operation and maintenance manual - beaver...

SEBU7695-15July 2011

Operation andMaintenanceManualC11, C13 and C15 On-highway EnginesKCA1-Up (Engine)KCB1-Up (Engine)JAM1-Up (Engine)BXS1-Up (Engine)MXS1-Up (Engine)NXS1-Up (Engine)RKS1-Up (Engine)JAX1-Up (Engine)

SAFETY.CAT.COM

i03991620

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread 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 warningsare 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 pictoriallypresented.

A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labelson the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. You mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. You should also ensure that the product will not be damaged or become unsafe bythe operation, lubrication, maintenance or repair procedures that you intend to use.The information, specifications, and illustrations in this publication are on the basis of information thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Cat dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Cat re-placement parts or parts with equivalent speci-fications including, but not limited to, physicaldimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

In the United States, the maintenance, replacement, or repair of the emission control devices andsystems may be performed by any repair establishment or individual of the owner's choosing.

SEBU7695-15 3Table of Contents

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Messages .................................................... 6

General Hazard Information ................................... 8

Burn Prevention ..................................................... 11

Fire Prevention and Explosion Prevention ............. 11

Crushing Prevention and Cutting Prevention ........ 13

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

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

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

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

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

Engine Electronics ................................................ 16

Product Information Section

General Information .............................................. 18

Product Identification Information ........................ 24

Operation Section

Lifting and Storage ................................................ 26

Features and Controls .......................................... 29

Engine Diagnostics ............................................... 32

Engine Starting ..................................................... 43

Engine Operation .................................................. 46

Cold Weather Operation ....................................... 57

Engine Stopping ................................................... 59

Maintenance Section

Refill Capacities .................................................... 61

Maintenance Recommendations .......................... 73

Maintenance Interval Schedule (C11 and C13Engines with 500 HP Field Up-Rates and 525 HPRV Ratings with Optional (Shallow) Oil Sumps) .. 76

Maintenance Interval Schedule (C11 and C13Engines with 500 HP Field Up-Rates and 525 HPRV Ratings with Standard (Deep) Oil Sumps) .... 77

Maintenance Interval Schedule (C11 and C13Engines with Optional Shallow Oil Sumps) ......... 79

Maintenance Interval Schedule (C11 , C13 , and C15Engines with Standard (Deep) Oil Sumps) ......... 80

Warranty Section

Warranty Information ........................................... 116

Reference Information Section

Customer Service ............................................... 122

Reference Materials ............................................ 124

Index Section

Index ................................................................... 129

4 SEBU7695-15Foreword

ForewordLiterature InformationThis manual contains safety, operation instructions,lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.

English is the primary language for all Caterpillarpublications. The English used facilitates translationand consistency in electronic media delivery.

Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Caterpillar dealer for the latestavailable information.

SafetyThis safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance andrepair on this product.

OperationOperating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.

The operation section is a reference for operators.Photographs and illustrations guide the operatorthrough procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic information.

MaintenanceThe maintenance section is a guide to engine care.The illustrated, step-by-step instructions are groupedby fuel consumption, service hours and/or calendartime maintenance intervals. Items in the maintenanceschedule are referenced to detailed instructions thatfollow.

Use fuel consumption or service hours to determineintervals. Calendar intervals shown (daily, annually,etc.) may be used instead of service meter intervalsif they provide more convenient schedules andapproximate the indicated service meter reading.

Recommended service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more frequent lubrication and maintenance than isspecified in the Maintenance Interval Schedule maybe necessary.

The maintenance schedule items are organized fora preventive maintenance management program. Ifthe preventive maintenance program is followed, aperiodic tune-up is not required. The implementationof a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.

Maintenance IntervalsPerform maintenance on items at multiples of theoriginal requirement. Each level and/or individualitems in each level should be shifted ahead or backdepending upon your specific maintenance practices,operation and application. We recommend thatthe maintenance schedules be reproduced anddisplayed near the engine as a convenient reminder.We also recommend that a maintenance record bemaintained as part of the engine's permanent record.

See the section in the Operation and MaintenanceManual, “Maintenance Records” for informationregarding documents that are generally acceptedas proof of maintenance or repair. Your authorizedCaterpillar dealer can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.

OverhaulMajor engine overhaul details are not covered in theOperation and Maintenance Manual except for theinterval and the maintenance items in that interval.Major repairs are best left to trained personnel oran authorized Caterpillar dealer. Your Caterpillardealer offers a variety of options regarding overhaulprograms. If you experience a major engine failure,there are also numerous after failure overhaul optionsavailable from your Caterpillar dealer. Consult withyour dealer for information regarding these options.

SEBU7695-15 5Foreword

California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

6 SEBU7695-15Safety SectionSafety Messages

Safety Sectioni01956922

Safety MessagesSMCS Code: 1000; 7405

There may be several specific warning signs on yourengine. The exact location and a description of thewarning signs are reviewed in this section. Pleasebecome familiar with all warning signs.

Ensure that all of the warning signs are legible. Cleanthe warning signs or replace the warning signs ifthe words cannot be read or if the illustrations arenot visible. Use a cloth, water, and soap to cleanthe warning signs. Do not use solvents, gasoline, orother harsh chemicals. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures thewarning signs. The warning signs that are loosenedcould drop off of the engine.

Replace any warning sign that is damaged ormissing. If a warning sign is attached to a part of theengine that is replaced, install a new warning signon the replacement part. Your Caterpillar dealer canprovide new warning signs.

g01017254Illustration 1

Typical exampleC15 is shown.(1) Universal Warning

SEBU7695-15 7Safety Section

Safety Messages


Typical example

C15 is shown.(1) Universal Warning

(1) Universal Warning

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions orheed the warnings could result in serious injuryor death.


8 SEBU7695-15Safety SectionGeneral Hazard Information

One warning label for the Universal Warning islocated on the valve cover base on the left side of theengine. The label is on the fourth flat surface from therear of the engine.

The other warning label for the Universal Warningis located on the vertical surface of the watertemperature regulator housing just below the roundboss that is cast into the housing.

i04075485

General Hazard InformationSMCS Code: 1000; 4450; 7405

Attach a “Do Not Operate” warning tag to the startswitch or to the controls before the engine is servicedor repaired. These warning tags (Special Instruction,SEHS7332) are available from your Caterpillardealer. Attach the warning tags to the engine andto each operator control station. When appropriate,disconnect the starting controls.


Do not allow unauthorized personnel on theengine or around the engine when the engine isserviced.


• Wear a hard hat, protective glasses, and otherprotective equipment, as required.

• Tampering with the engine installation or tamperingwith the OEM supplied wiring can be dangerous.Personal injury, death and/or engine damage couldresult.

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

• Do not release the secondary brake or the parkingbrake systems unless the vehicle is blocked orunless the vehicle is restrained.

• When work is performed around an engine that isoperating, wear protective devices for ears in orderto help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can snagon controls or on other parts of the engine.

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

• Never put maintenance fluids into glass containers.Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, perform themaintenance under the following conditions:

• The engine is stopped. Ensure that the enginecannot be started.

• The protective locks or the controls are in theapplied position.

• Engage the secondary brakes or parking brakes.

• Block the vehicle or restrain the vehicle beforemaintenance or repairs are performed.

• Disconnect the batteries when maintenanceis performed or when the electrical system isserviced. Disconnect the battery ground leads.Tape the leads in order to help prevent sparks.

• Disconnect the connector for the unit injector thatis located on the valve cover base. This procedurewill help prevent personal injury from the highvoltage to the unit injectors. Do not come in contactwith the unit injector terminals while the engine isoperating.

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


General Hazard Information

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

• When starting a new engine or an engine whichhas not been started since service has beenperformed, make provisions to stop the engine if anoverspeed occurs. Shutting down the engine maybe accomplished by shutting off the fuel supplyand/or the air supply to the engine.

• Start the engine from the operator station (cab).Never short across the starting motor terminalsor the batteries which could bypass the engineneutral start system and/or the electrical systemcould be damaged.

Cautiously remove the following parts:

Note: To help prevent spraying or splashing ofpressurized fluids, hold a rag over the part that isbeing removed.

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed.Gradually loosen but do not remove the last two boltsor nuts that are located at opposite ends of the coverplate or the device. Before removing the last twobolts or nuts, pry the cover loose in order to relieveany spring pressure or other pressure.

Pressurized Air and WaterPressurized air and/or water can cause debris and/orhot water to be blown out which could result inpersonal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded and used with effective chipguarding (if applicable) and personal protectiveequipment. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).Always wear eye protection for cleaning the coolingsystem.

Fluid Penetration


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid Spillage

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” or refer to Special Pub-lication, PECJ0003, “Caterpillar Shop Supplies andTools Catalog” for tools and supplies suitable to col-lect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations andmandates.

10 SEBU7695-15Safety SectionGeneral Hazard Information

Inhalation


Exhaust

Use caution. Exhaust fumes can be hazardous toyour health. If you operate the equipment in anenclosed area, adequate ventilation is necessary.

Asbestos Information

Caterpillar equipment and replacement parts thatare shipped from Caterpillar are asbestos free.Caterpillar recommends the use of only genuineCat replacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestosmaterials.

• A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.

• Use exhaust ventilation on permanent machiningjobs.

• Wear an approved respirator if there is no otherway to control the dust.

• Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposalof asbestos.

• Stay away from areas that might have asbestosparticles in the air.

Lines, Tubes, and HosesDo not bend or strike high-pressure lines. Do notinstall lines, tubes, or hoses that are damaged.

Repair any fuel lines, oil lines, tubes, or hoses thatare loose or damaged. Leaks can cause fires.

Inspect all lines, tubes, and hoses carefully. Donot use bare hands to check for leaks. Alwaysuse a board or cardboard for checking enginecomponents for leaks. Tighten all connections to therecommended torque.

Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Wire that is exposed in reinforced hose

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

Ensure that all of the clamps, the guards, andthe heat shields are installed correctly. Correctinstallation of these components will help to preventthese effects: vibration, rubbing against other parts,and excessive heat during operation.


Burn Prevention

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

i01480768

Burn PreventionSMCS Code: 1000; 4450; 7405

Do not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level after the engine has stoppedand the engine has been allowed to cool.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

i01806909

Fire Prevention and ExplosionPreventionSMCS Code: 1000; 4450; 7405


All fuels, most lubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency shutdown.

Determine whether the engine will be operated in anenvironment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.

12 SEBU7695-15Safety SectionFire Prevention and Explosion Prevention

If the application involves the presence of combustiblegases, consult your Caterpillar dealer for additionalinformation about suitable protection devices.

Remove all flammable materials such as fuel, oil, anddebris from the engine. Do not allow any flammablematerials to accumulate on the engine.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

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

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding or flame cutting.

Wiring must be kept in good condition. All electricalwires must be properly routed and securely attached.Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate theengine. Clean all electrical connections and tightenall electrical connections.

Eliminate all wiring that is unattached or unnecessary.Do not use any wires or cables that are smaller thanthe recommended gauge. Do not bypass any fusesand/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and properlymaintained battery cables will help to prevent arcingor sparking.

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.

Oil filters and fuel filters must be properly installed.The filter housings must be tightened to the propertorque.


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.


Crushing Prevention and Cutting Prevention

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may cause anexplosion.

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

Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Ether (If Equipped)Ether is flammable and poisonous.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

Do not store ether cylinders in living areas or in theengine compartment. Do not store ether cylindersin direct sunlight or in temperatures above 49 °C(120 °F). Keep ether cylinders away from openflames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

DO NOT USE ETHER (starting fluids) unlessspecifically instructed to do so. If the engine isequipped with an Air Inlet Heater (electrically orfuel ignited manifold heater), DO NOT use ether(starting fluids) at any time. The use could resultin engine damage and/or personal injury.

Do not spray ether into an engine if the engine isequipped with a thermal starting aid for cold weatherstarting.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Caterpillar dealer forrepair or for replacement parts.

Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

i01359666

Crushing Prevention andCutting PreventionSMCS Code: 1000; 4450; 7405

Support the component properly when work beneaththe component is performed.

Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.

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

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

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

Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.

14 SEBU7695-15Safety SectionMounting and Dismounting

i01372247

Mounting and DismountingSMCS Code: 1000; 4450; 7405

Inspect the steps, the handholds, and the work areabefore mounting the engine. Keep these items cleanand keep these items in good repair.

Mount the engine and dismount the engine only atlocations that have steps and/or handholds. Do notclimb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine ordismount the engine. Maintain a three-point contactwith the steps and handholds. Use two feet and onehand or use one foot and two hands. Do not use anycontrols as handholds.

Do not stand on components which cannot supportyour weight. Use an adequate ladder or use a workplatform. Secure the climbing equipment so that theequipment will not move.

Do not carry tools or supplies when you mount theengine or when you dismount the engine. Use a handline to raise and lower tools or supplies.

i03560601

Before Starting EngineSMCS Code: 1000

NOTICEFor initial start-up of a new or rebuilt engine, and forstart-up of an engine that has been serviced, makeprovision to shut the engine off should an overspeedoccur. This may be accomplished by shutting off theair and/or fuel supply to the engine.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

Inspect the engine for potential hazards.

Do not start the engine or move any of the controlsif there is a “DO NOT OPERATE” warning tag orsimilar warning tag attached to the start switch or tothe controls.

Before starting the engine, ensure that no one is on,underneath, or close to the engine. Ensure that thearea is free of personnel.

If equipped, ensure that the lighting system for theengine is suitable for the conditions. Ensure that alllights work properly, if equipped.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuits areprovided in order to help prevent personal injury. Thecircuits are also provided in order to help preventengine damage.

See the Service Manual for repairs and foradjustments.

i01807173

Engine StartingSMCS Code: 1000

If a warning tag is attached to the engine start switchor to the controls, do not start the engine or move thecontrols. Also, do not disengage the parking brakes.Consult with the person that attached the warning tagbefore the engine is started.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine from the operator's station (cab).Never short across the starting motor terminals orthe batteries. This could bypass the engine neutralstart system and/or the electrical system could bedamaged.

Always start the engine according to the procedurethat is described in the Operation and MaintenanceManual, “Engine Starting” topic (Operation Section).Knowing the correct procedure will help to preventmajor damage to the engine components. Knowingthe 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 workingproperly, check the water temperature gauge and theoil temperature gauge during the heater operation.

Engine exhaust contains products of combustionthat can be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is started in an enclosed area,vent the engine exhaust to the outside.


Engine Stopping

Ether (If Equipped)

DO NOT USE ETHER (starting fluids) unlessspecifically instructed to do so. If the engine isequipped with an Air Inlet Heater (electrically orfuel ignited manifold heater), DO NOT use ether(starting fluids) at any time. The use could resultin engine damage and/or personal injury.

Ether is poisonous and flammable. Do not inhaleether, and do not allow ether to contact the skin.Personal injury could result. Do not smoke whileether cylinders are changed. Use ether in wellventilated areas.

Keep ether cylinders out of the reach of unauthorizedpersons. Store ether cylinders in authorized storageareas only. Do not store ether cylinders in directsunlight or at temperatures above 39 °C (102 °F).Discard the ether cylinders in a safe place. Do notpuncture the ether cylinders. Do not burn the ethercylinders.

i01462046

Engine StoppingSMCS Code: 1000

Stop the engine according to the procedure inthe Operation and Maintenance Manual, “EngineStopping (Operation Section)” in order to avoidoverheating of the engine and accelerated wear ofthe engine components.

Use the Emergency Stop Button (if equipped) ONLYin an emergency situation. Do not use the EmergencyStop Button for normal engine stopping. After anemergency stop, DO NOT start the engine until theproblem that caused the emergency stop has beencorrected.

Stop the engine if an overspeed condition occursduring the initial start-up of a new engine or an enginethat has been overhauled. This may be accomplishedby shutting off the fuel supply to the engine and/orshutting off the air supply to the engine.

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

i02463889

Electrical SystemSMCS Code: 1000; 1400

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

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative “−” jump start cable should be connectedlast from the external power source to the negative“−” terminal of the starting motor. If the starting motoris not equipped with a negative “−” terminal, connectthe jump start cable to the engine block.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is started. Repair all frayedelectrical wires before the engine is started. See yourOperation and Maintenance Manual, “Starting theEngine” for specific starting instructions.

16 SEBU7695-15Safety SectionEngine Electronics

Grounding Practices

g00943987Illustration 12Typical exampleEngine ground

(1) Recommended connections (2) Alternate connections

g00944000Illustration 13Typical example

Frame ground(1) Recommended connections(2) Alternate connections

Proper grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Improper grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearingjournal surfaces, and to aluminum components.

Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.

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

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

i02784356

Engine ElectronicsSMCS Code: 1000; 1900

Tampering with the electronic system installationor the OEM wiring installation can be dangerousand could result in personal injury or death and/orengine damage.


Engine Electronics

This engine has a comprehensive, programmableEngine Monitoring System. The Engine ControlModule (ECM) has the ability to monitor the engineoperating conditions. If any of the engine parametersextend outside an allowable range, the ECM willinitiate an immediate action.

The following actions are available for enginemonitoring control: WARNING, DERATE, andSHUTDOWN. These engine monitoring modes havethe ability to limit engine speed and/or the enginepower.

Many of the parameters that are monitored by theECM can be programmed for the engine monitoringfunctions. The following parameters can be monitoredas a part of the Engine Monitoring System:

• Operating Altitude

• Engine Coolant Level

• Engine Coolant Temperature

• Engine Oil Pressure

• Engine Speed

• Fuel Temperature

• Intake Manifold Air Temperature

• System Voltage

The Engine Monitoring package can vary for differentengine models and different engine applications.However, the monitoring system and the enginemonitoring control will be similar for all engines.

Note:Many of the engine control systems and displaymodules that are available for Caterpillar Engineswill work in unison with the Engine MonitoringSystem. Together, the two controls will provide theengine monitoring function for the specific engineapplication. Refer to the Troubleshooting Manual formore information.

18 SEBU7695-15Product Information SectionGeneral Information

Product InformationSection

General Informationi03012627

Model View IllustrationsSMCS Code: 1000

C11 and C13 On-highway EnginesKCA1-UP

KCB1-UP

JAM1-UP

g01525065Illustration 14View of the left side of a typical C11 or C13 On-highway Engine

(1) Engine crankcase breather(2) Lifting eyes(3) Engine control module (ECM)

(4) Fuel filter(5) Fuel transfer pump(6) Fuel priming pump

(7) Engine oil filler(8) Air compressor(9) Inlet air manifold

SEBU7695-15 19Product Information Section

General Information

g01525066Illustration 15View of the right side of a typical C11 or C13 On-highway Engine

(10) Low pressure turbocharger(11) High pressure turbocharger(12) Cooler

(13) Water temperature regulator(14) Belt tensioner(15) Vibration damper

(16) Engine oil pump(17) Water pump(18) Engine oil filter

C15 On-highway EnginesBXS1-UP


View of the left side of a typical C15 On-highway Engine

(4) Fuel filter (5) Fuel transfer pump (8) Air compressor


g01525119Illustration 17View of the right side of a typical C15 On-highway Engine

(1) Engine crankcase breather(2) Lifting eyes(10) Low pressure turbocharger(11) High pressure turbocharger

(12) Cooler(13) Water temperature regulator (housing)(15) Vibration damper(17) Water pump

(18) Engine oil filter(19) Exhaust manifold

C15 On-highway EnginesMXS1-UP

NXS1-UP

RXS1-UP

g01525121Illustration 18View of the left side of a typical C15 On-highway Engine

(1) Engine crankcase breather (8) Air compressor (5) Fuel transfer pump


General Information

g01525122Illustration 19View of the right side of a typical C15 On-highway Engine

(2) Lifting eyes(9) Inlet air manifold(10) Low pressure turbocharger

(11) High pressure turbocharger(12) Cooler(13) Water temperature regulator (housing)

(15) Vibration damper(17) Water pump(18) Engine oil filter

i04439612

Product DescriptionSMCS Code: 1000; 4450; 4491

Table 1

C11 (S/N: KCA) On-highway Engine Specifications

Cylinders and Arrangement In-line six-cylinder

Bore 130 mm (5.2 inch)

Stroke 140 mm (5.5 inch)

Displacement 11.1 L (677 in3)

Firing Order 1-5-3-6-2-4

Rotation (flywheel end) Counterclockwise

Table 2

C13 (S/N: KCB; JAM; JAX) On-highwayEngine Specifications


Bore 130 mm (5.2 inch)

Stroke 157 mm (6.2 inch)




Table 3

C15 (S/N: BXS; MXS; NXS; RKS) On-highwayEngine Specifications


Bore 137.2 mm (5.4 inch)

Stroke 171.5 mm (6.8 inch)




The electronic on-highway engines that are coveredby this manual have the following characteristics:direct fuel injection, electronic unit injection that ismechanically actuated, turbocharged, and air-to-airaftercooled (ATAAC).

The electronic engine control system provides thefollowing functions: electronic governing, automaticair to fuel ratio control, torque rise shaping, injectiontiming control, and system diagnostics.

Several programmable features are included inthe electronic control: cruise control, governingthe PTO, vehicle speed limiting, rpm limit for highgears, rpm limit for low gears, top engine limit, idleshutdown timer, and control for the engine retarder(compression brake).


Additional benefits provide engine fuel economy,serviceability, and operator comfort. The additionalbenefits include the following features: improvedcold starting capability, resistance to tampering,diagnostics, progressive shift engine speed control,data link (SAE J1587 ) for the American TruckingAssociation (ATA), and optional Engine MonitoringPackage.

An electronic governor controls the output of the unitinjectors in order to maintain the engine rpm thatis desired. The functions of the governor include aprogrammable low idle and a 20 rpm to 200 rpmgovernor overrun.

High injection pressures are produced byelectronically controlled, mechanically actuated unitinjectors. The injectors combine the pumping and theelectronic fuel metering (duration and timing) duringinjection. The unit injectors accurately control smokelimiting, white smoke, and engine acceleration rates.

Each cylinder has one unit injector. Individual unitinjectors meter the fuel. The individual unit injectorsalso pump the fuel. The metering and the pumping isdone under high pressure. High injection pressureshelp to reduce fuel consumption and emissions.The use of this type of unit injector provides totalelectronic control of injection timing. The injectiontiming varies with engine operating conditions. Theengine performance is optimized in the followingareas:

• Starting

• Emissions

• Noise

• Fuel consumption

• Driveability

The timing advance is achieved through precisecontrol of the injector firing. Engine speed is controlledby adjusting the firing duration. The information isprovided to the Engine Control Module (ECM) by anengine speed/timing sensor. The information is fordetection of cylinder position and engine speed.

The engines have built-in diagnostics in order toensure that all of the components are functioning andoperating properly. If a system component deviatesfrom the programmed limits, the operator is alertedby a “CHECK ENGINE/DIAGNOSTIC” lamp mountedon the dashboard. A Cat provided electronic servicetool or the cruise control switches may be usedto read the numerical code of the diagnostic flashcode. There are three types of diagnostic codes:ACTIVE, LOGGED, and EVENT. These codes arelogged and stored in the ECM. Refer to the Operationand Maintenance Manual, “Engine Diagnostics” foradditional information.

The cooling system consists of the following items:a centrifugal pump that is driven by a gear, watertemperature regulator, an oil cooler, and an OEMsupplied radiator that incorporates a shunt system.

The engine lubricating oil is supplied by a gear pump.The engine lubricating oil is cooled and filtered.Bypass valves provide unrestricted flow of lubricationoil to the engine parts when the oil viscosity is highand when the oil cooler or the oil filter elementsbecome plugged.

Engine efficiency, efficiency of emission controls, andengine performance depend on adherence to properoperation and maintenance recommendations. Thesemaintenance recommendations include the use ofrecommended fuels, coolants, and lubrication oils.

Multitorque Rating (If Equipped)The multitorque ratings provide additional torqueas engine load increases. This feature provideshigher torque levels. This feature also provides betterdriveability while the truck is only in the top gears.The engine electronics are able to determine whenthe vehicle is in the top gears by calculating theengine rpm/vehicle speed ratio.

With the additional torque, the following benefits areprovided: less shifting in rolling terrain, less wear,more responsive, and better engine performance.


General Information

Aftermarket Products and CatEngines

NOTICEIn order to meet expected fuel system componentlife, 4 micron(c) absolute or less secondary fuel fil-tration is required for all Caterpillar Diesel Enginesthat are equipped with unit injected fuel systems. Notethat all current Caterpillar Diesel Engines are factoryequipped with Caterpillar Advanced Efficiency 4 mi-cron(c) absolute fuel filters.

Caterpillar does not warrant the quality or perfor-mance of non-Caterpillar fluids and filters.

The use of auxiliary devices, accessories, orconsumables (filters, additives, catalysts, and otherdevices) which are made by other manufacturers onCat products does not affect the Caterpillar warranty.

However, failures that result from the installationor use of devices from other manufacturers,accessories, or consumables are NOT Caterpillardefects. Therefore, the defects are NOT coveredunder the Caterpillar warranty.

24 SEBU7695-15Product Information SectionProduct Identification Information

Product IdentificationInformation

i04439702

Plate Locations and FilmLocationsSMCS Code: 1000; 4450

Serial Number Plate


C11 and C13 The serial number plate is located onthe left side of the cylinder block near the rear of theengine.


C15 The serial number plate is located on the rightside of the cylinder block near the lower rear cornerof the engine.

The following information is stamped on the serialnumber plate: engine serial number, model, andarrangement number.

Information Plate


C11 and C13 The Information Plate is located on theright side of the engine. The information plate is onthe front half of the inlet manifold.

C15 The Information Plate is located on the front,angled portion of the cylinder head near the sectionof the inlet manifold.

i00844066

Emissions Certification FilmSMCS Code: 1000; 7405

g00284658Illustration 23EPA Emissions Certification Film

g00415538Illustration 24European Emissions Certification Film


Product Identification Information

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

i04440501

Reference InformationSMCS Code: 1000; 4450

Information for the following items may be neededfor ordering parts. Locate the information for yourengine. Record the information in the appropriatespace. Make a copy of this list for your records andretain the information for future reference.

Chassis serial number_____________________________________

Engine model________________________________________________

Engine serial number______________________________________

Engine arrangement number_____________________________

Modification number_______________________________________

Engine low idle rpm________________________________________

Engine full load rpm________________________________________

Performance specification number_____________________

Engine hp____________________________________________________

Primary fuel filter part number___________________________

Water separator element number_______________________

Secondary fuel filter element number__________________

Lubrication oil filter element number___________________

Auxiliary oil filter element number_______________________

Supplemental coolant additive maintenance elementnumber (optional)___________________________________________

Air cleaner element number______________________________

Fan drive belt number_____________________________________

Alternator belt number_____________________________________

Total lubrication system capacity________________________

Total cooling system capacity____________________________

26 SEBU7695-15Operation SectionLifting and Storage

Operation Section

Lifting and Storagei02123539

Product LiftingSMCS Code: 7000; 7002


NOTICENever bend the eyebolts and the brackets. Only loadthe eyebolts and the brackets under tension. Remem-ber that the capacity of an eyebolt is less as the anglebetween the supporting members and the object be-comes less than 90 degrees.

When it is necessary to remove a component at anangle, only use a link bracket that is properly rated forthe weight.

Use a hoist to remove heavy components. Usean adjustable lifting beam to lift the engine. Allsupporting members (chains and cables) should beparallel to each other. The chains and cables shouldbe perpendicular to the top of the object that is beinglifted.

Some removals require lifting the fixtures in order toobtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes thatare on the engine. If the lifting eyes are missing, referto the Parts Manual for the proper lifting eyes andbolts.

Lifting eyes are designed for the specific enginearrangement. These lifting eyes are installed whenthe engine is manufactured. Alterations to the liftingeyes and/or the engine make the lifting eyes andthe lifting fixtures obsolete. If alterations are made,ensure that proper lifting devices are provided.Consult your Caterpillar dealer for informationregarding fixtures for proper engine lifting.

i04137650

Product StorageSMCS Code: 7002

Storage (Less Than One Year)If an engine is not used, oil can run off the followingparts that normally receive lubrication: cylinder walls,piston rings, main bearings, connecting rod bearings,crankshaft, and gears.

This lack of lubricant allows corrosion to begin toappear on the metal. This condition is worse in areasof high humidity.

When the engine is started again, metal to metalcontact will cause wear before the surfaces receiveoil. To minimize this wear, use the starter to turn theengine with the throttle in the FUEL OFF position.When oil pressure is shown on the pressure gauge,start the engine.

1. Clean the engine of any dirt, rust, grease, and oil.Inspect the exterior. Paint areas that contain paintdamage with a good quality paint.

2. Remove dirt from the air cleaners. Check all seals,gaskets, and the filter element for damage.

3. Apply lubricant to all points in this Operationand Maintenance Manual, “Maintenance IntervalSchedule”.

4. Drain the crankcase oil. Replace the crankcase oiland change the oil filters. For the proper procedure,refer to this Operation and Maintenance Manual.

5. If the engine is equipped with an air startingmotor, fill the reservoir with the followingmixture: 50 percent volatile corrosion inhibitoroil (<nomen>VCI oil</nomen>) and 50 percentengine oil.

6. Add VCI oil to the crankcase oil. The volumeof VCI oil in the crankcase oil should be 3 to 4percent.

Note: If the engine crankcase is full, drain enoughengine oil so the mixture can be added.

SEBU7695-15 27Operation SectionLifting and Storage

7. Remove the air filter elements. Turn the engine atcranking speed with the throttle control in FUELOFF position. Use a sprayer to add a mixture of50 percent VCI oil and 50 percent engine oil intothe air inlet or turbocharger inlet.

Note: The mixture of VCI oil can be added to theinlet by removing the plug for checking turbochargerboost pressure. The minimum application rate for theVCI oil mixture is 5.5 mL per L (3 oz per 1000 cu in)of engine displacement.

8. Use a sprayer to apply a mixture of 50 percent VCIoil and 50 percent crankcase oil into the exhaustopenings. The minimum application rate for the oilmixture is 5.5 mL per L (3 oz per 1000 cu in) ofengine displacement. Seal the exhaust pipe andseal any drain holes in the muffler.

