Manual Motor Cat c9 (073 127) 1

72
Maintenance Section
Maintenance Interval Schedule
i01660955 Initial 500 Service Hours

Maintenance Interval Schedule Engine Valve Lash - Inspect/Adjust ...................... 97
SMCS Code: 1000; 7500 Every 6000 Service Hours or 6 Years

Operating conditions and oil API Classifications Cooling System Coolant (ELC) - Change ............. 82
will determine the amount of service hours for the
PM Level 1 Maintenance Interval Schedule. Refer PM Level 1 - Every 10 400 L (2750 US gal) of
to Operation and Maintenance Manual, “Engine Oil Fuel or 250 Service Hours or 6 Months
and Filter - Change” for your specific oil change
interval. Air Compressor Filter - Clean/Replace ................. 75
Battery Electrolyte Level - Check .......................... 77
Note: Ensure that the Safety Information, warnings, Cooling System Supplemental Coolant Additive
and instructions are read and understood (SCA) - Test/Add ................................................. 85
before operation or maintenance procedures are Engine Oil Sample - Obtain .................................. 92
performed. Engine Oil and Filter - Change ............................. 93
Fan Drive Bearing - Lubricate ............................... 98
Note: Use fuel consumption, service hours, or Fuel System Primary Filter/Water Separator Element
calendar time, whichever occurs first in order to - Replace ........................................................... 100
determine the maintenance intervals. Engines that Fuel System Secondary Filter - Replace ............ 101
operate in severe operating conditions may require Fuel Tank Water and Sediment - Drain ............... 102
more frequent maintenance. Hoses and Clamps - Inspect/Replace ................ 102
Radiator - Clean .................................................. 107
Before each consecutive interval is performed, all
of the maintenance requirements from the previous PM Level 1 - Every 20 800 L (5500 US gal) of
interval must also be performed. Fuel or 500 Service Hours or 6 Months
Air Compressor Filter - Clean/Replace ................. 75
When Required
Battery Electrolyte Level - Check .......................... 77
Battery - Replace .................................................. 76 Cooling System Supplemental Coolant Additive
Battery or Battery Cable - Disconnect .................. 77 (SCA) - Test/Add ................................................. 85
Engine Air Cleaner Element (Dual Element) - Engine Oil Sample - Obtain .................................. 92
Clean/Replace .................................................... 88 Engine Oil and Filter - Change ............................. 93
Engine Storage Procedure - Check ...................... 97 Fan Drive Bearing - Lubricate ............................... 98
Ether Starting Aid Cylinder - Replace ................... 98 Fuel System Primary Filter/Water Separator Element
Fuel System - Prime ............................................. 98 - Replace ........................................................... 100
Severe Service Application - Check .................... 107 Fuel System Secondary Filter - Replace ............ 101
Fuel Tank Water and Sediment - Drain ............... 102
Daily Hoses and Clamps - Inspect/Replace ................ 102
Radiator - Clean .................................................. 107
Air Tank Moisture and Sediment - Drain ............... 76
Cooling System Coolant Level - Check ................ 84 PM Level 2 - Every 83 250 L (22 000 US gal)
Driven Equipment - Check .................................... 87 of Fuel or 2000 Service Hours or 1 Year
Engine Air Cleaner Service Indicator - Inspect ..... 90
Engine Oil Level - Check ...................................... 92 Aftercooler Core - Inspect ..................................... 74
Fuel System Primary Filter/Water Separator - Alternator - Inspect ............................................... 76
Drain ................................................................... 99 Engine Crankcase Breather - Clean ..................... 91
Power Take-Off Clutch - Check/Adjust/ Engine Valve Lash - Inspect/Adjust ...................... 97
Lubricate ........................................................... 106 Engine Valve Rotators - Inspect ............................ 97
Walk-Around Inspection ...................................... 109
PM Level 3 - Every 166 500 L (44 000 US gal)
Initial 20 to 40 Service Hours of Fuel or 4000 Service Hours or 2 Years
Belt - Inspect ......................................................... 78 Aftercooler Core - Clean/Test ............................... 74
Air Compressor - Inspect ...................................... 75
Every Week Belt Tensioner - Inspect ........................................ 80
Cooling System Coolant (DEAC) - Change .......... 80
Battery Charger - Check ....................................... 78 Cooling System Coolant Extender (ELC) - Add .... 84
Jacket Water Heater - Check .............................. 103 Cooling System Water Temperature Regulator -
Replace ............................................................... 86
Crankshaft Vibration Damper - Inspect ................. 86
73
Maintenance Section
Maintenance Interval Schedule
Engine - Clean ...................................................... 87

Engine Mounts - Inspect ....................................... 91
Every 340 000 L (90 000 US gal) of Fuel or

10 000 Service Hours
Cylinder Head Grounding Stud - Inspect/Clean/
Tighten ................................................................ 87
Overhaul Considerations .................................... 103
Every 208 000 L (55 000 US gal) of Fuel or

5000 Service Hours
Starting Motor - Inspect ...................................... 108
Turbocharger - Inspect ........................................ 108
Water Pump - Inspect ......................................... 110
74
Maintenance Section
Aftercooler Core - Clean/Test
i01546702 7. Inspect the core in order to ensure cleanliness.

Pressure test the core. Many shops that service
Aftercooler Core - Clean/Test radiators are equipped to perform pressure tests.
If necessary, repair the core.
SMCS Code: 1064-070; 1064-081
8. Install the core. Refer to the Service Manual for
1. Remove the core. Refer to the Service Manual the procedure.
for the procedure.
For more information on cleaning the core, consult
2. Turn the aftercooler core upside-down in order your Caterpillar dealer.
to remove debris.
i01468985
NOTICE
Do not use a high concentration of caustic cleaner to Aftercooler Core - Inspect
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause SMCS Code: 1064-040
leakage. Only use the recommended concentration of
cleaner. Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
3. Back flush the core with cleaner.
Inspect the aftercooler for these items: damaged
Caterpillar recommends the use of Hydrosolv fins, corrosion, dirt, grease, insects, leaves, oil, and
liquid cleaner. Table 35 lists Hydrosolv liquid other debris. Clean the aftercooler, if necessary.
cleaners that are available from your Caterpillar
dealer. For air-to-air aftercoolers, use the same methods
that are used for cleaning radiators.
Table 35
Hydrosolv Liquid Cleaners(1)
Part
Description Size Personal injury can result from air pressure.
Number
1U-5490 Hydrosolv 4165 19 L (5 US gallon) Personal injury can result without following prop-
174-6854 Hydrosolv 100 19 L (5 US gallon) er procedure. When using pressure air, wear a pro-
(1)
tective face shield and protective clothing.
Use a two to five percent concentration of the cleaner
at temperatures up to 93C (200F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more Maximum air pressure at the nozzle must be less
information. than 205 kPa (30 psi) for cleaning purposes.
4. Steam clean the core in order to remove any

residue. Flush the fins of the aftercooler core. Pressurized air is the preferred method for removing
Remove any other trapped debris. loose debris. Direct the air in the opposite direction
of the fan’s air flow. Hold the nozzle approximately
5. Wash the core with hot, soapy water. Rinse the 6 mm (.25 inch) away from the fins. Slowly move
core thoroughly with clean water. the air nozzle in a direction that is parallel with the
tubes. This will remove debris that is between the
tubes.
Pressurized water may also be used for cleaning.

Personal injury can result from air pressure. The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
Personal injury can result without following prop- water in order to soften mud. Clean the core from
er procedure. When using pressure air, wear a pro- both sides.
Use a degreaser and steam for removal of oil and
Maximum air pressure at the nozzle must be less grease. Clean both sides of the core. Wash the core
than 205 kPa (30 psi) for cleaning purposes. with detergent and hot water. Thoroughly rinse the
core with clean water.
6. Dry the core with compressed air. Direct the air
in the reverse direction of the normal flow.
75
Maintenance Section
Air Compressor - Inspect
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.
If the air compressor pressure relief valve that is
Use a light bulb behind the core in order to inspect
mounted in the air compressor cylinder head is
the core for cleanliness. Repeat the cleaning, if
bypassing compressed air, there is a malfunction
necessary.
in the air system, possibly ice blockage. Under
these conditions, your engine may have insuffi-
Inspect the fins for damage. Bent fins may be
cient air for normal brake operation.
opened with a “comb”.
Do not operate the engine until the reason for the
Note: If parts of the aftercooler system are repaired
air bypass is identified and corrected. Failure to
or replaced, a leak test is highly recommended.
heed this warning could lead to property damage,
The FT1984 Aftercooler Testing Group is used
personal injury, or death to the operator or by-
to perform leak tests on the aftercooler. Refer to
standers.
the Systems Operation/Testing and Adjusting,
“Aftercooler - Test” and the Special Instruction,
SEHS8622 for the proper testing procedure. The function of the air compressor pressure relief
valve is to bypass air when there is a malfunction in
Inspect these items for good condition: welds, the air compressor system.
mounting brackets, air lines, connections, clamps,
and seals. Make repairs, if necessary. The air compressor pressure relief valve releases
air at 1723 kPa (250 psi). It is very important that
For more detailed information on cleaning and all personnel stand clear of the air compressor
inspection, see Special Publication, SEBD0518, pressure relief valve when compressed air is
“Know Your Cooling System”. released. All personnel should also stay clear of the
air compressor when the engine is operating and
the air compressor is exposed.
i01183385
Air Compressor - Inspect Refer to the Service Manual or refer to the OEM
specifications in order to find information concerning
SMCS Code: 1803-040 the air compressor. Consult your Caterpillar dealer
for assistance.
i01544231
Do not disconnect the air line from the air com-
pressor governor without purging the air brake Air Compressor Filter -
and the auxiliary air systems. Failure to purge the Clean/Replace
air brake and the auxiliary air systems before re-
moving the air compressor and/or the air lines (If Equipped)
could cause personal injury.
SMCS Code: 1803-070-FQ; 1803-510-FQ
One of the single most important aspects of

preventive maintenance for the air compressor is
the induction of clean air. The type of maintenance
that is required for the air compressor and the
maintenance interval depends on the type of air
induction system that is used. Operating conditions
(dust, dirt and debris) may require more frequent
service.
Refer to the Service Manual for the type of

air compressor that is installed on the engine.
Follow the maintenance recommendations that are
provided by the OEM of the air compressor. Some
g00633741 engines use boost air pressure so the engine air
Illustration 31
cleaner will require servicing.
(1) Air compressor pressure relief valve
76
Maintenance Section
Air Tank Moisture and Sediment - Drain
i00847451 Check the alternator and the battery charger for

proper operation. If the batteries are properly
Air Tank Moisture and charged, the ammeter reading should be very near
Sediment - Drain zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
(If Equipped) affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
SMCS Code: 1466-543-M&S not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time
Moisture and sediment in the air starting system or if the engine is run for short periods, the batteries
can cause the following conditions: may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
• Freezing
• Corrosion of internal parts i01492550
• Malfunction of the air starting system

Battery - Replace
SMCS Code: 1401-510
When opening the drain valve, wear protective

gloves, a protective face shield, protective cloth- Batteries give off combustible gases which can
ing, and protective shoes. Pressurized air could explode. A spark can cause the combustible gas-
cause debris to be blown and result in personal es to ignite. This can result in severe personal in-
injury. jury or death.
1. Open the drain valve that is on the bottom of Ensure proper ventilation for batteries that are in
the air tank. Allow the moisture and sediment an enclosure. Follow the proper procedures in or-
to drain. der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
2. Close the drain valve. serviced.
3. Check the air supply pressure. The air starting

motor requires a minimum of 620 kPa (90 psi) of
air pressure to operate properly. The maximum
air pressure must not exceed 1550 kPa (225 psi). The battery cables or the batteries should not be
The normal air pressure will be 758 to 965 kPa removed with the battery cover in place. The bat-
(110 to 140 psi). tery cover should be removed before any servic-
ing is attempted.
i00072207 Removing the battery cables or the batteries with

the cover in place may cause a battery explosion
Alternator - Inspect resulting in personal injury.
SMCS Code: 1405-040
1. Turn the key start switch to the OFF position.
Caterpillar recommends a scheduled inspection Remove the key and all electrical loads.
of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect 2. Turn OFF the battery charger. Disconnect the
the ammeter (if equipped) during engine operation charger.
in order to ensure proper battery performance
and/or proper performance of the electrical system. 3. The NEGATIVE “-” cable connects the NEGATIVE
Make repairs, as required. Refer to the Service “-” battery terminal to the ground plane.
Manual. Disconnect the cable from the NEGATIVE “-”
battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE

“+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+”
battery terminal.
77
Maintenance Section
Battery Electrolyte Level - Check
Note: Always recycle a battery. Never discard a • A mixture of 0.1 L (0.11 qt) of ammonia and
battery. Return used batteries to an appropriate 1 L (1 qt) of clean water
recycling facility.
Thoroughly rinse the battery case with clean
5. Remove the used battery. water.
6. Install the new battery. Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
Note: Before the cables are connected, ensure that until the surfaces are bright or shiny. DO NOT
the key start switch is OFF. remove material excessively. Excessive removal
of material can cause the clamps to not fit
7. Connect the cable from the starting motor to the properly. Coat the clamps and the terminals with
POSITIVE “+” battery terminal. 5N-5561 Silicone Lubricant, petroleum jelly or
MPGM grease.
8. Connect the cable from the ground plane to the
NEGATIVE “-” battery terminal.
i01492654
i01639002 Battery or Battery Cable -

Battery Electrolyte Level - Disconnect
Check SMCS Code: 1402-029
SMCS Code: 1401-535
When the engine is not run for long periods of The battery cables or the batteries should not be
time or when the engine is run for short periods, removed with the battery cover in place. The bat-
the batteries may not fully recharge. Ensure a full tery cover should be removed before any servic-
charge in order to help prevent the battery from ing is attempted.
freezing. If batteries are properly charged, ammeter
reading should be very near zero. Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
All lead-acid batteries contain sulfuric acid which 1. Turn the start switch to the OFF position. Turn the
can burn the skin and clothing. Always wear a face ignition switch (if equipped) to the OFF position
shield and protective clothing when working on or and remove the key and all electrical loads.
near batteries.
2. Disconnect the negative battery terminal at the
1. Remove the filler caps. Maintain the electrolyte battery that goes to the start switch. Ensure that
level to the “FULL” mark on the battery. the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side
If the addition of water is necessary, use distilled of two batteries must be disconnected.
water. If distilled water is not available use
clean water that is low in minerals. Do not use 3. Tape the leads in order to help prevent accidental
artificially softened water. starting.
2. Check the condition of the electrolyte with the 4. Proceed with necessary system repairs. Reverse
1U-7298 Coolant/Battery Tester (C) or the the steps in order to reconnect all of the cables.
1U-7297 Coolant/Battery Tester (F).
3. Keep the batteries clean.
Clean the battery case with one of the following

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

1 L (1 qt) of clean water
78
Maintenance Section
Battery Charger - Check
i01039758 • The battery emits smoke or a dense vapor (gas).

