SEBU7011-15

April 2005

Operation and
Maintenance
Manual
3126B and 3126E Truck Engines

BKD1-Up (Engine)
G3E1-Up (Engine)
DPF1-Up (Engine)
1AJ1-Up (Engine)
8YL1-Up (Engine)
CKM1-Up (Engine)
CRP1-Up (Engine)
7AS1-Up (Engine)
8SZ1-Up (Engine)
9SZ1-Up (Engine)
 i01658146

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by
Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also
ensure that the product will not be damaged or be made unsafe by the operation, lubrication,
maintenance or repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this product Caterpillar rec-
ommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type,
strength and material.
Failure to heed this warning can lead to premature failures, product
damage, personal injury or death.
SEBU7011-15 3
Table of Contents

Table of Contents
Foreword .................................................................................................. 5

Safety Section
Safety Messages ..................................................................................... 8

General Hazard Information .................................................................. 11

Burn Prevention ..................................................................................... 14

Fire Prevention and Explosion Prevention ............................................. 16

Crushing Prevention and Cutting Prevention ......................................... 18

Mounting and Dismounting .................................................................... 18

Before Starting Engine ........................................................................... 19

Engine Starting ...................................................................................... 19

Engine Stopping .................................................................................... 20

Electrical System ................................................................................... 21

Engine Electronics ................................................................................. 24

Product Information Section

Model Views .......................................................................................... 26

Product Identification Information ......................................................... 33

Operation Section
Lifting and Storage ................................................................................. 42

Gauges and Indicators ........................................................................... 44

Features and Controls ........................................................................... 47

Engine Diagnostics ................................................................................ 56

4 SEBU7011-15
Table of Contents

Engine Starting ...................................................................................... 69

Engine Operation ................................................................................... 78

Engine Stopping .................................................................................... 93

Cold Weather Operation ........................................................................ 95

Maintenance Section
Refill Capacities ..................................................................................... 99

Maintenance Interval Schedule (Engines with a Deep Oil Sump) ....... 111

Maintenance Interval Schedule (Engines with a Shallow Oil Sump) ... 114

Warranty Section
Warranty Information ........................................................................... 198

Reference Information Section

Customer Service ................................................................................ 209

Reference Materials ............................................................................. 213

Index Section
Index .................................................................................................... 221
SEBU7011-15 5
Foreword

Foreword
Literature Information
This manual contains safety, operation instructions, lubrication and
maintenance information. This manual should be stored in or near the
engine area in a literature holder or literature storage area. Read, study
and keep it with the literature and engine information.

English is the primary language for all Caterpillar publications. The English
used facilitates translation and consistency in electronic media delivery.

Some photographs or illustrations in this manual show details or

attachments that may be different from your engine. Guards and
covers may have been removed for illustrative purposes. Continuing
improvement and advancement of product design may have caused
changes to your engine which are not included in this manual. Whenever
a question arises regarding your engine, or this manual, please consult
with your Caterpillar dealer for the latest available information.

Safety
This safety section lists basic safety precautions. In addition, this section
identifies hazardous, warning situations. Read and understand the basic
precautions listed in the safety section before operating or performing
lubrication, maintenance and repair on this product.

Operation
Operating techniques outlined in this manual are basic. They assist with
developing the skills and techniques required to operate the engine more
efficiently and economically. Skill and techniques develop as the operator
gains knowledge of the engine and its capabilities.

The operation section is a reference for operators. Photographs and

illustrations guide the operator through procedures of inspecting, starting,
operating and stopping the engine. This section also includes a discussion
of electronic diagnostic information.
6 SEBU7011-15
Foreword

Maintenance
The maintenance section is a guide to engine care. The illustrated
step-by-step instructions are grouped by distance (odometer), fuel
consumption, service hours, and/or calendar time maintenance intervals.
Items in the maintenance schedule are referenced to detailed instructions
that follow.

Use fuel consumption, distance (odometer), service hours, or calendar

time, whichever occurs first, in order to determine the maintenance
intervals. Recommended service should be performed at the appropriate
intervals as indicated in the Maintenance Interval Schedule. The actual
operating environment of the engine also governs the Maintenance
Interval Schedule. Therefore, under extremely severe, dusty, wet,
or freezing cold operating conditions, more frequent lubrication and
maintenance than is specified in the Maintenance Interval Schedule
may be necessary.

The maintenance schedule items are organized for a preventative

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

Maintenance Intervals
Perform maintenance on items at multiples of the original requirement.
Each level and/or individual items in each level should be shifted ahead
or back depending upon your specific maintenance practices, operation
and application. We recommend that the maintenance schedules be
reproduced and displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be maintained as part
of the engine’s permanent record.

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

Records” for information regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized Caterpillar dealer can
assist you in adjusting your maintenance schedule to meet the needs of
your operating environment.
SEBU7011-15 7
Foreword

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

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State
of California to cause cancer, birth defects, and other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead
compounds. Wash hands after handling.

Certified Engine Maintenance

Proper maintenance and repair is essential to keep the engine and
machine systems operating correctly. As the on-highway truck diesel
engine owner, you are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation and Maintenance
Manual, and Service Manual.

It is prohibited for any person engaged in the business of repairing,

servicing, selling, leasing, or trading engines or machines to remove,
alter or render inoperative any emission related device or element of
design installed on or in an engine or machine that is in compliance with
the regulations (40 CFR Part 89). Certain elements of the machine and
engine such as the exhaust system, fuel system, electrical system, intake
air system and cooling system may be emission related and should not
be altered unless approved by Caterpillar.
8 SEBU7011-15
Safety Section
Safety Messages

Safety Section
i02005611

Safety Messages
SMCS Code: 1000; 7405

There may be several specific warning signs on an engine. The exact

location of the hazards and the description of the hazards are reviewed in
this section. Please become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean the warning signs
or replace the warning signs if the words cannot be read or if the pictures
are not visible. When the warning signs are cleaned, use a cloth, water,
and soap. Do not use solvent, gasoline, or other harsh chemicals to clean
the warning signs. Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the warning signs. The warning signs that are
loosened could drop off of the engine.

Replace any damaged safety signs or missing safety signs. If a safety

sign is attached to a part of the engine that is replaced, install a new
safety sign on the replacement part. Any Caterpillar dealer can provide
new safety signs.

Do not operate or work on this engine unless you

have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Caterpillar dealer for replacement manuals.
Proper care is your responsibility.

Do not work on the engine and do not operate the engine unless the
instructions and the warnings in the Operation and Maintenance Manual
are understood. Proper care is your responsibility. Failure to follow the
instructions or failure to heed the warnings could result in injury or in
death.

The following section illustrates and the following section describes the
safety labels which may be found on the engine.
SEBU7011-15 9
Safety Section
Safety Messages

g01037410
Illustration 1
10 SEBU7011-15
Safety Section
Safety Messages

Hydraulic Electronic Unit Injectors (1)

The warning label for the hydraulic electronic unit injector is located on
the top of the valve cover.

g00907230

Explosion hazard, do not spray ether in the en-

gine. Electrocution hazard. Hydraulic fluid under
pressure. These hazards could cause personal
injury or death. Read the Operation and Mainte-
nance Manual before you service the engine.

The Electronic Control Module (ECM) sends a high voltage signal to

the injector solenoid. To help prevent personal injury, disconnect the
electronic unit injector enable circuit connector. Do not come in contact
with the electronic unit injector terminals while the engine is running.
SEBU7011-15 11
Safety Section
General Hazard Information

Starting Aid (2)

The safety sign for the starting aid is located on the hydraulic pump for
the HEUI injectors.

g00283559

If equipped with an air inlet heater (AIH) for cold

weather starting, do not use aerosal types of start-
ing aids such as ether. Such use could result in an
explosion and personal injury.

i00909638

General Hazard Information

SMCS Code: 1000; 7405

Attach a “Do Not Operate” warning tag or a similar warning tag to the
start switch or to the controls before the engine is serviced or before the
engine is repaired. These warning tags (Special Instruction, SEHS7332)
are available from your Caterpillar dealer. Attach the warning tags to
the engine and to each operator control station. When it is appropriate,
disconnect the starting controls.
12 SEBU7011-15
Safety Section
General Hazard Information

g00104545
Illustration 2

Do not allow unauthorized personnel on the engine or around the

engine when the engine is serviced.

• Tampering with the engine installation or tampering with the truck OEM
wiring installation can be dangerous. Personal injury, death and/or
engine damage could result.

• Vent the engine exhaust to the outside when the engine is operated in
an enclosed area.

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

the parking brake systems unless the vehicle is blocked or unless the
vehicle is restrained.

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

as required.

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

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

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

other parts of the engine.

• Ensure that all protective guards and all covers are secured in place
on the engine.

• Never put maintenance fluids into glass containers. Glass containers

can break.
SEBU7011-15 13
Safety Section
General Hazard Information

• Use all cleaning solutions with care.

• Report all necessary repairs.
Unless other instructions are provided, perform the maintenance under
the following conditions:

• The engine is stopped.

• The protective locks or the controls are in the applied position.
• Engage the secondary brakes or parking brakes.
• Block the vehicle or restrain the vehicle before maintenance or repairs
are performed.

• Disconnect the batteries when maintenance is performed or when the

electrical system is serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.

• Do not attempt any repairs or any adjustments to the engine while the
engine is operating.

• Do not attempt any repairs that are not understood. Use the proper
tools. Replace any equipment that is damaged or repair the equipment.

• For initial start-up of a new engine or for starting an engine that has
been serviced, make provisions to stop the engine if an overspeed
occurs. This may be accomplished by shutting off the fuel supply and/or
the air supply to the engine.

• Start the engine from the operator’s station (cab). Never short across
the starting motor terminals or the batteries. This could bypass the
engine neutral start system and/or the electrical system could be
damaged.

Pressure Air and Water

Pressurized air and/or water can cause debris and/or hot water to be
blown out. This could result in personal injury. When pressure air is
used for cleaning, wear a protective face shield, protective clothing, and
protective shoes. The maximum air pressure for cleaning purposes must
be below 205 kPa (30 psi). The maximum water pressure for cleaning
purposes must be below 275 kPa (40 psi). Always wear eye protection for
cleaning the cooling system.
14 SEBU7011-15
Safety Section
Burn Prevention

Fluid Penetration
Always use a board or cardboard when the engine components are
checked for leaks. Leaking fluid that is under pressure can cause serious
injury or possible death. This includes leaks that are the size of a pin
hole. If fluid is injected into the skin, seek treatment immediately. Seek
treatment from a doctor that is familiar with this type of injury.

Fluid Spillage
Care must be used in order to ensure that the fluids are contained during
the inspection, the maintenance, the testing, the adjusting, and the
repair of the engine. Make provision to collect the fluid with a suitable
container before any compartment is opened or before any component
is disassembled. Refer to the Special Publication, NENG2500. This
publication explains the items that are needed for collecting and for
containing fluids that are used in Caterpillar engines. Dispose of fluids
according to local regulations.

Asbestos Information
Caterpillar equipment and replacement parts that are shipped from
Caterpillar are asbestos free. Caterpillar recommends the use of only
genuine Caterpillar replacement parts.

i00910250

Burn Prevention
SMCS Code: 1000; 7405

Do not touch any part of an operating engine. Allow the engine to cool
before any maintenance is performed on the engine. Relieve all pressure
in the lubrication system, in the fuel system, or in the cooling system
before any lines, fittings or related items are disconnected.

Coolant
When the engine is at operating temperature, the engine coolant is hot.
The coolant is also under pressure. The radiator and all lines to the
heaters or to the engine contain hot coolant. When pressure is relieved
rapidly, the hot coolant can turn into steam.
SEBU7011-15 15
Safety Section
Burn Prevention

Any contact with hot coolant or with steam can cause severe burns. Allow
cooling system components to cool before the cooling system is drained.

Check the coolant level only after the engine has been stopped.

Do not step on the engine in order to remove the filler cap. Use a ladder, if
necessary. Ensure that the filler cap is cool before removing the filler cap.
Remove the filler cap slowly in order to relieve pressure.

Cooling system conditioner contains alkali. Alkali can cause personal

injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

Oils
Hot oil and hot components can cause personal injury. Do not allow hot oil
or hot components to contact the skin.

Keep all of the exhaust manifold and turbocharger shields in place in

order to protect components from oil spray if there is a failure of a line, a
tube, or a seal.

Batteries
Electrolyte is an acid. Electrolyte can cause personal injury. Do not
allow electrolyte to contact the skin or the eyes. Always wear protective
glasses for servicing batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.

Batteries give off combustible gases which can explode. Ensure proper
ventilation for batteries that are in an enclosure. Never disconnect any
charging unit circuit or battery circuit cable from the battery when the
charging unit is operating. A spark can cause the combustible gases to
ignite. Do not smoke when batteries are serviced.

Always thaw a frozen battery before jump starting the battery. Frozen
batteries can explode.
16 SEBU7011-15
Safety Section
Fire Prevention and Explosion Prevention

i01028355

Fire Prevention and Explosion Prevention

SMCS Code: 1000; 7405

Fire may result from lubricating oil or from fuel that is sprayed on hot
surfaces. Fire may cause personal injury and property damage. Inspect
all lines and tubes for wear or for deterioration. The lines must be properly
routed. The lines must have adequate support and secure clamps. Tighten
all connections to the recommended torque. Leaks can cause fires.

Determine whether the engine will be operated in an environment that

allows combustible gases to be drawn in through the air inlet system.
These gases could cause the engine to overspeed. This could result in
bodily injury, property damage, or damage to the engine.

If the application involves the presence of combustible gases, consult

your Caterpillar dealer in order to obtain additional information concerning
suitable protection devices.

Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical
components can cause a fire.

All fuels, most lubricants, and some coolant mixtures are flammable.
Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel
fumes and gasoline fumes is extremely explosive.

Do not smoke while the engine is refueled. Do not smoke in the refueling
area.

Store all fuels and all lubricants in properly marked containers. Store the
protective containers in a safe place.

Do not smoke in battery charging areas. Batteries give off flammable

fumes which can explode.

Do not smoke in areas that contain flammable material.

Store oily rags and other flammable material in protective containers.

Do not weld on pipes or tubes that contain flammable fluids. Do not flame
cut pipes or tubes that contain flammable fluids. Before pipes or tubes are
welded or flame cut, clean the inside and clean the outside of the pipes
or tubes thoroughly with nonflammable solvent.
SEBU7011-15 17
Safety Section
Fire Prevention and Explosion Prevention

Do not allow flammable materials to accumulate on the engine.

Do not expose the engine to flames.

Exhaust shields (if equipped) protect hot exhaust components from oil
or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields
must be installed correctly.

Dispose of oil according to local regulations. Oil filters and fuel filters must
be properly installed. The housing covers must be tightened to the proper
torque when the housing covers are reinstalled.

Batteries must be kept clean. The covers (if equipped) must be kept on
the cells. Use the recommended cables, connections, and battery box
covers when the engine is operated.

When the engine is started from an external source, always connect the
positive “+” jump start cable to the positive “+” terminal of the battery of
the engine that is being started. Make this connection before the negative
“−” jump start cable is connected.

To help prevent sparks from igniting combustible gases that are produced
by some batteries, the negative “−” jump start cable should be connected
last from the external power source to the negative “−” terminal of the
starting motor. If the starting motor is not equipped with a negative “−”
terminal, connect the jump start cable to the engine block.

Check the electrical wires daily for wires that are loose or frayed. Before
the engine is operated, tighten all loose electrical wires. Repair all frayed
electrical wires.

Wiring must be kept in good condition. Wires must be properly routed

and securely attached. Routinely inspect the wiring for wear or for
deterioration. Loose wiring, unattached wiring, or unnecessary wiring
must be eliminated. All wires and all cables must be of the recommended
gauge. The wires and cables must be connected to a fuse or to a circuit
breaker, as required. Do not bypass fuses and/or circuit breakers. Do not
use a wire of a smaller gauge. Arcing or sparking could cause a fire.
Secure connections, recommended wiring, and properly maintained
battery cables will help to prevent arcing or sparking.
18 SEBU7011-15
Safety Section
Crushing Prevention and Cutting Prevention

Fire Extinguisher
Ensure 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. Service the fire extinguisher according to the
recommendations on the instruction plate.

i01359666

Crushing Prevention and Cutting

Prevention
SMCS Code: 1000; 7405

Support the component properly when work beneath the component is

performed.

Unless other maintenance instructions are provided, never attempt

adjustments while the engine is running.

Stay clear of all rotating parts and of all moving parts. Leave the guards in
place until maintenance is performed. After the maintenance is performed,
reinstall the guards.

Keep objects away from moving fan blades. The fan blades will throw
objects or cut objects.

When objects are struck, wear protective glasses in order to avoid injury
to the eyes.

Chips or other debris may fly off objects when objects are struck. Before
objects are struck, ensure that no one will be injured by flying debris.

i00910430

Mounting and Dismounting

SMCS Code: 1000; 7405

Do not climb on the engine, and do not jump off the engine. Do not stand
on components which cannot support your weight. Use an adequate
ladder. Clean the steps, the handholds and the areas of the vehicle that
will be worked on.
SEBU7011-15 19
Safety Section
Before Starting Engine

i00911989

Before Starting Engine

SMCS Code: 1000

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on, underneath, or

close to the engine. All protective guards and all protective covers must
be installed if the engine must be started in order to perform service
procedures. To help prevent an accident that is caused by parts in
rotation, work around the parts carefully.

Do not bypass the automatic shutoff circuits. Do not disable the automatic
shutoff circuits. The circuits are provided in order to help prevent personal
injury. The circuits are also provided in order to help prevent engine
damage.

On the initial start-up of a new engine or an engine that has been

serviced, prepare to stop the engine if an overspeed condition occurs.
This may be accomplished by shutting off the fuel supply to the engine
and/or shutting off the air supply to the engine.

See the Service Manual for repairs and for adjustments.

i00910470

Engine Starting
SMCS Code: 1000

If a warning tag is attached to the engine start switch or to the controls,

do not start the engine or move the controls. Also, do not disengage the
parking brakes. Consult with the person that attached the warning tag
before the engine is started.

All protective guards and all protective covers must be installed if the
engine must be started in order to perform service procedures. To help
prevent an accident that is caused by parts in rotation, work around the
parts carefully.

Start the engine from the operator’s station (cab). Never short across the
starting motor terminals or the batteries. This could bypass the engine
neutral start system and/or the electrical system could be damaged.
20 SEBU7011-15
Safety Section
Engine Stopping

Always start the engine according to the procedure that is described in the
Operation and Maintenance Manual, “Engine Starting” topic (Operation
Section). Knowing the correct procedure will help to prevent major
damage to the engine components. Knowing the procedure will also help
to prevent personal injury.

To ensure that the jacket water heater (if equipped) and/or the lube oil
heater (if equipped) is working properly, check the water temperature
gauge and the oil temperature gauge during the heater operation.

Engine exhaust contains products of combustion that can be harmful to

your health. Always start the engine and operate the engine in a well
ventilated area. If the engine is started in an enclosed area, vent the
engine exhaust to the outside.

Ether
Ether is poisonous and flammable. Do not inhale ether, and do not allow
ether to contact the skin. Personal injury could result. Do not smoke while
ether cylinders are changed. Use ether in well ventilated areas.

Keep ether cylinders out of the reach of unauthorized persons. Store ether
cylinders in authorized storage areas only. Do not store ether cylinders
in direct sunlight or at temperatures above 39 °C (102 °F). Discard the
ether cylinders in a safe place. Do not puncture the ether cylinders. Do
not burn the ether cylinders.

i01462046

Engine Stopping
SMCS Code: 1000

Stop the engine according to the procedure in the Operation and

Maintenance Manual, “Engine Stopping (Operation Section)” in order
to avoid overheating of the engine and accelerated wear of the engine
components.

Use the Emergency Stop Button (if equipped) ONLY in an emergency

situation. Do not use the Emergency Stop Button for normal engine
stopping. After an emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been corrected.
SEBU7011-15 21
Safety Section
Electrical System

Stop the engine if an overspeed condition occurs during the initial start-up
of a new engine or an engine that has been overhauled. This may be
accomplished by shutting off the fuel supply to the engine and/or shutting
off the air supply to the engine.

To stop an electronically controlled engine, cut the power to the engine.

i01481981

Electrical System
SMCS Code: 1000; 1400

Never disconnect any charging unit circuit or battery circuit cable from
the battery when the charging unit is operating. A spark can cause the
combustible gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible gases that are produced
by some batteries, the negative “−” jump start cable should be connected
last from the external power source to the negative “−” terminal of the
starting motor. If the starting motor is not equipped with a negative “−”
terminal, connect the jump start cable to the engine block.

Check the electrical wires daily for wires that are loose or frayed. Tighten
all loose electrical wires before the engine is started. Repair all frayed
electrical wires before the engine is started. See the Operation and
Maintenance Manual for specific starting instructions.
22 SEBU7011-15
Safety Section
Electrical System

Grounding Practices

g00771448
Illustration 3
Typical example
Grounding Stud To Battery Ground
SEBU7011-15 23
Safety Section
Electrical System

g00771487
Illustration 4
Typical example
Alternate Grounding Stud To Battery Ground

Proper grounding for the engine electrical system is necessary for

optimum engine performance and reliability. Improper grounding will
result in uncontrolled electrical circuit paths and in unreliable electrical
circuit paths.

Uncontrolled electrical circuit paths can result in damage to main bearings,

to crankshaft bearing journal surfaces, and to aluminum components.

Engines that are installed without engine-to-frame ground straps can be

damaged by electrical discharge.
24 SEBU7011-15
Safety Section
Engine Electronics

To ensure that the engine and the engine electrical systems function
properly, an engine-to-frame ground strap with a direct path to the battery
must be used. This path may be provided by way of a starting motor
ground, a starting motor ground to the frame, or a direct engine ground
to the frame.

All grounds should be tight and free of corrosion. The engine alternator
must be grounded to the negative “-” battery terminal with a wire that is
adequate to handle the full charging current of the alternator.

i01563743

Engine Electronics
SMCS Code: 1000; 1400; 1900

Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine damage.

This engine has a comprehensive, programmable Engine Monitoring

System. The Engine Control Module (ECM) has the ability to monitor
the engine operating conditions. If any of the engine parameters extend
outside an allowable range, the ECM will initiate an immediate action.

The following actions are available for engine monitoring control:

WARNING, DERATE, and SHUTDOWN. These engine monitoring modes
have the ability to limit engine speed and/or the engine power.

Many of the parameters that are monitored by the ECM can be

programmed for the engine monitoring functions. The following
parameters can be monitored as a part of the Engine Monitoring System:

• Operating Altitude
• Engine Coolant Level
• Engine Coolant Temperature
• Engine Oil Pressure
SEBU7011-15 25
Safety Section
Engine Electronics

• 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.

Note: Many of the engine control systems and display modules that
are available for Caterpillar Engines will work in unison with the Engine
Monitoring System. Together, the two controls will provide the engine
monitoring function for the specific engine application. Refer to the
Electronic Troubleshooting Manual for more information on the Engine
Monitoring System.
26 SEBU7011-15
Product Information Section
Model Views

Product Information Section

Model Views
i01091979

Model View Illustrations

SMCS Code: 1000

g00405078
Illustration 5
Right side view
(1) Lifting eye (5) Water temperature (8) Crankshaft vibration
(2) Engine crankcase regulator housing damper
breather (6) Belt tensioner (9) Oil filter
(3) Turbocharger (7) Water drain plug (10) Jacket water pump
(4) Oil filler
SEBU7011-15 27
Product Information Section
Model Views

g00409318
Illustration 6
Left side view
(11) Oil filler (15) Oil level gauge (18) Cylinder head
(12) Lifting eye (16) Electronic Control grounding stud
(13) Fuel filter Module (ECM) (19) Oil drain plug
(14) Fuel priming pump (if (17) Air compressor
equipped)

i01474860

Engine Description
SMCS Code: 1000

The Caterpillar 3126B and 3126E Truck Engines are designed primarily
for on-highway trucks with medium-duty applications. The engines have
the following characteristics: air-to-air aftercooled, direct fuel injection,
four stroke cycle, and in-line 6 cylinder.

Engine 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.
28 SEBU7011-15
Product Information Section
Model Views

g00407141
Illustration 7
Cylinder and valve location
(A) Exhaust valve
(B) Inlet valve

Table 1

3126B and 3126E Truck Engine Specifications

Arrangement and
In-Line 6 cylinder
Cylinders
Bore 110 mm (4.3 inch)
Stroke 127 mm (5.0 inch)
Aspiration ATAAC(1)
Displacement 7.2 L (440 in3)
Firing Order 1-5-3-6-2-4
Rotation (flywheel end) Counterclockwise
Valve Lash (inlet) 0.38 mm (0.015 inch)
Valve Lash (exhaust) 0.64 mm (0.025 inch)
(1) Air-to-air aftercooled
SEBU7011-15 29
Product Information Section
Model Views

Electronic Engine Features

The Caterpillar 3126B and 3126E Truck Engines are designed for
electronic controls. The integral on board computer controls the operation
of the engine. Current operating conditions are monitored. The Electronic
Control Module (ECM) controls the response of the engine to these
conditions and to the demands of the operator. These conditions and
operator demands determine the precise control of fuel injection by
the ECM. The electronic engine control system provides the following
features:

• Engine speed governor

• Automatic air/fuel ratio control
• Torque rise shaping
• Injection timing control
• System diagnostics
The following programmable features are included in the electronic
control:

• Cruise control
• Governing of PTO
• Vehicle speed limiter
• Idle shutdown
• Compression brake operation control
For more information on electronic engine features, refer to the Operation
and Maintenance Manual, “Engine Features and Controls” topic
(Operation Section).

Additional Features
The following additional features provide increased engine fuel economy
and serviceability:

• Cold starting capability

30 SEBU7011-15
Product Information Section
Model Views

• Tampering detection
• Diagnostics
• American Trucking Association (ATA) data link (“SAE J1587”)

Hydraulic Electronic Unit Injectors

Hydraulically Actuated Electronic Unit Injectors (HEUI) perform the
following functions: pumping of fuel, fuel metering, and fuel timing.

The unit injectors are controlled by the ECM which uses the camshaft
position and the engine speed signals from the engine speed/timing
sensors and the inlet air pressure sensors. The engine’s rated rpm is
identified on the Information Plate.

Engine Diagnostics
The engine has built-in diagnostics in order to ensure that all of the
components are functioning properly. In the event of a deviation from
the programmed limits, the operator will be alerted to the condition by a
“DIAGNOSTIC” lamp that is mounted on the dashboard. Under certain
conditions, the engine horsepower and the vehicle speed may be limited.
A Caterpillar electronic service tool or the vehicle’s cruise control switches
(if equipped) may be used to display the diagnostic code.

There are three types of diagnostic codes: active, logged, and event.

Most of the diagnostic codes are logged and stored in the ECM. For
additional information, refer to the Operation and Maintenance Manual,
“Engine Diagnostics” topic (Operation Section).

The ECM provides an electronic governor that controls the injector

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

Engine Cooling and Lubrication

The cooling system consists of the following components:

• Centrifugal pump that is driven by belts

• Water temperature regulator which regulates the engine coolant
temperature
SEBU7011-15 31
Product Information Section
Model Views

• Oil cooler and radiator which incorporates a shunt system

The engine lubricating oil that is supplied is cooled. The engine lubricating
oil is also filtered. Bypass valves provide unrestricted flow of lubrication oil
to the engine components during the following conditions:

• High oil viscosity

• Plugged oil cooler or plugged oil filter elements (paper cartridge)

Engine Service Life

Engine efficiency and maximum utilization of engine performance
depend on the adherence to proper operation and maintenance
recommendations. In addition, use recommended fuels, coolants and
lubricants. Use the Operation and Maintenance Manual as a guide for
required engine maintenance.

Expected engine life is generally predicted by the average power that

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

Aftermarket Products and Caterpillar Engines

NOTICE
In order to maximize fuel system life and prevent
premature wear out from abrasive particles in the
fuel, a two micron absolute high efficiency fuel filter
is required for all Caterpillar Electronic Unit Injectors.
Caterpillar High Efficiency Fuel Filters meet these
requirements. Consult your Caterpillar dealer for the
proper part numbers.

When auxiliary devices, accessories, or consumables (filters, additives,

catalysts, etc) which are made by other manufacturers are used on
Caterpillar products, the Caterpillar warranty is not affected simply
because of such use.
32 SEBU7011-15
Product Information Section
Model Views

However, failures that result from the installation or use of other

manufacturers’ devices, accessories, or consumables are NOT
Caterpillar defects. Therefore, the defects are NOT covered under
the Caterpillar warranty.

Welding and Caterpillar Electronic Engines

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.

To help avoid damage to the electronic controls, proper welding

procedures are necessary. Before welding on a vehicle that is equipped
with an electronic engine, observe the following precautions:

1. Turn off the engine. Place the key start switch in the OFF position.

2. If the vehicle has a battery disconnect switch, open the switch.

Otherwise, disconnect the negative “-” battery cable from the battery
of the vehicle.

NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other com-
ponents.

Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.

3. Clamp the ground cable from the welder to the component that will be
welded. Place the clamp as close as possible to the weld.

4. Protect wiring harnesses from welding debris and spatter. Use proper
welding procedures.
SEBU7011-15 33
Product Information Section
Product Identification Information

Product Identification Information

i01028428

Engine Identification
SMCS Code: 1000

Caterpillar engines are identified with serial numbers, with performance

specification numbers, and with arrangement numbers. In some of the
cases, modification numbers are used. These numbers are shown on
the Serial Number Plate and the Information Plate that are mounted on
the engine.

Caterpillar dealers need these numbers in order to determine the

components that were included with the engine. This permits accurate
identification of replacement part numbers.

i01461841

Serial Number Plate

SMCS Code: 1000

g00764267
Illustration 8

The Serial Number Plate is located on the right side of the cylinder block
near the rear of the engine.