9. Remove the fuel from the secondary fuel filterhousing. Alternately, empty and reinstall thespin-on fuel filter element in order to remove anydirt and water. Drain any sleeve metering fuelpump.

Clean the primary fuel filter. Fill with calibrationfluid or kerosene. Install the primary fuel filterand operate the priming pump. This procedurewill send clean oil to the secondary filter and theengine.

Open the fuel tank drain valve in order to drainany water and dirt from the fuel tank. Apply aspray of calibration fluid or kerosene at the rateof 30 mL per 30 L (1 oz per 7.50 gal US) of fueltank capacity in order to prevent rust in the fueltank. Add 0.15 mL per L (.02 oz per 1 gal US) ofcommercial biocide such as Biobor JF to the fuel.

Apply a small amount of oil to the threads onthe fuel tank filler neck and install the cap. Sealall openings to the tank in order to preventevaporation of the fuel and as a preservative.

10.Remove the fuel nozzles or spark plugs. Apply30 mL (1 oz) of the mixture of oils (50 percent VCIoil and 50 percent engine oil) into each cylinder.

Use a bar or a turning tool in order to turn overthe engine slowly. This procedure puts the oil onthe cylinder walls. Install all fuel nozzles or sparkplugs and tighten to the correct torque.

11.Spray a thin amount of a mixture of 50 percentVCI oil and 50 percent engine oil onto the followingcomponents: flywheel, ring gear teeth, and starterpinion. Install the covers in order to preventevaporation of the vapors from the VCI oil.

12.Apply a heavy amount of Cat MultipurposeGrease (MPGM) to all outside parts that move,such as rod threads, ball joints, linkage.

Note: Install all covers. Ensure that tape has beeninstalled over all openings, air inlets, exhaustopenings, the flywheel housing, the crankcasebreathers, the dipstick tubes.

Ensure that all covers are airtight andweatherproof. Use a waterproof weather resistanttape such as Kendall No. 231 or an equivalent. Donot use duct tape. Duct tape will only seal for ashort time.

13.Under most conditions, removing the batteriesis the best procedure. As an alternative, placethe batteries in storage. As needed, periodicallycharge the batteries while the batteries are instorage.

If the batteries are not removed, wash the topsof the batteries until the tops are clean. Apply anelectrical charge to the batteries in order to obtaina specific gravity of 1.225.

Disconnect the battery terminals. Place a plasticcover over the batteries.

Note: For additional information, refer to SpecialInstruction, SEHS7633, “Battery Test Procedure”.

14. Loosen all belts.

15.Place a waterproof cover over the engine. Ensurethat the engine cover is secure. The cover shouldbe loose enough to allow air to circulate aroundthe engine in order to prevent damage fromcondensation.

16.Attach a tag with the storage date to the engine.

17.Remove the waterproof cover at 2 month or 3month intervals in order to check the engine forcorrosion. If the engine has signs of corrosion,repeat the protection procedure.

Coolant System

Completely fill the cooling system before storage.

Refer to this Operation and Maintenance Manual,“Fluid Recommendations” for more information aboutcoolants.

Removal from Storage1. Remove all outside protective covers.

2. Change the oil and filters.

28 SEBU7695-15Operation SectionLifting and Storage

3. Check the condition of the fan and alternatorbelts. Replace the belts, if necessary. Refer tothis Operation and Maintenance Manual, “Belts -Inspect/Adjust/Replace” for the correct procedure.

4. Replace the fuel filter elements.

5. Remove the plastic covers from the air cleanerelements.

6. Use a bar or a turning tool in order to turn theengine in the normal direction of rotation. Theprocedure ensures that no hydraulic locks orresistance exist.

7. Before starting the engine, remove the valve coveror covers. Put a large amount of engine oil on thecamshaft, cam followers, and valve mechanism inorder to prevent damage to the mechanism.

8. Pressure-lubricate the engine before starting theengine. Pressure lubricating the engine ensuresimmediate lubrication and prevents damage tothe engine during the first few minutes of engineoperation. If the engine is not equipped witha prelube pump, contact your Cat dealer forinformation about lubrication of the engine beforestarting the engine.

9. Check the condition of all rubber hoses. Replaceany worn hoses. Replace any damaged hoses.

10.Before start-up, test the cooling system for a 3percent ro a 6 percent concentration of coolantconditioner. Add liquid coolant conditioner or acoolant conditioner element, if equipped.

Test the coolant mixture for proper nitrite level. Ifnecessary, adjust the coolant mixture.

Prime the engine with clean diesel fuel beforestarting.

11.Ensure that the cooling system is clean. Ensurethat the system is full. Ensure that the systemhas the correct amount of supplemental coolingsystem conditioner.

12.On the first day of operation, check the entireengine several times for leaks and correctoperation.

13. If the engine was removed from storage in whichtemperatures of less than -12°C (10°F) wereencountered, refer to Service Manual, SEBU5898,“Cold Weather Recommendations Operation andMaintenance”.

SEBU7695-15 29Operation Section

Features and Controls

Features and Controlsi01955111

Cold Start StrategySMCS Code: 1450; 1456; 1900

These engines use a cold start strategy that limitspower until the coolant temperature reaches28 °C (82 °F). This cold start strategy is called coldmode. The electronic system will automatically idlethe C11 and C13 engines at 800 RPM . The electronicsystem will automatically idle C15 engines at 600RPM . Cold mode will also vary the fuel injectionamount, the timing for the maximum start-up, and thetiming for the control of white smoke. Cold mode willprovide reduced emissions and reduced warm-uptimes. Cold mode will be disabled and the enginerpm will drop to the programmed low idle speed if thethrottle, the service brake, or the clutch is depressed.

The engine should be operated at low rpm and lowpower demand until the engine reaches normaloperating temperature. The engine will reach normaloperating temperature faster when the engine isoperated at low rpm and low power demand insteadof idling the engine until the engine reaches normaloperating temperature.

NOTICEA truck should not be moved until it is out of the coldmode. If the truck is operated while in cold mode, pow-er will be noticeably reduced.

i02433210

Gauges and IndicatorsSMCS Code: 7450

Your engine may not have the same gauges or all ofthe gauges that are described. For more informationabout the gauge package, see the literature from theOEM.

Gauges provide indications of engine performance.Ensure that the gauges are in good working order.Determine the normal operating range by observingthe gauges over a period of time.

Noticeable changes in gauge readings indicatepotential gauge or engine problems. Problems mayalso be indicated by gauge readings that changeeven if the readings are within specifications.Determine the cause of any significant change in thereadings. Then, correct any cause of any significantchange in the readings. Consult your Caterpillardealer for assistance.

Electronically controlled engines require one lampin addition to the gauge package that is normallyprovided.

The “Diagnostic” lamp is yellow or amber. The“Diagnostic” lamp will communicate the status of theengine's electronic system.

An optional “Warning” lamp is available. Thisred “Warning” lamp warns the operator of engineproblems.

The following conditions are some examples of theproblems:

• Low oil pressure

• High coolant temperature

• Low coolant level

• High inlet air temperature

Engine Oil Pressure – Typical oilpressure for an engine at rated speedwith SAE 10W30 or with SAE 15W40 is

207 to 310 kPa (30 to 45 psi) for the C11. Typicaloil pressure for an engine at rated speed with SAE10W30 or with SAE 15W40 is 276 to 606 kPa(40 to 88 psi) for the C13, and C15.

A higher oil pressure is normal with cold oil when theengine is started. A lower oil pressure is normal atlow idle. If the load is stable and the gauge readingchanges, 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 theproper amount.

The diagnostic lamp will turn on if the oil pressuredrops below 35 kPa (5 psi) at low idle rpm. Thediagnostic code will be logged in the Engine ControlModule (ECM).

Engine Oil Temperature – This gaugeindicates the engine oil temperature. Anoil temperature that is higher than normal

indicates a heat problem in the lubrication systemand/or the cooling system. This problem can damagethe cylinder heads, the cylinder liners, the pistons,and the crankshaft bearings.

30 SEBU7695-15Operation SectionFeatures and Controls

Jacket Water Coolant Temperature –Typical temperature range is 87 to 98° C(189 to 208° F). The maximum allowable

temperature with the pressurized cooling system is102° C (216° F) for the C11. The maximum allowabletemperature with the pressurized cooling systemis 107° C (225° F) for the C13, and C15. Highertemperatures may occur under certain conditions.The water temperature reading may vary accordingto load. The reading should never exceed the boilingpoint for the pressurized system that is being used.

If the engine is operating above the normal rangeand steam becomes apparent, perform the followingprocedure:

1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut downimmediately or if the engine can be cooled byreducing the load.

NOTICEDo not exceed 2300 rpm in any situation or 2100 rpmif equipped with an auxiliary engine brake system.

Tachometer – This gauge indicates enginespeed. The engine can be operated athigh idle without damage, but the engine

should not be allowed to overspeed. The enginecan overspeed by downshifting or by going downhill.An overspeed can result in serious damage to theengine.

Note: The high idle rpm and the full load rpm arestamped on the Information Plate.

Ammeter – This gauge indicates theamount of a charge or of discharge in thebattery charging circuit. Operation of the

indicator should be to the right side of “0”(zero). Thecharging system should be checked for a malfunctionif the indicator is constantly to the left side of “0”(zero)or if the indicator shows an excessive charge duringnormal operation. Correct any problems.

Service Hour Meter – This gaugeindicates the total operating hours of theengine. Hours of operation are logged in

the ECM. A service tool is needed to retrieve thehours from the ECM. A Service Hour Meter may beinstalled on the engine.

Fuel Pressure – This gauge indicates fuelpressure to the electronic unit injectors fromthe fuel filter. The indicator should indicate

the “NORMAL” range. A decrease in fuel pressureusually indicates a plugged fuel filter.

Fuel Level – This gauge indicates thelevel of fuel in the fuel tank. The fuel levelgauge registers the fuel level only when the

ignition switch is in the ON position.

i03636164

Monitoring SystemSMCS Code: 1900; 7400; 7450; 7451

If the Shutdown mode has been selected and thewarning indicator activates, engine shutdownmaytake as little as 20 seconds from the time the warn-ing indicator is activated. Depending on the ap-plication, special precautions should be taken toavoid personal injury. The engine can be restartedfollowing shutdown for emergency maneuvers, ifnecessary.

NOTICEThe Engine Monitoring System is not a guaranteeagainst catastrophic failures. Programmed delaysand derate schedules are designed to minimize falsealarms and provide time for the operator to stop theengine.

Programmable features monitor the followingconditions:

• Coolant temperature

• Oil pressure

• Inlet manifold air 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 thefollowing options:

“ENABLED” – The system will monitor the inputfrom the coolant level sensor. The system isprogrammed to this value when the engine is shippedby Caterpillar.


Features and Controls

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

Programmable Options andSystems Operation

If the Warning/Derate/Shutdown mode has beenselected and the warning indicator activates,bring the engine to a stop whenever possible. De-pending on the application, special precautionsshould be taken to avoid personal injury.

The engine can be programmed to the followingmodes:

• “OFF”

• “Warning”

• “Warning/Derate”

• “Warning/Derate/Shutdown”

“Warning”

The “DIAGNOSTIC” lamp and the warning signal (redlamp or buzzer) turn “ON” and the warning signal isactivated continuously in order to alert the operatorthat one or more of the engine parameters is notwithin normal operating range.

“Warning/Derate”

The “DIAGNOSTIC” lamp turns “ON” and the warningsignal (red lamp or buzzer) is activated. After thewarning, the engine will derate rpm and power. Thewarning lamp will begin to flash when the deratingoccurs.

When the engine is fully derated, the engine power islimited to 120 kW (160 hp). During a low oil pressurecondition, the engine can be limited to 1350 rpm.

“Warning/Derate/Shutdown”

The “DIAGNOSTIC” lamp turns “ON” and the warningsignal (red lamp or buzzer) is activated. After thewarning, the engine will derate rpm and power. Theengine will continue to derate rpm until a shutdown ofthe engine occurs. The engine can be restarted aftera shutdown for use in an emergency.

A shutdown of the engine may occur in as littleas 20 seconds. The engine can be restarted aftera 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 20seconds.

If there is a signal for coolant loss, there will be a 10second delay in order to verify the condition. Thesystem will derate the engine rpm for 40 secondsbefore the engine will shut down if the engine hasbeen programmed to shut down.

If there is a signal for low oil pressure or for coolanttemperature, there will be a two second delay inorder to verify the condition. The system will deratethe engine rpm for 30 seconds before the enginewill shut down if the engine has been programmedto shutdown.

For more information or assistance for repairs,consult your Caterpillar dealer.

Note: The customer specified parameters may besecured by customer passwords. The engine mayhave all of the parameters that are programmedor any combination of the parameters thatare programmed. Refer to the Operation andMaintenance Manual, “Configuration Parameters”topic for more information on the programmedparameters of the engine.

32 SEBU7695-15Operation SectionEngine Diagnostics

Engine Diagnosticsi01563934

Self-DiagnosticsSMCS Code: 1000; 1900; 1901; 1902

Caterpillar Electronic Engines have the capability toperform a self-diagnostics test. When the systemdetects an active problem, the “DIAGNOSTIC”lamp is activated. Diagnostic codes will be stored inpermanent memory in the Electronic Control Module(ECM). The diagnostic codes can be retrieved byusing the following components:

• Caterpillar electronic service tools

• “DIAGNOSTIC” lamp

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

Some installations have electronic displays thatprovide direct readouts of the engine diagnosticcodes. Refer to the manual that is provided by theOEM for more information on retrieving enginediagnostic codes.

Active codes represent problems that currently exist.These problems should be investigated first. If a codeis active, the “DIAGNOSTIC” lamp will flash the flashcode at five second intervals.

Logged codes represent the following items:

• Intermittent problems

• Recorded events

• Performance history

The problems may have been repaired since thelogging of the code. These codes do not indicate thata repair is needed. The codes are guides or signalswhen a situation exists. Codes may be helpful totroubleshoot problems.

When the problems have been corrected, thecorresponding logged fault codes should be cleared.

i01563946

Diagnostic LampSMCS Code: 1000; 1900; 1901; 1902; 7451

The “DIAGNOSTIC” lamp is used to indicatethe existence of a fault by flashing codes. The“DIAGNOSTIC” lamp that is on the dashboard isusually “YELLOW”.

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

• The “DIAGNOSTIC” lamp will illuminate for fiveseconds.

• The “DIAGNOSTIC” lamp will turn off.

Whenever the Engine Control Module (ECM) detectsan active fault or condition the lamp will flash at fivesecond intervals. If the lamp turns on and if the lampstays on after initial start-up, the ECM has detecteda system problem.

The “DIAGNOSTIC” lamp is also used for the IdleShutdown Timer. The lamp will start to flash at arapid rate 90 seconds before the programmed idletime expires. The engine will shut down after the90 second interval. To disable the Idle ShutdownTimer, the “ALLOW IDLE SHUTDOWN OVERRIDE”must be programmed to “YES”. The clutch pedal orthe service brake pedal must be depressed duringthe final 90 seconds while the “YELLOW” lamp isflashing. A diagnostic “EVENT” code or Override ofthe Idle Shutdown Timer will be logged in the ECM.

i03102344

Diagnostic Flash CodeRetrievalSMCS Code: 1000; 1900; 1901; 1902

“Diagnostic” LampUse the “DIAGNOSTIC” Lamp or a Caterpillarelectronic service tool to determine the diagnosticflash code.

Use the following procedure to retrieve the diagnosticcodes if the engine is equipped with a “DIAGNOSTIC”lamp:

1. Turn the cruise control ON/OFF switch to the OFFposition.

SEBU7695-15 33Operation SectionEngine Diagnostics

2. Move the SET/RESUME switch to either position.Hold that position until the “YELLOW” lamp beginsto flash.

The “YELLOW” lamp will flash in order to indicatea two digit flash code and the SET/RESUMEswitch may be released. The sequence of flashesrepresents the system diagnostic message. Countthe first sequence of flashes in order to determine thefirst digit of the diagnostic code. After a two secondpause, the second sequence of flashes will identifythe second digit of the diagnostic code.

Any additional diagnostic codes will follow aftera pause. The additional diagnostic codes will bedisplayed in the same manner. Flash Code 55 signalsthat No Detected Faults have occurred since theignition keyswitch has been turned to the ON position.

Refer to the Service Manual or consult an authorizedCaterpillar dealer for the following items.

• Further information

• Assistance for repairs

• Troubleshooting

The electronic diagnostic codes are listed anddescribed in Table 4.

Note: Table 4 indicates the potential effect on engineperformance with “ACTIVE” flash codes.

Some codes record events or some codes indicatethat a mechanical system needs attention rather thanindicating a performance problem. Troubleshooting isnot required for codes “35”, “41”, “47” and “55”. Code“01” will not flash. Some codes will limit the operationor the performance of the engine.

Table 4 indicates the potential effect on the engineperformance with active flash codes. Table 4 alsoforms a list of Electronic diagnostic codes anddescriptions.

Table 4

Diagnostic Flash Code or Engine Performance Relationship

Effect On EnginePerformance(1)

Suggested Action of theOperator

DiagnosticFlash Code

Misfire LowPower

LossofRPM

ShutDown

StopEngine(1)

ServiceEngine(2)

ScheduleEngineService(3)

01IdleShutdownOverride

12CoolantLevel SensorFault(5)

X

(continued)


(Table 4, contd)





Misfire LowPower

LossofRPM

ShutDown

StopEngine(1)

ServiceEngine(2)


13FuelTemperatureSensor Fault

X

14RetarderSolenoidFault

X

21

SensorSupplyVoltageFault(5)(6)

X X

24Oil PressureSensor fault(5)

X

25

BoostPressureSensorFault(6)

X X

26

BarometricPressureSensorFault(6)

X

27CoolantTemperatureSensorFault(5)(6)

X

28

AcceleratorPedalPositionOut ofCalibration

X

29PTO ThrottlePositionSensor Fault

X X

31

Loss ofVehicleSpeedSignal

X X

32AcceleratorPedalPositionInvalid

X X

34 Engine RPMSignal Fault X X X X

35EngineOverspeedWarning

(continued)


(Table 4, contd)





Misfire LowPower

LossofRPM

ShutDown

StopEngine(1)

ServiceEngine(2)


36

Wheel-BasedVehicleSpeedSignal Fault

X X

38

IntakeManifold AirTemperatureSensorFault(5)(6)

X

41

Wheel-BasedVehicleOverspeedWarning

42

CheckEngineSpeedSensorCalibrations

X X

46Low OilPressureWarning

X X X X X

47Idle or PTOShutdownOccurrence

X

51

IntermittentBatteryPower toECM

X X X X

55 No DetectedFaults

CheckCustomerParametersor SystemParameters

X X X

56CheckCustomerTransmissionParameters

59IncorrectEngineSoftware

X

61High CoolantTemperatureWarning

X X X

(continued)


(Table 4, contd)





Misfire LowPower

LossofRPM

ShutDown

StopEngine(1)

ServiceEngine(2)


62Low CoolantLevelWarning

X X X

64

High IntakeManifold AirTemperatureWarning

X

65High FuelTemperatureWarning

X

66AuxiliaryOutput # 6Fault

X

67AuxiliaryOutput #7Fault

X

68TransmissionNotResponding

X

69MultifunctionNo. 1 OutputFault

X

71IgnitionKeyswitchFault

X

72 Cylinder 1 or2 Fault X X X



92Intake ValveActuator 1 or2 Fault

X


X


X

95

Intake ValveActuationOil PressureVoltage Fault

X

(continued)


(Table 4, contd)





Misfire LowPower

LossofRPM

ShutDown

StopEngine(1)

ServiceEngine(2)


97

Intake ValveActuationSystem OilPressureSolenoidCurrent Fault

X

98

EngineCoolantDiverterSolenoidFault

X

(1) An “X” indicates that the effect on engine performance may occur, if the code is active.This depends on the exact failure.

(1) Stop the Engine: Operate the engine cautiously. Get immediate service. Severe enginedamage may result.

(2) The operator should go to the nearest location that has a qualified service program.(3) Schedule Service: The problem should be investigated when the operator has accessto a qualified service program.

(5) When the diagnostic flash code is active, the effectiveness of the Engine Monitoringfeature is reduced.

(6) The system may be affected by these Diagnostic Flash Codes, only under specificenvironmental conditions. This includes engine start-up at cold temperature, coldweather operation at high altitudes, etc.

For further information or assistance for repair,consult an authorized Caterpillar dealer.

i01174828

ECM SnapshotSMCS Code: 1901

The ECM can record a snapshot of the engineparameters and vehicle parameters. The snapshotrecords the parameters for a period of 13 secondsthat surrounds the event, 9 seconds before thetrigger and 4 seconds after the trigger. A techniciancan use a service tool in order to view this snapshotinformation.

Triggering Snapshot InformationAn operator can aid in the troubleshooting ofintermittent problems by taking a “snapshot” whenthe problem is experienced. A snapshot can betriggered by using the Cruise Control Set/ResumeSwitch. Use the following procedure in order toperform this function:

g00627693Illustration 26(1) OFF position(2) SET position(3) RESUME position

1. Toggle the switch quickly from the OFF position(1) to the SET position (2).

2. Toggle the switch quickly from the SET position(2) to the RESUME position (3).

3. Toggle the switch quickly from the RESUMEposition (3) back to the OFF position (1).


Note: The switch must be toggled within a onesecond time period in order to take a snapshot ofthe engine parameters. The procedure can also beperformed in the reverse order.

Storage of Snapshots In the ECMThe ECM can store a maximum of four snapshotsthat are triggered manually. The newest snapshot willreplace the oldest snapshot if a fifth snapshot that istriggered manually is taken.

Snapshots are automatically cleared by the ECMafter 100 hours of operation. Also, the snapshots canbe cleared manually by using an Electronic ServiceTool.

i03840813

Fault LoggingSMCS 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 belogged in the memory of the ECM. The codes thathave been logged in the memory of the ECM canbe retrieved with Caterpillar electronic service tools.The codes that have been logged can be clearedwith Caterpillar electronic service tools. The codesthat have been logged in the memory of the ECMwill be automatically cleared from the memory after100 hours. The following faults cannot be clearedfrom the memory of the ECM without using a factorypassword: overspeed, low engine oil pressure, andhigh engine coolant temperature.

i02922329

Engine Operation with ActiveDiagnostic CodesSMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp stays on during normal engineoperation, the system has identified a situation that isnot within the specification. Use Caterpillar electronicservice tools to check the active diagnostic codes.

Note: If the customer has selected “DERATE” and ifthere is a low oil pressure condition, the ElectronicControl Module (ECM) will limit the engine poweruntil the problem is corrected. If the oil pressure iswithin the normal range, the engine may be operatedat the rated speed and load. However, maintenanceshould be performed as soon as possible.

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

Operation of the engine and performance of theengine can be limited as a result of the activediagnostic code that is generated. Acceleration ratesmay be significantly slower.

Refer to the following publications for moreinformation on flash codes: Operation andMaintenance Manual, “Diagnostic Flash CodeRetrieval” and Troubleshooting, “Effect of DiagnosticCodes on Engine Performance”.


i01710618

Engine Operation withIntermittent Diagnostic CodesSMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp illuminates during normalengine operation and the diagnostic lamp shuts off,an intermittent fault may have occurred. If a fault hasoccurred, the fault will be logged into the memory ofthe Electronic Control Module (ECM).

In most cases, it is not necessary to stop the enginebecause of an intermittent code. However, theoperator should retrieve the logged fault codesand the operator should reference the appropriateinformation in order to identify the nature of the event.The operator should log any observation that couldhave caused the lamp to light.

• Low power

• Limits of the engine speed

• Excessive smoke, etc

This information can be useful to help troubleshootthe situation. The information can also be used forfuture reference. For more information on diagnosticcodes, refer to the Troubleshooting Guide for thisengine.

i03636115

Configuration ParametersSMCS Code: 1000; 1900; 1901; 1902

There are two types of configurationparameters:system configuration parametersand customer configuration parameters.

System Configuration ParametersSystem configuration parameters affect the emissionsof the engine or the power of the engine. Theparameters are stored in the Engine Control Module(ECM). Use the Caterpillar Electronic Technician (ET)to view the values of the parameters and change thevalues of the parameters. Refer to TroubleshootingGuide, “System Configuration Parameters” for furtherinformation.

Customer ConfigurationParametersCustomer specified parameters allow the vehicleowner to influence the operating technique of a driver.Some parameters may affect engine operation in away that would not be expected by an inadequatelytrained driver. These parameters may lead to poweror performance complaints even though the engine'sperformance is within the engine's specification.

Customer parameters may be changed repeatedlyas a customer's operation changes or as new driversare assigned to a truck. Customer passwords arerequired to change these parameters. The customerpassword must be programmed into the EngineControl Module (ECM).

Refer to Troubleshooting Guide, “Customer SpecifiedParameters” and refer to Troubleshooting Guide,“Customer Specified Parameters Table” for furtherinformation.

Worksheet for Customer SpecifiedParameters

Use the following worksheet in order to record theparameters for your engine.

Table 5

Selected Engine Rating

Rating Number

Rating Type

Multitorque Ratio

Advertised Power

Governed Speed

Rated Peak Torque

Top Engine Speed Range

Test Spec

Test Spec with BrakeSaver

Table 6

ECM Identification Parameters

Vehicle ID

Engine Serial Number

ECM Serial Number

Personality Module PartNumber

Personality ModuleRelease Date


Table 7

Security Access Parameters

Total Tattletale

Last Tool to changeCustomer Parameters

Last Tool to change SystemParameters

ECM WirelessCommunication Enable

Table 8

Vehicle Speed Parameters

Vehicle Speed Calibration

Vehicle Speed Cal (J1939- Trans)

Vehicle Speed Cal (J1939- ABS)

Vehicle Speed Limit (VSL)

VSL Protection

Tachometer Calibration

Soft Vehicle Speed Limit

Two Speed Axle - LowSpeed Range Axle Ratio

Nominal Axle Ratio - HighSpeed Range Axle Ratio

Table 9

Cruise Control Parameters

Low Cruise Control SpeedSet Limit

High Cruise Control SpeedSet Limit

Cruise/Idle/PTO SwitchConfiguration

Soft Cruise Control

Adaptive Cruise ControlEnable

Table 10

Idle Parameters

Idle Vehicle Speed Limit

Idle RPM Limit

Idle/PTO RPM Ramp Rate

Idle/PTO Bump RPM

Table 11

Dedicated PTO Parameters

PTO Configuration

PTO Top Engine Limit

PTO Engine RPM SetSpeed (0 = Off)

PTO Engine RPM SetSpeed

PTO Engine RPM SetSpeed A

PTO Engine RPM SetSpeed B

PTO to Set Speed

Maximum PTO EnableSpeed

PTO Cab Controls RPMLimit

PTO Kickout VehicleSpeed Limit

Max PTO Vehicle Speed

Torque Limit

PTO Shutdown Time (0 =Off)

PTO Shutdown TimerMaximum RPM

PTO Activates Cooling Fan


Table 12

Engine/Gear Parameters

Lower Gears Engine rpmLimit

Lower Gears Turn OffSpeed

Intermediate Gears EngineRPM Limit

Intermediate Gears TurnOff Speed

Gear Down ProtectionRPM Limit

Gear Down ProtectionTurn On Speed

Low Idle Engine RPM

Transmission Style

Eaton Top 2 Override withCruise Switch

Top Gear Ratio

Top Gear Minus One Ratio

Top Gear Minus Two Ratio

Governor Type

Table 13

Timer Parameters

Idle Shutdown Time (0 =Off)

Idle Shutdown TimerMaximum RPM

Allow Idle ShutdownOverride

Minimum Idle ShutdownOutside Temp

Maximum Idle ShutdownOutside Temp

A/C Switch Fan On-Time(0 = Off)

Table 14

Smart Idle Parameters

Battery Monitor and EngineControl Voltage

Table 15

Engine Monitoring Parameters

Engine Monitoring Mode

Engine Monitoring Lamps

Coolant Level Sensor

Engine CoolantTemperature DerateEnable Status

Table 16

Maintenance Parameters

Maintenance IndicatorMode

PM 1 Interval

Engine Oil Capacity

Table 17

Trip Parameters

Fuel Correction Factor

Dash - Change FuelCorrection Factor

Dash - PM 1 Reset

Dash - Fleet Trip Reset

Dash - State Selection

Theft Deterrent SystemControl

Theft Deterrent Password

Quick Stop Rate

Vehicle OverspeedThreshold

Table 18

Vehicle Activity Report Parameters

Minimum Idle Time (0 =Off)

Table 19

Driver Reward

Driver Reward Enable


Table 20

Input Selections

Fan Override Switch

Transmission NeutralSwitch

Ignore Brake/Clutch Switch

Torque Limit Switch

Diagnostic Enable

PTO On/Off Switch

Remote PTO Set Switch

Remote PTO ResumeSwitch

PTO Engine RPM SetSpeed Input A

PTO Engine RPM SetSpeed Input B

Starting Aid On/Off Switch

Two Speed Axle Switch

Cruise Control On/OffSwitch

Cruise ControlSet/Resume/Accel/DecelSwitch

Cruise Control PauseSwitch

Clutch Pedal PositionSwitch

Service Brake PedalPosition Switch #1

Accelerator Pedal Position

Vehicle Speed Input

Table 21

Output Selections

Engine Running Output

Engine Shutdown Output

Auxiliary Brake

Starting Aid Output

Air Inlet Shutoff RelayControl

Fan Control Type

PTO Active Output

Table 22

Customer Passwords

Customer Password #1

Customer Password #2

Table 23

Data Link Parameters

Power train Data Link

Lifetime Totals Worksheet

Table 24

Lifetime Totals Worksheet

Total Time

Total PTO Time

Total Idle Time

Total Distance

Total Fuel

Total PTO Fuel

Total Idle Fuel

Total Maximum Fuel

Average Load Factor

SEBU7695-15 43Operation SectionEngine Starting

Engine Startingi01710630

Starting the EngineSMCS Code: 1000; 1450

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

Under-the-Hood InspectionPerform the required daily maintenance and otherperiodic maintenance before the engine is started.Inspect the engine compartment. This inspection canhelp prevent major repairs at a later date. Refer to theOperation and Maintenance Manual, “Walk-AroundInspection” topic (Maintenance Section) for moreinformation.