Battery Charger - Check Perform one of the following procedures if the
battery shows symptoms of overcharging:
SMCS Code: 1401-535
• Reduce the rate of charging by a significant
Checking Before Start-Up amount. Complete the charging at the reduced
rate.
Check the battery charger for proper operation. If
the batteries are properly charged, the needle of • Turn OFF the charger.
the ammeter will register near “0” (zero).
Table 36 describes the effects of overcharging on
The battery charger must not produce excessive different types of batteries.
current during start-up. Alternatively, the charger
Table 36
must be automatically disconnected for start-up.
If the engine has an alternator, the charger must Effects of Overcharging Batteries
be automatically disconnected during start-up and
Type of Battery Effect
during engine operation.
Charging the Battery Caterpillar General Service All of the battery cells have
Batteries a low level of electrolyte.
Caterpillar Premium High
Output Batteries
Never disconnect any charging unit circuit or bat-

tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an explo- When the plates of the
sion from the flammable vapor mixture of hydro- battery are inspected
gen and oxygen that is released from the elec- through the filler holes, the
trolyte through the battery outlets. Injury to per- plates may appear to be
sonnel can be the result. warped. This is caused by
an excessive temperature.
Perform the following procedure to charge the The battery may not pass
a load test.
battery:
Caterpillar Maintenance The battery may not accept
1. Ensure that the charger is turned OFF. Free Batteries a charging current.
The battery may not pass
2. Adjust the voltage of the charger in order to a load test.
match the voltage of the battery.
3. Connect the POSITIVE “+” lead of the charger Checking After Stopping
to the POSITIVE “+” battery terminal. Connect
the NEGATIVE “-” lead of the charger to the Ensure that the battery charger is connected
NEGATIVE “-” battery terminal. properly. Observe the meter of the charger. Record
the amperage.
4. Turn ON the battery charger.
Overcharging of Batteries i01539754
Overcharging reduces the service life of batteries. Belt - Inspect

Use a battery charger that will not overcharge the
battery. DO NOT charge the battery if the meter of SMCS Code: 1357-040; 1357; 1397-040; 1397
the battery charger is in the RED zone.
Inspection
Overcharging is indicated by the following
symptoms: Belt tension should be checked initially between
the first 20 to 40 hours of engine operation.
• The battery is very warm to the touch.
After the initial check, the belt tension should be
• A strong odor of acid is present. checked at every oil change.
79
Maintenance Section
Belt - Inspect
To maximize the engine performance, inspect the Adjustment

belts for wear and for cracking. Replace belts that
are worn or damaged. Alternator Belt
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to
carry more load because the older belt is stretched.
The additional load on the new belt could cause the
new belt to break.
If the belts are too loose, vibration causes

unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
If the belts are too tight, unnecessary stresses are

placed on the pulley bearings and on the belts. This
may shorten the service life of the components.
Remove the belt guard, if equipped. Inspect the

condition and adjustment of the alternator belts and
accessory drive belts (if equipped).
To check the belt tension, apply 110 N (25 lb ft)

of force midway between the pulleys. A correctly
adjusted belt will deflect 9 mm (0.35 inch) to 15 mm
(0.59 inch).
If the belt does not require replacement or

adjustment, install the belt guard. If the belt requires
adjustment or replacement, perform the following
procedure to adjust the belt tension. Illustration 32 g00768640
(1) Nut
(2) Adjusting Nut
(3) Bolt
(4) Nut
1. Slightly loosen mounting bolt (3) and nut (4).
2. Loosen nut (1).
3. Tighten adjusting bolt (2) and mounting bolts

(3) and (4). Tighten bolt (1). Refer to the
Operation and Maintenance Manual, “Torque
Specifications” topic (Maintenance Section).
If new belts are installed, check the belt tension

again after 30 minutes of engine operation at the
rated rpm.
80
Maintenance Section
Belt Tensioner - Inspect
Water Pump Belt i01555583
Belt Tensioner - Inspect

(If Equipped)
SMCS Code: 1358-040
g00426869
Illustration 33
Typical example
Exploded view of the drive assembly for a water pump belt
(1) Mounting bolt
(2) Square hole g00426964
(3) Adjusting bolt Illustration 34
Belt tensioner
1. Slightly loosen mounting bolt (1) and adjusting
bolt (3). Inspect the belt tensioner for unusual noise,
excessive looseness and/or shaking of the bearings.
2. Adjust the belt tension with a square drive in
square hole (2). If the belt tensioner should require disassembly,
refer to the Service Manual for the procedure.
3. Tighten adjusting bolt (3) and mounting bolt (1).
Refer to the Operation and Maintenance Manual,
“Torque Specifications” topic (Maintenance i01206425
Section). Cooling System Coolant

4. Install the belt guard, if equipped. (DEAC) - Change
If new belts are installed, check the belt tension after SMCS Code: 1350-070; 1395-044
30 minutes of engine operation at the rated rpm.
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.

• Foaming is observed.
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the

NOTICE
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
81
Maintenance Section
Cooling System Coolant (DEAC) - Change
Note: Inspect the water pump and the water 3. Fill the cooling system with a mixture of clean
temperature regulator after the cooling system has water and Caterpillar Fast Acting Cooling System
been drained. This is a good opportunity to replace Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
the water pump, the water temperature regulator (4 US gal) of the cooling system capacity. Install
and the hoses, if necessary. the cooling system filler cap.
4. Start and run the engine at low idle for a

Drain minimum of 30 minutes. The coolant temperature
should be at least 82 C (180 F).
NOTICE
Pressurized System: Hot coolant can cause seri-
Improper or incomplete rinsing of the cooling system
ous burns. To open the cooling system filler cap,
can result in damage to copper and other metal com-
stop the engine and wait until the cooling system
ponents.
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
To avoid damage to the cooling system, make sure
sure.
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
1. Stop the engine and allow the engine to cool. cleaning agent are gone.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. 5. Stop the engine and allow the engine to cool.
2. Open the cooling system drain valve (if in order to relieve any pressure. Remove the
equipped). If the cooling system is not equipped cooling system filler cap. Open the drain valve
with a drain valve, remove one of the drain plugs. (if equipped) or remove the cooling system
drain plugs. Allow the water to drain. Flush the
Allow the coolant to drain. cooling system with clean water. Close the drain
valve (if equipped). Clean the drain plugs. Install
the drain plugs. Refer to the Operation and
NOTICE Maintenance Manual, “Torque Specifications”
Dispose of used engine coolant properly or recycle. topic (Maintenance Section) for more information
Various methods have been proposed to reclaim used on the proper torques.
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant. Cooling Systems with Heavy
Deposits or Plugging
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar Note: For the following procedure to be effective,
dealer or consult Caterpillar Service Technology there must be some active flow through the cooling
Group: system components.
Outside Illinois: 1-800-542-TOOL 1. Flush the cooling system with clean water in
Inside Illinois: 1-800-541-TOOL order to remove any debris.
Canada: 1-800-523-TOOL
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the
Flush Operation and Maintenance Manual, “Torque
Specifications” topic (Maintenance Section) for
1. Flush the cooling system with clean water in more information on the proper torques.
order to remove any debris.
2. Close the drain valve (if equipped). Clean the NOTICE

drain plugs. Install the drain plugs. Refer to the Fill the cooling system no faster than 19 L (5 US gal)
Operation and Maintenance Manual, “Torque per minute to avoid air locks.
more information on the proper torques. 3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
NOTICE Cleaner. Add 0.5 L (1 pint) of cleaner per
Fill the cooling system no faster than 19 L (5 US gal) 3.8 to 7.6 L (1 to 2 US gal) of the cooling system
per minute to avoid air locks. capacity. Install the cooling system filler cap.
82
Maintenance Section
Cooling System Coolant (ELC) - Change
4. Start and run the engine at low idle for a 4. Clean the cooling system filler cap. Inspect the
minimum of 90 minutes. The coolant temperature gasket that is on the cooling system filler cap. If
should be at least 82 C (180 F). the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
NOTICE cap and install a new cooling system filler cap.
Improper or incomplete rinsing of the cooling system If the gasket that is on the cooling system filler
can result in damage to copper and other metal com- cap is not damaged, perform a pressure test. A
ponents. 9S-8140 Pressurizing Pump is used to perform
the pressure test. The correct pressure for the
To avoid damage to the cooling system, make sure cooling system filler cap is stamped on the face
to completely flush the cooling system with clear wa- of the cooling system filler cap. If the cooling
ter. Continue to flush the system until all signs of the system filler cap does not retain the correct
cleaning agent are gone. pressure, install a new cooling system filler cap.
5. Start the engine. Inspect the cooling system for

5. Stop the engine and allow the engine to cool. leaks and for proper operating temperature.
i01206445
cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system
drain plugs. Allow the water to drain. Flush the
Cooling System Coolant (ELC)
cooling system with clean water. Close the drain - Change
valve (if equipped). Clean the drain plugs. Install
the drain plugs. Refer to the Operation and SMCS Code: 1350-070; 1395-044
Maintenance Manual, “Torque Specifications”
topic (Maintenance Section) for more information Clean the cooling system and flush the cooling
on the proper torques. system before the recommended maintenance
interval if the following conditions exist:
Fill • The engine overheats frequently.
NOTICE • Foaming is observed.
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks. • The oil has entered the cooling system and the
1. Fill the cooling system with coolant/antifreeze.
Refer to the Operation and Maintenance • The fuel has entered the cooling system and the
Manual, “Cooling System Specifications” topic coolant is contaminated.
(Maintenance Section) for more information on
cooling system specifications. Do not install the Note: When the cooling system is cleaned, only
cooling system filler cap. clean water is needed when the ELC is drained
and replaced.
2. Start and run the engine at low idle. Increase the
engine rpm to 1500 rpm. Run the engine at high Note: Inspect the water pump and the water
idle for one minute in order to purge the air from temperature regulator after the cooling system has
the cavities of the engine block. Stop the engine. been drained. This is a good opportunity to replace
the water pump, the water temperature regulator
3. Check the coolant level. Maintain the coolant and the hoses, if necessary.
level within 13 mm (0.5 inch) below the bottom
of the pipe for filling. Maintain the coolant level Drain
within 13 mm (0.5 inch) to the proper level on the
sight glass (if equipped).

sure.
83
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 Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the in order to relieve any pressure. Remove the
cooling system filler cap. cooling system filler cap. Open the drain valve
(if equipped) or remove the cooling system
2. Open the cooling system drain valve (if drain plugs. Allow the water to drain. Flush the
equipped). If the cooling system is not equipped cooling system with clean water. Close the drain
with a drain valve, remove the cooling system valve (if equipped). Clean the drain plugs. Install
drain plugs. the drain plugs. Refer to the Operation and
Maintenance Manual, “Torque Specifications”
Allow the coolant to drain. topic (Maintenance Section) for more information
on the proper torques.
NOTICE
Dispose of used engine coolant properly or recycle. Fill
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
NOTICE
distillation procedure is the only method acceptable by Fill the cooling system no faster than 19 L (5 US gal)
Caterpillar to reclaim the used coolant.
per minute to avoid air locks.
For information regarding the disposal and the

1. Fill the cooling system with Extended Life Coolant
recycling of used coolant, consult your Caterpillar (ELC). Refer to the Operation and Maintenance
dealer or consult Caterpillar Service Technology Manual, “Cooling System Specifications” topic
Group:
(Maintenance Section) for more information on
cooling system specifications. Do not install the
Outside Illinois: 1-800-542-TOOL cooling system filler cap.
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL 2. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
Flush idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
1. Flush the cooling system with clean water in
order to remove any debris. 3. Check the coolant level. Maintain the coolant
level within 13 mm (0.5 inch) below the bottom
2. Close the drain valve (if equipped). Clean the of the pipe for filling. Maintain the coolant level
drain plugs. Install the drain plugs. Refer to the within 13 mm (0.5 inch) to the proper level on the
Operation and Maintenance Manual, “Torque sight glass (if equipped).
more information on the proper torques. 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
Fill the cooling system no faster than 19 L (5 US gal) is damaged, discard the old cooling system filler
per minute to avoid air locks. cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap
is not damaged, use a 9S-8140 Pressurizing
3. Fill the cooling system with clean water. Install Pump in order to pressure test the cooling
the cooling system filler cap. system filler cap. The correct pressure for the
cooling system filler cap is stamped on the face
4. Start and run the engine at low idle until the of the cooling system filler cap. If the cooling
temperature reaches 49 to 66 C (120 to 150 F). system filler cap does not retain the correct
pressure, install a new cooling system filler cap.

leaks and for proper operating temperature.
84
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i00259474
Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352-045; 1395-081
Caterpillar Extended Life Coolant (ELC) does not

require the frequent Supplemental Coolant Additive
(SCA) additions associated with the present
conventional coolants. The Extender only needs to
be added once.
Check the cooling system only when the engine is

stopped and cool. Illustration 35
g00285520
Cooling system filler cap

1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling
system filler cap.
2. It may be necessary to drain enough coolant Pressurized System: Hot coolant can cause seri-
from the cooling system in order to add the ous burns. To open the cooling system filler cap,
Extender. stop the engine and wait until the cooling system
3. Add Extender according to the requirements for pressure cap slowly in order to relieve the pres-
your engine’s cooling system capacity. Refer to sure.
the Operation and Maintenance Manual, “Refill
Capacities” in the Maintenance Section for the
capacity of the cooling system for your engine. 1. Remove the cooling system filler cap slowly in
Refer to the Operation and Maintenance Manual, order to relieve pressure.
“Cooling System Specifications” information for
the Caterpillar ELC Extender additions. 2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
4. Clean the cooling system filler cap. Inspect the equipped with a sight glass, maintain the coolant
cooling system filler cap gaskets. Replace the level to the proper level in the sight glass.
cooling system filler cap if the cooling system
filler cap gaskets are damaged. Install the
cooling system filler cap.
i01197583
Cooling System Coolant Level

- Check
SMCS Code: 1395-082
Check the coolant level when the engine is stopped

and cool.
g00103639
Illustration 36
Typical filler cap gaskets
3. Clean the cooling system filler cap and check the

condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets
are damaged. Reinstall the cooling system filler
cap.
4. Inspect the cooling system for leaks.