The following information is stamped on the Serial Number Plate: engine

serial number, engine model, and arrangement number.
34 SEBU7011-15
Product Information Section
Product Identification Information

i01484593

Information Plate
SMCS Code: 1000

g00764335
Illustration 9

The Information Plate is on the valve cover. The following information is

on the Information Plate: engine serial number, engine model, engine
arrangement number, maximum altitude of the engine that is necessary
to achieve the rated power, horsepower, high idle, full load rpm, fuel
settings, and other information.

i00836358

Reference Numbers
SMCS Code: 1000

Information for the following items may be needed to order parts. Locate
the information for your engine. Record the information on the appropriate
space. Make a copy of this list for a record. Retain the information for
future reference.

Record for Reference

Chassis Serial No. ___________________________________________________________________

Engine Model _________________________________________________________________________

SEBU7011-15 35
Product Information Section
Product Identification Information

Engine Serial No. ____________________________________________________________________

Engine Arrangement No. ___________________________________________________________

Modification No. ______________________________________________________________________

Engine Low Idle rpm ________________________________________________________________

Engine Full Load rpm _______________________________________________________________

Performance Specification No. ____________________________________________________

Engine hp ______________________________________________________________________________

Primary Fuel Filter No. ______________________________________________________________

Water Separator Element No. _____________________________________________________

Secondary Fuel Filter Element No. ______________________________________________

Lubrication Oil Filter Element No. ________________________________________________

Auxiliary Oil Filter Element No. ___________________________________________________

Supplemental Coolant Additive Maintenance Element No. (Optional)

____________________________________________________________________________________________

Total Lubrication System Capacity _______________________________________________

Total Cooling System Capacity ___________________________________________________

Air Cleaner Element No. ____________________________________________________________

Fan Drive Belt No. ___________________________________________________________________

Alternator Belt No. ___________________________________________________________________

36 SEBU7011-15
Product Information Section
Product Identification Information

i00844066

Emissions Certification Film

SMCS Code: 1000; 7405

g00284658
Illustration 10
EPA Emissions Certification Film

g00415538
Illustration 11
European Emissions Certification Film

The EPA Emissions Certification Film (if equipped) and/or the European
Emissions Certification Film (if equipped) is located on the side of the
engine.

i01633960

Customer Specified Parameters

SMCS Code: 1000

To record programmed specifications, use the following blanks.

SEBU7011-15 37
Product Information Section
Product Identification Information

Identification Parameters

• “Rating Number”___________________________________________________________________
• “Rating Selection” (A-E)__________________________________________________________
• “Engine Serial Number”__________________________________________________________
• “Power Rating” (hp at rpm)______________________________________________________
• “Vehicle ID”__________________________________________________________________________
“Truck Manufacturer Parameters”

• “Truck Manufacturer”______________________________________________________________
Vehicle Speed Parameters

• “Vehicle Speed Calibration”___________________________ pulses per km (mile)

_________________________________________________________________________________________

• “Vehicle Speed Calibration (J1939-Trans)”___________________________________

• “Vehicle Speed Calibration (J1939-ABS)”____________________________________
• “Vehicle Speed Limit”______________________________________________ km/h (mph)
• “VSL Protection”___________________________________________________________________
• “Tachometer Calibration”_____________________________ pulses per revolution
• “Soft Vehicle Speed Limit”_______________________________________________________
• “Low Speed Range Axle Ratio”_________________________________________________
• “High Speed Range Axle Ratio”________________________________________________
Cruise Control Parameters

• “Low Cruise Control Speed Set Limit”_________________________ km/h (mph)

• “High Cruise Control Speed Set Limit”_________________________ km/h (mph)
• “Engine Brake”_____________________________________________________________________
• “Cruise/Idle/PTO Switch Configuration”_______________________________________
38 SEBU7011-15
Product Information Section
Product Identification Information

• “Soft Cruise Control”______________________________________________________________

Idle Parameters

• “Idle Vehicle Speed Limit” ________________________________________ km/h (mph)

• “Idle RPM Limit” ___________________________________________________________________
• “Idle/PTO Engine Speed Ramp Rate” _____________________________ rpm/sec
• “Idle/PTO Bump RPM” ___________________________________________________________
• “Fast Idle RPM #1”________________________________________________________________
• “Fast Idle RPM #2”________________________________________________________________
• “Idle Speed for Warm Up Mode”________________________________________________
Dedicated PTO Parameters

• “PTO Configuration” ______________________________________________________________

• “PTO Top Engine Limit” __________________________________________________________
• “PTO Engine RPM Set Speed” _________________________________________________
• “PTO Engine RPM Set Speed A”_______________________________________________
• “PTO Engine RPM Set Speed B”_______________________________________________
• “PTO to Set Speed” ______________________________________________________________
• “Maximum PTO Enable Speed”________________________________________________
• “PTO Cab Throttle RPM Limit” _________________________________________________
• “PTO Vehicle Speed Limit” ______________________________________________________
• “Torque Limit” _________________________________________________________ N·m (lb ft)
• “PTO Shutdown Time” ___________________________________________________________
• “PTO Activation of Cooling Fan (If Equipped)” ______________________________
Engine/Gear Parameters
SEBU7011-15 39
Product Information Section
Product Identification Information

• “Lower Gears Engine RPM Limit” _____________________________________________

• “Lower Gears Turn Off Speed” _________________________________ km/h (mph)
• “Intermediate Gears Engine RPM Limit” _____________________________________
• “Intermediate Gears Turn Off Speed” _________________________ km/h (mph)
• “Gear Down Protection RPM Limit” ___________________________________________
• “Gear Down Protection Turn On Speed” _____________________ km/h (mph)
• “Low Idle Engine RPM” __________________________________________________________
• “Idle Quality Calibration” _________________________________________________________
• “Transmission Style (If Equipped)” ____________________________________________
• “AT/MT/HT Part Throttle Shift Speed”_________________________________________
• “Starting Aid Output Mode”______________________________________________________
• “Governor Type”____________________________________________________________________
Timer Parameters

• “Idle Shutdown Time” ____________________________________________________________

• “ Allow Idle Shutdown Override” _______________________________________________
• “A/C Pressure Switch Fan On-Time (If Equipped)” ________________________
• “Fan with Engine Brake On-Full (If Equipped)” _____________________________
• “Exhaust Brake/Warm up Enable”______________________________________________
Smart Idle Parameters

• “Battery Monitor and Engine Control Voltage”_______________________________

• “Battery Monitor and Low Idle Engine Speed”_______________________________
Engine Monitoring Parameters
40 SEBU7011-15
Product Information Section
Product Identification Information

• “Engine Monitoring Mode” ___________________________________________Warning,

Warning/Derate, Warning/Derate/Shutdown, and Coolant Level Sensor
Enable/Disable (If Equipped)

• “Engine Monitoring Lamps (If Equipped)” ____________________________________

• “Coolant Level Sensor” __________________________________________________________
• “Engine Oil Pressure Sensor” __________________________________________________
• “Oil Level Switch (If Equipped)” ________________________________________________
Maintenance Parameters

• “Maintenance Indicator Mode”_______________________________Manual-Hours,

Auto-Hours, Manual-Fuel, and Auto-Fuel

• “PM1 Interval”_______________________________________________________________________
• “Engine Oil Capacity”_____________________________________________________________
Fuel Tank Parameters

• “Primary Fuel Tank Capacity (If Equipped)”__________________________________

• “Secondary Fuel Tank Capacity (If Equipped)”______________________________
Trip Parameters

• “Dash-PM1 Reset” ________________________________________________________________

• “Dash-Customer Parameters” ___________________________________________Theft
Deterrent System Control and Quick-Stop Rate

Input Selections

• “Fan Override Switch”_____________________________________________________________

• “Transmission Neutral Switch”__________________________________________________
• “Exhaust Brake Switch”___________________________________________________________
• “Ignore Brake/Clutch Switch”____________________________________________________
• “Two Speed Axle Switch”________________________________________________________
SEBU7011-15 41
Product Information Section
Product Identification Information

• “Vehicle Speed Input”_____________________________________________________________

• “PTO Engine Shutdown Switch”________________________________________________
• “Torque Limit Switch”______________________________________________________________
• “PTO Engine RPM Set Speed Input A”_______________________________________
• “PTO Engine RPM Set Speed Input B”_______________________________________
• “Diagnostic Enable Switch”______________________________________________________
• “Cruise Control ON/Off Switch”_________________________________________________
• “Cruise Control Set/Resume /Accel/Decel Switch”_________________________
• “Cruise Control Pause Switch”__________________________________________________
• “Clutch Pedal Position Switch”__________________________________________________
• “Service Brake Pedal Position Switch #1”____________________________________
Output Selections

• “Fan Control Type (If Equipped)” ______________________________________________

• “PTO Active Output”_______________________________________________________________
• “PTO Switch ON Lamp”__________________________________________________________
• “Fast Idle Enabled Lamp”________________________________________________________
• “Change Oil Lamp”________________________________________________________________
• “Engine Running Output”_________________________________________________________
• “Starting Aid Output”______________________________________________________________
Data Link Parameters

• “Powertrain Data Link” ___________________________________________________________

42 SEBU7011-15
Operation Section
Lifting and Storage

Operation Section

Lifting and Storage

i01689171

Engine Lifting
SMCS Code: 1000; 1122

g00103219
Illustration 12

NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.

When it is necessary to remove a component at an

angle, only use a link bracket that is properly rated for
the weight.

Use a hoist to remove heavy components. Use an adjustable lifting beam

to lift the engine. All supporting members (chains and cables) should be
parallel to each other. The chains and cables should be perpendicular to
the top of the object that is being lifted.
SEBU7011-15 43
Operation Section
Lifting and Storage

Use the lifting eyes to support the weight of the engine ONLY. Some
engines may require lifting eyes to be attached to the engine. Refer to
the Disassembly and Assembly manual for the proper tools for your
application. The use of the proper tools allow you to obtain the proper
balance of the engine for a safe removal.

Lifting eyes are designed and installed for the specific engine
arrangement. Alterations to the lifting eyes and/or the engine make the
lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your Caterpillar dealer for
information regarding fixtures for proper engine lifting.

i02126500

Product Storage
SMCS Code: 1000; 1404; 7002

If the engine will not be started for several weeks, the lubricating oil will
drain from the cylinder walls and from the piston rings. Rust can form on
the cylinder liner surface. Rust on the cylinder liner surface will cause
increased engine wear and a reduction in engine service life.

To help prevent excessive engine wear, use the following guidelines:

• Complete all of the lubrication recommendations that are listed in this

Operation and Maintenance Manual, “Maintenance Interval Schedule”
(Maintenance Section).

• If freezing temperatures are expected, check the cooling system

for adequate protection against freezing. See this Operation and
Maintenance Manual, “Refill Capacities and Recommendations”
(Maintenance Section).

If an engine is out of operation and if use of the engine is not planned,

special precautions should be made. If the engine will be stored for more
than one month, a complete protection procedure is recommended.

For more detailed information on engine storage, see Special Instruction,

SEHS9031, “Storage Procedure For Caterpillar Products”.

Your Caterpillar dealer can assist in preparing the engine for extended
storage periods.
44 SEBU7011-15
Operation Section
Gauges and Indicators

Gauges and Indicators

i02154799

Gauges and Indicators

SMCS Code: 1900; 7450

Your engine may not have the same gauges or all of the gauges that
are described. For more information about the gauge package, see the
literature that is provided by the OEM.

Gauges provide indications of engine performance. Ensure that the

gauges are in good working order. Determine the normal operating range
by observing the gauges over a period of time.

Noticeable changes in gauge readings indicate potential gauge or engine

problems. Problems may also be indicated by gauge readings that
change even if the readings are within specifications. Determine the
cause of any significant change in the readings. Then, correct any cause
of any significant change in the readings. Consult your Caterpillar dealer
for assistance.

Caterpillar requires one lamp in addition to the gauge package that

is normally provided. The “Diagnostic” lamp is yellow or amber. The
“Diagnostic” lamp will communicate the status of the engine’s electronic
system. The optional red “Warning” lamp is also available. This red
“Warning” lamp warns the operator of engine problems.

The following conditions are some examples of the engine problems:

• Low oil pressure

• High coolant temperature
• Low coolant level
• High inlet air temperature
Engine Oil Pressure – Typical oil pressure for an engine
at rated speed with SAE 10W30 or with SAE 15W40 is
235 to 395 kPa (30 to 60 psi).
SEBU7011-15 45
Operation Section
Gauges and Indicators

A lower oil pressure is normal at low idle. If the load is stable and the
gauge reading changes, perform the following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check the oil level. Maintain the oil level at the proper amount.

The diagnostic lamp will turn on if the oil pressure drops below 35 kPa
(5 psi) at low idle rpm. The diagnostic code will be logged in the Engine
Control Module (ECM).

Engine Oil Temperature – This gauge indicates the engine

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

Jacket Water Coolant Temperature – Typical temperature

range is 88 to 102 °C (190 to 215 °F). The maximum allowable
temperature with the pressurized cooling system is 105 °C
(220 °F). Higher temperatures may occur under certain conditions. The
water temperature reading may vary according to load. The reading
should never exceed the boiling point for the pressurized system that is
being used.

If the engine is operating above the normal range and steam becomes
apparent, perform the following procedure:

1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut down immediately or if the engine

can be cooled by reducing the load.

Tachometer – This gauge indicates engine speed. When the

throttle control lever is moved to the full throttle position without
load, the engine is running at high idle. The engine is running
at the full load rpm when the throttle control lever is at the full throttle
position with maximum rated load.

Note: The high idle rpm and the full load rpm are stamped on the
Information Plate.
46 SEBU7011-15
Operation Section
Gauges and Indicators

Ammeter – This gauge indicates the amount of a charge or

of discharge in the battery charging circuit. Operation of the
indicator should be to the right side of “0”(zero).

Service Hour Meter – This gauge indicates the number of

clock hours of engine operation. The hours of operation are
logged in the ECM. A service tool is needed to retrieve the hours
from the ECM. A Service Hour Meter may be installed on the engine.

Fuel Pressure – This gauge indicates fuel pressure to the

electronic unit injectors from the fuel filter. The indicator should
indicate the “NORMAL” range. A decrease in fuel pressure
usually indicates a plugged fuel filter.

Fuel Level – This gauge indicates the level of fuel in the fuel
tank. The fuel level gauge registers the fuel level only when the
ignition switch is in the ON position.
SEBU7011-15 47
Operation Section
Features and Controls

Features and Controls

i00838698

Emergency Vehicle Engine Features

SMCS Code: 1000

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

The emergency vehicle engine features have the following modifications:

Top Tank Design Temperature (maximum allowable
temperature) ............................................................... 110° C (230° F)
High Coolant Temperature Warning ........................... 113° C (235° F)
Very High Coolant Temperature Warning ................... 115° C (240° F)
Very High Coolant Temperature Shutdown (OEM installation) .. 115° C
(240° F)

If the emergency vehicle engine is programmed to derate, reduced power

will begin when the fault code for the High Coolant Temperature Warning
flashes. The engine will continue to derate until the coolant temperature
reaches 115° C (240° F).

i00837998

Monitoring System
SMCS Code: 1900; 7400; 7402; 7450; 7451

If the Shutdown mode has been selected and the

warning indicator activates, engine shutdown
may take as little as 20 seconds from the time
the warning indicator is activated. Depending on
the application, special precautions should be
taken to avoid personal injury. The engine can
be restarted following shutdown for emergency
maneuvers, if necessary.
48 SEBU7011-15
Operation Section
Features and Controls

NOTICE
The Engine Monitoring System is not a guarantee
against catastrophic failures. Programmed delays
and derate schedules are designed to minimize false
alarms and provide time for the operator to stop the
engine.

Programmable features monitor the following conditions:

• Coolant temperature
• Cooling system level (if equipped)

Coolant Level Sensor (If Equipped)

Note: The coolant level sensor is an optional feature.

The system can be programmed with one of the following options:

“ENABLED” – The system will monitor the input from the coolant level
sensor. The system is programmed to this value when the engine is
shipped by Caterpillar.

“DISABLED” – The system will not monitor the input from the coolant
level sensor.

Programmable Options and Systems Operation

If the Warning/Derate/Shutdown mode has been

selected and the warning indicator activates,
bring the engine to a stop whenever possible. De-
pending on the application, special precautions
should be taken to avoid personal injruy.

The engine can be programmed to the following modes:

• “OFF”
• “Warning”
SEBU7011-15 49
Operation Section
Features and Controls

• “Warning/Derate”
• “Warning/Derate/Shutdown”
“Warning”
The “DIAGNOSTIC” lamp and the warning signal (red lamp or buzzer)
turn “ON” and the warning signal is activated continuously in order to
alert the operator that one or more of the engine parameters is not within
normal operating range.

“Warning/Derate”
The “DIAGNOSTIC” lamp turns “ON” and the warning signal (red lamp
or buzzer) is activated. After the warning, the engine will derate rpm and
power. The warning lamp will begin to flash when the derating occurs.

When the engine is fully derated, the engine power is limited to 90 kW

(120 hp). The vehicle speed is limited to 72 km/h (45 mph).

“Warning/Derate/Shutdown”
The “DIAGNOSTIC” lamp turns “ON” and the warning signal (red lamp
or buzzer) is activated. After the warning, the engine will derate rpm and
power. The engine will continue to derate rpm until a shutdown of the
engine occurs. The engine can be restarted after a shutdown for use in
an emergency.

A shutdown of the engine may occur in as little as 20 seconds. The engine

can be restarted after a shutdown for use in an emergency. However, the
cause of the initial shutdown may still exist. The engine may shut down
again in as little as 20 seconds.

If there is a signal for coolant loss, there will be a 10 second delay in

order to verify the condition. The system will derate the engine rpm for
40 seconds before the engine will shut down if the engine has been
programmed to shut down.

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

For more information or assistance for repairs, consult your Caterpillar

dealer.
50 SEBU7011-15
Operation Section
Features and Controls

Note: The Customer Specified Parameters may be secured by customer

passwords. The engine may have all of the parameters that are
programmed or any combination of the parameters that are programmed.
Refer to the Operation and Maintenance Manual, “Customer Specified
Parameters” topic (Product Information Section) for more information
on the programmed parameters of the engine. Refer to the Electronic
Troubleshooting for more information.

i01631738

Sensors and Electrical Components

SMCS Code: 1900; 7400

Sensor Locations
Illustration 13 shows the typical locations of the sensors for a 3126B and
3126E Truck Engine. Specific engines may appear different from the
illustration due to differences in applications.
SEBU7011-15 51
Operation Section
Features and Controls

g00666008
Illustration 13
Left side view
(1) Injection actuation (4) Boost pressure sensor (7) Coolant temperature
pressure sensor (5) Engine oil temperature sensor
(2) Inlet air temperature sensor (8) Engine oil pressure
sensor (6) Engine speed/timing sensor
(3) Atmospheric pressure sensor
sensor

Failure of Sensors
All Sensors
A failure of any of the sensors may be caused by one of the following
malfunctions:

• Sensor output is open.

52 SEBU7011-15
Operation Section
Features and Controls

• Sensor output is shorted to “- battery” or “+ battery”.

• Measured reading of the sensor is out of specification.

Atmospheric Pressure Sensor

Atmospheric pressure sensor (3) measures the atmospheric pressure in
the crankcase. A signal is sent to the Electronic Control Module (ECM).

Table 2
Atmospheric Pressure Sensor
Operating pressure
0 to 116 kPa (0 to 16.8 psi)
range

Boost Pressure Sensor

Boost pressure sensor (4) provides a signal which corresponds to
turbocharger outlet pressure to the ECM. The air/fuel ratio control utilizes
the actual engine speed and the turbocharger outlet pressure in order to
control the transient smoke level. The ECM can control injection timing
and the amount of fuel that is injected. When the throttle is increased and
when the engine demands more fuel, the fuel limit is controlled in order to
reduce overall smoke levels of the engine exhaust.

Failure of the Boost Pressure Sensor

The ECM will detect failure of the boost pressure sensor. The operator will
be warned of the problem through the diagnostic lamp. The strategies that
are related to the boost will be disabled. Engine power will be severely
reduced in the event of a failure of the boost pressure sensor. A failure of
the boost pressure sensor will not cause a shutdown of the engine.

Coolant Temperature Sensor

Coolant temperature sensor (7) monitors engine coolant temperature.
The output of the ECM can indicate a high coolant temperature through a
relay or a lamp. The coolant temperature sensor is used by the ECM to
determine initiation of the Cold Start Strategy.
SEBU7011-15 53
Operation Section
Features and Controls

Table 3
Coolant Temperature Sensor
Activation temperature for the high
103°C (217°F)
coolant temperature fault
Activation temperature for the very
106°C (229°F)
high coolant temperature fault

Failure of the Coolant Temperature Sensor

The ECM will detect a failure of the coolant temperature sensor. The
diagnostic lamp will warn the operator about the status of the coolant
temperature sensor. The cold start strategies will be disabled if failure
occurs. A failure of the coolant temperature sensor will not cause a
shutdown of the engine or any horsepower change.

Engine Oil Pressure Sensor

Engine oil pressure sensor (8) is an absolute pressure sensor that
measures the engine oil pressure in the main oil gallery. The engine oil
pressure sensor detects engine oil pressure for diagnostic purposes. The
engine oil pressure sensor sends a signal to the ECM.

Table 4
Engine Oil Pressure Sensor
Operating pressure
0 to 690 kPa (0 to 100 psi)
range

Low Oil Pressure Warning

The setpoint is dependent upon the engine speed. The fault will be active
and logged only if the engine has been running for more than 15 seconds.

Very Low Oil Pressure Warning

The very low oil pressure setpoint is dependent upon the engine speed. If
the DERATE mode of the engine monitoring system is selected, the ECM
will derate the engine power. The engine horsepower will be limited.
54 SEBU7011-15
Operation Section
Features and Controls

Failure of the Engine Oil Pressure Sensor

The ECM will detect failure of the engine oil pressure sensor. The
diagnostic lamp warns the user about the status of the engine oil pressure
sensor. The engine oil pressure related strategies will be disabled in
the event of a failure of the engine oil pressure sensor. A failure of the
engine oil pressure sensor will not cause a shutdown of the engine or any
horsepower change.

Engine Oil Temperature Sensor

Engine oil temperature sensor (5) monitors the temperature of the engine
oil. The ECM uses the information from the engine oil temperature sensor
in order to adjust the timing of the fuel injection and the pressure of the
fuel injection.

Table 5

Engine Oil Temperature Sensor

Operating temperature
−40 to 120°C (−40 to 258°F)
range

Engine Speed/Timing Sensor

If the ECM does not receive a signal from primary speed/timing sensor
(6), the “DIAGNOSTIC” lamp will indicate a diagnostic fault code which
will be logged in the ECM memory.

If the ECM does not receive a signal from the primary speed/timing sensor,
the ECM will read the signal from the secondary speed/timing sensor. The
ECM continually checks in order to determine if there is a signal from both
sensors. If either sensor fails, the faulty sensor should be replaced.

Intermittent failure of the sensors will cause erratic engine control.

Injection Actuation Pressure Sensor

Injection actuation pressure sensor (1) provides a signal of the injection
actuation pressure to the ECM. The ECM modifies the current to the
injection actuation pressure control valve (not shown) in order to control
the injection actuation pressure. The desired actuation pressure is based
on the following engine parameters: quantity of fuel, injection timing,
engine speed, and engine operating mode.
SEBU7011-15 55
Operation Section
Features and Controls

Inlet Air Temperature Sensor

Inlet air temperature sensor (2) measures the inlet air temperature.
A signal is sent to the Electronic Control Module (ECM). The inlet air
temperature sensor is also used by the ECM to determine initiation of the
Cold Start Strategy.

Table 6

Inlet Air Temperature Sensor

Operating temperature
−40 to 120°C (−40 to 258°F)
range

Primary Fuel Level Sensor

This sensor that is supplied by the OEM is located in the fuel tank. The
sensor is offered only in specific applications.

Secondary Fuel Level Sensor

This sensor that is supplied by the OEM is located in the fuel tank. The
sensor is offered only in specific applications.

Throttle Position Sensor

The Throttle Position Sensor (TPS) sends a signal to the ECM. The signal
from the TPS is required in order to govern engine speed. The throttle
position sensor signal is used by the ECM in order to calculate the desired
engine speed. The TPS is calibrated during the initial installation of the
engine.

Note: The throttle position sensor is not shown in the illustration.

Failure of the Throttle Position Sensor

An intermittent failure in the TPS causes the engine speed to vary
erratically. The ECM will perform the following process:

• The ECM will detect the failure of the TPS.

• The ECM will warn the operator of the failure through the diagnostic
lamp.

• The ECM will set the desired engine speed to low idle.
56 SEBU7011-15
Operation Section
Engine Diagnostics

Engine Diagnostics
i01563934

Self-Diagnostics
SMCS Code: 1000; 1900; 1901; 1902

Caterpillar Electronic Engines have the capability to perform a

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

• Caterpillar electronic service tools

• “DIAGNOSTIC” lamp
Note: The “DIAGNOSTIC” lamp must be installed by the OEM or by the
customer.

Some installations have electronic displays that provide direct readouts of

the engine diagnostic codes. Refer to the manual that is provided by the
OEM for more information on retrieving engine diagnostic codes.

Active codes represent problems that currently exist. These problems

should be investigated first. If a code is active, the “DIAGNOSTIC” lamp
will flash the flash code at five second intervals.

Logged codes represent the following items:

• Intermittent problems
• Recorded events
• Performance history
The problems may have been repaired since the logging of the code.
These codes do not indicate that a repair is needed. The codes are
guides or signals when a situation exists. Codes may be helpful to
troubleshoot problems.

When the problems have been corrected, the corresponding logged fault
codes should be cleared.
SEBU7011-15 57
Operation Section
Engine Diagnostics

i01563946

Diagnostic Lamp
SMCS Code: 1000; 1900; 1901; 1902; 7451

The “DIAGNOSTIC” lamp is used to indicate the existence of a fault by

flashing codes. The “DIAGNOSTIC” lamp that is on the dashboard is
usually “YELLOW”.

When the ignition switch is first turned on, the “DIAGNOSTIC” lamp will
go through the following procedure:

• The “DIAGNOSTIC” lamp will illuminate for five seconds.

• The “DIAGNOSTIC” lamp will turn off.
Whenever the Engine Control Module (ECM) detects an active fault or
condition the lamp will flash at five second intervals. If the lamp turns on
and if the lamp stays on after initial start-up, the ECM has detected a
system problem.

The “DIAGNOSTIC” lamp is also used for the Idle Shutdown Timer. The
lamp will start to flash at a rapid rate 90 seconds before the programmed
idle time expires. The engine will shut down after the 90 second interval.
To disable the Idle Shutdown Timer, the “ALLOW IDLE SHUTDOWN
OVERRIDE” must be programmed to “YES”. The clutch pedal or the
service brake pedal must be depressed during the final 90 seconds while
the “YELLOW” lamp is flashing. A diagnostic “EVENT” code or Override
of the Idle Shutdown Timer will be logged in the ECM.

i02286780

Diagnostic Flash Code Retrieval

SMCS Code: 1000; 1900; 1901; 1902

“Diagnostic” Lamp
Use the “DIAGNOSTIC” Lamp or a Caterpillar electronic service tool to
determine the diagnostic flash code.

Use the following procedure to retrieve the flash codes if the engine is
equipped with a “DIAGNOSTIC” lamp:
58 SEBU7011-15
Operation Section
Engine Diagnostics

1. Turn the ignition key to the ON position.

2. Turn the engine switch to the OFF position.

3. Turn the cruise control ON/OFF switch to the OFF position.

4. Move the SET/RESUME switch to either position. Hold that position

until the “YELLOW” lamp begins to flash.

The “YELLOW” lamp will flash in order to indicate a two digit flash code
and the SET/RESUME switch may be released. The sequence of flashes
represents the system diagnostic message. Count the first sequence of
flashes in order to determine the first digit of the flash code. After a two
second pause, the second sequence of flashes will identify the second
digit of the flash code.

Any additional flash codes will follow after a pause. These codes will be
displayed in the same manner. Flash Code 55 indicates that No Detected
Faults have occurred since the ignition key switch has been turned to
the ON position.

For further information, assistance for repairs, or troubleshooting, refer to

the Service Manual or consult an authorized Caterpillar dealer.

Table 7 lists the flash codes and the table also gives a brief description of
the flash codes.

Note: Table 7indicates the potential effect on engine performance with

“ACTIVE” flash codes.

Some codes record events. Also, some codes may also indicate that a
mechanical system needs attention. Troubleshooting is not required for
codes “35”, “41”, “47” and “55”. Code 01 will not display a flash code.
Some codes will limit the operation or the performance of the engine.

