October 2005
Operation and
Maintenance
Manual
C7 Industrial Engine
JRA1-Up (Engine)
JTF1-Up (Engine)
i01658146
Operation Section
Gauges and Indicators .......................................... 22
Maintenance Section
Refill Capacities .................................................... 44
Safety Section
i02285826
Safety Messages
SMCS Code: 1000; 7405
g00986753
Illustration 1
(1) Universal warning label
SEBU8089 7
Safety Section
General Hazard Information
g00934493
Illustration 2
The Universal warning label is typically located on Attach a Do Not Operate warning tag or a similar
each side of the valve cover base. warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. These warning tags (Special Instruction,
i02327617
SEHS7332) are available from your Caterpillar
General Hazard Information dealer. Attach the warning tags to the engine and to
each operator control station. When it is appropriate,
SMCS Code: 1000; 7405 disconnect the starting controls.
Illustration 3
g00104545 Filler caps
Grease fittings
Pressure taps
Breathers
Drain plugs
8 SEBU8089
Safety Section
General Hazard Information
Use caution when cover plates are removed. Pressurized Air and Water
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of Pressurized air and/or water can cause debris
the cover plate or the device. Before removing the and/or hot water to be blown out. This could result in
last two bolts or nuts, pry the cover loose in order to personal injury.
relieve any spring pressure or other pressure.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
Fluid Penetration
g00702020
Illustration 4
g00702022
Illustration 6
Use a wet method in order to clean up asbestos Do not touch any part of an operating engine.
materials. Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
A vacuum cleaner that is equipped with a high in the air system, in the hydraulic system, in the
efficiency particulate air filter (HEPA) can also be lubrication system, in the fuel system, or in the
used. cooling system before any lines, fittings or related
items are disconnected.
Use exhaust ventilation on permanent machining
jobs.
Coolant
Wear an approved respirator if there is no other When the engine is at operating temperature, the
way to control the dust.
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
10 SEBU8089
Safety Section
Fire Prevention and Explosion Prevention
Any contact with hot coolant or with steam can cause Flammable fluids that are leaking or spilled onto hot
severe burns. Allow cooling system components to surfaces or onto electrical components can cause
cool before the cooling system is drained. a fire. Fire may cause personal injury and property
damage.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool. A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
Ensure that the filler cap is cool before removing the an emergency shutdown.
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in Determine whether the engine will be operated in an
order to relieve pressure. environment that allows combustible gases to be
drawn into the air inlet system. These gases could
Cooling system conditioner contains alkali. Alkali can cause the engine to overspeed. Personal injury,
cause personal injury. Do not allow alkali to contact property damage, or engine damage could result.
the skin, the eyes, or the mouth.
If the application involves the presence of combustible
gases, consult your Caterpillar dealer for additional
Oils information about suitable protection devices.
Hot oil and hot lubricating components can cause
Remove all flammable materials such as fuel, oil, and
personal injury. Do not allow hot oil to contact the
debris from the engine. Do not allow any flammable
skin. Also, do not allow hot components to contact
the skin. materials to accumulate on the engine.
Inspect all lines and hoses for wear or for Gases from a battery can explode. Keep any open
deterioration. The hoses must be properly routed. flames or sparks away from the top of a battery. Do
The lines and hoses must have adequate support not smoke in battery charging areas.
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires. Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
Oil filters and fuel filters must be properly installed. a hydrometer.
The filter housings must be tightened to the proper
torque. Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Illustration 9
g00704059 Ether
Ether is flammable and poisonous.
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not Use ether in well ventilated areas. Do not smoke
refuel an engine near open flames or sparks. Always while you are replacing an ether cylinder or while you
stop the engine before refueling. are using an ether spray.
Outer coverings are chafed or cut. Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
Wires are exposed. climb on the engine, and do not jump off the engine.
Outer coverings are ballooning. Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
Flexible part of the hoses are kinked. with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
Outer covers have embedded armoring. controls as handholds.
End fittings are displaced. Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
Make sure that all clamps, guards, and heat shields platform. Secure the climbing equipment so that the
are installed correctly. During engine operation, this equipment will not move.
will help to prevent vibration, rubbing against other
parts, and excessive heat. Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
i01359666
Support the component properly when work beneath Inspect the engine for potential hazards.
the component is performed.
Before starting the engine, ensure that no one is on,
Unless other maintenance instructions are provided, underneath, or close to the engine. All protective
never attempt adjustments while the engine is guards and all protective covers must be installed
running. if the engine must be started in order to perform
service procedures. To help prevent an accident that
Stay clear of all rotating parts and of all moving is caused by parts in rotation, work around the parts
parts. Leave the guards in place until maintenance carefully.
is performed. After the maintenance is performed,
reinstall the guards. Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
Keep objects away from moving fan blades. The fan provided in order to help prevent personal injury. The
blades will throw objects or cut objects. circuits are also provided in order to help prevent
engine damage.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes. On the initial start-up of a new engine or an engine
that has been serviced, prepare to stop the engine
Chips or other debris may fly off objects when objects if an overspeed condition occurs. This may be
are struck. Before objects are struck, ensure that no accomplished by shutting off the fuel supply to the
one will be injured by flying debris. engine and/or shutting off the air supply to the engine.
i00910470 i01462046
If a warning tag is attached to the engine start switch Stop the engine according to the procedure in
or to the controls, do not start the engine or move the the Operation and Maintenance Manual, Engine
controls. Also, do not disengage the parking brakes. Stopping (Operation Section) in order to avoid
Consult with the person that attached the warning tag overheating of the engine and accelerated wear of
before the engine is started. the engine components.
All protective guards and all protective covers must Use the Emergency Stop Button (if equipped) ONLY
be installed if the engine must be started in order in an emergency situation. Do not use the Emergency
to perform service procedures. To help prevent an Stop Button for normal engine stopping. After an
accident that is caused by parts in rotation, work emergency stop, DO NOT start the engine until the
around the parts carefully. problem that caused the emergency stop has been
corrected.
Start the engine from the operators station (cab).
Never short across the starting motor terminals or Stop the engine if an overspeed condition occurs
the batteries. This could bypass the engine neutral during the initial start-up of a new engine or an engine
start system and/or the electrical system could be that has been overhauled. This may be accomplished
damaged. by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.
Always start the engine according to the procedure
that is described in the Operation and Maintenance To stop an electronically controlled engine, cut the
Manual, Engine Starting topic (Operation Section). power to the engine.
Knowing the correct procedure will help to prevent
major damage to the engine components. Knowing
i01489749
the procedure will also help to prevent personal injury.
Grounding Practices
g00774088
Illustration 12
g00774062 Typical example
Illustration 11
Typical example Alternate Grounding Stud To Battery Ground
Grounding Stud To Battery Ground
Proper grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
i01563743
Engine Electronics
SMCS Code: 1000; 1400; 1900
Operating Altitude
Engine Coolant Level
Engine Coolant Temperature
Engine Oil Pressure
Engine Speed
Fuel Temperature
Intake Manifold Air Temperature
System Voltage
The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Product Information
Section
General Information
i02276735
NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
Clamp the ground cable from the welder to the com- 4. Connect the welding ground cable directly to the
ponent that will be welded. Place the clamp as close part that will be welded. Place the ground cable as
as possible to the weld. This will help reduce the pos- close as possible to the weld in order to reduce the
sibility of damage. possibility of welding current damage to bearings,
hydraulic components, electrical components, and
ground straps.
1. Stop the engine. Turn the switched power to the
OFF position. Note: If electrical/electronic components are used
as a ground for the welder, or electrical/electronic
2. Disconnect the negative battery cable from the components are located between the welder ground
battery. If a battery disconnect switch is provided, and the weld, current flow from the welder could
open the switch. severely damage the component.
3. Disconnect the J1/P1 and J2/P2 connectors from 5. Protect the wiring harness from welding debris
the ECM. Move the harness to a position that will and spatter.
not allow the harness to accidentally move back
and make contact with any of the ECM pins. 6. Use standard welding practices to weld the
materials.
SEBU8089 17
Product Information Section
Model Views
Model Views
i02112288
g01075656
Illustration 15
Right side view
(12) Exhaust manifold
(13) Turbocharger
(14) Engine oil filter
(15) Alternator
g01075652 i02413944
Illustration 14
Left side view Engine Description
(1) Belt tensioner
(2) Lifting eyes SMCS Code: 1000
(3) Engine oil level gauge
(4) Air inlet heater relay
(5) Engine control module (ECM) The Caterpillar C7 Industrial Engine has the following
(6) Engine oil filler characteristics:
(7) Fuel priming pump
(8) Fuel filter
(9) Unit injector hydraulic pump In-Line 6 cylinder
(10) Air compressor
(11) Crankcase breather Four stroke cycle
Hydraulically Actuated Electronic Unit Injection
(HEUI)
Turbocharged
Air-to-air aftercooled
Engine Specifications
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.
18 SEBU8089
Product Information Section
Model Views
System diagnostics
For more information on electronic engine features,
refer to the Operation and Maintenance Manual,
Engine Features and Controls topic (Operation
Section).