85
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
i01463635 Level 1
Cooling System Supplemental Level 1 is a basic analysis of the coolant. The
Coolant Additive (SCA) - following items are tested:
Test/Add • Glycol Concentration
SMCS Code: 1352-045; 1395-081 • Concentration of SCA
• pH
Cooling system coolant additive contains alkali. • Conductivity

To help prevent personal injury, avoid contact with
the skin and the eyes. Do not drink cooling system The results are reported, and recommendations
coolant additive. are made according to the results. Consult your
Caterpillar dealer for information on the benefits of
managing your equipment with an S·O·S Coolant
Note: Test the concentration of the Supplemental Analysis.
Coolant Additive (SCA) or test the SCA concentration
as part of an S·O·S Coolant Analysis. Level 2
Test for SCA Concentration This level coolant analysis is recommended
when the engine is overhauled. Refer to the
Coolant/Antifreeze and SCA Operations and Maintenance Manual, “Overhaul
Considerations” for further information.
NOTICE
Do not exceed the recommended six percent supple- Add the SCA, If Necessary
mental coolant additive concentration.
NOTICE
Use the 8T-5296 Coolant Conditioner Test Kit or Do not exceed the recommended amount of sup-
use the 4C-9301 Coolant Conditioner Test Kit in plemental coolant additive concentration. Excessive
order to check the concentration of the SCA. Refer supplemental coolant additive concentration can form
to the Operation and Maintenance Manual for more deposits on the higher temperature surfaces of the
information. cooling system, reducing the engine’s heat transfer
characteristics. Reduced heat transfer could cause
Water and SCA cracking of the cylinder head and other high temper-
ature components. Excessive supplemental coolant
additive concentration could also result in radiator
NOTICE tube blockage, overheating, and/or accelerated water
Do not exceed the recommended eight percent sup- pump seal wear. Never use both liquid supplemental
plemental coolant additive concentration. coolant additive and the spin-on element (if equipped)
at the same time. The use of those additives together
Test the concentration of the SCA with the 8T-5296 could result in supplemental coolant additive concen-
Coolant Conditioner Test Kit. Refer to the Operation tration exceeding the recommended maximum.
and Maintenance Manual, “Water/Supplemental
Coolant Additive (SCA)” topic (Maintenance
Section). Refer to the Operation and Maintenance
Manual, “Conventional Coolant/Antifreeze Cooling
System Maintenance” topic (Maintenance Section). Pressurized System: Hot coolant can cause seri-
S·O·S Coolant Analysis components are cool. Loosen the cooling system
S·O·S coolant samples can be analyzed at your sure.
Caterpillar dealer. S·O·S Coolant Analysis is a
program that is based on periodic samples.
1. Slowly loosen the cooling system filler cap in
order to relieve the pressure. Remove the cooling
system filler cap.
86
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Note: Always discard drained fluids according to

local regulations. NOTICE
Failure to replace your water temperature regulator
2. If necessary, drain some coolant from the cooling on a regularly scheduled basis could cause severe
system into a suitable container in order to allow engine damage.
space for the extra SCA.
Caterpillar engines incorporate a shunt design cooling
3. Add the proper amount of SCA. Refer to the system and require operating the engine with a water
Operation and Maintenance Manual for more temperature regulator installed.
information on SCA requirements.
If the water temperature regulator is installed incor-
4. Clean the cooling system filler cap. Inspect the rectly, the engine may overheat, causing cylinder head
gaskets of the cooling system filler cap. If the damage. Ensure that the new water temperature reg-
gaskets are damaged, replace the old cooling ulator is installed in the original position. Ensure that
system filler cap with a new cooling system filler the water temperature regulator vent hole is open.
cap. Install the cooling system filler cap.
Do not use liquid gasket material on the gasket or
cylinder head surface.
i00912898
Cooling System Water Refer to the Service Manual for the replacement
Temperature Regulator - procedure of the water temperature regulator, or
consult your Caterpillar dealer.
Replace
Note: If only the water temperature regulators are
SMCS Code: 1355-510 replaced, drain the coolant from the cooling system
to a level that is below the water temperature
Replace the water temperature regulator before regulator housing.
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulator reduces i00072369
the chances for unscheduled downtime.
Crankshaft Vibration Damper
A water temperature regulator that fails in a - Inspect
partially opened position can cause overheating or
overcooling of the engine. SMCS Code: 1205-040
A water temperature regulator that fails in the Damage to the crankshaft vibration damper or
closed position can cause excessive overheating. failure of the crankshaft vibration damper can
Excessive overheating could result in cracking of increase torsional vibrations. This can result in
the cylinder head or piston seizure problems. damage to the crankshaft and to other engine
components. A deteriorating damper can cause
A water temperature regulator that fails in the open excessive gear train noise at variable points in the
position will cause the engine operating temperature speed range.
to be too low during partial load operation. Low
engine operating temperatures during partial loads The damper is mounted to the crankshaft which is
could cause an excessive carbon buildup inside located behind the belt guard on the front of the
the cylinders. This excessive carbon buildup could engine.
result in an accelerated wear of the piston rings and
wear of the cylinder liner.
Removal and Installation
Refer to the Service Manual for the damper
removal procedure and for the damper installation
procedure.
87
Maintenance Section
Cylinder Head Grounding Stud - Inspect/Clean/Tighten
Visconic Damper i00174798
The visconic damper has a weight that is located Driven Equipment - Check
inside a fluid filled case. The weight moves in the
case in order to limit torsional vibration. Inspect SMCS Code: 3279-535
the damper for evidence of dents, cracks or leaks
of the fluid. Refer to the OEM specifications for more information
on the following maintenance recommendations for
Replace the damper if the damper is dented, the driven equipment:
cracked or leaking. Refer to the Service Manual
or consult your Caterpillar dealer for damper • Inspection
replacement.
• Adjustment
i01473487 • Lubrication
Cylinder Head Grounding Stud • Other maintenance recommendations
- Inspect/Clean/Tighten
Perform any maintenance for the driven equipment
SMCS Code: 7423-040; 7423-070; 7423-079 which is recommended by the OEM.
i01646701
Engine - Clean
SMCS Code: 1000-070
Personal injury or death can result from high volt-

age.
Moisture can create paths of electrical conductiv-

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

out the starting controls and tag the controls “DO
NOT OPERATE”.
NOTICE
g00768411 Accumulated grease and oil on an engine is a fire haz-
Illustration 37
Typical example ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
Inspect the OEM harness for good connections and the engine.
condition.
Periodic cleaning of the engine is recommended.
The electrical grounding stud must have a wire Steam cleaning the engine will remove accumulated
ground to the battery. Tighten the electrical oil and grease. A clean engine provides the
grounding stud at every oil change. Ground wires following benefits:
and straps should be combined at engine grounds.
All grounds should be tight and free of corrosion.
• Easy detection of fluid leaks
• If the connections are corroded, clean the • Maximum heat transfer characteristics
connections with a solution of baking soda and
water.
• Ease of maintenance
• Keep the electrical grounding stud and the
strap clean and coated with MPGM grease or
petroleum jelly.
88
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Note: Caution must be used in order to prevent Replace the dirty paper air cleaner elements with
electrical components from being damaged by clean air cleaner elements. Before installation, the
excessive water when you clean the engine. Avoid air cleaner elements should be thoroughly checked
electrical components such as the alternator, the for tears and/or holes in the filter material. Inspect
starter, and the ECM. the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner
elements for replacement purposes.
i01553486
Engine Air Cleaner Element Dual Element Air Cleaners

(Dual Element) - Clean/Replace The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner
SMCS Code: 1054-037; 1054-510 element. The primary air cleaner element can be
used up to six times if the element is properly
NOTICE cleaned and inspected. The primary air cleaner
Never run the engine without an air cleaner element element should be replaced at least one time
installed. Never run the engine with a damaged air per year. This replacement should be performed
cleaner element. Do not use air cleaner elements with regardless of the number of cleanings.
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine The secondary air cleaner element is not serviceable
components. Air cleaner elements help to prevent air- or washable. The secondary air cleaner element
borne debris from entering the air inlet. should be removed and discarded for every three
cleanings of the primary air cleaner element. When
the engine is operating in environments that are
NOTICE dusty or dirty, air cleaner elements may require
Never service the air cleaner element with the engine more frequent replacement.
running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements

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

accumulation of dirt and debris. Remove any dirt
g00736431
and debris, as needed. Illustration 38
(1) Cover
• Operating conditions (dust, dirt and debris) may (2) Primary air cleaner element
require more frequent service of the air cleaner (3) Secondary air cleaner element
element. (4) Turbocharger air inlet
1. Remove the cover. Remove the primary air

• The air cleaner element may be cleaned up to
six times if the element is properly cleaned and cleaner element.
inspected.
2. The secondary air cleaner element should be
removed and discarded for every three cleanings
• The air cleaner element should be replaced
at least one time per year. This replacement of the primary air cleaner element.
should be performed regardless of the number
of cleanings. Note: Refer to “Cleaning the Primary Air Cleaner
Elements”.
3. Cover the turbocharger air inlet with tape in

order to keep dirt out.
4. Clean the inside of the air cleaner cover and

body with a clean, dry cloth.
89
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
5. Remove the tape for the turbocharger air inlet. Visually inspect the primary air cleaner elements
Install the secondary air cleaner element. Install before cleaning. Inspect the air cleaner elements
a primary air cleaner element that is new or for damage to the seal, the gaskets, and the outer
cleaned. cover. Discard any damaged air cleaner elements.
6. Install the air cleaner cover. There are two common methods that are used to
clean primary air cleaner elements:
7. Reset the air cleaner service indicator.
• Pressurized air
Cleaning the Primary Air Cleaner
• Vacuum cleaning
Elements
Pressurized Air
NOTICE
Caterpillar recommends certified air filter cleaning Pressurized air can be used to clean primary air
services that are available at Caterpillar dealers. The cleaner elements that have not been cleaned more
Caterpillar cleaning process uses proven procedures than two times. Pressurized air will not remove
to assure consistent quality and sufficient filter life. deposits of carbon and oil. Use filtered, dry air with
a maximum pressure of 207 kPa (30 psi).
Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to remove

dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
g00281692
Do not use air filters with damaged pleats, gaskets, or Illustration 39
seals. Dirt entering the engine will cause damage to
engine components. Note: When the primary air cleaner elements are
cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
The primary air cleaner element can be used up (outside).
to six times if the element is properly cleaned and
inspected. When the primary air cleaner element is Aim the hose so that the air flows inside the element
cleaned, check for rips or tears in the filter material. along the length of the filter in order to help prevent
The primary air cleaner element should be replaced damage to the paper pleats. Do not aim the stream
at least one time per year. This replacement of air directly at the primary air cleaner element. Dirt
should be performed regardless of the number of could be forced further into the pleats.
cleanings.
Note: Refer to “Inspecting the Primary Air Cleaner
Use clean primary air cleaner elements while dirty Elements”.
elements are being cleaned.
Vacuum Cleaning
NOTICE
Do not clean the air cleaner elements by bumping or Vacuum cleaning is a good method for cleaning
tapping. This could damage the seals. Do not use el- primary air cleaner elements which require daily
ements with damaged pleats, gaskets or seals. Dam- cleaning because of a dry, dusty environment.
aged elements will allow dirt to pass through. Engine Cleaning with pressurized air is recommended
damage could result. prior to vacuum cleaning. Vacuum cleaning will not
remove deposits of carbon and oil.
Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.
90
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Inspecting the Primary Air Cleaner Do not use paint, a waterproof cover, or plastic as a
Elements protective covering for storage. An airflow restriction
may result. To protect against dirt and damage,
wrap the primary air cleaner elements in Volatile
Corrosion Inhibited (VCI) paper.
Place the primary air cleaner element into a box

for storage. For identification, mark the outside of
the box and mark the primary air cleaner element.
Include the following information:
• Date of cleaning
• Number of cleanings
Store the box in a dry location.
g00281693
Illustration 40
i01175055
Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a
Engine Air Cleaner Service
similar facility. Place the blue light in the primary Indicator - Inspect
air cleaner element. Rotate the primary air cleaner
element. Inspect the primary air cleaner element for SMCS Code: 7452-040
tears and/or holes. Inspect the primary air cleaner
element for light that may show through the filter Some engines may be equipped with a different
material. If it is necessary in order to confirm the service indicator.
result, compare the primary air cleaner element
to a new primary air cleaner element that has the Some engines are equipped with a differential
same part number. gauge for inlet air pressure. The differential gauge
for inlet air pressure displays the difference in the
Do not use a primary air cleaner element that has pressure that is measured before the air cleaner
any tears and/or holes in the filter material. Do not element and the pressure that is measured after
use a primary air cleaner element with damaged the air cleaner element. As the air cleaner element
pleats, gaskets or seals. Discard damaged primary becomes dirty, the pressure differential rises. If your
air cleaner elements. engine is equipped with a different type of service
indicator, follow the OEM recommendations in order
Storing Primary Air Cleaner Elements to service the air cleaner service indicator.
If a primary air cleaner element that passes The service indicator may be mounted on the air
inspection will not be used, the primary air cleaner cleaner element or in a remote location.
element can be stored for future use.
g00103777
Illustration 42
g00281694 Typical service indicator
Illustration 41
91
Maintenance Section
Engine Crankcase Breather - Clean
Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner
element should be replaced when one of the
following conditions occur:
• The yellow diaphragm enters the red zone.