Table 7 indicates the potential effect on the engine performance with

active flash codes. Table 7 also forms a list of Electronic diagnostic codes
and descriptions.
Table 7
Flash Codes for C7 and C9 On-highway Engines
Effect On Engine Performance(1) Suggested Operator Action
SEBU7011-15

Diagnostic Flash Code Reduced Shut

Engine Low Engine Schedule
Engine Down the Service(3)
Misfire Power Shutdown Service.(4)
Speed Engine(2)
Coolant Level
12 Sensor Circuit Fault X
(5)(6)

An Injection
15 Actuation Pressure X X X
Sensor Circuit Fault
Injection Actuation
17 Pressure Sensor X X X X
Out of Range
Driver Fault for the
Injection Actuation
18 X X X
Pressure Control
Valve
Sensor Supply
21 X X
Voltage Fault (7)
Oil Pressure Sensor
24 X X
fault (6)
(continued)
Engine Diagnostics
Operation Section
59
 60
(Table 7, contd)
Flash Codes for C7 and C9 On-highway Engines
Effect On Engine Performance(1) Suggested Operator Action

Diagnostic Flash Code Reduced Shut

Engine Low Engine Schedule
Engine Down the Service(3)
Operation Section

Misfire Power Shutdown Service.(4)

Engine Diagnostics

Speed Engine(2)
An Inlet Air Pressure
25 X X
Sensor Circuit Fault
Atmospheric
26 Pressure Sensor X
Fault (6)(7)
Coolant
27 Temperature Sensor X
Fault(5)(7)
Check Throttle
28 X X
Sensor Adjustment
Check PTO Throttle
29 X X
Sensor Adjustment(6)
Loss of Vehicle
31 X X
Speed Signal
Throttle Position
32 X X
Sensor Fault
(continued)
SEBU7011-15
(Table 7, contd)
Flash Codes for C7 and C9 On-highway Engines
Effect On Engine Performance(1) Suggested Operator Action
SEBU7011-15

Diagnostic Flash Code Reduced Shut

Engine Low Engine Schedule
Engine Down the Service(3)
Misfire Power Shutdown Service.(4)
Speed Engine(2)
Turbo Wastegate
33 Solenoid Circuit X X X
Fault
Engine RPM Signal
34 X X X X
Fault
Engine Overspeed
35 X
Warning
Vehicle Speed
36 X X
Signal Fault
An Inlet Air
38 Temperature Sensor X X
Fault (7)
Injection Actuation
39 Pressure System X X X X
Fault
Vehicle Overspeed
41 X X
Warning
(continued)
Engine Diagnostics
Operation Section
61
 62
(Table 7, contd)
Flash Codes for C7 and C9 On-highway Engines
Effect On Engine Performance(1) Suggested Operator Action

Diagnostic Flash Code Reduced Shut

Engine Low Engine Schedule
Engine Down the Service(3)
Operation Section

Misfire Power Shutdown Service.(4)

Engine Diagnostics

Speed Engine(2)
Check Timing
42 X X
Sensor Calibrations
Fuel Level Sensor
44 X
Circuit Fault (6)
Very Low Oil
46 X X X X X X
Pressure (6)
Shutdown
47 X
Occurrence
Inlet Air Heater
49 X
Circuit Fault
Intermittent Battery X X X X
51
Power to ECM
55 No Detected Faults
Check Customer
56 Parameters or X X X
System Parameters
(continued)
SEBU7011-15
(Table 7, contd)
Flash Codes for C7 and C9 On-highway Engines
Effect On Engine Performance(1) Suggested Operator Action
SEBU7011-15

Diagnostic Flash Code Reduced Shut

Engine Low Engine Schedule
Engine Down the Service(3)
Misfire Power Shutdown Service.(4)
Speed Engine(2)
Transmission
57 Datalink Engine X
Derate
A Powertrain Data
58 X
Link Fault
Incorrect Engine
59 X
Software
High Coolant
61 Temperature X X X X
Warning
Low Coolant Level
62 X X X X
Warning
Very High Intake
Manifold Air
64 X X X X
Temperature
Warning
Ignition Key Switch
71 X X X X
Circuit Fault
(continued)
Engine Diagnostics
Operation Section
63
 64
(Table 7, contd)
Flash Codes for C7 and C9 On-highway Engines
Effect On Engine Performance(1) Suggested Operator Action

Diagnostic Flash Code Reduced Shut

Engine Low Engine Schedule
Engine Down the Service(3)
Operation Section

Misfire Power Shutdown Service.(4)

Engine Diagnostics

Speed Engine(2)
Cylinder 1 Fault or
72 X X X
Cylinder 2 Fault
Cylinder 3 Fault or
73 X X X
Cylinder 4 Fault
Cylinder 5 Fault or
74 X X X
Cylinder 6 Fault
(1) An “X” indicates that the effect on engine performance may occur if the code is active.
(2) Shut Down the Engine: Operate the engine cautiously. Get immediate service. Severe engine damage may result.
(3) The operator should go to the nearest location that has a qualified service program.
(4) Schedule Service: The problem should be investigated when the operator has access to a qualified service program.
(5) These Flash Codes reduce the effectiveness of the Engine Monitoring feature when the codes are active.
(6) The code will flash if the sensor is used for this application.
(7) These Flash Codes may affect the system under specific environmental conditions such as engine start-up at cold temperature and
cold weather operation at high altitudes.
SEBU7011-15
SEBU7011-15 65
Operation Section
Engine Diagnostics

For further information or assistance for repairs, consult an authorized

Caterpillar dealer.

i01463504

Fault Logging
SMCS Code: 1000; 1900; 1901; 1902

The system provides the capability of Fault Logging. When the Electronic
Control Module (ECM) generates an active diagnostic code, the code will
be logged in the memory of the ECM. The codes that have been logged
in the memory of the ECM can be retrieved with Caterpillar electronic
service tools. The codes that have been logged can be cleared with
Caterpillar electronic service tools. The codes that have been logged in
the memory of the ECM will be automatically cleared from the memory
after 100 hours. The following faults can not be cleared from the memory
of the ECM without using a factory password: overspeed, low engine oil
pressure, and high engine coolant temperature.
66 SEBU7011-15
Operation Section
Engine Diagnostics

i01563981

Engine Operation with Active Diagnostic

Codes
SMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp starts to flash codes during normal engine

operation, the system has identified a situation that is not within the
specification. Use Caterpillar electronic service tools to check the active
diagnostic codes.

Note: If the customer has selected “DERATE” and if there is a low oil
pressure condition, the Electronic Control Module (ECM) will limit the
engine power until the problem is corrected. If the oil pressure is within
the normal range, the engine may be operated at the rated speed and
load. However, maintenance should be performed as soon as possible.
Refer to Operation and Maintenance Manual, “Diagnostic Flash Code
Retrieval” for more information on flash codes.

The active diagnostic code should be investigated. The cause of the

problem should be corrected as soon as possible. If the cause of the
active diagnostic code is repaired and there is only one active diagnostic
code, the diagnostic lamp will turn off.

Operation of the engine and performance of the engine can be limited as

a result of the active diagnostic code that is generated. Acceleration rates
may be significantly slower. Refer to the Operation and Maintenance
Manual for more information on the relationship between these active
diagnostic codes and engine performance.
SEBU7011-15 67
Operation Section
Engine Diagnostics

i01456915

Engine Operation with Intermittent

Diagnostic Codes
SMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp starts to flash codes during normal engine operation
and the diagnostic lamp shuts off, an intermittent fault may have occurred.
If a fault has occurred, the fault will be logged into the memory of the
Electronic Control Module (ECM).

In most cases, it is not necessary to stop the engine because of an

intermittent code. However, the operator should retrieve the logged fault
codes and the operator should reference the appropriate information in
order to identify the nature of the event. The operator should log any
observation that could have caused the lamp to light.

• Low power
• Limits of the engine speed
• Excessive smoke, etc
This information can be useful to help troubleshoot the situation. The
information can also be used for future reference. For more information
on diagnostic codes, refer to the Troubleshooting Guide for this engine.
68 SEBU7011-15
Operation Section
Engine Diagnostics

i01563987

Customer Specified Parameters

SMCS Code: 1000; 1900; 1901; 1902

Customer specified parameters that will enhance the fuel efficiency and
the operator’s convenience can be programmed into the Electronic
Control Module (ECM). Some parameters may affect engine operation.
This may lead to complaints from the operator about power or about
performance. Certain engine parameters may be programmed by the
customer by using Caterpillar electronic service tools in order to influence
the operation of the engine:

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, “Customer Specified Parameters”
(Product Information Section). For detailed instructions on programming
the engine for optimum performance and for optimum fuel economy,
consult your Caterpillar dealer.
SEBU7011-15 69
Operation Section
Engine Starting

Engine Starting
i01635755

Starting the Engine

SMCS Code: 1000; 1450

Engine exhaust contains products of combustion

which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.

Under-the-Hood Inspection
Perform the required daily maintenance and other periodic maintenance
before you start the engine. Inspect the engine compartment. This
inspection can help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, “Walk-Around Inspection” topic
(Maintenance Section) for more information.

• For the maximum service life of the engine, make a thorough inspection
before you start the engine. Look for the following items: oil leaks,
coolant leaks, loose bolts, and trash buildup. Remove trash buildup and
arrange for repairs, as needed.

• Inspect the cooling system hoses for cracks and for loose clamps.
• Inspect the alternator and accessory drive belts for cracks, breaks,
and other damage.

• Inspect the wiring for loose connections and for worn wires or frayed
wires.

• Check the fuel supply. Drain water from the water separator (if
equipped). Open the fuel supply valve.
70 SEBU7011-15
Operation Section
Engine Starting

NOTICE
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.

• Do not start the engine or do not move any of the controls if there is a
“DO NOT OPERATE” warning tag or similar warning tag attached to
the start switch or to the controls.

• Ensure that the areas around the rotating parts are clear.
• All of the guards must be put in place. Check for damaged guards or
for missing guards. Repair any damaged guards. Replace damaged
guards and/or missing guards.

• Disconnect any battery chargers that are not protected against the
high current drain that is created when the electric starting motor (if
equipped) is engaged. Check electrical cables and check the battery
for poor connections and for corrosion.

• Reset all of the shutoffs or alarm components.

• Check the engine lubrication oil level. Maintain the oil level between the
“ADD” mark and the “FULL” mark on the oil level gauge.

• Check the coolant level. Observe the coolant level in the coolant
recovery tank (if equipped). Maintain the coolant level to the “FULL”
mark on the coolant recovery tank.

• If the engine is not equipped with a coolant recovery tank maintain the
coolant level within 13 mm (.5 inch) of the bottom of the filler pipe. If
the engine is equipped with a sight glass, maintain the coolant level in
the sight glass.

• Observe the air cleaner service indicator (if equipped). Service the air
cleaner when the yellow diaphragm enters the red zone, or when the
red piston locks in the visible position.

• Ensure that any driven equipment has been disengaged. Remove any
electrical loads.
SEBU7011-15 71
Operation Section
Engine Starting

Cold Weather Starting

Starting the engine and operation in cold weather is dependent on the
type of fuel that is used, the oil viscosity, and other optional starting aids.
For more information, refer to the Operation and Maintenance Manual,
“Cold Weather Operation” topic (Operation Section).

Air Inlet Heater

DO NOT USE ETHER (starting fluids) unless

specifically instructed to do so. If the engine is
equipped with an Air Inlet Heater (electrically or
fuel ignited manifold heater), DO NOT use ether
(starting fluids) at any time. The use could result
in engine damage and/or personal injury.

Note: There will be an indicator lamp on the dashboard of the vehicle that
is marked “AIR INLET HEATER”.

For detailed information on the operation of the Air Inlet Heater, refer to
System Operation, “Air Inlet and Exhaust”.

Use the following procedure in order to start the engine:

1. Engage the parking brake. Place the transmission in NEUTRAL. If

the vehicle is equipped with a manual transmission, depress the
clutch pedal in order to disengage the flywheel clutch. This reduces
transmission drag and this prevents movement of the vehicle.
Depressing the clutch helps to reduce the battery drain. In cold
weather, this can mean the difference between starting the engine
and not starting the engine.

The “CHECK ENGINE/DIAGNOSTIC” lamp will flash while the engine

is cranking. The lamp should turn off after proper engine oil pressure is
achieved. If the lamp fails to flash, notify your authorized Caterpillar
dealer. If the lamp continues to flash, the ECM has detected a problem
in the system. Refer to the Operation and Maintenance Manual,
“Engine Diagnostics” topic (Operation Section).

2. Turn the keyswitch to the ON position. The air inlet heater can preheat
the system in order to improve cold weather starting.
72 SEBU7011-15
Operation Section
Engine Starting

Note: The “AIR INLET HEATER” indicator lamp will flash for a minimum
of two seconds regardless of the coolant temperature. If the “AIR INLET
HEATER” indicator lamp flashes for more than two seconds, wait until
the indicator lamp stops flashing (approximately 30 seconds) before
attempting to start the engine. If the indicator lamp continues to flash,
the ECM will control the air inlet heater during a restart of the engine.
Restarting the engine at this point can cause excessive white smoke.

NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.

If the engine fails to start within 30 seconds, release

the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.

3. Turn the keyswitch to the START position in order to crank the engine.
The air inlet heater will turn ON if the sum of the coolant temperature
and the inlet air temperature is less than 25 °C or 109 °F. Do not push
the throttle or do not hold the throttle downward while the engine is
cranked. The system will automatically provide the correct amount
of fuel in order to start the engine. If the engine does not start after
15 to 20 seconds of cranking, release the keyswitch. If the sum of
the coolant temperature and the inlet air temperature is less than 25
°C or 109 °F, the preheat for the air inlet heater will restart. Turn the
keyswitch to the OFF position. Allow the starting motor to cool for two
minutes. Repeat Steps 2 and 3.

NOTICE
Oil pressure should rise within 15 seconds after the
engine starts. Do not increase engine speed until the
oil pressure gauge indicates normal. If oil pressure
is not indicated on the gauge within 15 seconds, DO
NOT operate the engine. STOP the engine, investi-
gate and correct the cause.

4. Release the keyswitch to the ON or RUN position immediately after

the engine starts. After the engine starts, check in order to ensure
that the transmission is still in the NEUTRAL position and release the
clutch pedal (manual transmission). Once a normal engine oil pressure
and air pressure are reached, the vehicle may be operated at a light
load and speed.
SEBU7011-15 73
Operation Section
Engine Starting

After the engine has started, the air inlet heater may continue to
operate in a “Continuous” mode and/or in an “Intermittent” mode. The
air inlet heater will turn OFF when the sum of the coolant temperature
and the air inlet temperature exceeds 35 °C or 127 °F.

If the engine is operated with a low load, the engine will reach normal
operating temperature sooner than idling the engine with no load.
When the engine is idled in cold weather, increase the engine rpm to
approximately 1000 to 1200 rpm. This will warm up the engine more
quickly. Do not exceed the recommended rpm in order to increase the
speed of the warm-up. Limit unnecessary idle time to ten minutes.

Ether Injection System

Personal injury or property damage can result

from alcohol or starting fluids.

Alcohol or starting fluids are highly flammable and

toxic and if improperly stored could result in injury
or property damage.

When using starting fluid (ether), follow the man-

ufacturer’s instructions carefully. Use the starting
fluid sparingly and spray only while cranking the
engine. Failure to do so could result in an explo-
sion and/or fire and personal injury.

NOTICE
The optional automatic ether injection system is the
only starting fluid system that is recommended. Ex-
cessive starting fluid can cause piston and ring dam-
age. Use starting fluid for cold starting purposes only.

Startability will be improved at temperatures below 0 °C (32 °F) by the

use of an automatic ether injection system and/or a jacket water heater.
This will help alleviate white smoke and misfire during start-up in cold
weather. Consult your Caterpillar dealer for other means of improving
startability in cold temperatures.
74 SEBU7011-15
Operation Section
Engine Starting

The “Starting Aid Output” can be programmed in order to allow the ECM
to automatically control a system for ether injection control. The reading
for the inlet manifold air temperature is used in order to determine if the
conditions require use of the Starting Aid. The reading for the Coolant
Temperature Sensor will be used if a fault condition exists with the sensor
circuit for the Inlet Manifold Air Temperature. If the temperature reading is
below 0 °C (32 °F) and an attempt is made in order to start the engine,
the “Starting Aid Output” will be enabled. The “Starting Aid Output” will
be disabled if the engine starts. The “Starting Aid Output” will also be
disabled if a condition occurs in order to prevent fuel injection.

Starting Problems
An occasional starting problem may be caused by one of the following
items:

• Low battery charge

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

If the other problems are suspected, perform the appropriate procedure

in order to start the engine.
SEBU7011-15 75
Operation Section
Engine Starting

Problems with the Wiring Harness

g00414720
Illustration 14
(1) Engine harness
(2) Connection for the chassis harness (vehicle OEM)

Locate the ECM. Two harness connectors are attached to the ECM. One
connector is engine harness (1) and the other connector is the chassis
harness. Check the connectors in order to ensure that the connectors are
secure. Lightly pull each of the wires in the chassis harness.

1. Pull each wire with approximately 4.5 kg (10 lb) of force. The wire
should remain in the connector.

2. If a wire is loose, push the wire back into the connector. Pull the wire
again in order to ensure that the wire is secure.

3. Start the engine. If the engine does not start, consult the nearest
Caterpillar dealer for assistance.
76 SEBU7011-15
Operation Section
Engine Starting

i02308903

Starting with Jump Start Cables

SMCS Code: 1000; 1401; 1402; 1900

Improper jump start cable connections can cause

an explosion resulting in personal injury.

Prevent sparks near the batteries. Sparks could

cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.

If the installation is not equipped with a backup battery system, it may be

necessary to start the engine from an external electrical source.

For information on troubleshooting the charging system, refer to Special

Instruction, REHS0354, “Charging System Troubleshooting”.

Many batteries which are considered unusable are still rechargeable. After
jump starting, the alternator may not be able to fully recharge batteries
that are severely discharged. The batteries must be charged to the proper
voltage with a battery charger. For information on testing and charging,
refer to the Special Instruction, SEHS7633, “Battery Test Procedure”.
SEBU7011-15 77
Operation Section
Engine Starting

NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.

Do not reverse the battery cables. The alternator can

be damaged. Attach ground cable last and remove
first.

When using an external electrical source to start the

engine, turn the engine control switch to the “OFF” po-
sition. Turn all electrical accessories OFF before at-
taching the jump start cables.

Ensure that the main power switch is in the OFF posi-

tion before attaching the jump start cables to the en-
gine being started.

1. Turn the start switch on the stalled engine to the OFF position. Turn
off all accessories.

2. Connect one positive end of the jump start cable to the positive cable
terminal of the discharged battery. Connect the other positive end of the
jump start cable to the positive cable terminal of the electrical source.

3. Connect one negative end of the jump start cable to the negative cable
terminal of the electrical source. Connect the other negative end of the
jump start cable to the engine block or to the chassis ground. This
procedure helps to prevent potential sparks from igniting combustible
gases that are produced by some batteries.

4. Charge the batteries. The engine will not continue to run after starting
if the batteries have not been charged.

5. Start the engine.

6. Immediately after the stalled engine is started, disconnect the jump

start cables in reverse order.

Refer to the Electrical Schematic for your engine. Consult your Caterpillar
dealer for more information.
78 SEBU7011-15
Operation Section
Engine Operation

Engine Operation
i02005421

Engine Operation
SMCS Code: 1000

Proper operation, driving techniques and maintenance are key factors in

obtaining the maximum service life and economy of Caterpillar engines.
The recommendations in this Operation and Maintenance Manual will
help to lower operating costs. For more information, refer to Special
Publication, LEDT2254, “CAT Answers Your Questions About Truck
Performance” or consult your Caterpillar dealer.

If the engine is operated at low idle or at low load for 24 or more

consecutive hours, the engine should be run at rated conditions for five
to fifteen minutes. Running the engine at rated conditions should clean
out the catalytic converter/muffler.

Idling
Idle speed is adjustable on Caterpillar electronic engines. Consult your
Caterpillar dealer for information. The idle rpm is preset between 700
and 750 rpm.

Avoid excess idling. If the vehicle is parked for more than five minutes,
stop the engine. An engine can burn from 2.8 L (0.7 US gal) to 5.7 L
(1.5 US gal) of fuel per hour while the engine is idling. Excessive idling
can cause carbon buildup and/or excessive idling can cause the engine to
slobber. This is harmful to the engine.

If extended idle time is required, control the engine rpm to 1000 rpm or
above 1000 rpm. Ensure that the coolant temperature exceeds 82° C
(180° F). Consult your Caterpillar dealer for assistance.

The engine may be programmed in order to provide an elevated idle

speed when the battery voltage drops below a level that is predetermined.
The engine rpm will increase to the preprogrammed amount for a time
of 5 minutes. At the end of that 5 minute period, the engine will return
to low idle. The engine will return to the elevated idle speed that is
programmed for another 5 minutes if the battery is still below the low limit
that is programmed. This cycle will continue until one of the following
occurrences takes place.
SEBU7011-15 79
Operation Section
Engine Operation

• The battery has recharged sufficiently.

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

Idle Shutdown Timer

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

• The idle shutdown feature is selected.

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

The following conditions must be met in order to override the idle

shutdown timer:

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

80 SEBU7011-15
Operation Section
Engine Operation

2. The “CHECK ENGINE/DIAGNOSTIC”lamp will flash rapidly

for 90 seconds prior to shutdown. Depress the service brake
or the clutch pedal during the 90 seconds when the “CHECK
ENGINE/DIAGNOSTIC” lamp flashes.

After an idle shutdown, the engine can be restarted without turning the
ignition key switch to the OFF position.

The override function is disabled if the “ALLOW IDLE SHUTDOWN

OVERRIDE” is programmed to “NO”.

Cold Mode Operation

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

Cold mode is deactivated when the temperature condition is met, or when

the engine has been operating for 12 minutes.

After the cold mode is completed, the engine should be operated at low
rpm and low load until normal operating temperature is reached. The
engine will reach normal operating temperature faster when the engine is
operated at low rpm and low power demand. This method is faster than
trying to reach operating temperature by idling with no load.

NOTICE
It is not recommended that the vehicle be moved until
the engine is out of cold mode. Power may be notice-
ably reduced if the vehicle is operated while the engine
is in cold mode. At a speed above 8 km/h (5 mph), the
low idle speed will be reduced to the customer pro-
grammed low idle speed. The power will still be re-
duced.

Cold mode is disabled if the throttle, the service brake, or the clutch (if
equipped) is depressed. The rpm for cold mode operation drops to the
programmed low idle speed in order to allow the transmission to be put
into gear.
SEBU7011-15 81
Operation Section
Engine Operation

Muffler and Converter (If Equipped)

The muffler and converter will become extrem-

ly hot during engine operation. A hot muffler
and converter can cause serious burns. Allow
adaquate cooling time before working on or near
the muffler and converter.

Proper operation, driving techniques and maintenance are key factors in

obtaining the maximum service life of the muffler and converter. Some
precautions should be taken if the engine is equipped with a muffler and
converter.

Avoid excess idling. Excessive idling can cause the muffler and converter
to plug. A plugged muffler and converter will lead to an increase in
exhaust back pressure. Operating the engine in extremely cold conditions
can cause the muffler and converter to plug sooner. Use the procedure
below to clean out the muffler and converter if extended idle periods or
extended low load periods are required.

If the engine is operated at low idle or at low load for 24 or more

consecutive hours, the engine should be run at rated conditions for five
to fifteen minutes. Running the engine at rated conditions should clean
out the muffler and converter. If the engine has low power or the engine
does not respond properly, refer to the Service Manual or an authorized
Caterpillar Service Center.

Diesel Particulate Filter (If Equipped)

The diesel particulate filter (DPF) may become restricted. The restriction
is caused by ash and soot from the exhaust. A restricted exhaust will
increase the exhaust back pressure. The amber colored warning light
will turn on when the exhaust back pressure reaches a level that is
unacceptable. The filter should be cleaned immediately. The red colored
warning light will flash when the engine has exceeded the safe level of
exhaust back pressure. This will cause the engine to go into the derate
mode. The power of the engine will be limited. The filter needs to be
cleaned immediately.

Note: The diagnostic module for the DPF will need to be reset if the red
warning light turns on. The engine derate will reset with the diagnostic
module for the DPF.
82 SEBU7011-15
Operation Section
Engine Operation

Getting Started
Caterpillar electronic engines do not require long warm-up periods that
needlessly waste fuel. Typically, the engine should be at normal operating
temperature in a few minutes. Begin operating the engine at low load.
After normal oil pressure is reached and the temperature gauges begin
to rise, the engine may be operated at full load.

To get the vehicle in motion, use a gear that will result in a smooth start.
Move the load without increasing the engine rpm above low idle or without
slipping the clutch. Engage the clutch smoothly. Slipping the clutch and
engaging the clutch can cause stress to occur on the drive train. This
can also cause fuel to be wasted.

Use progressive shifting techniques. Progressive shifting is using only the

rpm that is required in order to upshift into the next gear. Progressive
shifting improves fuel economy.

• Keep the engine rpm to a minimum. Use an rpm that is from 1400 to
2000 rpm.

• Use only enough rpm to pick up the next gear.

Progressive shifting also reduces the acceleration rate. Top gear is
reached sooner because less time is needed to synchronize the gears
during shifting. In addition, the engine is operating at the highest range of
torque.

The amount of rpm that is required to upshift increases as the vehicle

speed increases, unless upshifts are made on upgrades. Experience
with the vehicle will show the amount of rpm that is required to upshift
under various conditions.

Note: These engines may be programmed to encourage progressive

shifting. The acceleration rate may slow down at certain rpm in lower
gears. If this occurs, progressive shift parameters may have been
programmed into the ECM. Progressive shift parameters will limit the
rpm when the vehicle is driven in higher gears. These parameters are
protected by customer passwords. If the vehicle can be operated in a
higher gear at a vehicle speed that is desired, select the highest gear that
is available to pull the load. This recommendation will help to obtain fuel
economy. The engine will be operating at the lowest rpm that is required
to pull the load.
SEBU7011-15 83
Operation Section
Engine Operation

Vehicle Efficiency
An efficient vehicle performs the desired amount of work while the power
demand on the engine is minimized. The following factors are major
contributors to power demand:

• Aerodynamic drag (wind resistance)

• Rolling resistance of the tires
• Gross weight of the vehicle
• Losses in the drive train and the load from the engine driven accessories
For more information about vehicle efficiency, refer to Special Publication,
LEDT2254, “CAT Answers Your Questions About Truck Performance”.

Fuel Economy
Fuel is the largest single operating cost of today’s on-highway vehicle
engines. Improved fuel economy can have a substantial impact on
operating profit. The following items are the most significant factors that
influence vehicle fuel economy:

• Driver techniques
• Vehicle efficiency
• Operating conditions
• Engine efficiency
A No. 1 grade of fuel contains less energy per volume and increases
fuel consumption. A greater volume of fuel must be injected in order to
yield the same amount of work as a No. 2 fuel. The difference in the fuel
economy between the two grades of fuel can be as great as 0.2 km/L
(0.5 mpg) to 0.3 km/L (0.7 mpg).

Engines with the serial number (S/N: DPF) require special diesel fuel. The
fuel must contain less than 15 ppm sulfur.

For more information about fuel economy, refer to Special Publication,

LEDT2254, “CAT Answers Your Questions About Truck Performance”.
84 SEBU7011-15
Operation Section
Engine Operation

Rolling hills provide a great opportunity to reduce fuel consumption. Avoid

downshifting on small hills. The vehicle should not be downshifted even if
the engine must be lugged down to an rpm that is below the peak torque
rpm. When the vehicle is going down a hill, use gravity instead of the
engine’s power to regain vehicle speed.

On grades that require more than one downshift, allow the engine to lug
to peak torque rpm. If the rpm stabilizes with the engine running at peak
torque rpm or above peak torque rpm remain in that gear.

Long steep down grades should be anticipated. Vehicle speed should be

reduced before cresting the top of a hill and proceeding down a long steep
grade. Minimize the amount of braking that is used in order to maintain a
safe speed for maximizing fuel efficiency.

The engine’s ability to hold the vehicle back increases with engine rpm.
Select a gear that runs the engine near the high engine rpm limit for long
steep hills when braking is required.

Speed reductions and future stops should be anticipated. Downshifts

should be avoided. The amount of braking should be minimized in order
to improve fuel consumption. By coasting to a stop, a vehicle can travel a
considerable distance without consuming any fuel.

Cruising
Vehicles that are driven faster consume more fuel. Increasing the cruising
speed from 88 km/h (55 mph) to 104 km/h (65 mph) will increase the
fuel consumption of a typical Class 8 vehicle by approximately 0.4 km/L
(1 mpg). When a vehicle is driven fast in order to allow more time for
stops, the stops become very expensive. Cruising allows the engine to
operate in the most efficient rpm range (1400 to 2000 rpm).

Cruise Control
The functionality of the cruise control can vary depending on the vehicle
manufacturer. The Cruise Control switch may be programmed to operate
in one of two modes:

• The SET position may operate as the SET/ACCEL SWITCH position

or the RESUME/DECEL position.

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

RESUME/ACCEL position.
SEBU7011-15 85
Operation Section
Engine Operation

Refer to the markings on the Cruise Control switch or refer to your “Truck
Service Manual”.

Perform the following steps in order to set the Cruise Control:

1. After accelerating to the desired speed, turn the “ON/OFF” switch to

the ON position.

2. Press the “SET/RESUME” switch to the SET position.

The ECM will control the vehicle speed until the clutch pedal or the service
brake is depressed or the “ON/OFF” switch is turned to the OFF position.

Note: The vehicle can also be accelerated to the desired speed and the
cruise control speed can be set by pressing the “SET/RESUME” switch to
the ACCEL position.

Perform the following step in order to reset the Cruise Control:

1. Press “RESUME” and the vehicle will return to the set speed.

Momentarily pressing or bumping the “SET/RESUME” switch to the

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

Soft Cruise Control

The Cruise Control can be programmed to operate in one of two modes,
“Soft Cruise = YES” or “Soft Cruise = NO”.

Soft Cruise Control provides an operating range of 8 km/h (5 mph) around

the setting for the cruise control. Engines that are shipped from Caterpillar
are programmed to operate in the “Soft Cruise = YES” mode. Soft Cruise
Control allows the vehicle to accelerate slightly while the engine is under
power. The vehicle can proceed down a hill while momentum is gained for
the next hill. Improved fuel economy can be gained in this mode.

When “Soft Cruise = NO” is programmed, the “SET” speed is maintained.

Consult your Caterpillar dealer for more information.
86 SEBU7011-15
Operation Section
Engine Operation

Idle Mode
The cruise control function of the electronic engine works as an engine
speed governor when the vehicle is stationary or when the vehicle is
operated at a vehicle speed below the idle vehicle speed limit. The
engine speed governor is activated and deactivated in the same way
as the cruise control.

The engine speed governor will operate at any engine rpm from low idle
to the maximum idle rpm limit. The maximum idle rpm limit is actually
less than the rated engine rpm. The maximum idle governor speed is
a Customer Specified Parameter.

Perform the following procedure in order to activate idle mode:

1. Set the “ON/OFF” switch to the ON position. The throttle can then be
used to determine the desired engine rpm.

2. When the desired engine rpm is reached, place the “SET/RESUME”

switch to the SET position and release the switch. The engine rpm
will be maintained at this speed.

Note: If the “SET/RESUME” switch is held for more than one second
in the ACCEL position, the ECM will increase the engine rpm until the
“SET/RESUME” switch is released. If the parameter is programmed, the
ECM will increase the engine rpm up to the idle engine rpm limit, or to
the top engine limit (TEL).