Additional Features
The following additional features provide increased
engine fuel economy and serviceability:
Illustration 16
g00407141 Tampering detection
Cylinder and valve location
Diagnostics
(A) Exhaust valve
(B) Inlet valve
Hydraulic Electronic Unit Injectors
Table 1
Hydraulically Actuated Electronic Unit Injectors
C7 Industrial Engine Specifications
(HEUI) perform the following functions: pumping of
Arrangement and fuel, fuel metering, and fuel timing.
In-Line 6 cylinder
Cylinders
The unit injectors are controlled by the ECM which
Bore 110 mm (4.3 inch)
uses the camshaft position and the engine speed
Stroke 127 mm (5.0 inch) signals from the engine speed/timing sensors and
the inlet air pressure sensors. The engines rated rpm
Aspiration Turbocharged
ATAAC(1)
is identified on the Information Plate.
Centrifugal pump that is driven by belts However, failures that result from the installation
or use of other manufacturers devices,
Water temperature regulator which regulates the accessories, or consumables are NOT Caterpillar
engine coolant temperature defects. Therefore, the defects are NOT covered
under the Caterpillar warranty.
Oil cooler and radiator which incorporates a shunt
system Welding and Caterpillar Electronic
The engine lubricating oil that is supplied is cooled. Engines
The engine lubricating oil is also filtered. Bypass
valves provide unrestricted flow of lubrication oil NOTICE
to the engine components during the following Because the strength of the frame may decrease,
conditions: some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
High oil viscosity ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
Plugged oil cooler or plugged oil filter elements
(paper cartridge)
To help avoid damage to the electronic controls,
proper welding procedures are necessary. Before
Engine Service Life welding on an engine that is equipped with electronic
controls, observe the following precautions:
Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper 1. Turn off the engine. Place the key start switch in
operation and maintenance recommendations. In the OFF position.
addition, use recommended fuels, coolants and
lubricants. Use the Operation and Maintenance 2. If the machine has a battery disconnect switch,
Manual as a guide for required engine maintenance. open the switch. Otherwise, disconnect the
negative - battery cable from the battery of the
Expected engine life is generally predicted by the vehicle.
average power that is demanded. The average power
that is demanded is based on fuel consumption of
the engine over a period of time. Reduced hours of NOTICE
operation at full throttle and/or operating at reduced Do not ground the welder to electrical components
throttle settings result in a lower average power such as the ECM or sensors. Improper grounding can
demand. Reduced hours of operation will increase cause damage to the drive train bearings, hydraulic
the length of operating time before an engine components, electrical components, and other com-
overhaul is required. For more information, refer to ponents.
the Operation and Maintenance Manual, Overhaul
Considerations topic (Maintenance Section). Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
Aftermarket Products and sibility of damage.
Caterpillar Engines
3. Clamp the ground cable from the welder to the
NOTICE component that will be welded. Place the clamp
In order to maximize fuel system life and prevent pre- as close as possible to the weld.
mature wear out from abrasive particles in the fuel,
a two micron absolute high efficiency fuel filter is re- 4. Protect wiring harnesses from welding debris and
quired for all Caterpillar Hydraulic Electronic Unit In- spatter. Use proper welding procedures.
jectors. Caterpillar High Efficiency Fuel Filters meet
these requirements. Consult your Caterpillar dealer
for the proper part numbers.
Engine Identification
Caterpillar engines are identified with serial numbers,
with performance specification numbers, and with Illustration 18
g00764335
arrangement numbers. In some of the cases,
Typical example
modification numbers are used. These numbers
are shown on the Serial Number Plate and the
The Information Plate is on the front valve cover.
Information Plate that are mounted on the engine.
The following information is on the Information
Plate: engine serial number, engine model, engine
Caterpillar dealers need these numbers in order to
arrangement number, maximum altitude of the
determine the components that were included with
engine that is possible to achieve the rated power,
the engine. This permits accurate identification of
horsepower, high idle, full load rpm, fuel settings, and
replacement part numbers.
other information.
g00764267
Illustration 17 g00284658
Illustration 19
The Serial Number Plate is located on the right side Film for EPA Emission Certification
of the cylinder block.
g00415538
Illustration 20
Film for European Emission Certification
i02238153 Manual-Fuel
Customer Specified Auto-Fuel
Parameters Auxiliary Pressure
SMCS Code: 1000
High Warning Set Point ________________________________
To record programmed specifications, use the
following blanks. Auxiliary Temperature
OFF ______________________________________________________
Warning _________________________________________________
Warning/Derate ________________________________________
Warning/Derate/Shutdown __________________________
Coolant Level Sensor Enable/Disable ____________
Fuel Pressure Sensor Enable/Disable ___________
Inlet Manifold Air Temperature Sensor
Enable/Disable _________________________________________
Equipment ID
Maintenance Indicator
Manual-Hours
Auto-Hours
22 SEBU8089
Operation Section
Gauges and Indicators
Caterpillar requires one lamp in addition to the gauge If the engine is operating above the normal range
package that is normally provided. The Diagnostic or steam becomes apparent, perform the following
lamp is yellow or amber. The Diagnostic lamp will procedure:
communicate the status of the engines electronic
system. The optional red Warning lamp is also 1. Reduce the load and the engine rpm.
available. This red Warning lamp warns the operator
of engine problems. 2. Inspect the cooling system for leaks.
The following conditions are some examples of the 3. Determine if the engine must be shut down
engine problems: immediately or if the engine can be cooled by
reducing the load.
Low oil pressure
High coolant temperature
Low coolant level Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
High inlet air temperature stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
Engine Oil Pressure Typical oil pressure cap slowly in order to relieve the pres-
pressure for an engine at rated speed sure.
with SAE 10W30 or with SAE 15W40 is
240 to 480 kPa (35 to 70 psi). 4. Check the coolant level.
Note: The default high idle rpm and the full load rpm
are stamped on the Information Plate.
i02238470
g00788015
Illustration 21
(1) Main unit (2) Tachometer (unit) (3) Quad gauge
g00595166
Illustration 23
(14) Engine oil pressure
(15) Engine coolant temperature
(16) Battery voltage
(17) Fuel pressure
Tachometer Unit
g00788023
Illustration 24
(18) Tachometer
Sensor Locations
Illustration 25 shows the typical locations of the
sensors for a C7 Industrial Engine. Specific engines
may appear different from the illustration due to
differences in applications.
g00805525
Illustration 25
Typical example
Left side view
(1) Injection actuation pressure sensor (5) Engine oil temperature sensor
(2) Inlet air temperature sensor (6) Engine speed/timing sensor
(3) Atmospheric pressure sensor (7) Coolant temperature sensor
(4) Boost pressure sensor (8) Engine oil pressure sensor
Table 7
The DIAGNOSTIC lamp will come on and 3. The DIAGNOSTIC lamp will flash in order to
the DIAGNOSTIC lamp will remain on for five indicate a two-digit code. The sequence of flashes
seconds. This checks the operation of the lamp. represents the system diagnostic message.
Each digit of the two-digit code is determined by
The DIAGNOSTIC lamp will turn off. counting the number of flashes. The lamp flashes
at a rate of two times per second. The lamp will
The DIAGNOSTIC lamp will come on again and pause for one second between digits. The lamp
the DIAGNOSTIC lamp will flash codes for any will pause for two seconds between codes.
active diagnostic codes. Not all diagnostic codes
have a unique flash code. Table 8 indicates the potential effect on the engine
performance with active flash codes. Table 8 also
The DIAGNOSTIC lamp will turn off for five forms a list of Electronic diagnostic codes and
seconds. descriptions.
i02414604
Diagnostic Lamp
Use the DIAGNOSTIC Lamp or Caterpillar
Electronic Technician (ET) in order to determine the
diagnostic flash code.
Table 8
Diagnostic Flash Codes for C7 Industrial Engine
Suggested Action by the
Effect On Engine Performance
Operator
(Table 8, contd)
Diagnostic Flash Codes for C7 Industrial Engine
Suggested Action by the
Effect On Engine Performance
Operator
i01463504 i01563981
i01456915 i02239577
If the diagnostic lamp starts to flash codes during Customer specified parameters that will enhance
normal engine operation and the diagnostic lamp the fuel efficiency and the operators convenience
shuts off, an intermittent fault may have occurred. If can be programmed into the Electronic Control
a fault has occurred, the fault will be logged into the Module (ECM). Some parameters may affect
memory of the Electronic Control Module (ECM). engine operation. This may lead to complaints from
the operator about power or about performance.
In most cases, it is not necessary to stop the engine The following engine related parameters may be
because of an intermittent code. However, the programmed by the customer by using Caterpillar
operator should retrieve the logged fault codes electronic service tools in order to influence the
and the operator should reference the appropriate operation of the engine:
information in order to identify the nature of the event.
The operator should log any observation that could Customer Passwords
have caused the lamp to light.
