702626

To maintain the cooling system, the Total Cooling Fluid Recommendations

System capacity must be known. The approximate
capacity for the engine cooling system is listed below. (Coolant Information)
External System capacities will vary among
applications. Refer to the OEM specifications for the SMCS Code: 1280; 1348; 1395; 7560
External System capacity. This capacity information
will be needed in order to determine the amount of NOTICE
coolant/antifreeze that is required for the Total Never add coolant to an overheated engine. Engine
Cooling System. damage could result. Allow the engine to cool first.

NOTICE
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside tem-
perature or drained completely to prevent damage.

NOTICE
Frequently check the specific gravity of the coolant
for proper freeze protection or for anti-boil protection.
SEBU7655-04 37
Maintenance Section
Coolant Information

Clean the cooling system for the following reasons: DO NOT use the following types of water in cooling
systems: hard water, softened water that has been
• Contamination of the cooling system conditioned with salt and sea water.
• Overheating of the engine If distilled water or deionized water is not available,
use water with the properties that are listed in table 5
• Foaming of the coolant .
Table 5
Note: Air pockets can form in the cooling system if Caterpillar Minimum Acceptable Water Requirements
the cooling system is filled at a rate that is greater
than 5 L (1.3 US gal) per minute. Property Maximum Limit ASTM Test

After you drain the cooling system and after you refill “D512”,
Chloride (Cl) 40 mL (1.4 oz)
the cooling system, operate the engine. Operate the “D4327”
engine without the filler cap until the coolant reaches Sulfate (SO4) 100 mL (3.4 oz) “D516”
normal operating temperature and the coolant level
stabilizes. Ensure that the coolant is maintained to Total Hardness 170 mL (5.8 oz) “D1126”
the proper level.
Total Solids 340 mL (11.6 oz) “D1888”
NOTICE Acidity pH of 5.5 to 9.0 “D1293”
Never operate an engine without water temperature
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 Additives help to protect the metal surfaces of the
pump, plugged radiators or heat exchangers and cooling system. A lack of coolant additives or
pitting of the cylinder liners. insufficient amounts of additives enable the following
These failures can be avoided with proper cooling conditions to occur:
system maintenance. Cooling system maintenance is
• Corrosion
as important as maintenance of the fuel system and
the lubrication system. Quality of the coolant is as • Formation of mineral deposits
important as the quality of the fuel and the lubricating
oil. • Rust
Coolant is normally composed of three elements:
water, additives and glycol. • Scale

• Pitting and erosion from cavitation of the cylinder

Water liner

• Foaming of the coolant

NOTICE
Never use water alone without Supplemental Coolant Many additives are depleted during engine operation.
Additives (SCA) or without inhibited coolant. Water These additives must be replaced periodically. This
alone is corrosive at engine operating temperatures. can be done by adding Supplemental Coolant
Water alone does not provide adequate protection Additives (SCA) to Diesel Engine Antifreeze/Coolant
against boiling or freezing. (DEAC) or by adding ELC Extender to Extended Life
Coolant (ELC).
Water is used in the cooling system in order to
transfer heat. Additives must be added at the proper concentration.
Distilled water or deionized water is Overconcentration of additives can cause the
recommended for use in engine cooling systems. inhibitors to drop out-of-solution. The deposits can
enable the following problems to occur:
• Formation of gel compounds
38 SEBU7655-04
Maintenance Section
Coolant Information

• Reduction of heat transfer To check the concentration of glycol, use the

1U-7298 Coolant/Battery Tester (Degrees Celsius)
• Leakage of the water pump seal or use the 1U-7297 Coolant/Battery Tester
(Degrees Fahrenheit). The testers give readings that
• Plugging of radiators, coolers, and small passages are immediate and accurate. The testers can be used
with ethylene or propylene glycol.
Glycol
Coolant Recommendations
Glycol in the coolant helps to provide protection
against the following conditions: The following two coolants are used in Caterpillar
diesel engines:
• Boiling
Preferred – Caterpillar Extended Life Coolant (ELC)
• Freezing or a commercial extended life coolant that meets the
Caterpillar EC-1 specification
• Cavitation of the water pump and the cylinder liner
Acceptable – A Caterpillar Diesel Engine
For optimum performance, Caterpillar recommends a Antifreeze/Coolant (DEAC) or a commercial heavy-
1:1 mixture of a water/glycol solution. duty coolant/antifreeze that meets “ASTM D4985” or
Note: Use a mixture that will provide protection “ASTM D5345” specifications
against the lowest ambient temperature.

Note: 100 percent pure glycol will freeze at a NOTICE

Do not use a commercial coolant/antifreeze that only
temperature of −23 °C (−9 °F). meets the ASTM D3306 or D4656 specification. This
Most conventional heavy-duty coolant/antifreezes type of coolant/antifreeze is made for light duty auto-
use ethylene glycol. Propylene glycol may also be motive applications.
used. In a 1:1 mixture with water, ethylene and
propylene glycol provide similar protection against Caterpillar recommends a 1:1 mixture of water and
freezing and boiling. Refer to table 6 and table 7 . glycol. This mixture of water and glycol will provide
Table 6 optimum heavy-duty performance as a coolant/
Ethylene Glycol antifreeze.

Freeze Note: Caterpillar DEAC DOES NOT require a

Concentration Boil Protection treatment with an SCA at the initial fill. Commercial
Protection
heavy-duty coolant or antifreeze that meets “ASTM
50 Percent −36 °C (−33 °F) 106 °C (223 °F)
D4985” or “ASTM D5345” specifications MAY require
60 Percent −51 °C (−60 °F) 111 °C (232 °F) a treatment with an SCA at the initial fill. Read the
label or the instructions that are provided by the OEM
of the product.
NOTICE In stationary engine applications and marine engine
Do not use propylene glycol in concentrations that
exceed 50 percent glycol because of propylene gly- applications that do not require anti-boil protection or
col's reduced heat transfer capability. Use ethylene freeze protection, a mixture of SCA and water is
glycol in conditions that require additional protection acceptable. Caterpillar recommends a six percent to
eight percent concentration of SCA in those cooling
against boiling or freezing.
systems. Distilled water or deionized water is
preferred. Water which has the recommended
Table 7 properties may be used.
Propylene Glycol
NOTICE
Freeze Anti-Boil All Caterpillar diesel engines equipped with air-to-air
Concentration
Protection Protection aftercooling (ATAAC) require a minimum of 30 per-
50 Percent −29 °C (−20 °F) 106 °C (223 °F) cent glycol to prevent water pump cavitation.

Table 8
Coolant Service Life
Coolant Type Service Life

(continued)
SEBU7655-04 39
Maintenance Section
Coolant Information

(Table 8, contd) Recommended Interval for S·O·S Coolant

Caterpillar ELC 6000 Service Hours or Six Years Sample
3000 Service Hours or Three Perform a coolant analysis (Level 1) at every 500
Caterpillar DEAC
Years
service hour interval. Perform a coolant analysis
Commercial Heavy-Duty Cool- (Level 2) annually, or perform a coolant analysis
ant/Antifreeze that meets 3000 Service Hours or Two Years (Level 2) when a problem is identified by a coolant
“ASTM D5345” analysis (Level 1).
Commercial Heavy-Duty Cool- Note: Check the standard coolant's Supplemental
ant/Antifreeze that meets 3000 Service Hours or One Year
Coolant Additive (SCA) at every oil change.
“ASTM D4985”
Caterpillar SCA and Water 3000 Service Hours or Two Years S·O·S Coolant Analysis (Level 1)
Commercial SCA and Water 3000 Service Hours or One Year
A coolant analysis (Level 1) is a test of the properties
of the coolant.
S·O·S Coolant Analysis The following properties of the coolant are tested:
Testing the engine coolant is important to ensure that • Glycol concentration for freeze protection and boil
the engine is protected from internal cavitation and protection
corrosion. The analysis also tests the ability of the
coolant to protect the engine from boiling and • Ability to protect from erosion and corrosion
freezing. S·O·S Coolant Analysis can be done at
your Caterpillar dealer. Caterpillar S·O·S Coolant • pH
Analysis is the best way to monitor the condition of
your coolant and your cooling system. S·O·S Coolant • Conductivity
Analysis is a program that is based on periodic
samples. • Visual analysis
• Odor analysis
NOTICE
Do not use the same vacuum sampling pump for ex-
The results are reported, and appropriate
tracting oil samples that is used for extracting coolant recommendations are made.
samples.
A small residue of either type sample may remain in S·O·S Coolant Analysis (Level 2)
the pump and may cause a false positive analysis for
the sample being taken. A coolant analysis (Level 2) is a comprehensive
chemical evaluation of the coolant. This analysis is
Always use a designated pump for oil sampling and a also a check of the overall condition of the inside of
designated pump for coolant sampling. the cooling system.
Failure to do so may cause a false analysis which The S·O·S Coolant Analysis has the following
could lead to customer and dealer concerns. features:
• Full coolant analysis (Level 1)
New Systems, Refilled Systems, and • Identification of the source of metal corrosion and
Converted Systems of contaminants
Perform a coolant analysis (Level 2) at 500 service • Water hardness
hours for new systems, for refilled systems, or for
converted systems that use Cat Extended Life • Identification of buildup of the impurities that
Coolant (ELC) or use Cat Diesel Engine Antifreeze/ cause corrosion
Coolant (DEAC). This 500 hour check will also check
for any residual cleaner that may have contaminated • Identification of buildup of the impurities that
the system. cause scaling
The results are reported, and appropriate
recommendations are made.
40 SEBU7655-04
Maintenance Section
Coolant Information

For more information on S·O·S Coolant Analysis, Note: Caterpillar developed the EC-1 specification.
consult your Caterpillar dealer. The EC-1 specification is an industry standard. The
EC-1 specification defines all of the performance
Extended Life Coolant (ELC) requirements that are needed for an engine coolant
to be sold as an extended life coolant for Caterpillar
Caterpillar provides Extended Life Coolant (ELC) for engines. ELC can be used in most OEM engines of
use in the following applications: the following types: diesel, gasoline and natural gas.
ELC meets the performance requirements of “ASTM
• Heavy-duty spark ignited gas engines D4985” and “ASTM D5345” for heavy-duty low
silicate antifreeze or coolants. ELC also meets the
• Heavy-duty diesel engines performance requirements of “ASTM D3306” and
“ASTM D4656” for automotive applications.
• Automotive applications
The anti-corrosion package for Caterpillar ELC is Diesel Engine Antifreeze/Coolant
different from the anti-corrosion package for other (DEAC)
coolants. Caterpillar ELC is an ethylene glycol base
coolant. However, Caterpillar ELC contains organic
corrosion inhibitors and antifoam agents with low Caterpillar recommends using Caterpillar Diesel
amounts of nitrite. Caterpillar ELC has been Engine Antifreeze/Coolant (DEAC) for cooling
formulated with the correct amount of these additives systems that require a heavy-duty coolant/antifreeze.
in order to provide superior corrosion protection for Caterpillar DEAC is an alkaline single-phase
all metals in engine cooling systems. ethylene glycol type antifreeze that contains
corrosion inhibitors and antifoam agents.
ELC extends the service life of the coolant to 12000
service hours or three years. ELC does not require a Caterpillar DEAC is formulated with the correct
frequent addition of a Supplemental Coolant Additive amount of Caterpillar Supplemental Coolant Additive
(SCA). An Extender is the only additional (SCA). Do not use SCA at the initial fill when DEAC is
maintenance that is needed at 6000 service hours or used.
one half of the ELC service life.
Containers of several sizes are available. Consult
The ELC is available in a 1:1 premixed cooling your Caterpillar dealer for the part numbers.
solution with distilled water. The Premixed ELC
provides freeze protection to −36 °C (−33 °F). The If concentrated DEAC is used, Caterpillar
Premixed ELC is recommended for the initial fill of recommends mixing the concentrate with distilled
the cooling system. The Premixed ELC is also water or with deionized water. If distilled water or
recommended for topping off the cooling system. deionized water is not available, use water which has
the required properties. For the water properties,
ELC Concentrate is also available. ELC Concentrate refer to Operation and Maintenance Manual,
can be used to lower the freezing point to −51 °C “General Coolant Information”.
(−60 °F) for arctic conditions.
Containers of several sizes are available. Consult
Supplemental Coolant Additive
your Caterpillar dealer for the part numbers. (SCA)
The use of SCA helps to prevent the following
conditions from occurring:

• Corrosion
• Formation of mineral deposits

• Cavitation erosion of the cylinder liners

• Foaming of the coolant
Caterpillar Diesel Engine Antifreeze/Coolant (DEAC)
is formulated with the correct level of Caterpillar SCA.
When the cooling system is initially filled with DEAC,
adding more SCA is not necessary until the
concentration of SCA has been depleted. To ensure
that the correct amount of SCA is in the cooling
system, the concentration of SCA must be tested on
a scheduled basis. Refer to the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
SEBU7655-04 41
Maintenance Section
Coolant Information

Containers of Cat SCA are available in several sizes. Note: Pure undiluted antifreeze freezes at −23 °C
Consult your Caterpillar dealer for the part numbers. (−9 °F).

Commercial Heavy-Duty Coolant/ In engine cooling systems that use water alone,
Caterpillar recommends the use of SCA. SCA helps
Antifreeze and SCA to prevent the following conditions from occurring:
If Caterpillar DEAC is not used, select a coolant/ • Corrosion
antifreeze with low silicate content for heavy-duty
applications that meets “ASTM D5345” or “ASTM • Formation of mineral deposits
D4985” specifications.
• Cavitation erosion of the cylinder liner
Note: When you are not using Caterpillar DEAC the
cooling system must be drained one time during • Foaming of the coolant
every year. The cooling system must be flushed at
this time as well. If Caterpillar SCA is not used, select a commercial
SCA. The commercial SCA must provide a minimum
When a heavy-duty coolant/antifreeze is used, treat of 2400 mg/L, 2400 ppm or 140 grains/US gal of
the cooling system with three to six percent nitrites in the final coolant mixture.
Caterpillar SCA by volume. For more information,
refer to Operation and Maintenance Manual, The quality of the water is a very important factor in
“Conventional Coolant/Antifreeze Cooling System this type of cooling system. Distilled water or
Maintenance”. deionized water is recommended for use in cooling
systems. If distilled water or deionized water is not
If Caterpillar SCA is not used, select a commercial available, use water that meets the minimum
SCA. The commercial SCA must provide a minimum requirements that are listed in the table for
of 1200 mg/L, 1200 ppm or 70 grains/US gal of recommended water properties in Operation and
nitrites in the final coolant mixture. Maintenance Manual, “General Coolant Information”.

Coolant or antifreeze that meets “ASTM D5345” or A cooling system that uses a mixture of SCA and
“ASTM D4985” specifications MAY require treatment water only needs more SCA than a cooling system
with SCA at the initial fill. These coolants WILL that uses a mixture of glycol and water. The SCA
require treatment with SCA on a maintenance basis. concentration in a cooling system that uses SCA and
water should be six to eight percent by volume. Refer
When concentrated coolant or antifreeze is mixed, to Table 9 for the amount of SCA that is required for
Caterpillar recommends mixing the concentrate with various capacities of the cooling system.
distilled water or with deionized water. If distilled
water or deionized water is not available, water which Table 9
has the required properties may be used. For the Caterpillar SCA Requirements for SCA and Water
water properties, refer to Operation and Maintenance Cooling Systems
Manual, “General Coolant Information”.
Cooling System Caterpillar SCA Caterpillar SCA
Water and Supplemental Coolant Capacity at Initial Fill at 250 Hours

Additive (SCA) 22 to 30 L
1.75 L (64 fl oz) 0.44 L (15 fl oz)
(6 to 8 US gal)

NOTICE 31 to 38 L
2.30 L (80 fl oz) 0.57 L (20 fl oz)
All Caterpillar diesel engines equipped with air-to-air (9 to 10 US gal)
aftercooling (ATAAC) require a minimum of 30 per- 39 to 49 L
cent glycol to prevent water pump cavitation. (11 to 13 US gal)
3.00 L (100 fl oz) 0.75 L (25 fl oz)

50 to 64 L
3.90 L (128 fl oz) 0.95 L (32 fl oz)
NOTICE (14 to 17 US gal)
Never use water alone without Supplemental Coolant 65 to 83 L
Additives (SCA) or without inhibited coolant. Water (18 to 22 US gal)
5.00 L (168 fl oz) 1.25 L (42 fl oz)
alone is corrosive at engine operating temperatures.
Water alone does not provide adequate protection 84 to 110 L
6.60 L (224 fl oz) 1.65 L (56 fl oz)
against boiling or freezing. (23 to 29 US gal)

111 to 145 L
8.75 L (296 fl oz) 2.19 L (74 fl oz)
Note: Premix the coolant solution in order to provide (30 to 38 US gal)
protection to the lowest ambient temperature that is 146 to 190 L
expected. 11.50 L (392 fl oz) 2.88 L (98 fl oz)
(39 to 50 US gal)

191 to 250 L
15.00 L (512 fl oz) 3.75 L (128 fl oz)
(51 to 66 US gal)
42 SEBU7655-04
Maintenance Section
Coolant Information

Refer to Table 10 for part numbers and for quantities STEP 3 – Add tap water to the vial up to the “20 ml”
of SCA. mark.
Table 10
STEP 5 – When the defined procedure is used, a
Caterpillar Liquid SCA concentration of six to eight percent will yield
between 20 drops and 27 drops. If the number of
Part Number Quantity
drops is below 20 drops, the concentration of SCA is
6V-3542 0.24 L (8 oz) low. If the number of drops is above 27 drops, the
concentration of SCA is high. Make the appropriate
111-2372 0.36 L (12 oz) adjustments to the concentration of SCA.
8T-1589 0.47 L (16 oz)
Test the concentration of SCA or submit a coolant
3P-2044 0.94 L (32 oz) sample to your Caterpillar dealer. Refer to Operation
and Maintenance Manual, “S·O·S Coolant Analysis”.
8C-3680 19 L (5 US gal)

5P-2907 208 L (55 US gal) Additions of SCA are based on the results of the test
or based on the results of the coolant analysis. The
size of the cooling system determines the amount of
Maintain the SCA in the same way as you would SCA that is required.
maintain a cooling system that uses heavy-duty
coolant or antifreeze. Adjust the maintenance for the Use the equation that is in Table 11 to determine the
amount of SCA additions. See table 9 for the amount amount of Caterpillar SCA that is required for
of SCA that is required. maintenance, if necessary:
Table 13
Cooling Systems with Larger Capacities The Addition Equation for SCA To Water For Maintenance