Perform one of the following procedures in order to disengage the idle

mode:

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

• Depress the clutch pedal.
• Depress the service brake pedal.
Perform the following procedure in order to resume the idle mode:

1. Ensure that the “Cruise/Idle ON/OFF” switch is in the ON position.

2. Move the “SET/RESUME” switch momentarily to the RESUME

position.
SEBU7011-15 87
Operation Section
Engine Operation

Note: If the “SET/RESUME” switch is held for more than one second in
the DECEL position, the ECM will decrease the engine rpm until the switch
is released. A new set rpm is established when the switch is released.

Uphill Operation
For optimum performance, allow the engine to lug downward to peak
torque rpm (1440 to 1550 rpm) before downshifting. Continue to downshift
in this manner until a gear that maintains the desired speed is reached.
Continue to operate at a low rpm (1440 to 1550 rpm) if the vehicle will
proceed to the top without a downshift. Begin upshifting as the grade of
the hill decreases and the engine begins to accelerate above 2000 rpm.
Driving this way will provide optimum fuel economy and performance.

Note: Allowing the engine to lug below peak torque is permissible if the
vehicle is cresting the top of a hill. However, extended operation at an
engine rpm that is below peak torque (1400 rpm) will raise the exhaust
temperature and the cylinder pressure. This can lead to reduced engine
service life.

Downhill Operation
NOTICE
DO NOT allow the engine rpm to exceed 2900 rpm,
engine damage can result.

On a downgrade, do not allow the vehicle to coast while the clutch pedal
is depressed or while the transmission is in the NEUTRAL position. If a
power loss is not desired, disengage the Cruise Control.

Select the correct gear that does not allow the engine rpm to exceed 2900
rpm. Use the service brakes to control the speed of the vehicle. As a basic
rule, select the same gear that would be required to go up the grade.
Refer to the rated rpm (full load) that is on the engine Information Plate.
88 SEBU7011-15
Operation Section
Engine Operation

i01637441

Exhaust Brake
SMCS Code: 1093

If your vehicle is equipped with an auxiliary brake,

follow the instructions provided in the auxiliary
brake owner’s manual. Failure to follow the in-
structions during wet or slippery conditions could
reduce vehicle control and result in personal in-
jury or death.

NOTICE
Auxiliary brakes should not be used as a primary or
service brake. The vehicle’s service brake must be
used in order to bring the vehicle to a complete stop.

Certain exhaust brakes are approved for use on these engines. Refer to
the Truck Engine Application and Installation Guide or see your Caterpillar
dealer for more information. For information on the specific exhaust brake
that is installed on your vehicle, refer to the information that is provided
by the OEM of the vehicle.

The anti-lock brake system (ABS) of this vehicle may interrupt the
operation of the auxiliary engine brake during the actuation of the ABS.
Compression brakes and exhaust brakes are typical examples of auxiliary
engine brakes. For information on the operation of the ABS, refer to the
literature that is provided by the OEM of the vehicle.

The exhaust brake may be used as a warm up device for the engine
in order to add parasitic load to the engine. This parasitic load will help
maintain normal engine operating temperatures. The engine will ramp to
the programmed Warm Up Mode Idle Speed and the exhaust brake will
be engaged when the engine is programmed to either “Warm Up Only” or
“Exhaust Brake & Warm Up”. Also, the switch for the exhaust brake must
be in the ON position if this switch has been installed.

Warm Up Mode will be disengaged when one of the following conditions

occurs.

• The engine is warmed up.

SEBU7011-15 89
Operation Section
Engine Operation

• The service brake is depressed.

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

• The vehicle is in gear. (Optional neutral switch)

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

An exhaust brake generates the maximum retarding effect at the engine’s

maximum rated rpm. As the engine rpm decreases, the performance of
the exhaust brake also decreases. For maximum available retarding, the
operator should select a gear which will provide the desired road speed at
the highest allowable engine rpm.

To maximize the benefit of the exhaust brake, the exhaust brake should be
used whenever the operator wants to slow the vehicle. The exhaust brake
should be kept in the ON position during all normal operating conditions.

The operation of any vehicle under slippery conditions requires caution.

This is also true when a vehicle with an exhaust brake is operated. As
a general rule, start with the exhaust brake in the OFF position and
ensure that the vehicle maintains control through natural retardation.
Then activate the exhaust brake at the lowest power setting. Increase the
power setting as conditions improve.
90 SEBU7011-15
Operation Section
Engine Operation

Operating the Exhaust Brake

The exhaust brake is controlled by a switch on the dashboard. Before
starting the engine, ensure that the switch is in the OFF position.

After the engine is started, turn the switch to the ON position. The switch
may stay in the ON position during engine operation. The exhaust brake
will only activate when no fuel is supplied to the engine. The exhaust
brake will help to slow the vehicle when no pressure is applied to the
throttle pedal or to the clutch pedal.

The exhaust brake may be programmed to one of three modes:

• “COAST”
• “LATCH”
• “MANUAL”
The “COAST” mode and the “LATCH” mode require the Cruise Control
switch to be in the ON position. The “COAST” mode and the “LATCH”
mode do not require the Cruise Control to be active. In the “COAST” mode
or the “LATCH” mode, the exhaust brake is activated by the service brake.
Using the service brake will deactivate the Cruise Control. However, the
service brake does not turn the Cruise Control to the OFF position.

In the “MANUAL” mode, it is not necessary to depress the service brake

in order to activate the exhaust brake.

If the “Cruise Control ON/OFF” switch is in the OFF position, the exhaust
brake will activate regardless of the service brake.

“COAST” Mode
If the exhaust brake is programmed to “COAST” and the Cruise Control
switch is in the ON position, the exhaust brake will activate when the
service brake is depressed. In the “COAST” mode, the braking power is
provided by both the service brake and the exhaust brake.

The exhaust brake will deactivate when the service brake is released.
SEBU7011-15 91
Operation Section
Engine Operation

“LATCH” Mode
If the exhaust brake is programmed to “LATCH” and the Cruise Control
switch is in the ON position, the exhaust brake will activate when the
service brake is depressed.

The exhaust brake remains active when the service brake is released.
The exhaust brake remains active until the throttle pedal or the clutch
pedal is depressed, or the engine speed drops below 900 rpm.

“MANUAL” Mode
If the exhaust brake is programmed to “MANUAL”, the exhaust brake
will activate regardless of the service brake or the position of the Cruise
Control switch.

The exhaust brake will turn off once the engine exceeds 900 rpm during
acceleration. Once you remove your foot from the accelerator pedal, the
exhaust brake should turn on again within 0.25 seconds. The exhaust
brake will only activate when no fuel is supplied to the engine. The
exhaust brake will activate when no pressure is applied to the throttle
pedal or to the clutch pedal.
92 SEBU7011-15
Operation Section
Engine Operation

i00911221

Caterpillar Driver Information Display

SMCS Code: 7490

The Caterpillar Driver Information Display (CAT ID) can display a variety
of engine and vehicle information. The CAT ID is an attachment that is
available from your Caterpillar dealer. The features of the CAT ID are
briefly described in the following text.

Diagnostic Data
The CAT ID identifies diagnostic codes with both a number and a brief
text explanation. The diagnostic codes, which can indicate a potentially
serious engine problem, are displayed automatically by the CAT ID.

Engine Operating Information

The CAT ID provides information on the following items: cruise control set
speed, PTO engine rpm set speed, fuel temperature to the engine, boost
pressure, oil pressure, and coolant temperature.

Vehicle Trip Information

The CAT ID provides information on the following items: fuel economy,
fuel consumption, average vehicle speed, idle time, PTO time, idle fuel,
and PTO fuel.

All of this information can be tied to the segments of the trip or to the
history of the engine.

Maintenance Information
The system has an oil and filter change indicator which allows the display
to indicate when the next maintenance is due.

Theft Deterrent
The Theft Deterrent helps in order to prevent the engine from starting
unless a security password has been entered.
SEBU7011-15 93
Operation Section
Engine Stopping

Engine Stopping
i00948324

Stopping the Engine

SMCS Code: 1000; 7000

NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and
accelerated wear of the engine components.

If the engine has been operating at high rpm and/or

high loads, run at low idle for at least three minutes to
reduce and stabilize internal engine temperature be-
fore stopping the engine.

Avoiding hot engine shutdowns will maximize tur-

bocharger shaft and bearing life.

Prior to stopping an engine that is being operated at low loads, operate

the engine at low idle for 30 seconds before stopping. If the engine has
been operating at highway speeds and/or at high loads, operate the
engine at low idle for at least three minutes. This procedure will cause the
internal engine temperature to be reduced and stabilized.

Ensure that the engine stopping procedure is understood. Stop the engine
according to the shutoff system on the vehicle or refer to the instructions
that are provided by the OEM of the vehicle.

• To stop the engine, turn the ignition key switch to the OFF position.

After Stopping the Engine

• Check the crankcase oil level. Maintain the oil level between the “ADD”
mark and the “FULL” mark on the oil level gauge.

• If necessary, perform minor adjustments. Repair any leaks and tighten

any loose bolts.
94 SEBU7011-15
Operation Section
Engine Stopping

• Note the service hour meter reading. Perform the maintenance that
is in the Operation and Maintenance Manual, “Maintenance Interval
Schedule”.

• Fill the fuel tank in order to help prevent accumulation of moisture in the
fuel. Do not overfill the fuel tank.

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

• Allow the engine to cool. Check the coolant level. Maintain the cooling
system at 13 mm (.5 inch) from the bottom of the pipe for filling.

• If freezing temperatures are expected, check the coolant for proper

antifreeze protection. The cooling system must be protected against
freezing to the lowest expected outside temperature. Add the proper
coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all driven equipment. This

maintenance is outlined in the instructions from the OEM.
SEBU7011-15 95
Operation Section
Cold Weather Operation

Cold Weather Operation

i01502338

Radiator Restrictions
SMCS Code: 1353; 1396

Caterpillar discourages the use of airflow restriction devices that are

mounted in front of radiators. Airflow restriction can cause the following
conditions:

• High exhaust temperatures

• Power loss
• Excessive fan usage
• Reduction in fuel economy
Shutters can be properly used for parking overnight, very cold
temperatures, and high winds. In those particular cases, the coolant
temperature and the inlet manifold temperature must be carefully
monitored and controlled.

NOTICE
Failure to open the winter fronts in the morning could
cause engine damage and/or loss of fuel economy.

i02118561

Fuel and the Effect from Cold Weather

SMCS Code: 1000; 1250

The following fuels are the grades that are available for Caterpillar
engines:

• No.1
• No.2
• Blend of No.1 and No.2
96 SEBU7011-15
Operation Section
Cold Weather Operation

No.2 diesel fuel is the most commonly used fuel. Either No.1 diesel fuel or
a blend of No.1 and No.2 is best suited for cold weather operation.

Note: Engines that are equipped with a Diesel Particulate Filter (DPF)
are required to use Ultra Low Sulfur Diesel (ULSD) diesel fuel. ULSD fuel
contains less than 15 ppm sulfur using ASTM D 2622 or DIN 51400. The
use of higher sulfur diesel fuel in an engine with a DPF will cause the
engine to produce emissions that are not in compliance with emissions
standards and deactivation of the catalyst within the DPF. The use of a
blend of No.1 and No.2 fuel is allowed in an engine that is equipped with
a DPF, if both of the base fuels meet the ULSD standard.

Quantities of No.1 diesel fuel are limited. No.1 diesel fuels are usually
available during the months of the winter in the colder climates. During
cold weather operation, if No.1 diesel fuel is not available, use No.2 diesel
fuel, if necessary.

There are three major differences between No.1 and No.2 diesel fuel.
No.1 diesel fuel has the following properties:

• Lower cloud point

• Lower pour point
• Lower rating of BTU per unit volume of fuel
When No.1 diesel fuel is used, a decrease in power and in fuel efficiency
may be noticed. Other operating effects should not be experienced.

The cloud point is the temperature when a cloud of wax crystals begins
to form in the fuel. These crystals can cause the fuel filters to plug. The
pour point is the temperature when diesel fuel will thicken. The diesel fuel
becomes more resistant to flow through fuel pumps and through fuel lines.

Be aware of these values when diesel fuel is purchased. Anticipate the

average ambient temperature of the location of the engine’s area of
operation. Engines that are fueled in one climate may not operate well
if the engines are moved to another climate. Problems can result due
to changes in temperature.

Before troubleshooting for low power or for poor performance in the

winter, check the type of fuel that is being used.

When No.2 diesel fuel is used the following components provide a means
of minimizing problems in cold weather:
SEBU7011-15 97
Operation Section
Cold Weather Operation

• Starting aids
• Engine oil pan heaters
• Engine coolant heaters
• Fuel heaters
• Fuel line insulation
For more information about fuel, refer to Special Publication, SEBU6385,
“Caterpillar On-highway Diesel Truck Engine Fluids Recommendations”.

i01502354

Fuel Related Components in Cold Weather

SMCS Code: 1000; 1250

Fuel Tanks
Condensation can form in partially filled fuel tanks. Top off the fuel tanks
after operating the engine.

Fuel tanks should contain some provision for draining water and sediment
from the bottom of the tanks. Some fuel tanks use supply pipes that allow
water and sediment to settle below the end of the fuel supply pipe.

Some fuel tanks use supply lines that take fuel directly from the bottom of
the tank. If the engine is equipped with this system, regular maintenance
of the fuel system filter is important.

Drain the water and sediment from any fuel storage tank at the following
intervals:

• Weekly
• Oil changes
• Refueling of the fuel tank
This will help prevent water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.
98 SEBU7011-15
Operation Section
Cold Weather Operation

Fuel Filters
A primary fuel filter and/or a water separator is installed between the fuel
tank and the engine mounted fuel filter. The location of the primary fuel
filter is important in cold weather operation. The primary fuel filter and the
fuel supply line are commonly affected by cold fuel. The best location for
the primary fuel filter is in the engine compartment. Here, the primary fuel
filter will benefit from the radiant heat of the engine. A primary fuel filter
that is mounted outside the frame rails or in any location that is exposed
to wind can be a persistent problem in cold weather.

Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging in cold weather due
to waxing. A fuel heater should be installed so that the fuel is heated
before the fuel enters the primary fuel filter.

Select a fuel heater that is mechanically simple, yet adequate for the
application. The fuel heater should also help to prevent overheating of
the fuel. High fuel temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater with a large heating
surface. The fuel heater should be practical in size. Small heaters can be
too hot due to the limited surface area.

Disconnect the fuel heater in warm weather.

Note: Fuel heaters that are controlled by the water temperature regulator
or self-regulating fuel heaters should be used with this engine. Fuel
heaters that are not controlled by the water temperature regulator can
heat the fuel in excess of 65 °C (149 °F). A loss of engine power can
occur if the fuel supply temperature exceeds 37 °C (100 °F).

Note: Heat exchanger type fuel heaters should have a bypass provision
in order to prevent overheating of the fuel in warm weather operation.

The following fuel heaters are recommended for use with Caterpillar
engines:

• 7C-3557 Fuel Heater Group

• 7C-3558 Heater Kit
For further information on fuel heaters, consult your Caterpillar dealer.
SEBU7011-15 99
Maintenance Section
Refill Capacities

Maintenance Section

Refill Capacities
i02005508

Refill Capacities and Recommendations

SMCS Code: 1348; 1395; 7560

Engine Oil
API Oils
The Engine Oil Licensing and Certification System by the American
Petroleum Institute (API) is recognized by Caterpillar. For detailed
information about this system, see the latest edition of the “API publication
No. 1509”. Engine oils that bear the API symbol are authorized by API.

g00546535
Illustration 15
Typical API symbol

Diesel engine oils CC, CD, CD-2, and CE have not been API authorized
classifications since 1 January 1996. Table 8 summarizes the status of
the classifications.
100 SEBU7011-15
Maintenance Section
Refill Capacities

Table 8
API Classifications
Current Obsolete
CI-4(1), CH-4(1), CG-4(2),
CE
CF-4(3)
CF (4) CC, CD
CF-2(5) CD-2(5)
(1) API CH-4 and CI-4 oils are acceptable if the requirements
of Caterpillar’s ECF-1 (Engine Crankcase Fluid
specification-1) are met. CH-4 and CI-4 oils that have not
met the requirements of Caterpillar’s ECF-1 Specification
may cause reduced engine life.
(2) API CG-4 oils are acceptable for all Caterpillar diesel engines.
When the API CG-4 oils are used, the oil drain interval should
not exceed 75 Percent of the standard oil drain interval for
your engine.
(3) API CF-4 oils are no longer recommended for Caterpillar
on-highway diesel engines.
(4) API CF oils are not recommended for Caterpillar on-highway
diesel engines.
(5) API CF-2 and CD-2 oils are classifications for two-cycle diesel
engines. Caterpillar does not sell engines that utilize the CD-2
and the API CF-2 oils.

Caterpillar Diesel Engine Oil (DEO)

Caterpillar Oils have been developed and tested in order to provide
the full performance and service life that has been designed and built
into Caterpillar Engines. Caterpillar Oils are currently used to fill diesel
engines at the factory. These oils are offered by Caterpillar dealers for
continued use when the engine oil is changed. Consult your Caterpillar
dealer for more information on these oils.

Due to significant variations in the quality and in the performance

of commercially available oils, Caterpillar makes the following
recommendations:

• Caterpillar Diesel Engine Oil (DEO) (10W-30)

• Caterpillar Diesel Engine Oil (DEO) (15W-40)
Commercial Oils
Engine Crankcase Fluid Recommendations for all Current and
Noncurrent Caterpillar On-highway Truck Diesel Engines:
SEBU7011-15 101
Maintenance Section
Refill Capacities

• API CH-4 oils and API CI-4 oils are acceptable if the requirements
of Caterpillar’s ECF-1 (Engine Crankcase Fluid specification-1) are
met. CH-4 oils and CI-4 oils that have not met the requirements of
Caterpillar’s ECF-1 Specification may cause reduced engine life.

• API CG-4 oils are acceptable for all Caterpillar diesel engines. When
the API CG-4 oils are used, the oil drain interval should not exceed 75
Percent of the standard oil drain interval for your engine.

• API CF-4 oils are no longer recommended.

NOTICE
In selecting oil for any engine application, both the oil
viscosity and oil performance classification/specifica-
tion as specified by the engine manufacturer must be
defined and satisfied. Using only one of these param-
eters will not sufficently define oil for an engine appli-
cation.

In order to make the proper choice of a commercial oil, refer to the

following explanations:

API CI-4 – API CI-4 oils were developed in order to meet the
requirements of high performance diesel engines that use cooled Exhaust
Gas Recirculation (EGR). API CI-4 oils are acceptable if the requirements
of Caterpillar’s ECF-1 (Engine Crankcase Fluid specification-1) are met.

API CH-4 – API CH-4 oils were developed in order to protect low
emissions diesel engines that use a 0.05 percent level of fuel sulfur.
However, API CH-4 oils may be used with higher sulfur fuels. API CH-4
oils are acceptable if the requirements of Caterpillar’s ECF-1 (Engine
Crankcase Fluid specification-1) are met.

Note: CH-4 oils and CI-4 oils that have not met the requirements of
Caterpillar’s ECF-1 Specification may cause reduced engine life.

NOTICE
Failure to follow these oil recommendations can cause
shortened engine service life due to deposits and/or
excessive wear.

Note: Refer to Special Publication, SEBU6385, “Caterpillar On-highway

Diesel Truck Engine Fluids Recommendations” for additional information
that relates to lubrication for your engine.
102 SEBU7011-15
Maintenance Section
Refill Capacities

Lubricant Viscosity Recommendations

The proper SAE viscosity grade of oil is determined by the minimum
ambient temperature during cold engine start-up, and the maximum
ambient temperature during engine operation.

Refer to Table 9 (minimum temperature) in order to determine the required

oil viscosity for starting a cold engine.

Refer to Table 9 (maximum temperature) in order to select the oil viscosity

for engine operation at the highest ambient temperature that is anticipated.

Note: Generally, use the highest oil viscosity that is available to meet the
requirement for the temperature at start-up.

If ambient temperature conditions at engine start-up require the use of

multigrade SAE 0W oil, SAE 0W-40 viscosity grade is preferred over
SAE 0W-20 or SAE 0W-30.

Note: SAE 10W-30 is the preferred viscosity grade for the following diesel
engines when the ambient temperature is above −18 °C (0 °F) and below
40 °C (104 °F).

• C7
• C9
• 3116
• 3126
SEBU7011-15 103
Maintenance Section
Refill Capacities

Table 9
Engine Oil Viscosities for Ambient Temperatures(1)
Ambient Temperature
Viscosity Grade Minimum Maximum
SAE 0W-20 −40 °C (−40 °F) 10 °C (50 °F)
SAE 0W-30 −40 °C (−40 °F) 30 °C (86 °F)
SAE 0W-40 −40 °C (−40 °F) 40 °C (104 °F)
SAE 5W-30 −30 °C (−22 °F) 30 °C (86 °F)
SAE 5W-40 −30 °C (−22 °F) 50 °C (122 °F)
SAE 10W-30(2) −18 °C (0 °F) 40 °C (104 °F)
SAE 10W-40 −18 °C (0 °F) 50 °C (122 °F)
SAE 15W-40 −9.5 °C (15 °F) 50 °C (122 °F)
(1) Refer to this publication, “Engine Oil (Recommendations)” for
recommendations of diesel engine oil type.
(2) SAE 10W-30 is the preferred viscosity grade for the 3116, 3126,
C7, and C9 diesel engines when the ambient temperature is
above −18 °C (0 °F) and below 40 °C (104 °F).

Note: Supplemental heat is recommended below the minimum

recommended ambient temperature.

S·O·S Oil Analysis

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

• Wear Analysis
• Oil condition
• Additional tests
The wear analysis monitors metal particles, some oil additives, and some
contaminants.

Oil condition uses infrared (IR) analysis to evaluate the chemistry of the
oil. Infrared analysis is also used to detect certain types of contamination.
104 SEBU7011-15
Maintenance Section
Refill Capacities

Additional tests are used to measure contamination levels from water,

fuel, or coolant. Oil viscosity and corrosion protection can be evaluated,
as needed.

Refer to Special Publication, SEBU6385, “Caterpillar On-highway Diesel

Truck Engine Fluids Recommendations” or contact your local Caterpillar
dealer for additional information concerning the S·O·S Oil Analysis
program.

Refill Capacities (Engine Oil)

The refill capacities for the engine crankcase reflect the approximate
capacity of the crankcase or sump plus standard oil filters. Auxiliary oil
filter systems will require additional oil. Refer to the OEM specifications
for the capacity of the auxiliary oil filter.

g00426230
Illustration 16
(1) Shallow oil sump
(2) Deep oil sump
SEBU7011-15 105
Maintenance Section
Refill Capacities

Table 10
3126 On-highway Engine
Approximate Refill Capacities
Compartment or System Liters Quarts
Oil Sump Capacity (Shallow
Sump) (1) 178 mm (7 inch) 21 22
deep
Capacity of Lube System
23 24
(Shallow Sump) (2)
Oil Sump Capacity (Deep
Sump) (1) 241 mm (9.5 inch) 28 30
deep
Capacity of Lube System
30 32
(Deep Sump) (2)
(1) These values are the approximate capacities for the crankcase
oil sump which include the standard oil filters that are installed
at the factory. Engines with auxiliary oil filters will require
additional oil. Refer to the OEM specifications for the capacity
of the auxiliary oil filter.
(2) This capacity includes the HEUI pump and lines.

Lubricating Grease
Caterpillar provides a range of moderate greases to extremely high
performance greases in order to service the entire line of Caterpillar
products that operate throughout the wide variety of climates. From this
variety of Caterpillar grease products, you will find at least one of the
Caterpillar greases that will meet or exceed the performance requirements
for any machine or equipment application.

Before selecting a grease product for any application, the performance

requirements must be determined. Consult the grease recommendations
that are made by the OEM for the equipment when the equipment is
operated in the expected conditions. Then, consult with your Caterpillar
dealer for a list of greases and the following related characteristics.

• Performance specifications
• Available sizes of containers
• Part numbers
106 SEBU7011-15
Maintenance Section
Refill Capacities

Always choose a grease that meets or exceeds the recommendations

that are specified by the equipment manufacturer for the application.

If it is necessary to choose a single grease to use for all of the equipment

at one site, always choose a grease that meets or exceeds the
requirements of the most demanding application. Remember, products
that barely meet the minimum performance requirements can be expected
to barely produce minimum parts life. It is false economy to use grease
that was purchased based on the lowest cost per pound. Instead, use
the grease that yields the lowest total operating cost. This cost should
be based on an analysis that includes the costs of parts, labor, and
downtime. , The cost of the amount of grease that is actually used should
be used in the analysis also.

Note: Caterpillar generally recommends that the old grease should be

purged from the joint when the type of grease is changed or the supplier
of the grease are changed. This is because some greases are not
chemically compatible. Consult your supplier in order to determine if the
greases are compatible.

If in doubt, Purge!

Note: All Caterpillar brand name greases are compatible with each
other.

Note: Refer to Special Publication, SEBU6385, “Caterpillar On-highway

Diesel Truck Engine Fluids Recommendations” for additional information
that relates to lubrication for your engine.

Fuel
Distillate Diesel Fuel
Caterpillar recommends that all distillate diesel fuel, including ULSD fuel
(ie fuel ≤ 15 ppm sulfur using ASTM D 2622 or DIN 51400) meet the
requirements of the Caterpillar Specifications for Distillate Diesel Fuel.

In North America, diesel fuel that is identified as No. 1-D or No. 2-D in
“ASTM D975” generally meet the specifications. Caterpillar recommends
diesel fuels that are distilled from crude oil. Diesel fuels from other
sources could exhibit detrimental properties that are not defined or
controlled by this specification.
SEBU7011-15 107
Maintenance Section
Refill Capacities

Note: Caterpillar recommends that fuel be filtered through a fuel filter

with a rating of less than five (5) microns absolute at the point that the
fuel is dispensed into the vehicle.

NOTICE
Operating with fuels that do not meet Caterpillar’s rec-
ommendations can cause the following effects: start-
ing difficulty, poor combustion, deposits in the fuel in-
jectors, reduced service life of the fuel system, de-
posits in the combustion chamber, and reduced ser-
vice life of the engine.

Note: Refer to Special Publication, SEBU6385, “Caterpillar On-highway

Diesel Truck Engine Fluids Recommendations” for the Caterpillar
Specification for distillate fuel and for additional information that relates to
fuel for your engine.

Refill Capacities (Fuel System)

Refer to the Operation and Maintenance Manual that is provided by the
OEM for capacities of the fuel system.

Coolant
NOTICE
Do not use a commercial coolant/antifreeze that on-
ly meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light duty automotive
applications.

The following two coolants are used in Caterpillar diesel engines:

Preferred – Caterpillar Extended Life Coolant (ELC) or a commercial

extended life coolant that meets the Caterpillar EC-1 specification

Acceptable – A Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) or

a commercial heavy-duty coolant/antifreeze that meets “ASTM D4985”, or
“ASTM D6210” specifications
108 SEBU7011-15
Maintenance Section
Refill Capacities

Note: Caterpillar DEAC does not require a treatment with an SCA at the
initial fill. A commercial heavy-duty coolant/antifreeze that meets “ASTM
D4985” or “ASTM D6210” specifications MAY require a treatment with
an SCA at the initial fill. These coolants WILL require a treatment with
an SCA on a maintenance basis.

Table 11
Service Life Before Flushing and Before Refilling
Coolant Service Life(1)(2)
Cat ELC 965,606 kilometers
(600,000 miles)
Commercial coolant that 482,803 kilometers
meets the Caterpillar EC-1 (300,000 miles)
specification
Cat DEAC 321,869 kilometers
(200,000 miles)
Commercial Heavy-Duty
Coolant/Antifreeze that 241,402 kilometers
meets “ASTM D4985” or (150,000 miles)
“ASTM D6210”
(1) Which ever comes first
(2) Refer to the specific engine Operation and Maintenance
Manual, “Maintenance Interval Schedule” for the Cooling
System Water Temperature Regulator Interval.

Glycol
Glycol in the coolant helps to provide protection against the following
conditions:

• Boiling
• Freezing
• Cavitation of the water pump and cylinder liners
For optimum performance, Caterpillar recommends a 1:1 mixture of a
water/glycol solution.

Note: Use a mixture that will provide protection against the lowest
ambient temperature.
SEBU7011-15 109
Maintenance Section
Refill Capacities

Note: 100 percent pure glycol will freeze at a temperature of −23 °C

(−9 °F).

Refer to table 12 and refer to table 13 for additional information.

Most conventional heavy-duty coolant/antifreezes use ethylene glycol.

Propylene glycol may also be used. In a 1:1 mixture with water, ethylene
and propylene glycol provide similar protection against freezing and
boiling. Refer to tables 12 and 13 for additional information.

Table 12
Ethylene Glycol
Freeze Boil
Concentration
Protection Protection
50 Percent −37 °C (−34 °F) 106 °C (223 °F)
60 Percent −51 °C (−60 °F) 111 °C (232 °F)

NOTICE
Do not use propylene glycol in concentrations that ex-
ceed 50 percent glycol because of propylene glycol’s
reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against
boiling or freezing.

Table 13

Propylene Glycol
Freeze Boil
Concentration
Protection Protection
50 Percent −32 °C (−26 °F) 106 °C (223 °F)

To check the concentration of glycol, use the 1U-7298 Coolant/Battery

Tester (Degree Celsius) or use the 1U-7297 Coolant/Battery Tester
(Degree Fahrenheit). The testers give readings that are immediate and
accurate. The testers can be used with ethylene or propylene glycol.
110 SEBU7011-15
Maintenance Section
Refill Capacities

Note: Propylene glycol coolant that is used in Caterpillar Diesel Engine

cooling systems must meet “ASTM D6211-98a "Fully-Formulated
Propylene Glycol-Based Engine Coolant for Heavy-Duty Engines”.
When Propylene glycol is used in heavy-duty diesel engines, a regular
addition of Supplemental Coolant Additive (SCA) is required for protection
against cavitation of the liners. Consult your Caterpillar dealer for more
information.