Power Rating (hp at rpm)
Low power
Rating Selection (A-E)
Limits of the engine speed
PTO Ramp Rate
Excessive smoke, etc
Engine Parameters: Low Idle, High Idle, Top
This information can be useful to help troubleshoot Engine Limit, Torque Limit, and Intermediate Speed
the situation. The information can also be used for
future reference. For more information on diagnostic Engine Monitoring Mode
codes, refer to the Troubleshooting Guide for this
engine. Equipment ID
Maintenance Indicator
Auxiliary Pressure
Auxiliary Temperature
Parameter Lock Out
The customer specified parameters can be changed
as often as needed. Password protection is provided
so that the customer can change the parameters. The
customer can authorize someone else to change the
parameters. Ensure that a record of the parameters
is kept in the Operation and Maintenance Manual.
For detailed instructions on programming the engine
for optimum performance and for optimum fuel
economy, consult your Caterpillar dealer.
34 SEBU8089
Operation Section
Engine Starting
Engine Starting Do not start the engine or move any of the controls
if there is a DO NOT OPERATE warning tag or
similar warning tag attached to the start switch or
i01486758 to the controls.
Before Starting Engine Ensure that the areas around the rotating parts are
clear.
SMCS Code: 1000; 1400; 1450
All of the guards must be put in place. Check for
Perform the required daily maintenance and other damaged guards or for missing guards. Repair
periodic maintenance before the engine is started. any damaged guards. Replace damaged guards
Inspect the engine compartment. This inspection can and/or missing guards.
help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, Maintenance Disconnect any battery chargers that are not
Interval Schedule for more information. protected against the high current drain that
is created when the electric starting motor (if
For the maximum service life of the engine, make equipped) is engaged. Check electrical cables
a thorough inspection before the engine is started. and check the battery for poor connections and
Look for the following items: oil leaks, coolant for corrosion.
leaks, loose bolts, and trash buildup. Remove trash
buildup and arrange for repairs, as needed. Reset all of the shutoffs or alarm components.
Inspect the cooling system hoses for cracks and Check the engine lubrication oil level. Maintain the
for loose clamps. oil level between the ADD mark and the FULL
mark on the oil level gauge.
Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage. Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
Inspect the wiring for loose connections and for the coolant level to the FULL mark on the coolant
worn wires or frayed wires. recovery tank.
Check the fuel supply. Drain water from the water If the engine is not equipped with a coolant
separator (if equipped). Open the fuel supply valve. recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If
NOTICE the engine is equipped with a sight glass, maintain
All valves in the fuel return line must be open before the coolant level in the sight glass.
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing Observe the air cleaner service indicator (if
failure or other damage. equipped). Service the air cleaner when the yellow
diaphragm enters the red zone, or when the red
piston locks in the visible position.
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air Ensure that any driven equipment has been
may have entered the filter housing. Also, when fuel disengaged. Minimize electrical loads or remove
filters have been changed, some air pockets will be any electrical loads.
trapped in the engine. In these instances, prime the
fuel system. Refer to the Operation and Maintenance
Manual, Fuel System - Prime for more information i02239598
on priming the fuel system.
Starting the Engine
SMCS Code: 1000; 1450
Initial Inspection Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
Perform the required daily maintenance and other the coolant level to the FULL mark on the coolant
periodic maintenance before you start the engine. recovery tank.
Inspect the engine compartment. This inspection can
help prevent major repairs at a later date. Refer to the If the engine is not equipped with a coolant
Operation and Maintenance Manual, Walk-Around recovery tank maintain the coolant level within
Inspection topic (Maintenance Section) for more 13 mm (.5 inch) of the bottom of the filler pipe. If
information. the engine is equipped with a sight glass, maintain
the coolant level in the sight glass.
For the maximum service life of the engine, make
a thorough inspection before you start the engine. Observe the air cleaner service indicator (if
Look for the following items: oil leaks, coolant equipped). Service the air cleaner when the yellow
leaks, loose bolts, and trash buildup. Remove trash diaphragm enters the red zone, or when the red
buildup and arrange for repairs, as needed. piston locks in the visible position.
Inspect the cooling system hoses for cracks and Ensure that any driven equipment has been
for loose clamps. disengaged. Remove any electrical loads.
Inspect the alternator and accessory drive belts for Cold Weather Starting
cracks, breaks, and other damage.
Starting the engine and operation in cold weather
Inspect the wiring for loose connections and for is dependent on the type of fuel that is used, the oil
worn wires or frayed wires. viscosity, and other optional starting aids. For more
information, refer to the Operation and Maintenance
Check the fuel supply. Drain water from the water Manual, Cold Weather Operation topic (Operation
separator (if equipped). Open the fuel supply valve. Section).
NOTICE
All valves in the fuel return line must be open before
Air Inlet Heater
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.
DO NOT USE ETHER (starting fluids) unless
specifically instructed to do so. If the engine is
Do not start the engine or do not move any of the equipped with an Air Inlet Heater (electrically or
controls if there is a DO NOT OPERATE warning fuel ignited manifold heater), DO NOT use ether
tag or similar warning tag attached to the start (starting fluids) at any time. The use could result
switch or to the controls. in engine damage and/or personal injury.
Ensure that the areas around the rotating parts are
clear. Note: There will be an indicator lamp on the control
panel that is marked AIR INLET HEATER.
All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair For detailed information on the operation of the Air
any damaged guards. Replace damaged guards Inlet Heater, refer to Troubleshooting Manual, Air
and/or missing guards. Inlet Heater Circuit - Test.
Disconnect any battery chargers that are not Refer to the Owners Manual of the OEM for your
protected against the high current drain that type of controls. Use the following procedure to start
is created when the electric starting motor (if the engine.
equipped) is engaged. Check electrical cables
and check the battery for poor connections and 1. Place the transmission in NEUTRAL. Disengage
for corrosion. the flywheel clutch in order to allow the engine to
start faster. This also reduces the draining of the
Reset all of the shutoffs or alarm components. battery.
Check the engine lubrication oil level. Maintain the 2. Turn the ignition switch to the ON position.
oil level between the ADD mark and the FULL
mark on the oil level gauge.
36 SEBU8089
Operation Section
Engine Starting
The WARNING and DIAGNOSTIC lamp (if Note: Oil pressures and fuel pressures should be in
equipped) will flash while the engine is cranking. the normal range on the instrument panel. Engines
The lamp should turn off after proper engine that are equipped with WARNING lamps do not
oil pressure is achieved. If the lamp fails to have an operating range. The WARNING and
flash, notify your authorized Caterpillar dealer. DIAGNOSTIC lamp (if equipped) will flash while
If the lamp continues to flash, the Electronic the engine is cranking. The lamp should turn off
Control Module (ECM) has detected a problem after proper engine oil pressure or fuel pressure
in the system. For more information, refer to the is achieved. Do not apply a load to the engine or
Operation and Maintenance Manual, Diagnostic increase engine rpm until the oil pressure gauge
Flash Code Retrival (Operation Section). indicates at least normal pressure. Inspect the engine
for leaks and/or unusual noises.
NOTICE
Do not engage the starting motor when flywheel is After the engine has started, the air inlet heater may
turning. Do not start the engine under load. continue to operate in a Continuous mode and/or in
an Intermittent mode. The air inlet heater will turn
If the engine fails to start within 30 seconds, release OFF when the sum of the coolant temperature and
the starter switch or button and wait two minutes to the air inlet temperature exceeds 35 C or 127 F.
allow the starting motor to cool before attempting to
start the engine again. If the engine is operated with a low load, the engine
will reach normal operating temperature sooner than
idling the engine with no load. When the engine is
3. Push the start button or turn the ignition switch to idled in cold weather, increase the engine rpm to
the START position in order to crank the engine. approximately 1000 to 1200 rpm. This will warm
up the engine more quickly. Do not exceed the
Do not push down or hold the throttle down recommended rpm in order to increase the speed
while the engine is cranked. The system will of the warm-up. Limit unnecessary idle time to ten
automatically provide the correct amount of fuel minutes.
that is needed to start the engine.
NOTICE
Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine rpm until the oil DO NOT USE ETHER (starting fluids) unless
pressure gauge indicates normal. If oil pressure is not specifically instructed to do so. If the engine is
indicated on the gauge within 15 seconds, DO NOT equipped with an Air Inlet Heater (electrically or
operate the engine. STOP the engine, investigate and fuel ignited manifold heater), DO NOT use ether
correct the cause. (starting fluids) at any time. The use could result
in engine damage and/or personal injury.
5. Allow the engine to idle for approximately
three minutes. Idle the engine until the water Starting Problems
temperature gauge has begun to rise. Check all
gauges during the warm-up period. An occasional starting problem may be caused by
one of the following items:
If the engine fuel system has been run dry, fill the i02308903
fuel tank and prime the fuel system. Refer to the
Operation and Maintenance Manual, Fuel System - Starting with Jump Start
Prime topic (Maintenance Section). Cables
If the other problems are suspected, perform the SMCS Code: 1000; 1401; 1402; 1900
appropriate procedure in order to start the engine.