Adding the SCA to Water at the Initial Fill V × 0.023 = X

V is the total volume of the cooling system.
Use the equation that is in table 11 to determine the
amount of Caterpillar SCA that is required at the X is the amount of SCA that is required.
initial fill. This equation is for a mixture of only SCA
and water.
Table 11 Table 14 is an example for using the equation that is
in table 11 .
Equation For Adding The SCA To Water At The Initial Fill Table 14
V × 0.07 = X The Example of an Additional Equation SCA To Water For
Maintenance
V is the total volume of the cooling system.
Total Volume of the Multiplication Amount of SCA
X is the amount of SCA that is required. Cooling System (V) Factor that is Required (X)

946 L × 0.023 22 L
Table 12 is an example for using the equation that is (250 US gal) (6 US gal)
in table 11 .
Table 12
Example Of The Equation For Adding The SCA To Water At Note: Specific engine applications may require
The Initial Fill maintenance practices to be periodically evaluated in
order to properly maintain the engine's cooling
Total Volume of the Multiplication Amount of SCA system.
Cooling System (V) Factor that is Required (X)

946 L × 0.07 66 L
(250 US gal) (18 US gal)

Adding the SCA to Water for Maintenance

For the recommended service interval, refer to

Operation and Maintenance Manual, “Maintenance
Interval Schedule”.
Use the 8T-5296 Coolant Conditioner Test Kit to
test the concentration of SCA. Make the following
modifications to Steps 3 and 5 of the 8T-5296
Coolant Conditioner Test Kit instructions:
SEBU7655-04 43
Maintenance Section
Coolant Information

Table 10 lists part numbers and quantities of SCA Table 15

that is available from your Caterpillar dealer.
Caterpillar SCA Requirements for Heavy-Duty Cool-
ant/Antifreeze
Conventional Coolant or Spin-on El-
Maintenance for Antifreeze Cooling ement at
250 Service 250 Service
System Cooling Sys-
Initial Fill(1) Hour Main- Hour Main-
tem Capacity
tenance(2) tenance (If
NOTICE Equipped)
(3)
Never operate an engine without water temperature
regulators in the cooling system. Water temperature 22 to 30 L 0.95 L 0.24 L 111-2370
regulators help to maintain the engine coolant at the (6 to 8 US gal) (32 fl oz) (8 fl oz) (1)
proper operating temperature. Cooling system prob-
lems can develop without water temperature 31 to 38 L 1.18 L 0.36 L 111-2369
regulators. (9 to 10 US gal) (40 fl oz) (12 fl oz) (1)

Check the coolant/antifreeze (glycol concentration) in 39 to 49 L 1.42 L 0.36 L 111-2369

order to ensure adequate protection against boiling (11 to 13 US gal) (48 fl oz) (12 fl oz) (1)
or freezing. Caterpillar recommends the use of a 50 to 64 L 1.90 L 0.47 L
refractometer for checking the glycol concentration. (14 to 17 US gal) (64 fl oz) (16 fl oz)
9N-3368 (1)
Use the 1U-7298 Coolant/Battery Tester (Degree
Celsius) or use the 1U-7297 Coolant/Battery Tester 65 to 83 L 2.37 L 0.60 L 111-2371
(Degree Fahrenheit). The testers give readings that (18 to 22 US gal) (80 fl oz) (20 fl oz) (1)
are immediate and accurate. The testers can be used
with ethylene or with propylene glycol. 84 to 114 L 3.32 L 0.95 L
9N-3718 (1)
(23 to 30 US gal) (112 fl oz) (32 fl oz)
Caterpillar engine cooling systems should be tested
115 to 163 L 4.75 L 1.18 L 111-2371
at 250 hour intervals for the concentration of
Supplemental Coolant Additive (SCA). SCA test kits (31 to 43 US gal) (160 fl oz) (40 fl oz) (2)
are available from your Caterpillar dealer. Test the 164 to 242 L 7.60 L 1.90 L
concentration of SCA or submit a coolant sample to 9N-3718 (2)
(44 to 64 US gal) (256 fl oz) (64 fl oz)
your Caterpillar dealer at 250 hour intervals. Refer to
(1) When the coolant system is first filled, the SCA is not required
S·O·S Coolant Analysis for more information on this
topic. to be used with Caterpillar DEAC.
(2) Do not exceed the six percent maximum concentration. Check
the concentration of SCA with a SCA test kit.
Additions of SCA are based on the results of the test (3) Do not use the maintenance element for the SCA and the liquid
or based on the results of the coolant analysis. An for the SCA at the same time.
SCA that is liquid or a maintenance element for an
SCA (if equipped) may be needed at 250 hour
Note: Specific engine applications may require
intervals.
maintenance practices to be periodically evaluated in
Table 15 lists the amount of Caterpillar SCA that is order to properly maintain the engine's cooling
needed at the initial fill in order to treat coolant/ system.
antifreeze. These amounts of SCA are for systems
that use heavy-duty coolant or antifreeze. Refer to table 16 for part numbers and for quantities
of SCA.
Table 15 also lists additions of SCA for liquid and for Table 16
maintenance elements at 250 hours. The additions
are required for Caterpillar DEAC and for commercial Caterpillar Liquid SCA
coolant/antifreezes.
Part Number Quantity

6V-3542 0.24 L (8 oz)

111-2372 0.36 L (12 oz)

8T-1589 0.47 L (16 oz)

3P-2044 0.94 L (32 oz)

8C-3680 19 L (5 US gal)

5P-2907 208 L (55 US gal)

44 SEBU7655-04
Maintenance Section
Coolant Information

Cooling Systems with Larger Capacities Use the equation that is in table 19 to determine the
amount of Caterpillar SCA that is required, if
Adding the SCA to Conventional Coolant or necessary:
Antifreeze at the Initial Fill Table 19
Equation For Adding The SCA To Conventional Coolant/Anti-
Note: Caterpillar DEAC DOES NOT require an freeze For Maintenance
addition of SCA when the cooling system is initially
filled. V × 0.014 = X
V is the total volume of the cooling system.
Commercial heavy-duty coolant or antifreeze that
meets “ASTM D4985” or “ASTM D5345” X is the amount of SCA that is required.
specifications MAY require an addition of SCA at the
initial fill. Read the label or the instructions that are
provided by the OEM of the product. Table 20 is an example for using the equation that is
in table 19 .
Use the equation that is in table 17 to determine the Table 20
amount of Caterpillar SCA that is required when the
cooling system is initially filled with the following Example Of The Equation For Adding The SCA To Conven-
fluids: tional Coolant/Antifreeze For Maintenance
Total Volume of the Multiplication Amount of SCA
• “ASTM D4985” Cooling System (V) Factor that is Required (X)

• “ASTM D5345” 946 L × 0.014 9L

(250 US gal) (4 US gal)
Table 17
Equation For Adding The SCA To Conventional Coolant/Anti-
freeze At The Initial Fill Note: Specific engine applications may require
maintenance practices to be periodically evaluated in
V × 0.045 = X order to properly maintain the engine's cooling
V is the total volume of the cooling system. system.
X is the amount of SCA that is required. Table 16 lists part numbers and quantities of SCA
that is available from your Caterpillar dealer.
Table 18 is an example for using the equation that is
in table 17 . Cleaning the System of Heavy-Duty
Table 18 Coolant/Antifreeze
Example Of The Equation For Adding The SCA To Conven-
Caterpillar cooling system cleaners are designed to
tional Coolant/Antifreeze At The Initial Fill
clean the cooling system of harmful scale and
Total Volume of the Multiplication Amount of SCA corrosion. Caterpillar cooling system cleaners
Cooling System (V) Factor that is Required (X) dissolve mineral scale, corrosion products, light oil
contamination and sludge.
946 L × 0.045 43 L
(250 US gal) (11 US gal) • Clean the cooling system after used coolant is
drained or before the cooling system is filled with
Adding the SCA to Conventional Coolant or new coolant.
Antifreeze For Maintenance • Clean the cooling system whenever the coolant is
Heavy duty coolant or antifreeze of all types contaminated or whenever the coolant is foaming.
REQUIRE periodic additions of an SCA.
Test the coolant/antifreeze periodically for the
concentration of SCA. For the interval, refer to
Operation and Maintenance Manual, “Maintenance
Interval Schedule”. SCA test kits are available from
your Caterpillar dealer. Test the concentration of SCA
or submit a coolant sample to your Caterpillar dealer.
Refer to Operation and Maintenance Manual, “S·O·S
Coolant Analysis”.
Additions of SCA are based on the results of the test
or based on the results of the coolant analysis. The
size of the cooling system determines the amount of
SCA that is needed.
SEBU7655-04 45
Maintenance Section
Fluid Recommendations

• For the recommended service interval, refer to Table 21

Operation and Maintenance Manual, API Classifications
“Maintenance Interval Schedule”.
Current Obsolete
i03814350 CI-4, CH-4, CG-4 (1) CE

Fluid Recommendations CF (2) CC, CD

(Lubricant Information) CF-2(3) CD-2(3)

(1) API CF-4 oils are no longer recommended for Caterpillar diesel
SMCS Code: 1280; 1348; 1395; 7560 engines.
(2) API CF oils are not recommended for Caterpillar diesel
engines.
General Information (3) API CF-2 and CD-2 oils are classifications for two-cycle diesel
engines. Caterpillar does not sell engines that utilize the CD-2
Because of government regulations regarding the and the API CF-2 oils.
certification of exhaust emissions, the lubricant
recommendations must be followed.
Grease
Engine Manufacturers Association The classifications of grease are based on the
(EMA) Oils “ASTM D217” worked penetration characteristics.
These characteristics for grease are given a defined
consistency number.
The “Engine Manufacturers Association
Recommended Guideline on Diesel Engine Oil” is
recognized by Caterpillar. For detailed information Terminology
about this guideline, see the latest edition of EMA
publication, “EMA LRG-1”. Certain abbreviations follow the nomenclature of
“SAE J754”. Some classifications follow “SAE J183”
abbreviations, and some classifications follow the
API Oils “EMA Recommended Guideline on Diesel Engine
Oil”. In addition to Caterpillar definitions, there are
The Engine Oil Licensing and Certification System by other definitions that will be of assistance in
the American Petroleum Institute (API) is recognized purchasing lubricants. Recommended oil viscosities
by Caterpillar. For detailed information about this can be found in Operation and Maintenance Manual,
system, see the latest edition of the “API publication “Engine Oil”.
No. 1509”. Engine oils that bear the API symbol are
authorized by API. Caterpillar Diesel Engine Oil
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:
• Caterpillar Diesel Engine Oil (10W30)
Illustration 25 g00546535 • Caterpillar Diesel Engine Oil (15W40)
Typical API symbol
Caterpillar multigrade Diesel Engine Oil is formulated
Diesel engine oils CC, CD, CD-2, and CE have not with the correct amounts of detergents, dispersants,
been API authorized classifications since January 1, and alkalinity in order to provide superior
1996. Table 21 summarizes the status of the performance in Caterpillar Diesel Engines.
classifications.
46 SEBU7655-04
Maintenance Section
Lubricant Information

Caterpillar multigrade Diesel Engine Oil is available LRG-1 oils will meet the needs of high performance
in two viscosity grades (10W30 and 15W40). For Caterpillar diesel engines that are operating in many
direct injection engines, see table 22 in order to applications. The tests and the test limits that are
choose the correct viscosity grade for the ambient used to define LRG-1 are similar to the new API CH-
temperature. Multigrade oils provide the correct 4 classification. The oils will meet the requirements of
viscosity for a broad range of operating the low emissions diesel engines. LRG-1 oils are
temperatures. designed to control the harmful effects of soot with
improved wear resistance and improved resistance
Multigrade oils are effective in maintaining low oil to plugging of the oil filter. These oils will also provide
consumption and low levels of piston deposits. superior control of piston deposit for engines with
either two-piece steel pistons or aluminum pistons.
Caterpillar multigrade Diesel Engine Oil can be used
in other diesel engines and in gasoline engines. See All LRG-1 oils must complete a full test program with
the engine manufacturer's guide for the the base stock and with the viscosity grade of the
recommended specifications. Compare the finished commercial oil. The use of “API Base Oil
specifications to the specifications of Caterpillar Interchange Guidelines” are not appropriate for LRG-
multigrade Diesel Engine Oil. The current industry 1 oils. This feature reduces the variation in
standards for Caterpillar Diesel Engine Oil are listed performance that can occur when base stocks are
on the product label and on the data sheets for the changed in commercial oil formulations.
product.
LRG-1 oils are recommended for use in extended oil
Consult your Caterpillar dealer for part numbers and change interval programs that optimize oil life. These
for available sizes of containers. oil change interval programs are based on oil
analysis. LRG-1 oils are recommended for conditions
that demand a premium oil. Your Caterpillar dealer
Commercial Oils has the specific guidelines for optimizing oil change
intervals.
The performance of commercial diesel engine oils is
based on American Petroleum Institute (API) API CH-4 – API CH-4 oils were developed in order to
classifications. These API classifications are meet the requirements of the new high performance
developed in order to provide commercial lubricants diesel engines. Also, the oil was designed to meet
for a broad range of diesel engines that operate at the requirements of the low emissions diesel
various conditions. engines. API CH-4 oils are also acceptable for use in
older diesel engines and in diesel engines that use
If Caterpillar multigrade Diesel Engine Oil is not used, high sulfur diesel fuel. API CH-4 oils may be used in
only use commercial oils that meet the following Caterpillar engines that use API CG-4. API CH-4 oils
classifications: will generally exceed the performance of API CG-4
oils in the following criteria: deposits on pistons,
• EMA LRG-1 multigrade oil (preferred oil) control of oil consumption, wear of piston rings, valve
train wear, viscosity control and corrosion.
• API CH-4 multigrade oil (preferred oil)

• API CG-4 multigrade oil (preferred oil) Three new engine tests were developed for the API
CH-4 oil. The first test specifically evaluates deposits
In order to make the proper choice of a commercial on pistons for engines with the two-piece steel piston.
oil, refer to the following explanations: This test (piston deposit) also measures the control
of oil consumption. A second test is conducted with
EMA LRG-1 – The Engine Manufacturers moderate oil soot. The second test measures the
Association (EMA) has developed lubricant following criteria: wear of piston rings, wear of
recommendations as an alternative to the API oil cylinder liners and resistance to corrosion. A third
classification system. LRG-1 is a Recommended new test measures the following characteristics with
Guideline that defines a level of oil performance for high levels of soot in the oil: wear of the valve train,
these types of diesel engines: high speed, four stroke resistance of the oil in plugging the oil filter and
cycle, heavy-duty and light duty. LRG-1 oils may be control of sludge.
used in Caterpillar engines when the following oils
are recommended: API CH-4 and API CG-4. LRG-1 In addition to the new tests, API CH-4 oils have
oils are intended to provide superior performance in tougher limits for viscosity control in applications that
comparison to API CG-4. generate high soot. The oils also have improved
oxidation resistance. API CH-4 oils must pass an
additional test (piston deposit) for engines that use
aluminum pistons (single piece). Oil performance is
also established for engines that operate in areas
with high sulfur diesel fuel.
SEBU7655-04 47
Maintenance Section
Lubricant Information

All of these improvements allow the API CH-4 oil to

achieve optimum oil change intervals. API CH-4 oils
are recommended for use in extended oil change
intervals. API CH-4 oils are recommended for
conditions that demand a premium oil. Your
Caterpillar dealer has specific guidelines for
optimizing oil change intervals.
API CG-4 – API CG-4 oils were developed primarily
for diesel engines that use a 0.05 percent level of fuel
sulfur. However, API CG-4 oils can be used with
higher sulfur fuels. The TBN of the new oil
determines the maximum fuel sulfur level for API CG-
4 oils. See illustration 26 .