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

Service indicators are important instruments.
• Check for ease of resetting. The service indicator

should reset in less than three pushes.
• Check the movement of the yellow core when the

engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.
g00768439
If the service indicator does not reset easily, or if the Illustration 43
yellow core does not latch at the greatest vacuum, (1) Breather assembly
the service indicator should be replaced. If the (2) Bolt
(3) Hose clamp
new service indicator will not reset, the hole for the (4) Hose
service indicator may be plugged.
1. Loosen hose clamp (3) and remove hose (4)
The service indicator may need to be replaced from breather assembly (1).
frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually 2. Remove bolt (2) and the washer. Remove the
regardless of the operating conditions. Replace the breather assembly (1) and the seal.
service indicator when the engine is overhauled,
and whenever major engine components are 3. Wash the breather element in solvent that is
replaced. clean and nonflammable. Allow the breather
element to dry before installation.
Note: When a new service indicator is installed,
excessive force may crack the top of the service 4. Install a breather element that is clean and dry.
indicator. Tighten the service indicator to a torque Install breather assembly (1) and the seal.
of 2 N·m (18 lb in).
5. Install bolt (2) and the washer. Refer to the
i01473536 Operation and Maintenance Manual for the
proper torque.
Engine Crankcase Breather -
6. Install hose (4) on breather assembly (1). Tighten
Clean hose clamp (3). Refer to the Operation and
Maintenance Manual, “Torque Specifications” for
SMCS Code: 1317-070
the proper torques.
NOTICE
Perform this maintenance with the engine stopped. i00687861
Engine Mounts - Inspect

NOTICE
If the crankcase breather is not maintained on a SMCS Code: 1152-040
regular basis, it can become plugged. A plugged
breather will cause excessive crankcase pressure Inspect the engine mounts for deterioration and for
that may cause crankshaft seal leakage. proper bolt torque. Engine vibration can be caused
by the following conditions:
• Improper mounting of the engine

92
Maintenance Section
Engine Oil Level - Check
• Deterioration of the engine mounts i01534451
Any engine mount that shows deterioration should Engine Oil Sample - Obtain
be replaced. Refer to the Service Manual for the
recommended torques. Refer to your Caterpillar SMCS Code: 1000-008; 1348-554-SM;
dealer for more information. 7542-554-OC, SM
In addition to a good preventive maintenance

i00623423 program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order
Engine Oil Level - Check to monitor the condition of the engine and the
maintenance requirements of the engine.
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
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:
g00110310
Illustration 44 • Engine model
(Y) “ADD” mark. (X) “FULL” mark.
• Service hours on the engine
NOTICE • The number of hours that have accumulated
Perform this maintenance with the engine stopped. since the last oil change
1. Maintain the oil level between “ADD” mark (Y) • The amount of oil that has been added since the
and “FULL” mark (X) on oil level gauge (1). Do last oil change
not fill the crankcase above “FULL” mark (X).
To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
NOTICE sample.
Operating your engine when the oil level is above the
“FULL” mark could cause your crankshaft to dip into To avoid contamination of the oil samples, the tools
the oil. The air bubbles created from the crankshaft and the supplies that are used for obtaining oil
dipping into the oil reduces the oil’s lubricating char- samples must be clean.
acteristics and could result in the loss of power.
Caterpillar recommends using the sampling valve
2. Remove the oil filler cap and add oil, if necessary. in order to obtain oil samples. The quality and the
Clean the oil filler cap. Install the oil filler cap. consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is

recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
93
Maintenance Section
Engine Oil and Filter - Change
NOTICE
Do not use the same vacuum sampling pump for ex-
tracting oil samples that is used for extracting coolant
samples.
A small residue of either type sample may remain in

the pump and may cause a false positive analysis for
the sample being taken.
Always use a designated pump for oil sampling and a

designated pump for coolant sampling.
Failure to do so may cause a false analysis which

could lead to customer and dealer concerns. g00783061
Illustration 45
API Trademark
If the engine is not equipped with a sampling valve, Commercial oils that are licensed by the American Petroleum
use the 1U-5718 Vacuum Pump. The pump is Institute (API) bear this trademark. Commercial oils that do
designed to accept sampling bottles. Disposable not bear this trademark are not licensed and these oils are
tubing must be attached to the pump for insertion not recommended. Oils that are not listed in Table 37 are not
into the sump. recommended.
For instructions, see Special Publication, PEHP6001, Abnormally harsh operating cycles or harsh
“How To Take A Good Oil Sample”. Consult your environments can shorten the service life of
Caterpillar dealer for complete information and the engine oil. Arctic temperatures, corrosive
assistance in establishing an S·O·S program for environments, or extremely dusty conditions may
your engine. require a reduction in engine oil change intervals
from the recommendations in Table 37. Poor
maintenance of air filters or of fuel filters requires
i01730738 reduced oil change intervals. See your Caterpillar
dealer for more information if this product will
Engine Oil and Filter - Change experience abnormally harsh operating cycles or
harsh environments.
SMCS Code: 1318-510; 1348-044
Selection of Oil Change Interval

NOTICE
This engine meets EPA Tier 2, Euro Stage II, or MOC
Step 2 emission regulations. A 500 hour engine oil
change interval is available, provided that operating
conditions and recommended multigrade oil types are
met. When these requirements are not met, shorten
the oil change interval to 250 hours, or use an S·O·S
oil sampling and analysis program to determine an
acceptable oil change interval.
If you select an interval for oil and filter change that is

too long, you may damage the engine.
Hot oil and hot components can cause personal

contact the skin.
Caterpillar oil filters are recommended for oil

changes. Recommended multigrade oil types are
listed in Table 37. Do not use single grade oils.
94
Maintenance Section
Table 37 Program A
Oil Change Interval for C-9 Industrial Engine (1)
Verification for an Oil Change Interval of 500 Hours
Operating Conditions
This program consists of three oil change intervals
Severe
of 500 hours. Oil sampling and analysis is done
Normal(2) High Fuel Altitude at 250 hours and 500 hours for each of the three
Load Sulfur above intervals for a total of six oil samples. The analysis
Multigrade Factor from 1830 m includes oil viscosity and infrared (IR) analysis of
Oil Type above 0.3% to (6000 ft) the oil. If all of the results are satisfactory, the 500
43 L 0.5% hour oil change interval is acceptable for the engine
(11 US
gal per
(4) in that application. Repeat Program A if you change
hour of the application of the engine.
fuel)
(3) If a sample does not pass the oil analysis, take one
of these actions:
Cat DEO
500 hr 500 hr 500 hr 250 hr(6)
Preferred
• Shorten the oil change interval to 250 hours.
API CH-4
11.0 • Proceed to Program B.
minimum 500 hr 500 hr 500 hr 250 hr(6)
TBN(4) • Change to a preferred oil type in Table 37.
Preferred
API CH-4 Program B
TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6)
below 11.0 Optimizing Oil Change Intervals
API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6) Begin with a 250 hour oil change interval. The
API CF-4 250 hr(5) 250 hr(6) 250 hr(6) 250 hr(6) oil change intervals are adjusted by increments.
(1)
Each interval is adjusted an additional 50 hours.
The standard oil change interval in this engine is 500 hours, if
the operating conditions and recommended oil types that are Periodic oil sampling and analysis is done during
listed in this table are met. The traditional oil change interval for each interval. The analysis includes oil viscosity and
engines is 250 hours. Improvements in the engine allow this infrared (IR) analysis of the oil. Repeat Program B if
engine oil change interval. This new standard interval is not you change the application of the engine.
permitted for other engines. Refer to the applicable Operation
and Maintenance Manuals for the other engines.
(2) Normal conditions include these factors: Fuel sulfur below If an oil sample does not pass the analysis, shorten
0.3%, altitude below 1830 m (6000 ft), and good air filter and the oil change interval, or change to a preferred
fuel filter maintenance. Normal conditions do not include high multigrade oil type in the listing above.
load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine oil. References
Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average Reference: Form, PEDP7035, “Optimizing Oil
fuel consumption of your engine exceed 43 L (11 US gal) per Change Intervals”
hour, follow the “High Load Factor” recommendations in Table
37. To determine average fuel consumption for your engine,
measure average fuel consumption for a period of 50 to 100
Reference: Form, PEDP7036, “S·O·S Fluid Analysis”
hours. If the application of the engine is changed, the average
fuel consumption may change. Reference: Form, PEDP7076, “Understanding the
(4) For sulfur content above 0.5%, refer to Operation and S·O·S Oil Analysis Tests”
Maintenance Manual, “Total Base Number (TBN) and Fuel
Sulfur Levels for Direct Injection (DI) Diesel Engines” in the
“Lubricant” section of this manual. Also, you may refer to this Oil Grade Plug
topic in Manual, SEBU6251.
(5) In order to verify an oil change interval of 500 hours, refer to The Oil Grade Plugs are used on the C-9 Industrial
“Program A” below.
(6) Use “Program B” below to determine an appropriate interval.
engine to enhance start-up in cold weather
conditions. When changing oil grades, the operator
must ensure that the corresponding plug is inserted
Adjustment of the Oil Change Interval into the wiring harness. The oil grade plugs can be
recognized by either the identification tags or by the
Note: Your Caterpillar dealer has additional color of the wires. For the location of the oil grade
information on these programs. plug, refer to Operation and Maintenance Manual ,
“Sensor and Electrical Components”.
95
Maintenance Section
The following plugs are used to inform the ECM 10W30 and 15W40 oil grade plugs are shipped
when a particular grade of oil is being used. with the engine. The 0W20 oil grade plug can be
ordered from the parts manual. Order the 214-7170
Repair Kit. The 0W20 oil grade plug can be made
from a 175-3700 Connector Repair Kit. Refer to
the Electrical Schematic or refer to Table 38 for the
proper pin locations.
Table 38
OIL GRADE PLUGS (214-7170)
Oil
Plug Wire Color Pin Connections
Grade
3 10W30 Green B-C
4 15W40 Red A-C
5 0W20 Black A-B-C

g00852969
Illustration 46
Oil grade plugs being shipped with the engine.
(1) Identification tag for 10W30 oil grade plug
Drain the Engine Oil
(2) Identification tag for 15W40 oil grade plug
After the engine has been run at the normal
operating temperature, stop the engine. Attach a
“DO NOT OPERATE” or a similar warning tag to the
ignition keyswitch before the engine is serviced.
Catch the oil in a suitable container. Recycle the
used oil, or dispose of the used oil properly.
1. Remove the oil drain plug in order to allow the

oil to drain.
2. After the oil has drained, the oil drain plug should
be cleaned and installed.
Replace the Oil Filter

NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
g00852892
the larger waste particles from unfiltered oil entering
Illustration 47 the engine lubricating system. Only use oil filters
214-7170 Repair Kit recommended by Caterpillar.
(3) 10W30 oil grade plug (Green wire)
(4) 15W40 oil grade plug (Red wire)
(5) 0W20 oil grade plug (Black wire) 1. Remove the oil filter with a 185-3630 Strap
Wrench.
96
Maintenance Section
4. Apply clean engine oil to the new oil filter gasket.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to
engine components.
5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that
are shown on the oil filter. Do not overtighten the
oil filter.
g00588944
Illustration 48
Element with debris
Fill the Engine Crankcase
2. Cut the oil filter open with a 175-7546 Oil Filter 1. Remove the oil filler cap. Refer to the
Cutter . Break apart the pleats and inspect the Operation and Maintenance Manual, “Lubricant
oil filter for metal debris. An excessive amount of Specifications” topic (Maintenance Section) for
metal debris in the oil filter may indicate early more information. Fill the crankcase with the
wear or a pending failure. proper amount of oil. Refer to the Operation and
Maintenance Manual, “Refill Capacities” topic
Use a magnet to differentiate between the (Maintenance Section) for more information.
ferrous metals and the nonferrous metals that
are found in the oil filter element. Ferrous metals NOTICE
may indicate wear on the steel and cast iron If equipped with an auxiliary oil filter or system, extra
parts of the engine. oil must be added when filling the crankcase. Follow
the OEM or filter manufacturer’s recommendations. If
Nonferrous metals may indicate wear on the the extra oil is not added, the engine may starve for
aluminum parts, brass parts or bronze parts of oil.
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads. NOTICE
To help prevent crankshaft or bearing damage, crank
Due to normal wear and friction, it is not engine to fill all filters before starting. Do not crank
uncommon to find small amounts of debris in the engine for more than 30 seconds.
oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive 2. Start the engine and run the engine at “LOW
amount of debris is found in the oil filter. IDLE” for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
3. Stop the engine and allow the oil to drain back

to the sump for a minimum of ten minutes.
4. Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the “ENGINE STOPPED”
side of the oil level gauge.
g00103713
Illustration 49
Typical filter mounting base and filter gasket
3. Clean the sealing surface of the filter mounting

base. Ensure that all of the old oil filter gasket
is removed.
97
Maintenance Section
Engine Storage Procedure - Check
i01430860
Engine Storage Procedure -

Ensure that the engine can not be started while
Check this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
SMCS Code: 1000-535 to turn the flywheel.
Caterpillar requires all engines that are stored for Hot engine components can cause burns. Allow
more than 3 months to follow storage procedures additional time for the engine to cool before mea-
and start-up procedures. These procedures provide suring/adjusting valve lash clearance.
maximum protection to internal engine components.
Refer to Special Instruction, SEHS9031, “Storage
Procedure For Caterpillar Products” for information Ensure that the engine is stopped before measuring
on these procedures. the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance
An extension of the oil change interval to 12 is performed.
months is permitted if you follow the required
procedures for storage and start-up. This extension Refer to the Service Manual for more information.
is permitted if the following intervals in the Operation
and Maintenance Manual, “Maintenance Interval i01597115
Schedule” have not been reached:
Engine Valve Rotators - Inspect
• Operating hours
SMCS Code: 1109-040
• Fuel consumption
i00869628
When inspecting the valve rotators, protective
Engine Valve Lash - glasses or face shield and protective clothing
Inspect/Adjust must be worn, to help prevent being burned by
hot oil or spray.
SMCS Code: 1102-025
Engine valve rotators rotate the valves when the
The initial valve lash adjustment on new engines, engine runs. This helps to prevent deposits from
rebuilt engines, or remanufactured engines is building up on the valves and the valve seats.
recommended at the first scheduled oil change.
The adjustment is necessary due to the initial wear Perform the following steps after the engine valve
of the valve train components and to the seating of lash is set, but before the valve covers are installed:
the valve train components.
1. Start the engine according to Operation
This maintenance is recommended by Caterpillar and Maintenance Manual, “Engine Starting”
as part of a lubrication and preventive maintenance (Operation Section) for the procedure.
schedule in order to help provide maximum engine
life. 2. Operate the engine at low idle.
NOTICE 3. Observe the top surface of each valve rotator.