2. If a wire is loose, push the wire back into the When using an external electrical source to start the
connector. Pull the wire again in order to ensure engine, turn the generator set control switch to the
that the wire is secure. OFF position. Turn all electrical accessories OFF be-
fore attaching the jump start cables.
3. Start the engine. If the engine does not start,
consult the nearest Caterpillar dealer for Ensure that the main power switch is in the OFF posi-
assistance. tion before attaching the jump start cables to the en-
gine being started.
i01646248
Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
possible in some applications.
NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.
NOTICE
Do not start the engine until the problem necessitating
the emergency stop has been located and corrected.
SEBU8089 41
Operation Section
Engine Stopping
i01646416 i01465494
Note: Individual applications will have different Note: Before you check the engine oil, do not operate
control systems. Ensure that the shutoff procedures the engine for at least 10 minutes in order to allow
are understood. Use the following general guidelines the engine oil to return to the oil pan.
in order to stop the engine.
Check the crankcase oil level. Maintain the oil level
1. Remove the load, when possible. Reduce the between the ADD mark and the FULL mark on
engine speed (rpm) to low idle. the oil level gauge.
2. Increase the engine speed (rpm) to no more than If necessary, perform minor adjustments. Repair
one-half of the rated rpm. Perform this procedure any leaks and tighten any loose bolts.
for three to five minutes in order to cool the engine.
Reduce the engine speed (rpm) to low idle. Note the service hour meter reading. Perform
the maintenance that is in the Operation and
3. After the cool down period, turn the key switch to Maintenance Manual, Maintenance Interval
the OFF position. Schedule.
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Coolant Specifications that are in the Operation
and Maintenance Manual. Failure to do so can cause
engine damage.
Cold Weather Operation Quantities of No. 1 diesel fuel are limited. No. 1 diesel
fuels are usually available during the months of the
winter in the colder climates. During cold weather
i01457051 operation, if No. 1 diesel fuel is not available, use No.
2 diesel fuel, if necessary.
Radiator Restrictions
There are three major differences between No. 1 and
SMCS Code: 1353; 1396 No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow Lower cloud point
restriction can cause the following conditions:
Lower pour point
High exhaust temperatures
Lower rating of kJ (BTU) per unit volume of fuel
Power loss
When No. 1 diesel fuel is used, a decrease in power
Excessive fan usage and in fuel efficiency may be noticed. Other operating
effects should not be experienced.
Reduction in fuel economy
The cloud point is the temperature when a cloud of
If an airflow restriction device must be used, the wax crystals begins to form in the fuel. These crystals
device should have a permanent opening directly can cause the fuel filters to plug. The pour point is
in line with the fan hub. The device must have a the temperature when diesel fuel will thicken. The
minimum opening dimension of at least 770 cm2 diesel fuel becomes more resistant to flow through
(120 in2). fuel pumps and through fuel lines.
A centered opening that is directly in line with the fan Be aware of these values when diesel fuel is
hub is specified in order to prevent an interrupted purchased. Anticipate the average ambient
airflow on the fan blades. Interrupted airflow on the temperature of the area. Engines that are fueled in
fan blades could cause a fan failure. one climate may not operate well if the engines are
moved to another climate. Problems can result due
Caterpillar recommends a warning device for the to changes in temperature.
inlet manifold temperature and/or the installation of
an inlet air temperature gauge. The warning device Before troubleshooting for low power or for poor
for the inlet manifold temperature should be set at performance in the winter, check the type of fuel that
75 C (167 F). The inlet manifold air temperature is being used.
should not exceed 75 C (167 F). Temperatures that
exceed this limit can cause power loss and potential When No. 2 diesel fuel is used the following
engine damage. components provide a means of minimizing problems
in cold weather:
i02237624
Starting aids
Fuel and the Effect from Cold
Engine oil pan heaters
Weather
Engine coolant heaters
SMCS Code: 1000; 1250
Fuel heaters
The following fuels are the grades that are available
for Caterpillar engines: Fuel line insulation
No. 1 For more information on cold weather operation,
see Special Publication, SEBU5898, Cold Weather
No. 2 Recommendations.
Oil changes Note: Fuel heaters that are controlled by the water
temperature regulator or self-regulating fuel heaters
Refueling of the fuel tank should be used with this engine. Fuel heaters that
are not controlled by the water temperature regulator
This will help prevent water and/or sediment from can heat the fuel in excess of 65 C (149 F). A
being pumped from the fuel storage tank and into loss of engine power can occur if the fuel supply
the engine fuel tank. temperature exceeds 37 C (100 F).
NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel,
a two micron absolute high efficiency fuel filter is re-
quired for all Caterpillar Hydraulic Electronic Unit In-
jectors. Caterpillar High Efficiency Fuel Filters meet
these requirements. Consult your Caterpillar dealer
for the proper part numbers.
44 SEBU8089
Maintenance Section
Refill Capacities
Table 11
C7 Industrial Engine
Approximate Refill Capacities
Refill Capacity for
Changing the Oil
System and the Filter
Liters Quarts
Shallow Oil Sump(1) 18.0 19.0
g00808467
Illustration 29
Deep Oil Sump(1) 25.0 26.5
(1) Shallow oil sump
(2) Deep oil sump (Aluminum)
(3) Deep oil sump (Stamped steel)
Performance specifications
Available sizes of containers
Part numbers
Always choose a grease that meets the
recommendations that are specified by the
equipment manufacturer for the application.
SEBU8089 47
Maintenance Section
Refill Capacities
Note: All Caterpillar brand name greases are Acceptable A Caterpillar Diesel Engine
compatible with each other. Antifreeze/Coolant (DEAC) or a commercial
heavy-duty antifreeze/coolant that meets ASTM
Note: Refer to Special Publication, SEBU6251, D4985, or ASTM D6210 specifications
Caterpillar Commercial Diesel Engine Fluids
Recommendations for additional information that Note: Caterpillar DEAC does not require a treatment
relates to lubrication for your engine. with an SCA at the initial fill. A commercial heavy-duty
antifreeze/coolant that meets ASTM D4985
or ASTM D6210 specifications MAY require a
Fuel treatment with an SCA at the initial fill. These
coolants WILL require a treatment with an SCA on a
Distillate Diesel Fuel maintenance basis.
Boiling
Freezing
48 SEBU8089
Maintenance Section
Refill Capacities
Cavitation of the water pump and cylinder liners SOS Coolant Analysis
For optimum performance, Caterpillar recommends a Testing the engine coolant is important to ensure that
1:1 mixture of a water/glycol solution. the engine is protected from internal cavitation and
from corrosion. The analysis also tests the ability of
Note: Use a mixture that will provide protection the coolant to protect the engine from boiling and
against the lowest ambient temperature. from freezing. The SOS Coolant Analysis can be
done at your Caterpillar dealer. Caterpillar SOS
Note: 100 percent pure glycol will freeze at a Coolant Analysis is the best way to monitor the
temperature of 23 C (9 F). condition of your coolant and your cooling system.
SOS Coolant Analysis is a program that is based
Refer to tables 13 and 14for additional information. on periodic samples.
The user is responsible for the performance of Cooling System Coolant Sample (Level 2) -
maintenance, including all adjustments, the use of Obtain ................................................................. 61
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure Every 3000 Service Hours or 3 Years
to adhere to proper maintenance intervals and Cooling System Coolant (DEAC) - Change .......... 56
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Every 6000 Service Hours or 3 Years
Use mileage, fuel consumption, service hours, or Cooling System Coolant Extender (ELC) - Add .... 60
calendar time, WHICH EVER OCCURS FIRST,
in order to determine the maintenance intervals. Every 12 000 Service Hours or 6 Years
Products that operate in severe operating conditions
may require more frequent maintenance. Cooling System Coolant (ELC) - Change ............. 58
Note: Before each consecutive interval is performed, PM Level 1 - Every 6625 L (1750 US gal) of
all maintenance from the previous interval must be Fuel or 250 Service Hours or 6 Months
performed.