API CG-4 oils are the first oils that are required to
pass industry standard tests for foam control and Illustration 26 g00799818
viscosity shear loss. API CG-4 oils must also pass (Y) TBN by “ASTM D2896”
tests that were developed for corrosion, wear and (X) Percentage of fuel sulfur by weight
oxidation. (1) TBN of new oil
(2) Change the oil when the TBN deteriorates to 50 percent of the
original TBN.
Note: Do not use single grade API CF oils or
multigrade API CF oils in Caterpillar Direct Injection Use the following guidelines for fuel sulfur levels that
(DI) Commercial Diesel Engines. exceed 1.5 percent:
Some commercial oils that meet the API • Choose an oil with the highest TBN that meets
classifications may require reduced oil change
intervals. To determine the oil change interval, one of these classifications: EMA LRG-1, API CH-
closely monitor the condition of the oil and perform a 4 and API CG-4.
wear metal analysis. Caterpillar's S·O·S oil analysis
program is the preferred method. • Reduce the oil change interval. Base the oil
change interval on the oil analysis. Ensure that the
oil analysis includes the condition of the oil and a
NOTICE
Failure to follow these oil recommendations can wear metal analysis.
cause shortened engine service life due to deposits
and/or excessive wear. Excessive piston deposits can be produced by an oil
with a high TBN. These deposits can lead to a loss of
control of the oil consumption and to the polishing of
the cylinder bore.
Total Base Number (TBN) and Fuel
Sulfur Levels for Direct Injection NOTICE
Operating Direct Injection (DI) diesel engines with
(DI) Diesel Engines fuel sulfur levels over 1.0 percent may require short-
ened oil change intervals in order to help maintain ad-
The Total Base Number (TBN) for an oil depends on equate wear protection.
the fuel sulfur level. For direct injection engines that
use distillate fuel, the minimum TBN of the new oil
must be 10 times the fuel sulfur level. The TBN is Lubricant Viscosity Recommendations
defined by “ASTM D2896”. The minimum TBN of the
oil is 5 regardless of fuel sulfur level. Illustration 26 for Direct Injection (DI) Diesel Engines
demonstrates the TBN.
The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during cold
engine start-up, and the maximum ambient
temperature during engine operation.
Refer to table 22 (minimum temperature) in order to
determine the required oil viscosity for starting a cold
engine.
Refer to table 22 (maximum temperature) in order to
select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
48 SEBU7655-04
Maintenance Section
Lubricant Information

Generally, use the highest oil viscosity that is • Oil consumption

available to meet the requirement for the temperature
at start-up.
Re-refined Basestock Oils
Table 22
Engine Oil Viscosity Re-refined basestock oils are acceptable for use in
Caterpillar engines. The oils must meet the
Caterpillar DEO Ambient Temperature performance requirements that are specified by
Multigrade Caterpillar.
EMA LRG-1
API CH-4
Minimum Maximum
Re-refined basestock oils can be used exclusively in
API CG-4 finished oil or in a combination with new basestock
Viscosity Grade oils. The US military specifications and the
specifications of other heavy equipment
SAE 0W20 −40 °C (−40 °F) 10 °C (50 °F) manufacturers also allow the use of re-refined
basestock oils that meet the same criteria.
SAE 0W30 −40 °C (−40 °F) 30 °C (86 °F)
The process that is used to make re-refined
SAE 0W40 −40 °C (−40 °F) 40 °C (104 °F)
basestock oil should adequately remove all wear
SAE 5W30 −30 °C (−22 °F) 30 °C (86 °F) metals that are in the used oil and all additives that
are in the used oil. Vacuum distillation and the
SAE 5W40 −30 °C (−22 °F) 40 °C (104 °F) hydrotreating of the used oil are acceptable
processes that are used for producing re-refined
SAE 10W30 −20 °C (−4 °F) 40 °C (104 °F) base oil.
SAE 15W40 −9.5 °C (15 °F) 50 °C (122 °F) Note: Filtering is inadequate for the production of
high quality re-refined basestock oils from used oil.
Synthetic Base Stock Oils Cold Weather Lubricants
Synthetic base oils are acceptable for use in When an engine is started and an engine is operated
Caterpillar engines. The oils must meet the in ambient temperatures below −20 °C (−4 °F), use
performance requirements that are specified by multigrade oils that are capable of flowing in low
Caterpillar for the engine. temperatures.
Synthetic base oils generally perform better than These oils have lubricant viscosity grades of SAE 0W
conventional oils in the following two areas: or SAE 5W.
• Synthetic base oils have improved flow at low When an engine is started and operated in ambient
temperatures. temperatures below −30 °C (−22 °F), use a synthetic
base stock multigrade oil with a 0W viscosity grade or
• Synthetic base oils have improved oxidation with a 5W viscosity grade. Use an oil with a pour
stability. point that is lower than −50 °C (−58 °F).
Some synthetic base oils have performance The number of acceptable lubricants is limited in cold
characteristics that enhance the service life of the oil. weather conditions. Caterpillar recommends the
Caterpillar does not recommend the automatic following lubricants for use in cold weather
extension of oil drain intervals for any type of oil. conditions:
Oil drain intervals for Caterpillar engines can only be First Choice – Use an oil with an EMA LRG-1
adjusted for a longer service interval after an oil Recommended Guideline or use a CH-4 oil that is
analysis program that contains the following data: API licensed with an SAE 0W20, SAE 0W30, SAE
0W40, SAE 5W30 or SAE 5W40 lubricant viscosity
• Oil condition, oil contamination, and wear metal grade. A CG-4 oil that is API licensed with an SAE
analysis (Caterpillar S·O·S Services oil analysis) 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE
5W40 lubricant viscosity grade may also be used. A
• Trend analysis CF-4 oil that is API licensed with an SAE 0W20, SAE
0W30, SAE 0W40, SAE 5W30, or SAE 5W40
lubricant viscosity grade may also be used.
• Fuel consumption

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

CG-4, or CF-4 additive package although the oil has
not been tested for the requirements of the API
license. The oil must have an SAE 0W20, SAE
0W30, SAE 0W40, SAE 5W30 or SAE 5W40
lubricant viscosity grade.
SEBU7655-04 49
Maintenance Section
Lubricant Information

Note: Some greases may not be used with other

NOTICE
Shortened engine service life could result if second greases. When a commercial grease is used, ensure
choice oils are used. that the grease is compatible with the grease that is
currently used in the system. If the commercial
grease is not compatible, the system must be
purged. If any questions arise concerning the
Aftermarket Oil Additives compatibility of a grease, consult the supplier.
Caterpillar does not recommend the use of
aftermarket additives in oil. It is not necessary to use Multipurpose Greases
aftermarket additives in order to achieve the engine's
maximum service life or rated performance. Fully Multipurpose Lithium Complex Grease
formulated, finished oils consist of base oils and of
commercial additive packages. These additive (MPGL)
packages are blended into the base oils at precise
percentages in order to help provide finished oils with Multipurpose Lithium Complex Grease (MPGL) is a
performance characteristics that meet industry general purpose lithium complex grease for medium-
standards. duty applications. This product has good
characteristics at high temperatures such as a
There are no industry standard tests that evaluate dropping point of 260 °C (500 °F). MPGL contains
the performance or the compatibility of aftermarket unleaded extreme pressure additives, antiwear
additives in finished oil. Aftermarket additives may inhibitors, and corrosion inhibitors that provide extra
not be compatible with the finished oil's additive protection in the following applications:
package, which could lower the performance of the
finished oil. The aftermarket additive could fail to mix • Construction
with the finished oil. This could produce sludge in the
crankcase. Caterpillar discourages the use of • Agricultural
aftermarket additives in finished oils.
• Automotive
To achieve the best performance from a Caterpillar
engine, conform to the following guidelines: MPGL meets the requirements for extended service
intervals of automotive chassis points. MPGL also
• Select the proper Caterpillar oil or a commercial meets the requirements for extended service
oil that meets the Caterpillar recommendations. intervals of wheel bearings with disc brakes in
automobiles, in vans and in light trucks. This product
• See the appropriate “Lubricant Viscosities” table in meets the NLGI certification of “GC-LB”. MPGL is
order to find the correct oil viscosity grade for your also available in a NLGI No. 2 grade. Normal
engine. operating temperatures for this product are
−28 to 149 °C (−18 to 300 °F). This product is also
• At the specified interval, service the engine available as a white lithium complex grease.
compartment. Use new oil and install a new oil
filter. Multipurpose Lithium Complex Grease
• Perform maintenance at the intervals that are
with Molybdenum (MPGM)
specified in the Operation and Maintenance
Multipurpose Lithium Complex Grease with
Manual, “Maintenance Interval Schedule”. Molybdenum (MPGM) is a general purpose lithium
complex grease that is used for light-duty
Lubricating Grease applications and for medium-duty applications. The
MPGM is available in the following grades: NLGI No.
Caterpillar provides greases in order to cover a 2 grade and NLGI No. 0 grade. The MPGM is
variety of applications and extreme temperature strengthened with a molybdenum disulfide and a
conditions. Consult your Caterpillar dealer for part polymer for extra lubrication and protection. MPGM
numbers and for available sizes of containers. contains unleaded additives. MPGM also contains
antiwear inhibitors, rust inhibitors, and corrosion
inhibitors that are for protection and lubrication in
many environments. The MPGM is formulated with a
base fluid that has high viscosity.
The MPGM has the following features:
• Increased protection against water washout
• Increased retention

• Resistance to heavy loads

50 SEBU7655-04
Maintenance Section
Lubricant Information

This product is recommended for heavily loaded pin This product meets the NLGI certification of “GC-LB”.
joints and for journal bearings. This product meets Normal operating temperatures for this product are
the certification of “GC-LB”. Normal operating −40 to 204°C (−40 to 400°F).
temperatures for this product are −28 to 149 °C
(−18 to 300 °F) for the NLGI No. 0 grade. Normal Caterpillar Premium Grease (CPG)
operating temperatures for this product are
−18 to 149 °C (0 to 300 °F) for the NLGI No. 2 grade.
Desert Gold (CPG)
Note: If MPGM is not available, use a multipurpose
type grease which contains three to five percent Desert Gold is a heavy-duty, premium synthetic
molybdenum. grease that is developed for the most extreme
operating environments. This grease is formulated
with the following characteristics: high viscosity
Special Purpose Grease (SPG) synthetic base fluid, polymers, molybdenum disulfide,
high viscosity index and high dropping point.
Bearing Lubricant (SPG)
Desert Gold will protect equipment against heavy
Bearing Lubricant (SPG) is available in a NLGI No. 2 shock loads. Desert Gold protects against corrosion
grade with a polyurea thickener. This grease is in extreme heat, in moist conditions, or in dusty
recommended for high temperature antifriction conditions. This product has excellent characteristics
bearings in the following applications: electric starting of adhesion and of stability. Desert Gold provides
motors, alternators, fan drives and generators. The longer protection than other greases. Desert Gold is
Bearing Lubricant (SPG) has an effective operating an environmentally friendly grease which does not
range of −29 to 177 °C (−20 to 350 °F). contain the following materials: antimony, sulfur,
barium, zinc, lead and phosphorous materials.
Water and Temperature Resistant Grease Normal operating temperatures are −6 to 230 °C
(21 to 450 °F). Desert Gold can operate at higher
(WTR) temperatures for short time periods. Desert Gold has
additional extreme pressure protection for highly
The Water and Temperature Resistant Grease is loaded pin joints.
designed for use whenever the following conditions
are a concern: water washout, severe corrosion and Arctic Platinum (CPG)
high operating temperatures. The Water and
Temperature Resistant Grease provides extreme
pressure protection, antiwear protection, rust Arctic Platinum is a super-premium extreme pressure
protection and corrosion protection. The Water and lubricating grease that is developed for lubrication in
Temperature Resistant Grease is an environmentally temperatures that are below zero to moderate
friendly grease which does not contain the following operating temperatures. Arctic Platinum is available
materials: antimony, sulfur, barium, zinc, lead and in grades 000, 00, 0, 1, and 2. These grades ensure
phosphorous materials. The Water and Temperature the pumpability in central lube systems in a variety of
Resistant Grease has excellent shear stability. Water ambient temperatures from −60 to 18 °C
and Temperature Resistant Grease can also resist (−76 to 65 °F). Arctic Platinum has a high dropping
breakdown in the presence of water. The Water and point. Arctic Platinum contains a five percent
Temperature Resistant Grease works well in the concentrate of molybdenum disulfide for protection
following applications: against extra heavy loads. Arctic Platinum provides
excellent corrosion protection and rust protection.
• Construction Arctic Platinum is an environmentally friendly grease
which does not contain the following materials:
• Agricultural antimony, sulfur, barium, zinc and phosphorous.

• Automotive
• Industrial

• Marine
SEBU7655-04 51
Maintenance Section
Fluid Recommendations

Arctic Platinum is designed for lubrication for long life For more information, see Special Publication,
of the following components: horizontal pivot PEDP7036, “S·O·S Fluid Analysis”. Consult your
bearings, lower link bearings, steering cylinders, Caterpillar dealer for complete information and
kingbolt bearings, upper hitch link bearings and assistance about the program.
ejector carrier roller bearings. This grease is extra
tacky for retention on excavator carbody bearings. i07435390
Arctic Platinum has additional extreme pressure
protection for highly loaded pin joints.
Fluid Recommendations
S·O·S Oil Analysis (Fuel Recommendations)
SMCS Code: 1280; 1348; 1395; 7560
Caterpillar recommends the use of the S·O·S oil
analysis program in order to monitor the condition Diesel engines have the ability to burn a wide variety
and the maintenance requirements of the equipment. of fuels. These fuels are divided into two general
The S·O·S oil analysis program will complement the groups. The two groups are called the preferred fuels
preventive maintenance program. and the permissible fuels.
The S·O·S oil analysis is a diagnostic tool that is The preferred fuels provide maximum engine service
used to determine oil performance and component life and performance. The preferred fuels are
wear rates. Contamination can be identified and distillate fuels. These fuels are commonly called
measured through the use of the S·O·S oil analysis. diesel fuel, furnace fuel, gas oil, or kerosene.
The S·O·S oil analysis includes the following tests:
The permissible fuels are crude oils or blended fuels.
• The Wear Rate Analysis monitors the wear of the Use of these fuels can result in higher maintenance
engine's metals. The amount of wear metal and costs and in reduced engine service life.
type of wear metal that is in the oil is analyzed.
The increase in the rate of engine wear metal in Diesel fuels that meet the specifications in Table 24
the oil is as important as the quantity of engine will help to provide maximum engine service life and
wear metal in the oil. For this reason, regular performance. In North America, diesel fuel that is
sampling at specified intervals is necessary in identified as No. 1-D or No. 2-D in “ASTM D975”
order to establish wear rates. Intermittent generally meet the specifications. Table 24 is for
sampling does not allow wear rate trend lines to diesel fuels that are distilled from crude oil. Diesel
fuels from other sources could exhibit detrimental
be established. Engine wear metals in the oil properties that are not defined or controlled by this
sample are compared to established Caterpillar specification.
norms in order to determine acceptability. Table 24
• Tests are conducted in order to detect 3054C Specifications for Distillate Diesel Fuel
contamination of the oil by water, glycol or fuel.
Specifications Requirements ASTM
• The Oil Condition Analysis determines the loss of Test
the oil's lubricating properties. An infrared analysis Aromatics 35% maximum “D1319”
is used to compare the properties of new oil to the
Ash 0.02% maximum (weight) “D482”
properties of the used oil sample. This analysis
allows technicians to determine the amount of Carbon Residue on 0.35% maximum (weight) “D524”
deterioration of the oil during use. This analysis 10% Bottoms
also allows technicians to verify the performance
Cetane Number 45 minimum “D613”
of the oil according to the specification during the
entire oil change interval. The cloud point must not ex- -
Cloud Point ceed the lowest expected am-
The test results of the oil samples will then be used bient temperature.
as a basis for determining the oil change interval for
the engine. The results of the S·O·S oil analysis may Copper Strip No. 3 maximum “D130”
allow the engine to operate longer between oil Corrosion
changes without the risk of engine damage. 10% at 282 °C (540 °F) “D86”
Table 23 maximum
Distillation
S·O·S Oil Analysis Interval 90% at 360 °C (680 °F)
maximum
Compartment Interval
Flash Point legal limit “D93”
Engine crankcase Every 250 Service Hours

(continued)
52 SEBU7655-04
Maintenance Section
Fuel Recommendations

(Table 24, contd) In the USA, 0.05 percent diesel fuels have been used
in all on-highway truck engines since January 1,
3054C Specifications for Distillate Diesel Fuel
1994. This low sulfur diesel fuel was mandated as a
Specifications Requirements ASTM means of directly reducing particulate emissions from
Test diesel truck engines. This low sulfur fuel, will also be
used in Caterpillar commercial diesel engines when
30 minimum “D287” low emissions are required or when the sources of
API Gravity
45 maximum
the fuel provide this type of fuel. Caterpillar has not
seen any detrimental effects with 0.05 percent sulfur
6 °C (10 °F) minimum below “D97” fuel in Caterpillar diesel engines.
Pour Point
ambient temperature

3% maximum “D3605” NOTICE

Sulfur (1) or
Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel
“D1552”
must NOT be used in Caterpillar diesel engines (ex-
cept in 3600 Series HFO engines). Severe compo-
Kinematic Viscosity 1.4 cSt minimum and 20.0 cSt “D445” nent wear and component failures will result if HFO
(2) maximum at 40 °C (104 °F) type fuels are used in engines that are configured to
use distillate fuel.
Water and 0.1% maximum “D1796”
Sediment
Water 0.1% maximum “D1744” In extreme cold ambient conditions, you may use the
distillate fuels that are specified in Table 24 .
Sediment 0.05% maximum (weight) “D473” However, the fuel that is selected must meet the
requirements that are specified in Table 24 . These
Gum and Resins (3) 10 mg per 100 mL maximum “D381” fuels are, intended to be used in operating
3100 g minimum “D6078” temperatures that are down to −54 °C (−65 °F).
Table 25
0.45 mm (0.018 inch) maxi-
Lubricity (4) mum at 60 °C (140 °F) Distillate Fuels (1)
“D6079”
0.38 mm (0.015 inch) maxi- Specification Grade
mum at 25 °C (77 °F)
“MIL-T-5624R” JP-5
(1) Caterpillar fuel systems and engine components can operate
on high sulfur fuels. Fuel sulfur levels affect exhaust emissions. “ASTM D1655” Jet-A-1
High sulfur fuels also increase the potential for corrosion of in-
ternal components. Fuel sulfur levels above 1.0 percent may “MIL-T-83133D” JP-8
significantly shorten the oil change interval. For additional infor- (1) The fuels that are listed in this Table may not meet the require-
mation, see this publication, “Engine Oil” topic (Maintenance ments that are specified in the “Caterpillar Specifications for
Section). Distillate Diesel Fuel” Table. Consult the supplier for the recom-
(2) The values of the fuel viscosity are the values as the fuel is de- mended additives in order to maintain the proper fuel lubricity.
livered to the fuel injection pumps. If a fuel with a low viscosity
is used. Cooling of the fuel may be required to maintain a 1.4 These fuels are lighter than the No. 2 grade fuels.
cSt viscosity at the fuel injection pump. Fuels with a high vis-
cosity might require fuel heaters to bring down the viscosity to a
The cetane number of the fuels in Table 24 must be
20 cSt viscosity. For additional information, see Special Publi-
at least 40. If the viscosity is below 1.4 cSt at 38 °C
cation, SEBD0717, “Diesel Fuel and Your Engine”. (100 °F), use the fuel only in temperatures below
(3) Follow the test conditions and procedures for gasoline (motor). 0 °C (32 °F). Do not use any fuels with a viscosity of
(4) The lubricity of a fuel is a concern with low sulfur fuel. To deter- less than 1.2 cSt at 38 °C (100 °F). Fuel cooling may
mine the lubricity of the fuel, use either the “ASTM D6078 be required to maintain the minimum viscosity of 1.4
Scuffing Load Wear Test (SBOCLE)” or the “ASTM D6079 High cSt at the fuel injection pump.
Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a
fuel does not meet the minimum requirements, consult your fuel
supplier. Do not treat the fuel without consulting the fuel suppli-
There are many other diesel fuel specifications that
er. Some additives are not compatible. These additives can are published by governments and by technological
cause problems in the fuel system. societies. Usually, those specifications do not review
all the requirements that are addressed in this
specification. To ensure optimum engine
NOTICE performance, a complete fuel analysis should be
Operating with fuels that do not meet Caterpillar's obtained before engine operation. The fuel analysis
recommendations can cause the following effects: should include all the properties that are listed in
starting difficulty, poor combustion, deposits in the Table 24 . For more information on diesel fuels, refer
fuel injectors, reduced service life of the fuel system, to Caterpillar Commercial Diesel Engine Fluids
deposits in the combustion chamber and reduced Recommendations, SEBU6251.
service life of the engine.
SEBU7655-04 53
Maintenance Section
Maintenance Interval Schedule

i05180760 “ Engine Air Cleaner Element (Dual Element) - Clean/

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Maintenance Interval Schedule “ Engine Air Cleaner Element (Single Element) -
SMCS Code: 1000; 7500 Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
“ Engine Oil and Filter - Change” . . . . . . . . . . . . . . 72
When Required
“ Fuel System Primary Filter (Water Separator)
“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 77
“ Battery or Battery Cable - Disconnect” . . . . . . . . 58 “ Fuel System Secondary Filter - Replace” . . . . . . 78
“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 “ Hoses and Clamps - Inspect/Replace” . . . . . . . . . .
“ Engine Air Cleaner Element (Dual Element) - Clean/ “ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
“ Engine Air Cleaner Element (Single Element) - Every 1000 Service Hours
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
“ Engine Valve Lash - Inspect/Adjust” . . . . . . . . . . 75
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 76
Every 2000 Service Hours
Daily
“ Aftercooler Core - Inspect” . . . . . . . . . . . . . . . . . . 55
“ Alternator and Fan Belts - Inspect/Adjust/Replace”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 “ Alternator - Inspect” . . . . . . . . . . . . . . . . . . . . . . . 56

“ Cooling System Coolant Level - Check” . . . . . . . 62 “ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 86

“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . 65 “ Water Pump - Inspect” . . . . . . . . . . . . . . . . . . . . . . .