Only qualified service personnel should perform this The valve rotators should turn slightly when the
maintenance. Refer to the Service Manual or your valves close.
Caterpillar dealer for the complete valve lash adjust-
ment procedure. NOTICE
A valve rotator which does not operate properly will
Operation of Caterpillar engines with improper valve accelerate valve face wear and valve seat wear and
adjustments can reduce engine efficiency. This re- shorten valve life. If a damaged rotator is not replaced,
duced efficiency could result in excessive fuel usage valve face guttering could result and cause pieces of
and/or shortened engine component life. the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
If a valve fails to rotate, consult your Caterpillar

dealer.
98
Maintenance Section
Ether Starting Aid Cylinder - Replace
i00805059 Lubricate the grease fitting that is on the fan drive

bearing with Bearing Lubricant or the equivalent.
Ether Starting Aid Cylinder -
Replace Inspect the fan drive pulley assembly for wear or for
damage. If the shaft is loose, an inspection of the
(If Equipped) internal components should be performed. Refer to
the Service Manual for additional information.
SMCS Code: 1456-510-CD
i01091827
Fuel System - Prime

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

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
g00104888
Illustration 50
Typical example NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
1. Loosen the ether cylinder clamp. Unscrew and clean the area around a fuel system component that
remove the empty ether cylinder. will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
2. Remove the used gasket. Install the new gasket
that is provided with each new ether cylinder. Prime the fuel system in order to fill the fuel filter.
Prime the fuel system in order to purge trapped
3. Install the new ether cylinder. Hand tighten the air. The fuel system should be primed under the
ether cylinder. Tighten the ether cylinder clamp following conditions:
securely.
• Running out of fuel
i01423301
• Storage
Fan Drive Bearing - Lubricate
• Replacement of the fuel filter
SMCS Code: 1359-086-BD
Engines that are Equipped with a
Fuel Priming Pump
NOTICE
Do not loosen the fuel lines at the fuel manifold. The
fittings may be damaged and/or a loss of priming pres-
sure may occur when the fuel lines are loosened.
1. Open the fuel priming pump and operate the

fuel priming pump until a strong pressure is felt.
This procedure will require considerable strokes.
Lock the fuel priming pump.
g00746166
Illustration 51
Typical location of the grease fitting that is for the fan drive bearing
NOTICE
Do not crank the engine continuously for more than
The pulley is shown with the belt guards removed
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
99
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
2. Promptly start the engine. If the engine runs Fuel Filter Bases that are Not Equipped
rough, continue to operate the engine at low idle. with a Plug
Do not raise the engine rpm above an idle, until
the engine operates smoothly.
NOTICE
3. If the engine does not start, open the fuel priming Do not crank the engine continuously for more than
pump and repeat Steps 1 and 2 in order to start 30 seconds. Allow the starting motor to cool for two
the engine. minutes before cranking the engine again.
Engines that are Not Equipped with 1. Operate the starting motor. This will fill the fuel
filter and the fuel lines with fuel.
a Fuel Priming Pump
2. Once the engine starts, operate the engine at
If the engine is not equipped with a fuel priming low idle. Do not raise the engine speed above
pump, you can use the following procedures to an idle, until the engine operates smoothly.
prime the fuel system. These procedures will allow
only filtered fuel to enter the fuel system.
i00259781
Fuel Filter Bases that are Equipped with Fuel System Primary
a Plug
Filter/Water Separator - Drain
NOTICE SMCS Code: 1260-543; 1263-543
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
g00430478
Illustration 52
(1) Plug
(2) Fuel filter
1. Remove plug (1) in order to fill fuel filter (2).

g00104007
Ensure that air is able to vent from the fitting of Illustration 53
the plug while the fuel filter is being filled. Clean (1) Element. (2) Bowl. (3) Drain.
up any spilled fuel immediately. Clean plug (1).
Install plug (1). Bowl (2) should be monitored daily for signs of
water. If water is present, drain the water from the
NOTICE bowl.
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two 1. Open drain (3). The drain is a self-ventilated
minutes before cranking the engine again. drain. Catch the draining water in a suitable
container. Dispose of the water properly.
2. Start the engine and operate the engine at low 2. Close drain (3).
idle. Do not raise the engine speed above an
idle, until the engine operates smoothly.
100
Maintenance Section
Fuel System Primary Filter/Water Separator Element - Replace
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
system.
i01488870
Fuel System Primary

Filter/Water Separator Element
- Replace
g00104012
Illustration 54
SMCS Code: 1260-510-FQ; 1263-510-FQ
(1) Element. (2) Bowl. (3) Drain.
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause a electronic unit injector 2. Remove element (1) from the element mounting
to fail. If the fuel has been contaminated with water, base while bowl (2) is attached.
the element should be changed before the regularly
scheduled interval. NOTICE
The primary filter/water separator also provides clean the area around a fuel system component that
filtration in order to help extend the life of the will be disconnected. Fit a suitable cover over any dis-
secondary fuel filter. The element should be connected fuel system components.
changed regularly. If a vacuum gauge is installed,
the primary filter/water separator should be changed
at 50 to 70 kPa (15 to 20 inches hg). NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
Replace the Element
3. Dispose of the fuel in the fuel filter element.
Remove bowl (2) from element (1). The bowl is
reusable. Do not discard the bowl. Dispose of
Fuel leaked or spilled onto hot surfaces or elec- the used element.
vent possible injury, turn the start switch off when 4. Remove the O-ring from the gland of the bowl.
changing fuel filters or water separator elements. Clean the following components:
• Bowl
Note: A 10 to 15 micron absolute high efficiency
fuel filter is required for Caterpillar Electronic Unit • O-ring
Injectors. Caterpillar High Efficiency Fuel Filters
meet these requirements. Consult your Caterpillar • Mounting base
dealer for the proper part number.
Inspect the O-ring for damage and for
1. Close the main fuel supply valve. deterioration. Replace the O-ring, if necessary.
5. Lubricate the O-ring with clean diesel fuel.
6. Install bowl (2) on a new element. Tighten the

bowl by hand. Do not use tools in order to tighten
the bowl.
101
Maintenance Section
Fuel System Secondary Filter - Replace
NOTICE NOTICE
The primary filter/water separator may be prefilled with Use a suitable container to catch any fuel that might
fuel to avoid rough running/stalling of the engine due spill. Clean up any spilled fuel immediately.
to air. Do not fill the secondary filter with fuel before
installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accel- 1. Stop the engine. Turn the ignition switch to the
erated wear to fuel system parts. OFF position or disconnect the battery. Refer
to the Operation and Maintenance Manual,
“Battery or Battery Cable - Disconnect” topic
7. Lubricate the top seal of element (1) with clean (Maintenance Section) for more information. Shut
diesel fuel. The element may be filled with fuel at off the fuel supply valve (if equipped).
this time. Install the new element on the mounting
base. Tighten the element by hand. 2. Remove the used fuel filter and discard the used
fuel filter.
NOTICE
The water separator is under suction during normal 3. Clean the gasket sealing surface of the fuel
engine operation. Ensure that the vent plug is tight- filter base. Ensure that all of the old gasket is
ened securely to help prevent air from entering the fu- removed.
el system.
4. Apply clean diesel fuel to the new fuel filter
gasket.
8. Open the main fuel supply valve.
NOTICE
9. Start the engine and check for leaks. Run the Do not fill the secondary fuel filter with fuel before in-
engine for one minute. Stop the engine and stalling. The fuel would not be filtered and could be
check for leaks again. contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
Detection of leaks is difficult while the engine
is running. The primary filter/water separator is
under suction. A leak will allow air to enter the NOTICE
fuel. The air in the fuel can cause low power In order to maximize fuel system life and prevent pre-
due to aeration of the fuel. If air enters the fuel, mature wear out from abrasive particles in the fuel,
check the components for overtightening or a two micron absolute high efficiency fuel filter is re-
under tightening. quired for all Caterpillar Hydraulic Electronic Unit In-
jectors. Caterpillar High Efficiency Fuel Filters meet
i01503750
these requirements. Consult your Caterpillar dealer for
the proper part numbers.
Fuel System Secondary Filter -
Replace 5. Install the new fuel filter. Spin the fuel filter onto
the fuel filter base until the gasket contacts the
SMCS Code: 1261-510-SE base. Use the rotation index marks on the filters
as a guide for proper tightening. Tighten the
filter for an additional one turn (360 degrees) by
hand. Do not overtighten the filter.
6. Open the fuel supply valve. Prime the fuel system.
Refer to the Operation and Maintenance Manual,
“Fuel System - Prime” topic (Maintenance
Section) for more information. Start the engine
and inspect the fuel system for leaks.
NOTICE NOTICE
Do not allow dirt to enter the fuel system. Thoroughly Do not crank the engine continuously for more than
clean the area around a fuel system component that 30 seconds. Allow the starting motor to cool for two
will be disconnected. Fit a suitable cover over any dis- minutes before cranking the engine again.
102
Maintenance Section
Fuel Tank Water and Sediment - Drain
Note: There should be enough residual fuel in the Fuel Storage Tanks
cylinder head in order to start the engine. If the
engine stops after starting, do not crank the engine Drain the water and the sediment from the fuel
for more than 30 seconds. Then allow the starting storage tank during the following conditions:
motor to cool for two minutes. Repeat this procedure
until the engine starts and the engine operates. • Weekly
i00073301
• Oil change
Fuel Tank Water and Sediment • Refill of the tank

- Drain This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
SMCS Code: 1273-543-M&S tank.
Fuel Tank If a bulk storage tank has been refilled or moved

recently, allow adequate time for the sediment to
Fuel quality is critical to the performance and to settle before filling the engine fuel tank. Internal
the service life of the engine. Water in the fuel can baffles in the bulk storage tank will also help trap
cause excessive fuel system wear. Condensation sediment. Filtering fuel that is pumped from the
occurs during the heating and cooling of fuel. The storage tank helps to ensure the quality of the fuel.
condensation occurs as the fuel passes through When possible, water separators should be used.
the fuel system and the fuel returns to the fuel tank.
This causes water to accumulate in fuel tanks. i00907072
Draining the fuel tank regularly and obtaining fuel
from reliable sources can help to eliminate water Hoses and Clamps -
in the fuel.
Inspect/Replace
Drain the Water and the Sediment SMCS Code: 7554-040; 7554-510
Fuel tanks should contain some provision for Inspect all hoses for leaks that are caused by the
draining water and draining sediment from the following conditions:
bottom of the fuel tanks.
• Cracking
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close • Softness
the drain valve.
• Loose clamps
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain Replace hoses that are cracked or soft. Tighten any
the water and sediment from the fuel tank after the loose clamps.
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
NOTICE
Do not bend or strike high pressure lines. Do not in-
Fill the fuel tank after operating the engine in
stall bent or damaged lines, tubes or hoses. Repair
order to drive out moist air. This will help prevent
any loose or damaged fuel and oil lines, tubes and
condensation. Do not fill the tank to the top. The
hoses. Leaks can cause fires. Inspect all lines, tubes
fuel expands as the fuel gets warm. The tank may
and hoses carefully. Tighten all connections to the rec-
overflow.
ommended torque.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel Check for the following conditions:
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If • End fittings that are damaged or leaking
the engine is equipped with this system, regular
maintenance of the fuel system filter is important. • Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
103
Maintenance Section
Jacket Water Heater - Check
• Flexible part of the hose that is kinked or crushed 7. Install the hose clamps with a torque wrench.
• Armoring that is embedded in the outer covering Note: For the proper coolant to use, see this
Operation and Maintenance Manual, “Coolant
A constant torque hose clamp can be used in Recommendations” (Maintenance Section).
place of any standard hose clamp. Ensure that the
constant torque hose clamp is the same size as 8. Refill the cooling system.
the standard clamp.
9. Clean the cooling system filler cap. Inspect the
Due to extreme temperature changes, the hose cooling system filler cap’s gaskets. Replace
will heat set. Heat setting causes hose clamps to the cooling system filler cap if the gaskets are
loosen. This can result in leaks. A constant torque damaged. Install the cooling system filler cap.
hose clamp will help to prevent loose hose clamps.
Each installation application can be different. The leaks.
differences depend on the following factors:
i01042517
• Type of hose
Jacket Water Heater - Check
• Type of fitting material
SMCS Code: 1383-535
• Anticipated expansion and contraction of the
hose Jacket water heaters help to improve startability in
ambient temperatures that are below 21 C (70 F).
• Anticipated expansion and contraction of the All installations that require automatic starting
fittings should have jacket water heaters.
Replace the Hoses and the Clamps Check the operation of the jacket water heater. For
an ambient temperature of 0 C (32 F), the heater
should maintain the jacket water temperature at
approximately 32 C (90 F).
ous burns. To open the cooling system filler cap, i01452713
components are cool. Loosen the cooling system Overhaul Considerations
sure. SMCS Code: 7595-043
Reduced hours of operation at full load will result

1. Stop the engine. Allow the engine to cool. in a lower average power demand. A decreased
average power demand should increase both the
2. Loosen the cooling system filler cap slowly engine service life and the overhaul interval.
cooling system filler cap. The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused. The following factors are important when a decision
is being made on the proper time for an engine
3. Drain the coolant from the cooling system to overhaul:
a level that is below the hose that is being
replaced. • The need for preventive maintenance
4. Remove the hose clamps. • The quality of the fuel that is being used
5. Disconnect the old hose. • The operating conditions
6. Replace the old hose with a new hose. • The results of the S·O·S analysis
Note: For torques on hose clamps, see this
Operation and Maintenance Manual, “Torque
Specifications” (Maintenance Section).
104
Maintenance Section
Overhaul Considerations
Oil Consumption as an Overhaul • Specially designed Caterpillar engine features