Air Compressor - Inspect ...................................... 51
When Required Air Compressor Filter - Clean/Replace ................. 52
Alternator - Inspect ............................................... 52
Battery - Replace .................................................. 53 Battery Electrolyte Level - Check .......................... 54
Battery or Battery Cable - Disconnect .................. 55 Belts - Inspect/Adjust ............................................ 55
Engine Air Cleaner Element (Dual Element) - Cooling System Supplemental Coolant Additive
Clean/Replace .................................................... 65 (SCA) - Test/Add ................................................. 62
Engine Storage Procedure - Check ...................... 73 Cylinder Head Grounding Stud - Inspect/Clean/
Fuel System - Prime ............................................. 74 Tighten ................................................................ 64
Severe Service Application - Check ..................... 83 Engine Crankcase Breather - Clean ..................... 68
Engine Oil Sample - Obtain .................................. 69
Daily Engine Oil and Filter - Change ............................. 70
Fan Drive Bearing - Lubricate ............................... 73
Air Tank Moisture and Sediment - Drain ............... 52 Fuel System Secondary Filter - Replace .............. 76
Cooling System Coolant Level - Check ................ 60 Fuel Tank Water and Sediment - Drain ................. 77
Driven Equipment - Check .................................... 64 Hoses and Clamps - Inspect/Replace .................. 78
Engine Air Cleaner Service Indicator - Inspect ..... 67 Radiator - Clean .................................................... 82
Engine Oil Level - Check ...................................... 69
Fuel System Primary Filter/Water Separator -
PM Level 2 - Every 52 990 L (14 000 US gal)
Drain ................................................................... 75
Fuel System Primary Filter (Water Separator) of Fuel or 2000 Service Hours or 1 Year
Element - Replace .............................................. 75 Aftercooler Core - Clean/Test ............................... 51
Power Take-Off Clutch - Check/Adjust/Lubricate .. 82 Engine Valve Lash - Inspect/Adjust ...................... 73
Walk-Around Inspection ........................................ 85
PM Level 3 - Every 105 980 L (28 000 US gal)
Initial 20 to 40 Service Hours of Fuel or 4000 Service Hours or 2 Years
Belts - Inspect/Adjust ............................................ 55 Belt Tensioner - Inspect ........................................ 55
Cooling System Water Temperature Regulator -
Every Week Replace ............................................................... 63
Battery Charger - Check ....................................... 53 Crankshaft Vibration Damper - Inspect ................. 63
Engine - Clean ...................................................... 64
Jacket Water Heater - Check ................................ 79
Engine Mounts - Inspect ....................................... 68
50 SEBU8089
Maintenance Section
Maintenance Interval Schedule
Overhaul
Overhaul Considerations ...................................... 79
SEBU8089 51
Maintenance Section
Aftercooler Core - Clean/Test
i02113479
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
Air Compressor - Inspect
can attack the internal metals of the core and cause SMCS Code: 1803-040
leakage. Only use the recommended concentration of
cleaner.
3. Back flush the core with cleaner. Do not disconnect the air line from the air com-
pressor governor without purging the air brake
Caterpillar recommends the use of Hydrosolv and the auxiliary air systems. Failure to purge the
liquid cleaner. Table 16 lists Hydrosolv liquid air brake and the auxiliary air systems before re-
cleaners that are available from your Caterpillar moving the air compressor and/or the air lines
dealer. could cause personal injury.
Table 16
Freezing
Corrosion of internal parts
Malfunction of the air starting system
SEBU8089 53
Maintenance Section
Battery - Replace
4. The POSITIVE + cable connects the POSITIVE 2. Adjust the voltage of the charger in order to match
+ battery terminal to the starting motor. the voltage of the battery.
Disconnect the cable from the POSITIVE +
battery terminal. 3. Connect the POSITIVE + lead of the charger
to the POSITIVE + battery terminal. Connect
Note: Always recycle a battery. Never discard a the NEGATIVE - lead of the charger to the
battery. Return used batteries to an appropriate NEGATIVE - battery terminal.
recycling facility.
4. Turn ON the battery charger.
5. Remove the used battery.
Overcharging of Batteries
6. Install the new battery.
Overcharging reduces the service life of batteries.
Note: Before the cables are connected, ensure that Use a battery charger that will not overcharge the
the key start switch is OFF. battery. DO NOT charge the battery if the meter of
the battery charger is in the RED zone.
7. Connect the cable from the starting motor to the
POSITIVE + battery terminal. Overcharging is indicated by the following symptoms:
The battery emits smoke or a dense vapor (gas). Battery Electrolyte Level -
Perform one of the following procedures if the battery
Check
shows symptoms of overcharging: SMCS Code: 1401-535
Reduce the rate of charging by a significant When the engine is not run for long periods of time or
amount. Complete the charging at the reduced when the engine is run for short periods, the batteries
rate. may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries
Turn OFF the charger. are properly charged, ammeter reading should be
very near zero, when the engine is in operation.
Table 17 describes the effects of overcharging on
different types of batteries.
Table 17
Effects of Overcharging Batteries All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
Type of Battery Effect shield and protective clothing when working on or
near batteries.
Caterpillar General Service All of the battery cells have
Batteries a low level of electrolyte. 1. Remove the filler caps. Maintain the electrolyte
Caterpillar Premium High level to the FULL mark on the battery.
Output Batteries
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
When the plates of the softened water.
battery are inspected
through the filler holes, the 2. Check the condition of the electrolyte with the
plates may appear to be
warped. This is caused by
245-5829 Coolant Battery Tester Refractometer.
an excessive temperature.
3. Keep the batteries clean.
The battery may not pass
a load test. Clean the battery case with one of the following
Caterpillar Maintenance The battery may not accept cleaning solutions:
Free Batteries a charging current.
A mixture of 0.1 kg (0.2 lb) of baking soda and
The battery may not pass 1 L (1 qt) of clean water
a load test.
A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
Checking After Stopping
Thoroughly rinse the battery case with clean water.
Ensure that the battery charger is connected
properly. Observe the meter of the charger. Record
Use a fine grade of sandpaper to clean the
the amperage.
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
SEBU8089 55
Maintenance Section
Battery or Battery Cable - Disconnect
Belts - Inspect/Adjust
The battery cables or the batteries should not be
removed with the battery cover in place. The bat- SMCS Code: 1357-025; 1357-040
tery cover should be removed before any servic-
ing is attempted. Inspection
Removing the battery cables or the batteries with Belt tension should be checked initially between
the cover in place may cause a battery explosion the first 20 to 40 hours of engine operation. Check
resulting in personal injury. the tension when the engine is stopped.
1. Turn the start switch to the OFF position. Turn the After the initial check, the belt tension should be
ignition switch (if equipped) to the OFF position checked at Every 250 Service Hours or Six Months.
and remove the key and all electrical loads.
To maximize the engine performance, inspect the
2. Disconnect the negative battery terminal at the belts for wear and for cracking. Replace belts that are
battery that goes to the start switch. Ensure that worn or damaged.
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of For applications that require multiple drive belts,
two batteries must be disconnected. replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to
3. Tape the leads in order to help prevent accidental carry more load because the older belt is stretched.
starting. The additional load on the new belt could cause the
new belt to break.
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables. If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
i01555583
If the belts are too tight, unnecessary stresses are
Belt Tensioner - Inspect placed on the pulley bearings and on the belts. This
(If Equipped) may shorten the service life of the components.
SMCS Code: 1358-040 Remove the belt guard. Inspect the condition and
adjustment of the alternator belts and accessory
drive belts (if equipped).
If the engine is not equipped with a refrigerant Water Pump Belt (IF EQUIPPED)
compressor, the alternator is used to adjust the
belt tension.
Adjustment
Alternator Belt
g00426869
Illustration 33
Exploded view of the drive assembly for a water pump belt
(1) Mounting bolt
(2) Square hole
(3) Adjusting bolt
2. Close the drain valve (if equipped). Clean the 2. Start and run the engine at low idle. Increase the
drain plugs. Install the drain plugs. Refer to the engine rpm to 1500 rpm. Run the engine at high
Specifications Manual, SENR3130, Torque idle for one minute in order to purge the air from
Specifications for more information on the proper the cavities of the engine block. Stop the engine.
torques.
3. Check the coolant level. Maintain the coolant level
NOTICE within 13 mm (0.5 inch) below the bottom of the
Fill the cooling system no faster than 19 L (5 US gal) pipe for filling. Maintain the coolant level within
per minute to avoid air locks. 13 mm (0.5 inch) to the proper level on the sight
glass (if equipped).
3. Fill the cooling system with a mixture of clean 4. Clean the cooling system filler cap. Inspect the
water and Caterpillar Fast Acting Cooling System gasket that is on the cooling system filler cap. If
Cleaner. Add 0.5 L (1 pint) of cleaner per the gasket that is on the cooling system filler cap
3.8 to 7.6 L (1 to 2 US gal) of the cooling system is damaged, discard the old cooling system filler
capacity. Install the cooling system filler cap. cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler
4. Start and run the engine at low idle for a minimum cap is not damaged, perform a pressure test. A
of 90 minutes. The coolant temperature should be 9S-8140 Pressurizing Pump is used to perform
at least 82 C (180 F). the pressure test. The correct pressure for the
cooling system filler cap is stamped on the face of
NOTICE the cooling system filler cap. If the cooling system
Improper or incomplete rinsing of the cooling system filler cap does not retain the correct pressure,
can result in damage to copper and other metal com- install a new cooling system filler cap.
ponents.
5. Start the engine. Inspect the cooling system for
To avoid damage to the cooling system, make sure leaks and for proper operating temperature.
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the i02173402
cleaning agent are gone.
Cooling System Coolant (ELC)
5. Stop the engine and allow the engine to cool. - Change
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the SMCS Code: 1350-070; 1395-044
cooling system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain Clean the cooling system and flush the cooling
plugs. Allow the water to drain. Flush the cooling system before the recommended maintenance
system with clean water. Close the drain valve interval if the following conditions exist:
(if equipped). Clean the drain plugs. Install the
drain plugs. Refer to the Specifications Manual, The engine overheats frequently.