“ Engine Air Cleaner Service Indicator - Inspect” . . . Every 2000 Service Hours or 1 Year
“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 71
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 71
“ Fuel System Primary Filter/Water Separator - Drain”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Every 2000 Service Hours or 2
“Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 86 Years
Every 50 Service Hours or Weekly “ Cooling System Coolant Extender (ELC) - Add”
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
“ Fuel Tank Water and Sediment - Drain” . . . . . . . . .
Every 3000 Service Hours
Every 250 Service Hours or 6 “ Fuel Injection Nozzles - Test/Exchange” . . . . . . . 75
Months
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 71 Every 3000 Service Hours or 2
Years
Every 500 Service Hours “ Cooling System Coolant (DEAC) - Change” . . . . . .
“ Cooling System Supplemental Coolant Additive
(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Every 500 Service Hours or 6

Months
“ Engine Protective Devices - Check” . . . . . . . . . . . .

Every 500 Service Hours or 1 Year

“ Battery Electrolyte Level - Check” . . . . . . . . . . . . . .
54 SEBU7655-04
Maintenance Section
Maintenance Interval Schedule

“ Cooling System Water Temperature Regulator -

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Every 4000 Service Hours

“ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . . 55

Every 6000 Service Hours or 3

Years
“ Cooling System Coolant (ELC) - Change” . . . . . 60

Overhaul
“ Engine Crankcase Breather - Clean” . . . . . . . . . . 70
“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . 83
SEBU7655-04 55
Maintenance Section
Aftercooler Core - Clean/Test

i02322260

Aftercooler Core - Clean/Test Personal injury can result from air pressure.
SMCS Code: 1064-070; 1064-081 Personal injury can result without following prop-
er procedure. When using pressure air, wear a
1. Remove the core. Refer to the OEM information for protective face shield and protective clothing.
the correct procedure.
Maximum air pressure at the nozzle must be less
2. Turn the aftercooler core upside-down in order to than 205 kPa (30 psi) for cleaning purposes.
remove debris.
8. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
Personal injury can result from air pressure. 9. Inspect the core in order to ensure cleanliness.
Pressure test the core. If necessary, repair the
Personal injury can result without following prop- core.
er procedure. When using pressure air, wear a
protective face shield and protective clothing. 10. Install the core. Refer to the OEM information for
the correct procedure.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes. 11. After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the
3. Pressurized air is the preferred method for removal of debris and drying of the core. Stop the
removing loose debris. Direct the air in the engine. Use a light bulb behind the core in order to
opposite direction of the fan's air flow. Hold the inspect the core for cleanliness. Repeat the
nozzle approximately 6 mm (.25 inch) away from cleaning, if necessary.
the fins. Slowly move the air nozzle in a direction
that is parallel with the tubes. This will remove i02322295
debris that is between the tubes.
4. Pressurized water may also be used for cleaning.
Aftercooler Core - Inspect
The maximum water pressure for cleaning SMCS Code: 1064-040
purposes must be less than 275 kPa (40 psi). Use
pressurized water in order to soften mud. Clean Note: Adjust the frequency of cleaning according to
the core from both sides. the effects of the operating environment.
Inspect the aftercooler for these items: damaged fins,
NOTICE corrosion, dirt, grease, insects, leaves, oil and other
Do not use a high concentration of caustic cleaner to debris. Clean the aftercooler, if necessary.
clean the core. A high concentration of caustic
cleaner can attack the internal metals of the core and For air-to-air aftercoolers, use the same methods that
cause leakage. Only use the recommended concen- are used for cleaning radiators.
tration of cleaner.

5. Back flush the core with a suitable cleaner.

Personal injury can result from air pressure.
6. Steam clean the core in order to remove any
residue. Flush the fins of the aftercooler core. Personal injury can result without following prop-
Remove any other trapped debris. er procedure. When using pressure air, wear a
protective face shield and protective clothing.
7. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water. Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.

After cleaning, start the engine and accelerate the

engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine. Use
a light bulb behind the core in order to inspect the
core for cleanliness. Repeat the cleaning, if
necessary.
56 SEBU7655-04
Maintenance Section
Alternator - Inspect

Inspect the fins for damage. Bent fins may be opened

with a “comb”.

Note: If parts of the aftercooler system are repaired

or replaced, a leak test is highly recommended.
Inspect these items for good condition: Welds,
mounting brackets, air lines, connections, clamps
and seals. Make repairs, if necessary.

i02676048

Alternator - Inspect
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection of Illustration 27 g01003936
the alternator. Inspect the alternator for loose Typical example
connections and proper battery charging. Inspect the (1) 144-0235 Belt Tension Gauge
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or Install the belt tension gauge (1) at the center of the
proper performance of the electrical system. Make longest free length and check the tension. The
repairs, as required. correct tension is 535 N (120 lb). If the tension of the
belt is below 250 N (56 lb) adjust the belt to 535 N
Check the alternator and the battery charger for
proper operation. If the batteries are properly (120 lb).
charged, the ammeter reading should be very near If twin belts are installed, check and adjust the
zero. All batteries should be kept charged. The tension on both belts.
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will Adjustment
not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time or
if the engine is run for short periods, the batteries
may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.

i03706461

Alternator and Fan Belts -

Inspect/Adjust/Replace
SMCS Code: 1357-039

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
Illustration 28 g01995054
additional load on the new belt could cause the new
belt to break. Typical example
If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose 1. Loosen The alternator pivot bolt (2) and the link
belts may slip enough to cause overheating. bolt (3).

To accurately check the belt tension, 144-0235 Belt

Tension Gauge should be used.
SEBU7655-04 57
Maintenance Section
Battery - Replace

2. Move the alternator in order to increase or Note: Always recycle a battery. Never discard a
decrease the belt tension. Tighten the alternator battery. Return used batteries to an appropriate
pivot bolt and the link bolt to 22 N·m (16 lb ft).(1). recycling facility.

6. Remove the used battery.

Replacement
7. Install the new battery.
Refer to the Disassembly and Assembly Manual for
the installation procedure and the removal procedure Note: Before the cables are connected, ensure that
for the belt. the key start switch is OFF.

i06738473 8. Connect the cable from the starting motor to the

POSITIVE “+” battery terminal.
Battery - Replace 9. Connect the cable from the ground plane to the
SMCS Code: 1401-510 NEGATIVE “-” battery terminal.

i07419560

Batteries give off combustible gases which can Battery Electrolyte Level -
explode. A spark can cause the combustible
gases to ignite. This can result in severe personal Check
injury or death. SMCS Code: 1401-535
Ensure proper ventilation for batteries that are in When the engine has not run for long or short periods
an enclosure. Follow the proper procedures in or- of time, the batteries may not fully recharge. Ensure a
der to help prevent electrical arcs and/or sparks full charge to help prevent the battery from freezing.
near batteries. Do not smoke when batteries are
serviced. In warmer climates, check the electrolyte level more
frequently.
Ensure that the electrolyte level is 13 mm (0.5 inch)
above the top of the separators.
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
can burn the skin and clothing. Always wear a
Removing the battery cables or the batteries with face shield and protective clothing when working
the cover in place may cause a battery explosion on or near batteries.
resulting in personal injury.

1. Remove the filler caps. Maintain the electrolyte

Note: Always recycle a battery. Never discard a level to the “FULL” mark on the battery.
battery. Return used batteries to an appropriate
recycling facility. If the addition of water is necessary, use distilled
water. If distilled water is not available, use clean
1. Turn the key start switch to the OFF position. water that is low in minerals. Do not use artificially
Remove the key and all electrical loads. softened water.
2. Turn OFF the battery charger. Disconnect the 2. Check the condition of the electrolyte with the
charger. 245-5829 Coolant Battery Tester Refractometer.
3. Turn battery isolator switch to OFF position. 3. Keep the batteries clean.
4. The NEGATIVE “-” cable connects the NEGATIVE Clean the battery case with one of the following
“-” battery terminal to the ground plane. cleaning solutions:
Disconnect the cable from the NEGATIVE “-”
battery terminal. • A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
5. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the starting motor. • A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
Disconnect the cable from the POSITIVE “+” (1 qt) of clean water
battery terminal.
58 SEBU7655-04
Maintenance Section
Battery or Battery Cable - Disconnect

Thoroughly rinse the battery case with clean 5. Use a fine grade of sandpaper to clean the
water. terminals and the cable clamps. Clean the items
Use the 1U-9921 Battery Service Tool to clean until the surfaces are bright or shiny. DO NOT
the battery terminals. Use a wire brush to clean remove material excessively. Excessive removal
the cable clamps. Clean the items until the of material can cause the clamps to not fit
surfaces are bright or shiny. DO NOT remove correctly. Coat the clamps and the terminals with a
material excessively. Excessive removal of suitable silicone lubricant or petroleum jelly.
material can cause the clamps to fit improperly.
Coat the clamps and the terminals with the Loctite 6. Tape the cable connections in order to help
®
product listed below, petroleum jelly or MPGM. prevent accidental starting.
• For Americas North - Loctite LB8632 7. Proceed with necessary system repairs.

• For Europe and Africa, Middle East, CIS 8. In order to connect the battery, connect the
(AMEC) - Loctite LB8104 positive connection before the negative connector.

• For Asia Pacific - Loctite LB8801 i05793911

• For Americas South - Loctite LB Superlube Cooling System Coolant

For ordering the products listed above, go to the (DEAC) - Change
following address.
SMCS Code: 1350-070; 1395-044
http://www.loctite.com/en/meta/meta-nav/ Clean the cooling system and flush the cooling
location-selector.html system before the recommended maintenance
interval if the following conditions exist:
i02323088
• The engine overheats frequently.
Battery or Battery Cable - • Foaming is observed.
Disconnect
• The oil has entered the cooling system and the
SMCS Code: 1402-029 coolant is contaminated.

• The fuel has entered the cooling system and the

coolant is contaminated.
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
NOTICE
tery cover should be removed before any servic- Use of commercially available cooling system
ing is attempted. cleaners may cause damage to cooling system com-
ponents. Use only cooling system cleaners that are
Removing the battery cables or the batteries with
approved for Caterpillar engines.
the cover in place may cause a battery explosion
resulting in personal injury.
Note: Inspect the water pump and the water
1. Turn the start switch to the OFF position. Turn the temperature regulator after the cooling system has
ignition switch (if equipped) to the OFF position been drained. This procedure is a good opportunity
and remove the key and all electrical loads. to replace the water pump, the water temperature
regulator, and the hoses, if necessary.
2. Disconnect the negative battery terminal. Ensure
that the cable cannot contact the terminal. When Drain
four 12 volt batteries are involved, two negative
connection must be disconnected.
3. Remove the positive connection.
Pressurized System: Hot coolant can cause seri-
4. Clean all disconnected connection and battery ous burns. To open the cooling system filler cap,
terminals. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
SEBU7655-04 59
Maintenance Section
Cooling System Coolant (DEAC) - Change

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

NOTICE
Loosen the cooling system filler cap slowly in Improper or incomplete rinsing of the cooling system
order to relieve any pressure. Remove the cooling can result in damage to copper and other metal
system filler cap. components.
2. Open the cooling system drain valve (if equipped). To avoid damage to the cooling system, make sure to
If the cooling system is not equipped with a drain completely flush the cooling system with clear water.
valve, remove one of the drain plugs. Continue to flush the system until all signs of the
cleaning agent are gone.
Note: If equipped, be sure to drain the heater and
any related supply and return lines.
5. Stop the engine and allow the engine to cool.
Allow the coolant to drain. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
NOTICE system filler cap. Open the drain valve (if
Dispose of used engine coolant properly or recycle. equipped) or remove the cooling system drain
Various methods have been proposed to reclaim plugs. Allow the water to drain. Flush the cooling
used coolant for reuse in engine cooling systems.
The full distillation procedure is the only method ac- system with clean water. If equipped, be sure to
ceptable by Caterpillar to reclaim the used coolant. flush the heater and any related supply and return
lines. Close the drain valve (if equipped). Clean
the drain plugs. Install the drain plugs. Refer to the
For information regarding the disposal and the Specifications Manual, SENR3130, “Torque
recycling of used coolant, consult your Cat dealer or
consult Cat Dealer Service Tool Group: Specifications” for more information on the proper
torques.
Outside Illinois 1-800-542-TOOL
Inside Illinois 1-800-541-TOOL Cooling Systems with Heavy
Canada 1-800-523-TOOL
Deposits or Plugging
Flush Note: For the following procedure to be effective,
there must be some active flow through the cooling
1. Flush the cooling system with clean water in order system components.
to remove any debris.
1. Flush the cooling system with clean water in order
2. Close the drain valve (if equipped). Clean the drain
to remove any debris.
plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, “Torque Note: If equipped, be sure to flush the heater and
Specifications” for more information on the proper any related supply and return lines.
torques.
2. Close the drain valve (if equipped). Clean the drain
NOTICE plugs. Install the drain plugs. Refer to the
Fill the cooling system no faster than 19 L (5 US gal) Specifications Manual, SENR3130, “Torque
per minute to avoid air locks. Specifications” for more information on the proper
torques.
3. Fill the cooling system with a mixture of clean
water and Cat Quick Flush cooling system cleaner. NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
Refer to the directions for the cleaner. For per minute to avoid air locks.
additional information on cooling system cleaners,
refer to the One Safe Source catalog. Install the
cooling system filler cap. 3. Fill the cooling system with a mixture of clean
water and Cat Fast Acting Cooling System
4. Start and run the engine at low idle for a minimum Cleaner. Add 0.5 L (1 pt) of cleaner per
of 30 minutes. The coolant temperature should be 3.8 to 7.6 L (1 to 2 US gal) of the cooling system
at least 82 °C (180 °F). capacity. Install the cooling system filler cap.
4. Start and run the engine at low idle for a minimum
of 90 minutes. The coolant temperature should be
at least 82 °C (180 °F).
60 SEBU7655-04
Maintenance Section
Cooling System Coolant (ELC) - Change

4. Clean the cooling system filler cap. Inspect the

NOTICE
Improper or incomplete rinsing of the cooling system gasket that is on the cooling system filler cap. If
can result in damage to copper and other metal the gasket that is on the cooling system filler cap is
components. damaged, discard the cap and install a new
cooling system filler cap. If the gasket that is on
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water. the cooling system filler cap is not damaged,
Continue to flush the system until all signs of the perform a pressure test. A 9S-8140 Pressurizing
cleaning agent are gone. Pump is used to perform the pressure test. The
correct pressure for the cooling system filler cap is
stamped on the face of the cooling system filler
5. Stop the engine and allow the engine to cool.
cap. If the cooling system filler cap does not retain
Loosen the cooling system filler cap slowly in
the correct pressure, install a new cooling system
order to relieve any pressure. Remove the cooling
filler cap.
system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain 5. Start the engine. Inspect the cooling system for
plugs. Allow the water to drain. Flush the cooling leaks and for proper operating temperature.
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain i03292691
plugs. Refer to the Specifications Manual,
SENR3130, “Torque Specifications” for more Cooling System Coolant (ELC)
information on the proper torques. - Change
Fill SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
NOTICE system before the recommended maintenance
Fill the cooling system no faster than 19 L (5 US gal) interval if the following conditions exist:
per minute to avoid air locks.
• The engine overheats frequently.