Indicator • Caterpillar dealer exchange components
Oil consumption, fuel consumption, and
maintenance information can be used to estimate • Caterpillar Inc. remanufactured exchange
components
the total operating cost for your Caterpillar engine.
Oil consumption can also be used to estimate
the required capacity of a makeup oil tank that is Overhaul Recommendation
suitable for the maintenance intervals.
To minimize downtime, Caterpillar Inc. recommends
Oil consumption is in proportion to the percentage a scheduled engine overhaul by your Caterpillar
of the rated engine load. As the percentage of the dealer before the engine fails. This will provide you
engine load is increased, the amount of oil that is with the best cost/value relationship.
consumed per hour also increases.
Note: Overhaul programs vary according to the
The oil consumption rate (brake specific oil engine application and according to the dealer
consumption) is measured in grams per kW/h that performs the overhaul. Consult your Caterpillar
(lb per bhp). The brake specific oil consumption dealer for specific information about the available
(BSOC) depends on the engine load. Consult your overhaul programs and about overhaul services for
Caterpillar dealer for assistance in determining the extending the engine life.
typical oil consumption rate for your engine.
If an overhaul is performed without overhaul service
When an engine’s oil consumption has risen to from your Caterpillar dealer, be aware of the
three times the original oil consumption rate due following maintenance recommendations.
to normal wear, an engine overhaul should be
scheduled. There may be a corresponding increase Rebuild or Exchange
in blowby and a slight increase in fuel consumption.
Cylinder Head Assembly, Cylinder Packs, Oil
Overhaul Options Pump, and Fuel Transfer Pump
Before Failure Overhaul These components should be inspected according

to the instructions that are found in various
A planned overhaul before failure may be the best Caterpillar reusability publications. The Special
value for the following reasons: Publication, SEBF8029 lists the reusability
publications that are needed for inspecting the
• Costly unplanned downtime can be avoided. engine parts.
• Many original parts can be reused according to If the parts comply with the established inspection
the standards for reusable parts. specifications that are expressed in the reusable
parts guideline, the parts should be reused.
• The engine’s service life can be extended without
the risk of a major catastrophe due to engine Parts that are not within the established inspection
failure. specifications should be dealt with in one of the
following manners:
• The best cost/value relationship per hour of
extended life can be attained. • Salvaging
After Failure Overhaul • Repairing
If a major engine failure occurs and the engine • Replacing
must be removed, many options are available. An
overhaul should be performed if the engine block Using out-of-spec parts can result in the following
or the crankshaft needs to be repaired. problems:
If the engine block is repairable and/or the • Unscheduled downtime

crankshaft is repairable, the overhaul cost should
be between 40 percent and 50 percent of the cost • Costly repairs
of a new engine with a similar exchange core.
• Damage to other engine parts
This lower cost can be attributed to three aspects:
• Reduced engine efficiency
105
Maintenance Section
Overhaul Considerations
• Increased fuel consumption • Camshaft followers

Reduced engine efficiency and increased fuel Caterpillar Inc. recommends replacing the
consumption translates into higher operating costs. crankshaft vibration damper.
Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts. Oil Cooler Core
Inspection and/or Replacement During an overhaul, Caterpillar Inc. recommends

the removal of the oil cooler core. Clean the oil
Crankshaft Bearings, Valve Rotators, and cooler core. Then, pressure test the oil cooler core.
Crankshaft Seals
NOTICE
The following components may not last until the Do not use caustic cleaners to clean the core.
second overhaul.
Caustic cleaners can attack the internal metals of the
• Thrust bearings core and cause leakage.
• Main bearings
Note: Use this cleaning procedure to clean the oil
• Rod bearings cooler core.
• Valve rotators 1. Remove the oil cooler core.
• Crankshaft seals 2. Remove any debris from the oil cooler core. To
remove debris from the oil cooler core, turn the
Caterpillar Inc. recommends the installation of new oil cooler core onto one end.
parts at each overhaul period.
3. Flush the oil cooler core internally with cleaner in
Inspect these parts while the engine is disassembled order to loosen foreign substances. This will also
for an overhaul. help to remove oil from the oil cooler core.
Inspect the crankshaft for any of the following Note: Caterpillar Inc. recommends the use of
conditions: Hydrosolv Liquid Cleaners. Table 39 lists the
Hydrosolv Liquid Cleaners that are available from
• Deflection your Caterpillar dealer.
Table 39
• Damage to the journals
HydrosolvLiquid Cleaners
• Bearing material that has seized to the journals Part
Description Size
Number
Check the journal taper and the profile of the
crankshaft journals. Check these components by 1U-8812 4 L (1 US gallon)
interpreting the wear patterns on the following 1U-5490 Hydrosolv4165 19 L (5 US gallon)
components:
8T-7570 208 L (55 US gallon)
• Rod bearing 1U-8804 4 L (1 US gallon)
• Main bearings 1U-5492 Hydrosolv100 19 L (5 US gallon)

8T-5571 208 L (55 US gallon)
Inspect the camshaft for damage to the journals
and to the lobes.
4. Use steam to clean the oil cooler core. This
Note: If the camshaft is removed for any reason, use removes any remaining residue from the cleaner.
the magnetic particle inspection process to check Flush the fins of the oil cooler core. Remove any
for cracks in the camshaft. other trapped debris.
Inspect the following components for signs of wear 5. Wash the oil cooler core with hot, soapy water.
or for signs of scuffing: Rinse the oil cooler core thoroughly with clean
water.
• Camshaft bearings
106
Maintenance Section
Power Take-Off Clutch - Check/Adjust/Lubricate
• Identification of metal corrosion
Personal injury can result from air pressure. • Identification of contaminants
Personal injury can result without following prop- • Identification of built up impurities (corrosion and
scale)
er procedure. When using pressure air, wear a pro-
S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
Maximum air pressure at the nozzle must be less
recommendations.
than 205 kPa (30 psi) for cleaning purposes.
For more information about coolant analysis, see
6. Dry the oil cooler core with compressed air. your Caterpillar dealer.
Direct the air in the reverse direction of the
normal flow.
i01506009
7. Inspect the components in order to ensure

cleanliness. The oil cooler core should be
Power Take-Off Clutch -
pressure tested. Repair the oil cooler core, if Check/Adjust/Lubricate
necessary. Install the oil cooler core.
SMCS Code: 3055-036; 3055-086
For more information about cleaning the cores,
consult your Caterpillar dealer. NOTICE
New power take-offs should have the clutch adjust-
Obtain Coolant Analysis ment checked before being placed into service. The
clutch adjustment should be checked again after the
The concentration of supplemental coolant additive first ten hours of operation. New clutch plates have a
(SCA) should be checked regularly with test kits “wear in” period, and the clutch may require several
or with S·O·S Coolant Analysis (Level 1). Further adjustments until the new plates are “worn in”.
coolant analysis is recommended when the engine
is overhauled.
For example, considerable deposits are found in the

water jacket areas on the external cooling system,
but the concentrations of coolant additives were
carefully maintained. The coolant water probably
contained minerals that were deposited on the
engine over time.
A coolant analysis can be conducted in order

to verify the condition of the water that is being
used in the cooling system. A full water analysis
can be obtained by consulting your local water
utility company or an agricultural agent. Private
laboratories are also available for water analysis. Illustration 55
g00781502
(1) Instruction plate

Caterpillar Inc. recommends an S·O·S Coolant (2) Serial number plate
Analysis (Level 2).
Check the clutch adjustment regularly after
S·O·S Coolant Analysis (Level 2) “wear in”. Heavy-duty applications which have
engagements that are frequent and relatively long
An S·O·S Coolant Analysis (Level 2) is a periods of clutch slippage require more frequent
comprehensive coolant analysis which completely adjustment than light-duty applications. The
analyzes the coolant and the effects on the cooling operating torque should be measured in order to
system. An S·O·S Coolant Analysis (Level 2) determine if a clutch adjustment is required.
provides the following information:
Refer to the OEM information and instruction plate
• Complete S·O·S Coolant Analysis (Level 1) (1) for instructions on lubrication, adjustment, and
other recommendations for service. Perform the
• Visual inspection of properties maintenance that is specified on the instruction
plate.
107
Maintenance Section
Radiator - Clean
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.
Do not operate the engine with the Instruction
Use a light bulb behind the core in order to inspect
Plate cover removed from the clutch. Personal
the core for cleanliness. Repeat the cleaning, if
injury may result.
necessary.
If the clutch is damaged to the point of burst fail-
Inspect the fins for damage. Bent fins may be
ure, expelled pieces can cause personal injury to
opened with a “comb”. Inspect these items for
anyone in the immediate area. Proper safeguards
good condition: welds, mounting brackets, air lines,
must be followed to help prevent accidents.
connections, clamps, and seals. Make repairs, if
necessary.
i01604510 For more detailed information on cleaning and
Radiator - Clean inspection, refer to Special Publication, SEBD0518,
“Know Your Cooling System”.
SMCS Code: 1353-070
i00151038
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. Severe Service Application -
Inspect the radiator for these items: damaged fins,
Check
corrosion, dirt, grease, insects, leaves, oil, and
SMCS Code: 1000-535
other debris. Clean the radiator, if necessary.
Severe service is an application of an engine
that exceeds current published standards for that
engine. Caterpillar maintains standards for the
Personal injury can result from air pressure. following engine parameters:
Personal injury can result without following prop- • Performance (power range, speed range, and
er procedure. When using pressure air, wear a pro- fuel consumption)
• Fuel quality
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes. • Altitude range
Pressurized air is the preferred method for removing

• Maintenance intervals
loose debris. Direct the air in the opposite direction
of the fan’s air flow. Hold the nozzle approximately
• Oil selection and maintenance
6 mm (0.25 inch) away from the fins. Slowly move
the air nozzle in a direction that is parallel with the
• Coolant selection and maintenance
tubes. This will remove debris that is between the
tubes.
• Environmental qualities
Pressurized water may also be used for cleaning.

• Installation
The maximum water pressure for cleaning purposes Refer to the standards for the engine or consult with
must be less than 275 kPa (40 psi). Use pressurized your Caterpillar dealer in order to determine if the
water in order to soften mud. Clean the core from engine is operating within the defined parameters.
both sides.
Severe service operation can accelerate component
Use a degreaser and steam for removal of oil and wear. Engines that operate under severe conditions
grease. Clean both sides of the core. Wash the core may need more frequent maintenance intervals in
with detergent and hot water. Thoroughly rinse the order to ensure maximum reliability and retention
core with clean water. of full service life.
Due to individual applications, it is not possible to

identify all of the factors which can contribute to
severe service operation. Consult your Caterpillar
dealer for the unique maintenance that is necessary
for the engine.
108
Maintenance Section
Starting Motor - Inspect
The operating environment, improper operating Check the starting motor for proper operation.
procedures and improper maintenance procedures Check the electrical connections and clean the
can be factors which contribute to severe service electrical connections. Refer to the Service Manual
conditions. for more information on the checking procedure and
for specifications or consult your Caterpillar dealer
for assistance.
Environmental Factors
Ambient temperatures – The engine may be i01539769
exposed to extended operation in extremely
cold environments or hot environments. Valve Turbocharger - Inspect
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very SMCS Code: 1052-040
cold temperatures. Extremely hot inlet air reduces
engine performance. Periodic inspection and cleaning is recommended
for the turbocharger compressor housing (inlet
Air Quality – The engine may be exposed to side). Any fumes from the crankcase are filtered
extended operation in an environment that is dirty through the air inlet system. Therefore, by-products
or dusty, unless the equipment is cleaned regularly. from oil and from combustion can collect in the
Mud, dirt and dust can encase components. turbocharger compressor housing. Over time, this
Maintenance can be very difficult. The buildup can buildup can contribute to loss of engine power,
contain corrosive chemicals. increased black smoke and overall loss of engine
efficiency.
Buildup – Compounds, elements, corrosive
chemicals and salt can damage some components. If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
Altitude – Problems can arise when the engine and/or to the engine may occur. Damage to
is operated at altitudes that are higher than the the turbocharger compressor wheel can cause
intended settings for that application. Necessary additional damage to the pistons, the valves, and
adjustments should be made. the cylinder head.
Improper Operating Procedures NOTICE

Turbocharger bearing failures can cause large quan-
• Extended operation at low idle tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
• Frequent hot shutdowns damage.
• Operating at excessive loads Minor leakage of a turbocharger housing under ex-

tended low idle operation should not cause problems
• Operating at excessive speeds as long as a turbocharger bearing failure has not oc-
curred.
• Operating outside the intended application
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
Improper Maintenance Procedures smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
• Extending the maintenance intervals replaced.
• Failure to use recommended fuel, lubricants and
coolant/antifreeze An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for
i00651416
potential damage to other engine parts.
Starting Motor - Inspect Note: Turbocharger components require precision
SMCS Code: 1451-040; 1453-040 clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Caterpillar Inc. recommends a scheduled inspection Applications can accelerate component wear.
of the starting motor. If the starting motor fails, the Severe Service Applications require more frequent
engine may not start in an emergency situation. inspections of the cartridge.
109
Maintenance Section
Walk-Around Inspection
Removal and Installation i01185304
For options regarding the removal, installation, Walk-Around Inspection

repair and replacement, consult your Caterpillar
dealer. Refer to the Service Manual for this engine SMCS Code: 1000-040
for the procedure and specifications.
Inspect the Engine for Leaks and
Cleaning and Inspecting for Loose Connections
1. Remove the exhaust outlet piping and remove A walk-around inspection should only take a few
the air inlet piping from the turbocharger. Visually minutes. When the time is taken to perform these
inspect the piping for the presence of oil. Clean checks, costly repairs and accidents can be
the interior of the pipes in order to prevent dirt avoided.
from entering during reassembly.
For maximum engine service life, make a thorough
2. Turn the compressor wheel and the turbine inspection of the engine compartment before
wheel by hand. The assembly should turn freely. starting the engine. Look for items such as oil leaks
Inspect the compressor wheel and the turbine or coolant leaks, loose bolts, worn belts, loose
wheel for contact with the turbocharger housing. connections and trash buildup. Make repairs, as
There should not be any visible signs of contact needed:
between the turbine wheel or compressor
wheel and the turbocharger housing. If there is • The guards must be in the proper place. Repair
any indication of contact between the rotating damaged guards or replace missing guards.
turbine wheel or the compressor wheel and the
turbocharger housing, the turbocharger must be • Wipe all caps and plugs before the engine is
reconditioned. serviced in order to reduce the chance of system
contamination.
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty, NOTICE
dirt and/or moisture is passing through the air For any type of leak (coolant, lube, or fuel) clean up the
filtering system. If oil is found only on the back fluid. If leaking is observed, find the source and correct
side of the wheel, there is a possibility of a failed the leak. If leaking is suspected, check the fluid levels
turbocharger oil seal. more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
The presence of oil may be the result of extended unwarranted.
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
for the inlet air (plugged air filters), which causes NOTICE
the turbocharger to slobber. Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
4. Use a dial indicator to check the end clearance or high pressure water.
on the shaft. If the measured end play is greater
than the Service Manual specifications, the
turbocharger should be repaired or replaced. • Ensure that the cooling lines are properly clamped
An end play measurement that is less than the and that the cooling lines are tight. Check for
minimum Service Manual specifications could leaks. Check the condition of all pipes.
indicate carbon buildup on the turbine wheel.
The turbocharger should be disassembled for • Inspect the water pumps for coolant leaks.
cleaning and for inspection if the measured end
play is less than the minimum Service Manual Note: The water pump seal is lubricated by coolant
specifications. in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
5. Inspect the bore of the turbine housing for the parts contract.
corrosion.
Excessive coolant leakage may indicate the need
6. Clean the turbocharger housing with standard to replace the water pump seal. For the removal of
shop solvents and a soft bristle brush. water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
7. Fasten the air inlet piping and the exhaust outlet engine or consult your Caterpillar dealer.
piping to the turbocharger housing.
110
Maintenance Section
Water Pump - Inspect
• Inspect the lubrication system for leaks at the • Other potential damage to the engine
front crankshaft seal, the rear crankshaft seal, the
oil pan, the oil filters and the valve cover. Visually inspect the water pump for leaks. If any
leaking is observed, replace the water pump
• Inspect the fuel system for leaks. Look for loose seal or the water pump assembly. Refer to the
fuel line clamps or for loose fuel line tie-wraps. Service Manual for the disassembly and assembly
procedure.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure Note: Refer to the Service Manual or consult your
that hoses and tubes are not contacting other Caterpillar dealer if any repair is needed or any
hoses, tubes, wiring harnesses, etc. replacement is needed.
• Inspect the alternator belt and the accessory

drive belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced

as matched sets. If only one belt is replaced, the
belt will carry more load than the belts that are
not replaced. The older belts are stretched. The
additional load on the new belt could cause the
belt to break.
• Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.
• Inspect the ground strap for a good connection

and for good condition.
• Inspect the ECM to the cylinder head ground

strap for a good connection and for good
condition.
• Disconnect any battery chargers that are not

protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.
• Check the condition of the gauges. Replace any

gauges that are cracked. Replace any gauge that
can not be calibrated.
i01057943
Water Pump - Inspect