SENR3130, Torque Specifications for more
information on the proper torques. Foaming is observed.
Fill The oil has entered the cooling system and the
coolant is contaminated.
NOTICE The fuel has entered the cooling system and the
Fill the cooling system no faster than 19 L (5 US gal) coolant is contaminated.
per minute to avoid air locks.
Note: When the cooling system is cleaned, only
1. Fill the cooling system with coolant/antifreeze. clean water is needed when the ELC is drained and
Refer to the Operation and Maintenance Manual, replaced.
Refill Capacitites and Recommendations topic
(Maintenance Section) for more information on Note: Inspect the water pump and the water
cooling system specifications. Do not install the temperature regulator after the cooling system has
cooling system filler cap. been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
SEBU8089 59
Maintenance Section
Cooling System Coolant (ELC) - Change
Drain 4. Start and run the engine at low idle until the
temperature reaches 49 to 66 C (120 to 150 F).
i02285855
2. It may be necessary to drain enough coolant from Pressurized System: Hot coolant can cause seri-
the cooling system in order to add the Extender. ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
3. Add Extender according to the requirements for components are cool. Loosen the cooling system
your engines cooling system capacity. Refer pressure cap slowly in order to relieve the pres-
to the Operation and Maintenance Manual, sure.
Refill Capacities and Recommendations in
the Maintenance Section for more information
concerning the Cat ELC Extender additions. 1. Remove the cooling system filler cap slowly in
order to relieve pressure.
4. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace 2. Maintain the coolant level within 13 mm (0.5 inch)
the cooling system filler cap if the gaskets are of the bottom of the filler pipe. If the engine is
damaged. Install the cooling system filler cap. equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
i01197583
g00103639
Illustration 35
Typical filler cap gaskets
Cat ELC Optional(2) Yearly(2) Place the sample in the mailing tube immediately
(1) This is the recommended interval for coolant samples for all after obtaining the sample in order to avoid
conventional heavy-duty coolant/antifreeze. This is also the contamination.
recommended interval for coolant samples of commercial
coolants that meet the Cat EC-1 specification for engine
coolant.
Never collect samples from expansion bottles.
(2) The Level 2 Coolant Analysis should be performed sooner if a
problem is suspected or identified. Never collect samples from the drain for a system.
Commercial long life coolants that meet the Submit the sample for Level 1 analysis.
Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1) For additional information about coolant analysis,
see Special Publication, SEBU6251, Caterpillar
Cat DEAC (Diesel Engine Antifreeze/Coolant) Commercial Diesel Engine Fluids Recommendations
or consult your Caterpillar dealer.
Commercial heavy-duty coolant/antifreeze
i01987714
NOTICE
Always use a designated pump for oil sampling, and Cooling System Coolant
use a separate designated pump for coolant sampling. Sample (Level 2) - Obtain
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This SMCS Code: 1350-008; 1395-008; 1395-554; 7542
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
NOTICE
dealers and customers.
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Note: Level 1 results may indicate a need for Using the same pump for both types of samples may
Level 2 Analysis. contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Submit the sample for Level 2 analysis. 4. Add 2 to 3 drops of the NITRITE INDICATOR
SOLUTION B to the mixing bottle. Move the bottle
For additional information about coolant in a circular motion in order to mix the solution.
analysis, see Special Publication, SEBU6251,
Caterpillar Commercial Diesel Engines Fluids 5. Add 1 drop of NITRITE TEST SOLUTION A to
Recommendations or consult your Caterpillar dealer. the mixing bottle. Move the bottle in a circular
motion in order to mix the solution.
i02017557
6. Repeat 5 until the solution changes color from red
Cooling System Supplemental to light gray, green, or blue. Record the number of
drops of NITRITE TEST SOLUTION A that were
Coolant Additive (SCA) - required to cause the color change.
Test/Add 7. Use Table 19 to interpret the results.
SMCS Code: 1352-045; 1395-081 Table 19
Number of Concentration Maintenance
Drops of SCA Required
Cooling system coolant additive contains alkali. Less than 25 Less than the Add SCA.
recommended Retest the
To help prevent personal injury, avoid contact with
concentration of coolant.
the skin and eyes. Do not drink cooling system SCA
coolant additive.
25 to 30 The None
recommended
Note: Caterpillar recommends an SOS coolant concentration of
analysis (Level 1). SCA
More than 30 More than the Remove the
Test the Concentration of the SCA recommended coolant.
concentration of Replace with
SCA water only
Coolant/Antifreeze and SCA Retest the
coolant.
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration. Add the SCA, If Necessary
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Follow the instructions
that are provided in the kit. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
Water and SCA stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
NOTICE pressure cap slowly in order to relieve the pres-
Do not exceed the recommended eight percent sup- sure.
plemental coolant additive concentration.
1. Remove the cooling system filler cap slowly.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Use the instructions Note: Always dispose of fluids according to local
that follow: regulations.
1. Fill the syringe to the 1.0 ml mark with the 2. If necessary, drain some coolant in order to allow
coolant. space for the addition of the SCA.
NOTICE NOTICE
Excessive supplemental coolant additive concentra- Failure to replace your water temperature regulator
tion can form deposits on the higher temperature sur- on a regularly scheduled basis could cause severe
faces of the cooling system, reducing the engines engine damage.
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other Caterpillar engines incorporate a shunt design cooling
high temperature components. system and require operating the engine with a water
temperature regulator installed.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat exchang- If the water temperature regulator is installed incor-
er, overheating, and/or accelerated wear of the water rectly, the engine may overheat, causing cylinder head
pump seal. damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
Do not exceed the recommended amount of supple- the water temperature regulator vent hole is open.
mental coolant additive concentration.
Do not use liquid gasket material on the gasket or
3. Add the proper amount of SCA. The concentration cylinder head surface.
of the SCA depends on the type of coolant that
is used. To determine the proper amount, see Refer to the Service Manual for the replacement
this Operation and Maintenance Manual, Refill procedure of the water temperature regulator, or
Capacities and Recommendations topic. consult your Caterpillar dealer.
4. Clean the cooling system filler cap. Install the Note: If only the water temperature regulators are
cooling system filler cap. replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
i00912898
Engine - Clean
SMCS Code: 1000-070
NOTICE
g00768411
Accumulated grease and oil on an engine is a fire haz-
Illustration 36 ard. Keep the engine clean. Remove debris and fluid
Typical example spills whenever a significant quantity accumulates on
the engine.
Inspect the OEM harness for good connections and
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 grounding oil and grease. A clean engine provides the following
stud at every oil change. Ground wires and straps benefits:
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
Note: Caution must be used in order to prevent
Keep the electrical grounding stud and the strap electrical components from being damaged by
clean and coated with MPGM grease or petroleum
jelly. excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
starter, and the ECM.
i00174798
The primary air cleaner element can be used up Aim the hose so that the air flows inside the element
to six times if the element is properly cleaned and along the length of the filter in order to help prevent
inspected. When the primary air cleaner element is damage to the paper pleats. Do not aim the stream
cleaned, check for rips or tears in the filter material. of air directly at the primary air cleaner element. Dirt
The primary air cleaner element should be replaced could be forced further into the pleats.
at least one time per year. This replacement should
be performed regardless of the number of cleanings. Note: Refer to Inspecting the Primary Air Cleaner
Elements.
Use clean primary air cleaner elements while dirty
elements are being cleaned. Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
NOTICE
primary air cleaner elements which require daily
Do not clean the air cleaner elements by bumping or
cleaning because of a dry, dusty environment.
tapping. This could damage the seals. Do not use el-
Cleaning with pressurized air is recommended prior
ements with damaged pleats, gaskets or seals. Dam-
to vacuum cleaning. Vacuum cleaning will not remove
aged elements will allow dirt to pass through. Engine
deposits of carbon and oil.
damage could result.
Note: Refer to Inspecting the Primary Air Cleaner
Visually inspect the primary air cleaner elements Elements.
before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.
Pressurized air
Vacuum cleaning
SEBU8089 67
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.
Date of cleaning
Number of cleanings
Store the box in a dry location.
g00281693
Illustration 39
i01900118
g00281694
Illustration 40
g00103777
Illustration 41
Typical service indicator
68 SEBU8089
Maintenance Section
Engine Crankcase Breather - Clean
Illustration 43
g00110310
Engine model
(Y) ADD mark. (X) FULL mark.
Service hours on the engine
NOTICE
The number of hours that have accumulated since
Perform this maintenance with the engine stopped. the last oil change
1. Maintain the oil level between ADD mark (Y) and The amount of oil that has been added since the
FULL mark (X) on oil level gauge (1). Do not fill last oil change
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 oils 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.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Normal(2) High Fuel Altitude Begin with a 250 hour oil change interval. The oil
Load Sulfur above change intervals are adjusted by increments. Each
Multigrade Factor from 1830 m interval is adjusted an additional 50 hours. Periodic oil
Oil Type above 0.3% to (6000 ft) sampling and analysis is done during each interval.