• For the maximum service life of the engine, makea thorough inspection before starting the engine.Look for the following items: oil leaks, coolantleaks, loose bolts, and trash buildup. Remove trashbuildup and arrange for repairs, as needed.

• Inspect the cooling system hoses for cracks andfor loose clamps.

• Inspect the alternator and accessory drive belts forcracks, breaks, and other damage.

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

• Check the fuel supply. Drain water from the waterseparator (if equipped). Open the fuel supply valve.

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

• Ensure that the areas around the rotating parts areclear.

• All of the guards must be put in place. Check fordamaged guards or for missing guards. Repairany damaged guards. Replace damaged guardsand/or missing guards.

• Disconnect any battery chargers that are notprotected against the high current drain thatis created when the electric starting motor (ifequipped) is engaged. Check electrical cablesand check the battery for poor connections andfor corrosion.

• Reset all of the shutoffs or alarm components.

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

• Check the coolant level. Observe the coolant levelin the coolant recovery tank (if equipped). Maintainthe coolant level to the “FULL” mark on the coolantrecovery tank.

• If the engine is not equipped with a coolantrecovery tank maintain the coolant level within13 mm (.5 inch) of the bottom of the filler pipe.

• Observe the air cleaner service indicator (ifequipped). Service the air cleaner when the yellowdiaphragm enters the red zone, or when the redpiston locks in the visible position.

• Ensure that any driven equipment has beendisengaged. Remove any electrical loads.

Cold Weather StartingStarting the engine and operation in cold weatheris dependent on the type of fuel that is used, the oilviscosity, and other optional starting aids. For moreinformation, refer to the Operation and MaintenanceManual, “Cold Weather Operation” topic (OperationSection).

Starting the Engine

DO NOT USE ETHER (starting fluids) unlessspecifically instructed to do so. The use couldresult in engine damage and/or personal injury.

When using starting fluid, follow the manufactur-er's instructions carefully. Use starting fluid spar-ingly and spray it ONLY WHILE CRANKING THEENGINE. Excessive ether can cause piston andring damage. Use ether for cold weather startingpurposes only.

Use the following procedure in order to start theengine:

44 SEBU7695-15Operation SectionEngine Starting

1. Engage the parking brake. Place the transmissionin NEUTRAL. If the vehicle is equipped with amanual transmission, depress the clutch pedalin order to disengage the flywheel clutch. Thisreduces transmission drag and this preventsmovement of the vehicle. Depressing the clutch incold weather can mean the difference betweenstarting the engine and not starting the engine.Depressing the clutch helps to reduce the batterydrain.

2. Turn the ignition key switch to the ON position.The “CHECK ENGINE/DIAGNOSTIC” lampwill illuminate for 5 seconds when the ignitionkey switch is first turned on. If the lamp failsto illuminate, notify your authorized Caterpillardealer. If the lamp continues to stay on, the ECMhas detected a problem in the system. Refer tothe Operation and Maintenance Manual, “EngineDiagnostics” topic (Operation Section).

NOTICEDo not engage the starting motor when flywheel isturning. Do not start the engine under load.

If the engine fails to start within 30 seconds, releasethe starter switch or button and wait two minutes toallow the starting motor to cool before attempting tostart the engine again.

3. Turn the ignition key switch to the START positionin order to crank the engine. Do not push thethrottle or hold the throttle downward while theengine is cranked. The system will automaticallyprovide the correct amount of fuel in order tostart the engine. If the engine does not start after30 seconds of cranking, release the ignition keyswitch. Turn the ignition key switch to the OFFposition. Allow the starting motor to cool for twominutes. Repeat Steps 2 and 3.

NOTICEOil pressure should rise within 15 seconds after theengine starts. Do not increase engine speed until theoil pressure gauge indicates normal. If oil pressureis not indicated on the gauge within 15 seconds, DONOT operate the engine. STOP the engine, investi-gate and correct the cause.

4. Release the ignition key switch to the ON or RUNposition immediately after the engine starts. Afterthe engine starts, ensure that the transmissionis still in the NEUTRAL position and releasethe clutch pedal (manual transmission). Once anormal engine oil pressure and air pressure arereached, the vehicle may be operated at a lightload and low speed.

Starting ProblemsAn occasional starting problem may be caused byone 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 thefuel tank and prime the fuel system. Refer to theOperation and Maintenance Manual, “Fuel System -Prime” topic (Maintenance Section).

If the other problems are suspected, perform theappropriate procedure in order to start the engine.

Problems with the Wiring HarnessLocate the ECM. Two harness connectors areattached to the ECM. The left connector is theengine harness and the right connector is the chassisharness. Check the connectors in order to ensurethat the connectors are secure. Lightly pull each ofthe wires in the chassis harness.

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

2. If a wire is loose, push the wire back into theconnector. Pull the wire again in order to ensurethat the wire is secure.

3. Start the engine. If the engine does not start,consult the nearest Caterpillar dealer forassistance.

i03640789

Starting with Jump StartCablesSMCS Code: 1000; 1401; 1402; 1900

Improper jump start cable connections can causean explosion resulting in personal injury.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jump startcable ends to contact each other or the engine.

If the installation is not equipped with a backupbattery system, it may be necessary to start theengine from an external electrical source.

SEBU7695-15 45Operation SectionEngine Starting

For information on troubleshooting the chargingsystem, refer to Special Instruction, REHS0354,“Charging System Troubleshooting”.

Many batteries which are considered unusable arestill rechargeable. After jump starting, the alternatormay not be able to fully recharge batteries thatare severely discharged. The batteries must becharged to the proper voltage with a battery charger.For information on testing and charging, refer tothe Special Instruction, SEHS7633, “Battery TestProcedure”.

NOTICEUse a battery that is sourced with the same voltage asthe electric starting motor. Use ONLY equal voltage forjump starting. The use of higher voltage will damagethe electrical system.

Do not reverse the battery cables. The alternator canbe damaged. Attach the negative battery cable lastand remove the negative battery cable first.

When an external electrical source is used to start theengine, turn the control switch on the generator set tothe “OFF” position. Turn all electrical accessories OFFbefore attaching the jump start cables.

Ensure that the main power switch is in the OFF po-sition before jump start cables are attached to the en-gine that is being started.

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

2. Connect one positive end of the jump start cableto the positive cable terminal of the dischargedbattery. Connect the other positive end of the jumpstart cable to the positive cable terminal of thecharging or starting source.

3. Connect one negative end of the jump start cableto the negative cable terminal of the charging orstarting source. Connect the other negative endof the jump start cable to the stalled engine blockor to the chassis ground. This procedure helps toprevent potential sparks from igniting combustiblegases that are produced by some batteries.

4. Charge the batteries. The engine will not continueto run after starting if the batteries have not beencharged.

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.

46 SEBU7695-15Operation SectionEngine Operation

Engine Operationi01955113

Engine OperationSMCS Code: 1000

Proper operation, driving techniques andmaintenance are key factors in obtaining themaximum service life and economy of Caterpillarengines. The recommendations in this Operationand Maintenance Manual will help to loweroperating costs. For more information, refer toSpecial Publication, LEDT2254, “CAT Answers YourQuestions About Truck Performance” or consult yourCaterpillar dealer.

IdlingIdle speed is adjustable on Caterpillar electronicengines. Consult your Caterpillar dealer forinformation. The idle rpm is preset at 600 rpm.

Avoid excess idling. If the vehicle is parked for morethan five minutes, stop the engine. An engine canburn from 2.8 L (.7 US gal) to 5.7 L (1.5 US gal) offuel per hour while the engine is idling. Excessiveidling can cause carbon buildup and/or excessiveidling can cause the engine to slobber. This is harmfulto the engine.

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

Fast idle can be programmed within the range of700 rpm to the top engine limit. Fast idle requires an“ON/OFF” switch on the dashboard. Consult yourCaterpillar dealer for assistance.

Idle Shutdown Timer

The idle shutdown timer can be programmed inorder to shut down the engine after a specific timeperiod of idling. The idle time can be programmedfrom three minutes to 1440 minutes (24 hours). Ifthe idle shutdown timer is set to 0 minutes, the idleshutdown feature is disabled. If the setting of thetimer is unknown, allow the engine to idle. Observethe time that elapses before the engine shuts down.The following conditions must be met in order toactivate the idle shutdown timer:

• The idle shutdown feature must be selected.

• No vehicle speed is detected by the ElectronicControl Module (ECM).

• The engine is not under load.

• The engine is at operating temperature. Theengine is not in Cold Mode.

After the vehicle is stationary, the idle shutdown timerbegins. The engine can be operating at low idle orat an idle rpm that is selected by the idle governor.The “CHECK ENGINE/DIAGNOSTIC” lamp will flashrapidly for 90 seconds prior to shutdown. Movementof the vehicle automatically resets the idle shutdowntimer to the programmed setting.

The following conditions must be met in order tooverride the idle shutdown timer:

1. Program the “ALLOW IDLE SHUTDOWNOVERRIDE” to “YES”.

2. The “CHECK ENGINE/DIAGNOSTIC” lamp willflash rapidly for 90 seconds prior to shutdown.Depress the service brake or the clutch pedalduring the 90 seconds when the “CHECKENGINE/DIAGNOSTIC” lamp flashes.

After an idle shutdown, the engine can be restartedwithout turning the ignition switch to the OFF position.

The override function is disabled if the “ALLOW IDLESHUTDOWN OVERRIDE” is programmed to “NO”.

Cold Mode OperationCold mode is initiated if the coolant temperature isbelow 28° C (82° F). Engine power is decreased untilthe coolant temperature reaches the above value. Incold mode, the idle is 800 rpm for the C11 and theC13. In cold mode, the idle is 600 rpm for the C15.The strategy for cold mode provides reduced smokeemission and faster warm-up time.

After the cold mode is completed, the engine shouldbe operated at low rpm and low load until normaloperating temperature is reached. The engine willreach normal operating temperature faster whenthe engine is operated at low rpm and low powerdemand. This method is faster than trying to reachoperating temperature by idling with no load.

NOTICEIt is not recommended that the vehicle be moved untilthe engine is out of cold mode. Power may be notice-ably reduced if the vehicle is operated while the engineis in cold mode. At a speed above 8 km/h (5 mph),the low idle speed will be reduced to the customerprogrammed low idle speed. The power will still bereduced.

SEBU7695-15 47Operation SectionEngine Operation

Cold mode is disabled if the throttle, the servicebrake, or the clutch (if equipped) is depressed.The rpm for cold mode operation drops to theprogrammed low idle speed in order to allow thetransmission to be put into gear.

Getting StartedCaterpillar electronic engines do not require longwarm-up periods that needlessly waste fuel. Typically,the engine should be at normal operating temperaturein a few minutes. Begin operating the engine at lowload. After normal oil pressure is reached and thetemperature gauges begin to rise, the engine maybe operated at full load.

To get the vehicle in motion, use a gear that will resultin a smooth start. Move the load without increasingthe engine rpm above low idle or without slippingthe clutch. Engage the clutch smoothly. Slipping theclutch and engaging the clutch can cause stress tooccur on the drive train. This can also cause fuel tobe wasted.

Use progressive shifting techniques. Progressiveshifting is using only the rpm that is required in orderto upshift into the next gear. Progressive shiftingimproves fuel economy.

• Keep the engine rpm to a minimum. Use an rpmthat is from 1200 to 1600 rpm.

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

Progressive shifting also reduces the accelerationrate. Top gear is reached sooner because less timeis needed to synchronize the gears during shifting. Inaddition, the engine is operating at the highest rangeof torque.

The amount of rpm that is required to upshiftincreases as the vehicle speed increases, unlessupshifts are made on upgrades. Experience with thevehicle will show the amount of rpm that is requiredto upshift under various conditions.

Note: These engines may be programmed toencourage progressive shifting. The accelerationrate may slow down at certain rpm in lower gears.If this occurs, progressive shift parameters mayhave been programmed into the ECM. Progressiveshift parameters will limit the rpm when the vehicleis driven in higher gears. These parameters areprotected by customer passwords. If the vehicle canbe operated in a higher gear at a vehicle speed thatis desired, select the highest gear that is available topull the load. This recommendation will help to obtainfuel economy. The engine will be operating at thelowest rpm that is required to pull the load.

Vehicle EfficiencyAn efficient vehicle performs the desired amountof work while the power demand on the engineis minimized. The following factors are majorcontributors 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 theengine driven accessories

For more information about vehicle efficiency, refer toSpecial Publication, LEDT2254, “CAT Answers YourQuestions About Truck Performance”.

Fuel EconomyFuel is the largest single operating cost of today'son-highway vehicle engines. Improved fuel economycan have a substantial impact on operating profit.The following items are the most significant factorsthat influence vehicle fuel economy:

• Driver techniques

• Vehicle efficiency

• Operating conditions

• Engine efficiency

A No. 1 grade of fuel contains less energy per volumeand increases fuel consumption. A greater volumeof fuel must be injected in order to yield the sameamount of work as a No. 2 fuel. The difference in thefuel economy between the two grades of fuel can beas great as 0.2 km/L (.5 mpg) to 0.3 km/L (.7 mpg).

For more information about fuel economy, refer toSpecial Publication, LEDT2254, “CAT Answers YourQuestions About Truck Performance”.

Rolling hills provide a great opportunity to reduce fuelconsumption. Avoid downshifting on small hills. Thevehicle should not be downshifted even if the enginemust be lugged down to an rpm that is below thepeak torque rpm. When the vehicle is going downa hill, use gravity instead of the engine's power toregain vehicle speed.

On grades that require more than one downshift,allow the engine to lug to peak torque rpm. If theengine is running at peak torque rpm or above peaktorque rpm and the rpm stabilizes, remain in thatgear.


Long steep down grades should be anticipated.Reduce the speed of the vehicles before you crestthe top of a hill and before you proceed down a long,steep grade. Minimize the amount of braking that isused in order to maintain a safe speed for maximizingfuel efficiency.

The engine's ability to hold the vehicle back increaseswith engine rpm. Select a gear that runs the enginenear the high engine rpm limit for long steep hillswhen braking is required.

Speed reductions and future stops should beanticipated. Downshifts should be avoided. Theamount of braking should be minimized in order toimprove fuel consumption. By coasting to a stop, avehicle can travel a considerable distance withoutconsuming any fuel.

CruisingVehicles that are driven faster consume morefuel. Increasing the cruising speed from 88 km/h(55 mph) to 104 km/h (65 mph) will increase thefuel consumption of a typical Class 8 vehicle byapproximately 0.4 km/L (1 mpg). When a vehicle isdriven fast in order to allow more time for stops, thestops become very expensive. Cruising allows theengine to operate in the most efficient rpm range(1100 to 1500 rpm).

Cruise ControlThe functionality of the cruise control can varydepending on the vehicle manufacturer. The CruiseControl switch may be programmed to operate in oneof two modes:

• The SET position may operate as the SET/ACCELSWITCH position or the SET/DECEL position.

• The RESUME position may operate as theRESUME/DECEL position or the RESUME/ACCELposition.

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

Perform the following steps in order to set the CruiseControl:

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

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

The ECM will control the vehicle speed until theclutch 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 thedesired speed and the cruise control speed can beset by pressing the “SET/RESUME” switch to theACCEL position.

Perform the following step in order to reset the CruiseControl:

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

Momentarily pressing or bumping the“SET/RESUME” switch to the ACCEL position willincrease vehicle speed by one mph. Press theswitch to the DECEL position in order to decreasethe speed by one mph. The operating range ofthe cruise control has been programmed into theECM.

Soft Cruise Control

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

Soft Cruise Control provides an operating range of8 km/h (5 mph) around the setting for the cruisecontrol. Engines that are shipped from Caterpillarare programmed to operate in the “Soft Cruise =YES” mode. Soft Cruise Control allows the vehicle toaccelerate slightly while the engine is under power.The vehicle can proceed down a hill while momentumis gained for the next hill. Improved fuel economy canbe gained in this mode.

When “Soft Cruise = NO” is programmed, the “SET”speed is maintained. Consult your Caterpillar dealerfor more information.

Eaton Top 2 TransmissionNote: The following information is applicable toengines with the EatonTop 2 transmission.

The ECM controls the shifting of the two highestgears of the transmission. A downshift of one gearfrom the top gear will occur automatically. Thedownshift will occur when the load that is on theengine increases. An example of an increasing loadwould be climbing a hill.

The Throttle Activated Downshift feature is availablein order to provide the operator with additional controlof the gears for the Top 2 transmission. The ThrottleActivated Downshift feature enables the operator todownshift faster than the automatic downshift.


Throttle Activated Downshift

The Throttle Activated Downshift enables theoperator to downshift easily. It is useful for passingor for climbing hills. The following conditions mustbe met in order for the Throttle Activated Downshiftto be used:

• The transmission is in the top gear.

• The engine rpm is below 1350 rpm fortransmissions with ten speeds forward.

• The engine rpm is below 1450 rpm fortransmissions with thirteen speeds forward.

• The engine rpm is below 1450 rpm fortransmissions with eighteen speeds forward.

Downshifting One Gear From the Top Gear

In order to downshift one gear from the top gear, thefollowing steps must be performed:

1. Release foot from the throttle pedal.

2. Fully depress the throttle pedal to the floor in orderto provide full throttle.

To allow synchronization of the downshift, the enginerpm may increase by 400 rpm.

Upshifting To The Top Gear From One GearBelow The Top Gear

The transmission can be shifted to the top gear whenthe transmission is one gear from the top gear. Inorder to upshift to the top gear, slightly release thethrottle from the full throttle position.

If the throttle is not slightly released, the transmissionwill automatically upshift to the top gear when theengine rpm reaches one of the following limits:

• 40 rpm below the programmed Top Engine Limit

• 40 rpm below the programmed Gear DownProtection limit

Preventing Downshifting One Gear From the TopGear

In order to prevent downshifting one gear from thetop gear, DO NOT release the throttle pedal and thenprovide full throttle.

If the conditions are met and the Throttle ActivatedDownshift is NOT desired, do not release the throttleand then provide full throttle. Continue driving thevehicle. A downshift of one gear from the top gear willoccur automatically. The downshift will occur whenthe load that is on the engine increases. An exampleof an increasing load would be climbing a hill.

Refer to the Eaton, “Driver Instructions” for moreinformation on the Top 2 transmission.

Uphill OperationFor optimum performance of the engine, lug down theengine between 1100 rpm and 1200 rpm, before thetransmission is downshifted. Continue to downshiftin this manner until you reach a gear that maintainsthe desired speed. Continue to operate the engineat 1100 rpm to 1200 rpm if the vehicle will crest thetop of the hill without a downshift in the transmission.Begin upshifting as the grade of the hill decreasesand the engine begins to accelerate above 1600 rpm.Driving this way will provide optimum fuel economyand performance.

Note: Allowing the engine to lug below peak torqueis permissible if the vehicle is cresting the top of ahill. However, extended operation at engine speedsbelow peak torque (1200 rpm) will raise the exhausttemperature and the cylinder pressure. This can leadto reduced engine service life.

Downhill Operation

NOTICEDo not exceed 2300 rpm in any situation or 2100 rpmif equipped with an auxiliary engine brake system.

On downgrades, do not coast while the clutch pedalis depressed. Do not coast with the transmission inneutral. If no engine power is needed, disengage theCruise Control.

Select the correct gear that does not allow the enginespeed (rpm) to exceed 2300 rpm. If equipped, usethe auxiliary brake in order to control the speed of thevehicle. Usually, the same gear that would be used togo up a hill can be used to go down the hill. Refer tothe rated rpm that is on the engine information plate.


i02594353

Compression Brake(If Equipped)SMCS Code: 1129

S/N: KCA1-Up

S/N: KCB1-Up

S/N: JAM1-Up

S/N: JAX1-Up

Note: For additional information that relates tocompression brakes, refer to the Operation andMaintenance Manual, “Auxiliary Engine Brakes”.

Compression Brake ControlsRead the following information in order to becomefamiliar with the compression brake controls that arein the vehicle.

The compression brake controls may vary slightlydepending on the design of the vehicle cab. Thebasic operation of the compression brake does notchange if the switches are in a different location.

Standard Operator Controls

ON/OFF Switch – This switch activates the systemfor the compression brake.

Progressive Braking Switch – This switch allowsvarious settings for different conditions.

LOW Setting – This switch position will activate thebraking function on two cylinders. This setting willprovide approximately one-third of the total availablebraking horsepower. This setting is typically used onflat roads when light loads are hauled.

MED Setting – This switch position will activate thebraking function on four cylinders. This setting willprovide approximately two-thirds of the total availablebraking horsepower. This setting is typically usedwhen the LOW setting is not adequate in order toprovide the desired braking horsepower.

HIGH Setting – This switch position will activatethe braking function on all six cylinders. This settingwill provide full braking horsepower. This setting istypically used on downhill grades or the setting isused when heavy loads are involved. Use this settingonly when there is good traction.

In addition to the switch controls that were previouslydiscussed, other switches are available. A controlswitch exists for the compression brake that isactivated by the position of the clutch pedal. Thereis also a switch that is activated by the position ofthe accelerator pedal.

The function of the compression brake operatesin much the same manner regardless of a manualtransmission or an automatic transmission.However, some vehicles are equipped with autoshifttransmissions. In this situation, the compressionbrake may actuate in order to help the transmissionmake an upshift. This feature is controlledautomatically through the transmission controlmodule. This automatic control can happen even ifthe compression brake switch is in the OFF position.

Additional system controls may temporarily interruptthe operation of the compression brake. Theseparameters vary by OEM, but the parameters mayoccur under the following conditions.

• Engine speed is below 1000 rpm.

• The vehicle slows to a preset speed.

• This may occur when the torque converter shifts outof lockup in vehicles with automatic transmissions.This is usually between 10 to 25 mph.

Compression Brake OperationThe information that is shown in the Operation andMaintenance Manual, “Auxiliary Engine Brakes” mustbe read and understood before proceeding to thefollowing information.

Additional Guidelines

• Before descending a long grade or a steep grade,test the compression brake in order to ensureproper operation.

• Never exceed a safe control speed.

• Do not use the compression brake when thevehicle is “bobtailed”.

• Do not use the compression brake when anempty trailer is pulled on wet pavement or slipperypavement. This is particularly important if thevehicle has a single drive axle.

• Do not shift gears without using the clutch whenthe compression brake is turned on. Do not makea double clutch when the compression brake isactivated. Power train damage may occur.


i01387704

Compression BrakeSMCS Code: 1129

S/N: BXS1-Up

S/N: MXS1-Up

S/N: NXS1-Up

S/N: RKS1-Up

Using Your Jacobs Engine Brake(Jake Brake®)Jake Brake is a registered Trademark of JacobsVehicle Systems.

NOTICEA compression brake is used to slow a vehicle, not tostop a vehicle. A compression brake is not a substitutefor the service braking system. The vehicles servicebrakes must be used to bring the vehicle to a com-plete stop. Proper use of the compression brake willkeep the service brakes cool. This will keep the ser-vice brakes ready to provide maximum stopping pow-er.

Driver Controls

It is important to be familiar with the Jake Brakecontrols in your vehicle. The Jake Brake controlswill vary slightly depending on the Jake Brakeconfiguration. The Jake Brake controls will varydepending on the design of the vehicle cab. However,basic operator controls will be similar for all models.The various types of dash switches that may beused in the cab of your vehicle are shown in theillustrations below.

Note: Switches that are supplied by Jacobs VehicleSystems may be different from the switches that areinstalled in your vehicle. The physical appearance ofthe dash switches may vary but the function of thedash switches should not change.

The following information is for a typical in-line sixcylinder engine.

g00731591Illustration 27“LOW/MED/HIGH” Switch

The “LOW” setting on the dash switch will activatetwo cylinders, which will provide approximatelyone-third of the braking horsepower. The “MED”setting on the dash switch will activate four cylinders,which will provide approximately two-thirds of thebraking horsepower. The “HIGH” setting on the dashswitch will activate all of the cylinders, which willprovide full braking horsepower.

Note: A foot-operated switch may be installed inthe cab of the vehicle. The foot-operated switch willcontrol the on/off functions of the compression brake.Some vehicle manufacturers may offer a switch thatis mounted on the gear selector for the Jake Brakecontrols.

Engine Controls

All Jake Brake applications have two additionalcontrols. One control is activated by the position ofthe clutch pedal and the other control is activatedby the position of the accelerator pedal. The twoadditional controls can provide fully automaticoperation of the Jake Brake.

Operation of the Jacobs EngineBrake (Jake Brake®)

NOTICEThe Jake Brake depends on the free flow of engine oilfor operation.Make sure that the engine is at full op-erating temperature before switching on the JakeBrake. Normally the Jake Brake is left in the ON posi-tion whenever you are driving. The exception is whenroads are slippery due to bad weather conditions. Re-fer to the Slippery Pavement topic in this Manual forspecific operating instructions.



The operation of the Jake Brake is fully automaticonce the brake is turned on. When your foot is offof the clutch and you remove your foot completelyfrom the accelerator pedal, the Jake Brake isautomatically activated. There are some systemsthat will activate the Jake Brake only once the brakepedal is depressed.


When you apply pressure to the accelerator pedal,the Jake Brake is deactivated.


During shifting, the Jake Brake is automaticallydeactivated when the clutch pedal is depressed.

NOTICEIf the Jake Brake is on, shifting without using the clutchor double-clutching (to use the compression brake toreduce engine rpm--also known as "Jake Shifting") isstrongly discouraged. Serious powertrain damage canresult.


Note: The Jake Brake will remain activated after thebrake pedal has been depressed. This function givesthe combined power of both the compression brakeand the service brakes to the drive wheels.

The ECM on vehicles that are equipped with ABS(Anti-Lock Brake System) has the ability to deactivatethe Jake Brake if wheel slippage is detected. TheJake Brake will be automatically reactivated whenwheel slippage is no longer detected.

The ECM will deactivate the Jake Brake when enginespeed falls below approximately 1000 rpm or whenthe vehicle slows down to a preset speed. Theseparameters may vary depending on the vehicle andthe engine configuration. This prevents stalling theengine.

NOTICEBe sure to turn the Jake Brake dash switch to the OFFposition when the engine is turned off. This will preventthe switch from being in the ON position at engine coldstart.


Automatic Transmissions

Operating the Jake Brake in a vehicle that isequipped with an automatic transmission is similarto operating the Jake Brake in a vehicle that isequipped with a manual transmission. The JakeBrake is activated when you move your foot off theaccelerator pedal. The Jake Brake is deactivatedwhen you apply pressure to the accelerator pedal.The ECM will deactivate the Jake Brake when theengine speed falls below approximately 1000 rpmor when the torque converter shifts out of lockup.The torque converter will usually shift out of lockupbetween 10 and 25 mph. This is dependent on thetype of transmission.

Note: With Autoshift transmissions, the Jake Brakemay actuate in order to help the transmission upshift.This is done automatically through the transmissioncontrol module. This can happen even if the JakeBrake dash switch is in the OFF position.

Cruise Control

There are several types of cruise control systems.The operation of the Jake Brake in vehicles thatare equipped with cruise control will depend on theengine and the options that are provided by theOEM. Some cruise controls are specifically designedto operate in conjunction with the Jake Brake. It maybe possible to program the activation of the JakeBrake during cruise control operation. When thecruise control is enabled, the ECM will activate theJake Brake when the vehicle exceeds the set speedof the cruise control. The Jake Brake will operateuntil the vehicle has slowed to one-half mph abovethe set speed of the cruise control. For additionalinformation, refer to the “Cruise Control” topic inthe Operation and Maintenance Manual, “EngineOperation” section.

Driving With Your Jacobs EngineBrake (Jake Brake®)


Since the Jake Brake is most effective at higherengine speeds, gear selection is very important.Maximum retarder performance is obtainedwhen you use the lowest possible gear withoutexceeding the recommended engine brakingspeed. Best retarding performance is obtained atengine speeds between 1800 rpm and rated enginespeed. Below 1700 rpm, retarding power may besignificantly reduced.

The Jake Brake must be turned ON at the dashswitch in order to operate. Once the Jake Brake isturned ON, remove your foot from the acceleratorpedal in order to slow your vehicle. Apply the servicebrakes in order to come to a complete stop. Refer tothe sections below for driving procedures for specificconditions.

Flat, Dry Pavement


Put the progressive braking switch in the “LOW”position while you are driving on flat, open stretchesof road with a light load. During these conditions,more slowing power is not required. If you are stillusing the service brakes, move the progressivebraking switch to a higher position until there is noneed for the service brakes to slow the vehicle.



The progressive braking switch should be in the“High” position under the following operatingconditions:

• Carrying heavy loads

• Descending a grade

• The pavement is dry.

• The traction is good.

Descending a Grade

Before beginning a long, steep descent, determineif your Jake Brake is operating properly. This can bedone by lifting your foot briefly off the acceleratorpedal. The Jake Brake is working correctly if thevehicle begins to slow down.

Note: The following road speeds and grades aregiven as examples only! Actual conditions andretarding performance will vary.


An explanation of control speed is helpful inunderstanding the use of the Jake Brake whileyou are descending a grade. Control speed is theconstant speed that occurs when the forces that arepushing the vehicle down a grade are equal to theforces that are holding the vehicle back without usingthe service brakes. In other words, vehicle speed willbe maintained without using the service brakes.


You may be able to safely descend a 6 percent gradeat 10 mph without using the service brakes or theJake Brake. This is dependent on the road conditionsand the load that is being carried.


It may be possible to maintain control of the vehiclewhile descending a 6 percent grade at 25 mphwithout using the service brakes with the Jake Brakeset to the “HIGH” position on the progressive brakingswitch.