SMCS Code: 1361-040; 1361
A failed water pump might cause severe engine

overheating problems that could result in the
following conditions:
• Cracks in the cylinder head

• A piston seizure
111
Warranty Section
Warranty Information
Warranty Section
Warranty Information
i01087950
Emissions Warranty
Information
SMCS Code: 1000
This engine may be certified to comply with

exhaust emission standards and gaseous emission
standards that are prescribed by law at the time
of manufacture, and this engine may be covered
by an Emissions Warranty. A detailed explanation
of the Emissions Warranty that is applicable to
emissions certified engines is found in Supplement,
SEBU6981, “Federal Emissions Control Warranty
Information”. Consult your authorized Caterpillar
dealer to determine if your engine is emissions
certified and if your engine is subject to an
Emissions Warranty.
112
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
SMCS Code: 1000 spent at full throttle. These rating definitions identify
the percent of time at full throttle. The definitions
All engine ratings are in compliance with the also identify the corresponding times below rated
following standard ambient air conditions of “SAE rpm.
J1349”:
Note: The examples of the applications are only
• 99 kPa (29.3 inches of Hg) for reference. For an exact determination of the
appropriate rating, follow the OEM specifications or
• 30 percent relative humidity consult your Caterpillar dealer.
• A temperature of 25 C (77 F) A Rating – This rating is used for heavy-duty

applications that are operated at rated load and at
Ratings relate to the standard conditions of rated rpm up to 100 percent. This rating is used
“ISO8665”, of “ISO3046/1”, of “DIN6271”, and of for engines that operate without interruption of load
“BS5514”. cycling. Typical applications include the following
examples: pipeline pumping and ventilation.
The engine ratings are based on the following fuel
specifications: B Rating – This rating is used when power and/or
rpm are cyclic. The engine should be run at full load.
• Low heat value (LHV)of the fuel of 42 780 kJ/kg The engine should not exceed 80 percent of the
(18,390 Btu/lb) at 29 C (84 F) duty cycle. Typical applications include the following
examples: irrigation, operation where normal pump
• Gravity (API) of 35 degrees at 15 C (60 F) demand is 85 percent of the engine rating, oil
pumping/drilling, field mechanical pumping/drilling,
• Specific gravity of .849 at 15 C (60 F) and stationary/plant air compressors.
• Density of 850 kg/m3 (7.085 lb/US gal) C Rating – This rating is used when power and/or
rpm are cyclic. The horsepower and the rpm of the
The engine ratings are gross output ratings. engine can be utilized continuously for one hour.
This is followed by one hour of operation at the A
Gross Output Ratings – The total output capability rating or below the A rating. The engine should
of the engine that is equipped with standard be run at full load. The engine should not exceed
accessories. 50 percent of the duty cycle. Typical applications
include the following examples: agricultural tractors,
Standard accessories include the following harvesters and combines, off-highway trucks, fire
components: pumps, blast hole drills, rock curshers, wood
chippers with high torque rise, and oil field hoisting.
• Oil pumps
D Rating – This rating is used when rated power
• Fuel pumps is required for periodic overloads. The maximum
horsepower and the rpm of the engine can be
• Water pumps utilized continuously for a maximum of 30 minutes.
This is followed by one hour of operation at the C
Subtract the power that is required to drive auxiliary rating. The engine should be run at full load. The
components from the gross output. This will produce engine should not exceed 10 percent of the duty
the net power that is available for the external load cycle. Typical applications include the following
(flywheel). examples: offshore cranes, runway snow blowers,
water well drills, portable air compressors, and fire
pump certification power.
113
Engine Ratings
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
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 re-
sult in shorter service life before overhaul.
114
Customer Service
Customer Service Latin America, Mexico, Carribean

Caterpillar Americas Co.
701 Waterford Way, Suite 200
i01706971 Miami, FL 33126-4670
USA
Customer Assistance Phone: 305-476-6800
Fax: 305-476-6801
SMCS Code: 1000
Europe, Africa, and Middle East
USA and Canada Caterpillar Overseas S.A.
76 Route de Frontenex
When a problem arises concerning the operation of P.O. Box 6000
an engine or concerning the service of an engine, CH-1211 Geneva 6
the problem will normally be managed by the dealer Switzerland
in your area. Phone: 22-849-4444
Fax: 22-849-4544
Your satisfaction is a primary concern to Caterpillar
and to Caterpillar dealers. If you have a problem Far East
that has not been handled to your complete Caterpillar Asia Pte. Ltd.
satisfaction, follow these steps: 7 Tractor Road
Jurong, Singapore 627968
1. Discuss your problem with a manager from the Republic of Singapore
dealership. Phone: 65-662-8333
Fax: 65-662-8302
2. If your problem cannot be resolved at the dealer
level without additional assistance, use the China
phone number that is listed below to talk with a Caterpillar China Ltd.
Field Service Coordinator: 37/F., The Lee Gardens
33 Hysan Avenue
1-800-447-4986 Causeway Bay
G.P.O. Box 3069
The normal hours are from 8:00 to 4:30 Monday Hong Kong
through Friday Central Standard Time. Phone: 852-2848-0333
Fax: 852-2848-0440
3. If your needs have not been met still, submit the
matter in writing to the following address: Japan
Shin Caterpillar Mitsubishi Ltd.
Caterpillar Inc. SBS Tower
Manager, Customer Service, Engine Division 10-1, Yoga 4-Chome
Mossville Bldg AC Setagaya-Ku, Tokyo 158-8530
P.O. Box 610 Japan
Mossville, Illinois 61552-0610 Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Please keep in mind: probably, your problem will
ultimately be solved at the dealership, using the Japan
dealership’s facilities, equipment, and personnel. Caterpillar Power Systems, Inc.
Therefore, follow the steps in sequence when a 8F, AIG Aoyama Bldg.
problem is experienced. 2-11-16, Minami-Aoyama
Minato-ku, Tokyo 107-0062
Phone: 81-3-5786-3803
Outside of the USA and of Canada Fax: 81-3-5786-3809
If a problem arises outside the USA and outside Australia and New Zealand
Canada, and if the problem cannot be resolved at Caterpillar of Australia Ltd.
the dealer level, consult the appropriate Caterpillar 1 Caterpillar Drive
office. Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
115
Customer Service
i01028392
Ordering Replacement Parts

SMCS Code: 7567
When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers’ parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.
When you order parts, please specify the following

information:
• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.
When a Caterpillar engine requires maintenance

and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).
Discuss the problem with the dealer. Inform the

dealer about the conditions of the problem and
the nature of the problem. Inform the dealer about
when the problem occurs. This will help the dealer
in troubleshooting the problem and solving the
problem faster.
116
Reference Materials
Reference Materials • Special Publication, PEHP0002, “Data Sheet

- Multipurpose Lithium Complex Grease with
Molybdenum (MPGM)”
i01498520
Reference Material • Special Publication, PEHP0017, “Data Sheet -

Special Purpose Grease (SPG) Bearing Lubricant”
SMCS Code: 1000
• Special Publication, NEHP5621, “How To Select
The Right Grease For Any Job”
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
• Special Publication, SEBD0970, “Coolant and Engine”
Your Engine”
• Special Publications, PEDP7036, “S·O·S Fluids
• Special Publication, PEHP4036, “Data Sheet- Analysis Cornerstone”
Extended Life Coolant”
Miscellaneous
• Special Publication, SEBD0518, “Know Your
Cooling System”
• Service Manual, SENR9595, “C-9 Industrial
Engine Service Manual”
• Special Publication, PEEP5027, “Label - ELC
Radiator Label”
• Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids
• Special Publication, PEHP7057, “S·O·S Coolant Recommendations For Lubricants, Diesel
Analysis” Fuel, and Coolants”
Fuels • Special Publication, PECP6026, “One Safe

Source”
• Special Publication, SENR9620, “Improving Fuel
System Durability” • Special Instruction, SMHS7001, “Assembly of Fan
Drive Pulley Assemblies”
• Special Publication, SEBD0717, “Diesel Fuels and
Your Engine” • Special Instruction, SEHS7633, “Battery Test
Procedure”
Lubricants • Special Publication, SEBF8062, “Guideline for
Reusable Parts - Procedure to Inspect and Clean
• Special Publication, PEDP7035, “Optimizing Oil Air Filters”
Change Intervals”
• Special Publication, SEBF8029, “Index to
• Special Publication, PEHP8038, “Data Sheet - Guidelines for Reusable Parts and Salvage
Caterpillar Diesel Engine Oils (DEO) (CH-4, CG-4,
Operations”
CF-4) (North America and Australia)”
• Special Publication, PEHP7041, “Product Data • Special Publication, PEDP0026, “Power Analysis
Report”
Sheet for Caterpillar Diesel Engine Oils (DEO)”
CG-4 engine oils (International markets)
• Special Publication, NEHS0526, “Service
Technology Application Guide”
• Special Publication, PEWP3014, “Cat Fluids
Selector Dial (International)”
• Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”
• Special Publication, PEWP9733, “Cat Fluids
Selector Dial (North America)”
• Specifications, SENR3130, “Torque Specifications
Module”
• Special Publication, NEDG6022, “Data Sheet -
Multipurpose Lithium Complex Grease (MPG)”
• Special Instruction, SEHS7768, “Use of 6V-2150
Starting/Charging Analyzer”
117
Reference Materials
• Special Instruction, SEHS8742, “Using the International Organization for Standardization

8T-8697 Electronic Control Analyzer Programmer (ISO)
(ECAP)” 1, rue de Varembé
Case postale 56
• Special Instruction, SEHS8622, “Using the FT- CH-1211 Genève 20
1984 Air-To-Air Aftercooler Leak Test Group” Switzerland
Telephone: +41 22 749 01 11
• Special Instruction, SEHS7332, “Warning Tag - Facsimile: +41 22 733 34 30
Danger Do Not Operate” E-mail: central@iso.ch
Web site: http://www.iso.ch
• Special Instruction, REHS0871, “Electronic
Installation Guide”. European classifications are established by the
Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
i01109461
Engines).
Additional Reference Material CIMAC Central Secretariat
SMCS Code: 1000 Lyoner Strasse 18
60528 Frankfurt
The “EMA Lubricating Oils Data Book” can Germany
be obtained from the following locations: local Telephone: +49 69 6603 1567
technological society, local library, and local college. Facsimile: +49 69 6603 1566
If necessary, consult EMA at the following address:
i00912149
Engine Manufacturers Associaton
401 N. Michigan Ave. Maintenance Records
Chicago, IL, USA 60611
Telephone: (312) 644-6610 ext. 3626 SMCS Code: 1000
The “Society of Automotive Engineers (SAE) Caterpillar Inc. recommends the retention
Specifications” can be found in your SAE handbook. of accurate maintenance records. Accurate
This publication can also be obtained from the maintenance records can be used for the following
following locations: local technological society, local purposes:
library, and local college. If necessary, consult SAE
at the following address: • Determine operating costs.
SAE International • Establish maintenance schedules for other
400 Commonwealth Drive engines that are operated in the same
Warrendale, PA, USA 15096-0001 environment.
Telephone: (724) 776-4841
• Show compliance with the required maintenance
The “American Petroleum Institute Publication No. practices and maintenance intervals.
1509” can be obtained from the following locations:
local technological society, local library, and local Maintenance records can be used for a variety of
college. If necessary, consult API at the following other business decisions that are related to engine
address: maintenance.
American Petroleum Institute Maintenance records are a key element of a

1220 L St. N.W. maintenance program that is well managed.
Washington, DC, USA 20005 Accurate maintenance records can help your
Telephone: (202) 682-8000 Caterpillar dealer to fine tune the recommended
maintenance intervals in order to meet the specific
The International Organization for Standardization operating situation. This should result in a lower
(ISO) offers information and customer service engine operating cost.
regarding international standards and standardizing
activities. ISO can also supply information on the Records should be kept for the following items:
following subjects that are not controlled by ISO:
national standards, regional standards, regulations,
certification, and related activities. Consult the
member of ISO in your country.
118
Reference Materials
Fuel Consumption – A record of fuel consumption