S·O·S Coolant Analysis

Testing the engine coolant is important to ensure that the engine is
protected from internal cavitation and from corrosion. The analysis also
tests the ability of the coolant to protect the engine from boiling and from
freezing. The S·O·S Coolant Analysis can be done at your Caterpillar
dealer. Caterpillar S·O·S Coolant Analysis is the best way to monitor
the condition of your coolant and your cooling system. S·O·S Coolant
Analysis is a program that is based on periodic samples.

Refer to Special Publication, SEBU6385-, “Caterpillar On-highway Diesel

Truck Engine Fluids Recommendations” for additional information.

Refill Capacity (Coolant System)

The total cooling system capacity will vary depending on the radiator that
is provided by the vehicle manufacturer. The table for the capacity of the
cooling system is blank. The customer should fill in the table.

Table 14

Approximate Capacity of the Cooling System

Compartment
Liters Quarts
or System
Total Cooling
System(1)
(1) The total cooling system capacity includes the following
components:the engine block, the radiator, and all coolant
hoses and lines.

Note: Refer to Special Publication, SEBU6385, “Caterpillar On-highway

Diesel Truck Engine Fluids Recommendations” for additional information
that relates to coolant for your engine.
SEBU7011-15 111
Maintenance Section
Maintenance Interval Schedule

i02317930

Maintenance Interval Schedule

(Engines with a Deep Oil Sump)
SMCS Code: 1000; 7500

Ensure that the Safety Information, Warnings, and Instructions are

read and understood before operation or maintenance procedures
are performed.

Note: Use fuel consumption, distance (odometer), service hours,

or calendar time, whichever occurs first , in order to determine
the maintenance intervals. Engines that operate in severe operating
conditions may require more frequent maintenance.

Before each consecutive interval is performed, all of the maintenance

requirements from the previous interval must also be performed.

Note: Some maintenance items are for optional equipment.

When Required
Air Dryer - Check ................................................................................. 122
Battery - Replace ................................................................................. 123
Battery or Battery Cable - Disconnect ................................................. 126
Engine Oil Level Gauge - Calibrate ..................................................... 154
Engine Storage Procedure - Check ..................................................... 165
Exhaust Particulate Filter - Clean ........................................................ 167
Exhaust Particulate Filter - Test ........................................................... 171
Fuel System - Prime ............................................................................ 178
Severe Service Application - Check .................................................... 191

Daily
Cooling System Coolant Level - Check ............................................... 139
Engine Air Cleaner Service Indicator - Inspect .................................... 147
Engine Oil Level - Check ..................................................................... 151
Fuel System Water Separator - Drain .................................................. 183
Walk-Around Inspection ....................................................................... 195

Initial 24 000 km (15 000 miles) or 5700 L (1500 US gal) of Fuel

or 400 Service Hours or 6 Months
Engine Valve Lash - Inspect/Adjust ..................................................... 166
112 SEBU7011-15
Maintenance Section
Maintenance Interval Schedule

PM Level 1 - Every 24 000 km (15 000 miles) or 5700 L

(1500 US gal) of Fuel or 400 Service Hours or 6 Months
Aftercooler Core - Inspect .................................................................... 118
Air Compressor Filter - Clean/Replace ................................................ 121
Battery Electrolyte Level - Check ......................................................... 124
Belt - Inspect ........................................................................................ 126
Cooling System Supplemental Coolant Additive (SCA) - Test/Add ..... 140
Cylinder Head Grounding Stud - Inspect/Clean/Tighten ...................... 145
Engine Crankcase Breather - Clean .................................................... 149
Engine Oil Sample - Obtain ................................................................. 156
Engine Oil and Filter - Change ............................................................ 158
Fan Drive Bearing - Lubricate .............................................................. 176
Fuel Inlet Screen - Clean/Inspect/Replace .......................................... 177
Fuel System Primary Filter - Clean/Replace ........................................ 181
Fuel System Secondary Filter - Replace ............................................. 181
Fuel Tank Water and Sediment - Drain ................................................ 185
Hoses and Clamps - Inspect/Replace ................................................. 186
Radiator - Clean ................................................................................... 190

PM Level 2 - Every 161 000 km (100 000 miles) or 56 850 L

(15 000 US gal) of Fuel or 2000 Service Hours or 2 Years
Aftercooler Core - Clean/Test .............................................................. 117
Air Compressor - Inspect ..................................................................... 120
Alternator - Inspect .............................................................................. 122
Belt Tensioner - Inspect ....................................................................... 130
Cooling System Water Temperature Regulator - Replace ................... 143
Crankshaft Vibration Damper - Inspect ................................................ 144
Engine - Clean ..................................................................................... 146
Engine Air Cleaner Element - Clean/Replace ...................................... 147
Engine Mounts - Inspect ...................................................................... 151
Engine Valve Lash - Inspect/Adjust ..................................................... 166
Starting Motor - Inspect ....................................................................... 192
Turbocharger - Inspect ......................................................................... 192
Water Pump - Inspect .......................................................................... 197

Every 3 Years or 322 000 km (200 000 miles)

Cooling System Coolant (DEAC) - Change ......................................... 130

Every 483 000 km (300 000 miles)

Cooling System Coolant Extender (ELC) - Add ................................... 138
SEBU7011-15 113
Maintenance Section
Maintenance Interval Schedule

Every 6 Years or 966 000 km (600 000 miles)

Cooling System Coolant (DEAC) - Change ......................................... 130
Cooling System Coolant (ELC) - Change ............................................ 135

Every 114 000 L (30 000 US gal) of Fuel

Overhaul Considerations ..................................................................... 189
114 SEBU7011-15
Maintenance Section
Maintenance Interval Schedule

i02317952

Maintenance Interval Schedule

(Engines with a Shallow Oil Sump)
SMCS Code: 1000; 7500

Ensure that the Safety Information, Warnings, and Instructions are

read and understood before operation or maintenance procedures
are performed.

Note: Use fuel consumption, distance (odometer), service hours,

or calendar time, whichever occurs first , in order to determine
the maintenance intervals. Engines that operate in severe operating
conditions may require more frequent maintenance.

Before each consecutive interval is performed, all of the maintenance

requirements from the previous interval must also be performed.

Note: Some maintenance items are for optional equipment.

When Required
Air Dryer - Check ................................................................................. 122
Battery - Replace ................................................................................. 123
Battery or Battery Cable - Disconnect ................................................. 126
Engine Oil Level Gauge - Calibrate ..................................................... 154
Engine Storage Procedure - Check ..................................................... 165
Exhaust Particulate Filter - Clean ........................................................ 167
Exhaust Particulate Filter - Test ........................................................... 171
Fuel System - Prime ............................................................................ 178
Severe Service Application - Check .................................................... 191

Daily
Cooling System Coolant Level - Check ............................................... 139
Engine Air Cleaner Service Indicator - Inspect .................................... 147
Engine Oil Level - Check ..................................................................... 151
Fuel System Water Separator - Drain .................................................. 183
Walk-Around Inspection ....................................................................... 195

Initial 17 700 km (11 000 miles) or 4150 L (1100 US gal) of Fuel

or 250 Service Hours or 6 Months
Engine Valve Lash - Inspect/Adjust ..................................................... 166
SEBU7011-15 115
Maintenance Section
Maintenance Interval Schedule

PM Level 1 - Every 17 700 km (11 000 miles) or 4150 L

(1100 US gal) of Fuel or 250 Service Hours or 6 Months
Aftercooler Core - Inspect .................................................................... 118
Air Compressor Filter - Clean/Replace ................................................ 121
Battery Electrolyte Level - Check ......................................................... 124
Belt - Inspect ........................................................................................ 126
Cooling System Supplemental Coolant Additive (SCA) - Test/Add ..... 140
Cylinder Head Grounding Stud - Inspect/Clean/Tighten ...................... 145
Engine Crankcase Breather - Clean .................................................... 149
Engine Oil Sample - Obtain ................................................................. 156
Engine Oil and Filter - Change ............................................................ 158
Fan Drive Bearing - Lubricate .............................................................. 176
Fuel Inlet Screen - Clean/Inspect/Replace .......................................... 177
Fuel System Primary Filter - Clean/Replace ........................................ 181
Fuel System Secondary Filter - Replace ............................................. 181
Fuel Tank Water and Sediment - Drain ................................................ 185
Hoses and Clamps - Inspect/Replace ................................................. 186
Radiator - Clean ................................................................................... 190

PM Level 2 - Every 161 000 km (100 000 miles) or 56 850 L

(15 000 US gal) of Fuel or 2000 Service Hours or 2 Years
Aftercooler Core - Clean/Test .............................................................. 117
Air Compressor - Inspect ..................................................................... 120
Alternator - Inspect .............................................................................. 122
Belt Tensioner - Inspect ....................................................................... 130
Cooling System Water Temperature Regulator - Replace ................... 143
Crankshaft Vibration Damper - Inspect ................................................ 144
Engine - Clean ..................................................................................... 146
Engine Air Cleaner Element - Clean/Replace ...................................... 147
Engine Mounts - Inspect ...................................................................... 151
Engine Valve Lash - Inspect/Adjust ..................................................... 166
Starting Motor - Inspect ....................................................................... 192
Turbocharger - Inspect ......................................................................... 192
Water Pump - Inspect .......................................................................... 197

Every 3 Years or 322 000 km (200 000 miles)

Cooling System Coolant (DEAC) - Change ......................................... 130

Every 483 000 km (300 000 miles)

Cooling System Coolant Extender (ELC) - Add ................................... 138
116 SEBU7011-15
Maintenance Section
Maintenance Interval Schedule

Every 6 Years or 966 000 km (600 000 miles)

Cooling System Coolant (DEAC) - Change ......................................... 130
Cooling System Coolant (ELC) - Change ............................................ 135

Every 114 000 L (30 000 US gal) of Fuel

Overhaul Considerations ..................................................................... 189
SEBU7011-15 117
Maintenance Section
Aftercooler Core - Clean/Test

i01546702

Aftercooler Core - Clean/Test

SMCS Code: 1064-070; 1064-081

1. Remove the core. Refer to the Service Manual for the procedure.

2. Turn the aftercooler core upside-down in order to remove debris.

NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
cleaner.

3. Back flush the core with cleaner.

Caterpillar recommends the use of Hydrosolv liquid cleaner. Table 15

lists Hydrosolv liquid cleaners that are available from your Caterpillar
dealer.

Table 15

Hydrosolv Liquid Cleaners(1)

Part
Description Size
Number
1U-5490 Hydrosolv 4165 19 L (5 US gallon)
174-6854 Hydrosolv 100 19 L (5 US gallon)
(1) Use a two to five percent concentration of the cleaner at
temperatures up to 93°C (200°F). Refer to Application Guide,
NEHS0526 or consult your Caterpillar dealer for more
information.

4. Steam clean the core in order to remove any residue. Flush the fins of
the aftercooler core. Remove any other trapped debris.

5. Wash the core with hot, soapy water. Rinse the core thoroughly with
clean water.
118 SEBU7011-15
Maintenance Section
Aftercooler Core - Inspect

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

6. Dry the core with compressed air. Direct the air in the reverse direction
of the normal flow.

7. Inspect the core in order to ensure cleanliness. Pressure test the core.
Many shops that service radiators are equipped to perform pressure
tests. If necessary, repair the core.

8. Install the core. Refer to the Service Manual for the procedure.

For more information on cleaning the core, consult your Caterpillar dealer.

i01468985

Aftercooler Core - Inspect

SMCS Code: 1064-040

Note: Adjust the frequency of cleaning according to the effects of the

operating environment.

Inspect the aftercooler for these items: damaged fins, corrosion, dirt,
grease, insects, leaves, oil, and other debris. Clean the aftercooler, if
necessary.

For air-to-air aftercoolers, use the same methods that are used for
cleaning radiators.
SEBU7011-15 119
Maintenance Section
Aftercooler Core - Inspect

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removing loose debris. Direct
the air in the opposite direction of the fan’s air flow. Hold the nozzle
approximately 6 mm (.25 inch) away from the fins. Slowly move the air
nozzle in a direction that is parallel with the tubes. This will remove debris
that is between the tubes.

Pressurized water may also be used for cleaning. The maximum water
pressure for cleaning purposes must be less than 275 kPa (40 psi). Use
pressurized water in order to soften mud. Clean the core from both sides.

Use a degreaser and steam for removal of oil and grease. Clean both
sides of the core. Wash the core with detergent and hot water. Thoroughly
rinse the core with clean water.

After cleaning, start the engine and accelerate the engine to high idle
rpm. This will help in the removal of debris and drying of the core. Stop
the engine. Use a light bulb behind the core in order to inspect the core
for cleanliness. Repeat the cleaning, if necessary.

Inspect the fins for damage. Bent fins may be opened with a “comb”.

Note: If parts of the aftercooler system are repaired or replaced, a leak

test is highly recommended. The FT1984 Aftercooler Testing Group
is used to perform leak tests on the aftercooler. Refer to the Systems
Operation/Testing and Adjusting, “Aftercooler - Test” and the Special
Instruction, SEHS8622 for the proper testing procedure.

Inspect these items for good condition: welds, mounting brackets, air
lines, connections, clamps, and seals. Make repairs, if necessary.

For more detailed information on cleaning and inspection, see Special

Publication, SEBD0518, “Know Your Cooling System”.
120 SEBU7011-15
Maintenance Section
Air Compressor - Inspect

i02113479

Air Compressor - Inspect

SMCS Code: 1803-040

Do not disconnect the air line from the air com-

pressor governor without purging the air brake
and the auxiliary air systems. Failure to purge
the air brake and the auxiliary air systems before
removing the air compressor and/or the air lines
could cause personal injury.

g01076630
Illustration 17
(1) Pressure relief valve
SEBU7011-15 121
Maintenance Section
Air Compressor Filter - Clean/Replace

If the air compressor pressure relief valve that is

mounted in the air compressor cylinder head is
bypassing compressed air, there is a malfunction
in the air system, possibly ice blockage. Under
these conditions, your engine may have insuffi-
cient air for normal brake operation.

Do not operate the engine until the reason for the

air bypass is identified and corrected. Failure to
heed this warning could lead to property dam-
age, personal injury, or death to the operator or
bystanders.

The function of the pressure relief valve is to bypass air when there is a
malfunction in the air compressor system.

The pressure relief valve releases air at 1723 kPa (250 psi). Do not stand
near the pressure relief valve. Compressed air may be released without
warning. All personnel should also stay clear of the air compressor when
the engine is operating and the air compressor is exposed.

Refer to the Service Manual or refer to the OEM specifications in order to

find information concerning the air compressor. Consult your Caterpillar
dealer for assistance.

i01491325

Air Compressor Filter - Clean/Replace

SMCS Code: 1803-070-FQ; 1803-510-FQ

One of the single most important aspects of preventive maintenance for

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

Refer to the Service Manual for the type of air compressor that is installed
on the engine. Follow the maintenance recommendations that are
provided by the OEM of the air compressor. Some engines use boost air
pressure so the engine air cleaner will require servicing.
122 SEBU7011-15
Maintenance Section
Air Dryer - Check

i00863920

Air Dryer - Check

SMCS Code: 4285-535

Follow the maintenance recommendations that are provided by the OEM

or consult your Caterpillar dealer for assistance.

i00072207

Alternator - Inspect
SMCS Code: 1405-040

Caterpillar recommends a scheduled inspection of the alternator. Inspect

the alternator for loose connections and proper battery charging. Inspect
the ammeter (if equipped) during engine operation in order to ensure
proper battery performance and/or proper performance of the electrical
system. Make repairs, as required. Refer to the Service Manual.

Check the alternator and the battery charger for proper operation. If the
batteries are properly charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The batteries should be kept
warm because temperature affects the cranking power. If the battery is
too cold, the battery will not crank the engine. The battery will not crank
the engine, even if the engine is warm. When the engine is not run for
long periods of time or if the engine is run for short periods, the batteries
may not fully charge. A battery with a low charge will freeze more easily
than a battery with a full charge.
SEBU7011-15 123
Maintenance Section
Battery - Replace

i02153996

Battery - Replace
SMCS Code: 1401-510

Batteries give off combustible gases which can

explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.

Ensure proper ventilation for batteries that are in

an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.

The battery cables or the batteries should not be

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

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion
resulting in personal injury.

1. Turn the key start switch to the OFF position. Remove the key and
all electrical loads.

2. Turn OFF the battery charger. Disconnect the charger.

3. The NEGATIVE “-” cable connects the NEGATIVE “-” battery terminal
to the ground plane. Disconnect the cable from the NEGATIVE “-”
battery terminal.

4. The POSITIVE “+” cable connects the POSITIVE “+” battery terminal
to the starting motor. Disconnect the cable from the POSITIVE “+”
battery terminal.
124 SEBU7011-15
Maintenance Section
Battery Electrolyte Level - Check

Note: Always recycle a battery. Never discard a battery. Return used

batteries to an appropriate recycling facility.

5. Remove the used battery.

6. Install the new battery.

Note: Before the cables are connected, ensure that the key start switch
is OFF.

7. Connect the cable from the starting motor to the POSITIVE “+” battery
terminal.

8. Connect the cable from the ground plane to the NEGATIVE “-” battery
terminal.

i02213936

Battery Electrolyte Level - Check

SMCS Code: 1401-535

When the engine is not run for long periods of time or when the engine is
run for short periods, the batteries may not fully recharge. Ensure a full
charge in order to help prevent the battery from freezing. If batteries are
properly charged, ammeter reading should be very near zero.

All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.

1. Remove the filler caps. Maintain the electrolyte level to the “FULL”
mark on the battery.

If the addition of water is necessary, use distilled water. If distilled

water is not available use clean water that is low in minerals. Do not
use artificially softened water.

2. Check the condition of the electrolyte with the 245-5829 Coolant

Battery Tester Refractometer.
SEBU7011-15 125
Maintenance Section
Battery Electrolyte Level - Check

3. Keep the batteries clean.

Clean the battery case with one of the following cleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and 1 L (1 qt) of clean

water

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

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean the terminals and the cable
clamps. Clean the items until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal of material can cause
the clamps to not fit properly. Coat the clamps and the terminals with
5N-5561 Silicone Lubricant, petroleum jelly or MPGM.
126 SEBU7011-15
Maintenance Section
Battery or Battery Cable - Disconnect

i01492654

Battery or Battery Cable - Disconnect

SMCS Code: 1402-029

The battery cables or the batteries should not be

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

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion
resulting in personal injury.

1. Turn the start switch to the OFF position. Turn the ignition switch (if
equipped) to the OFF position and remove the key and all electrical
loads.

2. Disconnect the negative battery terminal at the battery that goes to the
start switch. Ensure that the cable cannot contact the terminal. When
four 12 volt batteries are involved, the negative side of two batteries
must be disconnected.

3. Tape the leads in order to help prevent accidental starting.

4. Proceed with necessary system repairs. Reverse the steps in order to

reconnect all of the cables.

i02149963

Belt - Inspect
SMCS Code: 1357-040; 1357; 1397-040; 1397

Inspection
Belt tension should be checked initially between the first 20 to 40
hours of engine operation.
SEBU7011-15 127
Maintenance Section
Belt - Inspect

Check the belt tension. Refer to the Operation and Maintenance Manual,
“Maintenance Interval Schedule” topic (Maintenance Section) for the
proper intervals.

To check the belt tension, apply 110 N (25 lb ft) of force midway between
the pulleys. A correctly adjusted belt will deflect 9 mm (0.35 inch) to
15 mm (0.59 inch).

To maximize the engine performance, inspect the belts for wear and for
cracking. Replace belts that are worn or damaged.

For applications that require multiple drive belts, replace the belts in
matched sets. Replacing only one belt of a matched set will cause the
new belt to carry more load because the older belt is stretched. The
additional load on the new belt could cause the new belt to break.

If the belts are too loose, vibration causes unnecessary wear on the belts
and pulleys. Loose belts may slip enough to cause overheating.

If the belts are too tight, unnecessary stresses are placed on the pulley
bearings and on the belts. This may shorten the service life of the
components.

Remove the belt guard. Inspect the condition and adjustment of the
alternator belts and accessory drive belts (if equipped).

If the belt does not require replacement or adjustment, install the belt
guard. If the belt requires adjustment or replacement, perform the
following procedure to adjust the belt tension.

• If the engine is equipped with a refrigerant compressor (air conditioner),

the belt for the fan drive, the alternator, and the accessories will have
an automatic belt tensioner.

• If the engine is not equipped with a refrigerant compressor, the

alternator is used to adjust the belt tension.
128 SEBU7011-15
Maintenance Section
Belt - Inspect

Adjustment
Alternator Belt

g01075759
Illustration 18
(1) Adjusting bolt
(2) Mounting bolts

1. Slightly loosen mounting bolts (2) and adjusting bolt (1).

2. Move the pulley in order to adjust the belt tension.

3. Tighten adjusting bolt (1) and mounting bolts (2). For the proper torque,
refer to the Specifications Manual, SENR3130, “Torque Specifications”.

4. Install the belt guard.

If new belts are installed, check the belt tension again after 30 minutes of
engine operation at the rated rpm.
SEBU7011-15 129
Maintenance Section
Belt - Inspect

Water Pump Belt

g01075753
Illustration 19
Exploded view of the drive assembly for a water pump belt
(1) Mounting bolt
(2) Square hole
(3) Adjusting bolt

1. Slightly loosen mounting bolts (1) and adjusting bolt (3).

2. Adjust the belt tension with a square drive in square hole (2).

3. Tighten adjusting bolt (3) and mounting bolt (1). For the proper torque,
refer to the Specifications Manual, SENR3130, “Torque Specifications”.

4. Install the belt guard.

If new belts are installed, check the belt tension after 30 minutes of engine
operation at the rated rpm.
130 SEBU7011-15
Maintenance Section
Belt Tensioner - Inspect

i01555583

Belt Tensioner - Inspect

(If Equipped)
SMCS Code: 1358-040

g00426964
Illustration 20
Belt tensioner

Inspect the belt tensioner for unusual noise, excessive looseness and/or
shaking of the bearings.

If the belt tensioner should require disassembly, refer to the Service

Manual for the procedure.

i02139869

Cooling System Coolant (DEAC) - Change

SMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the cooling system before the
recommended maintenance interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.
• The oil has entered the cooling system and the coolant is contaminated.
SEBU7011-15 131
Maintenance Section
Cooling System Coolant (DEAC) - Change

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

NOTICE
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are
approved for Caterpillar engines.

Note: Inspect the water pump and the water temperature regulator after
the cooling system has been drained. This is a good opportunity to
replace the water pump, the water temperature regulator and the hoses, if
necessary.

Drain

Pressurized System: Hot coolant can cause seri-

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

1. Stop the engine and allow the engine to cool. Loosen the cooling
system filler cap slowly in order to relieve any pressure. Remove the
cooling system filler cap.

2. Open the cooling system drain valve (if equipped). If the cooling system
is not equipped with a drain valve, remove one of the drain plugs.

Note: If equipped, be sure to drain the heater and any related supply
and return lines.

Allow the coolant to drain.

NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
132 SEBU7011-15
Maintenance Section
Cooling System Coolant (DEAC) - Change

For information regarding the disposal and the recycling of used coolant,
consult your Caterpillar dealer or consult Caterpillar Dealer Service Tool
Group:

Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

Flush
1. Flush the cooling system with clean water in order to remove any
debris.

2. Close the drain valve (if equipped). Clean the drain plugs. Install the
drain plugs. Refer to the Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper torques.

NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

3. Fill the cooling system with a mixture of clean water and Caterpillar
Fast Acting Cooling System Cleaner. Add 0.5 L (1 pint) of cleaner
per 15 L (4 US gal) of the cooling system capacity. Install the cooling
system filler cap.

4. Start and run the engine at low idle for a minimum of 30 minutes. The
coolant temperature should be at least 82 °C (180 °F).

NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.

To avoid damage to the cooling system, make sure

to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
SEBU7011-15 133
Maintenance Section
Cooling System Coolant (DEAC) - Change

5. Stop the engine and allow the engine to cool. Loosen the cooling
system filler cap slowly in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if equipped) or remove
the cooling system drain plugs. Allow the water to drain. Flush the
cooling system with clean water. If equipped, be sure to flush the
heater and any related supply and return lines. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, “Torque Specifications” for more
information on the proper torques.

Cooling Systems with Heavy Deposits or

Plugging
Note: For the following procedure to be effective, there must be some
active flow through the cooling system components.

1. Flush the cooling system with clean water in order to remove any
debris.

Note: If equipped, be sure to flush the heater and any related supply
and return lines.

2. Close the drain valve (if equipped). Clean the drain plugs. Install the
drain plugs. Refer to the Specifications Manual, SENR3130, “Torque
Specifications” for more information on the proper torques.

NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

3. Fill the cooling system with a mixture of clean water and Caterpillar
Fast Acting Cooling System Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system capacity. Install the
cooling system filler cap.

4. Start and run the engine at low idle for a minimum of 90 minutes. The
coolant temperature should be at least 82 °C (180 °F).
134 SEBU7011-15
Maintenance Section
Cooling System Coolant (DEAC) - Change

NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.

To avoid damage to the cooling system, make sure

to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.

5. Stop the engine and allow the engine to cool. Loosen the cooling
system filler cap slowly in order to relieve any pressure. Remove
the cooling system filler cap. Open the drain valve (if equipped) or
remove the cooling system drain plugs. Allow the water to drain.
Flush the cooling system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain plugs. Refer to the
Specifications Manual, SENR3130, “Torque Specifications” for more
information on the proper torques.

Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

1. Fill the cooling system with coolant/antifreeze. Refer to the Operation

and Maintenance Manual, “Refill Capacitites and Recommendations”
topic (Maintenance Section) for more information on cooling system
specifications. Do not install the cooling system filler cap.

2. Start and run the engine at low idle. Increase the engine rpm to 1500
rpm. Run the engine at high idle for one minute in order to purge the
air from the cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant level within 13 mm

(0.5 inch) below the bottom of the pipe for filling. Maintain the coolant
level within 13 mm (0.5 inch) to the proper level on the sight glass (if
equipped).
SEBU7011-15 135
Maintenance Section
Cooling System Coolant (ELC) - Change

4. Clean the cooling system filler cap. Inspect the gasket that is on the
cooling system filler cap. If the gasket that is on the cooling system filler
cap is damaged, discard the old cooling system filler cap and install
a new cooling system filler cap. If the gasket that is on the cooling
system filler cap is not damaged, perform a pressure test. A 9S-8140
Pressurizing Pump is used to perform the pressure test. The correct
pressure for the cooling system filler cap is stamped on the face of the
cooling system filler cap. If the cooling system filler cap does not retain
the correct pressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system for leaks and for proper
operating temperature.

i02173402

Cooling System Coolant (ELC) - Change

SMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the cooling system before the
recommended maintenance interval if the following conditions exist:

• The engine overheats frequently.

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

Note: When the cooling system is cleaned, only clean water is needed
when the ELC is drained and replaced.

Note: Inspect the water pump and the water temperature regulator after
the cooling system has been drained. This is a good opportunity to
replace the water pump, the water temperature regulator and the hoses, if
necessary.
136 SEBU7011-15
Maintenance Section
Cooling System Coolant (ELC) - Change

Drain

Pressurized System: Hot coolant can cause seri-

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

1. Stop the engine and allow the engine to cool. Loosen the cooling
system filler cap slowly in order to relieve any pressure. Remove the
cooling system filler cap.

2. Open the cooling system drain valve (if equipped). If the cooling
system is not equipped with a drain valve, remove the cooling system
drain plugs.

Allow the coolant to drain.

NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.

For information regarding the disposal and the recycling of used coolant,
consult your Caterpillar dealer or consult Caterpillar Dealer Service Tool
Group:

Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

Flush
1. Flush the cooling system with clean water in order to remove any
debris.

Note: If equipped, be sure to flush the heater and any related supply
and return lines.
SEBU7011-15 137
Maintenance Section
Cooling System Coolant (ELC) - Change

2. Close the drain valve (if equipped). Clean the drain plugs. Install the
drain plugs. For the proper torque, refer to the Specifications Manual,
SENR3130, “Torque Specifications”.

NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

3. Fill the cooling system with clean water. Install the cooling system
filler cap.

4. Start and run the engine at low idle until the temperature reaches
49 to 66 °C (120 to 150 °F).

5. Stop the engine and allow the engine to cool. Loosen the cooling
system filler cap slowly in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if equipped) or remove
the cooling system drain plugs. Allow the water to drain. Flush the
cooling system with clean water. Close the drain valve (if equipped).
Clean the drain plugs. Install the drain plugs. For the proper torque,
refer to the Specifications Manual, SENR3130, “Torque Specifications”.

Fill
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.

1. Fill the cooling system with Extended Life Coolant (ELC). See Special
Publication, SEBU6385, “Caterpillar On-highway Diesel Truck Engine
Fluids Recommendations” for more information on cooling system
specifications. Do not install the cooling system filler cap.

2. Start and run the engine at low idle. Increase the engine rpm to high
idle. Run the engine at high idle for one minute in order to purge the air
from the cavities of the engine block. Stop the engine.

3. Check the coolant level. Maintain the coolant level within 13 mm

(0.5 inch) below the bottom of the pipe for filling. Maintain the coolant
level within 13 mm (0.5 inch) to the proper level on the sight glass (if
equipped).
138 SEBU7011-15
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

4. Clean the cooling system filler cap. Inspect the gasket that is on the
cooling system filler cap. If the gasket that is on the cooling system filler
cap is damaged, discard the old cooling system filler cap and install
a new cooling system filler cap. If the gasket that is on the cooling
system filler cap is not damaged, use a 9S-8140 Pressurizing Pump
in order to pressure test the cooling system filler cap. The correct
pressure for the cooling system filler cap is stamped on the face of the
cooling system filler cap. If the cooling system filler cap does not retain
the correct pressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system for leaks and for proper
operating temperature.

i02285855

Cooling System Coolant Extender (ELC) -

Add
SMCS Code: 1352-045; 1395-081

Cat ELC (Extended Life Coolant) does not require the frequent
Supplemental Coolant Additive (SCA) additions which are associated
with the present conventional coolants. The Extender only needs to be
added once.