Note: The Jake Brake can be kept on for as long asneeded without any risk of engine overheating ordamage.



Under some circumstances, you may want todescend a grade at a faster rate than the controlspeed. This can be done by selecting a higher gear,or a lower position on the progressive braking switch.However, you may need to apply the service brakesintermittently. Applying the service brakes will helpprevent engine overspeed. Applying the servicebrakes will also help keep the vehicle at a safe speed.

NOTICEFrequent use of the service brakes will cause the ser-vice brakes to heat up, reducing the stopping ability ofthe vehicle. The result can be a dangerous conditioncalled brake fade.

There may be circumstances when you might wantto descend a grade at a rate that is slower than thecontrol speed. This is done by selecting a lower gear.Do not select a gear that is low enough to result in anengine overspeed. You may need to apply the servicebrakes in order to obtain the desired lower speed.

The Jake Brake can be misused. Look at the exampleof descending the 6 percent grade under controlonly at 10 mph without a compression brake, but at25 mph with a compression brake. You could notexpect to maintain control of the vehicle on the samegrade at 50 mph. Become familiar with the amountof retarding power that can be provided by your JakeBrake. Never exceed a safe control speed.

Slippery Pavement

The operation of any vehicle can be unpredictable inslippery conditions. Be careful when you are testingthe Jake Brake on slippery roads.

The Jake Brake will not affect the operation of theABS. The ECM will deactivate the Jake Brake whenthe ABS senses wheel slippage (loss of traction).The Jake Brake will be reactivated when traction isregained.

Become familiar with the operation of the Jake Brakebefore attempting to use the Jake Brake on slipperyroads until you have some experience with the JakeBrake on dry pavement.

NOTICEDo not use the Jake Brake when bobtailing or pullingan empty trailer on wet or slippery pavement, espe-cially when operating a single drive axle vehicle.

Driving Procedures for Slippery Pavement

When you are driving in wet conditions or icyconditions, begin with the dash switch in the OFFposition. Use the same gear that would normally beused for these conditions.

Before activating the Jake Brake, ensure that thefollowing conditions exist:

• There is adequate distance between your vehicleand other vehicles.

• Traffic conditions are adequate for testing thebraking ability of the vehicle.

• The vehicle is able to maintain traction and stabilityduring deceleration without the use of the JakeBrake.

If there is any loss of traction during decelerationwithout the use of the Jake Brake, do not attempt touse the Jake Brake until road conditions improve.


If the vehicle is maintaining traction, activate the JakeBrake by turning the progressive braking switch tothe “LOW” position.


If the drive wheels begin to lock or the rear of thetrailer begins to move, immediately turn the dashswitch to the OFF position. Do not turn the Jake Braketo the ON position until road conditions improve.


If there is no tendency for the drive wheels to losetraction and you desire greater braking performance,move the progressive braking switch to the nexthighest position.

If the drive wheels begin to lock or the rear of thetrailer begins to move, immediately move the dashswitch back to the original position. Do not attempt touse a higher position until road conditions improve.

Note: Check your progressive braking switch for theproper position often. Road conditions can changerapidly. Remember: In slippery road conditions, neverskip a step when you are operating the progressivebraking switch. Always begin with the switch in theLOW position. Continue moving the switch to thenext highest position as the road conditions improve.

On single trailers or combinations, a light applicationof the trailer brakes may be necessary to helpkeep the trailer in line with the tractor. Follow themanufacturer's recommended operating procedurewhen using your trailer brakes.

If the tractor is equipped with tandem axles and apower divider, the Jake Brake will not change thenormal usage of this equipment on slippery roads.See the manufacturer's recommendations for theproper use of this equipment.


Cold Weather Operation

Cold Weather Operationi01502338

Radiator RestrictionsSMCS Code: 1353; 1396

Caterpillar discourages the use of airflow restrictiondevices that are mounted in front of radiators. Airflowrestriction 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 thoseparticular cases, the coolant temperature andthe inlet manifold temperature must be carefullymonitored and controlled.

NOTICEFailure to open the winter fronts in the morning couldcause engine damage and/or loss of fuel economy.

i02118561

Fuel and the Effect from ColdWeatherSMCS Code: 1000; 1250; 1280

The following fuels are the grades that are availablefor Caterpillar engines:

• No.1

• No.2

• Blend of No.1 and No.2

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

Note: Engines that are equipped with a DieselParticulate Filter (DPF) are required to use Ultra LowSulfur Diesel (ULSD) diesel fuel. ULSD fuel containsless than 15 ppm sulfur using ASTM D 2622 or DIN51400. The use of higher sulfur diesel fuel in anengine with a DPF will cause the engine to produceemissions that are not in compliance with emissionsstandards and deactivation of the catalyst within theDPF. The use of a blend of No.1 and No.2 fuel isallowed in an engine that is equipped with a DPF, ifboth of the base fuels meet the ULSD standard.

Quantities of No.1 diesel fuel are limited. No.1 dieselfuels are usually available during the months of thewinter in the colder climates. During cold weatheroperation, if No.1 diesel fuel is not available, useNo.2 diesel fuel, if necessary.

There are three major differences between No.1 andNo.2 diesel fuel. No.1 diesel fuel has the followingproperties:

• 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 powerand in fuel efficiency may be noticed. Other operatingeffects should not be experienced.

The cloud point is the temperature when a cloud ofwax crystals begins to form in the fuel. These crystalscan cause the fuel filters to plug. The pour point isthe temperature when diesel fuel will thicken. Thediesel fuel becomes more resistant to flow throughfuel pumps and through fuel lines.

Be aware of these values when diesel fuel ispurchased. Anticipate the average ambienttemperature of the location of the engine's area ofoperation. Engines that are fueled in one climatemay not operate well if the engines are moved toanother climate. Problems can result due to changesin temperature.

Before troubleshooting for low power or for poorperformance in the winter, check the type of fuel thatis being used.

When No.2 diesel fuel is used the followingcomponents provide a means of minimizing problemsin cold weather:

• Starting aids

• Engine oil pan heaters

• Engine coolant heaters

58 SEBU7695-15Operation SectionCold Weather Operation

• Fuel heaters

• Fuel line insulation

For more information about fuel, refer to SpecialPublication, SEBU6385, “Caterpillar On-highwayDiesel Truck Engine Fluids Recommendations”.

i02645589

Fuel Related Components inCold WeatherSMCS Code: 1000; 1250; 1280

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

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

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

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

• Weekly

• Oil changes

• Refueling of the fuel tank

This will help prevent water and/or sediment frombeing pumped from the fuel storage tank and intothe engine fuel tank.

Fuel FiltersA primary fuel filter and/or a water separator isinstalled between the fuel tank and the enginemounted fuel filter. The location of the primaryfuel filter is important in cold weather operation.The primary fuel filter and the fuel supply line arecommonly affected by cold fuel. The best location forthe primary fuel filter is in the engine compartment.Here, the primary fuel filter will benefit from theradiant heat of the engine. A primary fuel filter that ismounted outside the frame rails or in any locationthat is exposed to wind can be a persistent problemin cold weather.

Fuel HeatersFuel heaters help to prevent fuel filters from pluggingin cold weather due to waxing. A fuel heater shouldbe installed. The fuel should be heated before thefuel enters the primary fuel filter.

Select a fuel heater that is mechanically simple, yetadequate for the application. The fuel heater shouldalso help to prevent overheating of the fuel. High fueltemperatures reduce engine performance and theavailability of engine power. Choose a fuel heaterwith a large heating surface. The fuel heater shouldbe practical in size. Small heaters can be too hot dueto the limited surface area.

Disconnect the fuel heater in warm weather.

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

Note: Heat exchanger type fuel heaters should havea bypass provision in order to prevent overheating ofthe fuel in warm weather operation.

For further information on fuel heaters, consult yourCaterpillar dealer.

SEBU7695-15 59Operation SectionEngine Stopping

Engine Stoppingi00948324

Stopping the EngineSMCS Code: 1000

NOTICEStopping the engine immediately after it has beenworking under load can result in overheating and ac-celerated wear of the engine components.

If the engine has been operating at high rpm and/orhigh loads, run at low idle for at least three minutesto reduce and stabilize internal engine temperaturebefore stopping the engine.

Avoiding hot engine shutdowns will maximize tur-bocharger shaft and bearing life.

Prior to stopping an engine that is being operatedat low loads, operate the engine at low idle for 30seconds before stopping. If the engine has beenoperating at highway speeds and/or at high loads,operate the engine at low idle for at least threeminutes. This procedure will cause the internalengine temperature to be reduced and stabilized.

Ensure that the engine stopping procedure isunderstood. Stop the engine according to the shutoffsystem on the vehicle or refer to the instructions thatare provided by the OEM of the vehicle.

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

After Stopping the Engine• Check the crankcase oil level. Maintain the oil levelbetween the “ADD” mark and the “FULL” mark onthe oil level gauge.

• If necessary, perform minor adjustments. Repairany leaks and tighten any loose bolts.

• Note the service hour meter reading. Performthe maintenance that is in the Operation andMaintenance Manual, “Maintenance IntervalSchedule”.

• Fill the fuel tank in order to help preventaccumulation of moisture in the fuel. Do not overfillthe fuel tank.

NOTICEOnly use antifreeze/coolant mixtures recommended inthe Coolant Specifications that are in the Operationand Maintenance Manual. Failure to do so can causeengine 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, checkthe coolant for proper antifreeze protection. Thecooling system must be protected against freezingto the lowest expected outside temperature. Addthe proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on alldriven equipment. This maintenance is outlined inthe instructions from the OEM.

60 SEBU7695-15Operation SectionEngine Stopping

i02811862

Emergency Stopping(Engines with Optional AirShutoff Systems)SMCS Code: 1000; 7418

The air inlet shutoff is available for certain engineratings. When an overspeed is detected, a relayactivates the air inlet shutoff system and fuel injectionis disabled. This is accomplished by activation ofa solenoid that closes a plate that is in the inlet airsystem in order to cut off the air supply to the engine.

The air inlet shutoff switch can be used to manuallyactivate the air inlet shutoff. When the switch isdepressed, a one second pulse is sent to the air inletshutoff relay. The transmission must be in neutralbefore the air inlet shutoff switch will become active.

g01402506Illustration 41Typical air shutoff

Once the air inlet shutoff is activated the indicatormust be manually reset to the open position beforethe engine can be restarted.

SEBU7695-15 61Maintenance Section

Refill Capacities

Maintenance Section

Refill Capacitiesi04440549

Refill CapacitiesSMCS Code: 1000; 1348; 1395; 7560

Refer to this Operation and Maintenance Manual,“Fluid Recommendations” for information aboutchoosing the correct fluids for your engine.

Lubrication SystemThe refill capacities for the engine crankcase reflectthe approximate capacity of the crankcase or sumpplus standard oil filters. Auxiliary oil filter systems willrequire additional oil. Refer to the OEM specificationsfor the capacity of the auxiliary oil filter.

Table 25

Approximate Refill Capacities of the EngineLubrication System

Compartmentor System C11 and C13 C15

Standard (Deep)Oil Sump(1) 37.7 L (39.8 qt) 37.7 L (39.8 qt)

Shallow OilSump 31.7 L (33.5 qt) N/A

Capacity of theAuxiliary Oil FilterSystem(2)

Total Capacityof theLubricationSystem(3)

(1) Approximate sump capacity of the crankcase includesstandard oil filters that are factory installed. Engines withauxiliary oil filters will require additional oil. Optional bypassoil filters that are supplied by Caterpillar require an additional2.5 L (2.6 qt) of oil. If the engine is equipped with another typeof auxiliary oil filter, refer to the OEM specifications for thecapacity of the auxiliary oil filter.

(2) Fill in the capacity of the auxiliary oil filter system (if equipped)in the space that is provided.

(3) Fill in the total capacity of the lubrication system. Add theauxiliary oil filter system to the correct capacity of the oil sumpin order to find the total capacity of the lubrication system.

Cooling SystemThe total cooling system capacity will vary dependingon the radiator that is provided by the vehiclemanufacturer. The table for the capacity of the coolingsystem is blank. The customer should fill in the table.

Table 26

Approximate Capacity of the Cooling System

Compartmentor System Liters Quarts

Total CoolingSystem(1)

(1) The total cooling system capacity includes the followingcomponents:the engine block, the radiator, and all coolanthoses and lines.

i04440895

Fluid RecommendationsSMCS Code: 1280; 1348; 1395; 7560

For more information, refer to Special Publication,SEBU6385, “Cat On-highway Diesel Engine FluidsRecommendations”.

Refer to this Operation and Maintenance Manual,“Severe Service Application” for information aboutoperating an engine in a severe service application.

Note: The interval for changing the coolant variesdepending on the type of coolant being replaced.Refer to this article, “Coolant Recommendations”, forthe intervals for changing the coolant.

Diesel Engine OilFor more information, refer to Special Publication,SEBU6385, “Cat On-highway Diesel Engine FluidsRecommendations” .

Cat Diesel Engine Oil (Cat DEO)

Cat oils have been developed and tested in order toprovide the full performance and service life that hasbeen designed and built into Cat engines. Cat oils arecurrently used to fill Cat Diesel Engines at the factory.These oils are offered by Cat dealers for continueduse when the engine oil is changed. Consult your Catdealer for more information on these oils.

Due to significant variations in the quality and inthe performance of commercially available oils,Caterpillar makes the following recommendations:

62 SEBU7695-15Maintenance SectionRefill Capacities

Table 27

Cat Lubricants Viscosity Grade

SAE 15W-40Cat DEO-ULS

SAE 10W-30

Cat DEO-ULS SYN SAE 5W-40Diesel EngineOil-Ultra Low

SulfurCat Cold Weather

DEO-ULS SAE 0W-40

SAE 15W-40Cat DEO

SAE 10W-30Diesel Engine Oil

Cat DEO SYN SAE 5W-40

Note: Cat DEO and Cat DEO-ULS multigrade oils arethe preferred oils for use in this Cat Diesel Engine.

Commercial Oil

Note: Non-Cat commercial oils are second choiceoils for your engine.

NOTICECaterpillar does not warrant the quality or perfor-mance of non-Cat fluids.

The three current Caterpillar ECF specifications are:Cat ECF-1-a, Cat ECF-2, and Cat ECF-3. Eachhigher Cat ECF specification provides increasedperformance over lower Cat ECF specifications.

A commercial oil must meet the following standardsto be considered an equivalent of a Cat DieselEngine Oil:

Table 28

Cat Engine Crankcase Fluids (ECF) Definitions

Cat PerformanceRequirement Cat ECF Specifications Requirements

Cat ECF-3 API CJ-4 Oil Category performance requirements

API CI-4 / CI-4 PLUS Oil Categoryperformance requirements

Passing standard Cat C13 engine testper API requirements

Cat ECF-2

Oils of sulfated ash > 1.50 percent are not allowed

API CH-4 Oil Category performance requirements

For oils that are between 1.30 percent and 1.50percent sulfated ash, passing one additional Cat1P SCOTE test (“ASTM D6681”) is required

Cat ECF-1-a

Oils of sulfated ash > 1.50 percent are not allowed


Refill Capacities

In selecting oil for any engine application, both of thefollowing must be satisfied: the oil viscosity and thecategory of oil performance or the specification for oilperformance . Using only one of these parameterswill not sufficiently define oil for an engine application.

The proper SAE viscosity grade of oil is determinedby the following temperatures: minimum ambienttemperature during cold engine start-up andmaximum ambient temperature during engineoperation.

Refer to Table 29 (minimum temperature) in orderto determine the required oil viscosity for starting acold engine.

Refer to Table 29 (maximum temperature) in orderto select the oil viscosity for engine operation at thehighest ambient temperature that is anticipated.

Note: Generally, use the highest oil viscosity that isavailable to meet the requirement for the temperatureat start-up.

Table 29

Lubricant Viscosities for Ambient Temperaturesfor Cat Diesel Engines

°C °FOil Type andPerformanceRequirements

ViscosityGrade Min Max Min Max

Cat ECF-1-aCat ECF-2Cat ECF-3

SAE 0W-30 −40 30 −40 86

Cat Cold WeatherDEO-ULSCat ECF-1-aCat ECF-2Cat ECF-3

SAE 0W-40 −40 40 −40 104

Cat DEO-ULSCat ECF-1-aCat ECF-2Cat ECF-3

SAE 5W-30 −30 30 −22 86

Cat DEO-ULS SYNCat DEO


SAE 5W-40 −30 50 −22 122


SAE 10W-30 −18 40 0 104

SAE 10W-40 −18 50 0 122Cat DEO-ULSCat DEO SAE 15W-40 −9.5 50 15 122


Note: A cold soaked start occurs when the enginehas not been operated recently, allowing the oilto become more viscous due to cooler ambienttemperatures. Supplemental heat is recommendedfor cold soaked starts below the minimum ambienttemperature. Supplemental heat may be necessaryfor cold soaked starts that are above the minimumtemperature depending on factors such as parasiticload.

Total Base Number (TBN) and Fuel SulfurLevels

The use of Cat S·O·S Services oil analysis isrecommended strongly for determining oil life.

The minimum required Total Base Number (TBN)for oil depends on the fuel sulfur level. The TBN fornew oil is typically determined by the “ASTM D2896”procedure. For direct injection engines that usedistillate fuel, the following guidelines apply:

Table 30

TBN recommendations for applications in Cat engines(1)

Fuel Sulfur Level percent(ppm) Cat Engine Oils

TBN ofCommercialEngine Oils

≤0.05 percent (≤500 ppm) Cat DEO-ULSCat DEO Min 7

0. 1- 0.05 percent(1000-500 ppm)

Cat DEO-ULSCat DEO Min 7

Above 0.1 percent (above1000 ppm)(2) Cat DEO(3) Min 10

(1) When using fuel with 0.10% sulfur (1000 ppm) or higher, refer to this Operation andMaintenance Manual, “Severe Service Application” for more information.

(2) For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm), refer to TBN and engineoil guidelines given in this section.

(3) Cat DEO-ULS may be used if an oil analysis program is followed. Base the oil changeinterval on the analysis.

S·O·S Services Oil Analysis

Caterpillar has developed a maintenance toolthat evaluates oil degradation. the maintenancemanagement also detects the early signs of wearon internal components. The Caterpillar tool for oilanalysis is called S·O·S oil analysis and the toolis part of the S·O·S Services program. S·O·S oilanalysis divides oil analysis into four categories:

• Component wear rate

• Oil condition

• Oil contamination

• Identification of oil

These four types of analysis are used to monitorthe condition of your equipment. The four types ofanalysis will also help you identify potential problems.A properly administered S·O·S oil analysis programwill reduce repair costs and the program will lessenthe impact of downtime.

The S·O·S Oil Analysis program uses a wide rangeof tests to determine the condition of the oil and thecrankcase. Guidelines that are based on experienceand a correlation to failures have been establishedfor these tests. Exceeding one or more of theseguidelines could indicate serious fluid degradationor a pending component failure. A trained person atyour Cat dealership should make the final analysis.


Refill Capacities

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Refer to Special Publication, SEBU6385, “CatOn-highway Diesel Engine Fluids Recommendations”in order to obtain additional information about S·O·SServices oil analysis. You can also contact your localCat dealer.

FuelNote: Caterpillar strongly recommends the filtrationof fuel through a fuel filter with a rating of fourmicrons(c) absolute or less. This filtration should belocated on the device that dispenses the fuel to thefuel tank for the engine. This filtration should also belocated on the device that dispenses fuel from thebulk storage tank. Series filtration is recommended.

NOTICEIn order to meet expected fuel system componentlife, 4 micron(c) absolute or less secondary fuel fil-tration is required for all Caterpillar Diesel Enginesthat are equipped with unit injected fuel systems. Notethat all current Caterpillar Diesel Engines are factoryequipped with Caterpillar Advanced Efficiency 4 mi-cron(c) absolute fuel filters.

Caterpillar does not warrant the quality or perfor-mance of non-Caterpillar fluids and filters.

Diesel engines can burn a wide variety of fuels.These fuels are divided into two general groups. Thetwo groups are called the preferred fuels and thepermissible fuels.

Note: The permissible fuels are some crude oils,some blends of crude oil with distillate fuel, somebiodiesel, and some marine diesel fuel. These fuelsare not suitable for use in all engine applications.The acceptability of these fuels for use is determinedon an individual basis. A complete fuel analysis isrequired.

For more information, refer to Special Publication,SEBU6385, “Cat On-highway Diesel Engine FluidsRecommendations” or consult your Cat dealer forfurther information.

Diesel Distillate Fuel

Diesel engines may burn a wide variety of fuels.These fuels are divided into two general groups. Thetwo groups are called the preferred fuels and thepermissible fuels.

The preferred fuels provide maximum engineservice life and performance. The preferred fuelsare distillate fuels. These fuels are commonly calleddiesel fuel, furnace oil, gas oil, or kerosene. Thesefuels must meet the “Cat Specification for DistillateDiesel Fuel for Off-Highway Diesel Engines” foundin this Special Publication, “Distillate Diesel Fuel”article.

Note: The permissible fuels are some crude oils,some blends of crude oil with distillate fuel, somebiodiesel, and some marine diesel fuel. These fuelsare not suitable for use in all engine applications.The acceptability of these fuels for use is determinedon a case by case basis. A complete fuel analysisis required. Consult your Cat dealer for furtherinformation.

NOTICEThe footnotes are a key part of the “Caterpillar Specifi-cation for Distillate Diesel Fuel for Off-Highway DieselEngines” Table. Read ALL of the footnotes.


Table 31

Caterpillar Specification for Distillate Fuel for Nonroad Diesel Engines

Specifications Requirements ASTM Test ISO Test

Aromatics 35% maximum “D1319” “ISO 3837”

Ash 0.01% maximum(weight) “D482” “ISO 6245”

Carbon Residue on10% Bottoms

0.35% maximum(weight) “D524” “ISO 4262”

40 minimum (DIengines)

Cetane Number (1)35 minimum (PCengines)

“D613”or

“D6890”“ISO 5165”

Cloud Point

The cloud point mustnot exceed the lowestexpected ambienttemperature.

“D2500” “ISO 3015”

Copper StripCorrosion No. 3 maximum “D130” “ISO 2160”

10% at 282 °C(540 °F)maximum

Distillation90% at 360 °C(680 °F)maximum

“D86” “ISO 3405”

Flash Point legal limit “D93” “ISO 2719”

Thermal StabilityMinimum of 80%reflectance afteraging for 180 minutesat 150 °C (302 °F)

“D6468” No equivalenttest

30 minimumAPI Gravity (2)

45 maximum“D287” No equivalent

test

Pour Point6 °C (10 °F) minimumbelow ambienttemperature

“D97” “ISO 3016”

Sulfur (3)(4)(5)“D5453”or

“D2622”

ISO 20846or

ISO 20884

1.4 cSt minimum and20.0 cSt maximum asdelivered to the fuelinjection pumps

Kinematic Viscosity1.4 cSt minimum and4.5 cSt maximum asdelivered to the rotaryfuel injection pumps

- -

Water and Sediment 0.05% maximum “D1796” or“D2709” “ISO 3734”

Water 0.05% maximum “D6304” No equivalenttest

Sediment 0.05% maximum(weight) “D473” “ISO 3735”

(continued)


Refill Capacities

(Table 31, contd)

Caterpillar Specification for Distillate Fuel for Nonroad Diesel Engines

Specifications Requirements ASTM Test ISO Test

Gums and Resins (6) 10 mg per 100 mLmaximum “D381” “ISO 6246”

Lubricity

0.52 mm(0.0205 inch)maximum at 60 °C(140 °F)

“D6079” No equivalenttest

(1) Alternatively, to ensure a minimum cetane number of 35 (PC engines), and 40 (DIengines), distillate diesel fuel should have a minimum cetane index of 37.5 (PC engines),and 44.2 (DI engines) when the “ASTM D4737-96a” test method is used. A fuel witha higher cetane number may be required for operation at a higher altitude or in coldweather.

(2) Via standards tables, the equivalent kg/m3 (kilograms per cubic meter) using the “ASTMD287” test method temperature of 15.56° C (60° F) for the minimum API gravity of 30 is875.7 kg/m3, and for the maximum API gravity of 45 is 801.3 kg/m3.

(3) ULSD 0.0015% (<15 ppm S) is required by law for Tier 4 engines and engines withaftertreatment devices.

(4) Certain Cat fuel systems and engine components can operate on fuel with amaximum sulfur content of 3%. Contact your Cat dealer for guidance about appropriatemaintenance intervals and fluids for engines using fuel with sulfur levels between 0.1%and 3%.

(5) An engine which operates on fuel with 0.1% (1000 ppm) of sulfur or more is operatingin a severe service application. Refer to this Operation and Maintenance Manual,“Severe Service Application” for information about operating an engine in a severeservice application.

(6) Follow the test conditions and procedures for gasoline (motor).

Biodiesel

A biodiesel blend of up to 20 percent may beused in the engine when the fuel blend meetsthe recommendations in table 32 and meetsthe recommendations in Special Publication,SEBU6385, “Cat On-highway Diesel Engine FluidsRecommendations”, “Biodiesel”.

Note: A complete Cat S·O·S Services oil analysisprogram is recommended strongly when usingbiodiesel blends above 5 percent.

Table 32

Biodiesel Blends for Cat On-highway Engines

Biodiesel blend stock Final blend Distillate diesel fuelused for blend

Caterpillar biodieselspecification, “ASTMD6751” or “EN14214”

B20: “ASTM D7467”and “API” gravity 30-45

Caterpillar distillate dieselfuel specification, “ASTM

D975” or “EN590”

Fuel Additives

Cat Diesel Fuel Conditioner

Cat Diesel Fuel Conditioner is a proprietaryformulation that has been extensively tested foruse with distillate diesel fuels for use in Cat DieselEngines. Cat Diesel Fuel Conditioner is a highperformance fuel conditioner for lower quality fuelsthat do not meet any of the following minimumrequirements:

• “Caterpillar Specification for Distillate Diesel Fuel”

• National Conference on Weights and Measures(NCWM) Premium Diesel definition (refer to the2004 or newer National Institute of Standards &Technology (NIST) Handbook).

• EN590 (non-arctic)

• ASTM D975


Cat Diesel Fuel Conditioner is the only fuelconditioner available that is tested and approved byCaterpillar for use in Cat Diesel Engines.

Refer to Special Publication, SEBU6385, “CatOn-highway Diesel Engine Fluids Recommendations”for information about the use of Cat Diesel FuelConditioner.

Cat Diesel Fuel System Cleaner

Note: Cat Diesel Fuel System Cleaner is the onlyfuel system cleaner that is tested and approved byCaterpillar for use in Cat Diesel Engines.

Cat Diesel Fuel System Cleaner is a provenhigh performance detergent product designedspecifically for cleaning deposits that form in the fuelsystem. Deposits in the fuel system reduce systemperformance and can increase fuel consumption. CatDiesel Fuel System Cleaner addresses the depositsformed due to the use of degraded diesel fuel, andpoor quality diesel fuel containing high quantities ofhigh molecular weight compounds. Cat Diesel FuelSystem Cleaner addresses deposits formed due tothe use of biodiesel, and biodiesel blends do not meetthe appropriate quality specifications. Continued useof Cat Diesel Fuel System Cleaner is proven to inhibitthe growth of new deposits.

Caterpillar strongly recommends that Cat DieselFuel System Cleaner be used with biodiesel andbiodiesel blends. Cat Diesel Fuel System Cleaner issuitable for use with biodiesel/biodiesel blends thatmeet Caterpillar biodiesel recommendations andrequirements. Not all fuel cleaners are suitable foruse with biodiesel/biodiesel blends. Read and followall applicable label usage instructions. Also, refer toSpecial Publication, SEBU6385, “Cat On-highwayDiesel Engine Fluids Recommendations”, “DistillateDiesel Fuel”, article and also refer to the “Biodiesel”article, which includes Caterpillar biodieselrecommendations and requirements.

Aftermarket Fuel Additives

There are many different types of fuel additives thatare available to use. Caterpillar does not generallyrecommend the use of fuel additives.

In special circumstances, Caterpillar recognizesthe need for fuel additives. Use fuel additives withcaution. The additive may not be compatible withthe fuel. Some additives may precipitate. This actioncauses deposits in the fuel system. The depositsmay cause seizure. Some additives may plug fuelfilters. Some additives may be corrosive, and someadditives may be harmful to the elastomers in thefuel system. Some additives may damage emissioncontrol systems. Some additives may raise fuel sulfurlevels above the maximum levels that are allowedby the following agencies: EPA and other regulatoryagencies. Contact your fuel supplier for thosecircumstances when fuel additives are required.Your fuel supplier can make recommendations foradditives to use and for the proper level of treatment.

Note: For best results, your fuel supplier should treatthe fuel when additives are needed.

Engine Equipped with a Diesel ParticulateFilters (DPF)

Note: For optimum engine system performance ofDPF equipped Cat diesel engines, the use of CatDEO-ULS is strongly recommended. For optimumengine system performance of DPF equipped Catdiesel engines, the use of ultralow sulfur diesel fuel(ULSD) is required.

Use of oil that does not meet the Cat ECF-3specification and the API CJ-4 oil category mayrequire more frequent DPF cleaning cycles and maycontribute to DPF plugging. When the recommendedand preferred Cat DEO-ULS is not used, it is stronglyrecommended that DPF equipped engines use oilthat meets the Cat ECF-3 specification and the APICJ-4 oil category.

Refer to Special Publication, SEBU6385, “CatOn-highway Diesel Engine Fluids Recommendations”for complete information.

Cooling SystemNote: Refer to Special Publication, SEBU6385, “CatOn-highway Diesel Engine Fluids Recommendations”for complete information about the proper fluids foruse in the cooling system.


Refill Capacities

The cooling system operates under pressurewhich is controlled by the radiator pressure cap.Removing the cap while the system is hot may al-low the escape of hot coolant and steam, causingserious burns.