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

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

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

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

• Owner’s repair costs
• Owner’s receipts
• Maintenance log
119
Reference Materials
i01176304
Maintenance Log
SMCS Code: 1000
Table 40
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity
Service Item Date Authorization
Hours Of Fuel
120
Index Section
Index
A Cooling System Coolant Level - Check ................. 84
Cooling System Specifications .............................. 59
Additional Reference Material ............................. 117 Cooling System Supplemental Coolant Additive
After Starting Engine ............................................. 44 (SCA) - Test/Add.................................................. 85
After Stopping Engine............................................ 47 Add the SCA, If Necessary ................................ 85
Aftercooler Core - Clean/Test ................................ 74 S·O·S Coolant Analysis...................................... 85
Aftercooler Core - Inspect...................................... 74 Test for SCA Concentration ............................... 85
Aftermarket Oil Additives ....................................... 54 Cooling System Water Temperature Regulator -
Air Compressor - Inspect....................................... 75 Replace................................................................ 86
Air Compressor Filter - Clean/Replace (If Crankshaft Vibration Damper - Inspect ................. 86
Equipped) ............................................................ 75 Removal and Installation.................................... 86
Air Tank Moisture and Sediment - Drain (If Visconic Damper................................................ 87
Equipped) ............................................................ 76 Crushing Prevention and Cutting Prevention......... 12
Alternator - Inspect ................................................ 76 Customer Assistance........................................... 114
Outside of the USA and of Canada.................. 114
USA and Canada ............................................. 114
B Customer Service ................................................ 114
Customer Specified Parameters...................... 23, 38
Battery - Replace................................................... 76 Cylinder Head Grounding Stud - Inspect/Clean/
Battery Charger - Check........................................ 78 Tighten................................................................. 87
Checking After Stopping .................................... 78
Checking Before Start-Up .................................. 78
Battery Electrolyte Level - Check .......................... 77 D
Battery or Battery Cable - Disconnect ................... 77
Before Starting Engine .................................... 13, 39 Diagnostic Flash Code Retrieval ........................... 34
Belt - Inspect.......................................................... 78 “Diagnostic” Lamp.............................................. 34
Adjustment ......................................................... 79 Diagnostic Lamp.................................................... 34
Inspection........................................................... 78 Diesel Engine Antifreeze/Coolant (DEAC) ............ 65
Belt Tensioner - Inspect (If Equipped) ................... 80 Driven Equipment - Check..................................... 87
Burn Prevention..................................................... 10
Batteries............................................................. 10
Coolant............................................................... 10 E
Oils..................................................................... 10
Electrical System................................................... 14
Grounding Practices .......................................... 14
C Emergency Stopping ............................................. 46
Emergency Stop Button ..................................... 46
Cold Weather Lubricants ....................................... 54 Emissions Certification Film .................................. 22
Cold Weather Operation........................................ 48 Emissions Warranty Information.......................... 111
Commercial Heavy-Duty Coolant/Antifreeze and Engaging the Driven Equipment............................ 45
SCA ..................................................................... 66 Engine - Clean....................................................... 87
Conventional Coolant/Antifreeze Cooling System Engine Air Cleaner Element (Dual Element) -
Maintenance ........................................................ 68 Clean/Replace ..................................................... 88
Cleaning the System of Heavy-Duty Cleaning the Primary Air Cleaner Elements ...... 89
Coolant/Antifreeze ........................................... 70 Servicing the Air Cleaner Elements ................... 88
Cooling Systems with Larger Capacities ........... 69 Engine Air Cleaner Service Indicator - Inspect...... 90
Coolant Recommendations ................................... 61 Test the Service Indicator .................................. 91
Cooling System Coolant (DEAC) - Change ........... 80 Engine Crankcase Breather - Clean...................... 91
Cooling Systems with Heavy Deposits or Engine Description ................................................ 18
Plugging ........................................................... 81 Aftermarket Products and Caterpillar Engines... 20
Drain .................................................................. 81 Electronic Engine Features ................................ 19
Fill ...................................................................... 82 Engine Cooling and Lubrication......................... 20
Flush .................................................................. 81 Engine Service Life ............................................ 20
Cooling System Coolant (ELC) - Change.............. 82 Engine Specifications......................................... 18
Drain .................................................................. 82 Welding and Caterpillar Electronic Engines....... 20
Fill ...................................................................... 83 Engine Diagnostics................................................ 34
Flush .................................................................. 83 Engine Electronics................................................. 15
Cooling System Coolant Extender (ELC) - Add..... 84 Engine Features and Controls............................... 30
121
Index Section
Engine Identification .............................................. 21 Foreword.................................................................. 5

Engine Lifting......................................................... 25 California Proposition 65 Warning ....................... 5
Engine Lifting and Storage .................................... 25 Literature Information........................................... 4
Engine Monitoring System (EMS) ......................... 27 Maintenance ........................................................ 4
Communication Data Link.................................. 29 Maintenance Intervals.......................................... 4
EMS Main Unit ................................................... 28 Operation ............................................................. 4
Quad Gauge Unit ............................................... 28 Overhaul .............................................................. 4
Tachometer Unit................................................. 29 Safety ................................................................... 4
Engine Mounts - Inspect........................................ 91 Fuel and the Effect from Cold Weather ................. 48
Engine Oil .............................................................. 50 Fuel Recommendations......................................... 57
Caterpillar Diesel Engine Oil .............................. 50 Fuel Related Components in Cold Weather .......... 49
Commercial Oils................................................. 51 Fuel Filters ......................................................... 49
Total Base Number (TBN) and Fuel Sulfur Levels Fuel Heaters ...................................................... 49
for Direct Injection (DI) Diesel Engines ............ 52 Fuel Tanks.......................................................... 49
Engine Oil and Filter - Change .............................. 93 Fuel Specifications ................................................ 57
Drain the Engine Oil........................................... 95 Fuel System - Prime.............................................. 98
Fill the Engine Crankcase .................................. 96 Engines that are Equipped with a Fuel Priming
Oil Grade Plug ................................................... 94 Pump................................................................ 98
Replace the Oil Filter ......................................... 95 Engines that are Not Equipped with a Fuel Priming
Selection of Oil Change Interval ........................ 93 Pump................................................................ 99
Engine Oil Level - Check ....................................... 92 Fuel System Primary Filter/Water Separator -
Engine Oil Sample - Obtain ................................... 92 Drain .................................................................... 99
Obtain the Sample and the Analysis.................. 92 Fuel System Primary Filter/Water Separator Element
Engine Operation................................................... 45 - Replace ........................................................... 100
Engine Operation with Active Diagnostic Codes ... 37 Replace the Element........................................ 100
Engine Operation with Intermittent Diagnostic Fuel System Secondary Filter - Replace............. 101
Codes .................................................................. 37 Fuel Tank Water and Sediment - Drain................ 102
Engine Rating Conditions .................................... 112 Drain the Water and the Sediment................... 102
Engine Rating Definitions .................................... 112 Fuel Storage Tanks .......................................... 102
Engine Ratings .................................................... 112 Fuel Tank ......................................................... 102
Engine Starting................................................ 13, 39
Ether .................................................................. 13
Engine Stopping .............................................. 14, 46 G
Engine Storage...................................................... 25
Engine Storage Procedure - Check....................... 97 Gauges and Indicators .......................................... 26
Engine Valve Lash - Inspect/Adjust ....................... 97 General Coolant Information ................................. 59
Engine Valve Rotators - Inspect ............................ 97 Additives ............................................................ 60
Ether Starting Aid Cylinder - Replace (If Glycol ................................................................. 60
Equipped) ............................................................ 98 Water ................................................................. 59
Extended Life Coolant (ELC)................................. 62 General Hazard Information .................................... 7
Extended Life Coolant (ELC) Cooling System Asbestos Information ........................................... 9
Maintenance ........................................................ 63 Containing Fluid Spillage ..................................... 9
Caterpillar ELC Extender .................................. 63 Dispose of Waste Properly ................................ 10
Changing to Caterpillar ELC .............................. 64 Fluid Penetration .................................................. 9
Commercial ELC................................................ 65 Pressure Air and Water........................................ 8
ELC Cooling System Cleaning........................... 64 General Information............................................... 17
ELC Cooling System Contamination.................. 65
Proper additions to the Extended Life Coolant .. 63
H
F Hoses and Clamps - Inspect/Replace ................. 102

Replace the Hoses and the Clamps ................ 103
Fan Drive Bearing - Lubricate................................ 98
Fault Logging......................................................... 36
Fire Prevention and Explosion Prevention............. 10 I
Ether .................................................................. 12
Fire Extinguisher ................................................ 12 Important Safety Information ................................... 2
Lines, Tubes and Hoses..................................... 12 Information Plate ................................................... 21
122
Index Section
J Refill Capacities..................................................... 71
Cooling System.................................................. 71
Jacket Water Heater - Check............................... 103 Lubrication System ............................................ 71
L S
Lubricant Information............................................. 50 S·O·S Coolant Analysis ......................................... 61

API Oils .............................................................. 50 New Systems, Refilled Systems, and Converted
Engine Manufacturers Association (EMA) Oils .. 50 Systems ........................................................... 62
General Information ........................................... 50 Recommended Interval for S·O·S Coolant
Lubricant Specifications ........................................ 50 Sample ............................................................. 62
Lubricating Grease ................................................ 54 S·O·S Coolant Analysis (Level 1)....................... 62
Caterpillar Premium Grease (CPG) ................... 56 S·O·S Coolant Analysis (Level 2)....................... 62
Multipurpose Greases........................................ 55 S·O·S Oil Analysis ................................................. 56
Special Purpose Grease (SPG)......................... 55 Safety Section ......................................................... 6
Safety Signs and Labels.......................................... 6
Sensors and Electrical Components ..................... 30
M Atmospheric Pressure Sensor ........................... 31
Coolant Temperature Sensor ............................. 31
Maintenance Interval Schedule ............................. 72 Crankshaft Position Sensor and Camshaft Position
Maintenance Log ................................................. 119 Sensor.............................................................. 32
Maintenance Records.......................................... 117 Engine Oil Pressure Sensor............................... 32
Maintenance Section ............................................. 50 Engine Oil Temperature Sensor......................... 32
Manual Stop Procedure......................................... 47 Failure of Sensors .............................................. 31
Model View Illustrations......................................... 18 Injection Actuation Pressure Sensor.................. 32
Model Views .......................................................... 18 Inlet Air Temperature Sensor ............................. 32
Mounting and Dismounting.................................... 13 Programmable Monitoring System (PMS) ......... 31
Sensor Locations ............................................... 30
Throttle Position Sensor..................................... 32
O Turbocharger Outlet Pressure Sensor ............... 31
Serial Number Plate .............................................. 21
Operation Section.................................................. 25 Severe Service Application - Check .................... 107
Ordering Replacement Parts............................... 115 Environmental Factors ..................................... 108
Overhaul Considerations ..................................... 103 Improper Maintenance Procedures.................. 108
Oil Consumption as an Overhaul Indicator ...... 104 Improper Operating Procedures ...................... 108
Overhaul Recommendation ............................. 104 Starting Motor - Inspect ....................................... 108
Starting the Engine................................................ 40
Air Inlet Heater ................................................... 40
P Cold Weather Starting ....................................... 40
Ether Injection System ....................................... 41
Power Take-Off Clutch - Check/Adjust/Lubricate.. 106 Initial Inspection ................................................. 40
Product Identification Information .......................... 21 Problems with the Wiring Harness..................... 42
Product Information Section .................................. 17 Starting Problems .............................................. 42
Starting with Jump Start Cables ............................ 43
Stopping the Engine .............................................. 46
R Supplemental Coolant Additive (SCA)................... 65
Synthetic Base Stock Oils ..................................... 53
Radiator - Clean .................................................. 107
Radiator Restrictions ............................................. 48
Re-refined Base Stock Oils ................................... 53 T
Reference Information Section ............................ 112
Reference Material .............................................. 116 Table of Contents..................................................... 3
Coolants........................................................... 116 Turbocharger - Inspect......................................... 108
Fuels ................................................................ 116 Cleaning and Inspecting .................................. 109
Lubricants ........................................................ 116 Removal and Installation.................................. 109
Miscellaneous .................................................. 116
Reference Materials ............................................ 116
Reference Numbers .............................................. 21
Record for Reference......................................... 21
123
Index Section
Walk-Around Inspection ...................................... 109

Inspect the Engine for Leaks and for Loose
Connections ................................................... 109
Warranty Information ........................................... 111
Warranty Section ................................................. 111
Water Pump - Inspect .......................................... 110
Water/Supplemental Coolant Additive (SCA) ........ 66
Cooling Systems with Larger Capacities ........... 67
Welding on Engines with Electronic Controls ........ 17
124
Index Section
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:
©2002 Caterpillar
All Rights Reserved Printed in U.S.A.

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72

i01660955 Initial 500 Service Hours

SMCS Code: 1000; 7500 Every 6000 Service Hours or 6 Years

Engine - Clean ...................................................... 87

Every 340 000 L (90 000 US gal) of Fuel or

Every 208 000 L (55 000 US gal) of Fuel or

i01546702 7. Inspect the core in order to ensure cleanliness.

4. Steam clean the core in order to remove any

Pressurized water may also be used for cleaning.

After cleaning, start the engine and accelerate the

One of the single most important aspects of

Refer to the Service Manual for the type of

i00847451 Check the alternator and the battery charger for

• Malfunction of the air starting system

When opening the drain valve, wear protective

3. Check the air supply pressure. The air starting

i00072207 Removing the battery cables or the batteries with

4. The POSITIVE “+” cable connects the POSITIVE

i01639002 Battery or Battery Cable -

SMCS Code: 1401-535

3. Keep the batteries clean.

Clean the battery case with one of the following

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

i01039758 • The battery emits smoke or a dense vapor (gas).

Never disconnect any charging unit circuit or bat-

Overcharging of Batteries i01539754

Overcharging reduces the service life of batteries. Belt - Inspect

To maximize the engine performance, inspect the Adjustment

If the belts are too loose, vibration causes

If the belts are too tight, unnecessary stresses are

Remove the belt guard, if equipped. Inspect the

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

If the belt does not require replacement or

1. Slightly loosen mounting bolt (3) and nut (4).

2. Loosen nut (1).

3. Tighten adjusting bolt (2) and mounting bolts

If new belts are installed, check the belt tension

Water Pump Belt i01555583

Belt Tensioner - Inspect

Section). Cooling System Coolant

• The engine overheats frequently.

• The fuel has entered the cooling system and the

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

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

5. Start the engine. Inspect the cooling system for

Pressurized System: Hot coolant can cause seri-

For information regarding the disposal and the

5. Start the engine. Inspect the cooling system for

Cooling System Coolant

Caterpillar Extended Life Coolant (ELC) does not

Check the cooling system only when the engine is

Cooling system filler cap

Cooling System Coolant Level

Check the coolant level when the engine is stopped

3. Clean the cooling system filler cap and check the

4. Inspect the cooling system for leaks.

Cooling system coolant additive contains alkali. • Conductivity

Note: Always discard drained fluids according to

Visconic Damper i00174798