Check the cooling system only when the engine is stopped and cool.

1. Loosen the cooling system filler cap slowly in order to relieve pressure.
Remove the cooling system filler cap.

2. It may be necessary to drain enough coolant from the cooling system

in order to add the Extender.

3. Add Extender according to the requirements for your engine’s cooling

system capacity. Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” in the Maintenance Section
for more information concerning the Cat ELC Extender additions.

4. Clean the cooling system filler cap. Inspect the gaskets on the cooling
system filler cap. Replace the cooling system filler cap if the gaskets
are damaged. Install the cooling system filler cap.
SEBU7011-15 139
Maintenance Section
Cooling System Coolant Level - Check

i01197583

Cooling System Coolant Level - Check

SMCS Code: 1395-082

Check the coolant level when the engine is stopped and cool.

g00285520
Illustration 21
Cooling system filler cap

Pressurized System: Hot coolant can cause seri-

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

1. Remove the cooling system filler cap slowly in order to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch) of the bottom of the
filler pipe. If the engine is equipped with a sight glass, maintain the
coolant level to the proper level in the sight glass.
140 SEBU7011-15
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

g00103639
Illustration 22
Typical filler cap gaskets

3. Clean the cooling system filler cap and check the condition of the filler
cap gaskets. Replace the cooling system filler cap if the filler cap
gaskets are damaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i02112523

Cooling System Supplemental Coolant

Additive (SCA) - Test/Add
SMCS Code: 1352-045; 1395-081

NOTICE
Cooling system coolant additive contains alkali. To
help prevent personal injury, avoid contact with the
skin and the eyes. Do not drink cooling system coolant
additive.

Note: Test the Supplemental Coolant Additive (SCA) or test the SCA
concentration as part of an S·O·S Coolant Analysis.
SEBU7011-15 141
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Test the SCA Concentration

Coolant/Antifreeze and SCA

NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.

Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact with
the skin and the eyes. Do not drink cooling system
coolant additive.

Use the 8T-5296 Coolant Conditioner Test Kit or use the 4C-9301
Coolant Conditioner Test Kit in order to check the concentration of the
SCA. See Special Publication, SEBU6385, “Caterpillar On-highway Diesel
Truck Engine Fluids Recommendations” for more information.

S·O·S Coolant Analysis

S·O·S coolant samples can be analyzed at your Caterpillar dealer. S·O·S
Coolant Analysis is a program that is based on periodic samples.

Level I
Level I is a basic analysis of the coolant. The following items are tested:

• Glycol Concentration
• Concentration of SCA
• pH
• Conductivity
The results are reported, and recommendations are made according to
the results. Consult your Caterpillar dealer for information on the benefits
of managing your equipment with an S·O·S Coolant Analysis.
142 SEBU7011-15
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Add the SCA, If Necessary

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

Pressurized System: Hot coolant can cause seri-

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

1. Slowly loosen the cooling system filler cap in order to relieve the
pressure. Remove the cooling system filler cap.

Note: Always discard drained fluids according to local regulations.

2. If necessary, drain some coolant from the cooling system into a

suitable container in order to allow space for the extra SCA.

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

Maintenance Manual for more information on SCA requirements.

4. Clean the cooling system filler cap. Inspect the gaskets of the cooling
system filler cap. If the gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler cap. Install the cooling
system filler cap.
SEBU7011-15 143
Maintenance Section
Cooling System Water Temperature Regulator - Replace

i00912898

Cooling System Water Temperature

Regulator - Replace
SMCS Code: 1355-510

Replace the water temperature regulator before the water temperature

regulator fails. This is a recommended preventive maintenance practice.
Replacing the water temperature regulator reduces the chances for
unscheduled downtime.

A water temperature regulator that fails in a partially opened position can

cause overheating or overcooling of the engine.

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

A water temperature regulator that fails in the open position will cause the
engine operating temperature to be too low during partial load operation.
Low engine operating temperatures during partial loads could cause an
excessive carbon buildup inside the cylinders. This excessive carbon
buildup could result in an accelerated wear of the piston rings and wear
of the cylinder liner.

NOTICE
Failure to replace your water temperature regulator on
a regularly scheduled basis could cause severe en-
gine damage.

Caterpillar engines incorporate a shunt design cooling

system and require operating the engine with a water
temperature regulator installed.

If the water temperature regulator is installed incor-

rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket or

cylinder head surface.
144 SEBU7011-15
Maintenance Section
Crankshaft Vibration Damper - Inspect

Refer to the Service Manual for the replacement procedure of the water
temperature regulator, or consult your Caterpillar dealer.

Note: If only the water temperature regulators are replaced, drain the
coolant from the cooling system to a level that is below the water
temperature regulator housing.

i00072369

Crankshaft Vibration Damper - Inspect

SMCS Code: 1205-040

Damage to the crankshaft vibration damper or failure of the crankshaft

vibration damper can increase torsional vibrations. This can result
in damage to the crankshaft and to other engine components. A
deteriorating damper can cause excessive gear train noise at variable
points in the speed range.

The damper is mounted to the crankshaft which is located behind the belt
guard on the front of the engine.

Removal and Installation

Refer to the Service Manual for the damper removal procedure and for
the damper installation procedure.

Visconic Damper
The visconic damper has a weight that is located inside a fluid filled case.
The weight moves in the case in order to limit torsional vibration. Inspect
the damper for evidence of dents, cracks or leaks of the fluid.

Replace the damper if the damper is dented, cracked or leaking. Refer

to the Service Manual or consult your Caterpillar dealer for damper
replacement.
SEBU7011-15 145
Maintenance Section
Cylinder Head Grounding Stud - Inspect/Clean/Tighten

i00856194

Cylinder Head Grounding Stud -

Inspect/Clean/Tighten
SMCS Code: 7423-040; 7423-070; 7423-079

g00427181
Illustration 23
Cylinder head grounding stud

Inspect the OEM harness for good connections and condition.

The cylinder head grounding stud must have a wire ground to the battery.
Tighten the cylinder head grounding stud at every oil change. Ground
wires and straps should be combined at engine grounds. All grounds
should be tight and free of corrosion.

• Clean the cylinder head grounding stud and the terminals for the
cylinder head ground strap with a clean cloth.

• If the connections are corroded, clean the connections with a solution

of baking soda and water.

• Keep the cylinder head grounding stud and the strap clean and coated
with MPGM grease or petroleum jelly.
146 SEBU7011-15
Maintenance Section
Engine - Clean

i01646701

Engine - Clean
SMCS Code: 1000-070

Personal injury or death can result from high volt-

age.

Moisture can create paths of electrical conductiv-

ity.

Make sure that the electrical system is OFF. Lock

out the starting controls and tag the controls “DO
NOT OPERATE”.

NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.

Periodic cleaning of the engine is recommended. Steam cleaning the

engine will remove accumulated oil and grease. A clean engine provides
the following benefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics
• Ease of maintenance
Note: Caution must be used in order to prevent electrical components
from being damaged by excessive water when you clean the engine.
Avoid electrical components such as the alternator, the starter, and the
ECM.
SEBU7011-15 147
Maintenance Section
Engine Air Cleaner Element - Clean/Replace

i00857000

Engine Air Cleaner Element -

Clean/Replace
SMCS Code: 1054-070; 1054-510

NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

If the air cleaner element becomes plugged, the air can split the material
of the air cleaner element. Unfiltered air will drastically accelerate internal
engine wear.

• Operating conditions (dust, dirt and debris) may require more frequent
service of the air cleaner element.

• The air cleaner element should be replaced at least one time per year.
This replacement should be performed regardless of the number of
cleanings.

Replace the dirty paper air cleaner elements with clean air cleaner
elements. Before installation, the air cleaner elements should be
thoroughly checked for tears and/or holes in the filter material. Inspect
the gasket or the seal of the air cleaner element for damage. Maintain a
supply of suitable air cleaner elements for replacement purposes.

Your Caterpillar dealer has the proper air cleaner elements for your
application. Consult your Caterpillar dealer for the correct air cleaner
element or follow the instructions that are provided by the OEM.

i01900118

Engine Air Cleaner Service Indicator -

Inspect
(If Equipped)
SMCS Code: 7452-040

Some engines may be equipped with a different service indicator.

148 SEBU7011-15
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

Some engines are equipped with a differential gauge for inlet air pressure.
The differential gauge for inlet air pressure displays the difference in
the pressure that is measured before the air cleaner element and the
pressure that is measured after the air cleaner element. As the air cleaner
element becomes dirty, the pressure differential rises. If your engine
is equipped with a different type of service indicator, follow the OEM
recommendations in order to service the air cleaner service indicator.

The service indicator may be mounted on the air cleaner housing or in a

remote location.

g00103777
Illustration 24
Typical service indicator

Observe the service indicator. The air cleaner element should be cleaned
or the air cleaner element should be replaced when one of the following
conditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service Indicator

Service indicators are important instruments.

• Check for ease of resetting. The service indicator should reset in less
than three pushes.
SEBU7011-15 149
Maintenance Section
Engine Crankcase Breather - Clean

• Check the movement of the yellow core when the engine is accelerated
to the engine rated speed. The yellow core should latch approximately
at the greatest vacuum that is attained.

If the service indicator does not reset easily, or if the yellow core does not
latch at the greatest vacuum, the service indicator should be replaced. If
the new service indicator will not reset, the hole for the service indicator
may be plugged.

The service indicator may need to be replaced frequently in environments

that are severely dusty, if necessary. Replace the service indicator
annually regardless of the operating conditions. Replace the service
indicator when the engine is overhauled, and whenever major engine
components are replaced.

Note: When a new service indicator is installed, excessive force may

crack the top of the service indicator. Tighten the service indicator to a
torque of 2 N·m (18 lb in).

i02150070

Engine Crankcase Breather - Clean

SMCS Code: 1317-070

NOTICE
Perform this maintenance with the engine stopped.

NOTICE
If the crankcase breather is not maintained on a regu-
lar basis, it can become plugged. A plugged breather
will cause excessive crankcase pressure that may
cause crankshaft seal leakage.
150 SEBU7011-15
Maintenance Section
Engine Crankcase Breather - Clean

g00428148
Illustration 25
(1) Bolt
(2) Hose clamp
(3) Breather assembly
(4) Hose

1. Loosen hose clamp (2) and remove the hose from breather assembly
(3).

2. Loosen the retaining clamp. Remove the breather assembly (3) and
the seal.

3. Wash the breather element in solvent that is clean and nonflammable.

Allow the breather element to dry before installation.

4. Install a breather element that is clean and dry. Install breather

assembly and seal (3) and install the retaining clamp. Refer to the
Operation and Maintenance Manual for the proper torques.

5. Install the hose. Install hose clamp (2). For proper torque, refer to the
Specifications Manual, SENR3130, “Torque Specifications”.
SEBU7011-15 151
Maintenance Section
Engine Mounts - Inspect

i02139969

Engine Mounts - Inspect

SMCS Code: 1152-040

Inspect the engine mounts for deterioration and for proper bolt torque.
Engine vibration can be caused by the following conditions:

• Improper mounting of the engine

• Deterioration of the engine mounts
Any engine mount that shows deterioration should be replaced. Refer to
the Specifications Manual, SENR3130, “Torque Specifications”. Refer to
your Caterpillar dealer for more information.

i02113104

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
152 SEBU7011-15
Maintenance Section
Engine Oil Level - Check

g01076429
Illustration 26
(1) Oil filler cap
(2) Oil level gauge

g00110310
Illustration 27
(Y) “ADD” mark
(X) “FULL” mark

NOTICE
Perform this maintenance with the engine stopped.

Note: Before you perform this maintenance, do not operate the engine for
at least 10 minutes in order to allow the engine oil to return to the oil pan.

1. Maintain the oil level between “ADD” mark (Y) and “FULL” mark (X) on
oil level gauge (1). Do not fill the crankcase above “FULL” mark (X).
SEBU7011-15 153
Maintenance Section
Engine Oil Level - Check

NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip-
stick).

An overfull crankcase can enable the crankshaft to

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

Excessive oil consumption will enable deposits to form

on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately.

2. Remove oil filler cap (2) and add oil, if necessary. For the correct oil to
use, refer to Special Publication, SEBU6251, “Caterpillar Commercial
Diesel Engine Fluids Recommendations”. Do not fill the crankcase
above “FULL” mark (X) on the oil level gauge. Clean the oil filler cap.
Install the oil filler cap.

3. Record the amount of oil that is added. For the next oil sample and
analysis, include the total amount of oil that has been added since
the previous sample. This will help to provide the most accurate oil
analysis.
154 SEBU7011-15
Maintenance Section
Engine Oil Level Gauge - Calibrate

i02005382

Engine Oil Level Gauge - Calibrate

SMCS Code: 1326-524

Check Calibration at the First Oil Change

The engine oil level will vary depending on the angle and the slant of
the engine installation. The angle is the front to back tilt. The slant is
the sideways tilt.

The oil level gauge markings must be verified in order to ensure that
the markings are correct. Verify the oil level gauge markings at the first
oil change.

Verify the “ADD” mark and verify the “FULL” mark that is on the oil level
gauge. Use the following procedure.

NOTICE
The vehicle must be parked on a level surface in order
to perform this maintenance procedure.

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

Stop the engine. Remove the crankcase oil drain plugs. The oil drain
plug from the deep portion of the oil pan should be removed. Drain the
oil from the crankcase for 20 minutes.

2. Remove the used oil filter(s). Install the new oil filter(s). Install the oil
drain plugs and tighten to 70 ± 15 N·m (50 ± 11 lb ft).

Note: Your engine may be equipped with auxiliary oil filters. The auxiliary
oil filters require a different volume of oil. Refer to the OEM specifications
for the auxiliary oil filter.
SEBU7011-15 155
Maintenance Section
Engine Oil Level Gauge - Calibrate

Table 16
Refill Capacities for 3126 On-highway Engines
“ADD” “Full” Total
Sump Additional
Mark Mark Fill
Shallow
(178 mm 16 L 21 L
4 L (4 qt) 1 L (1 qt)
(7 inch) (17 qt) (22 qt)
deep)
Deep
(241 mm 23 L 28 L
4 L (4 qt) 1 L (1 qt)
(9.5 inch) (24 qt) (30 qt)
deep)

3. Determine the sump that is installed on the engine and locate the
sump capacity in table 16.

4. Pour the correct volume of oil into the crankcase. The correct volume
will be found under the “ADD” Mark in table 16. Allow enough time for
the oil to drain into the crankcase. Approximately 20 minutes should be
allowed. Check the oil level. Wait for several minutes and check the oil
level again. Proceed after the oil level stops changing.

5. Check the oil level on the oil level gauge. The oil level should be at the
“ADD” mark. If the oil level is not at the existing “ADD” mark, grind off
the “ADD” mark and engrave the new “ADD” level. Use an engraving
pen in order to engrave the new “ADD” mark.

6. Locate the sump capacity of the engine again in table 16. Pour the
correct volume of oil into the crankcase. The correct volume will be
found under the “Full” Mark in table 16. Allow enough time for the oil to
drain into the crankcase.

7. Check the oil level on the oil level gauge. The oil level should be at the
“FULL” mark. If the oil level is not at the existing “FULL” mark, grind
off the “FULL” mark. Use an engraving pen in order to engrave the
new “FULL” mark.

8. Locate the sump capacity of the engine again in table 16 and add the
“additional” amount in order to allow oil to fill the engine oil filter.
156 SEBU7011-15
Maintenance Section
Engine Oil Sample - Obtain

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

9. Start the engine and run the engine enough to ensure that the
lubrication system is filled. Inspect the engine for oil leaks.

10. Stop the engine and allow enough time for the oil to drain into the
crankcase.

11. Check the oil level on the oil level gauge. If the oil level is not at the
calibrated “FULL” mark, fill the crankcase to the calibrated “FULL”
mark. Record the amount of oil that was added. This additional oil and
the “Total Fill” volume of oil that was in the crankcase is the oil capacity
of the lubrication system. Record the oil capacity of the lubrication
system for future oil changes.

i01935337

Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1348-554-SM; 7542-554-OC, SM

In addition to a good preventive maintenance program, Caterpillar

recommends using S·O·S oil analysis at regularly scheduled intervals
in order to monitor the condition of the engine and the maintenance
requirements of the engine. S·O·S oil analysis provides infrared analysis,
which is required for determining nitration and oxidation levels.

Obtain the Sample and the Analysis

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.

Before you take the oil sample, complete the Label, PEEP5031 for
identification of the sample. In order to help obtain the most accurate
analysis, provide the following information:
SEBU7011-15 157
Maintenance Section
Engine Oil Sample - Obtain

• Engine model
• Service hours on the engine
• The number of hours that have accumulated since the last oil change
• The amount of oil that has been added since the last oil change
To ensure that the sample is representative of the oil in the crankcase,
obtain a warm, well mixed oil sample.

To avoid contamination of the oil samples, the tools and the supplies that
are used for obtaining oil samples must be clean.

Caterpillar recommends using the sampling valve in order to obtain oil

samples. The quality and the consistency of the samples are better when
the sampling valve is used. The location of the sampling valve allows
oil that is flowing under pressure to be obtained during normal engine
operation.

The 169-8373 Fluid Sampling Bottle is recommended for use with the
sampling valve. The fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are also provided.

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.

If the engine is not equipped with a sampling valve, use the 1U-5718
Vacuum Pump. The pump is designed to accept sampling bottles.
Disposable tubing must be attached to the pump for insertion into the
sump.

For instructions, see Special Publication, PEHP6001, “How To Take

A Good Oil Sample”. Consult your Caterpillar dealer for complete
information and assistance in establishing an S·O·S program for your
engine.
158 SEBU7011-15
Maintenance Section
Engine Oil and Filter - Change

i01947041

Engine Oil and Filter - Change

SMCS Code: 1318-510; 1348-044

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.

NOTICE
The vehicle must be parked on a level surface for this
maintenance procedure.

Do not drain the oil when the engine is cold. As the oil cools, suspended
waste particles settle on the bottom of the oil pan. The waste particles
are not removed with the draining cold oil. Drain the crankcase with the
engine stopped. Drain the crankcase while the oil is warm. This draining
method will allow the waste particles that are suspended in the oil to be
properly drained.

Failure to follow this recommended procedure will cause the waste

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

Drain the Engine Oil

After the engine has been run at the normal operating temperature, stop
the engine. Attach a “DO NOT OPERATE” or a similar warning tag to the
ignition key switch before the engine is serviced. Catch the oil in a suitable
container. Recycle the used oil, or dispose of the used oil properly.

1. Remove the oil drain plug in order to allow the oil to drain.

2. After the oil has drained, the oil drain plug should be cleaned and
installed.

Tighten the oil drain plug to the following torque: .............. 70 ± 15 N·m
(50 ± 11 lb ft)
SEBU7011-15 159
Maintenance Section
Engine Oil and Filter - Change

Replace the Oil Filter

NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.

1. Remove the oil filter with a 185-3630 Chain Wrench.

g00588944
Illustration 28
Element with debris

2. Cut the oil filter open with a 175-7546 Oil Filter Cutter. Break apart the
pleats and inspect the oil filter for metal debris. An excessive amount of
metal debris in the oil filter may indicate early wear or a pending failure.

Use a magnet to differentiate between the ferrous metals and the

nonferrous metals that are found in the oil filter element. Ferrous
metals may indicate wear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on the aluminum parts, brass

parts or bronze parts of the engine. Parts that may be affected
include the following items: main bearings, rod bearings, turbocharger
bearings, and cylinder heads.
160 SEBU7011-15
Maintenance Section
Engine Oil and Filter - Change

Due to normal wear and friction, it is not uncommon to find small

amounts of debris in the oil filter. Consult your Caterpillar dealer in
order to arrange for a further analysis if an excessive amount of debris
is found in the oil filter.

g00103713
Illustration 29
Typical filter mounting base and filter gasket

3. Clean the sealing surface of the filter mounting base. Ensure that all of
the old oil filter gasket is removed.

4. Apply clean engine oil to the new oil filter gasket.

NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to
engine components.

5. Install the oil filter. Tighten the oil filter until the oil filter gasket contacts
the base. Tighten the oil filter by hand according to the instructions that
are shown on the oil filter. Do not overtighten the oil filter.

Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations” topic (Maintenance
Section) for more information. Fill the crankcase with the proper
amount of oil.
SEBU7011-15 161
Maintenance Section
Engine Oil and Filter - Change

NOTICE
If equipped with an auxiliary oil filter or system, extra
oil must be added when filling the crankcase. Follow
the OEM or filter manufacturer’s recommendations. If
the extra oil is not added, the engine may starve for
oil.

NOTICE
To help prevent crankshaft or bearing damage, crank
engine to fill all filters before starting. Do not crank
engine for more than 30 seconds.

2. Start the engine and run the engine at “LOW IDLE” for two minutes.
Perform this procedure in order to ensure that the lubrication system
has oil and that the oil filters are filled. Inspect the oil filter for oil leaks.

3. Stop the engine and allow the oil to drain back to the sump for a
minimum of ten minutes.

4. Remove the oil level gauge in order to check the oil level. Maintain
the oil level between the “ADD” and “FULL” marks on the “ENGINE
STOPPED” side of the oil level gauge.

Oil Change Interval Adjustments

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

Due to the manufacturing tolerances, the engine application, and the

maintenance variations, all engines do not consume fuel and oil at the
same rate. The amount of fuel that is consumed is in direct relation to the
maximum oil change interval that is selected. It is essential to include
an S·O·S oil analysis before an adjustment of the oil change interval is
considered. For more information on extending oil change intervals,
contact your local Caterpillar dealer. S·O·S oil analysis should be used to
verify the oil change interval adjustments. Table 17 can be used in order
to determine the oil change interval adjustments.
162 SEBU7011-15
Maintenance Section
Engine Oil and Filter - Change

S·O·S oil analysis should be used to verify the oil change interval
adjustments. Table 17 can be used in order to determine your oil change
interval adjustments.

Table for the Oil Change Interval Adjustments

Note: Metric units are listed before English units.

Note: Use of table 17 assumes the use of a recommended oil type.

Table 17
Permissible Oil Change Interval
Oil Vehicle Applications
Capacity
of the Light Medium Heavy Severe
Engine Duty(1) Duty(2) Duty(3) Service(4)
in Liters KM (Miles) to Next Oil Change
(quarts)
18 (20) 19,320 16,000 12,890 9,670
(12,000) (10,000) (8,000) (6,000)
21 (22)(5) 21,260 17,710 14,170 10,960
(13,200) (11,000) (8,800) (6,800)(6)
23 (24) 23,190 19,320 15,460 12,230
(14,400) (12,000) (9,600) (7,600)
25 (26) 25,110 20,930 16,750 13,530
(15,600) (13,000) (10,400) (8,400)
27 (28) 27,040 22,540 18,040 14,810
(16,800) (14,000) (11,200) (9,200)
28 (30)(7) 28,980 24,000 19,320 16,100
(18,000) (15,000) (12,000) (10,000)(6)
30 (32) 30,900 25,760 20,510 17,380
(19,200) (16,000) (12,800) (10,800)
32 (34) 32,850 27,370 21,900 18,670
(20,400) (17,000) (13,600) (11,600)
34 (36) 34,770 28,980 23,190 19,970
(21,600) (18,000) (14,400) (12,400)
36 (38) 36,700 30,590 24,470 21,260
(22,800) (19,000) (15,200) (13,200)
(continued)
SEBU7011-15 163
Maintenance Section
Engine Oil and Filter - Change

(Table 17, contd)

38 (40) 38,640 32,200 25,760 22,540

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

There are many applications of medium duty truck engines. It is important

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

Instructions for the Table

1. Determine your type of vehicle application. Locate the column which
lists your type of vehicle application.

2. Determine your available oil in liters or quarts. The oil quantity equals
the sum of the capacities of the oil sump and the oil filter. Locate the
row which lists your available oil.

3. The intersection of the column and the row lists the maximum
permissible number of kilometers or miles between oil change intervals.
164 SEBU7011-15
Maintenance Section
Engine Oil and Filter - Change

Example

You determined that the vehicle application is light duty commercial. The
oil capacity of the engine is 21 L (22 qt) and the oil capacity of the auxiliary
oil filter is 10 L (10 qt). With S·O·S Oil Analysis verification, the maximum
permissible oil change interval is 30900 kilometers (19200 miles).

For more information on optimizing oil change intervals, see your

Caterpillar dealer.
SEBU7011-15 165
Maintenance Section
Engine Storage Procedure - Check

i01458399

Engine Storage Procedure - Check

SMCS Code: 1000-535

The oil change interval may be extended to 12 months for a vehicle that
is operated seasonally and placed in storage for the remainder of the
year by using the required storage procedures and the required start-up
procedures. This extension is permitted if the following categories for oil
change intervals in the Operation and Maintenance Manual, “Maintenance
Interval Schedule” have not been reached:

• Mileage
• Operating hours
• Fuel consumption
If an engine is out of operation and if use of the engine is not planned,
special precautions should be made. If the engine will be stored for more
than three months, a complete protection procedure is recommended.
For more detailed information on engine storage, see Special Instruction,
SEHS9031, “Storage Procedure For Caterpillar Products”.

If the engine will not be started for several weeks, the lubricating oil will
drain from the cylinder walls and from the piston rings. Rust can form on
the cylinder liner surface. Rust on the cylinder liner surface will cause
increased engine wear and a reduction in engine service life. Caterpillar
recommends the use of volatile corrosion inhibitor (VCI) oil in order to
prevent internal engine damage due to moisture during storage. These
inhibitors in the VCI oil act by evaporating inside the engine. The inhibitors
then condense over the inside surfaces of the engine. The evaporation
process and the condensing process offers full protection to surfaces
that cannot be reached with preservatives. 0.9 L (1.0 qt) of 4C-6792
VCI oil will treat 28.4 L (30.0 qt) of engine oil. This will give a 3 percent
concentration of VCI oil. The engine must be completely sealed when
the engine is stored in order for the VCI oil to function properly. The VCI
oil is easily cleaned from the engine when you remove the engine from
storage. The volatile vapors are removed by simply running the engine to
operating temperature. A mineral oil base is left behind after the volatile
vapors are removed.
166 SEBU7011-15
Maintenance Section
Engine Valve Lash - Inspect/Adjust

i00869628

Engine Valve Lash - Inspect/Adjust

SMCS Code: 1102-025

The initial valve lash adjustment on new engines, rebuilt engines, or

remanufactured engines is recommended at the first scheduled oil
change. The adjustment is necessary due to the initial wear of the valve
train components and to the seating of the valve train components.

This maintenance is recommended by Caterpillar as part of a lubrication

and preventive maintenance schedule in order to help provide maximum
engine life.

NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.

Operation of Caterpillar engines with improper valve

adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.

Ensure that the engine can not be started while

this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.

Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuring the valve lash. To
obtain an accurate measurement, allow the valves to cool before this
maintenance is performed.

Refer to the Service Manual for more information.

SEBU7011-15 167
Maintenance Section
Exhaust Particulate Filter - Clean

i02304456

Exhaust Particulate Filter - Clean

SMCS Code: 1091-070
S/N: DPF1-Up

The Diesel Particulate Filter (DPF) can be cleaned. Perform a back

pressure test in order to determine if the DPF needs to be cleaned. Refer
to Operation and Maintenance Manual, “Exhaust Particulate Filter - Test”.
The following equipment is required to clean the DPF: dry pressurized air
supply with 690 kPa (100 psi), air nozzle with a short rubber hose on the
end of the nozzle, and a way to collect the dust.

Wear goggles, gloves, protective clothing and a

dust respirator certified by the National Institute
for Occupational Safety and Health (NIOSH) and
by the Mine Safety and Health Administration
(MSHA) when cleaning the diesel particulate filter.
Failure to do so could result in personal injury.

Note: If the red warning light has been activated Do Not perform a back
pressure test. The catalyst section could begin to regenerate. This will
damage the DPF.

Caterpillar recommends recording when the DPF is cleaned. Record the

cleaning in the Operation and Maintenance Manual, “Maintenance Log”.
Perform a back pressure test prior to cleaning the DPF and record the
results. After the cleaning of the DPF run the engine on high idle for 5 to
15 minutes. Perform another back pressure test and record the results.

Collection of Ash
A filter bag is required to collect the ash from the DPF. The filter bags are
available from your Caterpillar Dealer. The filter bag will trap particles as
small as 5 microns. A filter bag can be used 5 to 10 times.

• 229-0766 Filter Bag

Note: Disposal of the filter bags must be in accordance with the following
regulations: Federal, State, and Local Laws.
168 SEBU7011-15
Maintenance Section
Exhaust Particulate Filter - Clean

Cleaning Procedure
Follow the recommended method for cleaning the DPF.

1. The DPF does not have labels on the inlet or outlet ends of the catalyst
section or the filter section. Mark the outside of both the filter section
and the catalyst section with a marker. This will identify the orientation
of the sections. This is important because you will reinstall the sections
in the opposite direction.

2. The filter section and the catalyst section need to be removed.

3. Carefully remove the sections. Inspect the outlet side of the filter
section. The outlet side should be white in color. Replace the filter
section if there are black deposits on the outlet side. The black
deposits are soot. Inspect the sections for damage to the internal
coatings and to external damage to the housings. If there is damage to
the section the section should be replaced.

Note: When the outlets of the sections are white in color ash has caused
the exhaust restriction. Only clean the filter section. Soot has caused
the exhaust restriction if the sections are black. Clean the filter and the
catalyst section.

4. Place a filter bag on the inlet side of the filter section. Secure the
filter bag to the section with the draw string. Position the section in
the vertical position. Positioning the section in this manner will allow
the ash to fall into the bag. Place a filter bag on the inlet side of the
catalyst section. Secure the filter bag to the section with the draw
string. Position the section in the vertical position. A holding fixture can
be fabricated from the fabricated part number FT2931. Positioning the
section in this manner will allow the ash to fall into the bag.
SEBU7011-15 169
Maintenance Section
Exhaust Particulate Filter - Clean

g00875156
Illustration 30
(1) Inlet side
(2) Rubber hose
(3) Filter section
(4) Outlet side
(5) Filter bag

5. Compressed air 690 kPa (100 psi) will be used to blow the ash from
the section. The air should be dry and free from oil. Attach a short
rubber hose onto the end of the nozzle. The rubber hose is used to
protect the coating from being hit with the air nozzle.