Before you remove the radiator cap, allow the sys-tem to cool. Use a thick cloth and turn the radiatorcap slowly to the first stop to allow pressure to es-cape before fully removing the cap.

Avoid contact with coolant.

NOTICENever add coolant to an overheated engine. Enginedamage could result. Allow the engine to cool first.

NOTICEIf the engine is to be stored in, or shipped to an areawith below freezing temperatures, the cooling systemmust be either protected to the lowest outside temper-ature or drained completely in order to prevent dam-age caused by freezing coolant.

NOTICENever operate an engine without water temperatureregulators in the cooling system. Water temperatureregulators help to maintain the engine coolant at theproper operating temperature. Cooling system prob-lems can develop without water temperature regula-tors. Removing the regulators allows some coolant tobypass the radiator, potentially causing overheating.


Coolant Recommendations

A Cat Diesel Engine equipped with air-to-airaftercooling (ATAAC) requires a minimum of 30percent glycol to help prevent water pump cavitation.

Table 33

Coolant Recommendations for Cat Diesel Engines

Recommen-dations Product Service

Hours(1)(2)(3)Required

Maintenance

Preferred Cat ELC and Cat ELI12000

hours or 6years

Add Cat ELCExtender at 6000service hoursor one half ofservice life

Minrequirements

Cat EC-1 specification and“ASTM D6210” andOrganic Additive

Technology (OAT) basedon a combination of amonocarboxylic acid anda dicarboxylic acid

Phosphate, borate, andsilicate free

Tolyltriazole: minimumtypical concentration

of 900 ppmNitrite: minimum typicalconcentration of 500 ppm

in new coolants

6000 hoursor 6 years

Add Extenderat 3000 servicehours or one halfof service life

Acceptable Cat DEAC 3000 hoursor 3 years

SCA atmaintenanceintervals

Minrequirementsfor fullyformulatedHeavy DutyCommercialcoolants

“ASTM D6210” andNitrite (as NO2)

concentration: Minimum of1200 ppm (70 grains/USgal) and maximum of 2400ppm (140 grains/US gal)Silicon concentration:

minimum of 100 ppm andmaximum of 275 ppm

3000 hoursor 2 years

SCA atmaintenanceintervals

Minrequirementsfor Commercial

coolantsrequiring SCAprecharge

“ASTM D4985” and(1)Nitrite (as NO2)

concentration: Minimum of1200 ppm (70 grains/USgal) and maximum of 2400ppm (140 grains/US gal)Silicon concentration:

minimum of 100 ppm andmaximum of 275 ppm

3000 hoursor 1 year

SCA at initialfill and SCA atmaintenanceintervals

(1) New Coolants at 50 volume percent diluted. Coolants that are prediluted at thecoolant manufacturer must be diluted with water that meets Reagent 4 “ASTM D1193”requirements.

(2) Maintain the in-service coolant at the given limits.(3) When referring to the service hours, use the interval that occurs first. These coolantchange intervals are only achievable with annual S·O·S Services Level 2 coolantsampling analysis.


Refill Capacities

NOTICEUse Only Approved SCAs and Extenders

Conventional coolants require the maintenance ad-dition of SCA throughout the expected life of thecoolants. Do NOT use an SCA with a coolant unlessapproved specifically by the coolant supplier. Thecoolant manufacturer is responsible for ensuringcompatibility and acceptable performance.

To help ensure expected performance, EC-1 coolantsrequire the one time maintenance addition of an ex-tender at coolant service mid-life. Do not use an ex-tender with a coolant unless the extender has beenapproved specifically for use by the coolant manufac-turer. The coolant manufacturer is responsible for en-suring compatibility and acceptable performance.

Failure to follow these recommendations can result inshortened cooling system component life.

Cat ELC can be recycled into conventional coolants.

For more information, refer to Special Publication,SEBU385, “Cat Commercial Engine FluidsRecommendations”.

S·O·S Services Coolant Analysis

Testing the engine coolant is important to ensurethat the engine is protected from internal cavitationand corrosion. The analysis also tests the ability ofthe coolant to protect the engine from boiling andfreezing. S·O·S coolant analysis can be done at yourCat dealer. Cat S·O·S coolant analysis is the bestway to monitor the condition of your coolant and yourcooling system. S·O·S coolant analysis is a programthat is based on periodic samples.

Table 34

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEACCat SCA

ConventionalHeavy-Duty Coolants

Every 250 hours Yearly(1)

Cat ELCCat ELI

Commercial EC-1Coolants

Optional(1) Yearly(1)

(1) The Level 2 Coolant Analysis should be performed sooner if a problem is suspected oridentified.

Note: Check the SCA (Supplemental CoolantAdditive) of the conventional coolant at every oilchange or at every 250 hours. Perform this check atthe interval that occurs first.

S·O·S Services Coolant Analysis (Level 1)

A coolant analysis (Level 1) is a test of the propertiesof the coolant.


The following properties of the coolant are tested:

• Glycol concentration for freeze protection and boilprotection

• Ability to protect from erosion and corrosion

• pH

• Conductivity

• Visual analysis

• Odor analysis

The results are reported, and appropriaterecommendations are made.

S·O·S Services Coolant Analysis (Level 2)

A coolant analysis (Level 2) is a comprehensivechemical evaluation of the coolant. This analysis isalso a check of the overall condition of the coolingsystem.

The S·O·S coolant analysis (Level 2) has thefollowing features:

• Full coolant analysis (Level 1)

• Identification of metal corrosion and ofcontaminants

• Identification of buildup of the impurities that causecorrosion

• Identification of buildup of the impurities that causescaling

• Determination of the possibility of electrolysiswithin the cooling system of the engine

The results are reported, and appropriaterecommendations are made.

For more information on S·O·S coolant analysis,consult your Cat dealer.

GreasesIf it is necessary to choose a single grease,always choose a grease that meets or exceeds therequirements of the most demanding application.Remember that the products which barely meetthe minimum performance requirements can beexpected to barely produce the minimum livesof your parts. False economy is being used if agrease is purchased with the lowest cost as the onlyconsideration. Instead, use the grease that yields thelowest total operating cost. The cost should be basedon an analysis that includes the costs of parts, labor,downtime, and the cost of the amount of grease thatis required.

For more information, refer to Special Publication,SEBU6385, “Cat On-highway Diesel Engine FluidsRecommendations”.


Maintenance Recommendations

MaintenanceRecommendations

i02909163

System Pressure ReleaseSMCS Code: 1250; 1300; 1350; 5050

Coolant System

Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.

To relieve the pressure from the coolant system, turnoff the engine. Allow the cooling system pressure capto cool. Remove the cooling system pressure capslowly in order to relieve pressure.

Fuel SystemTo relieve the pressure from the fuel system, turn offthe engine.

High Pressure Fuel Lines (If Equipped)

Contact with high pressure fuel may cause fluidpenetration and burn hazards. High pressure fu-el spray may cause a fire hazard. Failure to fol-low these inspection, maintenance and service in-structions may cause personal injury or death.

The high pressure fuel lines are the fuel lines thatare between the high pressure fuel pump and thehigh pressure fuel manifold and the fuel lines that arebetween the fuel manifold and cylinder head. Thesefuel lines are different from fuel lines on other fuelsystems.

This is because of the following differences:

• The high pressure fuel lines are constantly chargedwith high pressure.

• The internal pressures of the high pressure fuellines are higher than other types of fuel system.

Before any service or repair is performed on theengine fuel lines, perform the following tasks:

1. Stop the engine.

2. Wait for ten minutes.

Do not loosen the high pressure fuel lines in order toremove air pressure from the fuel system.

Engine OilTo relieve pressure from the lubricating system, turnoff the engine.

i03642798

Welding on Engines withElectronic ControlsSMCS Code: 1000

NOTICEBecause the strength of the frame may decrease,some manufacturers do not recommend welding ontoa chassis frame or rail. Consult the OEM of the equip-ment or your Caterpillar dealer regarding welding ona chassis frame or rail.

Proper welding procedures are necessary in orderto avoid damage to the engine's ECM, sensors,and associated components. When possible,remove the component from the unit and thenweld the component. If removal of the componentis not possible, the following procedure must befollowed when you weld on a unit that is equippedwith a Caterpillar Electronic Engine. The followingprocedure is considered to be the safest procedure toweld on a component. This procedure should providea minimum risk of damage to electronic components.

NOTICEDo not ground the welder to electrical componentssuch as the ECM or sensors. Improper grounding cancause damage to the drive train, the bearings, hy-draulic components, electrical components, and othercomponents.

Do not ground the welder across the centerline of thepackage. Improper grounding could cause damage tothe bearings, the crankshaft, the rotor shaft, and othercomponents.

Clamp the ground cable from the welder to the com-ponent that will be welded. Place the clamp as closeas possible to the weld. This will help reduce the pos-sibility of damage.

Note: Perform the welding in areas that are free fromexplosive hazards.

74 SEBU7695-15Maintenance SectionMaintenance Recommendations

1. Stop the engine. Turn the switched power to theOFF position.

2. Disconnect the negative battery cable from thebattery. If a battery disconnect switch is provided,open the switch.

3. Disconnect the J1/P1 and J2/P2 connectors fromthe ECM. Move the harness to a position that willnot allow the harness to accidentally move backand make contact with any of the ECM pins.


Use the example above. The current flow from the welder tothe ground clamp of the welder will not cause damage to anyassociated components.

(1) Engine(2) Welding electrode(3) Keyswitch in the OFF position(4) Battery disconnect switch in the open position(5) Disconnected battery cables(6) Battery(7) Electrical/Electronic component(8) Minimum distance between the component that is being welded

and any electrical/electronic component(9) The component that is being welded(10) Current path of the welder(11) Ground clamp for the welder

4. Connect the welding ground cable directly to thepart that will be welded. Place the ground cable asclose as possible to the weld in order to reduce thepossibility of welding current damage to bearings,hydraulic components, electrical components, andground straps.

Note: If electrical/electronic components are usedas a ground for the welder, or electrical/electroniccomponents are located between the welder groundand the weld, current flow from the welder couldseverely damage the component.

5. Protect the wiring harness from welding debrisand spatter.

6. Use standard welding practices to weld thematerials.

i04445692

Severe Service ApplicationSMCS Code: 1000

An engine which operates outside of normalconditions is operating in a severe serviceapplication.

An engine that operates in a severe serviceapplication may need more frequent maintenanceintervals in order to maximize the following conditions:

• Reliability

• Service life

The number of individual applications cause theimpossibility of identifying all of the factors which maycontribute to severe service operation. Consult yourCat dealer for the unique maintenance that may benecessary for your engine.

An application is a severe service application if anyof the following conditions apply:

Severe Environmental Factors• Frequent operation in dirty air

• Frequent operation at an altitude which is above1525 m (5000 ft)

• Frequent operation in ambient temperatures whichare above 32° C (90° F)

• Frequent operation in ambient temperatures whichare below 0° C (32° F)

Severe Operating Conditions• Frequent operation with inlet air which has acorrosive content

• Operation with inlet air which has a combustiblecontent


Maintenance Recommendations

• Operation which is outside of the intendedapplication

• Operation with a plugged fuel filter

• Extended operation at low idle (more than 20% ofhours)

• Frequent cold starts at temperatures below 0° C(32° F)

• Frequent dry starts (starting after more than 72hours of shutdown)

• Frequent hot shutdowns (shutting down the enginewithout the minimum of 2 minutes to 5 minutes ofcool down time)

• Operation above the engine rated speed

• Operation below the peak torque speed

• Operating with fuel which does not meetthe standards for distillate diesel fuel asstated in Special Publication, SEBU6385,“Caterpillar On-highway Diesel Engine FluidsRecommendations”, “Distillate Diesel Fuel”

• Operating with fuel which contains greater than1000 ppm (0.1%) sulfur

• Operating with a blend of distillate fuel whichcontains more than 5 percent biodiesel

Improper Maintenance Procedures(Maintenance Procedures WhichMay Contribute to a Severe ServiceApplication)• Inadequate maintenance of fuel storage tanks fromcauses such as excessive water, sediment, andmicroorganism growth.

• Extending maintenance intervals beyond therecommended intervals

• Using fluids which are not recommended in SpecialPublication, SEBU6251, “Caterpillar On-highwayDiesel Engine Fluids Recommendations”

• Extending maintenance intervals for changingthe engine oil and engine coolant without S·O·Svalidation

• Extending maintenance intervals for changing airfilters, oil filters, and fuel filters

• Failure to use a water separator

• Using filters which are not recommended bySpecial Publication, PEWJ0074, “2008 Cat Filterand Fluid Application Guide”

• Storing the engine for more than 3 months but lessthan 1 yr (For information about engine storage,refer to Special Publication, SEHS9031, “StorageProcedure for Cat Products”)

• Storing the engine for 1 yr to 2 years (Forinformation about engine storage, refer to SpecialInstruction, SEHS5001, “The Long Term Storageand Recovery of Certain Commercial Engines”)

76 SEBU7695-15Maintenance SectionMaintenance Interval Schedule

i04458554

Maintenance Interval Schedule(C11 and C13 Engines with500 HP Field Up-Rates and 525HP RV Ratings with Optional(Shallow) Oil Sumps)SMCS Code: 1000; 4450; 7500

S/N: KCA1-Up

S/N: KCB1-Up

S/N: JAM1-Up

S/N: JAX1-Up

Ensure that all safety information, warnings,and instructions are read and understood beforeany operation or any maintenance proceduresare performed. The user is responsible for theperformance of all maintenance including thefollowing procedures: all adjustments, the use ofproper lubricants, fluids, filters, and the installationof new components due to normal wear and aging .The performance of this product may be diminished ifproper maintenance intervals and procedures are notfollowed. Components may experience acceleratedwear if proper maintenance intervals and proceduresare not followed.

Note: Use whichever of the following that occurs firstin order to determine the maintenance intervals: fuelconsumption, service hours, mileage, and calendartime . Before each consecutive interval is performed,all maintenance from the previous intervals must beperformed.

Products that operate in severe operating conditionsmay require more frequent maintenance.

When Required

Battery - Replace .................................................. 82Battery or Battery Cable - Disconnect .................. 83Coolant - Change .................................................. 86Coolant Extender (ELC) - Add .............................. 88Coolant Sample (Level 1) - Obtain ....................... 90Coolant Sample (Level 2) - Obtain ....................... 91Engine Air Cleaner Element (Single Element) -Inspect/Clean/Replace ........................................ 93Engine Oil Level Gauge - Calibrate ...................... 97Fuel System - Prime ........................................... 105

Daily

Coolant Level - Check .......................................... 89Engine Air Cleaner Service Indicator - Inspect ..... 95Engine Oil Level - Check ...................................... 97Fuel System Water Separator - Check/Drain ...... 108

Walk-Around Inspection ....................................... 114

PM Level 1 - Every 24 000 km (15 000 miles)or 5700 L (1500 US gal) of Fuel or 400 ServiceHours or 6 Months

Hoses and Clamps - Inspect/Replace ................. 111

Every 24 140 km (15 000 miles) or 7950 L(2100 US gal) of Fuel or 230 Service Hours

Engine Oil Sample - Obtain .................................. 99Engine Oil and Filter - Change ............................. 99

PM Level 1 - Every 48 000 km (30 000 miles)or 15 520 L (4100 US gal) of Fuel or 500Service Hours

Air Compressor Filter - Clean/Replace ................. 81Air Shutoff - Test ................................................... 81Alternator - Inspect ............................................... 82Battery Electrolyte Level - Check .......................... 83Belt Tensioner - Check .......................................... 83Belts - Inspect/Adjust/Replace .............................. 84Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 91Engine Crankcase Breather - Clean ..................... 96Fuel System Primary Filter - Replace ................. 106Fuel System Secondary Filter - Replace ............ 107Fuel Tank Water and Sediment - Drain ............... 108Grounding Stud - Inspect/Clean/Tighten .............. 110Hoses and Clamps - Inspect/Replace ................. 111

Between 24 000 and 96 000 km (15 000 and60 000 miles)

Engine Valve Lash - Check ................................. 104Fuel Injector - Check ........................................... 104Valve Actuators - Check ...................................... 114

PM Level 2 - Every 320 000 km (200 000 miles)or 125 000 L (33 000 US gal) of Fuel or 4000Service Hours or 2 Years

Aftercooler Core - Clean/Test ............................... 81Coolant Temperature Regulator - Replace ........... 91Fan Drive Bearing - Lubricate ............................. 104Radiator - Clean ................................................... 113


Air Compressor - Check ....................................... 81Crankshaft Vibration Damper - Inspect ................. 92Engine - Clean ...................................................... 93Engine Valve Lash - Check ................................. 104Fuel Injector - Check ........................................... 104Turbocharger - Inspect ......................................... 114Valve Actuators - Check ...................................... 114


Maintenance Interval Schedule

i04458553

Maintenance Interval Schedule(C11 and C13 Engines with500 HP Field Up-Rates and 525HP RV Ratings with Standard(Deep) Oil Sumps)SMCS Code: 1000; 4450; 7500

S/N: KCA1-Up

S/N: KCB1-Up

S/N: JAM1-Up

S/N: JAX1-Up




When Required


Daily

Coolant Level - Check .......................................... 89Engine Air Cleaner Service Indicator - Inspect ..... 95Engine Oil Level - Check ...................................... 97Fuel System Water Separator - Check/Drain ...... 108

Walk-Around Inspection ....................................... 114









Between 24 000 and 96 000 km(15 000 and 60 000 miles) (Betweenthe First and Fourth Oil Change)

Fuel Injector - Check ........................................... 104




Air Compressor - Check ....................................... 81Crankshaft Vibration Damper - Inspect ................. 92Engine - Clean ...................................................... 93


Engine Valve Lash - Check ................................. 104Fuel Injector - Check ........................................... 104Turbocharger - Inspect ......................................... 114Valve Actuators - Check ...................................... 114


Maintenance Interval Schedule

i04458552

Maintenance Interval Schedule(C11 and C13 Engines withOptional Shallow Oil Sumps)SMCS Code: 1000; 4450; 7500

S/N: KCA1-Up

S/N: KCB1-Up

S/N: JAM1-Up

S/N: JAX1-Up




When Required


Daily

Coolant Level - Check .......................................... 89Engine Air Cleaner Service Indicator - Inspect ..... 95Engine Oil Level - Check ...................................... 97Fuel System Water Separator - Check/Drain ...... 108Walk-Around Inspection ....................................... 114












Air Compressor - Check ....................................... 81Crankshaft Vibration Damper - Inspect ................. 92Engine - Clean ...................................................... 93Engine Valve Lash - Check ................................. 104Fuel Injector - Check ........................................... 104Turbocharger - Inspect ......................................... 114Valve Actuators - Check ...................................... 114


i04458527

Maintenance Interval Schedule(C11 , C13 , and C15 Engineswith Standard (Deep) OilSumps)SMCS Code: 1000; 4450; 7500




When Required


Daily

Coolant Level - Check .......................................... 89Engine Air Cleaner Service Indicator - Inspect ..... 95Engine Oil Level - Check ...................................... 97Fuel System Water Separator - Check/Drain ...... 108Walk-Around Inspection ....................................... 114




Air Compressor Filter - Clean/Replace ................. 81Air Shutoff - Test ................................................... 81Alternator - Inspect ............................................... 82Battery Electrolyte Level - Check .......................... 83Belt Tensioner - Check .......................................... 83Belts - Inspect/Adjust/Replace .............................. 84Cooling System Supplemental Coolant Additive(SCA) - Test/Add ................................................. 91Engine Crankcase Breather - Clean ..................... 96Engine Oil Sample - Obtain .................................. 99Engine Oil and Filter - Change ............................. 99Fuel System Primary Filter - Replace ................. 106Fuel System Secondary Filter - Replace ............ 107Fuel Tank Water and Sediment - Drain ............... 108Grounding Stud - Inspect/Clean/Tighten .............. 110Hoses and Clamps - Inspect/Replace ................. 111






Air Compressor - Check ....................................... 81Compression Brake - Inspect/Adjust/Replace ...... 85Crankshaft Vibration Damper - Inspect ................. 92Engine - Clean ...................................................... 93Engine Valve Lash - Check ................................. 104Fuel Injector - Check ........................................... 104Turbocharger - Inspect ......................................... 114Valve Actuators - Check ...................................... 114

PM Level 4 - Every 966 000 km (600 000 miles)or 380 000 L (100 000 US gal) of Fuel or 12000 Service Hours or 6 Years

Compression Brake - Inspect/Adjust/Replace ...... 85


Aftercooler Core - Clean/Test

i01807350

Aftercooler Core - Clean/Test(Air-To-Air Aftercooler)SMCS Code: 1064-070; 1064-081

The air-to-air aftercooler is OEM installed in manyapplications. Please refer to the OEM specificationsfor information that is related to the aftercooler.

i04371922

Air Compressor - CheckSMCS Code: 1803-535

Do not disconnect the air line from the air com-pressor governor without purging the air brakeand the auxiliary air systems. Failure to purge theair brake and the auxiliary air systems before re-moving the air compressor and/or the air linescould cause personal injury.


Typical installation of an air compressor

If the air compressor pressure relief valve that ismounted in the air compressor cylinder head isbypassing compressed air, there is a malfunctionin the air system, possibly ice blockage. Underthese conditions, your engine may have insuffi-cient air for normal brake operation.

Do not operate the engine until the reason for theair bypass is identified and corrected. Failure toheed this warning could lead to property damage,personal injury, or death to the operator or by-standers.

The function of the air compressor pressure reliefvalve is to bypass air when there is a malfunction inthe air compressor system.

The air compressor pressure relief valve releases airat 1723 kPa (250 psi). All personnel must stand clearof the air compressor pressure relief valve whencompressed air is released. All personnel should alsostay clear of the air compressor when the engine isoperating and the air compressor is exposed.

Refer to the Disassembly and Assembly Manual,“Air Compressor - Remove and Install” for moreinformation or consult with your Cat dealer.

i01544231

Air Compressor Filter -Clean/Replace(If Equipped)SMCS Code: 1054; 1803-070-FQ; 1803-510-FQ;1803; 5502

One of the single most important aspects ofpreventive maintenance for the air compressor is theinduction of clean air. The type of maintenance that isrequired for the air compressor and the maintenanceinterval depends on the type of air induction systemthat is used. Operating conditions (dust, dirt anddebris) may require more frequent service.

Refer to the Service Manual for the type of aircompressor that is installed on the engine. Followthe maintenance recommendations that are providedby the OEM of the air compressor. Some enginesuse boost air pressure so the engine air cleaner willrequire servicing.

i02811865

Air Shutoff - Test(Engines that are Equippedwith Optional Air ShutoffSystems)SMCS Code: 1078-081

The air inlet shutoff switch can be used to manuallyactivate the air inlet shutoff. When the switch isdepressed, a one second pulse is sent to the air inletshutoff relay.

In order to test the air shutoff system, perform thefollowing steps:

• Start the engine.

82 SEBU7695-15Maintenance SectionAlternator - Inspect

• Place the transmission in the NEUTRAL position.

• Push the “AIR SHUTOFF” switch.

The engine should shut down.

g01402506Illustration 44Typical air shutoff

The air shutoff must be manually reset before furtherengine operation. The “OPEN/CLOSED” switch willbe open during engine operation. Move the indicatorfrom the CLOSED position to the OPEN position.

If the engine does not shut down, further testing of theair shutoffs may be accomplished through the use ofCat ET. Refer to the Troubleshooting Guide, “Air InletShutoff Circuit - Test” information for your engine.

i02676048

Alternator - InspectSMCS Code: 1405-040

Caterpillar recommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and proper battery charging. Inspect theammeter (if equipped) during engine operation inorder to ensure proper battery performance and/orproper performance of the electrical system. Makerepairs, as required.

Check the alternator and the battery charger forproper operation. If the batteries are properlycharged, the ammeter reading should be very nearzero. All batteries should be kept charged. Thebatteries should be kept warm because temperatureaffects the cranking power. If the battery is too cold,the battery will not crank the engine. The battery willnot crank the engine, even if the engine is warm.When the engine is not run for long periods of timeor if the engine is run for short periods, the batteriesmay not fully charge. A battery with a low charge willfreeze more easily than a battery with a full charge.

i02153996

Battery - ReplaceSMCS Code: 1401-510

Batteries give off combustible gases which canexplode. 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 inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

The battery cables or the batteries should not beremoved 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 withthe cover in place may cause a battery explosionresulting 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 thecharger.

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

Note: Always recycle a battery. Never discard abattery. Return used batteries to an appropriaterecycling facility.

5. Remove the used battery.

6. Install the new battery.

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

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


Battery Electrolyte Level - Check

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

i02601752

Battery Electrolyte Level -CheckSMCS Code: 1401-535-FLV

When the engine is not run for long periods of time orwhen the engine is run for short periods, the batteriesmay not fully recharge. Ensure a full charge in orderto help prevent the battery from freezing.

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on ornear batteries.

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

If the addition of water is necessary, use distilledwater. If distilled water is not available use cleanwater that is low in minerals. Do not use artificiallysoftened water.

2. Check the condition of the electrolyte with the245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• A mixture of 0.1 kg (0.2 lb) of baking soda and1 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 theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fit properly.Coat the clamps and the terminals with 5N-5561Silicone Lubricant, petroleum jelly or MPGM.

i01492654

Battery or Battery Cable -DisconnectSMCS Code: 1401; 1402-029

The battery cables or the batteries should not beremoved 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 withthe cover in place may cause a battery explosionresulting in personal injury.

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

2. Disconnect the negative battery terminal at thebattery that goes to the start switch. Ensure thatthe cable cannot contact the terminal. When four12 volt batteries are involved, the negative side oftwo batteries must be disconnected.

3. Tape the leads in order to help prevent accidentalstarting.

4. Proceed with necessary system repairs. Reversethe steps in order to reconnect all of the cables.

i04442852

Belt Tensioner - CheckSMCS Code: 1358-535

Check the position of the belt tensioner to maintainthe proper belt tension. A film (decal) is located onthe side of the belt tensioner. The decal indicateswhen the belts have stretched too far to be properlyadjusted by the belt tensioner.

84 SEBU7695-15Maintenance SectionBelts - Inspect/Adjust/Replace

g01526739Illustration 45Side view of the belt tensioner(1) Pointer(2) Red zone(3) Green zone

If the pointer is in green zone, the belt tension iscorrect. If the pointer is in the upper red zone, the belthas stretched. The tension must be adjusted or thebelt must be replaced. If the pointer is in the lower redzone, the belt is too short. The belt must be replaced.

i04172210

Belts - Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510

InspectionBelt tension should be checked initially betweenthe first 20 to 40 hours of engine operation.

After the initial check, the belt tension should bechecked at Every PM Level 1 months or 3 months.

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

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

If the belts are too loose, vibration causesunnecessary wear on the belts and pulleys. Loosebelts may slip enough to cause overheating.

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

Remove the belt guard. Inspect the condition andadjustment of the alternator belts and accessorydrive belts (if equipped).

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

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

• If the engine is equipped with a refrigerantcompressor, the following components will have anautomatic belt tensioner: the belt for the fan drive,the alternator, and accessories.

• If the engine is not equipped with a refrigerantcompressor, the alternator is used to adjust thebelt tension.

Adjustment

Alternator Belt

g00485289Illustration 46Typical alternator mounting

(1) Adjusting nuts(2) Mounting bolts

1. Slightly loosen mounting bolt (2) and adjustingnut (1).

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

3. Tighten adjusting nuts (1) and mounting bolts(2). Refer to the Specifications Manual, “TorqueSpecifications” topic.

4. Install the belt guard.

If new belts are installed, check the belt tension againafter 30 minutes of engine operation at the rated rpm.


Compression Brake - Inspect/Adjust/Replace

i01426993

Compression Brake -Inspect/Adjust/ReplaceSMCS Code: 1129-025; 1129-040; 1129-510

S/N: BXS1-Up

S/N: RKS1-Up

The maintenance of the compression brake shouldbe performed in conjunction with scheduled enginemaintenance. The correct tune-up kit is requiredwhen parts are replaced on the compression brake.Refer to the Parts Manual for additional information.

Note: The slave piston lash adjustment must beperformed after the engine valve lash adjustmentis performed. Make the slave piston adjustmentwhile the engine is stopped. Refer to the SystemsOperation, Testing and Adjusting Module foradditional information.

Refer to the Disassembly and Assembly Module forinstructions on replacing the components.

86 SEBU7695-15Maintenance SectionCoolant - Change

Table 35

Component Required Maintenance(300,000 miles)

Required Maintenance(600,000 miles)

Wiring and TerminalConnections Inspect Inspect

Clutch/Throttle/BufferScrew Adjust/Replace Adjust/Replace

Slave Piston LashAdjusting Screw Adjust/Inspect Adjust/Replace

Solenoid Valves Inspect Replace

Crosshead Bridges/Valve Stem Caps Inspect Inspect

Injector/Exhaust RockerArm Screws Inspect Inspect

Master Piston/ForkAssembly Inspect Inspect

Slave pistons Inspect Inspect

External Hose Assembly Inspect Inspect

Housings Inspect Inspect

Fuel Pipes Inspect Inspect

Hold Down Bolts Inspect Replace

Accumulator Springs(1) Replace Inspect

Solenoid Harness(1) Replace Inspect

Solenoid Seal Rings(1) Replace Inspect

Control Valve Springs(1) Replace Inspect

Control Valves(1) Replace Inspect

Oil Seal Rings(1) Replace Inspect

Master Piston ReturnSprings(1) Replace Inspect

Terminal Lead Out(1) Replace Inspect

Crosshead PinAssembly(1) Replace Inspect

(1) Contained in tune-up kits

i04317341

Coolant - ChangeSMCS Code: 1350-044; 1352; 1395-044; 1395

Refer to this Operation and Maintenance Manual,“Fluid Recommendations” for the correct intervalsfor changing the coolant.

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

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

SEBU7695-15 87Maintenance SectionCoolant - Change

Drain the Coolant

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, “Cat DealerService Tool Catalog” or refer to Special Publication,PECJ0003, “Cat Shop Supplies and Tools Catalog” fortools and supplies suitable to collect and contain fluidson Cat products.