1. Fill the cooling system with coolant/antifreeze. • Foaming is observed.

Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic • The oil has entered the cooling system and the
coolant is contaminated.
(Maintenance Section) for more information on
cooling system specifications. Do not install the • The fuel has entered the cooling system and the
cooling system filler cap. coolant is contaminated.
2. Start and run the engine at low idle. Increase the Note: When the cooling system is cleaned, only
engine rpm to 1500 rpm. Run the engine at high clean water is needed when the ELC is drained and
idle for 1 minute in order to purge the air from the replaced.
cavities of the engine block. Stop the engine.
Note: Inspect the water pump and the water
3. Check the coolant level. Maintain the coolant level temperature regulator after the cooling system has
within 13 mm (0.5 inch) below the bottom of the been drained. This is a good opportunity to replace
pipe for filling. Maintain the coolant level within the water pump, the water temperature regulator and
13 mm (0.5 inch) to the proper level on the sight the hoses, if necessary.
glass (if equipped).
Drain

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
SEBU7655-04 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).
plugs. Allow the water to drain. Flush the cooling
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. For the proper torque, refer to the
Specifications Manual, SENR3130, “Torque
NOTICE Specifications”.
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim
used coolant for reuse in engine cooling systems. Fill
The full distillation procedure is the only method ac-
ceptable by Caterpillar to reclaim the used coolant. NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tool 1. Fill the cooling system with Extended Life Coolant
Group: (ELC). See Special Publication, SEBU6385,
“Caterpillar On-highway Diesel Truck Engine
Outside Illinois 1-800-542-TOOL
Inside Illinois 1-800-541-TOOL Fluids Recommendations” for more information on
Canada 1-800-523-TOOL cooling system specifications. Do not install the
cooling system filler cap.
Flush 2. Start and run the engine at low idle for 5 minutes.
Then, increase the engine rpm to high idle. Run
1. Flush the cooling system with clean water in order the engine at high idle for one minute in order to
to remove any debris. purge the air from the cavities of the engine block.
Note: If equipped, be sure to flush the heater and 3. Check the coolant level. Maintain the coolant level
any related supply and return lines. within 13 mm (0.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
2. Close the drain valve (if equipped). Clean the drain 13 mm (0.5 inch) to the proper level on the sight
plugs. Install the drain plugs. For the proper glass (if equipped).
torque, refer to the Specifications Manual,
SENR3130, “Torque Specifications”. 4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
NOTICE the gasket that is on the cooling system filler cap is
Fill the cooling system no faster than 19 L (5 US gal) damaged, discard the old cooling system filler cap
per minute to avoid air locks. and install a new cooling system filler cap. If the
gasket that is on the cooling system filler cap is not
3. Fill the cooling system with clean water. Install the damaged, use a 9S-8140 Pressurizing Pump in
cooling system filler cap. order to pressure test the cooling system filler cap.
The correct pressure for the cooling system filler
4. Start and run the engine at low idle until the
cap is stamped on the face of the cooling system
temperature reaches 49 to 66 °C (120 to 150 °F).
filler cap. If the cooling system filler cap does not
retain the correct pressure, install a new cooling
system filler cap.
62 SEBU7655-04
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.
Be prepared to collect the fluid with suitable contain-
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
i03699519
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
the coolant is hot, the hose can come off causing Engines With a Coolant Recovery
burns. Tank
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes. Note: The cooling system may not have been
provided by Caterpillar. The procedure that follows is
for typical cooling systems. Refer to the OEM
information for the correct procedures.
Check the coolant level when the engine is stopped
and cool.
1. Observe the coolant level in the coolant recovery
tank. Maintain the coolant level to “COLD FULL”
mark on the coolant recovery tank.
SEBU7655-04 63
Maintenance Section
Cooling System Coolant Level - Check

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.

2. Loosen filler cap slowly in order to relieve any

pressure. Remove the filler cap.
3. Pour the correct coolant mixture into the tank.
Refer to the Operation and Maintenance Manual,
“Refill Capacities” for information on the correct
mixture and type of coolant. Refer to the Operation Illustration 30 g00285520
and Maintenance Manual, “Refill Capacities” for Cooling system filler cap
the cooling system capacity. Do not fill the coolant
recovery tank above “COLD FULL” mark.

Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.

1. Remove the cooling system filler cap slowly in

order to relieve pressure.
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the correct level in the sight glass.
Illustration 29 g00103639
3. Clean the cooling system filler cap and inspect the
gasket. If the gasket is damaged, discard the old
4. Clean filler cap and the receptacle. Reinstall the
filler cap and install a new filler cap. If the gasket is
filler cap and inspect the cooling system for leaks.
not damaged, use a suitable pressurizing pump in
Note: The coolant will expand as the coolant heats order to pressure test the filler cap. The correct
up during normal engine operation. The additional pressure is stamped on the face of the filler cap. If
volume will be forced into the coolant recovery tank the filler cap does not retain the correct pressure,
during engine operation. When the engine is stopped install a new filler cap.
and cool, the coolant will return to the engine.

Engines Without a Coolant

Recovery Tank
Check the coolant level when the engine is stopped
and cool.
64 SEBU7655-04
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

4. Inspect the cooling system for leaks. • Glycol Concentration

i02456600
• Concentration of SCA

• pH
Cooling System Supplemental
Coolant Additive (SCA) - Test/ • Conductivity

Add The results are reported, and recommendations are

made according to the results. Consult your
SMCS Code: 1352-045; 1395-081 Caterpillar dealer for information on the benefits of
managing your equipment with an S·O·S Coolant
Analysis.

Cooling system coolant additive contains alkali. Level 2

To help prevent personal injury, avoid contact
with the skin and the eyes. Do not drink cooling This level coolant analysis is recommended when the
system coolant additive. engine is overhauled. Refer to this Operations and
Maintenance Manual, “Overhaul Considerations” for
further information.
Note: Test the concentration of the Supplemental
Coolant Additive (SCA) or test the SCA concentration Add the SCA, If Necessary
as part of an S·O·S Coolant Analysis.
NOTICE
Test for SCA Concentration Do not exceed the recommended amount of supple-
mental coolant additive concentration. Excessive
supplemental coolant additive concentration can form
Coolant and SCA deposits on the higher temperature surfaces of the
cooling system, reducing the engine's heat transfer
NOTICE characteristics. Reduced heat transfer could cause
Do not exceed the recommended six percent supple- cracking of the cylinder head and other high tempera-
mental coolant additive concentration. ture components. Excessive supplemental coolant
additive concentration could also result in radiator
Use the 8T-5296 Coolant Conditioner Test Kit or tube blockage, overheating, and/or accelerated water
use the 4C-9301 Coolant Conditioner Test Kit in pump seal wear. Never use both liquid supplemental
order to check the concentration of the SCA. Refer to coolant additive and the spin-on element (if
this Operation and Maintenance Manual, “Refill equipped) at the same time. The use of those addi-
Capacities and Recommendations” for more tives together could result in supplemental coolant
information. additive concentration exceeding the recommended
maximum.
Water and SCA

NOTICE
Do not exceed the recommended eight percent sup-
plemental coolant additive concentration. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
Test the concentration of the SCA with the 8T-5296 stop the engine and wait until the cooling system
Coolant Conditioner Test Kit. Refer to the Special components are cool. Loosen the cooling system
Publication, SEBU6251, “Caterpillar Commercial pressure cap slowly in order to relieve the
Diesel Engine Fluids Recommendations” for more pressure.
information.
1. Slowly loosen the cooling system filler cap in order
S·O·S Coolant Analysis to relieve the pressure. Remove the cooling
system filler cap.
S·O·S coolant samples can be analyzed at your
Caterpillar dealer. S·O·S Coolant Analysis is a Note: Always discard drained fluids according to
program that is based on periodic samples. local regulations.
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
following items are tested: space for the extra SCA.
SEBU7655-04 65
Maintenance Section
Cooling System Water Temperature Regulator - Replace

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

NOTICE
Special Publication, SEBU6251, “Caterpillar Failure to replace your water temperature regulator
Commercial Diesel Engines Fluids on a regularly scheduled basis could cause severe
Recommendations” for more information on SCA engine damage.
requirements.
Caterpillar engines incorporate a shunt design cool-
4. Clean the cooling system filler cap. Inspect the ing system and require operating the engine with a
gaskets of the cooling system filler cap. If the water temperature regulator installed.
gaskets are damaged, replace the old cooling If the water temperature regulator is installed incor-
system filler cap with a new cooling system filler rectly, the engine may overheat, causing cylinder
cap. Install the cooling system filler cap. head damage. Ensure that the new water tempera-
ture regulator is installed in the original position. En-
i03645060 sure that the water temperature regulator vent hole is
open.
Cooling System Water Do not use liquid gasket material on the gasket or cyl-
Temperature Regulator - inder head surface.

Replace
Refer to two articles in the Disassembly and
SMCS Code: 1355-510 Assembly Manual, “Water Temperature Regulators -
Remove and Water Temperature Regulators - Install”
Replace the water temperature regulator before the for the replacement procedure of the water
water temperature regulator fails. This is a temperature regulator, or consult your Caterpillar
recommended preventive maintenance practice. dealer.
Replacing the water temperature regulator reduces
the chances for unscheduled downtime. Refer to this Note: If only the water temperature regulators are
Operation and Maintenance Manual, “Maintenance replaced, drain the coolant from the cooling system
Interval Schedule” for the proper maintenance
interval. to a level that is below the water temperature
regulator housing.
A water temperature regulator that fails in a partially
opened position can cause overheating or i00174798
overcooling of the engine.
A water temperature regulator that fails in the closed Driven Equipment - Check
position can cause excessive overheating. Excessive SMCS Code: 3279-535
overheating could result in cracking of the cylinder
head or piston seizure problems. Refer to the OEM specifications for more information
on the following maintenance recommendations for
A water temperature regulator that fails in the open the driven equipment:
position will cause the engine operating temperature
to be too low during partial load operation. Low • Inspection
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the • Adjustment
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear of • Lubrication
the cylinder liner.
• Other maintenance recommendations
Perform any maintenance for the driven equipment
which is recommended by the OEM.
66 SEBU7655-04
Maintenance Section
Engine - Clean

i02708606 i04404720

Engine - Clean Engine Air Cleaner Element

SMCS Code: 1000-070 (Dual Element) - Clean/Replace
SMCS Code: 1054-510; 1054-037

Personal injury or death can result from high NOTICE

voltage. Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
Moisture can create paths of electrical cleaner element. Do not use air cleaner elements
conductivity. with damaged pleats, gaskets or seals. Dirt entering
the engine causes premature wear and damage to
Make sure that the electrical system is OFF. Lock engine components. Air cleaner elements help to pre-
out the starting controls and tag the controls “ DO vent airborne debris from entering the air inlet.
NOT OPERATE”” .

NOTICE
NOTICE Never service the air cleaner element with the engine
Accumulated grease and oil on an engine is a fire running since this will allow dirt to enter the engine.
hazard. Keep the engine clean. Remove debris and
fluid spills whenever a significant quantity accumu-
lates on the engine. Servicing the Air Cleaner Elements
If the air cleaner element becomes plugged, the air
NOTICE can split the material of the air cleaner element.
Failure to protect some engine components from Unfiltered air will drastically accelerate internal
washing may make your engine warranty invalid. Al- engine wear. Your Caterpillar dealer has the proper
low the engine to cool for one hour before washing air cleaner elements for your application. Consult
the engine. your Caterpillar dealer for the correct air cleaner
element.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated • Check the precleaner (if equipped) daily for
oil and grease. A clean engine provides the following accumulation of dirt and debris. Remove any dirt
benefits: and debris, as needed.
• Easy detection of fluid leaks • Operating conditions (dust, dirt, and debris) may
require more frequent service of the air cleaner
• Maximum heat transfer characteristics
element.
• Ease of maintenance
• The air cleaner element may be cleaned up to six
Note: Caution must be used in order to prevent times if the element is properly cleaned and
electrical components from being damaged by inspected.
excessive water when the engine is cleaned. When a
• The air cleaner element should be replaced at
pressure washer or steam cleaner is used to clean
least one time per year. This replacement should
the engine, a minimum distance of 300 mm (12 inch)
be performed regardless of the number of
must be maintained between the components of the
cleanings.
engine and the jet nozzle of the pressure washer or
steam cleaner. Pressure washers and steam Replace the dirty paper air cleaner elements with
cleaners should not be directed at any electrical clean air cleaner elements. Before installation, the air
connectors or the junction of cables into the rear of cleaner elements should be thoroughly checked for
the connectors. Avoid electrical components such as tears and/or holes in the filter material. Inspect the
the alternator and the starter. Protect the fuel gasket or the seal of the air cleaner element for
injection pump from fluids in order to wash the damage. Maintain a supply of suitable air cleaner
engine. elements for replacement purposes.
SEBU7655-04 67
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

Dual Element Air Cleaners 7. Reset the air cleaner service indicator.
The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner
Cleaning the Primary Air Cleaner
element. The primary air cleaner element can be Elements
used up to six times if the element is properly
cleaned and inspected. The primary air cleaner
element should be replaced at least one time per NOTICE
year. This replacement should be performed Caterpillar recommends certified air filter cleaning
regardless of the number of cleanings. services that are available at Cat dealers. The Cat
cleaning process uses proven procedures to assure
The secondary air cleaner element is not serviceable consistent quality and sufficient filter life.
or washable. The secondary air cleaner element
should be removed and discarded for every three Observe the following guidelines if you attempt to
cleanings of the primary air cleaner element. When clean the filter element:
the engine is operating in environments that are Do not tap or strike the filter element in order to re-
dusty or dirty, air cleaner elements may require more move dust.
frequent replacement.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets,
or seals. Dirt entering the engine will cause damage
to engine components.

The primary air cleaner element can be used up to

six times if the element is properly cleaned and
inspected. When the primary air cleaner element is
cleaned, check for rips or tears in the filter material.
Illustration 31 g00736431
The primary air cleaner element should be replaced
(1) Cover at least one time per year. This replacement should
(2) Primary air cleaner element be performed regardless of the number of cleanings.
(3) Secondary air cleaner element
(4) Turbocharger air inlet
Use clean primary air cleaner elements while dirty
elements are being cleaned.
1. Remove the cover. Remove the primary air cleaner
element. NOTICE
Do not clean the air cleaner elements by bumping or
2. The secondary air cleaner element should be tapping. This could damage the seals. Do not use el-
removed and discarded for every three cleanings ements with damaged pleats, gaskets or seals. Dam-
of the primary air cleaner element. aged elements will allow dirt to pass through. Engine
damage could result.
Note: Refer to “Cleaning the Primary Air Cleaner
Elements”.
Visually inspect the primary air cleaner elements
3. Cover the turbocharger air inlet with tape in order before cleaning. Inspect the air cleaner elements for
to keep out dirt. damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth. There are two common methods that are used to
clean primary air cleaner elements:
5. Remove the tape for the turbocharger air inlet.
Install the secondary air cleaner element. Install a • Pressurized air
primary air cleaner element that is new or cleaned. • Vacuum cleaning
6. Install the air cleaner cover.
68 SEBU7655-04
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

Pressurized Air Inspecting the Primary Air Cleaner

Pressurized air can be used to clean primary air
Elements
cleaner elements that have not been cleaned more
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).

Illustration 33 g00281693

Inspect the clean, dry primary air cleaner element.

Illustration 32 g00281692 Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
Note: When the primary air cleaner elements are element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears and/
cleaned, always begin with the clean side (inside) in
or holes. Inspect the primary air cleaner element for
order to force dirt particles toward the dirty side light that may show through the filter material. If it is
(outside). necessary in order to confirm the result, compare the
primary air cleaner element to a new primary air
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent cleaner element that has the same part number.
damage to the paper pleats. Do not aim the stream of Do not use a primary air cleaner element that has
air directly at the primary air cleaner element. Dirt any tears and/or holes in the filter material. Do not
could be forced further into the pleats. use a primary air cleaner element with damaged
pleats, gaskets, or seals. Discard damaged primary
Note: Refer to “Inspecting the Primary Air Cleaner
air cleaner elements.
Elements”.

Vacuum Cleaning Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes
Vacuum cleaning is a good method for cleaning inspection will not be used, the primary air cleaner
primary air cleaner elements which require daily element can be stored for future use.
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not
remove deposits of carbon and oil.
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
SEBU7655-04 69
Maintenance Section
Engine Air Cleaner Element (Single Element) - Replace

Illustration 35 g00109823
(1) Air cleaner element. (2) Clamp.

1. Loosen clamp (2) which fastens air cleaner

element (1) to the air inlet. Remove the dirty air
cleaner element and clamp.
Illustration 34 g02595738
2. Install clamp (2) on new air cleaner element (1).
Typical example
3. Install new air cleaner element (1) to the air inlet
Do not use paint, a waterproof cover, or plastic as a and tighten clamp (2). Refer to the Operation and
protective covering for storage. An airflow restriction Maintenance Manual for more information on
may result. To protect against dirt and damage, wrap torque specifications.
the primary air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
i06103548
Place the primary air cleaner element into a box for
storage. For identification, mark the outside of the Engine Air Cleaner Service
box and mark the primary air cleaner element.
Include the following information: Indicator - Inspect
• Date of cleaning (If Equipped)
SMCS Code: 7452-040
• Number of cleanings
Some engines may be equipped with a different
Store the box in a dry location. service indicator.

i00619873
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
Engine Air Cleaner Element that is measured before and after the air cleaner
(Single Element) - Replace element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
SMCS Code: 1051; 1054-510 equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
NOTICE
Never service the air cleaner element with the engine The service indicator may be mounted on the clean
running since this will allow dirt to enter the engine. side of the air cleaner housing or in a remote
location.
70 SEBU7655-04
Maintenance Section
Engine Crankcase Breather - 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).

i03701661

Engine Crankcase Breather -

Clean
SMCS Code: 1317-070

NOTICE
Keep all parts clean from contaminants.
Illustration 36 g00103777
Contaminants may cause rapid wear and shortened
Typical service indicator component life.
Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element
should be replaced when one of the following NOTICE
conditions occur: Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
• The yellow diaphragm enters the red zone. nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
• The red piston locks in the visible position. ers before opening any compartment or disassem-
bling any component containing fluids.
Test the Service Indicator Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
Service indicators are important instruments. suitable to collect and contain fluids on Caterpillar
products.
• Check for ease of resetting. The service indicator
should reset in less than three pushes. Dispose of all fluids according to local regulations
and mandates.
• Check the movement of the service indicator core
when the engine is run at full load speed. The core
should latch approximately at the greatest vacuum NOTICE
that is attained. Make sure that the components of the breather as-
sembly are installed correctly. Engine damage may
If the service indicator does not reset easily, or if the occur if the breather assembly is not working
core does not latch at the greatest vacuum, the properly.
service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be plugged. 1. The diaphragm for the crankcase breather can be
If necessary, replace the service indicator more inspected and cleaned. For the correct procedure
frequently in environments that are severely dusty. to remove the diaphragm, refer to Disassembly
Replace the service indicator annually regardless of and Assembly, “Crankcase Breather - Remove
the operating conditions. Replace the service and Install”. For the correct procedure to install the
indicator when the engine is overhauled, and diaphragm, refer to Disassembly and Assembly,
whenever major engine components are replaced. “Crankcase Breather - Remove and Install”.

Note: The canister for the crankcase breather is an

nonserviceable component. Damage to the canister
may occur if the lid of the canister is removed in order
to clean the element. Damage to the canister may
occur if the element is removed. The canister should
be exchanged if the lubricating oil becomes
contaminated. The canister should be replaced at an
overhaul of the engine.
SEBU7655-04 71
Maintenance Section
Engine Mounts - Inspect

i03699562
NOTICE
Operating your engine when the oil level is above the
Engine Mounts - Inspect “FULL” mark could cause your crankshaft to dip into
SMCS Code: 1152-040 the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oil's lubricating char-
Inspect the engine mounts for deterioration and for acteristics and could result in the loss of power.
proper bolt torque. Engine vibration can be caused
by the following conditions: 2. Remove the oil filler cap and add oil, if necessary.
• Improper mounting of the engine Clean the oil filler cap. Install the oil filler cap.

