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GATERPiLLAR ® Gerald L. Shaheen
Vice President
Caterpillar inc.
Engine Division
Daniel M. Murphy
Vice President
Caterpillar, Inc.
Engine Division
Dear Valued Customer:
We want to thank you for purchasing a Caterpillar powered truck.
We have a goal to supply customers with the highest quality engines.
If at anytime you have problems or feel that you have not received the
reliability that you have purchased, please contact your authorized
Caterpillar truck engine dealer or contact Caterpillar directly by dialing
1-800-447-4986.
We have enclosed in your owners information package the Caterpillar
Authorized Truck Engine Parts and Service Directory to assist you.
Engine Division strives for the highest customer satisfaction possible.
Therefore, we offer you our fullest cooperation to treat you as a valued
partner in business. Thank you for your trust in purchasing Caterpillar
products.
Sincerely, Sincerely,
xA__W^-pv ^-^t_»_^tj»e-i—-
Dealer Locating Serwice 1
Information Section
Table of Contents
Customer Assistance
When a problem arises concerning the sale, operation or service of your Table of Contents
engine, it will normally be handled by the distributor or dealer in your
area. Please refer to the Caterpillar Truck Engine Parts & Service Directory
which will identify the facility nearest you, the hours of operation, phone Information Section
number and how to locate the dealer.
Foreword 3
Caterpillar has authorized parts & service outlets throughout North
America to satisfy your needs. These authorized dealers provide: Safety Section
Important Safety Information 5
• Factory Trained Service Personnel
6
• At many locations, 24 hour a day service and parts availability Safety
• Complete offering of Remanufactured Components Warning Signs and Labels 6
• Product information and published service literature General Hazard Information 8
Burn Prevention 10
Your satisfaction is a primary concern to Caterpillar, its distributors and Fire or Explosion Prevention 11
their dealers. If you have a problem that has not been handled to your Crushing or Cutting Prevention 12
satisfaction, we suggest the steps that follow. Mounting and Dismounting 12
Before Starting the Engine 12
Step One
Engine Starting 13
Discuss your problem with a member of management from the Electrical System 14
distributorship or dealership. If your problem originates with a dealer, Caterpillar Electronic Engines , 15
explain the matter to a management member of the distributorship with
whom the dealer has his parts and service agreement. Product Information Section
Model Views 16
Step Two
Engine Information 17
fj.
When it appears that your problem cannot be readily resolved at the Product Identification 21
distributor level without additional assistance, contact your Caterpillar
District Office. The phone number is available at the dealer/distributor. Reference Numbers and Ordering Parts 23
Emergency Vehicle Engine Features 25
Step Three
Engine Lifting and Storage 26
If you are still not satisfied, call Caterpillar Factory Customer Services
(24 hour service) at 1-800-447-4986. Operation Section
Gauges 27
When contacting Caterpillar direct, please keep in mind that ultimately
your problem will likely be resolved at the distributorship/dealership using Engine Diagnostics 29
their facilities, equipment and personnel. Therefore, it is suggested that Starting the Engine 35
you follow the above steps in sequence when experiencing a problem.
Operating the Engine 42
Auxiliary Engine Brakes 50
Cold Weather Operation 53
Stopping the Engine 63
Information Section
Table of Contents Information Section
Foreword
Maintenance Section
Torque Specifications .... ,__,. Foreword
D4
Lubricant Specifications -~
DO
Fuel Specifications 77 Literature Information
Coolant Specifications 7q This manual contains safety, operation instructions, lubrication and
S®0«S Oil Analysis Q1 maintenance information. Read, study and keep it with the vehicle
S*0*S Coolant Analysis qo literature and engine information.
Terminology qc_ Some photographs or illustrations in this manual show details or
Maintenance Section attachments that may be different from your engine. Guards and covers
may have been removed for illustrative purposes. Continuing
Refill Capacities qR
improvement and advancement of product design may have caused
Maintenance Schedule Recommendations 97 changes to your engine which are not included in this manual. Whenever
a question arises regarding your engine, or this manual, please consult
Maintenance Schedule - Engines with a Shallow Oil Sump 97
your Caterpillar dealer for the latest available information.