6. The air nozzle should be 12.70 mm (0.5 inch) away from the section.
Use slow circular motions to clean the section. Work from the center
of the section toward the outside. Cleaning the DPF will require 20
to 40 minutes per section.
170 SEBU7011-15
Maintenance Section
Exhaust Particulate Filter - Clean

g00875998
Illustration 31
Typical example
Orientation of the module
(6) Inlet section
(7) Catalyst section
(3) Filter section
(8) Outlet section
(9) Test location
(10) Tee fitting
(11) Copper tubing
(12) Thermocouple

7. When you install the filter section and the catalyst section, new gaskets
should be used. The filter section and the catalyst section should be
installed in the opposite direction. Refer to the identification marks
that are on the filter. The inlet side of filter should now be outlet side
of the filter.

Tighten the clamps to the following torque. ................. 20 N·m (15 lb ft)

8. Reset the diagnostic module if any alarms have been activated.

Perform a back pressure test after cleaning the DPF. The engine should
be at operating temperature. Refer to Operation and Maintenance
Manual, “Exhaust Particulate Filter - Test” for the testing procedure.
SEBU7011-15 171
Maintenance Section
Exhaust Particulate Filter - Test

i01746658

Exhaust Particulate Filter - Test

SMCS Code: 1091-081
S/N: DPF1-Up

The Diesel Particulate Filter (DPF) will become restricted with ash and
soot from the engine. The restriction will cause the DPF exhaust back
pressure to increase. Testing the back pressure of the exhaust system
will determine when the filter module and catalyst module needs to be
cleaned.

Testing Back Pressure

Table 18
Required Tools
Part
Part Name Quantity
Number
1U-5470 Engine Pressure Group
or or
198-4240 Digital Pressure Indicator 1
or or
220-3778 Adapter Cable As

g00293196
Illustration 32
1U-5470 Engine Pressure Group
172 SEBU7011-15
Maintenance Section
Exhaust Particulate Filter - Test

g00885031
Illustration 33
DPF diagnostic module
(1) Mounting holes
(2) “System status”
(3) “Over-pressure alarm”
(4) “Over-temp alarm”
(5) “System problem”
(6) “Alarm reset button”
(7) “Pressure transducer port”
(8) Wire passage
(9) “Serial data comm port”

Back pressure can be measured in many different ways. The diagnostic

module for the DPF can be connected to a computer and port (9) with
220-3778 Adapter Cable As. You will be able to monitor the back
pressure. The history of the back pressure can be downloaded. Refer to
Special Instruction, REHS1342, “CRTdm Interface Software Guide”.

The back pressure can also be measured with 198-4240 Digital

Pressure Indicator. Refer to Special Instruction, NEHS0818, “Using the
198-4240 Digital Pressure Indicator” for the instructions that are needed
to use the tool.

The 1U-5470 Engine Pressure Group can also be used to measure

the back pressure. Refer to Special Instruction, SEHS8907, “Using the
1U-5470 Engine Pressure Group” for the instructions that are needed
to use the tool.

Back pressure measurements are required at the following intervals:

• Amber dash light turns on.

SEBU7011-15 173
Maintenance Section
Exhaust Particulate Filter - Test

• Every 6 months
• 40,234 kilometers (25,000 miles)

The muffler and converter will become extrem-

ly hot during engine operation. A hot muffler
and converter can cause serious burns. Allow
adaquate cooling time before working on or near
the muffler and converter.

Making contact with a running engine can cause

burns from hot parts and can cause injury from
rotating parts.

When working on an engine that is running, avoid

contact with hot parts and rotating parts.
174 SEBU7011-15
Maintenance Section
Exhaust Particulate Filter - Test

g00885195
Illustration 34
Typical example
(10) Inlet module
(11) Catalyst module
(12) Filter module
(13) Outlet module
(14) Test location
(15) Tee fitting
(16) Copper tubing
(17) Thermocouple

Note: Do Not test the exhaust back pressure if the “Over-pressure

alarm” (3) has been activated. Clean the DPF. Refer to Operation and
Maintenance Manual, SEBU7011, “Exhaust Particulate Filter - Clean”
for the proper procedure.

1. Remove Tee fitting (15) from test port (14). The test location is on the
Diesel Particulate Filter.

2. Connect the pressure port of the differential pressure gauge to the

test port.

3. Leave the vacuum port of the differential pressure gauge open to the
atmosphere.
SEBU7011-15 175
Maintenance Section
Exhaust Particulate Filter - Test

Note: Watch the back pressure reading as the engine begins to warm
up. Stop the test immediately if the back pressure goes above 25 kPa
(100 inch of H2O). The filter module needs to be cleaned. Refer to
Operation and Maintenance Manual, “Exhaust Particulate Filter - Clean”
for the proper cleaning procedure.

4. Start the engine and run the engine in the no-load condition at high
idle until the engine reaches normal operating temperature.

5. Record the value while the engine is operating at high idle.

6. Multiply the value from 5 by 1.8.

7. If the results from Step 6 are greater than 25 kPa (100 inch of H2O) the
DPF needs to be cleaned. Refer to the Operation and Maintenance
Manual, SEBU7011, “Exhaust Particulate Filter - Clean” for the proper
cleaning procedure.
176 SEBU7011-15
Maintenance Section
Fan Drive Bearing - Lubricate

i02239650

Fan Drive Bearing - Lubricate

SMCS Code: 1359-086-BD

Some of the fan drives have grease fittings and some of the fan drives do
not have grease fittings. If there is no grease fitting, periodic lubrication
is not required. The fan drive requires grease only if the fan drive is
equipped with a zerk.

g00746166
Illustration 35
Typical location of the grease fitting (if equipped) that is for the
fan drive bearing
The pulley is shown with the belt guards that have been removed.

Lubricate the grease fitting that is on the fan drive bearing with Bearing
Lubricant or the equivalent.

Inspect the fan drive pulley assembly for wear or for damage. If the shaft
is loose, an inspection of the internal components should be performed.
Refer to the Service Manual for additional information.
SEBU7011-15 177
Maintenance Section
Fuel Inlet Screen - Clean/Inspect/Replace

i01632506

Fuel Inlet Screen - Clean/Inspect/Replace

(If Equipped)
SMCS Code: 1250-510-Z3; 1250-571-Z3; 1252-040-Z3; 1252-070-Z3;
1252-510-Z3; 1252-571; 1252-571-Z3; 1252; 1256-040-Z3;
1256-070-Z3; 1256-070; 1256-510-Z3; 1256

g00845620
Illustration 36

1. Remove the fuel inlet screen. The fuel inlet screen is positioned at
the inlet to the fuel transfer pump.

2. Wash the fuel inlet screen in a clean, nonflammable solvent.

3. Inspect the fuel inlet screen. If the fuel inlet screen is damaged, replace
the fuel inlet screen.

4. Use pressure air to dry the fuel inlet screen.

5. Inspect the seal in the fuel transfer pump. If the seal is damaged,
replace the seal.

6. Install the seal in the fuel transfer pump. Install the clean fuel inlet
screen in the fuel transfer pump.
178 SEBU7011-15
Maintenance Section
Fuel System - Prime

i02113137

Fuel System - Prime

SMCS Code: 1258-548

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

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

Prime the fuel system in order to fill the fuel filter. Prime the fuel system in
order to purge trapped air. The fuel system should be primed under the
following conditions:

• Running out of fuel

• Storage
• Replacement of the fuel filter

Engines that are Equipped with a Fuel Priming

Pump
NOTICE
Do not loosen the fuel lines at the fuel manifold. The
fittings may be damaged and/or a loss of priming pres-
sure may occur when the fuel lines are loosened.

1. Open the fuel priming pump and operate the fuel priming pump until
a strong pressure is felt. This procedure will require considerable
strokes. Lock the fuel priming pump.
SEBU7011-15 179
Maintenance Section
Fuel System - Prime

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

2. Promptly start the engine. If the engine runs rough, continue to operate
the engine at low idle. Do not raise the engine rpm above an idle,
until the engine operates smoothly.

3. If the engine does not start, open the fuel priming pump and repeat
Steps 1 and 2 in order to start the engine.

Engines that are Not Equipped with a Fuel

Priming Pump
If the engine is not equipped with a fuel priming pump, you can use the
following procedures to prime the fuel system. These procedures will
allow only filtered fuel to enter the fuel system.

Fuel Filter Bases that are Equipped with a Plug

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
180 SEBU7011-15
Maintenance Section
Fuel System - Prime

g01076450
Illustration 37
(1) Plug
(2) Fuel filter

1. Remove plug (1) in order to fill fuel filter (2). Ensure that air is able to
vent from the fitting of the plug while the fuel filter is being filled. Clean
up any spilled fuel immediately. Clean plug (1). Install plug (1).

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

2. Start the engine and operate the engine at low idle. Do not raise the
engine speed above an idle, until the engine operates smoothly.

Fuel Filter Bases that are Not Equipped with a Plug

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

1. Operate the starting motor. This will fill the fuel filter and the fuel lines
with fuel.

2. Once the engine starts, operate the engine at low idle. Do not raise the
engine speed above an idle, until the engine operates smoothly.
SEBU7011-15 181
Maintenance Section
Fuel System Primary Filter - Clean/Replace

i00861167

Fuel System Primary Filter - Clean/Replace

SMCS Code: 1260-070; 1260-510

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

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

For more information on the maintenance of the primary fuel filter, refer to
the literature that is provided by the OEM of the vehicle, or refer to the
literature that is provided by the OEM of the primary fuel filter.

i01503750

Fuel System Secondary Filter - Replace

SMCS Code: 1261-510-SE

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
182 SEBU7011-15
Maintenance Section
Fuel System Secondary Filter - Replace

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

NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.

1. Stop the engine. Turn the ignition switch to the OFF position or
disconnect the battery. Refer to the Operation and Maintenance
Manual, “Battery or Battery Cable - Disconnect” topic (Maintenance
Section) for more information. Shut off the fuel supply valve (if
equipped).

2. Remove the used fuel filter and discard the used fuel filter.

3. Clean the gasket sealing surface of the fuel filter base. Ensure that
all of the old gasket is removed.

4. Apply clean diesel fuel to the new fuel filter gasket.

NOTICE
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.

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.
SEBU7011-15 183
Maintenance Section
Fuel System Water Separator - Drain

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 as a guide for proper tightening. Tighten the filter for an
additional one turn (360 degrees) by hand. Do not overtighten the filter.

6. Open the fuel supply valve. Prime the fuel system. Refer to the
Operation and Maintenance Manual, “Fuel System - Prime” topic
(Maintenance Section) for more information. Start the engine and
inspect the fuel system for leaks.

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

Note: There should be enough residual fuel in the cylinder head in order
to start the engine. If the engine stops after starting, do not crank the
engine for more than 30 seconds. Then allow the starting motor to cool
for two minutes. Repeat this procedure until the engine starts and the
engine operates.

i02112513

Fuel System Water Separator - Drain

SMCS Code: 1263-543

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
The water separator is not a filter. It separates water
from the fuel.

The engine should never be allowed to run with the

water level in the separator more than 1/2 full or en-
gine damage may result.
184 SEBU7011-15
Maintenance Section
Fuel System Water Separator - Drain

A water separator is recommended. The water separator should be

installed between the fuel tank and the engine fuel inlet. Drain the water
and sediment from the water separator on a daily basis.

g01076474
Illustration 38
(1) Drain

1. Open drain (1). Catch the draining water in a suitable container.

Dispose of the water properly.

NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
system.

2. Close drain (1).

SEBU7011-15 185
Maintenance Section
Fuel Tank Water and Sediment - Drain

i01877350

Fuel Tank Water and Sediment - Drain

SMCS Code: 1273-543-M&S

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpil-

lar Tools and Shop Products Guide” for tools and
supplies suitable to collect and contain fluids on
Caterpillar products.

Dispose of all fluids according to local regulations and

mandates.

Fuel Tank
Fuel quality is critical to the performance and to the service life of
the engine. Water in the fuel can cause excessive wear to the fuel
system. Condensation occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the fuel system and the
fuel returns to the fuel tank. This causes water to accumulate in fuel tanks.
Draining the fuel tank regularly and obtaining fuel from reliable sources
can help to eliminate water in the fuel.

Drain the Water and the Sediment

Fuel tanks should contain some provision for draining water and draining
sediment from the bottom of the fuel tanks.

Open the drain valve on the bottom of the fuel tank in order to drain the
water and the sediment. Close the drain valve.

Check the fuel daily. Drain the water and sediment from the fuel tank
after operating the engine or drain the water and sediment from the fuel
tank after the fuel tank has been filled. Allow five to ten minutes before
performing this procedure.
186 SEBU7011-15
Maintenance Section
Hoses and Clamps - Inspect/Replace

Fill the fuel tank after operating the engine in order to drive out moist air.
This will help prevent condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may overflow.

Some fuel tanks use supply pipes that allow water and sediment to settle
below the end of the fuel supply pipe. Some fuel tanks use supply lines
that take fuel directly from the bottom of the tank. If the engine is equipped
with this system, regular maintenance of the fuel system filter is important.

Fuel Storage Tanks

Drain the water and the sediment from the fuel storage tank during the
following conditions:

• Weekly
• Oil change
• Refill of the tank
This will help prevent water or sediment from being pumped from the
storage tank into the engine fuel tank.

If a bulk storage tank has been refilled or moved recently, allow adequate
time for the sediment to settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap sediment. Filtering fuel
that is pumped from the storage tank helps to ensure the quality of the
fuel. When possible, water separators should be used.

i02121526

Hoses and Clamps - Inspect/Replace

SMCS Code: 7554-040; 7554-510

Inspect all hoses for leaks that are caused by the following conditions:

• Cracking
• Softness
• Loose clamps
Replace hoses that are cracked or soft. Tighten any loose clamps.
SEBU7011-15 187
Maintenance Section
Hoses and Clamps - Inspect/Replace

NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
ommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
A constant torque hose clamp can be used in place of any standard hose
clamp. Ensure that the constant torque hose clamp is the same size as
the standard clamp.

Due to extreme temperature changes, the hose will heat set. Heat setting
causes hose clamps to loosen. This can result in leaks. A constant torque
hose clamp will help to prevent loose hose clamps.

Each installation application can be different. The differences depend on

the following factors:

• Type of hose
• Type of fitting material
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the fittings
188 SEBU7011-15
Maintenance Section
Hoses and Clamps - Inspect/Replace

Replace the Hoses and the Clamps

Pressurized System: Hot coolant can cause seri-

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

1. Stop the engine. Allow the engine to cool.

2. Loosen the cooling system filler cap slowly in order to relieve any
pressure. Remove the cooling system filler cap.

Note: Drain the coolant into a suitable, clean container. The coolant can
be reused.

3. Drain the coolant from the cooling system to a level that is below the
hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: Refer to the Specifications, SENR3130, “Torque Specifications” in

order to locate the proper torques.

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect the cooling system filler
cap’s gaskets. Replace the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.

10. Start the engine. Inspect the cooling system for leaks.
SEBU7011-15 189
Maintenance Section
Overhaul Considerations

i00911166

Overhaul Considerations
SMCS Code: 7595-043

Refer to the Operation and Maintenance Manual, “Maintenance Interval

Schedule” topic (Maintenance Section) for the proper intervals in order to
perform an overhaul of the engine.

Several factors are important when an overhaul of the engine is

considered. The following factors are included:

• The performance of preventive maintenance

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

A top end overhaul is generally indicated by increased fuel consumption

and reduced power. This interval consists of completely reconditioning
the cylinder head. Normally, it is not necessary to repair the cylinder
components at this time.

A major overhaul is an interval when the items that have major wear in
the engine should be replaced. Items that can have major wear include
the following items: piston rings, main bearings, rods, and valves.
190 SEBU7011-15
Maintenance Section
Radiator - Clean

Overhaul Options
Caterpillar Dealer – Consult your Caterpillar dealer in order to schedule
a before failure overhaul.

i01604510

Radiator - Clean
SMCS Code: 1353-070

Note: Adjust the frequency of cleaning according to the effects of the

operating environment.

Inspect the radiator for these items: damaged fins, corrosion, dirt, grease,
insects, leaves, oil, and other debris. Clean the radiator, if necessary.

Personal injury can result from air pressure.

Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removing loose debris. Direct
the air in the opposite direction of the fan’s air flow. Hold the nozzle
approximately 6 mm (0.25 inch) away from the fins. Slowly move the
air nozzle in a direction that is parallel with the tubes. This will remove
debris that is between the tubes.

Pressurized water may also be used for cleaning. The maximum water
pressure for cleaning purposes must be less than 275 kPa (40 psi). Use
pressurized water in order to soften mud. Clean the core from both sides.

Use a degreaser and steam for removal of oil and grease. Clean both
sides of the core. Wash the core with detergent and hot water. Thoroughly
rinse the core with clean water.
SEBU7011-15 191
Maintenance Section
Severe Service Application - Check

After cleaning, start the engine and accelerate the engine to high idle
rpm. This will help in the removal of debris and drying of the core. Stop
the engine. Use a light bulb behind the core in order to inspect the core
for cleanliness. Repeat the cleaning, if necessary.

Inspect the fins for damage. Bent fins may be opened with a “comb”.
Inspect these items for good condition: welds, mounting brackets, air
lines, connections, clamps, and seals. Make repairs, if necessary.

For more detailed information on cleaning and inspection, refer to Special

Publication, SEBD0518, “Know Your Cooling System”.

i01250215

Severe Service Application - Check

SMCS Code: 1000-535

Operation and maintenance practices affect the service life of the

component when the engine is operated in certain applications that
require severe service.

The level of maintenance is crucial to the service life of the engine. Other
major factors that affect service life are operating speed and loads.

Reduce the maintenance intervals for engines that operate under

conditions that are severe.

• Frequent operation with more than 22700 kg (50000 lb) of gross vehicle
weight

• Frequent low speed operation (less than 20 Miles per Hour)

• Use of API CF-4 oil
• Use of fuel with more than 0.5% sulfur
• No water separator
• Frequent operation in dusty conditions or off-highway operation
• High load factor operation (less than 6 miles per gallon or off-highway
operation)

• Frequent high altitude operation above 1525 m (5000 ft)

192 SEBU7011-15
Maintenance Section
Starting Motor - Inspect

• Frequent operation at low idle (more than 20%)

• Frequent cold starts at temperatures below −18 °C (0 °F)
• Frequent dry starting (starting after more than 3 days of shutdown)
• Frequent hot shutdowns (minimum three minute cool down periods
after high load factor operation)

• Storage over 3 months. For more detailed information on engine

storage, see Special Instruction, SEHS9031, “Storage Procedure for
Caterpillar Products”.

i00651416

Starting Motor - Inspect

SMCS Code: 1451-040; 1453-040

Caterpillar Inc. recommends a scheduled inspection of the starting motor.

If the starting motor fails, the engine may not start in an emergency
situation.

Check the starting motor for proper operation. Check the electrical
connections and clean the electrical connections. Refer to the Service
Manual for more information on the checking procedure and for
specifications or consult your Caterpillar dealer for assistance.

i01539769

Turbocharger - Inspect
SMCS Code: 1052-040; 1052

Periodic inspection and cleaning is recommended for the turbocharger

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

If the turbocharger fails during engine operation, damage to the

turbocharger compressor wheel and/or to the engine may occur. Damage
to the turbocharger compressor wheel can cause additional damage to
the pistons, the valves, and the cylinder head.
SEBU7011-15 193
Maintenance Section
Turbocharger - Inspect

NOTICE
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.

Minor leakage of a turbocharger housing under ex-

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

When a turbocharger bearing failure is accompanied

by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.

An inspection of the turbocharger can minimize unscheduled downtime.

An inspection of the turbocharger can also reduce the chance for potential
damage to other engine parts.

Note: Turbocharger components require precision clearances. The

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

Removal and Installation

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

Cleaning and Inspecting

1. Remove the exhaust outlet piping and remove the air inlet piping from
the turbocharger. Visually inspect the piping for the presence of oil.
Clean the interior of the pipes in order to prevent dirt from entering
during reassembly.
194 SEBU7011-15
Maintenance Section
Turbocharger - Inspect

2. Turn the compressor wheel and the turbine wheel by hand. The
assembly should turn freely. Inspect the compressor wheel and
the turbine wheel for contact with the turbocharger housing. There
should not be any visible signs of contact between the turbine wheel
or compressor wheel and the turbocharger housing. If there is any
indication of contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing, the turbocharger
must be reconditioned.

3. Check the compressor wheel for cleanliness. If only the blade side
of the wheel is dirty, dirt and/or moisture is passing through the air
filtering system. If oil is found only on the back side of the wheel, there
is a possibility of a failed turbocharger oil seal.

The presence of oil may be the result of extended engine operation

at low idle. The presence of oil may also be the result of a restriction
of the line for the inlet air (plugged air filters), which causes the
turbocharger to slobber.

4. Use a dial indicator to check the end clearance on the shaft. If the
measured end play is greater than the Service Manual specifications,
the turbocharger should be repaired or replaced. An end play
measurement that is less than the minimum Service Manual
specifications could indicate carbon buildup on the turbine wheel. The
turbocharger should be disassembled for cleaning and for inspection
if the measured end play is less than the minimum Service Manual
specifications.

5. Inspect the bore of the turbine housing for corrosion.

6. Clean the turbocharger housing with standard shop solvents and

a soft bristle brush.

7. Fasten the air inlet piping and the exhaust outlet piping to the
turbocharger housing.
SEBU7011-15 195
Maintenance Section
Walk-Around Inspection

i01185304

Walk-Around Inspection
SMCS Code: 1000-040

Inspect the Engine for Leaks and for Loose

Connections
A walk-around inspection should only take a few minutes. When the
time is taken to perform these checks, costly repairs and accidents can
be avoided.

For maximum engine service life, make a thorough inspection of the

engine compartment before starting the engine. Look for items such as
oil leaks or coolant leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:

• The guards must be in the proper place. Repair damaged guards or

replace missing guards.

• Wipe all caps and plugs before the engine is serviced in order to reduce
the chance of system contamination.

NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.

NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.

• Ensure that the cooling lines are properly clamped and that the cooling
lines are tight. Check for leaks. Check the condition of all pipes.

• Inspect the water pumps for coolant leaks.

196 SEBU7011-15
Maintenance Section
Walk-Around Inspection

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

Excessive coolant leakage may indicate the need to replace the water
pump seal. For the removal of water pumps and the installation of water
pumps and/or seals, refer to the Service Manual for the engine or consult
your Caterpillar dealer.

• Inspect the lubrication system for leaks at the front crankshaft seal, the
rear crankshaft seal, the oil pan, the oil filters and the valve cover.

• Inspect the fuel system for leaks. Look for loose fuel line clamps or for
loose fuel line tie-wraps.

• Inspect the piping for the air inlet system and the elbows for cracks and
for loose clamps. Ensure that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.

• Inspect the alternator belt and the accessory drive belts for cracks,
breaks or other damage.

Belts for multiple groove pulleys must be replaced as matched sets. If

only one belt is replaced, the belt will carry more load than the belts that
are not replaced. The older belts are stretched. The additional load on the
new belt could cause the belt to break.

• Drain the water and the sediment from fuel tanks on a daily basis in
order to ensure that only clean fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for loose connections and
for worn wires or frayed wires.

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

• Disconnect any battery chargers that are not protected against the
current drain of the starting motor. Check the condition and the
electrolyte level of the batteries, unless the engine is equipped with a
maintenance free battery.

• Check the condition of the gauges. Replace any gauges that are
cracked. Replace any gauge that can not be calibrated.
SEBU7011-15 197
Maintenance Section
Water Pump - Inspect

i00864339

Water Pump - Inspect

SMCS Code: 1361-040; 1361

Overconcentration of coolant additive (conditioner), mineral deposits from

hard water, or cooling system contamination can accelerate the wear on
the water pump seal.

Replace the Water Pump Seal, If Necessary

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

Removal and Installation

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

Inspect the Bearing for the Water Pump Pulley

Inspect the water pump pulley for unusual noise, excessive looseness
and/or vibration of the bearings.

Refer to the Service Manual for more information on the removal and
installation of the water pump pulley, or consult your Caterpillar dealer
for assistance.
198 SEBU7011-15
Warranty Section
Warranty Information

Warranty Section

Warranty Information
i01902123

Federal Emission Control Warranty

SMCS Code: 1000

Emissions Warranty
New 3126 and C7 Engines Powering On-highway Vehicles.

Caterpillar Inc. warrants new 3126 and C7 engines to the initial owner
and to the subsequent owner of a diesel engine (powering an on-highway
truck) that such an engine is:

1. Designed, built and equipped so as to conform, at the time of sale, with

all applicable regulations adopted by the United States Environmental
Protection Agency (EPA).

2. Free from defects in materials and workmanship in specific emission

related parts for the following periods:

• For new engines powering on-highway vehicles, other than

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

• For new engines powering school buses, recreational vehicles, fire

trucks, emergency service vehicles, ambulances, the standard
warranty period is 60 months or 6000 operating hours, whichever
occurs first, after date of delivery to the first user.

• For new engines powering specialty trucks (i.e., trucks equipped for
pulling trailers or fifth-wheel-type trailers) the standard warranty
period is 60 months or 241,402 kilometers (150,000 miles) or 3600
operating hours, whichever occurs first, after date of delivery to
the first user.
SEBU7011-15 199
Warranty Section
Warranty Information

Note: This warranty only applies to specialty trucks that are used solely for
personal purposes and are not used for commercial (revenue producing)
purposes. Pulling recreational trailers or trailers for recreational or hobby
activities, such as boats, horses, race cars, etc., is considered personal
use.

Following the standard warranty periods specified above, the emission

warranty of 60 months, 161,000 kilometers (100,000 miles) or 3000
service hours of operation, whichever occurs first, after the date of
delivery to the initial owner would be effective.

If an emission related part fails during the warranty period, the part will be
repaired or replaced. Any such part repaired or replaced under warranty
is warranted for the remainder of the warranty period.

During the term of this warranty, Caterpillar Inc. will provide through
a Caterpillar dealer or other establishment authorized by it, repair or
replacement of any warranted part at no charge to the truck engine owner.

In an emergency, repairs may be performed at any service establishment,

or by the owner, using any replacement part. It is recommended that
emission related parts be replaced with genuine Caterpillar Inc. parts.

Caterpillar Inc. will reimburse the owner for their expenses, including
diagnostic charges for such an emergency repair. These expenses shall
not exceed the Caterpillar Inc. suggested retail price for all warranted
parts replaced, and labor charges based on Caterpillar Inc. recommended
time allowance for the warranty repair and the geographically appropriate
hourly labor rate.

As a condition of reimbursement, replaced parts and receipted invoices

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

Limitations and Responsibilities

The warranty is subject to the following:

Caterpillar Inc. Responsibilities

During the emission warranty period, if a defect in material or workmanship

of an emission related part or component is found, Caterpillar Inc. will
provide:
200 SEBU7011-15
Warranty Section
Warranty Information

• New, Remanufactured or repaired parts and/or components, approved

pursuant to EPA Regulations, required to correct the defect.

Note: Items replaced under this warranty become the property of

Caterpillar Inc.

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

required to make the warranty repair. This includes labor in order to
remove and install the engine, if necessary.

Owner Responsibilities

During the emission warranty period, the owner is responsible for:

• Premium or overtime labor costs, unless essential to prevent loss to

perishable goods.

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

Caterpillar Inc. material or workmanship.

• Providing timely notice of a warrantable failure and promptly making the

product available for repair

Limitations

Caterpillar Inc. is not responsible for resultant damages to an emission

related part or component resulting from:

• Any application or installation Caterpillar Inc. deems improper.

• Attachments, accessory items or parts not sold nor approved by
Caterpillar Inc.

• Improper truck engine maintenance, repair or abuse

• Owner’s unreasonable delay in making the product available after
being notified of a potential product problem

This warranty is in addition to Caterpillar Inc. standard warranty, applicable

to the truck engine product involved.

Remedies under this warranty are limited to the provision of material

and services as specified herein. Caterpillar Inc. is not responsible for
incidental or consequential damages.
SEBU7011-15 201
Warranty Section
Warranty Information

i01902268

California Emission Control Warranty

Statement
SMCS Code: 1000

Owner Warranty Rights and Obligations

The California Air Resources Board (CARB) and Caterpillar Inc. are
pleased to explain the emission control system warranty on your 2003
or later truck engine.

In California, new motor vehicle engines must be designed, built and

equipped to meet the state’s stringent anti-smog standards. Caterpillar
Inc. must warrant the emission control system on your truck engine for
the duration of time listed below provided there has not been any abuse,
neglect or improper maintenance of your truck engine.

Your emission control system may include parts such as the fuel injection
system and engine computer, if equipped. Also included may be hoses,
connectors, clamps and other emission related components.

Where a warrantable condition exists, Caterpillar Inc. will repair the truck
engine at no cost to the owner including diagnosis, parts and labor.

Manufacturer’s Warranty Coverage

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

• For new engines powering school buses, recreational vehicles, fire

trucks, emergency service vehicles, ambulances, the standard
warranty period is 60 months or 6000 operating hours, whichever
occurs first, after date of delivery to the first user.

• For new engines powering specialty trucks (i.e., trucks equipped for
pulling trailers or fifth-wheel-type trailers) the standard warranty
period is 60 months or 241,402 kilometers (150,000 miles) or 3600
operating hours, whichever occurs first, after date of delivery to the
first user.
202 SEBU7011-15
Warranty Section
Warranty Information

Note: This warranty only applies to specialty trucks that are used solely for
personal purposes and are not used for commercial (revenue producing)
purposes. Pulling recreational trailers or trailers for recreational or hobby
activities, such as boats, horses, race cars, etc., is considered personal
use.