• Deterioration of the engine mounts i04237495

• Loose engine mounts Engine Oil Sample - Obtain

Any engine mount that shows deterioration should be SMCS Code: 1000-008; 1348-554-SM; 7542-554-
replaced. Refer to the Specifications Manual, OC; 7542-554-SM
SENR3130, “Torque Specifications”. Refer to your
Caterpillar dealer for more information. In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
i03699581 analysis at regularly scheduled intervals. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
Engine Oil Level - Check
SMCS Code: 1348-535-FLV Obtain the Sample and the
Analysis
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.

Before you take the oil sample, complete the Label,

PEEP5031 for identification of the sample. In order to
help obtain the most accurate analysis, provide the
following information:
• Engine model

• Service hours on the engine

• The number of hours that have accumulated since
the last oil change
• The amount of oil that has been added since the
last oil change
Illustration 37 g01165836
(Y) “Min” mark. (X) “Max” mark.
To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, mixed oil sample.

NOTICE To avoid contamination of the oil samples, the tools

Perform this maintenance with the engine stopped. and the supplies that are used for obtaining oil
samples must be clean.

1. Maintain the oil level between “Min” mark (Y) and Caterpillar recommends using the sampling valve in
“Max” mark (X) on oil level gauge (1). Do not fill order to obtain oil samples. The quality and the
the crankcase above “Max” mark (X). 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.
72 SEBU7655-04
Maintenance Section
Engine Oil and Filter - Change

The 169-8373 Fluid Sampling Bottle is Drain the Engine Oil

recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.

If the engine is not equipped with a sampling valve,

use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable Illustration 38 g01003623
tubing must be attached to the pump for insertion into Typical example
the sump.
For instructions, see Special Publication, PEGJ0047, After the engine has been run at the normal
“How To Take A Good S·O·S Oil Sample”. Consult operating temperature, stop the engine. Use one of
your Cat dealer for complete information and the following methods to drain the engine crankcase
assistance in establishing an S·O·S program for your oil:
engine.
• If the engine is equipped with a drain valve, turn
the drain valve knob counterclockwise in order to
i03701760
drain the oil. After the oil has drained, turn the
drain valve knob clockwise in order to close the
Engine Oil and Filter - Change drain valve.
SMCS Code: 1318-510; 1348-044
• If the engine is not equipped with a drain valve,
remove the oil drain plug (1) in order to allow the
oil to drain. If the engine is equipped with a
shallow sump, remove the bottom oil drain plugs
Hot oil and hot components can cause personal from both ends of the oil pan.
injury. Do not allow hot oil or hot components to
contact the skin. After the oil has drained, the oil drain plugs should be
cleaned and installed. If necessary, renew the O ring
Do not drain the oil when the engine is cold. As the oil seal on the drain plug.
cools, suspended waste particles settle on the
bottom of the oil pan. The waste particles are not Some types of oil pans have oil drain plugs that are
removed with the draining cold oil. Drain the on both sides of the oil pan, because of the shape of
crankcase with the engine stopped. Drain the the pan. This type of oil pan requires the engine oil to
crankcase with the oil warm. This draining method be drained from both plugs.
allows the waste particles that are suspended in the
oil to be drained properly.
Replace the Spin-on Oil Filter
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through NOTICE
the engine lubrication system with the new oil. Caterpillar oil filters are built to Caterpillar specifica-
tions. Use of an oil filter not recommended by Cater-
pillar could result in severe engine damage to the
engine bearings, crankshaft, etc., as a result of the
larger waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recom-
mended by Caterpillar.

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

Wrench.
SEBU7655-04 73
Maintenance Section
Engine Oil and Filter - Change

Note: The following actions can be carried out as 5. Install the oil filter. Tighten the oil filter by hand
part of the preventive maintenance program. according to the instructions that are shown on the
oil filter. Do not overtighten the oil filter.
2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount of
Replace the Element for the Oil
metal debris in the oil filter may indicate early wear Filter
or a pending failure.
NOTICE
Use a magnet to differentiate between the ferrous Caterpillar oil filters are built to Caterpillar specifica-
metals and the nonferrous metals that are found in tions. Use of an oil filter not recommended by Cater-
the oil filter element. Ferrous metals may indicate pillar could result in severe engine damage to the
wear on the steel and cast iron parts of the engine. engine bearings, crankshaft, etc., as a result of the
larger waste particles from unfiltered oil entering the
Nonferrous metals may indicate wear on the
engine lubricating system. Only use oil filters recom-
aluminum parts, brass parts or bronze parts of the
mended by Caterpillar.
engine. Parts that may be affected include the
following items: main bearings, rod bearings,
turbocharger bearings and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter.

Illustration 40 g01003662
Typical example
(1) Drain plug
(2) Square hole
(3) Filter bowl
Illustration 39 g01003628
Typical example 1. Place a suitable container under the oil filter.
(2) Filter head Remove the drain plug (1) and the seal, from the
(3) O ring seal oil filter.

3. Clean the sealing surface of the oil filter head (2). 2. Locate a suitable wrench into the square hole (2)
Ensure that the union (not shown) in the oil filter in order to remove the filter bowl (3).
head is secure. 3. Remove the filter bowl (3) and remove the element
4. Apply clean engine oil to the O ring seal (3) on the from the filter bowl. Clean the filter bowl.
oil filter. 4. Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the
NOTICE oil filter for metal debris. An excessive amount of
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami- metal debris in the oil filter may indicate early wear
nated. Contaminated oil can cause accelerated wear or a pending failure.
to engine components.
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.
74 SEBU7655-04
Maintenance Section
Engine Protective Devices - Check

Nonferrous metals may indicate wear on the

aluminum parts, brass parts or bronze parts of the NOTICE
If equipped with an auxiliary oil filter system or a re-
engine. Parts that may be affected include the mote oil filter system, follow the OEM or filter manu-
following items: main bearings, rod bearings, facturer's recommendations. Under filling or
turbocharger bearings and cylinder heads. overfilling the crankcase with oil can cause engine
Due to normal wear and friction, it is not damage.
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order to
arrange for a further analysis if an excessive NOTICE
amount of debris is found in the oil filter. To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.

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

for two minutes. Perform this procedure in order to
ensure that the lubrication system has oil and that
the oil filters are filled. Inspect the oil filter for oil
leaks.
3. Stop the engine and allow the oil to drain back to
the sump for a minimum of ten minutes.

Illustration 41 g01003675
Typical example
(4) O ring seal
(5) Element
(6) Filter head

5. Install a new O ring (4) onto the filter bowl and Illustration 42 g00998024
lubricate the O ring with clean engine oil. Install (Y) “ADD” mark. (X) “FULL” mark.
the filter element (5) into the filter bowl.
4. Remove the oil level gauge in order to check the oil
NOTICE level. Maintain the oil level between the “ADD” and
Do not fill the oil filters with oil before installing them. “FULL” marks on the oil level gauge.
This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear
to engine components. i05264151

6. Install the filter bowl into the oil filter head (6).
Engine Protective Devices -
Tighten the filter bowl to the following torque Check
25 N·m (18 lb ft). SMCS Code: 7400-535
7. Install a new seal onto the drain plug (1) and install Alarms and shutoffs must function properly. Alarms
the drain plug into the oil filter. Tighten the drain provide timely warning to the operator. Shutoffs help
plug to the following torque 12 N·m (8 lb ft). to prevent damage to the engine. Determining if the
engine protective devices are in good working order
Note: Some engines may have a horizontally during normal operation is impossible. Malfunctions
mounted oil filter. This oil filter has a drain plug that is must be simulated in order to test the engine
located in the oil filter head. protective devices.
A calibration check of the engine protective devices
Fill the Engine Crankcase will ensure that the alarms and shutoffs activate at
the setpoints. Ensure that the engine protective
1. Remove the oil filler cap. Refer to Operation and devices are functioning properly.
Maintenance Manual for more information on refill
capacities and lubricant specifications.
SEBU7655-04 75
Maintenance Section
Engine Valve Lash - Inspect/Adjust

Refer to Systems Operation, Testing and Adjusting,

NOTICE “Engine Valve Lash - Inspect/Adjust” for more
During testing, abnormal operating conditions must
be simulated. information.

The tests must be performed correctly in order to pre- i00626014

vent possible damage to the engine.
Fuel Injection Nozzles - Test/
To prevent damage to the engine, only authorized Exchange
service personnel or your Cat dealer should perform
the tests. SMCS Code: 1254-081; 1254-013

Visual Inspection
Visually check the condition of all gauges, sensors, Fuel leaked or spilled onto hot surfaces or electri-
and wiring. Look for wiring and components that are cal components can cause a fire.
loose, broken, or damaged. Damaged wiring or
components should be repaired or replaced
immediately. NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
i03701660 clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Engine Valve Lash - Inspect/
Adjust Fuel injection nozzles are subject to tip wear. Tip
wear is a result of fuel contamination. Tip wear can
SMCS Code: 1102-025 cause the following problems:
This maintenance is recommended by Caterpillar as • Increased fuel consumption
part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine • Black smoke
life.
• 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 Injection nozzles should be cleaned, inspected,
Bridge Adjustment” article or consult your Caterpillar tested, and replaced, if necessary. Refer to Special
dealer for the complete valve lash adjustment Instruction, SEHS7292 for using the 8S-2245
procedure. Injection Cleaning Tool Group. Consult your
Caterpillar dealer about cleaning the fuel injection
Operation of Caterpillar engines with improper valve nozzle and testing the fuel injection nozzle.
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage NOTICE
and/or shortened engine component life. 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- The following items are symptoms of a malfunction of
vent possible injury, do not use the starting motor the fuel injection nozzle:
to turn the flywheel.
• Abnormal engine operation
Hot engine components can cause burns. Allow
additional time for the engine to cool before • Smoke emission
measuring/adjusting valve lash clearance.
• Engine knock
Ensure that the engine is stopped before measuring Each fuel injection nozzle must be isolated one at a
the valve lash. To obtain an accurate measurement, time in order to determine the malfunctioning fuel
allow the valves to cool before this maintenance is injection nozzle.
performed.
1. Start the engine.
76 SEBU7655-04
Maintenance Section
Fuel System - Prime

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.
3. A defective fuel injection nozzle may be identified
when a fuel line nut is loosened and the following
conditions are present:

• The exhaust smoke is partially eliminated or

the exhaust smoke is completely eliminated.

• Engine performance is not affected.

A fuel injection nozzle that is suspected of being Illustration 43 g01003929
defective should be removed. A new fuel injection
nozzle should be installed in the cylinder in order Typical example
to determine if the removed fuel injection nozzle is
defective. 2. Crank the engine with the throttle lever in the
CLOSED position until the engine starts.
Removal and Installation of the Note: If necessary, loosen the union nuts (1) on the
Fuel Injection Nozzles fuel injection lines at the connection with the fuel
injector until fuel is evident. Stop cranking the engine.
For the removal and the installation of fuel injection Tighten the union nuts (1) to a torque of 30 N·m
nozzles, special tooling is required. Refer to the (22 lb ft).
Service Manual for more information. Consult your
Caterpillar dealer for assistance. 3. Start the engine and run the engine at idle for one
minute.
i03701682
NOTICE
Fuel System - Prime Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
SMCS Code: 1258-548 minutes before cranking the engine again.
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be 4. Cycle the throttle lever from the low idle position to
started. Air can enter the fuel system when the the high idle position three times. The cycle time
following events occur: for the throttle lever is one second to six seconds
• The fuel tank is empty or the fuel tank has been for one complete cycle.
partially drained. Note: In order to purge air from the fuel injection
• The low pressure fuel lines are disconnected. pump on engines with a fixed throttle, the engine
should be run at full load for thirty seconds. The load
• A leak exists in the low pressure fuel system. should then be decreased until the engine is at high
idle. This should be repeated three times. This will
• The fuel filter is replaced. assist in removing trapped air from the fuel injection
pump.
Use the following procedure in order to remove air
from the fuel system: 5. Check for leaks in the fuel system.
1. Turn the keyswitch to the RUN position. Leave the
keyswitch in the RUN position for three minutes. If
a manual purging screw is installed, the purging
screw should be slackened during priming the fuel
system.
SEBU7655-04 77
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

i03701721 2. Place a suitable container under the water

separator. Clean the outside of the water
Fuel System Primary Filter separator.
(Water Separator) Element - 3. Open the drain (5). Allow the fluid to drain into the
Replace container.
SMCS Code: 1260-510-FQ; 1263-510-FQ 4. Tighten the drain (5) by hand pressure only.
5. Hold the element (2) and remove the screw (1).
Remove the element and the glass bowl (3) from
the base. Discard the old element.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent 6. Clean the glass bowl (4). Clean the bottom cover
possible injury, turn the start switch off when (6).
changing fuel filters or water separator elements.
Clean up fuel spills immediately. 7. Install the new O ring seal. Install the bottom cover
onto the new element. Install the assembly onto
the base.
NOTICE
Ensure that the engine is stopped before any servic- 8. Install the screw (1) and tighten the screw to a
ing or repair is performed. torque of 8 N·m (6 lb ft).
9. Remove the container and dispose of the fuel
safely.
10. Open the fuel supply valve.
11. Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime” for
more information.

i03701724

Fuel System Primary Filter/

Water Separator - Drain
SMCS Code: 1260-543; 1263-543

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
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
The water separator is not a filter. The water separa-
tor separates water from the fuel. The engine should
never be allowed to run with the water separator
Illustration 44 g01118416
more than half full. Engine damage may result.
Typical example
(1) Screw NOTICE
(2) Element The water separator is under suction during normal
(3) Glass bowl
(4) Sensor connection
engine operation. Ensure that the drain valve is tight-
(5) Drain ened securely to help prevent air from entering the
(6) Bottom cover fuel system.

1. Turn the fuel supply valve (if equipped) to the OFF

position.
78 SEBU7655-04
Maintenance Section
Fuel System Secondary Filter - Replace

i03701680

Fuel System Secondary Filter -

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
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.

Element filter
Turn the valves for the fuel lines (if equipped) to the
OFF position before performing this maintenance.
Place a tray under the fuel filter in order to catch any
Illustration 45 g01118416 fuel that might spill. Clean up any spilled fuel
immediately.
Typical example
(1) Screw
(2) Element
(3) Glass bowl
(4) Sensor connection
(5) Drain
(6) Bottom cover

1. Place a suitable container below the water

separator.
2. Open the drain (5). Allow the fluid to drain into the
container.
3. When clean fuel drains from the water separator
close the drain (5). Tighten the drain by hand
pressure only. Dispose of the drained fluid
correctly.

Illustration 46 g01010637
Typical example
(1) Drain
(2) Filter bowl

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

SEBU7655-04 79
Maintenance Section
Fuel System Secondary Filter - Replace

2. Clean the outside of the fuel filter assembly. Open 9. Open the valves for the fuel lines (if equipped).
the fuel drain (1) and drain the fuel into a suitable
container. Spin-on filter
Turn the valves for the fuel lines (if equipped) to the
OFF position before performing this maintenance.
Place a tray under the fuel filter in order to catch any
fuel that might spill. Clean up any spilled fuel
immediately.

Illustration 47 g01010595
Typical example
(3) O ring seal
(4) Element
(5) Filter head

3. Remove the filter bowl (2) from the filter head (5).
Press on the element (4). Rotate the element
counterclockwise in order to release the element
for the filter bowl and remove the element from the
bowl. Discard the used element.
Illustration 48 g01121396
4. Remove the O ring (3) from the filter bowl and
clean the filter bowl. Check that the threads of the Typical example
filter bowl are not damaged. (1) Filter Head
(2) Spin-on filter
5. Install a new O ring seal (3) to the filter bowl (2). (3) Drain

6. Locate a new filter element (4) into the filter bowl. 1. Clean the outside of the fuel filter assembly. Open
Press on the element and rotate the element the fuel drain (3) and drain the fuel into a suitable
clockwise in order to lock the element into the filter container.
bowl.
2. Use a suitable tool in order to remove the spin-on
7. Install the filter bowl (4) into the top of the filter filter (2) from the filter head (1).
head (5).
3. Ensure that the fuel drain (3) on the new spin-on
8. Tighten the filter bowl by hand until the filter bowl filter is closed.
contacts the filter head. Rotate the filter bowl
through 90 degrees.

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

80 SEBU7655-04
Maintenance Section
Fuel Tank Water and Sediment - Drain

Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel. The
fuel tank utilizes a fuel tank vent to prevent an air lock
or vacuum. Ensure that the vent is free of debris and
not damaged.

Drain the Water and the Sediment

Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Prepare to catch water and sediment in an
appropriate container. Connect a hose (if necessary)
Illustration 49 g01121723 to the valve prior to opening the valve.
Typical example Open the drain valve on the bottom of the fuel tank in
order to drain the water and the sediment. Close the
4. Lubricate the sealing ring (4) with clean fuel oil. drain valve.
5. Install the spin-on filter (2) into the top of the filter Note: Failure to close the drain properly could result
head (1). in fuel leakage, which could have detrimental results
to performance.
6. Tighten the spin-on filter by hand until the sealing
ring contacts the filter head. Rotate the spin-on Check the fuel daily. Drain the water and sediment
filter through 90 degrees. from the fuel tank after operating the engine. Drain
the water and sediment from the fuel tank after the
7. Prime the fuel system. Refer to Operation and fuel tank has been filled. Allow 5 to 10 minutes before
Maintenance Manual, “Fuel System - Prime”. performing this procedure.
Fill the fuel tank after operating the engine in order to
i06104305
drive out moist air. This procedure will help prevent
condensation. Do not fill the tank to the top. The fuel
Fuel Tank Water and Sediment expands as the fuel gets warm. The tank may
- Drain overflow.