43 L 0.5% The analysis includes oil viscosity and infrared (IR)
(11 US
gal per
(4) analysis of the oil. Repeat Program B if you change
hour of the application of the engine.
fuel)
(3) If an oil sample does not pass the analysis, shorten
the oil change interval, or change to a preferred
Cat DEO multigrade oil type in the listing above.
250 hr 250 hr 250 hr 250 hr(6)
Preferred
API CH-4 References
11.0
minimum 250 hr 250 hr 250 hr 250 hr(6) Reference: Form, PEDP7035, Optimizing Oil
TBN(4) Change Intervals
Preferred
API CH-4 Reference: Form, PEDP7036, SOS Fluid Analysis
TBN(4) 250 hr 250 hr 250 hr(5) 250 hr(6)
below 11.0 Reference: Form, PEDP7076, Understanding the
SOS Oil Analysis Tests
API CG-4 250 hr 250 hr(5) 250 hr(5) 250 hr(6)
(1) The standard oil change interval in this engine is 250 hours,
if the operating conditions and recommended oil types that Drain the Engine Oil
are listed in this table are met. Oil change intervals may be
increased to 500 hours, depending on the type of oil, quality and After the engine has been run at the normal operating
operating conditions. Refer to Special Publication, PEDP7035, temperature, stop the engine. Attach a DO NOT
Optimizing Oil Change Intervals in order to determine if the oil
change interval can be extended beyond 250 hours.
OPERATE or a similar warning tag to the ignition
(2) Normal conditions include these factors: Fuel sulfur below keyswitch before the engine is serviced. Catch the
0.3%, altitude below 1830 m (6000 ft), and good air filter and oil in a suitable container. Recycle the used oil, or
fuel filter maintenance. Normal conditions do not include high dispose of the used oil properly.
load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine oil. 1. Remove the oil drain plug in order to allow the oil
Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These to drain.
factors deplete the oil additives more rapidly. If the average
fuel consumption of your engine exceed 43 L (11 US gal) per 2. After the oil has drained, the oil drain plug should
hour, follow the High Load Factor recommendations in Table be cleaned and installed.
20. To determine average fuel consumption for your engine,
measure average fuel consumption for a period of 50 to 100
hours. If the application of the engine is changed, the average
fuel consumption may change.
Replace the Oil Filter
(4) For sulfur content above 0.5%, refer to, Total Base Number
(TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel NOTICE
Engines in Special Publication, SEBU6251, Caterpillar
Commercial Diesel Engine Fluids Recommendations.
Caterpillar oil filters are built to Caterpillar speci-
(5) In order to verify an oil change interval of 500 hours, refer to
fications. Use of an oil filter not recommended by
Program A below. Caterpillar could result in severe engine damage to
(6) Use Program B below to determine an appropriate interval. the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
Adjustment of the Oil Change Interval the engine lubricating system. Only use oil filters
recommended by Caterpillar.
Note: Your Caterpillar dealer has additional
information on these programs. 1. Remove the oil filter with a 185-3630 Strap
Wrench.
Program A
Proceed to Program B.
72 SEBU8089
Maintenance Section
Engine Oil and Filter - Change
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 45
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. Fill the crankcase with
Cutter . Break apart the pleats and inspect the the proper amount of oil. Refer to the Operation
oil filter for metal debris. An excessive amount and Maintenance Manual, Refill Capacities and
of metal debris in the oil filter may indicate early Recommendations topic (Maintenance Section)
wear or a pending failure. for more information.
g00103713
Illustration 46
Typical filter mounting base and filter gasket
i01430860
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
Do not crank the engine continuously for more than
3. If the engine does not start, open the fuel priming 30 seconds. Allow the starting motor to cool for two
pump and repeat Steps 1 and 2 in order to start minutes before cranking the engine again.
the engine.
SEBU8089 75
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
1. Operate the starting motor. This will fill the fuel i02241591
filter and the fuel lines with fuel.
Fuel System Primary Filter
2. Once the engine starts, operate the engine at low
idle. Do not raise the engine speed above an idle,
(Water Separator) Element -
until the engine operates smoothly. Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
i00259781
Water in the fuel can cause the engine to run rough.
Fuel System Primary Water in the fuel may cause a electronic unit injector
Filter/Water Separator - Drain to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
SMCS Code: 1260-543; 1263-543 scheduled interval.
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.
g00104012
Illustration 50
(1) Element. (2) Bowl. (3) Drain.
i01503750
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
Fuel System Secondary Filter -
Replace
3. Dispose of the fuel in the fuel filter element. SMCS Code: 1261-510-SE
Remove bowl (2) from element (1). The bowl is
reusable. Do not discard the bowl. Dispose of the
used element.
4. Remove the O-ring from the gland of the bowl. Fuel leaked or spilled onto hot surfaces or elec-
Clean the following components: trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
Bowl changing fuel filters or water separator elements.
Clean up fuel spills immediately.
O-ring
NOTICE
Mounting base Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
Inspect the O-ring for damage and for
will be disconnected. Fit a suitable cover over any dis-
deterioration. Replace the O-ring, if necessary.
connected fuel system components.
5. Lubricate the O-ring with clean diesel fuel.
NOTICE
6. Install bowl (2) on a new element. Tighten the Use a suitable container to catch any fuel that might
bowl by hand. Do not use tools in order to tighten spill. Clean up any spilled fuel immediately.
the bowl.
Fuel Tank
NOTICE
In order to maximize fuel system life and prevent pre- Fuel quality is critical to the performance and to the
mature wear out from abrasive particles in the fuel, service life of the engine. Water in the fuel can cause
a two micron absolute high efficiency fuel filter is re- excessive wear to the fuel system. Condensation
quired for all Caterpillar Hydraulic Electronic Unit In- occurs during the heating and cooling of fuel. The
jectors. Caterpillar High Efficiency Fuel Filters meet condensation occurs as the fuel passes through the
these requirements. Consult your Caterpillar dealer fuel system and the fuel returns to the fuel tank. This
for the proper part numbers. causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
5. Install the new fuel filter. Spin the fuel filter onto
the fuel filter base until the gasket contacts the
base. Use the rotation index marks on the filters Drain the Water and the Sediment
as a guide for proper tightening. Tighten the filter
for an additional one turn (360 degrees) by hand. Fuel tanks should contain some provision for draining
Do not overtighten the filter. water and draining sediment from the bottom of the
fuel tanks.
6. Open the fuel supply valve. Prime the fuel system.
Refer to the Operation and Maintenance Manual, Open the drain valve on the bottom of the fuel tank
Fuel System - Prime topic (Maintenance Section) in order to drain the water and the sediment. Close
for more information. Start the engine and inspect the drain valve.
the fuel system for leaks.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
NOTICE the water and sediment from the fuel tank after the
Do not crank the engine continuously for more than fuel tank has been filled. Allow five to ten minutes
30 seconds. Allow the starting motor to cool for two before performing this procedure.
minutes before cranking the engine again.
Fill the fuel tank after operating the engine in
Note: There should be enough residual fuel in the order to drive out moist air. This will help prevent
cylinder head in order to start the engine. If the condensation. Do not fill the tank to the top. The
engine stops after starting, do not crank the engine fuel expands as the fuel gets warm. The tank may
for more than 30 seconds. Then allow the starting overflow.
motor to cool for two minutes. Repeat this procedure
until the engine starts and the engine operates. Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
i02436696 take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
Fuel Tank Water and Sediment maintenance of the fuel system filter is important.
- Drain
Fuel Storage Tanks
SMCS Code: 1273-543-M&S
Drain the water and the sediment from the fuel
NOTICE storage tank during the following conditions:
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Weekly
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- Oil change
ing any compartment or disassembling any compo-
nent containing fluids. Refill of the tank
Refer to Special Publication, NENG2500, Caterpillar This will help prevent water or sediment from being
Dealer Service Tool Catalog for tools and supplies pumped from the storage tank into the engine fuel
suitable to collect and contain fluids on Caterpillar tank. A 2 micron filter for the breather vent on the
products. fuel tank is also recommended. Refer to Special
Publication, SENR9620, Improving Fuel System
Dispose of all fluids according to local regulations and Durablity.
mandates.
78 SEBU8089
Maintenance Section
Hoses and Clamps - Inspect/Replace
If a bulk storage tank has been refilled or moved Each installation application can be different. The
recently, allow adequate time for the sediment to differences depend on the following factors:
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap Type of hose
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel. Type of fitting material
When possible, water separators should be used.
Anticipated expansion and contraction of the hose
i02121526
Anticipated expansion and contraction of the
Hoses and Clamps - fittings
End fittings that are damaged or leaking 5. Disconnect the old hose.
Outer covering that is chafed or cut 6. Replace the old hose with a new hose.
Exposed wire that is used for reinforcement 7. Install the hose clamps with a torque wrench.
Outer covering that is ballooning locally Note: Refer to the Specifications, SENR3130,
Torque Specifications in order to locate the proper
Flexible part of the hose that is kinked or crushed torques.
Armoring that is embedded in the outer covering 8. Refill the cooling system.