Maintenance Schedule - Engines with a Deep Oil Sump 100
N0tes
IZl02 Safety
Severe Service Application 151
The safety section lists basic safety precautions. In addition, this section
Maintenance Records _, _-n
I !_>__. identifies hazardous, warning situations. Read and understand the basic
Maintenance Log _.,-_ precautions listed in the safety section before operating or performing
lubrication, maintenance and repair on this product.
Warranty Section
Federal Emission Control Warranty 154 I. Operation
California Emission Control Warranty Statement 157 Operating techniques outlined in this manual are basic. This manual will
Emissions Warranty Information 162 assist with developing the skills and techniques required to operate the
Engine Protection Plans 165
engine more efficiently and economically.
The operation section is a reference for operators. Photographs and
Reference Information Section illustrations guide the operator through correct procedures of inspecting,
Customer Assistance .. ,<?n starting, operating and stopping the engine. This section also includes a
166
Ordering Replacement Parts discussion of gauges, indicators, features and controls, engine starting,
170
operating and stopping and diagnostic information.
Reference Materials 171
MHP
Information Section Safety Section
Foreword Important Safety Information
Recommended service should always be performed at the fuel Important Safety Information
consumption interval first, however Caterpillar recognizes that
distance traveled (kilometers/miles) or time (service hours) are more
convenient. Under very severe, dusty or freezing cold operating
conditions, more frequent maintenance than is specified in the Most accidents involving product operation, maintenance and repair are caused by
Maintenance Schedule may be necessary. Refer to the Severe failure to observe basic safety rules or precautions. An accident can often be avoided
Service Application topics in this publication for the information. by recognizing potentially hazardous situations before an accident occurs. A person
must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.
Maintenance Intervals
Improper operation, lubrication, maintenance or repair of this product can be
Perform maintenance on items at multiples of the original requirement. dangerous and could result in injury or death.
The maintenance interval for each item listed in the Maintenance
Do not operate or perform any lubrication, maintenance or repair on this
Schedule is primarily based on the item and its relationship to either product, until you have read and understood the operation, lubrication,
engine speed or load. Caterpillar recommends that a maintenance record maintenance and repair information.
be maintained as part of the engine's permanent record.
Safety precautions and warnings are provided in this manual and on the product. If
See the Maintenance Records section in this manual for information these hazard warnings are not heeded, bodily injury or death could occur to you or
regarding documents that are generally accepted as proof of other persons.
maintenance or repair. Your authorized Caterpillar dealer can assist you in The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word"
tailoring your Maintenance Schedule to meet the needs of your operating such as "WARNING" as shown below.
environment.
Safety
There may be several specific safety signs on your engine. Please take
the time to familiarize yourself with the safety signs.
Make sure that you can read all safety signs. Clean or replace these if you
cannot read the words or see the pictures. When cleaning the labels use
a cloth, water and soap. Do not use solvents, gasoline, etc, to clean
safety signs. The use of solvents, gasoline, etc, could loosen the sign's
adhesive and cause the sign to fall off.
Ether, Unit Injectors, High Pressure, Read Manual warning
You must replace a label if it is damaged, missing or cannot be read. If a label.
label is attached to a part, and that part is replaced, make sure a new
-label is installed on the replaced part. See your Caterpillar dealer for new The following paragraphs describe the warnings that are depicted on the
labels. warning label.
Do not operate or work on the engine unless you have read and Ether
understand the instructions and warnings in this Manual. Failure to follow The engine is equipped with an air inlet heater for cold weather starting
the instructions or heed the warnings could result in injury or death. Do not spray aerosol types of starting aids such as ether into the air inlet.
Consult your Caterpillar dealer for replacement manuals. Proper care is Such use could result in an explosion and personal injury.
your responsibility.
yl. Unit Injectors
Ether, Unit Injectors, High Pressure, Read Manual O,
This engine uses high voltage to the unit injectors. Disconnect the unit
injector connector to prevent personal injury. Do not come in contact with
the injector harness connector while the engine is operating.
High Pressure
High pressure fluid spray can inject fluid into the body resulting in serious
injury or death. Always use a piece of cardboard or a board to detect
leaks. Never use your hand. \
Read Manual
Do not operate or work on this engine unless you have read and
understand the instructions and warnings in the Operation and
D04471 Maintenance Manual. Failure to follow the instructions or heed the
warnings could result in injury or death.
The Ether, Unit Injectors, High Pressure, Read Manual
warning label is located on the valve cover.