1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

2. Open the cooling system drain valve (if equipped).If the cooling system is not equipped with a drainvalve, remove one of the drain plugs.

Note: If equipped, be sure to drain the heater andany related supply and return lines.

Allow the coolant to drain.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

For information regarding the disposal and therecycling of used coolant, consult your Cat dealer orconsult Cat Dealer Service Tool Group:

Inside USA: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOLInternational: 1-309-578-7372

Flush

Systems Filled with Cat ELC, Cat ELI, or aConventional Coolant that Meets the CatEC-1 Requirements and the Standardsof ASTM D6210

3. Flush the cooling system with clean water in orderto remove any debris.

4. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer tothe Specifications Manual, SENR3130, “TorqueSpecifications” for more information on the propertorques.

NOTICEFill the cooling system no faster than 19 L (5 US gal)per minute to avoid air locks.

5. Fill the cooling system with clean water. Install thecooling system filler cap.

6. Start and run the engine at low idle until thetemperature reaches 49 to 66 °C (120 to 150 °F).

7. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve(if equipped). Clean the drain plugs. Install thedrain plugs. Refer to the Specifications Manual,SENR3130, “Torque Specifications” for moreinformation on the proper torques.

Systems Filled with Cat DEAC orConventional Coolant which does notMeet the Cat EC-1 Requirements

3. Flush the cooling system with clean water in orderto remove any debris.

4. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer tothe Specifications Manual, SENR3130, “TorqueSpecifications” for more information on the propertorques.


5. Fill the cooling system with a mixture of cleanwater and Cat Fast Acting Cooling SystemCleaner.

88 SEBU7695-15Maintenance SectionCoolant Extender (ELC) - Add

6. Choose 1 of the following options.

• Add 0.5 L (1 pint) of cleaner per 15 L (4 US gal)of the cooling system capacity.

• For cooling systems with heavy deposits orplugging, add 0.5 L (1 pint) of cleaner per3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity.

7. Install the cooling system filler cap.

8. Start and run the engine at low idle for a minimumof 30 minutes. The coolant temperature should beat least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

9. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. If equipped, be sure toflush the heater and any related supply and returnlines. Close the drain valve (if equipped). Cleanthe drain plugs. Install the drain plugs. Refer tothe Specifications Manual, SENR3130, “TorqueSpecifications” for more information on the propertorques.

Fill


10. Fill the cooling system. Refer to this Operation andMaintenance Manual, “Fluid Recommendations”for more information on cooling systemspecifications Refer to this Operation andMaintenance Manual, “Refill Capacities” forinformation about the capacity of the coolingsystem. Do not install the cooling system filler cap.

11.Start and run the engine at low idle. Increase theengine rpm to high idle. Run the engine at highidle for 1 minute in order to purge the air from thecavities of the engine block. Stop the engine.

12.Check the coolant level. Maintain the coolantlevel within 13 mm (0.5 inch) below the bottom ofthe pipe for filling. Maintain the coolant level within13 mm (0.5 inch) to the proper level on the sightglass (if equipped).

13.Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap.Only install the used filler cap if the gasket is notdamaged. Use a 9S-8140 Pressurizing Pump topressure test a reinstalled cooling system fillercap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install a newcooling system filler cap.

14.Start the engine. Inspect the cooling system forleaks and for proper operating temperature.

i04445671

Coolant Extender (ELC) - AddSMCS Code: 1352-544-NL

Note: Refer to this Operation and MaintenanceManual, “Fluid Recommendations” (Cooling System)for the maintenance interval for the addition of thecoolant extender.

Cat ELC (Extended Life Coolant) and Cat ELI(Extended Life Inhibitor) do not require the frequentadditions of any supplemental cooling additives. TheCat ELC Extender will only be added one time.

Note: Do not use conventional supplemental coolantadditive (SCA) with Cat ELC or with Cat ELI.

Check the cooling system only when the engine isstopped and cool.

SEBU7695-15 89Maintenance SectionCoolant Level - Check

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.




1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. If necessary, drain enough coolant from thecooling system in order to add the Cat ELCExtender.

3. Add Cat ELC Extender according to therequirements for the cooling system capacity.Refer to this Operation and Maintenance Manual,“Refill Capacities” for the coolant capacity.

4. Clean the cooling system filler cap. Inspect thegaskets on the cooling system filler cap. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system filler cap.

For further information, refer to this Operation andMaintenance Interval, , “Fluid Recommendations”.

i04156593

Coolant Level - CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.

g00285520Illustration 47Cooling system filler cap


1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine isequipped with a sight glass, maintain the coolantlevel to the proper level in the sight glass.

g00103639Illustration 48Typical filler cap gaskets

90 SEBU7695-15Maintenance SectionCoolant Sample (Level 1) - Obtain

3. Clean the cooling system filler cap and check thecondition of the filler cap gaskets. Replace thecooling system filler cap if the filler cap gaskets aredamaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i04333559

Coolant Sample (Level 1) -ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542

Testing the engine coolant is important to ensurethat the engine is protected from internal cavitationand corrosion. The analysis also tests the ability ofthe coolant to protect the engine from boiling andfreezing. S·O·S Systems Coolant Analysis can bedone at your Cat dealer. Cat S·O·S coolant analysis isthe best way to monitor the condition of your coolantand your cooling system. S·O·S coolant analysis is aprogram that is based on periodic samples.

Note: Obtaining a Coolant Sample (Level 1) isoptional if the cooling system is filled with one ofthe following coolants: Cat ELC (Extended LifeCoolant)., Cat ELI (Extended Life Inhibitor), andConventional Heavy-Duty Coolant.

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any of the followingcoolants: Cat DEAC, Cat SCA, and ConventionalHeavy-Duty Coolants.

For additional information about coolant analysisand about other coolants, see this Operation andMaintenance Manual, “Fluid Recommendations” orconsult your Cat dealer.

Sampling ConditionsIf the engine is equipped with a sampling port, theengine should be running at operating temperaturewhen the sample is obtained.

If the engine is not equipped with a sampling port, thecoolant should be warm.

Use the following guidelines for proper sampling ofthe coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

Timing of the SamplingTable 36

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEACCat SCA

ConventionalHeavy-DutyCoolants

Every 250 hours Yearly(1)

Cat ELCCat ELI

CommercialEC-1 Coolants

Optional(1) Yearly(1)

(1) The Level 2 Coolant Analysis should be performed sooner if aproblem is suspected or identified.

Note: Check the SCA (Supplemental CoolantAdditive) of the conventional coolant at every oilchange or at every 250 hours. Perform this check atthe interval that occurs first.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In order toreceive the full effect of S·O·S analysis, establisha consistent trend of data. In order to establisha pertinent history of data, perform consistentsamplings that are evenly spaced. Supplies forcollecting samples can be obtained from your Catdealer.


Submit the sample for Level 1 analysis.

Note: Level 1 results may indicate a need for Level2 Analysis.


Coolant Sample (Level 2) - Obtain

i04169969

Coolant Sample (Level 2) -ObtainSMCS Code: 1350-008; 1395-008; 1395-554; 7542

Refer to Operation and Maintenance Manual,“Coolant Sample (Level 1) - Obtain” for the guidelinesfor proper sampling of the coolant.

Submit the sample for Level 2 analysis.

For further information, refer to this Operation andMaintenance Manual, “Fluid Recommendations”.

i04240223

Coolant TemperatureRegulator - ReplaceSMCS Code: 1355-510

Replace the water temperature regulator before thewater temperature regulator fails. Replacing thewater temperature regulator reduces the chances forunscheduled downtime.

A water temperature regulator that fails in apartially opened position can cause overheating orovercooling of the engine.

A water temperature regulator that fails in the openposition will cause the engine operating temperatureto be too low during partial load operation. Lowengine operating temperatures during partial loadscould cause an excessive carbon buildup inside thecylinders. This excessive carbon buildup could resultin an accelerated wear of the piston rings and wearof the cylinder liner.

A water temperature regulator that fails in the closedposition can cause excessive overheating. Excessiveoverheating could result in cracking of the cylinderhead or piston seizure problems.

NOTICEFailure to replace your water temperature regulatoron a regularly scheduled basis could cause severeengine damage.

Caterpillar engines incorporate a shunt design coolingsystem and require operating the engine with a watertemperature regulator installed.

If the water temperature regulator is installed incor-rectly, the enginemay overheat, causing cylinder headdamage. Ensure that the new water temperature reg-ulator is installed in the original position. Ensure thatthe water temperature regulator vent hole is open.

Do not use liquid gasket material on the gasket orcylinder head surface.




Note: If replacing only the water temperatureregulator, only drain the coolant to a level that isbelow the water temperature regulator housing.

Refer to two articles in the Disassembly andAssembly Manual, “Water Temperature Regulator -Remove and Water Temperature Regulator - Install”for the replacement procedure or consult your Catdealer.

i03085828

Cooling System SupplementalCoolant Additive (SCA) -Test/AddSMCS Code: 1352-045; 1395-081

Note: This procedure is NOT required for applicationsthat use Cat Extended Life Coolant (ELC).

92 SEBU7695-15Maintenance SectionCrankshaft Vibration Damper - Inspect

NOTICECooling system coolant additive contains alkali. Tohelp prevent personal injury, avoid contact with theskin and the eyes. Do not drink cooling system coolantadditive.

Note: Test the Supplemental Coolant Additive (SCA)or test the SCA concentration as part of an S·O·SCoolant Analysis.

Test the SCA Concentration

Coolant, Antifreeze and SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and the eyes. Do not drink cooling systemcoolant additive.

Use the 4C-9301 Coolant Conditioner Test Kit inorder to check the concentration of the SCA. Referto the Special Publication, SEBU6385, “CaterpillarOn-highway Diesel Engine Fluid Recommendations”for more information.

Add the SCA, If Necessary

NOTICEDo not exceed the recommended amount of sup-plemental coolant additive concentration. Excessivesupplemental coolant additive concentration can formdeposits on the higher temperature surfaces of thecooling system, reducing the engine's heat transfercharacteristics. Reduced heat transfer could causecracking of the cylinder head and other high temper-ature components. Excessive supplemental coolantadditive concentration could also result in radiatortube blockage, overheating, and/or accelerated waterpump seal wear. Never use both liquid supplementalcoolant additive and the spin-on element (if equipped)at the same time. The use of those additives togethercould result in supplemental coolant additive concen-tration exceeding the recommended maximum.


Follow the instructions that are provided by the OEMor follow the instructions that are provided by themanufacturer of the coolant conditioner element onengines that are equipped with a coolant conditionerelement.

1. Slowly loosen the cooling system filler cap inorder to relieve the pressure. Remove the coolingsystem filler cap.

Note: Always discard drained fluids according tolocal regulations.

2. If necessary, drain some coolant from the coolingsystem into a suitable container in order to allowspace for the extra SCA.

3. Add the proper amount of SCA. Refer to SpecialPublication, SEBU6385, “Caterpillar On-highwayDiesel Truck Engine Fluid Recommendations” formore information on SCA requirements.

4. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets are damaged, replace the old coolingsystem filler cap with a new cooling system fillercap. Install the cooling system filler cap.

i02933380

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040

Damage to the crankshaft vibration damper or failureof the crankshaft vibration damper can increasetorsional vibrations. This can result in damage tothe crankshaft and to other engine components. Adamper that is damaged can cause excessive geartrain noise at variable points in the speed range.

The damper is mounted to the crankshaft which islocated behind the belt guard on the front of theengine.


Engine - Clean

Visconic DamperThe visconic damper has a weight that is locatedinside a fluid filled case. The weight moves in thecase in order to limit torsional vibration.

Inspect the damper for evidence of fluid leaks. Ifa fluid leak is found, determine the type of fluid.The fluid in the damper is silicone. Silicone hasthe following characteristics: transparent, viscous,smooth, and adhering.

If the fluid leak is oil, inspect the crankshaft seals forleaks. If a leak is observed, replace the crankshaftseals.

Inspect the damper and repair or replace the damperfor any of the following reasons:

• The damper is dented, cracked, or leaking.

• The paint on the damper is discolored from heat.

• The engine has had a failure because of a brokencrankshaft.

• Analysis of the oil has revealed that the front mainbearing is badly worn.

• There is a large amount of gear train wear that isnot caused by a lack of oil.

Refer to the Disassembly and Assembly Manual,“Vibration Damper and Pulley - Remove and Install”or consult your Caterpillar dealer for informationabout damper replacement.

i01646701

Engine - CleanSMCS 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. Lockout the starting controls and tag the controls “DONOT OPERATE”.

NOTICEAccumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluidspills whenever a significant quantity accumulates onthe engine.

Periodic cleaning of the engine is recommended.Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides the followingbenefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

Note: Caution must be used in order to preventelectrical components from being damaged byexcessive water when you clean the engine. Avoidelectrical components such as the alternator, thestarter, and the ECM.

i04441631

Engine Air CleanerElement (Single Element) -Inspect/Clean/ReplaceSMCS Code: 1051; 1054-040; 1054-070; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged aircleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

If the air cleaner element becomes plugged, the aircan split the material of the air cleaner element.Unfiltered air will drastically accelerate internalengine wear. Your Cat dealer has the proper aircleaner elements for your application. Consult yourCat dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily foraccumulation of dirt and debris. Remove any dirtand debris, as needed.

• Operating conditions (dust, dirt, and debris) mayrequire more frequent service of the air cleanerelement.

94 SEBU7695-15Maintenance SectionEngine Air Cleaner Element (Single Element) - Inspect/Clean/Replace

• The air cleaner element should be replaced at leastone time per year. This replacement should beperformed regardless of the number of cleanings.

Cleaning the Air Cleaner ElementUse a clean air cleaner element while dirty elementsare being cleaned.

NOTICEDo not clean the air cleaner elements by bumping ortapping. This could damage the seals. Do not use el-ements with damaged pleats, gaskets or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the air cleaner elements beforecleaning. Inspect the air cleaner elements for damageto the seal, the gaskets, and the outer cover. Inspectthe filter material for rips and for tears. Discard anydamaged air cleaner elements.

There are two common methods that are used toclean air cleaner elements:

• Pressurized air

• Vacuum cleaning

Pressurized Air

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.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded.


Typical air cleaner element

Note: When the air cleaner elements are cleaned,always begin with the clean side (inside) in order toforce dirt particles toward the dirty side (outside).

Aim the hose towards the inside of the element alongthe length of the filter to help prevent damage to thepaper pleats. Do not aim the stream of air directly atthe air cleaner element. Dirt could be forced furtherinto the pleats.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningair cleaner elements which require daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuumcleaning. Vacuum cleaning will not remove depositsof carbon and oil.

Inspecting the Air Cleaner Element


Typical air cleaner element

Inspect the clean, dry air cleaner element. Use a 60W blue light in a dark room or in a similar facility.Place the blue light in the air cleaner element. Rotatethe air cleaner element. Inspect the air cleanerelement for tears and/or holes. Inspect the air cleanerelement for light that may show through the filtermaterial. , Compare the air cleaner element to a newair cleaner element that has the same part number todetermine if the filter is clean.

Do not use an air cleaner element that has any tearsand/or holes in the filter material. Do not use an aircleaner element with damaged pleats, gaskets, orseals. Discard damaged air cleaner elements.

Replacing the Air Cleaner ElementNote: Replace an old air cleaner element with a newair cleaner element after the old element has beencleaned six times.


Engine Air Cleaner Service Indicator - Inspect

Storing the Air Cleaner ElementsIf an air cleaner element that passes inspection willnot be used, the air cleaner element can be storedfor future use.


Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An air flow restrictionmay result. To protect against dirt and damage,wrap the air cleaner elements in Volatile CorrosionInhibited (VCI) paper.

Place the air cleaner element into a box for storage.For identification, mark the outside of the box andmark the air cleaner element. Include the followinginformation:

• Date of cleaning

• Number of cleanings

Store the box in a dry location.

i01900118

Engine Air Cleaner ServiceIndicator - Inspect(If Equipped)SMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differential gaugefor inlet air pressure. The differential gauge for inletair pressure displays the difference in the pressurethat is measured before the air cleaner element andthe pressure that is measured after the air cleanerelement. As the air cleaner element becomes dirty,the pressure differential rises. If your engine isequipped with a different type of service indicator,follow the OEM recommendations in order to servicethe air cleaner service indicator.

The service indicator may be mounted on the aircleaner housing or in a remote location.

g00103777Illustration 52Typical service indicator

Observe the service indicator. The air cleanerelement should be cleaned or the air cleaner elementshould be replaced when one of the followingconditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service IndicatorService indicators are important instruments.

• Check for ease of resetting. The service indicatorshould reset in less than three pushes.

• Check the movement of the yellow core when theengine is accelerated to the engine rated speed.The yellow core should latch approximately at thegreatest vacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If the newservice indicator will not reset, the hole for the serviceindicator may be plugged.

The service indicator may need to be replacedfrequently in environments that are severely dusty, ifnecessary. Replace the service indicator annuallyregardless of the operating conditions. Replace theservice indicator when the engine is overhauled, andwhenever major engine components are replaced.

Note: When a new service indicator is installed,excessive force may crack the top of the serviceindicator. Tighten the service indicator to a torqueof 2 N·m (18 lb in).

96 SEBU7695-15Maintenance SectionEngine Crankcase Breather - Clean

i03018600

Engine Crankcase Breather -CleanSMCS Code: 1317-070

NOTICEPerform this maintenance with the engine stopped.

If the crankcase breather is not maintained on aregular basis, the crankcase breather will becomeplugged. A plugged crankcase breather will causeexcessive crankcase pressure that may causecrankshaft seal leakage.

Your engine will have one of the following enginecrankcase breathers.

Type 1

g01136454Illustration 53Typical example

1. Loosen hose clamp (1) and remove the hose frombreather assembly (2).

2. Loosen retaining clamp (3). Remove the breatherassembly and seal (4).

3. Wash the breather element in solvent that is cleanand nonflammable. Allow the breather element todry before installation.

4. Install a breather element that is clean and dry.Install the seal, the breather assembly, and theclamp. Refer to the Specifications, SENR3130 inorder to locate the proper torques.

5. Install the hose. Install the hose clamp. Refer toSpecifications, SENR3130 in order to locate theproper torques.

Type 2


1. Loosen hose clamp (5) and remove hose (6) fromvalve cover (7).

2. Remove valve cover (7). Refer to the Disassemblyand Assembly Manual for instructions on removingthe valve cover..


3. Wash breather (8) in solvent that is clean andnonflammable. Allow the breather to dry beforeinstallation.

4. Install a breather element that is clean and dry.

5. Install valve cover (7). Refer to the Disassemblyand Assembly Manual for instructions oninstalling the valve cover. Refer to Specifications,SENR3130 in order to locate the proper torques.

6. Install hose (6) on valve cover (7). Install hoseclamp (5). Refer to Specifications, SENR3130 inorder to locate the proper torques.


Engine Oil Level - Check

i04445750

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.


Partial view of the oil level gauge(Y) “ADD” mark(X) “FULL” mark

NOTICEPerform this maintenance with the engine stopped.

NOTICEEngine damage can occur if the crankcase is filledabove the “FULL” mark on the oil level gauge (dip-stick).

An overfull crankcase can cause the crankshaft to dipinto the oil. This will reduce the power that is devel-oped and also force air bubbles into the oil. Thesebubbles (foam) can cause the following problems: re-duction of the oil's ability to lubricate, reduction of oilpressure, inadequate cooling, oil blowing out of thecrankcase breathers, and excessive oil consumption.

Excessive oil consumption will cause deposits to formon the pistons and in the combustion chamber. De-posits in the combustion chamber lead to the followingproblems: guttering of the valves, packing of carbonunder the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil levelgauge, drain some of the oil immediately.

1. Remove the oil filler cap and check the oil level.Maintain the oil level between the “ADD” mark (Y)and the “FULL” mark (X) on the oil level gauge (1).Do not fill the crankcase above “FULL” mark (X).

2. In order to choose the correct type of oil for thisengine, refer to this Operation and MaintenanceManual, “Fluid Recommendations”.

3. Clean the oil filler cap. Install the oil filler cap.

4. Record the amount of oil that is added. Includethe total amount of oil added since the previoussample to provide the most accurate oil analysis.

i02921153

Engine Oil Level Gauge -CalibrateSMCS Code: 1326-524; 1326

Check the Calibration at the FirstOil ChangeNote: For Caterpillar C11 and for C13 On-highwayEngines, determine whether the oil pan is shallow ordeep by referring to this Operation and MaintenanceManual , “Refill Recommendations and Capacities”.Caterpillar C15 On-highway Engines use standard(deep) oil pans.

The engine oil level will vary depending on the angleand the slant of the engine installation. The angle isthe front to back tilt. The slant is the sideways tilt.

The oil level gauge markings must be verified in orderto ensure that it is correct. Verify the oil level gaugemarkings at the first oil change.

Use the following procedure in order to verify the“ADD” mark and verify the “FULL” mark that is onthe oil level gauge.

NOTICEThe vehicle must be parked on a level surface in orderto perform this maintenance procedure.




98 SEBU7695-15Maintenance SectionEngine Oil Level Gauge - Calibrate

1. Operate the engine until normal operatingtemperature is achieved. Stop the engine.Remove the crankcase oil drain plugs. The oildrain plug from the deep portion of the oil panshould be removed. The oil drain plug from theshallow portion of the oil pan should be removed.This will allow all of the oil to drain. Drain the oilfrom the crankcase for 20 minutes.

2. Remove the used oil filter(s). Install the new oilfilter(s). Install the oil drain plugs and tighten to70 ± 15 N·m (50 ± 11 lb ft).

Your engine may be equipped with auxiliary oilfilters. The auxiliary oil filters require a differentvolume of oil. Refer to the OEM specifications forthe auxiliary oil filter.

3. Refer to table 37 in order to determine the correctamount of oil that should be poured into thecrankcase. Pour the correct amount of oil into thecrankcase.

Table 37

Engine C11 or C13 C15

Oil pan Shallow Deep Deep (Standard)

Quantity of oil 22.5 L (23.8 qt) 28.5 L (30.1 qt) 26.5 L (28 qt)

1. Allow enough time for the oil to drain into thecrankcase. Approximately 20 minutes shouldbe allowed. Check the oil level. Wait for severalminutes and check the oil level again. Proceedafter the oil level stops changing.

2. Check the oil level on the oil level gauge. The oillevel should be at the “ADD” mark. If the oil level isnot at the existing “ADD” mark, grind off the “ADD”mark and engrave the new “ADD” level.

3. Pour 5.7 L (6 qt) of oil into the crankcase. Allowenough time for the oil to drain into the crankcase.

4. Check the oil level on the oil level gauge. The oillevel should be at the “FULL” mark. If the oil levelis not at the existing “FULL” mark, grind off the“FULL” mark and engrave the new “FULL” mark.

5. Refer to table 38 in order to determine the correctamount of oil that should be poured into thecrankcase. Pour the correct amount of oil into thecrankcase.

Table 38

Engine C11 or C13 C15

Oil Pan Shallow Deep Deep (Standard)

Quantity of oil 3.5 L (3.7 qt) 3.5 L (3.7 qt) 5.5 L (5.8qt)


Engine Oil Sample - Obtain

1. Start the engine and run the engine enough toensure that the lubrication system is filled. Inspectthe engine for oil leaks.

2. Stop the engine and allow enough time for the oilto drain into the crankcase.

3. Check the oil level on the oil level gauge. If the oillevel is not at the calibrated “FULL” mark, fill thecrankcase to the calibrated “FULL” mark. Includethe oil that was added in order to raise the level ofoil to the “FULL” mark and record the oil capacityof the lubrication system for future oil changes.

i04237495

Engine Oil Sample - ObtainSMCS Code: 1348-554-SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at regularly scheduled intervals. S·O·S oilanalysis provides infrared analysis, which is requiredfor determining nitration and oxidation levels.

Obtain the Sample and the Analysis


Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In orderto help obtain the most accurate analysis, providethe following information:

• Engine model

• Service hours on the engine

• The number of hours that have accumulated sincethe last oil change

• The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of the oilin the crankcase, obtain a warm, mixed oil sample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when thesampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.


If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEGJ0047,“How To Take A Good S·O·S Oil Sample”. Consultyour Cat dealer for complete information andassistance in establishing an S·O·S program for yourengine.

i02812032

Engine Oil and Filter - ChangeSMCS Code: 1318-510


NOTICEThe vehicle must be parked on a level surface for thismaintenance procedure.

Do not drain the engine oil when the engine is cold.As the engine oil cools, suspended waste particlessettle on the bottom of the engine oil pan. The wasteparticles are not removed with the draining coldengine oil. Drain the crankcase while the engineis stopped. Drain the crankcase while the engineoil is warm. This draining method allows the wasteparticles that are suspended in the engine oil to bedrained properly.

100 SEBU7695-15Maintenance SectionEngine Oil and Filter - Change

Failure to follow this recommended procedure willcause the waste particles to be recirculated throughthe engine lubrication system with the new engine oil.




Drain the Engine OilAfter the engine has been run at the normal operatingtemperature, stop the engine. Attach a “DO NOTOPERATE” or a similar warning tag to the ignitionkeyswitch before the engine is serviced. Use one ofthe following methods to drain the engine crankcaseoil:

• If the engine is equipped with a drain valve, turn thedrain valve knob counterclockwise in order to drainthe engine oil. After the engine oil has drained, turnthe drain valve knob clockwise in order to closethe drain valve.

• If the engine is not equipped with a drain valve,remove the oil drain plug in order to allow theengine oil to drain. If the engine is equipped with ashallow sump, remove the bottom oil drain plugsfrom both ends of the engine oil pan.

After the engine oil has drained, the oil drain plugsshould be cleaned and installed. Tighten the oildrain plugs to the proper torque. Refer to theSpecifications Module, “Engine Oil Pan” topic foradditional information.

Replace the Oil Filter

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

1. Remove the oil filter with a 185-3630 ChainWrench.

2. Cut the oil filter open with a 175-7546 Oil FilterCutter. Break apart the pleats and inspect theoil filter for metal debris. An excessive amountof metal debris in the oil filter may indicate earlywear or a pending failure.

Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are found inthe oil filter element. Ferrous metals may indicatewear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts ofthe engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is notuncommon to find small amounts of debris in theoil filter. Consult your Caterpillar dealer in orderto arrange for a further analysis if an excessiveamount of debris is found in the oil filter.


3. Clean the sealing surface of the filter mountingbase. Ensure that all of the old oil filter gasket isremoved.

4. Apply clean engine oil to the new oil filter gasket.

NOTICEDo 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 toengine components.

5. Install the new oil filter. Tighten the oil filter untilthe oil filter gasket contacts the base. Tighten theoil filter by hand according to the instructions thatare shown on the oil filter. Do not overtighten theoil filter.


Engine Oil and Filter - Change

Fill the Engine Crankcase1. Remove the oil filler cap. Refer to the Operationand Maintenance Manual, “Refill Capacities andRecommendations” topic for more informationabout: selecting the correct engine oil and findingthe correct refill capacity for your engine. Fill thecrankcase with the proper amount of engine oil.

NOTICEIf equipped with an auxiliary oil filter or system, extraoil must be added when filling the crankcase. Followthe OEM or filter manufacturer's recommendations. Ifthe extra oil is not added, the engine may starve foroil.

NOTICETo help prevent crankshaft or bearing damage, crankengine to fill all filters before starting. Do not crankengine for more than 30 seconds.

2. Start the engine and run the engine at “LOWIDLE” for two minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain back tothe sump for a minimum of ten minutes.

4. Remove the oil level gauge in order to check theoil level. Maintain the oil level between the “ADD”and “FULL” marks on the oil level gauge.

5. Remove the “DO NOT OPERATE” tag from theignition keyswitch.

Adjustments to the Oil ChangeIntervalsMany conditions affect the selection of an oil changeinterval. Proper oil change intervals are importantfor maintaining engine service life and engineperformance and fully utilizing the lubricant. Theengine oil must be able to control the following items:corrosion, oxidation, soot, and wear metals. Theengine oil must be able to control the conditionsduring the time between oil changes.

In some severe service applications, reducing theoil change interval may be necessary in order tomaintain the integrity of the engine lubricant. Referto this Operation and Maintenance Manual, “SevereService Operation - Check” or consult with your Catdealer in order to determine whether your engine isoperating under severe service conditions.

Fuel consumption and oil consumption are the mostimportant factors that are used in order to calculatean oil change interval. All engines do not consumefuel and oil at the same rate due to several factors:manufacturing tolerances, maintenance variations,and engine application.

Extended Oil Change Intervals

Requirements for Use of Extended OilChange Intervals

The following requirements must be met in orderto use Tables 39, 40, and 41:

• Cat DEO-ULS is used or an oil that meets therequirements of the Caterpillar ECF-3 (EngineCrankcase Fluid specification-3) specification isused.

• S·O·S Services oil analysis is performed at16,100 km (10,000 mile) intervals and all oil changeintervals. The S·O·S Services lab must be notifiedof the extended oil change interval. The use of anextended oil change interval makes a difference inthe interpretation of the data.

• A Cat High Efficiency Fuel Filter is used.

• Fuel with 0.05% (500 ppm) or less sulfur is used.

NOTICEContact your Caterpillar dealer for more informationabout extended oil change intervals.

Note: Caterpillar cannot guarantee the performanceof lubricants or filters that are not sold by Caterpillar.The performance guarantee of any commerciallyavailable lubricant is the responsibility of that oilcompany. The performance guarantee of anycommercially available filter is the responsibility ofthe filter manufacturer.

Tables for Extended Oil Change Intervals

In order to understand the tables for maximumpermissible oil change intervals, use the followingprocedures.

1. Determine the average fuel consumption of thevehicle.

2. Determine the gross vehicle weight (GVW) of thevehicle.

102 SEBU7695-15Maintenance SectionEngine Oil and Filter - Change

3. Determine the percent of idle time for the vehicle.A download of the histogram data from the ECMcan provide a more accurate “percent idle time”measurement. Contact your nearest Caterpillardealer for information on obtaining data from theECM.