SMCS Code: 1273-543-M&S Some fuel tanks use stand pipes that allow water and
sediment to settle below the end of the fuel stand
pipe. Some fuel tanks use supply lines that take fuel
NOTICE directly from the bottom of the tank. If the engine is
Care must be taken to ensure that fluids are con- equipped with this system, regular maintenance of
tained during performance of inspection, mainte- the fuel system filter is important.
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Fuel Storage Tanks
bling any component containing fluids.
Drain the water and the sediment from the fuel
Refer to Special Publication, NENG2500, “Cat Dealer storage tank during the following conditions:
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” • Weekly
for tools and supplies suitable to collect and contain
fluids on Cat products. • Refill of the tank
This procedure will help prevent water or sediment
Dispose of all fluids according to local regulations from being pumped from the storage tank into the
and mandates. engine fuel tank. A four micron(c) absolute filter for
the breather vent on the fuel tank is also
recommended.
SEBU7655-04 81
Maintenance Section
Hoses and Clamps - Inspect/Replace

If a bulk storage tank has been refilled or moved Inspect all clamps for the following conditions.
recently, allow adequate time for the sediment to Replace any clamp which exhibits signs of any of the
settle before filling the engine fuel tank. Internal following conditions.
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the • Cracking
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. • Looseness
• Damage
i06825542
Inspect all couplings for leaks. Replace any coupling
Hoses and Clamps - Inspect/ which exhibits signs of leaks.
Replace Each installation application can be different. The
SMCS Code: 7554-040; 7554-510 differences depend on the following factors:

Hoses and clamps must be inspected periodically • Type of hose

and replaced at the recommended interval to ensure
safe and continuous operation of the engine. Failure • Type of fitting material
to replace a fuel hose at the recommended change
interval may result in a hazardous situation. Take • Anticipated expansion and contraction of the hose
proper safety precautions before inspecting or
replacing hoses and clamps. • Anticipated expansion and contraction of the
fittings
Note: Always use a board or cardboard when the
engine components are checked for leaks. Leaking Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen
fluid that is under pressure can cause serious injury which can result in leaks. A constant torque hose
or possible death. Leaks that are the size of a pin clamp will help to prevent loose hose clamps.
hole are included. Refer to Operation and
Maintenance Manual, “General Hazard Information” Replace hoses that are cracked or soft. Replace
for more information. hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps
Note: Ensure that the hose is compatible with the that are cracked or damaged. Tighten or replace
application. hose clamps which are loose.

Inspect Tubes, Hoses, Bellows, and Replace the Hoses and the Clamps
Clamps
NOTICE
Inspect all tubes and hoses for leaks that are caused Care must be taken to ensure that fluids are con-
by the following conditions. Replace any tube or hose tained during performance of inspection, mainte-
which exhibits any of the following conditions. Failure nance, testing, adjusting, and repair of the product.
to replace a tube or hose which exhibits any of the Be prepared to collect the fluid with suitable contain-
following conditions may result in a hazardous ers before opening any compartment or disassem-
situation. bling any component containing fluids.

• Hoses which are cracked Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
• Hoses which are soft PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
• Outer covering that is chafed or cut fluids on Cat products.

• Exposed wire that is used for reinforcement Dispose of all fluids according to local regulations
and mandates.
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

• Exhaust bellows for leaks or damage

• Hoses which exhibit signs of leakage which are

not the result of loose couplings or clamps
82 SEBU7655-04
Maintenance Section
Hoses and Clamps - Inspect/Replace

Cooling System Fuel System

Pressurized System: Hot coolant can cause seri- Personal injury can result from removing hoses
ous burns. To open the cooling system filler cap, or fittings in a pressure system.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system Failure to relieve pressure can cause personal
pressure cap slowly in order to relieve the injury.
pressure.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.

Personal injury can result from removing hoses

or fittings in a pressure system.
Contact with high pressure fuel may cause fluid
Failure to relieve pressure can cause personal penetration and burn hazards. High pressure fuel
injury. spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
Do not disconnect or remove hoses or fittings un- structions may cause personal injury or death.
til all pressure in the system has been relieved.

1. Stop the engine. NOTICE

Do not bend or strike high pressure lines. Do not in-
2. Allow the engine to cool. stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
3. Before servicing a coolant hose, slowly loosen the hoses. Leaks can cause fires. Inspect all lines, tubes
filler cap for the cooling system to relieve any and hoses carefully. Tighten all connections to the
pressure. recommended torque.

4. Remove the filler cap for the cooling system.

NOTICE
5. Drain the coolant from the cooling system to a Do not allow dirt to enter the fuel system. Thoroughly
level that is below the hose that is being replaced. clean the area around a fuel system component that
Drain the coolant into a suitable clean container. will be disconnected. Fit a suitable cover over any
The coolant can be reused. disconnected fuel system components.
6. Remove the hose clamps.
Note: High-pressure fuel lines may be installed
7. Disconnect the old hose. between the high-pressure fuel pump and the fuel
8. Replace the old hose with a new hose. injectors. High-pressure fuel lines are constantly
charged with high pressure. Do not check the high-
9. Install hose clamps which have been inspected or pressure fuel lines with the engine or the starting
install new hose clamps. Refer to Specifications, motor in operation. Wait for 10 minutes after the
SENR3130, “Torque Specifications” “Hose engine stops before you perform any service or
Clamps” for information about selecting and repair on high-pressure fuel lines. Waiting for 10
installing the proper hose clamps. minutes will allow the pressure to be purged.

10. Refill the cooling system. 1. Drain the fuel from the fuel system to a level that is
below the hose that is being replaced.
11. Clean the coolant filler cap. Inspect the gaskets
on the filler cap. Inspect the gasket seat. Inspect 2. Remove the hose clamps.
the vacuum valve and seat for debris or damage.
3. Disconnect the old hose.
Replace the filler cap if the gaskets are damaged.
Install the filler cap. Note: When servicing fuel system, use cap/s or
12. Start the engine. Inspect the cooling system for cover/s as required to protect the system and
maintain fuel system cleanliness.
leaks.
4. Replace the old hose with a new hose.
SEBU7655-04 83
Maintenance Section
Overhaul Considerations

5. Install hose clamps which have been inspected or 4. Install hose clamps which have been inspected or
install new hose clamps. Refer to Specifications, install new hose clamps. Refer to Specifications,
SENR3130, “Torque Specifications” “Hose SENR3130, “Torque Specifications” “Hose
Clamps” for information about selecting and Clamps” for information about selecting and
installing the proper hose clamps. installing the proper hose clamps.
6. Carefully inspect the engine for any spilled fuel. Note: The bellows and the V-clamps that are used on
Make sure that no fuel remains on or close to the the exhaust bellows should never be reused.
engine.
5. Start the engine. Inspect the air lines for leaks.
Note: Fuel must be added to the fuel system ahead
of the fuel filter. i01515272

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

Maintenance Manual, “Fuel System - Prime” for
Overhaul Considerations
information about priming the engine with fuel. SMCS Code: 7595-043
8. Start the engine. Inspect the fuel system for leaks. Reduced hours of operation at full load will result in a
lower average power demand. A decreased average
Lubrication System power demand should increase both the engine
service life and the overhaul interval.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
Hot oil and hot components can cause personal The following factors are important when a decision
injury. Do not allow hot oil or hot components to is being made on the proper time for an engine
contact the skin. overhaul:

1. Drain the oil from the lubrication system to a level • The need for preventive maintenance
that is below the hose that is being replaced. • The quality of the fuel that is being used
2. Remove the hose clamps.
• The operating conditions
3. Disconnect the old hose.
• The results of the S·O·S analysis
4. Replace the old hose with a new hose.
5. Install hose clamps which have been inspected or Oil Consumption as an Overhaul
install new hose clamps. Refer to Specifications, Indicator
SENR3130, “Torque Specifications” “Hose
Clamps” for information about selecting and Oil consumption, fuel consumption, and maintenance
installing the proper hose clamps. information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
6. Refill the lubrication system. Refer to this consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
Operation and Maintenance Manual, “Engine Oil
for the maintenance intervals.
Level - Check” to ensure that the lubrication
system is filled with the proper amount of engine Oil consumption is in proportion to the percentage of
oil. the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
7. Start the engine. Inspect the lubrication system for consumed per hour also increases.
leaks.
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
Air System bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
1. Remove the hose clamps. dealer for assistance in determining the typical oil
2. Disconnect the old hose. consumption rate for your engine.

3. Replace the old hose with a new hose. When an engine's oil consumption has risen to three
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
84 SEBU7655-04
Maintenance Section
Overhaul Considerations

Overhaul Options Rebuild or Exchange

Before Failure Overhaul Cylinder Head Assembly, Oil Pump, and Fuel
Transfer Pump
A planned overhaul before failure may be the best
value for the following reasons: These components should be inspected according to
the instructions that are found in various Caterpillar
• Costly unplanned downtime can be avoided. reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
• Many original parts can be reused according to the needed for inspecting the engine parts.
standards for reusable parts.
If the parts comply with the established inspection
• The engine's service life can be extended without specifications that are expressed in the reusable
the risk of a major catastrophe due to engine parts guideline, the parts should be reused.
failure.
Parts that are not within the established inspection
• The best cost/value relationship per hour of specifications should be dealt with in one of the
extended life can be attained. following manners:

After Failure Overhaul • Salvaging

If a major engine failure occurs and the engine must • Repairing

be removed, many options are available. An overhaul
should be performed if the engine block or the • Replacing
crankshaft needs to be repaired.
Using out-of-spec parts can result in the following
If the engine block is repairable and/or the crankshaft problems:
is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine • Unscheduled downtime
with a similar exchange core.
• Costly repairs
This lower cost can be attributed to three aspects:
• Damage to other engine parts
• Specially designed Caterpillar engine features
• Reduced engine efficiency
• Caterpillar dealer exchange components
• Increased fuel consumption
• Caterpillar Inc. remanufactured exchange
components Reduced engine efficiency and increased fuel
consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing out-
Overhaul Recommendation of-spec parts or replacing out-of-spec parts.
To minimize downtime, Caterpillar Inc. recommends
a scheduled engine overhaul by your Caterpillar Inspection and/or Replacement
dealer before the engine fails. This will provide you
with the best cost/value relationship. Crankshaft Bearings and Crankshaft Seals

Note: Overhaul programs vary according to the The following components may not last until the
engine application and according to the dealer that second overhaul.
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available • Thrust bearings
overhaul programs and about overhaul services for • Main bearings
extending the engine life.
• Rod bearings
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the following • Crankshaft seals
maintenance recommendations.
Caterpillar Inc. recommends the installation of new
parts at each overhaul period.
Inspect these parts while the engine is disassembled
for an overhaul.
Inspect the crankshaft for any of the following
conditions:
SEBU7655-04 85
Maintenance Section
Overhaul Considerations

• Deflection Table 26
Hydrosolv Liquid Cleaners
• Damage to the journals
Part Number Description Size
• Bearing material that has seized to the journals
1U-5490 Hydrosolv 4165 19 L (5 US gal)
Check the journal taper and the profile of the
crankshaft journals. Check these components by 1U-5492 Hydrosolv 100 19 L (5 US gallon)
interpreting the wear patterns on the following
components:
4. Use steam to clean the oil cooler core. This
• Rod bearing removes any remaining residue from the cleaner.
Flush the fins of the oil cooler core. Remove any
• Main bearings other trapped debris.
Inspect the camshaft for damage to the journals and 5. Wash the oil cooler core with hot, soapy water.
to the lobes. Rinse the oil cooler core thoroughly with clean
Note: If the camshaft is removed for any reason, use water.
the magnetic particle inspection process to check for
cracks in the camshaft.
Inspect the following components for signs of wear or Personal injury can result from air pressure.
for signs of scuffing:
Personal injury can result without following prop-
• Camshaft bearings er procedure. When using pressure air, wear a
protective face shield and protective clothing.
• Lifters
Maximum air pressure at the nozzle must be less
Caterpillar Inc. recommends replacing the crankshaft than 205 kPa (30 psi) for cleaning purposes.
vibration damper.
6. Dry the oil cooler core with compressed air. Direct
Oil Cooler Core
the air in the reverse direction of the normal flow.
During an overhaul, Caterpillar Inc. recommends the 7. Inspect the components in order to ensure
removal of the oil cooler core. Clean the oil cooler
core. Then, pressure test the oil cooler core. cleanliness. The oil cooler core should be
pressure tested. Repair the oil cooler core, if
NOTICE necessary. Install the oil cooler core.
Do not use caustic cleaners to clean the core.
For more information about cleaning the cores,
Caustic cleaners can attack the internal metals of the consult your Caterpillar dealer.
core and cause leakage.
Obtain Coolant Analysis
Note: Use this cleaning procedure to clean the oil
The concentration of supplemental coolant additive
cooler core. (SCA) should be checked regularly with test kits or
with S·O·S Coolant Analysis (Level 1). Further
1. Remove the oil cooler core. coolant analysis is recommended when the engine is
2. Remove any debris from the oil cooler core. To overhauled.
remove debris from the oil cooler core, turn the oil For example, considerable deposits are found in the
cooler core onto one end. water jacket areas on the external cooling system,
but the concentrations of coolant additives were
3. Flush the oil cooler core internally with cleaner in carefully maintained. The coolant water probably
order to loosen foreign substances. This will also contained minerals that were deposited on the
help to remove oil from the oil cooler core. engine over time.

Note: Caterpillar Inc. recommends the use of A coolant analysis can be conducted in order to verify
Hydrosolv Liquid Cleaners. Table 26 lists the the condition of the water that is being used in the
Hydrosolv Liquid Cleaners that are available from cooling system. A full water analysis can be obtained
your Caterpillar dealer. by consulting your local water utility company or an
agricultural agent. Private laboratories are also
available for water analysis.
86 SEBU7655-04
Maintenance Section
Radiator - Clean

Caterpillar Inc. recommends an S·O·S Coolant Pressurized water may also be used for cleaning.
Analysis (Level 2). The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
S·O·S Coolant Analysis (Level 2) water in order to soften mud. Clean the core from
both sides.
An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely Use a degreaser and steam for removal of oil and
analyzes the coolant and the effects on the cooling grease. Clean both sides of the core. Wash the core
system. An S·O·S Coolant Analysis (Level 2) with detergent and hot water. Thoroughly rinse the
provides the following information: core with clean water.
After cleaning, start the engine and accelerate the
• Complete S·O·S Coolant Analysis (Level 1) engine to high idle rpm. This procedure will help in
the removal of debris and drying of the core. Stop the
• Visual inspection of properties engine. Use a light bulb behind the core in order to
• Identification of metal corrosion inspect the core for cleanliness. Repeat the cleaning,
if necessary.
• Identification of contaminants
Inspect the fins for damage. Bent fins may be opened
• Identification of built up impurities (corrosion and with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
scale)
clamps and seals. Make repairs, if necessary.
S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance i00651416
recommendations.
For more information about coolant analysis, see
Starting Motor - Inspect
your Caterpillar dealer. SMCS Code: 1451-040; 1453-040

i04020194
Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
Radiator - Clean
SMCS Code: 1353-070 Check the starting motor for proper operation. Check
the electrical connections and clean the electrical
connections. Refer to the Service Manual for more
Note: Adjust the frequency of cleaning according to information on the checking procedure and for
the effects of the operating environment. specifications or consult your Caterpillar dealer for
assistance.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil and other
i01185304
debris. Clean the radiator, if necessary.
Walk-Around Inspection
SMCS Code: 1000-040
Personal injury can result from air pressure.
Personal injury can result without following prop-
Inspect the Engine for Leaks and
er procedure. When using pressure air, wear a for Loose Connections
protective face shield and protective clothing.
A walk-around inspection should only take a few
The maximum air pressure for cleaning purposes minutes. When the time is taken to perform these
must be reduced to 205 kPa (30 psi) when the air checks, costly repairs and accidents can be avoided.
nozzle is deadheaded.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting
Pressurized air is the preferred method for removing the engine. Look for items such as oil leaks or
loose debris. Direct the air in the opposite direction of coolant leaks, loose bolts, worn belts, loose
the air flow. Hold the nozzle approximately 6 mm connections and trash buildup. Make repairs, as
(0.25 inch) away from the fins. Slowly move the air needed:
nozzle in a direction that is parallel with the tubes.
This movement will remove debris that is between • The guards must be in the proper place. Repair
the tubes. damaged guards or replace missing guards.
SEBU7655-04 87
Maintenance Section
Water Pump - Inspect

• Wipe all caps and plugs before the engine is • Inspect the ground strap for a good connection
serviced in order to reduce the chance of system and for good condition.
contamination.
• Inspect the ECM to the cylinder head ground strap
for a good connection and for good condition.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up
• Disconnect any battery chargers that are not
the fluid. If leaking is observed, find the source and
correct the leak. If leaking is suspected, check the flu- protected against the current drain of the starting
id levels more often than recommended until the leak motor. Check the condition and the electrolyte
is found or fixed, or until the suspicion of a leak is level of the batteries, unless the engine is
proved to be unwarranted. equipped with a maintenance free battery.
• Check the condition of the gauges. Replace any
NOTICE gauges that are cracked. Replace any gauge that
Accumulated grease and/or oil on an engine or deck can not be calibrated.
is a fire hazard. Remove this debris with steam clean-
ing or high pressure water. i05264233

• Ensure that the cooling lines are properly clamped

Water Pump - Inspect
and that the cooling lines are tight. Check for SMCS Code: 1361; 1361-040
leaks. Check the condition of all pipes.
A failed water pump might cause severe engine
• Inspect the water pumps for coolant leaks. overheating problems that could result in the
following conditions:
Note: The water pump seal is lubricated by coolant in
the cooling system. It is normal for a small amount of • Cracks in the cylinder head
leakage to occur as the engine cools down and the
• A piston seizure
parts contract.
Excessive coolant leakage may indicate the need to • Other potential damage to the engine
replace the water pump seal. For the removal of A failed water pump might cause severe engine
water pumps and the installation of water pumps and/ overheating problems. Overheating could result in
or seals, refer to the Service Manual for the engine or cracks in the cylinder head, a piston seizure, or other
consult your Caterpillar dealer. potential damage to the engine.
• Inspect the lubrication system for leaks at the front Visually inspect the water pump for leaks. If leaking
crankshaft seal, the rear crankshaft seal, the oil of the water pump seals is observed, replace all of
pan, the oil filters and the valve cover. the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump -
• Inspect the fuel system for leaks. Look for loose Disassemble and Water Pump - Assemble” for the
fuel line clamps or for loose fuel line tie-wraps. disassembly and assembly procedure. If necessary
to remove the water pump, refer to two articles in the
• Inspect the piping for the air inlet system and the Disassembly and Assembly Manual, “Water Pump -
elbows for cracks and for loose clamps. Ensure Remove and Water Pump - Install”.
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc. Inspect the water pump for wear, cracks, pin holes,
and proper operation. Refer to the Parts Manual for
• Inspect the alternator belt and the accessory drive the correct part numbers for your engine or consult
belts for cracks, breaks or other damage. your Cat dealer if repair is needed or replacement is
needed.
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.
88 SEBU7655-04
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
SEBU7655-04 89
Reference Information Section
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.
90 SEBU7655-04
Reference Information Section
Customer Service

Customer Service Europe, Africa, and Middle East

Caterpillar Overseas S.A.
76 Route de Frontenex
i07240427
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
Designated Compliance Officer Heavy-Duty and Phone: 81-3-5717-1150
Nonroad Engine Group 6403-J, Fax: 81-3-5717-1177
US Ave, NW, Washington,
DC 20460 Japan
Email address: [email protected]. 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 Fax: 81-3-5797-4359
problem is experienced.