8
Safety Section Safety Section
Safety Safety
Consult any Caterpillar dealer for replacement labels. Proper care is your UNLESS INSTRUCTED DIFFERENTLY, PERFORM ALL
responsibility. MAINTENANCE AS FOLLOWS:
• Stop the engine.
General Hazard Information • Ensure the protective locks or controls are in the applied position.
• Engage the secondary (emergency) or parking brakes.
. Block or restrain the vehicle before performing maintenance or repair.
• Disconnect the batteries whenever performing any maintenance or
before servicing the electrical system.
• Do NOT attempt repairs you do not understand.
. When starting an engine after repairs have been made to the fuel
system make provisions for shutting off the engine's inlet air and/or fuel
supply (to stop the engine), in case there is an overspeed on start-up.
• Start the engine only from the operator's station (cab). Never short
across the starting motor terminals or the batteries as this could bypass
the engine neutral start system as well as damage the electncal system.
Asbestos Information Batteries give off flammable fumes which can explode. Always thaw a
frozen battery before jump starting. Frozen batteries can explode. Do not
This Caterpillar product and replacement parts shipped from the factory
smoke when observing the battery electrolyte levels.
are asbestos free. Caterpillar recommends the use of only genuine
Caterpillar replacement parts.
Fire or Explosion Prevention
Burn Prevention Determine whether the engine will be operated in an environment in which
combustible gases could be drawn through the air inlet system. These
Do not touch any part of an operating engine. Allow the engine and
gasls could cause the engine to overspeed, which in turn could seriously
components to cool before any repair or maintenance is performed on the
damage the engine and result in bodily injury or property damage. If your
engine. Relieve all pressure in air, oil, fuel or cooling systems before any
lines, fittings or related items are disconnected or removed. application involves the presence of combustible gases, consult your
Caterpillar dealer to obtain additional information concerning protection
devices suitable for the application involved.
Coolant
If equipped with an air conditioner, do not smoke when servicing,
To prevent personal injury, do not step up on engine to remove the filler charqinq or working around air conditioner leaks. Inhaling freon gas
cap, if applicable. Use an adequate ladder. At operating temperature, the through a lit cigarette or other smoking method, or inhahng fumes
engine coolant is hot and under pressure. The radiator and all lines to released from a flame contacting freon could cause bodily harm or death.
heaters or the engine contain hot coolant. Check the coolant level only DO NOT allow these situations to occur when servicing air conditioners or
after the engine has been stopped and the filler cap is cool enough to where freon gas may be present.
remove with your bare hand.
All fuels, most lubricants and some coolant mixtures are flammable.
Remove the cooling system filler cap slowly to relieve pressure. Allow Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and
cooling system components to cool before draining. When pressure is gasoline fumes are extremely explosive. Do not smoke while refueling or
relieved rapidly, this hot coolant water can turn into steam. Any contact
in a refueling area.
with hot water or steam can cause severe burns.
Keep all fuels and lubricants stored in properly marked containers and
Cooling system supplemental additive (conditioner) contains alkali. To away from all unauthorized persons.
prevent personal injury, avoid contact with the skin and eyes and do not
drink. Store all oily rags or other flammable material in a protective container, in
a safe place. Remove all flammable materials such as fuel, oil and other
Oils debris before they accumulate on the engine. Do not expose the engine
to flames, burning brush, etc, if at all possible.
Hot oil and components can cause personal injury. Do not allow hot oil or
components to contact the skin. Do not weld or flame cut on pipes or tubes that contain flammable fluids.
Clean them thoroughly with nonflammable solvent before welding or flame
Batteries cutting on them.
Exhaust shields (if equipped), which protect hot exhaust components from
Battery electrolyte contains acid and can cause injury. Avoid contact with
the skin and eyes. Wash hands after touching batteries and connectors. oil or fuel spray in the event of a line, tube or seal failure, must be
Use of gloves is recommended. Always wear protective glasses when installed correctly.
working with batteries. Provide adequate and proper waste oil disposal. Oil and fuel filters must
be properly installed and housing covers tightened to proper torque when
being changed.
12 13
Safety Section Safety Section
Safety Safety
Fire Extinguisher Determine the settings that have been selected for the Engine Monitoring
Have a fire extinguisher available and know how to use it. Inspect and System and for the idle shutdown timer. These settings should be
have it serviced as recommended on its instruction plate. recorded in the General Section of this manual under the Reference
Numbers chart. If you do not know these settings, consult your Caterpillar
dealer for assistance.