4. The intersection of the column and the row liststhe maximum number of kilometers or milesbetween oil change intervals.

For example, a C13 Engine with an average fuelconsumption of 3 km/L (7 mpg) in a light-dutyapplication will have a maximum permissible oilchange interval of 40,250 kilometers (25,000 miles)with a shallow oil sump. The maximum permissibleoil change interval for the same situation with a Deepoil sump would be 64,350 km (40,000 miles).

Table 39

Maximum Permissible Oil Change Intervals for C11 and C13On-highway Engines with Shallow Sumps and 500 HP Field

Up-rates and 525 HP RV Ratings

Severe Duty Normal Duty Light Duty

Fuel ConsumptionKilometers Per Liter(Miles Per Gallon)

Less than 2.6km/L (6 MPG)

2.6 km/L (6MPG) to 3 km/L(7 MPG)

Greater than3 km/L (7MPG)

Gross Vehicle Weight More than36287 kg(80000 lb)

36287 kg(80000 lb) or

less

36287 kg(80000 lb)or less

Minimum Oil SumpCapacity(1) 31.7 L (33.5 qt) 31.7 L (33.5 qt) 31.7 L

(33.5 qt)

Idle Time More than 40% 20% to 40% Less than20%

Oil Classification Cat DEO-ULS or an oil that meets therequirements of the Caterpillar ECF-3

specification

Kilometers (Miles)24,150kilometers

(15,000 miles)

32,200kilometers

(20,000 miles)

40,250kilometers(25,000miles)

(1) If the oil sump capacity is greater than the oil sump capacity that is listed in Table 40,the oil change interval can be extended 1600 kilometers (1000 miles) for every 2 L(2 qt) increase in oil sump capacity.


Engine Oil and Filter - Change

Table 40

Maximum Permissible Oil Change Intervals for C11 and C13On-highway Engines with Deep Sumps (Standard)



Less than 2.6km/L (6 MPG)

2.6 km/L (6MPG) to 3km/L (7 MPG)

Greater than3 km/L (7MPG)





(39.8 qt)

Idle Time More than40%

20% to 40% Less than20%


specification

Kilometers (Miles)32,200

kilometers(20,000 miles)

48,300kilometers

(30,000 miles)



Table 41

Maximum Permissible Oil Change Intervals for C15 On-highwayEngines with Deep Sumps (Standard)



Less than2.3 km/L (5.5

MPG)

2.3 km/L (5.5MPG) to 2.8km/L (6.5MPG)

Greater than2.8 km/L (6.5

MPG)





(39.8 qt)

Idle Time More than40%

20% to 40% Less than20%


specification

Kilometers (Miles)32,200

kilometers(20,000 miles)

48,300kilometers

(30,000 miles)



104 SEBU7695-15Maintenance SectionEngine Valve Lash - Check

i04242309

Engine Valve Lash - CheckSMCS Code: 1105-535

The initial valve lash adjustment on new engines,rebuilt engines, or remanufactured engines isrecommended at the first scheduled oil change. Theadjustment is necessary due to the initial wear ofthe valve train components and to the seating of thevalve train components.

The maintenance is recommended by Caterpillar aspart of a lubrication and preventive maintenanceschedule to help provide maximum engine life.

Note: Only qualified service personnel shouldperform this maintenance. For procedures onadjusting the valve lash and adjusting the valvebridge, see System Systems Operation/Testing andAdjusting, “Engine Valve Lash - Inspect/Adjust”.Consult your Cat dealer for assistance.

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

i01771215

Fan Drive Bearing - LubricateSMCS Code: 1359-086-BD

g00746166Illustration 58Typical location of the grease fitting that is for the fan drive bearingThe belt guards have been removed in this illustration.

Note: In some applications, the fan drives aresupplied by the OEM. Refer to the OEM specificationsif the fan drive is not supplied by Caterpillar.

Lubricate the grease fitting that is on the fan drivebearing with Bearing Lubricant or the equivalent.

Inspect the fan drive pulley assembly for wear or fordamage. If the shaft is loose, an inspection of theinternal components should be performed. Refer tothe Service Manual for additional information.

i04191470

Fuel Injector - CheckSMCS Code: 1290-535

Be sure the engine cannot be started while thismaintenance is being performed. To prevent pos-sible injury, do not use the starting motor to turnthe flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting the unit injectors.

The electronic unit injectors use high voltage. Dis-connect the unit injector enable circuit connectorin order to prevent personal injury. Do not comein contact with the injector terminals while the en-gine is running.

The operation of Cat engines with improperadjustments of the electronic unit injector can reduceengine efficiency. This reduced efficiency could resultin excessive fuel usage and/or shortened enginecomponent life.

Only qualified service personnel should performthis maintenance. Refer to the following topicsfor your engine for the correct procedure: Referto the Systems Operation, Testing and Adjusting,“Electronic Unit Injector - Test” for the test procedure,and Systems Operation, Testing and Adjusting,“Electronic Unit Injector - Adjust” for the correctprocedure for adjusting the injectors.

NOTICEThe camshafts must be correctly timed with the crank-shaft before an adjustment of the lash for the fuel in-jector is made. The timing pins must be removed fromthe camshafts before the crankshaft is turned or dam-age to the cylinder block will be the result.

SEBU7695-15 105Maintenance SectionFuel System - Prime

i03086300

Fuel System - PrimeSMCS Code: 1250-548; 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 whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.




NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

NOTICEDo not crank the engine for more than 30 seconds.Allow the starting motor to cool for two minutes beforecranking again.

g01568053Illustration 59C11 and C13 On-highway Engines(1) Fuel priming pump(2) Air purge screw(3) Priming valve (If equipped)


C15 On-highway Engines(1) Fuel priming pump(2) Air purge screw(3) Priming valve (If equipped)

The engine may need to be primed in the followingcircumstances:

• The engine runs out of fuel.

• The secondary fuel filter is replaced.

If the engine runs out of fuel, take the following stepsbefore you prime the engine:

1. Turn the ignition to the OFF position.

2. Fill the fuel tank with clean diesel fuel.

Note: Refer to Operation and Maintenance Manual,“Fuel System Secondary Filter - Replace” forinformation on replacing the filter.

106 SEBU7695-15Maintenance SectionFuel System Primary Filter - Replace

Using the Engine to Prime the FuelSystem1. Turn the ignition switch to the OFF position.

2. Unlock the fuel priming pump (if equipped) byturning the cap counterclockwise.

3. Purging air from the fuel system requires the airpurge screw to be opened. Turn the air purgescrew counterclockwise by three full turns. Do notremove the screw.

4. Turn the ignition switch to the ON position.

5. Crank the engine for 30 seconds. Use a suitablecontainer to catch the fuel while you crank theengine. Allow the starting motor to cool for twominutes.

Note: Most of the air should be purged from thesystem after four or five cranking cycles.

6. Repeat Step 5 until the engine starts and runs.If the engine runs rough, continue to operate theengine at low idle until the engine runs smoothly.

7. Observe the air purge screw. When a small drop offuel appears at the threads of the air purge screw,close the air purge screw. After the air purge screwis closed, tighten the air purge screw. Refer toSpecifications, SENR3130 for the correct torque.

Note: Failure to tighten the screw could result inserious fuel leaks.

8. After the engine has operated smoothly for 30seconds, turn the priming valve to the LOCKposition.

Note: The life of the injectors may be shortened if thepriming valve is left in the unlocked position.

9. Clean any residual fuel from the enginecomponents.

10.Once the engine runs smoothly, stop the engine.Turn the ignition switch to the OFF position.

Using the Fuel Priming Pump(If Equipped) to Prime the FuelSystem1. Turn the ignition to the OFF position.

2. Unlock the priming pump by turning the capcounterclockwise.

3. Purging air from the fuel system requires the airpurge screw to be opened three full turns. Openthe air purge screw. Do not remove the screw.

4. Continue to operate the fuel priming pump untila strong resistance is felt. Listen for an audibleclick from the fuel manifold. The click will indicatethat the valve has opened and the fuel system ispressurized. Lock the fuel priming pump.

Note: The life of the injectors may be shortened if thepriming valve is left in the unlocked position.

5. Turn the ignition to the ON position.

6. Crank the engine. If the engine starts but theengine runs rough, continue to operate the engineat low idle until the engine runs smoothly.

Note: If the engine will not start, further primingis necessary. If the engine starts but the enginecontinues to misfire, further priming is necessary.

7. Observe the air purge screw. When a small drop offuel appears at the threads of the air purge screw,close the air purge screw. After the air purge screwis closed, tighten the air purge screw. Refer toSpecifications, SENR3130 for the correct torque.

Note: Failure to tighten the screw could result inserious fuel leaks.

8. Clean any residual fuel from the enginecomponents.

9. Once the engine runs smoothly, stop the engine.Turn the ignition switch to the OFF position.

i03017559

Fuel System Primary Filter -ReplaceSMCS Code: 1260-510; 1260; 1261


NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over any dis-connected fuel system components.


Fuel System Secondary Filter - Replace




Note: Caterpillar requires the filtration of all fuelsthrough a primary fuel filter that has a rating of noless than ten microns(c) absolute and no more than15 microns(c) absolute.

For information on the maintenance of the primaryfuel filter, refer to the literature that is provided by theOEM of the vehicle.

i03017560

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE






1. Stop the engine. Turn the ignition switch to theOFF position or disconnect the battery. Refer tothe Operation and Maintenance Manual, “Batteryor Battery Cable - Disconnect” topic (MaintenanceSection) for more information. Shut off the fuelsupply valve (if equipped).


(1) Air purge fitting

2. In order to relieve fuel pressure, turn the air purgefitting counterclockwise by three full turns. Do notremove the fitting.

3. Remove the used fuel filter and discard the usedfuel filter.

4. Close the air purge fitting. Refer to SpecialPublication, SENR3130, “Torque Specifications”for the proper torque.

5. Clean the gasket sealing surface of the fuel filterbase. Ensure that all of the old gasket is removed.Apply clean diesel fuel to the new fuel filter gasket.

NOTICECaterpillar requires the use of a 4 micron(c) absolutehigh efficiency secondary fuel filter.

108 SEBU7695-15Maintenance SectionFuel System Water Separator - Check/Drain

NOTICEDo not fill the secondary fuel filter with fuel before in-stalling. The fuel would not be filtered and could becontaminated. Contaminated fuel will cause acceler-ated wear to fuel system parts.

6. Install the new fuel filter. Spin the fuel filter ontothe fuel filter base until the gasket contactsthe base. Instructions for the installation of thefilter are printed on the side of each Caterpillarspin-on filter. For non-Caterpillar filters, refer tothe installation instructions that are provided bythe supplier of the filter.

7. Open the fuel supply valve. Turn the ignitionswitch to the ON position or reconnect the battery.Open the fuel supply valve (if equipped).

8. Prime the fuel system. Refer to the Operation andMaintenance Manual, “Fuel System - Prime” topic(Maintenance Section) for more information. Startthe engine and inspect the fuel system for leaks.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

i03009440

Fuel System Water Separator- Check/DrainSMCS Code: 1263-535; 1263-543




Drain any water from the water separator daily.

For more information on the checking and drainingprocedures for the water separator, refer to theliterature that is provided by the OEM of the vehicle,or refer to the literature that is provided by the OEMof the water separator.

i04363480

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-M&S




Fuel TankFuel quality is critical to the performance and to theservice life of the engine. Water in the fuel can causeexcessive wear to the fuel system. Condensationoccurs during the heating and cooling of fuel. Thecondensation occurs as the fuel passes through thefuel system and the fuel returns to the fuel tank. Thiscauses water to accumulate in fuel tanks. Drainingthe fuel tank regularly and obtaining fuel from reliablesources can help to eliminate water in the fuel.

Drain the Water and the SedimentFuel tanks should contain some provision for drainingwater and draining sediment from the bottom of thefuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

Note: Failure to properly close the drain can allow airinto the system, which could have detrimental resultsto performance.


Fuel Tank Water and Sediment - Drain

Check the fuel daily. Drain the water and sedimentfrom the fuel tank after operating the engine or drainthe water and sediment from the fuel tank after thefuel tank has been filled. Allow five to ten minutesbefore performing this procedure.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayoverflow.

Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel directly from the bottom of the tank. Ifthe engine is equipped with this system, regularmaintenance of the fuel system filter is important.

Fuel Storage TanksDrain the water and the sediment from the fuelstorage tank during the following conditions:

• Weekly

• Oil change

• Refill of the tank

This will help prevent water or sediment from beingpumped from the storage tank into the engine fueltank. A four micron(c) absolute filter for the breathervent on the fuel tank is also recommended.

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaffles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from thestorage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

110 SEBU7695-15Maintenance SectionGrounding Stud - Inspect/Clean/Tighten

i04441709

Grounding Stud -Inspect/Clean/TightenSMCS Code: 7423-040; 7423-070; 7423-079

g00931100Illustration 62C11 and C13 On-highway Engines

(1) Grounding stud

g00931103Illustration 63C15 On-highway Engines

(2) Grounding stud

Inspect the OEM vehicle wiring harness for thefollowing conditions:

• Connections that are loose or disconnected

• Mounting hardware that is missing

• Insulation that is chafed or cut

• Wires that are bare


Hoses and Clamps - Inspect/Replace

The cylinder head grounding stud must have a wireground to the battery. Tighten the cylinder headgrounding stud at every oil change. Ground wiresand straps should be combined at engine grounds.All grounds should be tight and free of corrosion.

1. Clean the cylinder head grounding stud and theterminals for the cylinder head ground strap witha clean cloth.

2. If the connections are corroded, clean theconnections with a solution of baking soda andwater.

3. Keep the cylinder head grounding stud and thestrap clean and coated with MPGM grease orpetroleum jelly.

i04301694

Hoses and Clamps -Inspect/ReplaceSMCS Code: 7554-040; 7554-510

Hoses and clamps must be inspected periodicallyin order to ensure safe operation and continuousoperation of the engine. Take proper safetyprecautions before inspecting or replacing hoses andclamps.

Note: Always use a board or cardboard when theengine components are checked for leaks. Leakingfluid that is under pressure can cause seriousinjury or possible death. Leaks that are the sizeof a pin hole are included. Refer to Operation andMaintenance Manual, “General Hazard Information”for more information.

Inspect the Hoses and the ClampsInspect all hoses for leaks that are caused by thefollowing conditions. Replace any hose which exhibitsany of the following conditions. Failure to replace ahose which exhibits any of the following conditionsmay result in a hazardous situation.

• Hoses which are cracked

• Hoses which are soft

• 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

• Hoses which exhibit signs of leakage which are notthe result of loose couplings or clamps

Inspect all clamps for the following conditions.Replace any clamp which exhibits signs of any of thefollowing conditions.

• Cracking

• Looseness

• Damage

Inspect all couplings for leaks. Replace any couplingwhich exhibits signs of leaks.

Each installation application can be different. Thedifferences depend on the following factors:

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Due to extreme temperature changes, the hose willheat set. Heat setting causes hose clamps to loosenwhich can result in leaks. A constant torque hoseclamp will help to prevent loose hose clamps.

Replace hoses that are cracked or soft. Replacehoses that show signs of leakage. Replace hosesthat show signs of damage. Replace hose clampsthat are cracked or damaged. Tighten or replacehose clamps which are loose.

Replace the Hoses and the Clamps




112 SEBU7695-15Maintenance SectionHoses and Clamps - Inspect/Replace

Cooling System


Personal injury can result from removing hoses orfittings in a pressure system.

Failure to relieve pressure can cause personal in-jury.

Do not disconnect or remove hoses or fittings un-til all pressure in the system has been relieved.

1. Stop the engine.

2. Allow the engine to cool.

3. Before servicing a coolant hose, slowly loosen thefiller cap for the cooling system in order to relieveany pressure.

4. Remove the filler cap for the cooling system.

5. Drain the coolant from the cooling system to alevel that is below the hose that is being replaced.Drain the coolant into a suitable clean container.The coolant can be reused.

6. Remove the hose clamps.

7. Disconnect the old hose.

8. Replace the old hose with a new hose.

9. Install hose clamps which have been inspected orinstall new hose clamps. Refer to Specifications,SENR3130, “Torque Specifications”, “HoseClamps” for information about selecting andinstalling the proper hose clamps.

10.Refill the cooling system.

11.Clean the filler cap for the cooling system. Inspectthe gaskets on the filler cap. Replace the filler capif the gaskets are damaged. Install the filler cap.

12.Start the engine. Inspect the cooling system forleaks.

Fuel System

Personal injury can result from removing hoses orfittings in a pressure system.

Failure to relieve pressure can cause personal in-jury.

Do not disconnect or remove hoses or fittings un-til all pressure in the system has been relieved.

Contact with high pressure fuel may cause fluidpenetration and burn hazards. High pressure fu-el spray may cause a fire hazard. Failure to fol-low these inspection, maintenance and service in-structions may cause personal injury or death.

NOTICEDo not bend or strike high pressure lines. Do not in-stall bent or damaged lines, tubes or hoses. Repairany loose or damaged fuel and oil lines, tubes andhoses. Leaks can cause fires. Inspect all lines, tubesand hoses carefully. Tighten all connections to the rec-ommended torque.


Note: High-pressure fuel lines may be installedbetween the high-pressure fuel pump and the fuelinjectors. High-pressure fuel lines are constantlycharged with high pressure. Do not check thehigh-pressure fuel lines with the engine or the startingmotor in operation. Wait for 10 minutes after theengine stops before you perform any service or repairon high-pressure fuel lines. Waiting for 10 minuteswill to allow the pressure to be purged.

1. Drain the fuel from the fuel system to a level thatis below the hose that is being replaced.





Radiator - Clean


6. Carefully inspect the engine for any spilled fuel.Make sure that no fuel remains on or close to theengine.

Note: Fuel must be added to the fuel system aheadof the fuel filter.

7. Refill the fuel system. Refer to this Operation andMaintenance Manual, “Fuel System - Prime” forinformation about priming the engine with fuel.

8. Start the engine. Inspect the fuel system for leaks.

Lubrication System


1. Drain the oil from the lubrication system to a levelthat is below the hose that is being replaced.





6. Refill the lubrication system. Refer to thisOperation and Maintenance Manual, “EngineOil Level - Check” in order to ensure that thelubrication system is filled with the proper amountof engine oil.

7. Start the engine. Inspect the lubrication systemfor leaks.

Air System





Note: The bellows and the V-clamps that are usedon the bellows should never be reused.

5. Start the engine. Inspect the air lines for leaks.

i04020194

Radiator - CleanSMCS Code: 1353-070

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

Inspect the radiator for these items: damaged fins,corrosion, dirt, grease, insects, leaves, oil, and otherdebris. 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.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the airnozzle is deadheaded.

Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the air flow. Hold the nozzle approximately 6 mm(0.25 inch) away from the fins. Slowly move the airnozzle in a direction that is parallel with the tubes.This movement will remove debris that is betweenthe tubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

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

114 SEBU7695-15Maintenance SectionTurbocharger - Inspect

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

Inspect the fins for damage. Bent fins may be openedwith a “comb”. Inspect these items for good condition:welds, mounting brackets, air lines, connections,clamps, and seals. Make repairs, if necessary.

i01894393

Turbocharger - InspectSMCS Code: 1052-040

Periodic inspection and cleaning is recommended forthe turbocharger compressor housing (inlet side).

If the turbocharger fails during engine operation,damage to the turbocharger compressor wheeland/or to the engine may occur. Damage to theturbocharger compressor wheel can cause additionaldamage to the pistons, the valves, and the cylinderhead.

NOTICETurbocharger 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 enginedamage.

Minor leakage of a turbocharger housing under ex-tended low idle operation should not cause problemsas long as a turbocharger bearing failure has not oc-curred.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is repaired orreplaced.

A periodic inspection of the turbocharger canminimize unscheduled downtime and the chance forpotential damage to other engine parts.

Note: Turbocharger components require precisionclearances with proper balancing in order to supporthigh operating speeds. Severe Service Applicationscan accelerate component wear. Therefore, morefrequent inspections of the cartridge are required.

Removal and InstallationFor options regarding the inspection, removal,installation, repair and replacement, consult yourauthorized Caterpillar service center. Refer to theService Manual for this engine for the procedure andspecifications.

i04443172

Valve Actuators - CheckSMCS Code: 1105-535

The valve actuators should be inspected and adjustedwhen adjustments to the following components occur:

• Valves

• Injectors

• Compression brakes

Refer to Systems Operation Testing and Adjusting,“Variable Valve Actuators - Inspect/Adjust” for theprocedure.

i02528180

Walk-Around InspectionSMCS Code: 1000-040

A walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can be avoided.


Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.



Walk-Around Inspection

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is foundor fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICEAccumulated grease and/or oil on an engine or deck isa fire hazard. Remove this debris with steam cleaningor high pressure water.

For maximum engine service life, make a thoroughinspection of the engine compartment before startingthe engine. Look for items such as oil leaks or coolantleaks, loose bolts, worn belts, loose connectionsand trash buildup. If it is necessary, make repairs orcorrect fluid levels.

• The guards must be in the proper place. Repairdamaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

• Check the cooling system coolant level. Ensurethat the cooling lines are properly clamped and thatthe cooling lines are tight. Check for leaks. Checkthe condition of all pipes.

• Inspect the water pumps for coolant leaks. Thewater pump seal is lubricated by coolant in thecooling system. It is normal for a small amount ofleakage to occur as the engine cools down andthe parts contract. Excessive coolant leakage mayindicate the need to replace the water pump seal.For the removal of water pumps and the installationof water pumps and/or seals, refer to the ServiceManual for the engine or consult your Caterpillardealer.

• Check the engine oil level. Inspect the lubricationsystem for leaks at the front crankshaft seal, therear crankshaft seal, the oil pan, the oil filters andthe valve cover.

• Inspect the fuel system for leaks. Look for loosefuel line clamps or for loose tie-wraps around fuellines.

• Check the water separator (if equipped) for wateron a daily basis. Drain any water from the waterseparator. If necessary, drain the water and thesediment from fuel tanks in order to ensure thatonly clean fuel enters the fuel system.

• Inspect the piping for the air inlet system and theelbows for cracks and for loose clamps. Ensurethat hoses and tubes are not contacting otherhoses, tubes, wiring harnesses, etc. Check the aircleaner service indicator (if equipped).

• Inspect the alternator belt and the accessory drivebelts for cracks, breaks or other damage. Beltsfor multiple groove pulleys must be replaced asmatched sets. If only one belt is replaced, thebelt will carry more load than the belts that arenot replaced. The older belts are stretched. Theadditional load on the new belt could cause thebelt to break.

• Inspect the wiring and the wiring harnesses forloose connections and for worn wires or frayedwires.

• Inspect the ground strap for a good connection andfor good condition.

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

• Disconnect any battery chargers that are notprotected against the current drain of the startingmotor. Check the condition and the electrolyte levelof the batteries, unless the engine is equipped witha maintenance free battery.

• Check the condition of the gauges. Replace anygauges that are cracked. Replace any gauge thatcan not be calibrated.

116 SEBU7695-15Warranty SectionWarranty Information

Warranty Section

Warranty Informationi01943914

Federal Emission ControlWarrantySMCS Code: 1000

Emissions WarrantyNew Heavy Duty Engines Powering On-highwayVehicles-10.3 liter up to and including 18.1 liter.

Caterpillar Inc. warrants to the initial owner and to thesubsequent owner of a diesel engine (powering anon-highway truck) that such an engine is:

1. Designed, built and equipped so as to conform,at the time of sale, with all applicable regulationsadopted by the United States EnvironmentalProtection Agency (EPA).

2. Caterpillar Inc. or any of its subsidiaries(Caterpillar) warrants new 10.3 liter up to andincluding 18.3 liter engines sold by it for use inpowering On-highway vehicles to be free fromdefects in materials and workmanship for thefollowing periods:

• The standard warranty period for new enginespowering on-highway vehicles, other than thosepowering recreational vehicles, fire trucks,emergency service vehicles and ambulances is24 months after date of delivery to the first user.

• The standard warranty period for newengines powering recreational vehicles,fire trucks, emergency service vehicles andambulances, is 60 months or 321,869 kilometers(200,000 miles), whichever occurs first, afterdate of delivery to the first user.

Extended Warranty

An extended warranty period applies to newengines powering on-highway vehicles (other thanthose powering recreational vehicles, fire trucks,emergency service vehicles and ambulances) andapplies solely to the following components: cylinderblock casting, crankshaft, connecting rod assemblies,cylinder head casting, camshaft, main bearing bolts,flywheel housing, oil cooler housing, water pumphousing, air intake housing, and electronic controlmodule.

These parts are warranted against defects inmaterial and workmanship for 60 months or804,672 kilometers (500,000 miles) or 10,000operating hours, whichever occurs first after dateof delivery to the first user. This warranty runsconcurrently with the standard warranty period.

Following the standard warranty periods specifiedabove, the emission warranty of 60 months,161,000 kilometers (100,000 miles) or 3000 servicehours of operation, whichever occurs first, after thedate of delivery to the initial owner would be effective.

If an emission related part fails during any of thewarranty periods, the part will be repaired or replaced.Any such part repaired or replaced under warranty iswarranted for the remainder of the warranty period.

During the term of this warranty, Caterpillar Inc.will provide through a Caterpillar dealer or otherestablishment authorized by it, repair or replacementof any warranted part at no charge to the truck engineowner.

In an emergency, repairs may be performed at anyservice establishment, or by the owner, using anyreplacement part. It is recommended that emissionrelated parts be replaced with genuine CaterpillarInc. parts.

Caterpillar Inc. will reimburse the owner for theirexpenses, including diagnostic charges for such anemergency repair. These expenses shall not exceedthe Caterpillar Inc. suggested retail price for allwarranted parts replaced, and labor charges basedon Caterpillar Inc. recommended time allowancefor the warranty repair and the geographicallyappropriate hourly labor rate.

As a condition of reimbursement, replaced partsand receipted invoices must be presented at aplace of business of a Caterpillar dealer or otherestablishment 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 inmaterial or workmanship of an emission related partor component is found, Caterpillar Inc. will provide:

• New, remanufactured or repaired parts and/orcomponents, approved pursuant to EPARegulations, required to correct the defect.

Note: Items replaced under this warranty becomethe property of Caterpillar Inc.

SEBU7695-15 117Warranty Section

Warranty Information

• Reasonable and customary labor, during normalworking hours that is required to make the warrantyrepair. This includes labor in order to remove andinstall the engine, if necessary.

Owner Responsibilities

During the emission warranty period, the owner isresponsible for:

• Premium or overtime labor costs, unless essentialto prevent loss to perishable goods.

• Costs to investigate complaints which are notcaused by a defect in Caterpillar Inc. material orworkmanship.

• Providing timely notice of a warrantable failure andpromptly making the product available for repair.

Limitations

Caterpillar Inc. is not responsible for resultantdamages to an emission related part or componentresulting from:

• Any application or installation Caterpillar Inc.deems improper.

• Attachments, accessory items or parts not sold norapproved by Caterpillar Inc.

• Improper truck engine maintenance, repair orabuse.

• Owner's unreasonable delay in making the productavailable after being notified of a potential productproblem.

This warranty is in addition to Caterpillar Inc. standardwarranty, applicable to the truck engine productinvolved.

Remedies under this warranty are limited to theprovision of material and services as specified herein.Caterpillar Inc. is not responsible for incidental orconsequential damages.

i01944137

California Emission ControlWarranty StatementSMCS Code: 1000

Owner Warranty Rights andObligationsThe California Air Resources Board (CARB) andCaterpillar Inc. are pleased to explain the emissioncontrol system warranty on your 2003 or later truckengine.

In California, new motor vehicle engines must bedesigned, built and equipped to meet the state'sstringent anti-smog standards. Caterpillar Inc. mustwarrant the emission control system on your truckengine for the duration of time listed below providedthere has not been any abuse, neglect or impropermaintenance of your truck engine.

Your emission control system may include parts suchas the fuel injection system and engine computer, ifequipped. 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 ownerincluding diagnosis, parts and labor.

Manufacturer's Warranty Coverage

1. Caterpillar Inc. or any of its subsidiaries(Caterpillar) warrants new 10.3 liter up to andincluding 18.3 liter engines sold by it for use inpowering On-highway vehicles to be free fromdefects in materials and workmanship for thefollowing periods:

• The standard warranty period for new enginespowering on-highway vehicles, other than thosepowering recreational vehicles, fire trucks,emergency service vehicles and ambulances is 24months after date of delivery to the first user.

• The standard warranty period for new enginespowering recreational vehicles, fire trucks,emergency service vehicles and ambulances, is60 months or 321,869 kilometers (200,000 miles),whichever occurs first, after date of delivery to thefirst user.


Extended Warranty

An extended warranty period applies to newengines powering on-highway vehicles (other thanthose powering recreational vehicles, fire trucks,emergency service vehicles and ambulances) andapplies solely to the following components: cylinderblock casting, crankshaft, connecting rod assemblies,cylinder head casting, camshaft, main bearing bolts,flywheel housing, oil cooler housing, water pumphousing, air intake housing, and electronic controlmodule.

These parts are warranted against defects inmaterial and workmanship for 60 months or804,672 kilometers (500,000 miles) or 10,000operating hours, whichever occurs first after dateof delivery to the first user. This warranty runsconcurrently with the standard warranty period.

Following the standard warranty periods specifiedabove, the emission warranty of 60 months,161,000 kilometers (100,000 miles) or 3000 servicehours of operation, whichever occurs first, after thedate of delivery to the initial owner would be effective.

If an emission related part or component on yourtruck engine is defective, the part or component willbe repaired or replaced by Caterpillar Inc. This isyour emission control system WARRANTY.

Owner's Warranty Responsibilities

• As the truck engine owner, you are responsible forthe performance of the required maintenance listedin the truck engine owner's manual (Operation andMaintenance Manual). Caterpillar Inc. recommendsthat you retain all receipts and records covering themaintenance on your truck engine, but cannot denywarranty solely for the lack of receipts and recordsor for your failure to ensure the performance of allscheduled maintenance.