Following the standard warranty periods specified above, the emission

warranty of 60 months, 161,000 kilometers (100,000 miles) or 3000
service hours of operation, whichever occurs first, after the date of
delivery to the initial owner would be effective.

If an emission related part or component on your truck engine is defective,

the part or component will be repaired or replaced by Caterpillar Inc. This
is your emission control system WARRANTY.

Owner’s Warranty Responsibilities

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

• You are responsible for presenting your truck engine to a Caterpillar

Inc. dealer as soon as a truck engine problem exists. The warranty
repairs should be completed in a reasonable amount of time, not to
exceed 30 days.

• As the truck engine owner, you should also be aware that Caterpillar
Inc. may deny you warranty coverage if your truck engine or an
emission component or part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.

If you have questions regarding your warranty rights and responsibilities,

contact:

Caterpillar Inc.
Manager, Truck Engine Business
P.O. Box 0600
Mossville, IL 61552
Phone 800-447-4986

OR
SEBU7011-15 203
Warranty Section
Warranty Information

California Air Resources Board (CARB)

9528 Telstar Ave.
El Monte, CA 91731

Emissions Warranty
Caterpillar Inc. warrants to the initial owner and subsequent owner of a
diesel engine (powering an on-highway truck), that such an engine is:

1. Designed, built and equipped so as to conform, at the time of sale,

with all applicable regulations adopted by the California Air Resources
Board (CARB).

2. Free from defects in materials and workmanship in specific emission

related parts for a period of 60 months, 161 000 km (100 000 miles)
or 3000 service hours of operation, whichever occurs first, after the
date of delivery to the initial owner.

If an emission related part fails during the warranty period, it will be

repaired or replaced. Any such part repaired or replaced under warranty
is warranted for the remainder of the warranty period.

During the term of this warranty, Caterpillar Inc. will provide through
a Caterpillar dealer or other establishment authorized by it, repair or
replacement of any warranted part at no charge to the truck engine owner.

In an emergency, where an authorized dealer is not reasonably available,

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

The manufacturer shall reimburse the owner for expenses, including

diagnosis not to exceed the manufacturer’s suggested retail price
for all warranted parts replaced and labor charges based on the
manufacturer’s recommended time allowance for the warranty repair and
the geographically appropriate hourly labor rate.

A part not being available within 30 days or a repair not being complete
within 30 days constitutes an emergency.

As a condition of reimbursement, replaced parts and receipted invoices

must be presented at a place of business of a Caterpillar dealer or other
establishment authorized by Caterpillar Inc.
204 SEBU7011-15
Warranty Section
Warranty Information

This warranty covers the following emission related parts and

components.

• Exhaust Aftertreatment System (If Equipped)

• Fuel Injection System
• Inlet Manifold
• Turbocharger System
• Electronic Engine Control System
• Miscellaneous hoses, clamps, connectors and sealing devices used in
the above systems.

Any replacement part may be used for maintenance or repairs. The owner
should ensure that such parts are equivalent in design and durability to
genuine Caterpillar parts. Use of non-genuine Caterpillar parts does not
invalidate the warranty. However, Caterpillar Inc. is not liable for parts
which are not genuine Caterpillar parts.

Limitations and Responsibilities

These warranties are subject to the following:

Caterpillar Inc. Responsibilities

During the emission warranty period, if a defect in material or workmanship

of a warranted part or component is found, Caterpillar Inc. will provide:

• New, Remanufactured or repaired parts and/or components required to

correct the defect.

Note: Items replaced under this warranty become the property of

Caterpillar Inc.

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

required to make the warranty repair. This includes diagnosis and labor
to remove and install the engine, if necessary.

Owner Responsibilities

During the emission warranty period, the owner is responsible for:

SEBU7011-15 205
Warranty Section
Warranty Information

• The performance of all required maintenance. A warranty claim will not

be denied because the scheduled maintenance was not performed.
However, if the lack of required maintenance was the reason for the
repair, then the claim will be denied.

• Premium or overtime labor costs, unless essential to prevent loss to

perishable goods.

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

Caterpillar Inc. material or workmanship.

• Providing timely notice of a warrantable failure and promptly making

the product available for repair.

Limitations

Caterpillar Inc. is not responsible for resultant damages to an emission

related part or component resulting from:

• Any application or installation Caterpillar Inc. deems improper as

explained in the Operation and Maintenance Manual.

• Attachments, accessory items or parts not authorized for use by

Caterpillar Inc.

• Improper truck engine maintenance, repair or abuse.

• Owner’s unreasonable delay in making the product available after
being notified of a potential product problem.

This warranty is in addition to Caterpillar Inc. standard warranty, applicable

to the truck engine product involved.

Remedies under this warranty are limited to the provision of material

and services as specified herein. Caterpillar Inc. is not responsible for
incidental or consequential damages such as downtime or loss-of-use
of truck.
206 SEBU7011-15
Warranty Section
Warranty Information

i02118591

Emissions Warranty Information

SMCS Code: 1000

Maintenance Recommendations
Caterpillar Inc. truck engines are certified by the United States
Environmental Protection Agency (EPA) in order to comply with exhaust
emission standards and gaseous emission standards that are prescribed
by Federal laws at the time of manufacture.

Efficiency of the emission control and the engine performance depends

on adherence to proper operation and maintenance recommendations
and use of recommended fuels and lubricating oils. According to
recommendations, major adjustments and repairs should be made by
your authorized Caterpillar dealer.

Various chemical fuel additives which claim to reduce visible smoke are
available commercially. Although additives have been used to solve some
isolated smoke problems in the field, additives are not recommended for
general use. The engines should be certified without smoke depressants
according to federal smoke regulations.

Take corrective steps immediately after worn parts which may affect
emission levels are discovered in order to ensure the proper operation
of the emission control systems. The use of genuine Caterpillar parts is
recommended. Suppliers of non-Caterpillar parts must ensure the owner
that the use of such parts will not adversely affect emission levels.

Regular maintenance intervals with a special emphasis on the following

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

The following information is an explanation of maintenance items for

emission related components. See the Operation and Maintenance
Manual, “Maintenance Interval Schedule” (Maintenance Section) for the
specific interval for the following items.
SEBU7011-15 207
Warranty Section
Warranty Information

EXHAUST AFTERTREATMENT SYSTEM – Aftertreatment devices

are sensitive to the type of fuel used and the operating schedule. Poor
quality fuel may cause increases in exhaust back pressure or clogging
resulting in loss of power. An authorized Caterpillar truck engine dealer
can determine if the aftertreatment device needs service.

UNIT INJECTORS – Unit injectors are subject to tip wear as a result of

fuel contamination. This damage can cause the following conditions: an
increase in fuel consumption, black smoke, misfire, and rough running
engine. The unit injector should be inspected, tested and replaced, if
necessary. Unit injectors can be tested by an authorized Caterpillar truck
engine dealer.

TURBOCHARGER – Check for any unusual sound or vibration in the

turbocharger. Inspect the inlet piping and connections and inspect the
exhaust piping and connections. Check the condition of the bearing.
Perform the maintenance that is described in the Operation and
Maintenance Manual, “Maintenance Interval Schedule” (Maintenance
Section).

ELECTRONIC ENGINE CONTROL – This component is a device that

is designed to control engine operation with respect to the amount of
fuel injected, the injection timing as well as controlling the black smoke
emission of the engine during the engine’s operation when low inlet
manifold pressure exists.

Any erratic engine behavior may indicate a need for replacement or repair.
Your Caterpillar dealer is equipped with the necessary tools, personnel
and procedures in order to perform this service.

The owner is encouraged to keep adequate maintenance records.

However, the absence of such records will not invalidate the warranty.
Refer to the Operation and Maintenance Manual, “Maintenance Log”
(Reference Materials Section).

The vehicle owner may perform routine maintenance, repairs and other
work that is outside of the warranty. The work may be done at any repair
facility. Such work does not need to be performed at a designated station
that is determined by the warranty in order for the warranty to remain
in force.
208 SEBU7011-15
Warranty Section
Warranty Information

Customer Assistance (Emission Control

Systems Warranty)
Caterpillar Inc. intends to ensure that the Emission Control Systems
Warranty is properly administered. If you do not receive adequate
warranty service under the Emission Control Systems Warranty, call or
write to the following address:

Caterpillar Inc.
Manager, Truck Engine Business
P.O. Box 0600 Mossville, IL 61552

Authorized dealers are recommended for major maintenance and for

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

Refer to the TEPS Directory for information regarding an authorized

dealer or call the following toll free number:

1-800-447-4986
SEBU7011-15 209
Reference Information Section
Customer Service

Reference Information Section

Customer Service
i02097871

Customer Assistance
SMCS Code: 1000

USA and Canada

When a problem arises concerning the operation of an engine or
concerning the service of an engine, the problem will normally be
managed by the dealer in your area.

Your satisfaction is a primary concern to Caterpillar and to Caterpillar

dealers. If you have a problem that has not been handled to your complete
satisfaction, follow these steps:

1. Discuss your problem with a manager from the dealership.

2. If your problem cannot be resolved at the dealer level without additional

assistance, use the phone number that is listed below to talk with a
Field Service Coordinator:

1-800-447-4986

The normal hours are from 8:00 to 4:30 Monday through Friday Central
Standard Time.

3. If your needs have not been met still, submit the matter in writing to the
following address:

Caterpillar Inc.
Manager, Customer Service, Engine Division
Mossville Bldg AC
P.O. Box 610
Mossville, Illinois 61552-0610
210 SEBU7011-15
Reference Information Section
Customer Service

Please keep in mind: probably, your problem will ultimately be solved

at the dealership, using the dealership’s facilities, equipment, and
personnel. Therefore, follow the steps in sequence when a problem
is experienced.

Outside of the USA and of Canada

If a problem arises outside the USA and outside Canada, and if the
problem cannot be resolved at the dealer level, consult the appropriate
Caterpillar office.

Latin America, Mexico, Carribean

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

Europe, Africa, and Middle East

Caterpillar Overseas S.A.
76 Route de Frontenex
P.O. Box 6000
CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
Fax: 22-849-4544

Far East
Caterpillar Asia Pte. Ltd.
7 Tractor Road
Jurong, Singapore 627968
Republic of Singapore
Phone: 65-662-8333
Fax: 65-662-8302

China
Caterpillar China Ltd.
37/F., The Lee Gardens
33 Hysan Avenue
Causeway Bay
G.P.O. Box 3069
Hong Kong
Phone: 852-2848-0333
Fax: 852-2848-0440
SEBU7011-15 211
Reference Information Section
Customer Service

Japan
Shin Caterpillar Mitsubishi Ltd.
SBS Tower
10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
Japan
Phone: 81-3-5717-1150
Fax: 81-3-5717-1177

Japan
Caterpillar Power Systems, Inc.
SBS Tower (14th floor)
4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Phone: 81-3-5797-4300
Fax: 81-3-5797-4359

Australia and New Zealand

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

i01028392

Ordering Replacement Parts

SMCS Code: 7567

When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
212 SEBU7011-15
Reference Information Section
Customer Service

Quality Caterpillar replacement parts are available from Caterpillar

dealers throughout the world. Caterpillar dealers’ parts inventories are
up-to-date. The parts stocks include all of the parts that are normally
needed to protect your Caterpillar engine investment.

When you order parts, please specify the following information:

• Part number
• Part name
• Quantity
If there is a question concerning the part number, please provide your
dealer with a complete description of the needed item.

When a Caterpillar engine requires maintenance and/or repair, provide

the dealer with all the information that is stamped on the Information
Plate. This information is described in this Operation and Maintenance
Manual (Product Information Section).

Discuss the problem with the dealer. Inform the dealer about the
conditions of the problem and the nature of the problem. Inform the
dealer about when the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem faster.
SEBU7011-15 213
Reference Information Section
Reference Materials

Reference Materials
i01499399

Reference Material
SMCS Code: 1000

The following literature can be obtained through any Caterpillar dealer.

Lubricants
• Special Publication, PEHP8038, “Data Sheet - CH-4 Diesel Engine Oil”
• Special Publication, PEHP7041, “Product Data Sheet for Caterpillar
Diesel Engine Oils (DEO)” CG-4 engine oils (International markets)

• Special Publication, PEWP3014, “Cat Fluids Selector Dial

(International)”

• Special Publication, PEWP9733, “Cat Fluids Selector Dial (North

America)”

• Special Publication, NEDG6022, “Caterpillar Lubricating Grease Any

Job. AnyTime. Any Place.”

• Special Publication, PEHP0002, “Data Sheet - Multipurpose Lithium

Complex Grease with Molybdenum (MPGM)”

• Special Publication, NEHP6015, “Data Sheet - Special Purpose

Grease”

• Special Publication, NEHP5621, “How To Select the Right Grease for

Any Job”

• Special Publication, PEHP6001, “How To Take A Good Oil Sample”

• Special Publication, SEBD0640, “Oil and Your Engine”
• Special Publication, PEDP7036, “SOS Fluids Analysis Cornerstone”

Fuels
• Special Publication, SEBD0717, “Diesel Fuels and Your Engine”
214 SEBU7011-15
Reference Information Section
Reference Materials

• Special Publication, SENR9620, “Improving Fuel System Durability”

Coolants
• Special Publication, SEBD0970, “Coolant and Your Engine”
• Special Publication, PEHP4036, “Data Sheet - Extended Life Coolant”
• Special Publication, SEBD0518, “Know Your Cooling System”
• Special Publication, PEHP7057, “Data Sheet - S·O·S Coolant Analysis”

Miscellaneous
• Service Manual, RENR1360, “3126B and 3126E Truck Engine”
• Special Publication, SEBU6385, “Caterpillar On-Highway Diesel Truck
Engine Fluids Recommendations”

• Special Publication, PECP6026, “One Safe Source”

• Special Instruction, REHS0184, “Removal and Installation for the
3126B and 3126E HEUI Injector”

• Special Instruction, SMHS7001, “Assembly of Fan Drive Pulley

Assemblies”

• Special Instruction, SEHS7633, “Battery Test Procedure”

• Special Instruction, LEDT2254, “Cat Answers Your Questions About
Truck Performance”

• Special Publication, SEBF8062, “Guideline for Reusable Parts -

Procedure to Inspect and Clean Air Filters”

• Special Publication, SEBF8029, “Index to Guidelines for Reusable

Parts and Salvage Operations”

• Special Publication, LEXT0023, “Programming Caterpillar Electronic

Truck Engines”

• Special Publication, NEHS0526, “Service Technology Application

Guide”
SEBU7011-15 215
Reference Information Section
Reference Materials

• Special Instruction, SEHS9031, “Storage Procedure for Caterpillar

Products”

• Specifications, SENR3130, “Torque Specifications Module”

• Special Instruction, SEHS7768, “Use of 6V-2150 Starting/Charging
Analyzer”

• Special Instruction, SEHS8742, “Using the 8T-8697 Electronic Control

Analyzer Programmer (ECAP)”

• Special Instruction, SEHS7332, “Warning Tag - Danger Do Not Operate”

• Special Publication, “Truck Engine Application and Installation Guide”
(See your Caterpillar dealer.)

i01771505

Additional Reference Material

SMCS Code: 1000

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

Engine Manufacturers Associaton

Two North LaSalle Street, Suite 2200
Chicago, IL, USA 60602
E-mail: [email protected]
(312) 827-8737

The “Society of Automotive Engineers (SAE) Specifications” can be found

in your SAE handbook. This publication can also be obtained from the
following locations: local technological society, local library, and local
college. If necessary, consult SAE at the following address:

SAE International
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
E-mail: www.sae.org
(724) 776-4841
216 SEBU7011-15
Reference Information Section
Reference Materials

The “American Petroleum Institute Publication No. 1509” can be obtained

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

American Petroleum Institute

1220 L St. N.W.
Washington, DC, USA 20005
E-mail: www.api.org
(202) 682-8000

For information regarding “Technology and Maintenance Council (TMC)

Specifications”, refer to the following address:

Technology and Maintenance Council

American Trucking Association
2200 Mill Road
Alexandria, VA, USA 22314
E-mail: www.trucking.org/cc/councils/tmc
(703) 838-1763

i00866435

Engine Protection Plans

SMCS Code: 1000

Extended Warranties and Service Contracts

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

• ESC (Extended Service Coverage)

• OPT (Overhaul Protection for Trucks)
• Remanufactured Extended Coverage
• TOPP (Truck Owner Protection Plan)
Consult your authorized Caterpillar Truck Engine dealer for more detailed
information on specific programs and coverage that is available. Ask for
the Engine Protection Plan Sales Manager.
SEBU7011-15 217
Reference Information Section
Reference Materials

i00912149

Maintenance Records
SMCS Code: 1000

Caterpillar Inc. recommends the retention of accurate maintenance

records. Accurate maintenance records can be used for the following
purposes:

• Determine operating costs.

• Establish maintenance schedules for other engines that are operated
in the same environment.

• Show compliance with the required maintenance practices and

maintenance intervals.

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

that are related to engine maintenance.

Maintenance records are a key element of a maintenance program that is

well managed. Accurate maintenance records can help your Caterpillar
dealer to fine tune the recommended maintenance intervals in order to
meet the specific operating situation. This should result in a lower engine
operating cost.

Records should be kept for the following items:

Fuel Consumption – A record of fuel consumption is essential in order

to determine when the load sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul intervals.

Service Hours – A record of service hours is essential to determine

when the speed sensitive components should be inspected or repaired.

Documents – These items should be easy to obtain, and these items

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

Keep the following types of documents as proof of maintenance for

warranty. Also, keep these types of documents as proof of repair for
warranty:
218 SEBU7011-15
Reference Information Section
Reference Materials

• Dealer work orders and itemized bills

• Owner’s repair costs
• Owner’s receipts
• Maintenance log

i00920302

Maintenance Log
SMCS Code: 1000

Table 19
Engine Model Customer Identifier

Serial Number Arrangement Number

Table 20

Service Quantity
Item Serviced Date Authorization
Hours of Fuel

(continued)
SEBU7011-15 219
Reference Information Section
Reference Materials

(Table 20, contd)

Service Quantity
Item Serviced Date Authorization
Hours of Fuel

(continued)
220 SEBU7011-15
Reference Information Section
Reference Materials

(Table 20, contd)

Service Quantity
Item Serviced Date Authorization
Hours of Fuel
SEBU7011-15 221
Index Section

Index
A

Additional Reference Material .............................................................. 215

Aftercooler Core - Clean/Test ............................................................... 117
Aftercooler Core - Inspect..................................................................... 118
Air Compressor - Inspect...................................................................... 120
Air Compressor Filter - Clean/Replace................................................. 121
Air Dryer - Check .................................................................................. 122
Alternator - Inspect ............................................................................... 122

Battery - Replace.................................................................................. 123

Battery Electrolyte Level - Check ......................................................... 124
Battery or Battery Cable - Disconnect .................................................. 126
Before Starting Engine ........................................................................... 19
Belt - Inspect......................................................................................... 126
Adjustment ........................................................................................ 128
Inspection.......................................................................................... 126
Belt Tensioner - Inspect (If Equipped) .................................................. 130
Burn Prevention...................................................................................... 14
Batteries.............................................................................................. 15
Coolant................................................................................................ 14
Oils...................................................................................................... 15

California Emission Control Warranty Statement ................................. 201

Emissions Warranty .......................................................................... 203
Owner Warranty Rights and Obligations........................................... 201
Caterpillar Driver Information Display..................................................... 92
Diagnostic Data................................................................................... 92
Engine Operating Information ............................................................. 92
Maintenance Information .................................................................... 92
Theft Deterrent.................................................................................... 92
Vehicle Trip Information ...................................................................... 92
Cold Weather Operation......................................................................... 95
222 SEBU7011-15
Index Section

Cooling System Coolant (DEAC) - Change.......................................... 130

Cooling Systems with Heavy Deposits or Plugging .......................... 133
Drain ................................................................................................. 131
Fill ..................................................................................................... 134
Flush ................................................................................................. 132
Cooling System Coolant (ELC) - Change............................................. 135
Drain ................................................................................................. 136
Fill ..................................................................................................... 137
Flush ................................................................................................. 136
Cooling System Coolant Extender (ELC) - Add.................................... 138
Cooling System Coolant Level - Check ................................................ 139
Cooling System Supplemental Coolant Additive (SCA) - Test/Add ...... 140
Add the SCA, If Necessary ............................................................... 142
S·O·S Coolant Analysis..................................................................... 141
Test the SCA Concentration.............................................................. 141
Cooling System Water Temperature Regulator - Replace.................... 143
Crankshaft Vibration Damper - Inspect ................................................ 144
Removal and Installation................................................................... 144
Visconic Damper............................................................................... 144
Crushing Prevention and Cutting Prevention ......................................... 18
Customer Assistance............................................................................ 209
Outside of the USA and of Canada................................................... 210
USA and Canada .............................................................................. 209
Customer Service ................................................................................. 209
Customer Specified Parameters....................................................... 36, 68
Cylinder Head Grounding Stud - Inspect/Clean/Tighten ...................... 145

Diagnostic Flash Code Retrieval ............................................................ 57

“Diagnostic” Lamp............................................................................... 57
Diagnostic Lamp..................................................................................... 57

Electrical System .................................................................................... 21

Grounding Practices ........................................................................... 22
Emergency Vehicle Engine Features ..................................................... 47
Emissions Certification Film ................................................................... 36
Emissions Warranty Information........................................................... 206
Customer Assistance (Emission Control Systems Warranty) ........... 208
Maintenance Recommendations ...................................................... 206
Engine - Clean...................................................................................... 146
Engine Air Cleaner Element - Clean/Replace ...................................... 147
SEBU7011-15 223
Index Section

Engine Air Cleaner Service Indicator - Inspect (If Equipped) ............... 147
Test the Service Indicator.................................................................. 148
Engine Crankcase Breather - Clean..................................................... 149
Engine Description ................................................................................. 27
Aftermarket Products and Caterpillar Engines.................................... 31
Electronic Engine Features................................................................. 29
Engine Cooling and Lubrication .......................................................... 30
Engine Service Life ............................................................................. 31
Engine Specifications.......................................................................... 27
Welding and Caterpillar Electronic Engines........................................ 32
Engine Diagnostics................................................................................. 56
Engine Electronics.................................................................................. 24
Engine Identification ............................................................................... 33
Engine Lifting.......................................................................................... 42
Engine Mounts - Inspect....................................................................... 151
Engine Oil and Filter - Change ............................................................. 158
Drain the Engine Oil.......................................................................... 158
Fill the Engine Crankcase ................................................................. 160
Oil Change Interval Adjustments ...................................................... 161
Replace the Oil Filter ........................................................................ 159
Engine Oil Level - Check ...................................................................... 151
Engine Oil Level Gauge - Calibrate ...................................................... 154
Check Calibration at the First Oil Change......................................... 154
Engine Oil Sample - Obtain .................................................................. 156
Obtain the Sample and the Analysis................................................. 156
Engine Operation.................................................................................... 78
Cold Mode Operation.......................................................................... 80
Cruise Control ..................................................................................... 84
Cruising............................................................................................... 84
Diesel Particulate Filter (If Equipped) ................................................. 81
Downhill Operation.............................................................................. 87
Fuel Economy ..................................................................................... 83
Getting Started.................................................................................... 82
Idle Mode ............................................................................................ 86
Idling ................................................................................................... 78
Muffler and Converter (If Equipped).................................................... 81
Uphill Operation .................................................................................. 87
Vehicle Efficiency ................................................................................ 83
Engine Operation with Active Diagnostic Codes .................................... 66
Engine Operation with Intermittent Diagnostic Codes ............................ 67
Engine Protection Plans ....................................................................... 216
Extended Warranties and Service Contracts .................................... 216
Engine Starting ................................................................................. 19, 69
Ether ................................................................................................... 20
Engine Stopping ............................................................................... 20, 93
Engine Storage Procedure - Check...................................................... 165
224 SEBU7011-15
Index Section

Engine Valve Lash - Inspect/Adjust ...................................................... 166

Exhaust Brake ........................................................................................ 88
Operating the Exhaust Brake.............................................................. 90
Exhaust Particulate Filter - Clean ......................................................... 167
Cleaning Procedure .......................................................................... 168
Collection of Ash ............................................................................... 167
Exhaust Particulate Filter - Test............................................................ 171
Testing Back Pressure ...................................................................... 171

Fan Drive Bearing - Lubricate............................................................... 176

Fault Logging.......................................................................................... 65
Features and Controls ............................................................................ 47
Federal Emission Control Warranty...................................................... 198
Emissions Warranty .......................................................................... 198
Fire Prevention and Explosion Prevention ............................................. 16
Fire Extinguisher ................................................................................. 18
Foreword .................................................................................................. 7
California Proposition 65 Warning ........................................................ 7
Certified Engine Maintenance............................................................... 7
Literature Information............................................................................ 5
Maintenance ......................................................................................... 6
Maintenance Intervals........................................................................... 6
Operation .............................................................................................. 5
Overhaul ............................................................................................... 7
Safety.................................................................................................... 5
Fuel and the Effect from Cold Weather .................................................. 95
Fuel Inlet Screen - Clean/Inspect/Replace (If Equipped) ..................... 177
Fuel Related Components in Cold Weather ........................................... 97
Fuel Filters .......................................................................................... 98
Fuel Heaters ....................................................................................... 98
Fuel Tanks........................................................................................... 97
Fuel System - Prime ............................................................................. 178
Engines that are Equipped with a Fuel Priming Pump...................... 178
Engines that are Not Equipped with a Fuel Priming Pump ............... 179
Fuel System Primary Filter - Clean/Replace ........................................ 181
Fuel System Secondary Filter - Replace .............................................. 181
Fuel System Water Separator - Drain .................................................. 183
Fuel Tank Water and Sediment - Drain ................................................ 185
Drain the Water and the Sediment.................................................... 185
Fuel Storage Tanks ........................................................................... 186
Fuel Tank .......................................................................................... 185
SEBU7011-15 225
Index Section

Gauges and Indicators ........................................................................... 44

General Hazard Information ................................................................... 11
Asbestos Information .......................................................................... 14
Fluid Penetration................................................................................. 14
Fluid Spillage ...................................................................................... 14
Pressure Air and Water....................................................................... 13

Hoses and Clamps - Inspect/Replace .................................................. 186

Replace the Hoses and the Clamps ................................................. 188

Important Safety Information .................................................................... 2

Information Plate .................................................................................... 34

Lifting and Storage ................................................................................. 42

Maintenance Interval Schedule (Engines with a Deep Oil Sump) ........ 111
Maintenance Interval Schedule (Engines with a Shallow Oil Sump) .... 114
Maintenance Log .................................................................................. 218
Maintenance Records........................................................................... 217
Maintenance Section .............................................................................. 99
Model View Illustrations.......................................................................... 26
Model Views ........................................................................................... 26
Monitoring System.................................................................................. 47
Coolant Level Sensor (If Equipped) .................................................... 48
Programmable Options and Systems Operation ................................ 48
Mounting and Dismounting..................................................................... 18

Operation Section................................................................................... 42
Ordering Replacement Parts ................................................................ 211
226 SEBU7011-15
Index Section

Overhaul Considerations ...................................................................... 189

Overhaul Options .............................................................................. 190

Product Identification Information ........................................................... 33

Product Information Section ................................................................... 26
Product Storage...................................................................................... 43

Radiator - Clean ................................................................................... 190

Radiator Restrictions .............................................................................. 95
Reference Information Section ............................................................. 209
Reference Material ............................................................................... 213
Coolants............................................................................................ 214
Fuels ................................................................................................. 213
Lubricants ......................................................................................... 213
Miscellaneous ................................................................................... 214
Reference Materials ............................................................................. 213
Reference Numbers ............................................................................... 34
Record for Reference.......................................................................... 34
Refill Capacities...................................................................................... 99
Refill Capacities and Recommendations................................................ 99
Coolant.............................................................................................. 107
Engine Oil ........................................................................................... 99
Fuel ................................................................................................... 106
Lubricating Grease............................................................................ 105

Safety Messages ...................................................................................... 8

Safety Section .......................................................................................... 8
Self-Diagnostics...................................................................................... 56
SEBU7011-15 227
Index Section

Sensors and Electrical Components ...................................................... 50

Atmospheric Pressure Sensor ............................................................ 52
Boost Pressure Sensor ....................................................................... 52
Coolant Temperature Sensor .............................................................. 52
Engine Oil Pressure Sensor................................................................ 53
Engine Oil Temperature Sensor.......................................................... 54
Engine Speed/Timing Sensor ............................................................. 54
Failure of Sensors............................................................................... 51
Injection Actuation Pressure Sensor................................................... 54
Inlet Air Temperature Sensor .............................................................. 55
Primary Fuel Level Sensor.................................................................. 55
Secondary Fuel Level Sensor............................................................. 55
Sensor Locations ................................................................................ 50
Throttle Position Sensor...................................................................... 55
Serial Number Plate ............................................................................... 33
Severe Service Application - Check ..................................................... 191
Starting Motor - Inspect ........................................................................ 192
Starting the Engine ................................................................................. 69
Air Inlet Heater .................................................................................... 71
Cold Weather Starting......................................................................... 71
Ether Injection System ........................................................................ 73
Problems with the Wiring Harness...................................................... 75
Starting Problems ............................................................................... 74
Under-the-Hood Inspection................................................................. 69
Starting with Jump Start Cables ............................................................. 76
Stopping the Engine ............................................................................... 93
After Stopping the Engine ................................................................... 93

Table of Contents...................................................................................... 3
Turbocharger - Inspect ......................................................................... 192
Cleaning and Inspecting ................................................................... 193
Removal and Installation................................................................... 193

Walk-Around Inspection ....................................................................... 195

Inspect the Engine for Leaks and for Loose Connections ................ 195
Warranty Information ............................................................................ 198
Warranty Section .................................................................................. 198
Water Pump - Inspect ........................................................................... 197
Inspect the Bearing for the Water Pump Pulley ................................ 197
Replace the Water Pump Seal, If Necessary.................................... 197
228 SEBU7011-15
Index Section
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification
Information” in the Operation and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
©2005 Caterpillar
All Rights Reserved Printed in U.S.A.