A constant torque hose clamp can be used in place 9. Clean the cooling system filler cap. Inspect the
of any standard hose clamp. Ensure that the constant cooling system filler caps gaskets. Replace
torque hose clamp is the same size as the standard the cooling system filler cap if the gaskets are
clamp. damaged. Install the cooling system filler cap.
Due to extreme temperature changes, the hose will 10. Start the engine. Inspect the cooling system for
heat set. Heat setting causes hose clamps to loosen. leaks.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
SEBU8089 79
Maintenance Section
Jacket Water Heater - Check
Reduced hours of operation at full load will result in A planned overhaul before failure may be the best
a lower average power demand and reduced fuel value for the following reasons:
consumption. A decreased average power demand
should increase both the engine service life and the Costly unplanned downtime can be avoided.
overhaul interval.
Many original parts can be reused according to the
The need for an overhaul is generally indicated standards for reusable parts.
by increased fuel consumption, increased oil
consumption, excessive engine blowby, and The engines service life can be extended without
reduced power. Arctic temperatures, extremely high the risk of a major catastrophe due to engine
temperatures, corrosive environments, or extremely failure.
dusty conditions contribute to premature wear and
the need for an overhaul. The best cost/value relationship per hour of
extended life can be attained.
The following factors are important when a decision
is being made on the proper time for an engine After Failure Overhaul
overhaul:
If a major engine failure occurs and the engine
The need for preventive maintenance must be removed, many options are available. An
overhaul should be performed if the engine block or
The quality of the fuel that is being used the crankshaft needs to be repaired.
The operating conditions If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
The results of the SOS analysis percent and 50 percent of the cost of a new engine
with a similar exchange core.
Oil Consumption as an Overhaul
This lower cost can be attributed to three aspects:
Indicator
Specially designed Caterpillar engine features
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total Caterpillar dealer exchange components
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the Caterpillar Inc. remanufactured exchange
required capacity of a makeup oil tank that is suitable components
for the maintenance intervals.
80 SEBU8089
Maintenance Section
Overhaul Considerations
If the parts comply with the established inspection Damage to the journals
specifications that are expressed in the reusable
parts guideline, the parts should be reused. Bearing material that has seized to the journals
Parts that are not within the established inspection Check the journal taper and the profile of the
specifications should be dealt with in one of the crankshaft journals. Check these components by
following manners: interpreting the wear patterns on the following
components:
Salvaging
Rod bearing
Repairing
Main bearings
Replacing
Inspect the camshaft for damage to the journals and
Using out-of-spec parts can result in the following to the lobes.
problems:
Note: If the camshaft is removed for any reason, use
Unscheduled downtime the magnetic particle inspection process to check for
cracks in the camshaft.
Costly repairs
Inspect the following components for signs of wear or
Damage to other engine parts for signs of scuffing:
Reduced engine efficiency and increased fuel Caterpillar Inc. recommends replacing the crankshaft
consumption translates into higher operating costs. vibration damper.
Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts.
SEBU8089 81
Maintenance Section
Overhaul Considerations
Identification of contaminants
Identification of built up impurities (corrosion and Do not operate the engine with the Instruction
scale)
Plate cover removed from the clutch. Personal
injury may result.
SOS Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
If the clutch is damaged to the point of burst fail-
recommendations.
ure, expelled pieces can cause personal injury to
anyone in the immediate area. Proper safeguards
For more information about coolant analysis, see
must be followed to help prevent accidents.
your Caterpillar dealer.
i01506009 i01604510
Inspect the fins for damage. Bent fins may be opened Environmental Factors
with a comb. Inspect these items for good condition:
welds, mounting brackets, air lines, connections, Ambient temperatures The engine may be
clamps, and seals. Make repairs, if necessary. exposed to extended operation in extremely
cold environments or hot environments. Valve
For more detailed information on cleaning and components can be damaged by carbon buildup if
inspection, refer to Special Publication, SEBD0518, the engine is frequently started and stopped in very
Know Your Cooling System. cold temperatures. Extremely hot inlet air reduces
engine performance.
i00151038
Air Quality The engine may be exposed to
Severe Service Application - extended operation in an environment that is dirty
or dusty, unless the equipment is cleaned regularly.
Check Mud, dirt and dust can encase components.
Maintenance can be very difficult. The buildup can
SMCS Code: 1000-535 contain corrosive chemicals.
i01185304 Inspect the fuel system for leaks. Look for loose
fuel line clamps or for loose fuel line tie-wraps.
Walk-Around Inspection
Inspect the piping for the air inlet system and the
SMCS Code: 1000-040 elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
Inspect the Engine for Leaks and hoses, tubes, wiring harnesses, etc.
for Loose Connections Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
A walk-around inspection should only take a few
minutes. When the time is taken to perform these Belts for multiple groove pulleys must be replaced as
checks, costly repairs and accidents can be avoided. matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
For maximum engine service life, make a thorough The older belts are stretched. The additional load on
inspection of the engine compartment before starting the new belt could cause the belt to break.
the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
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.
The guards must be in the proper place. Repair
damaged guards or replace missing guards.
Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
Wipe all caps and plugs before the engine is wires.
serviced in order to reduce the chance of system
contamination.
Inspect the ground strap for a good connection and
for good condition.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the Inspect the ECM to the cylinder head ground strap
fluid. If leaking is observed, find the source and correct for a good connection and for good condition.
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found Disconnect any battery chargers that are not
or fixed, or until the suspicion of a leak is proved to be protected against the current drain of the starting
unwarranted. motor. Check the condition and the electrolyte level
of the batteries, unless the engine is equipped with
a maintenance free battery.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauge that
or high pressure water.
can not be calibrated.
Warranty Section
Warranty Information
i01087950
Emissions Warranty
Information
SMCS Code: 1000
Density of 850 kg/m3 (7.085 lb/US gal) C Rating This rating is used when power and/or
rpm are cyclic. The horsepower and the rpm of the
The engine ratings are gross output ratings. engine can be utilized continuously for one hour. This
is followed by one hour of operation at the A rating
Gross Output Ratings The total output capability or below the A rating. The engine should be run at
of the engine that is equipped with standard full load. The engine should not exceed 50 percent
accessories. of the duty cycle. Typical applications include the
following examples: agricultural tractors, harvesters
Standard accessories include the following and combines, off-highway trucks, fire pumps, blast
components: hole drills, rock curshers, wood chippers with high
torque rise, and oil field hoisting.
Oil pumps
D Rating This rating is used when rated power
Fuel pumps is required for periodic overloads. The maximum
horsepower and the rpm of the engine can be utilized
Water pumps continuously for a maximum of 30 minutes. This is
followed by one hour of operation at the C rating. The
Subtract the power that is required to drive auxiliary engine should be run at full load. The engine should
components from the gross output. This will produce not exceed 10 percent of the duty cycle. Typical
the net power that is available for the external load applications include the following examples: offshore
(flywheel). cranes, runway snow blowers, water well drills,
portable air compressors, and fire pump certification
power.
SEBU8089 89
Reference Information Section
Engine Ratings
NOTICE
Operating engines above the rating definitions can re-
sult in shorter service life before overhaul.
90 SEBU8089
Reference Information Section
Customer Service
i01028392
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.
Special Instruction, SEHS8622, Using the FT- International Organization for Standardization
1984 Air-To-Air Aftercooler Leak Test Group (ISO)
1, rue de Varemb
Special Instruction, SEHS7332, Warning Tag - Case postale 56
Danger Do Not Operate CH-1211 Genve 20
Switzerland
Special Instruction, REHS0871, Electronic Telephone: +41 22 749 01 11
Installation Guide. Facsimile: +41 22 733 34 30
E-mail: central@iso.ch
Additional Reference Material Web site: http://www.iso.ch
i01176304
Maintenance Log
SMCS Code: 1000
Table 22
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity
Service Item Date Authorization
Hours Of Fuel
96 SEBU8089
Index Section
Index
A Crankshaft Vibration Damper - Inspect ................. 63
Removal and Installation.................................... 63
After Starting Engine ............................................. 38 Visconic Damper................................................ 63
After Stopping Engine............................................ 41 Crushing Prevention and Cutting Prevention ........ 12
Aftercooler Core - Clean/Test ................................ 51 Customer Assistance............................................. 90
Air Compressor - Inspect....................................... 51 Outside of the USA and of Canada.................... 90
Air Compressor Filter - Clean/Replace (If USA and Canada ............................................... 90
Equipped) ............................................................ 52 Customer Service .................................................. 90
Air Tank Moisture and Sediment - Drain (If Customer Specified Parameters...................... 21, 33
Equipped) ............................................................ 52 Cylinder Head Grounding Stud - Inspect/Clean/
Alternator - Inspect ................................................ 52 Tighten................................................................. 64
B D
Table of Contents..................................................... 3
Turbocharger - Inspect .......................................... 84
Cleaning and Inspecting .................................... 84
Removal and Installation.................................... 84
Product and Dealer Information
Note: For product identification plate locations, see the section Product Identification Information in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
2005 Caterpillar
All Rights Reserved Printed in U.S.A.