• You are responsible for presenting your truckengine to a Caterpillar Inc. dealer as soon as atruck engine problem exists. The warranty repairsshould be completed in a reasonable amount oftime, not to exceed 30 days.

• As the truck engine owner, you should also beaware that Caterpillar Inc. may deny you warrantycoverage if your truck engine or an emissioncomponent or part has failed due to abuse,neglect, improper maintenance or unapprovedmodifications.

If you have questions regarding your warranty rightsand responsibilities, contact:

Caterpillar Inc.Manager, Truck Engine BusinessP.O. Box 0600Mossville, IL 61552Phone 800-447-4986

OR

California Air Resources Board (CARB)9528 Telstar Ave.El Monte, CA 91731

Emissions WarrantyCaterpillar Inc. warrants to the initial owner andsubsequent owner of a diesel engine (powering anon-highway truck), that such an engine is:

1. Designed, built and equipped so as to conform,at the time of sale, with all applicable regulationsadopted by the California Air Resources Board(CARB).

2. Free from defects in materials and workmanshipin specific emission related parts for a period of60 months, 161 000 km (100 000 miles) or 3000service hours of operation, whichever occurs first,after the date of delivery to the initial owner.

If an emission related part fails during the warrantyperiod, it will be repaired or replaced. Any such partrepaired or replaced under warranty is warranted forthe remainder of the warranty period.

During the term of this warranty, Caterpillar Inc.will provide through a Caterpillar dealer or otherestablishment authorized by it, repair or replacementof any warranted part at no charge to the truck engineowner.

In an emergency, repairs may be performed at anyservice establishment, or by the owner, using anyreplacement part. It is recommended that emissionrelated parts be replaced with genuine CaterpillarInc. parts.

The manufacturer shall reimburse the owner forexpenses, including diagnosis not to exceed themanufacturer's suggested retail price for all warrantedparts replaced and labor charges based on themanufacturer's recommended time allowance for thewarranty repair and the geographically appropriatehourly labor rate.

A part not being available within 30 days or a repairnot being complete within 30 days constitutes anemergency.



As a condition of reimbursement, replaced partsand receipted invoices must be presented at aplace of business of a Caterpillar dealer or otherestablishment authorized by Caterpillar Inc.

This warranty covers the following emission relatedparts and components.

• Exhaust Aftertreatment System (If Equipped)

• Fuel Injection System

• Inlet Manifold

• Turbocharger System

• Electronic Engine Control System

• Miscellaneous hoses, clamps, connectors andsealing devices used in the above systems.

Any replacement part may be used for maintenanceor repairs. The owner should ensure that such partsare equivalent in design and durability to genuineCaterpillar parts. Use of non-genuine Caterpillarparts does not invalidate the warranty. However,Caterpillar Inc. is not liable for parts which are notgenuine Caterpillar parts.

Limitations and Responsibilities

These warranties are subject to the following:

Caterpillar Inc. Responsibilities

During the emission warranty period, if a defectin material or workmanship of a warranted part orcomponent is found, Caterpillar Inc. will provide:

• New, Remanufactured or repaired parts and/orcomponents required to correct the defect.

Note: Items replaced under this warranty becomethe property of Caterpillar Inc.

• Reasonable and customary labor, during normalworking hours that is required to make the warrantyrepair. This includes diagnosis and labor to removeand install the engine, if necessary.

Owner Responsibilities

During the emission warranty period, the owner isresponsible for:

• The performance of all required maintenance.A warranty claim will not be denied becausethe scheduled maintenance was not performed.However, if the lack of required maintenance wasthe reason for the repair, then the claim will bedenied.

• Premium or overtime labor costs, unless essentialto prevent loss to perishable goods.

• Costs to investigate complaints which are notcaused by a defect in Caterpillar Inc. material orworkmanship.

• Providing timely notice of a warrantable failure andpromptly making the product available for repair.

Limitations

Caterpillar Inc. is not responsible for resultantdamages to an emission related part or componentresulting from:

• Any application or installation Caterpillar Inc.deems improper as explained in the Operation andMaintenance Manual.

• Attachments, accessory items or parts notauthorized for use by Caterpillar Inc.

• Improper truck engine maintenance, repair orabuse.

• Owner's unreasonable delay in making the productavailable after being notified of a potential productproblem.

This warranty is in addition to Caterpillar Inc. standardwarranty, applicable to the truck engine productinvolved.

Remedies under this warranty are limited to theprovision of material and services as specified herein.Caterpillar Inc. is not responsible for incidentalor consequential damages such as downtime orloss-of-use of truck.

i02118591

Emissions WarrantyInformationSMCS Code: 1000

Maintenance RecommendationsCaterpillar Inc. truck engines are certified by theUnited States Environmental Protection Agency(EPA) in order to comply with exhaust emissionstandards and gaseous emission standards thatare prescribed by Federal laws at the time ofmanufacture.


Efficiency of the emission control and the engineperformance depends on adherence to properoperation and maintenance recommendations anduse of recommended fuels and lubricating oils.According to recommendations, major adjustmentsand repairs should be made by your authorizedCaterpillar dealer.

Various chemical fuel additives which claim to reducevisible smoke are available commercially. Althoughadditives have been used to solve some isolatedsmoke problems in the field, additives are notrecommended for general use. The engines shouldbe certified without smoke depressants according tofederal smoke regulations.

Take corrective steps immediately after worn partswhich may affect emission levels are discovered inorder to ensure the proper operation of the emissioncontrol systems. The use of genuine Caterpillar partsis recommended. Suppliers of non-Caterpillar partsmust ensure the owner that the use of such parts willnot adversely affect emission levels.

Regular maintenance intervals with a specialemphasis on the following items are necessary inorder to keep exhaust emissions within acceptablelimits for the useful life of the engine. Refer to theOperation and Maintenance Manual, “Severe ServiceApplication - Check” topic (Maintenance Section).If the engine is operating under severe conditions,adjust the maintenance schedule accordingly.See your authorized Caterpillar dealer in order tohelp analyze your specific application, operatingenvironment and maintenance schedule adjustments.

The following information is an explanation ofmaintenance items for emission related components.See the Operation and Maintenance Manual,“Maintenance Interval Schedule” (MaintenanceSection) for the specific interval for the followingitems.

EXHAUST AFTERTREATMENT SYSTEM –Aftertreatment devices are sensitive to the type offuel used and the operating schedule. Poor qualityfuel may cause increases in exhaust back pressureor clogging resulting in loss of power. An authorizedCaterpillar truck engine dealer can determine if theaftertreatment device needs service.

UNIT INJECTORS – Unit injectors are subject to tipwear as a result of fuel contamination. This damagecan cause the following conditions: an increase infuel consumption, black smoke, misfire, and roughrunning engine. The unit injector should be inspected,tested and replaced, if necessary. Unit injectors canbe tested by an authorized Caterpillar truck enginedealer.

TURBOCHARGER – Check for any unusual soundor vibration in the turbocharger. Inspect the inletpiping and connections and inspect the exhaustpiping and connections. Check the condition ofthe bearing. Perform the maintenance that isdescribed in the Operation and Maintenance Manual,“Maintenance Interval Schedule” (MaintenanceSection).

ELECTRONIC ENGINE CONTROL – Thiscomponent is a device that is designed to controlengine operation with respect to the amount of fuelinjected, the injection timing as well as controllingthe black smoke emission of the engine during theengine's operation when low inlet manifold pressureexists.

Any erratic engine behavior may indicate a needfor replacement or repair. Your Caterpillar dealer isequipped with the necessary tools, personnel andprocedures in order to perform this service.

The owner is encouraged to keep adequatemaintenance records. However, the absence of suchrecords will not invalidate the warranty. Refer to theOperation and Maintenance Manual, “MaintenanceLog” (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. Suchwork does not need to be performed at a designatedstation that is determined by the warranty in order forthe warranty to remain in force.

Customer Assistance (EmissionControl Systems Warranty)Caterpillar Inc. intends to ensure that the EmissionControl Systems Warranty is properly administered. Ifyou do not receive adequate warranty service underthe Emission Control Systems Warranty, call or writeto the following address:

Caterpillar Inc.Manager, Truck Engine BusinessP.O. Box 0600 Mossville, IL 61552

Authorized dealers are recommended for majormaintenance and for repair work. Authorized dealersare staffed with trained personnel and propertools. Authorized dealers are aware of the latestmaintenance methods and procedures. If owners orother persons desire to perform the work, a ServiceManual should be purchased and current serviceinformation should be obtained from a Caterpillardealer.

Refer to the TEPS Directory for information regardingan authorized dealer or call the following toll freenumber:



1-800-447-4986

122 SEBU7695-15Reference Information SectionCustomer Service

Reference InformationSection

Customer Servicei03910306

Customer AssistanceSMCS Code: 1000; 4450

USA and CanadaWhen a problem arises concerning the operation orthe service of an engine, the problem will normally bemanaged by the dealer in your area.

Your satisfaction is a primary concern to Caterpillarand to Caterpillar dealers. If you have a problem thathas not been handled to your complete satisfaction,follow these steps:

1. Discuss your problem with a manager from thedealership.

2. If your problem cannot be resolved at the dealerlevel, use the phone number that is listed below totalk with a Field Service Coordinator:

1-800-447-4986

The normal hours are from 8:00 to 4:30 Mondaythrough Friday Central Standard Time.

3. If your needs have not been met still, submit thematter in writing to the following address:

Caterpillar Inc.Manager, Customer Service, Engine DivisionMossville Bldg ACP.O. Box 610Mossville, Illinois 61552-0610

Please keep in mind: probably, your problem willultimately be solved at the dealership, using thedealership facilities, equipment, and personnel.Therefore, follow the steps in sequence when aproblem is experienced.

Outside of the USA and of CanadaIf a problem arises outside the USA and outsideCanada, and if the problem cannot be resolved at thedealer level, consult the appropriate Caterpillar office.

Latin America, Mexico, CarribeanCaterpillar Americas Co.701 Waterford Way, Suite 200Miami, FL 33126-4670USAPhone: 305-476-6800Fax: 305-476-6801

Europe, Africa, and Middle EastCaterpillar Overseas S.A.76 Route de FrontenexP.O. Box 6000CH-1211 Geneva 6SwitzerlandPhone: 22-849-4444Fax: 22-849-4544

Far EastCaterpillar Asia Pte. Ltd.7 Tractor RoadJurong, Singapore 627968Republic of SingaporePhone: 65-662-8333Fax: 65-662-8302

ChinaCaterpillar China Ltd.37/F., The Lee Gardens33 Hysan AvenueCauseway BayG.P.O. Box 3069Hong KongPhone: 852-2848-0333Fax: 852-2848-0440

JapanShin Caterpillar Mitsubishi Ltd.SBS Tower10-1, Yoga 4-ChomeSetagaya-Ku, Tokyo 158-8530JapanPhone: 81-3-5717-1150Fax: 81-3-5717-1177

JapanCaterpillar Power Systems, Inc.SBS Tower (14th floor)4-10-1, YogaSetagaya-Ku, Tokyo 158-0097Phone: 81-3-5797-4300Fax: 81-3-5797-4359

Australia and New ZealandCaterpillar of Australia Ltd.1 Caterpillar DrivePrivate Mail Bag 4Tullamarine, Victoria 3043AustraliaPhone: 03-9953-9333Fax: 03-9335-3366

SEBU7695-15 123Reference Information Section

Customer Service

i01028392

Ordering Replacement PartsSMCS Code: 4450; 7567

When replacement parts are required for thisproduct Caterpillar recommends using Caterpillarreplacement parts or parts with equivalent spec-ifications including, but not limited to, physicaldimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

Quality Caterpillar replacement parts are availablefrom Caterpillar dealers throughout the world.Caterpillar dealers' parts inventories are up-to-date.The parts stocks include all of the parts that arenormally needed to protect your Caterpillar engineinvestment.

When you order parts, please specify the followinginformation:

• Part number

• Part name

• Quantity

If there is a question concerning the part number,please provide your dealer with a completedescription of the needed item.

When a Caterpillar engine requires maintenanceand/or repair, provide the dealer with all theinformation that is stamped on the Information Plate.This information is described in this Operation andMaintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform thedealer about the conditions of the problem and thenature of the problem. Inform the dealer about whenthe problem occurs. This will help the dealer introubleshooting the problem and solving the problemfaster.

124 SEBU7695-15Reference Information SectionReference Materials

Reference Materialsi00912149

Maintenance RecordsSMCS Code: 1000; 4450

Caterpillar Inc. recommends the retention of accuratemaintenance records. Accurate maintenance recordscan be used for the following purposes:

• Determine operating costs.

• Establish maintenance schedules for other enginesthat are operated in the same environment.

• Show compliance with the required maintenancepractices and maintenance intervals.

Maintenance records can be used for a variety ofother business decisions that are related to enginemaintenance.

Maintenance records are a key element of amaintenance program that is well managed. Accuratemaintenance records can help your Caterpillar dealerto fine tune the recommended maintenance intervalsin order to meet the specific operating situation. Thisshould result in a lower engine operating cost.

Records should be kept for the following items:

Fuel Consumption – A record of fuel consumptionis essential in order to determine when the loadsensitive components should be inspected orrepaired. Fuel consumption also determines overhaulintervals.

Service Hours – A record of service hours isessential to determine when the speed sensitivecomponents should be inspected or repaired.

Documents – These items should be easy toobtain, and these items should be kept in the enginehistory file. All of the documents should show thisinformation: date, service hours, fuel consumption,unit number, and engine serial number. The followingtypes of documents should be kept as proof ofmaintenance or repair for warranty:

Keep the following types of documents as proof ofmaintenance for warranty. Also, keep these types ofdocuments as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owner's repair costs

• Owner's receipts

• Maintenance log


Reference Materials

i01412401

Maintenance LogSMCS Code: 1000; 4450

Table 42

Engine Model Customer Identifier

Serial Number Arrangement Number


Table 43

ServiceHours

Quantityof Fuel Serviced Item Date Authorization


Reference Materials

i02952419

Reference MaterialSMCS Code: 1000; 4450

The following literature can be obtained through anyCaterpillar dealer.

Note: The information that is found in this publicationand the information that is found in the publicationsthat are listed below may be changed without notice.

Coolants• Special Publication, PEEP5027, “Label - ELCRadiator Label”

• Special Publication, PELJ0176, “Cat ELC(Extended Life Coolant)223-9116 Coolant Test Kit”

• Special Publication, PEHJ0067, “Cat ELC(Worldwide Formulation)”

• Special Publication, SEBD0518, “Know YourCooling System”

Fuels• Special Publication, SEBD0717, “Diesel Fuels andYour Engine”

• Special Publication, SENR9620, “Improving FuelSystem Durability”

Greases• Special Publication, NEHP5621, “How To SelectThe Right Grease For Any Job”

• Special Instruction, NEHP6011, “Arctic PlatinumGrease Spec Sheet”

• Data Sheet, NEHP6015, “Caterpillar SpecialPurpose Grease”

• Special Publication, PEHP0002, “Data Sheet- Multipurpose Lithium Complex Grease withMolybdenum (MPGM)”

• Data Sheet, PEHP0088, “Cat MultiPurposeGrease”

Lubricants• Special Publication, PEDP7035, “Optimizing OilChange Intervals”

• Data Sheet, PEHJ0008, “Cat Arctic DEO SYN”

• Data Sheet, PEHJ0021, “Product Data Sheet forCat DEO (Diesel Engine Oil) APD, EAME, LACDOnly ”

• Data Sheet, PEHJ0059, “Cat DEO (for NorthAmerica)”

• Data Sheet, PEHJ0072, “Cat DEO (Brazil only)”

• Data Sheet, PEHJ0091, “Cat DEO (Egypt andSaudi Arabia)”

• Special Publication, PEHP6001, “How To Take AGood Oil Sample”

• Data Sheet, PEHP7062, “Full Synthetic DieselEngine Oil Data Sheet”

• Special Publication, PELJ0179, “Caterpillar EngineCrankcase Fluid-1 Specifications” All InternationalMarkets

• Special Publication, SEBD0640, “Oil and YourEngine”

S·O·S Information• Special Publication, NEHP6013, “S·O·S FluidsAnalysis Products”

• Special Publications, PEDP7036, “S·O·S FluidsAnalysis Cornerstone”

• Special Publication, PEHP7057, “Data Sheet -S·O·S Coolant Analysis”

• Special Publication, PEHP7076, “UnderstandingS·O·S Services Tests”

Miscellaneous• Service Manual, SENR9700, “C11 and C13On-highway Engine”

• Service Manual, SENR9695, “C15 and C18On-highway Engine”

• Special Instruction, LEDT2254, “Cat Answers YourQuestions About Truck Performance”

• Special Publication, LEWT5622, “MaintenanceProducts Application Chart for Cat Truck Engines”

• Special Publication, NEHS0526, “ServiceTechnology Application Guide”

• Service Manual, NENG2500, “Cat Dealer ServiceTool Catalog”

• Special Publication, PECP9067, “One SafeSource” English Language for use in NACD


• Special Publication, PEDP0026, “Power AnalysisReport”

• Specifications, REHS0354, “Charging SystemTroubleshooting for All Engines”

• Special Instruction, REHS0871, “ElectronicInstallation Guide”.

• Special Publication, SEBF8029, “Index toGuidelines for Reusable Parts and SalvageOperations”

• Special Publication, SEBF8062, “Guideline forReusable Parts - Procedure to Inspect and CleanAir Filters”

• Special Publication, SEBU6385, “Cat On-HighwayEngine Fluids Recommendations”

• Special Instruction, SEHS7332, “Warning Tag -Danger Do Not Operate”

• Special Instruction, SEHS7633, “Battery TestProcedure”

• Special Instruction, SEHS8622, “Using theFT-1984 Aftercooler Testing Group”

• Special Instruction, SEHS8742, “Using the8T-8697 Electronic Control Analyzer Programmer(ECAP)”

• Special Instruction, SEHS9031, “StorageProcedure for Caterpillar Products”

• Specifications, SENR3130, “Torque SpecificationsModule”

• Special Publication, SENR9620, “Improving FuelSystem Component Durability”

• Special Instruction, SMHS7001, “Assembly of FanDrive Pulley Assemblies”

• Special Publication, “Truck Engine Application andInstallation Guide” (See your Caterpillar dealer.)

Additional Reference MaterialThe “Engine Fluids Data Book” can be obtained fromthe following locations: local technological society,local library, and local college. If necessary, consultEMA at the following address:

Engine Manufacturers AssociatonTwo North LaSalle Street, Suite 2200Chicago, IL, USA 60602E-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 thefollowing locations: local technological society, locallibrary, and local college. If necessary, consult SAEat the following address:

SAE International400 Commonwealth DriveWarrendale, PA, USA 15096-0001E-mail: www.sae.org(724) 776-4841

The “American Petroleum Institute Publication No.1509” can be obtained from the following locations:local technological society, local library, and localcollege. If necessary, consult API at the followingaddress:

American Petroleum Institute1220 L St. N.W.Washington, DC, USA 20005E-mail: www.api.org(202) 682-8000

For information regarding “Technology andMaintenance Council (TMC) Specifications”, refer tothe following address:

Technology and Maintenance CouncilAmerican Trucking Association2200 Mill RoadAlexandria, VA, USA 22314E-mail: www.trucking.org/cc/councils/tmc(703) 838-1763

SEBU7695-15 129Index Section

Index

A

Aftercooler Core - Clean/Test (Air-To-AirAftercooler) .......................................................... 81Air Compressor - Check ........................................ 81Air Compressor Filter - Clean/Replace (IfEquipped) ............................................................ 81Air Shutoff - Test (Engines that are Equipped withOptional Air Shutoff Systems).............................. 81Alternator - Inspect ................................................ 82

B

Battery - Replace................................................... 82Battery Electrolyte Level - Check .......................... 83Battery or Battery Cable - Disconnect ................... 83Before Starting Engine .......................................... 14Belt Tensioner - Check .......................................... 83Belts - Inspect/Adjust/Replace............................... 84Adjustment ......................................................... 84Inspection........................................................... 84

Burn Prevention...................................................... 11Batteries.............................................................. 11Coolant................................................................ 11Oils...................................................................... 11

C

California Emission Control Warranty Statement .. 117Emissions Warranty .......................................... 118Owner Warranty Rights and Obligations........... 117

Cold Start Strategy ................................................ 29Cold Weather Operation........................................ 57Compression Brake............................................... 51Driving With Your Jacobs Engine Brake (JakeBrake®)............................................................ 53Operation of the Jacobs Engine Brake (JakeBrake®)............................................................ 51Using Your Jacobs Engine Brake (JakeBrake®)............................................................ 51

Compression Brake - Inspect/Adjust/Replace....... 85Compression Brake (If Equipped) ......................... 50Compression Brake Controls ............................. 50Compression Brake Operation........................... 50

Configuration Parameters...................................... 39Customer Configuration Parameters ................. 39System Configuration Parameters ..................... 39

Coolant - Change .................................................. 86Drain the Coolant ............................................... 87Fill ...................................................................... 88Flush .................................................................. 87

Coolant Extender (ELC) - Add............................... 88Coolant Level - Check ........................................... 89Coolant Sample (Level 1) - Obtain ........................ 90Sampling Conditions .......................................... 90Timing of the Sampling ...................................... 90

Coolant Sample (Level 2) - Obtain ........................ 91Coolant Temperature Regulator - Replace............ 91Cooling System Supplemental Coolant Additive(SCA) - Test/Add.................................................. 91Add the SCA, If Necessary ................................ 92Test the SCA Concentration............................... 92

Crankshaft Vibration Damper - Inspect ................. 92Visconic Damper................................................ 93

Crushing Prevention and Cutting Prevention ........ 13Customer Assistance........................................... 122Outside of the USA and of Canada.................. 122USA and Canada............................................. 122

Customer Service ................................................ 122

D

Diagnostic Flash Code Retrieval ........................... 32“Diagnostic” Lamp.............................................. 32

Diagnostic Lamp.................................................... 32

E

ECM Snapshot ...................................................... 37Storage of Snapshots In the ECM ..................... 38Triggering Snapshot Information........................ 37

Electrical System................................................... 15Grounding Practices .......................................... 16

Emergency Stopping (Engines with Optional AirShutoff Systems) ................................................. 60Emissions Certification Film .................................. 24Emissions Warranty Information........................... 119Customer Assistance (Emission Control SystemsWarranty) ....................................................... 120Maintenance Recommendations ...................... 119

Engine - Clean....................................................... 93Engine Air Cleaner Element (Single Element) -Inspect/Clean/Replace......................................... 93Cleaning the Air Cleaner Element...................... 94Inspecting the Air Cleaner Element ................... 94Replacing the Air Cleaner Element.................... 94Storing the Air Cleaner Elements....................... 95

Engine Air Cleaner Service Indicator - Inspect (IfEquipped) ............................................................ 95Test the Service Indicator................................... 95

Engine Crankcase Breather - Clean...................... 96Type 1 ................................................................ 96Type 2 ................................................................ 96

Engine Diagnostics................................................ 32Engine Electronics................................................. 16Engine Oil and Filter - Change .............................. 99Adjustments to the Oil Change Intervals.......... 101Drain the Engine Oil......................................... 100Extended Oil Change Intervals ........................ 101Fill the Engine Crankcase................................ 101Replace the Oil Filter ....................................... 100

Engine Oil Level - Check....................................... 97

130 SEBU7695-15Index Section

Engine Oil Level Gauge - Calibrate ....................... 97Check the Calibration at the First Oil Change.... 97

Engine Oil Sample - Obtain ................................... 99Obtain the Sample and the Analysis.................. 99

Engine Operation................................................... 46Cold Mode Operation......................................... 46Cruise Control .................................................... 48Cruising.............................................................. 48Downhill Operation............................................. 49Eaton Top 2 Transmission ................................. 48Fuel Economy.................................................... 47Getting Started................................................... 47Idling .................................................................. 46Uphill Operation ................................................. 49Vehicle Efficiency ............................................... 47

Engine Operation with Active Diagnostic Codes ... 38Engine Operation with Intermittent DiagnosticCodes .................................................................. 39Engine Starting ................................................ 14, 43Ether (If Equipped)............................................. 15

Engine Stopping .............................................. 15, 59Engine Valve Lash - Check ................................. 104

F

Fan Drive Bearing - Lubricate.............................. 104Fault Logging......................................................... 38Features and Controls ........................................... 29Federal Emission Control Warranty...................... 116Emissions Warranty .......................................... 116

Fire Prevention and Explosion Prevention ............. 11Ether (If Equipped)............................................. 13Fire Extinguisher ................................................ 13Lines, Tubes and Hoses .................................... 13

Fluid Recommendations........................................ 61Cooling System.................................................. 68Diesel Engine Oil ............................................... 61Fuel .................................................................... 65Greases ............................................................. 72

Foreword ................................................................. 5California Proposition 65 Warning ....................... 5Literature Information........................................... 4Maintenance ........................................................ 4Maintenance Intervals.......................................... 4Operation ............................................................. 4Overhaul .............................................................. 4Safety................................................................... 4

Fuel and the Effect from Cold Weather ................. 57Fuel Injector - Check ........................................... 104Fuel Related Components in Cold Weather .......... 58Fuel Filters ......................................................... 58Fuel Heaters ...................................................... 58Fuel Tanks.......................................................... 58

Fuel System - Prime............................................ 105Using the Engine to Prime the Fuel System .... 106Using the Fuel Priming Pump (If Equipped) toPrime the Fuel System................................... 106

Fuel System Primary Filter - Replace.................. 106Fuel System Secondary Filter - Replace............. 107Fuel System Water Separator - Check/Drain ...... 108

Fuel Tank Water and Sediment - Drain ............... 108Drain the Water and the Sediment................... 108Fuel Storage Tanks .......................................... 109Fuel Tank ......................................................... 108

G

Gauges and Indicators .......................................... 29General Hazard Information .................................... 8Containing Fluid Spillage ..................................... 9Dispose of Waste Properly ................................. 11Fluid Penetration.................................................. 9Inhalation ........................................................... 10Lines, Tubes, and Hoses ................................... 10Pressurized Air and Water ................................... 9

General Information............................................... 18Grounding Stud - Inspect/Clean/Tighten .............. 110

H

Hoses and Clamps - Inspect/Replace .................. 111Inspect the Hoses and the Clamps ................... 111Replace the Hoses and the Clamps ................. 111

I

Important Safety Information ................................... 2

L

Lifting and Storage ................................................ 26

M

Maintenance Interval Schedule (C11 , C13 , and C15Engines with Standard (Deep) Oil Sumps) .......... 80Maintenance Interval Schedule (C11 and C13Engines with 500 HP Field Up-Rates and 525 HPRV Ratings with Optional (Shallow) Oil Sumps) .. 76Maintenance Interval Schedule (C11 and C13Engines with 500 HP Field Up-Rates and 525 HPRV Ratings with Standard (Deep) Oil Sumps)..... 77Maintenance Interval Schedule (C11 and C13Engines with Optional Shallow Oil Sumps).......... 79Maintenance Log................................................. 125Maintenance Recommendations........................... 73Maintenance Records.......................................... 124Maintenance Section............................................. 61Model View Illustrations......................................... 18C11 and C13 On-highway Engines.................... 18C15 On-highway Engines ........................... 19–20

Monitoring System................................................. 30Coolant Level Sensor (If Equipped) ................... 30Programmable Options and SystemsOperation ......................................................... 31

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

SEBU7695-15 131Index Section

O

Operation Section.................................................. 26Ordering Replacement Parts ............................... 123

P

Plate Locations and Film Locations....................... 24Information Plate................................................ 24Serial Number Plate........................................... 24

Product Description ............................................... 21Aftermarket Products and Cat Engines.............. 23Multitorque Rating (If Equipped) ........................ 22

Product Identification Information .......................... 24Product Information Section .................................. 18Product Lifting........................................................ 26Product Storage..................................................... 26Removal from Storage....................................... 27Storage (Less Than One Year) .......................... 26

R

Radiator - Clean ................................................... 113Radiator Restrictions ............................................. 57Reference Information ........................................... 25Reference Information Section ............................ 122Reference Material .............................................. 127Additional Reference Material.......................... 128Coolants........................................................... 127Fuels ................................................................ 127Greases ........................................................... 127Lubricants ........................................................ 127Miscellaneous .................................................. 127S·O·S Information ............................................ 127

Reference Materials ............................................ 124Refill Capacities..................................................... 61Cooling System.................................................. 61Lubrication System ............................................ 61

S

Safety Messages..................................................... 6(1) Universal Warning .......................................... 7

Safety Section ......................................................... 6Self-Diagnostics..................................................... 32Severe Service Application.................................... 74Improper Maintenance Procedures (MaintenanceProcedures Which May Contribute to a SevereService Application) ......................................... 75Severe Environmental Factors........................... 74Severe Operating Conditions............................. 74

Starting the Engine................................................ 43Cold Weather Starting........................................ 43Problems with the Wiring Harness..................... 44Starting Problems .............................................. 44Starting the Engine ............................................ 43Under-the-Hood Inspection................................ 43

Starting with Jump Start Cables ............................ 44

Stopping the Engine .............................................. 59After Stopping the Engine.................................. 59

System Pressure Release..................................... 73Coolant System.................................................. 73Engine Oil .......................................................... 73Fuel System....................................................... 73

T

Table of Contents..................................................... 3Turbocharger - Inspect ......................................... 114Removal and Installation................................... 114

V

Valve Actuators - Check ....................................... 114

W

Walk-Around Inspection ....................................... 114Warranty Information ............................................ 116Warranty Section .................................................. 116Welding on Engines with Electronic Controls ........ 73

132 SEBU7695-15Index Section

Product and Dealer InformationNote: For product identification plate locations, see the section “Product Identification Information” in the Operationand Maintenance Manual.

Delivery Date:

Product InformationModel:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer InformationName: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:

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