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
SEBU7655-04 91
Reference Information Section
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

i07254661

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.
92 SEBU7655-04
Reference Information Section
Reference Materials

Reference Materials • Data Sheet, PEHP0002, “Cat Advanced 3Moly

Grease” NLGI grade 2
i02420633 • Data Sheet, NEHP6015, “Cat High Speed Ball
Bearing Grease” NLGI grade 2
Reference Material
• Special Publication, PEGJ0035, “Grease
SMCS Code: 1000 Selection Guide”
The following literature can be obtained through any
Caterpillar dealer. • Special Publication, PEHP6001, “How To Take A
Good Oil Sample”
Coolants • Special Publication, SEBD0640, “Oil and Your
Engine”
• Special Publication, SEBD0970, “Coolant and
Your Engine” • Special Publications, PEDP7036, “S·O·S Fluids
Analysis Cornerstone”
• Data Sheet, PEHJ0067, “Cat ELC (Extended Life
Coolant)” Miscellaneous
• Special Publication, SEBD0518, “Know Your Special Publication, PECP6026, “One Safe Source”
Cooling System” English language for use in NACD
• Special Publication, PEEP5027, “Label - ELC Special Publication, PECP6027, “One Safe Source”
Radiator Label” English language for use in COSA
• Data Sheet, PEHP7057, “S·O·S Coolant Analysis” Special Publication, PECP6028, “One Safe Source”
English language for use in non NACD and non
Fuels COSA

• Special Publication, SEBD0717, “Diesel Fuels and • Service Manual, SENR9595, “C-9 Industrial
Your Engine” Engine Service Manual”
• Special Publication, SEBU6251, “Caterpillar
Lubricants Commercial Diesel Engine Fluids
Recommendations For Lubricants, Diesel Fuel,
• Data Sheet, PEHJ0059, “Cat DEO (SAE 10W-30 and Coolants”
and SAE 15W-40)” Canada, Mexico, and the
United States • Service Manual, SENR9595, “C-9 Industrial
Engine Service Manual”
• Data Sheet, PEHJ0021, “Cat DEO (SAE 10W-30
and SAE 15W-40)” Worldwide except North • Special Publication, SEBU6251, “Caterpillar
America, Egypt, Saudi Arabia, and Brazil Commercial Diesel Engine Fluids
Recommendations For Lubricants, Diesel Fuel,
• Data Sheet, PEHJ0072, “Cat DEO (SAE 10W-30 and Coolants”
and SAE 15W-40)” Brazil
• Special Publication, PECP9067, “One Safe
• Data Sheet, PEHJ0091, “Cat DEO (SAE 10W-30 Source”
and SAE 15W-40)” Egypt and Saudi Arabia
• Special Instruction, SMHS7001, “Assembly of Fan
• Special Publication, PEHP9516, “Product Data Drive Pulley Assemblies”
Sheet for Special Application Engine Oil For
Caterpillar 3116 and 3126 Marine Diesel Engines • Special Instruction, SEHS7633, “Battery Test
with Mechanical Unit Injectors” Procedure”

• Special Publication, PEWP3014, “Cat Fluids • Special Publication, SEBF8062, “Guideline for
Selector Dial (International)” Reusable Parts - Procedure to Inspect and Clean
Air Filters”
• Special Publication, PEWP9733, “Cat Fluids
Selector Dial (North America)” • Special Publication, SEBF8029, “Index to
Guidelines for Reusable Parts and Salvage
• Data Sheet, PEHJ0088, “Cat Multipurpose Operations”
Grease”
SEBU7655-04 93
Reference Information Section
Additional Reference Material

• Special Publication, PEDP0026, “Power Analysis International Organization for Standardization

Report” (ISO)
1, rue de Varembé
• Special Publication, NEHS0526, “Service Case postale 56
Technology Application Guide” CH-1211 Genève 20
Switzerland
• Special Instruction, SEHS9031, “Storage Telephone +41 22 749 01 11
Procedure for Caterpillar Products” Facsimile +41 22 733 34 30
E-mail [email protected]
• Specifications, SENR3130, “Torque Specifications
Module” Web site http://www.iso.ch
European classifications are established by the
• Special Instruction, SEHS8742, “Using the 8T- Counseil International Des Machines a Combustion
8697 Electronic Control Analyzer Programmer (CIMAC) (International Council on Combustion
(ECAP)” Engines).
• Special Instruction, SEHS8622, “Using the FT- CIMAC Central Secretariat
1984 Air-To-Air Aftercooler Leak Test Group” Lyoner Strasse 18
60528 Frankfurt
• Special Instruction, SEHS7332, “Warning Tag - Germany
Danger Do Not Operate” Telephone +49 69 6603 1567
• Special Instruction, REHS0871, “Electronic Facsimile +49 69 6603 1566
Installation Guide”
i05264255

i02780825
Maintenance Records
Additional Reference Material SMCS Code: 1000
SMCS Code: 1000 Caterpillar Inc. recommends the retention of accurate
maintenance records. Accurate maintenance records
The “Society of Automotive Engineers (SAE) can be used for the following purposes:
Specifications” can be found in your SAE handbook.
This publication can also be obtained from the • Determine operating costs.
following locations: local technological society, local
library and local college. If necessary, consult SAE at • Establish maintenance schedules for other
the following address: engines that are operated in the same
environment.
SAE International
400 Commonwealth Drive • Show compliance with the required maintenance
Warrendale, PA, USA 15096-0001 practices and maintenance intervals.
Telephone (724) 776-4841
Maintenance records can be used for various other
The “American Petroleum Institute Publication No. business decisions that are related to engine
1509” can be obtained from the following locations: maintenance.
local technological society, local library and local
college. If necessary, consult API at the following Maintenance records are a key element of a
address: maintenance program that is managed. Accurate
maintenance records can help your Cat dealer to
American Petroleum Institute fine-tune the recommended maintenance intervals in
1220 L St. N.W. order to meet the specific operating situation. This
Washington, DC, USA 20005 should result in a lower engine operating cost.
Telephone (202) 682-8000
Records should be kept for the following items:
The International Organization for Standardization
Fuel Consumption – A record of fuel consumption is
(ISO) offers information and customer service
essential in order to determine when the load
regarding international standards and standardizing sensitive components should be inspected or
activities. ISO can also supply information on the repaired. Fuel consumption also determines overhaul
following subjects that are not controlled by ISO: intervals.
national standards, regional standards, regulations,
certification and related activities. Consult the Service Hours – A record of service hours is
member of ISO in your country. essential to determine when the speed sensitive
components should be inspected or repaired.
94 SEBU7655-04
Reference Information Section
Maintenance Log

Documents – These items should be easy to obtain,

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

Keep the following types of documents as proof of

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

• Owner repair costs

• Owner receipts
• Maintenance log

i01176304

Maintenance Log
SMCS Code: 1000

Table 27
Engine Model Customer Identifier

Serial Number Arrangement Number

Service Quantity Of
Service Item Date Authorization
Hours Fuel

(continued)
SEBU7655-04 95
Reference Information Section
Maintenance Log

(Table 27, contd)

96 SEBU7655-04
Index Section

Index
A Cooling System Water Temperature Regulator -
Replace ......................................................... 65
Additional Reference Material ......................... 93
Crushing Prevention and Cutting Prevention.. 14
After Starting Engine ....................................... 28
Customer Assistance ...................................... 90
After Stopping Engine ..................................... 33
Outside of the USA and of Canada ............. 90
Aftercooler Core - Clean/Test.......................... 55
USA and Canada......................................... 90
Aftercooler Core - Inspect ............................... 55
Customer Service............................................ 90
Alternator - Inspect .......................................... 56
Alternator and Fan Belts - Inspect/Adjust/
Replace ......................................................... 56 D
Adjustment................................................... 56 Driven Equipment - Check .............................. 65
Inspection .................................................... 56
Replacement................................................ 57
E

B Electrical System............................................. 15
Grounding Practices .................................... 16
Battery - Replace............................................. 57 Emergency Stopping....................................... 32
Battery Electrolyte Level - Check .................... 57 Emergency Stop Button............................... 32
Battery or Battery Cable - Disconnect............. 58 Emissions Certification Film ............................ 22
Before Starting Engine .............................. 14, 26 Engaging the Driven Equipment ..................... 30
Burn Prevention................................................11 Engine - Clean................................................. 66
Batteries....................................................... 12 Engine Air Cleaner Element (Dual Element)
Coolant .........................................................11 - Clean/Replace............................................. 66
Oils............................................................... 12 Cleaning the Primary Air Cleaner
Elements .................................................... 67
C Servicing the Air Cleaner Elements............. 66
Engine Air Cleaner Element (Single
Cold Weather Operation ................................. 34
Element) - Replace........................................ 69
Cold Weather Starting ..................................... 27
Engine Air Cleaner Service Indicator -
Cooling System Coolant (DEAC) - Change .... 58
Inspect (If Equipped) ..................................... 69
Cooling Systems with Heavy Deposits or
Test the Service Indicator ............................ 70
Plugging ..................................................... 59
Engine Crankcase Breather - Clean ............... 70
Drain ............................................................ 58
Engine Description .......................................... 18
Fill ................................................................ 60
Aftermarket Products and Caterpillar
Flush ............................................................ 59
Engines ...................................................... 19
Cooling System Coolant (ELC) - Change ....... 60
Engine Cooling and Lubrication .................. 19
Drain ............................................................ 60
Engine Service Life...................................... 19
Fill ................................................................ 61
Engine Specifications .................................. 19
Flush ............................................................ 61
Engine Identification........................................ 20
Cooling System Coolant Extender (ELC) -
Engine Mounts - Inspect.................................. 71
Add ................................................................ 62
Engine Oil and Filter - Change ........................ 72
Cooling System Coolant Level - Check........... 62
Drain the Engine Oil..................................... 72
Engines With a Coolant Recovery Tank ...... 62
Fill the Engine Crankcase............................ 74
Engines Without a Coolant Recovery
Replace the Element for the Oil Filter.......... 73
Tank............................................................ 63
Replace the Spin-on Oil Filter...................... 72
Cooling System Supplemental Coolant
Engine Oil Level - Check................................. 71
Additive (SCA) - Test/Add.............................. 64
Engine Oil Sample - Obtain............................. 71
Add the SCA, If Necessary .......................... 64
Obtain the Sample and the Analysis ........... 71
S·O·S Coolant Analysis............................... 64
Engine Operation ............................................ 29
Test for SCA Concentration ......................... 64
SEBU7655-04 97
Index Section

Engine Operation (Hydrocarbon Mitigation) ... 29 Lubricating Grease ...................................... 49

Hydrocarbon Mitigation................................ 29 Multipurpose Greases ................................. 49
Engine Protective Devices - Check................. 74 Re-refined Basestock Oils ........................... 48
Visual Inspection.......................................... 75 S·O·S Oil Analysis ....................................... 51
Engine Rating Conditions................................ 88 Special Purpose Grease (SPG) .................. 50
Engine Rating Definitions................................ 88 Synthetic Base Stock Oils ........................... 48
Engine Ratings ................................................ 88 Total Base Number (TBN) and Fuel Sulfur
Engine Shutoffs and Engine Alarms ............... 25 Levels for Direct Injection (DI) Diesel
Alarms.......................................................... 25 Engines ...................................................... 47
Shutoffs........................................................ 25 Foreword ........................................................... 4
Testing the Shutoff and Alarm System ........ 25 California Proposition 65 Warning ................. 4
Engine Starting.......................................... 15, 26 Literature Information .................................... 4
Engine Stopping ........................................ 15, 32 Maintenance .................................................. 4
Engine Valve Lash - Inspect/Adjust................. 75 Maintenance Intervals ................................... 5
Engine Warm-up ............................................. 30 Operation ....................................................... 4
Overhaul ........................................................ 5
F Safety............................................................. 4
Fuel and the Effect from Cold Weather ........... 34
Features and Controls..................................... 25 Fuel Conservation Practices ........................... 30
Fire Prevention and Explosion Prevention...... 12 Fuel Injection Nozzles - Test/Exchange .......... 75
Ether ............................................................ 13 Removal and Installation of the Fuel Injection
Fire Extinguisher.......................................... 13 Nozzles ...................................................... 76
Lines, Tubes, and Hoses ............................. 14 Fuel Related Components in Cold Weather ... 34
Fluid Recommendations (Coolant Fuel Filters ................................................... 35
Information) ................................................... 36 Fuel Heaters ................................................ 35
Additives ...................................................... 37 Fuel Tanks ................................................... 34
Commercial Heavy-Duty Coolant/Antifreeze Fuel System - Prime........................................ 76
and SCA..................................................... 41 Fuel System Primary Filter (Water
Conventional Coolant or Maintenance for Separator) Element - Replace....................... 77
Antifreeze Cooling System ........................ 43 Fuel System Primary Filter/Water
Coolant Recommendations ......................... 38 Separator - Drain ........................................... 77
Diesel Engine Antifreeze/Coolant (DEAC) .. 40 Fuel System Secondary Filter - Replace ........ 78
Extended Life Coolant (ELC)....................... 40 Element filter................................................ 78
Glycol ........................................................... 38 Spin-on filter................................................. 79
S·O·S Coolant Analysis............................... 39 Fuel Tank Water and Sediment - Drain ........... 80
Supplemental Coolant Additive (SCA) ........ 40 Drain the Water and the Sediment .............. 80
Water ........................................................... 37 Fuel Storage Tanks...................................... 80
Water and Supplemental Coolant Additive Fuel Tank ..................................................... 80
(SCA) ......................................................... 41
Fluid Recommendations (Fuel
G
Recommendations) ....................................... 51
Fluid Recommendations (Lubricant Gauges and Indicators .................................... 24
Information) ................................................... 45 General Hazard Information.............................. 8
Aftermarket Oil Additives ............................. 49 Containing Fluid Spillage............................... 9
API Oils ........................................................ 45 Dispose of Waste Properly ...........................11
Caterpillar Diesel Engine Oil....................... 45 Fluid Penetration ........................................... 9
Caterpillar Premium Grease (CPG)............ 50 Inhalation ..................................................... 10
Cold Weather Lubricants ............................. 48 Lines, Tubes, and Hoses ............................. 10
Commercial Oils .......................................... 46 Pressurized Air and Water............................. 9
Engine Manufacturers Association (EMA) Softwrap........................................................11
Oils ............................................................. 45 Static Electricity Hazard when Fueling with
General Information..................................... 45 Ultra-low Sulfur Diesel Fuel ....................... 10
98 SEBU7655-04
Index Section

H P
Hoses and Clamps - Inspect/Replace............. 81 Product Identification Information ................... 20
Inspect Tubes, Hoses, Bellows, and Product Information Section............................ 17
Clamps....................................................... 81 Product Lifting ................................................. 23
Replace the Hoses and the Clamps ............ 81 Product Storage .............................................. 23

I R
Important Safety Information............................. 2 Radiator - Clean .............................................. 86
Information Plate ............................................. 20 Radiator Restrictions....................................... 34
Reference Information Section ....................... 88
L Reference Material .......................................... 92
Coolants....................................................... 92
Lifting and Storage .......................................... 23 Fuels ............................................................ 92
Lubricants .................................................... 92
M Miscellaneous .............................................. 92
Reference Materials ........................................ 92
Maintenance Interval Schedule....................... 53
Reference Numbers ........................................ 21
Daily ............................................................. 53
Record for Reference .................................. 21
Every 1000 Service Hours........................... 53
Refill Capacities............................................... 36
Every 2000 Service Hours........................... 53
Cooling System............................................ 36
Every 2000 Service Hours or 1 Year ........... 53
Lubrication System ...................................... 36
Every 2000 Service Hours or 2 Years ......... 53
Every 250 Service Hours or 6 Months......... 53
Every 3000 Service Hours........................... 53 S
Every 3000 Service Hours or 2 Years ......... 53 Safety Messages............................................... 6
Every 4000 Service Hours........................... 54 (1) Universal Warning .................................... 6
Every 50 Service Hours or Weekly.............. 53 (2) Ether ......................................................... 7
Every 500 Service Hours ............................. 53 Clutch............................................................. 7
Every 500 Service Hours or 1 Year ............. 53 Safety Section ................................................... 6
Every 500 Service Hours or 6 Months......... 53 Serial Number Plate ........................................ 20
Every 6000 Service Hours or 3 Years ......... 54 Starting Motor - Inspect ................................... 86
Overhaul ...................................................... 54 Starting the Engine.......................................... 26
When Required............................................ 53 Starting with Jump Start Cables...................... 27
Maintenance Log............................................. 94 Stopping the Engine ........................................ 32
Maintenance Records ..................................... 93
Maintenance Section....................................... 36
T
Manual Stop Procedure .................................. 32
Model View Illustrations .................................. 17 Table of Contents .............................................. 3
Engine Model Views .................................... 17
Model Views .................................................... 17 W
Mounting and Dismounting ............................. 14
Walk-Around Inspection .................................. 86
Inspect the Engine for Leaks and for Loose
O
Connections ............................................... 86
Operation Section............................................ 23 Water Pump - Inspect...................................... 87
Ordering Replacement Parts........................... 91
Overhaul Considerations................................. 83
Oil Consumption as an Overhaul Indicator.. 83
Overhaul Recommendation......................... 84
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:
SEBU7655 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2018 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.

100 July 2018