Crushing or Cutting Prevention
Support equipment and attachments properly when working beneath Engine Starting
them. Never work under a partially tilted cab unless it is properly secured.
Do not start the engine or move any of the controls or disengage the
Never attempt adjustments while the vehicle is moving or while the engine parking brakes if there is a warning tag attached to the controls. Check
is operating unless otherwise specified in this manual. Stay clear of all with the person who attached the tag before starting.
rotating and moving parts. Guards should be in place whenever
maintenance is not being performed. Keep objects away from moving fan Make sure no one is working on, or close to the engine or engine driven
blades. They will throw or cut any object or tool that falls or is pushed into components before starting it. Always make an inspection of the engine
them. before and after starting.
• Wear protective glasses when striking objects to avoid injury to your eyes. Enqine exhaust contains products of combustion which may be harmful
-Chips or other debris can fly off objects when struck. Make sure no one to your health. Always start and operate the engine in a well-ventilated
can be injured by flying debris before striking any object. area and, if in an enclosed area, vent the exhaust to the outside.
Start the engine only from the operator's station (cab). Never short across
Mounting and Dismounting the electric starting motor terminals or the batteries to start the engine as
this could bypass the engine neutral-start system as well as damage the
Do not climb on, or jump off the engine. Do not stand on components electrical system. Always start the engine according to the required
which cannot support your weight. Use an adequate ladder. Clean steps, Engine Starting procedure described in this manual to prevent major
handholds and areas of the vehicle that you will be working on or around. engine component damage and personal injury.
Electrical System To prevent potential sparks from igniting combustible gases produced by
some batteries, attach the negative (-) boost ground cable last, to the
Grounding Practices starting motor negative (-) terminal (if equipped) or to the engine block.
Proper grounding for the vehicle and for the engine electrical system is Check regularly for loose or frayed electrical wires. Have all loose or
necessary for proper vehicle performance and reliability. Improper frayed electrical wires tightened, repaired or replaced before operating the
grounding will result in uncontrolled and unreliable electrical circuit paths. vehicle. See the Operation Section of this manual for specific starting
instructions.
Uncontrolled engine electrical circuit paths can result in damage to main
bearings, crankshaft journal surfaces and aluminum components. Caterpillar Electronic Engines
Uncontrolled electrical circuit paths can also cause electrical noise which
may degrade the performance of the vehicle and the radio. Tampering with the engine electronic system installation or with the
vehicle OEM wiring installation can be dangerous and could result in
To prevent damage from electrical discharge, check to make sure that the personal injury or death and/or engine damage.
engine's electrical system has an engine to frame ground strap. For
engines with the alternator connected to an engine component, the This engine uses high voltage to the electronic unit injectors. Do not
ground strap must connect that component to the frame which in turn come in contact with the electronic unit injector connector while the
must be connected to the negative (-) battery terminal. engine is operating.
To insure proper functioning of the vehicle and the engine electrical This engine is equipped with customer selected monitoring features that
system, an engine-to-frame ground strap with a direct path to the battery may cause reduced power under certain conditions. The monitoring
must be used. This may be provided by way of a starting motor ground, a features and the idle features can only be programmed and/or changed
frame-to-starting motor ground, or a direct frame to engine ground. with electronic service tools and passwords. The engine may also be
equipped by the vehicle OEM with a shutdown that will shut the engine
The cylinder head must be grounded to the negative (-) battery terminal. down under certain conditions. The shutdown may take as little as 20
An engine-to-frame ground strap may be used from the cylinder head seconds from the time the warning indicator is activated. Read and
ground stud to the frame and to the negative (-) battery terminal. understand the information in this manual concerning the programmable
Alternatively, use a ground strap from the cylinder head ground stud to engine monitoring options and the idle shutdown timer. Also refer to the
the starting motor and to the negative (-) battery terminal. Reference Numbers section in this manual for the specific settings of your
The engine alternator must be grounded with a wire of a size that is engine.
adequate to handle the full charging current of the alternator. When selected or programmed, high coolant temperature can cause the
All grounds must be tight and free of corrosion. Ground wires and ground engine power and vehicle speed to be limited.
straps should be combined only at the points that are dedicated for The OEM may use a shutdown feature that will shut the engine down
ground use. when a warning indicator activates. If possible, the vehicle should be
Never disconnect any charging unit circuit or battery cable from the steered carefully off the roadway and brought to a stop. The vehicle can
battery when the charging unit is operating. A spark can cause the be restarted following the shut down if necessary for emergency repairs.
flammable vapor mixture of hydrogen and oxygen to explode. Refer to the OEM for information about your particular electronic engine
shutdown features.
16 17
Product Information Section Product Information Section
Model Views Engine Information
The 3116 and 3126 HEUI Air-to-Air Aftercooling (ATAAC) Engines are
designed primarily for on-highway medium duty applications. The engines
are four stroke cycle, in-line six cylinder engines with direct fuel injection.
6 5 4 3 2 1
E00996
(1) Lifting eye. (2) Oil filler cap. (3)-Oil level gage. (4) Crankcase breather.
(5) Cylinder head ground stud. (6) Air compressor. (7) Oil drain-plug. (8) Fuel
filter. (9) Electronic control module (ECM). (10) Water temperature regulator
(thermostat) housing. (11) Belt tensioner. (12) Water drain plug.
(13) Turbocharger. (14) Oil filter. (15) Water pump. (16) Crankshaft vibration
damper.
• 19
18
Product Information Section Product Information Section
Engine Information Engine Information
NOTE: Some 3116 Engines have the following features: high gear rpm The engine lubricating oil, which is both cooled and filtered, is supplied
limiting, low gear rpm limiting, and progressive shift engine speed control. by a qear type pump. Bypass valves provide flow of lubrication oil to the
engine when oil viscosity is high, or if either the oil cooler or the oil filter
Additional features such as improved cold starting capability, tamper elements become plugged.
resistance, diagnostics, an American Trucking Association (ATA) data link
(SAE J1587), and an optional Engine Monitoring Package provide I Engine efficiency, efficiency of emission controls and engine performance
increased engine fuel economy and serviceability. depend on adherence to proper operation and maintenance
recommendations, and the use of recommended fuels lubrication oils,
Hydraulically Actuated Electronic Unit Injectors (HEUI) perform fuel and coolants. Follow the maintenance recommendations in the
pumping, fuel metering, and fuel timing functions. The unit injectors are Maintenance Schedule.
controlled by the Electronic Control Module (ECM) using the camshaft
position and the engine speed signals from the speed/timing sensors as
well as inlet manifold pressure from the boost sensor. The engine's rated Aftermarket Products and Caterpillar Engines
rpm is identified on the Information Film. When auxiliary devices, accessories, or consumables (such as filters, oil
additives catalysts, etc) which are made by other manufacturers are used
on Caterpillar products, the Caterpillar warranty is not effected simply
because of such use. However, failures that result from the installation
or use of other manufacturers' devices, accessories, or consumables
are NOT Caterpillar factory defects and therefore are NOT covered
under the Caterpillar warranty.
21
20
Product Information Section
Product Information Section
Engine Information Product Identification
The Serial Number Plate is located on the side of the cylinder block.
C v X*% iA, #4 A i / ii /*»• TJ 4 /f XO
4 £. "f 10 0 0 7
A0\/ 3 3 2 HfZH-U.Q
22 23
Product Information Section Product Information Section
Product identification Reference Numbers and Ordering Parts
llll
lift
Cooling System Capacity (Total) If the emergency vehicle engine is programmed to derate, reduced power
will begin when the High Coolant Temperature Warning [113°C (235°F)]
fault code flashes. The derate will continue until the coolant temperature
Engine Monitoring System Parameters reaches 115°C(240°F).
Engine Monitoring Mode Selected
DOff
• Warning Only
D Derate (Warn/Derate) "
Idle Shutdown Timer. . Minutes
26 27
Product Information Section Operation Section
Engine Lifting and Storage # Gauges
:
•
Engine Lifting and Storage Gauges
Engine Lifting Refer to the Truck Owners Manual for information on the layout of your
gauge package. Gauges provide a "look" inside the engine. Be sure they
NOTICE are in good working order. Determine what is the "normal" operating
When it is necessary to remove a component, remember that the capa- range by observing your gauges over a period of time.
city of an eyebolt is less as the angle between the supporting members
and the object becomes less than 90 degrees. Eye bolts and brackets Noticeable changes in gauge readings are an indicator of potential gauge
should never be bent and should only be loaded in tension. or engine problems. This also applies to gauge readings that have
changed significantly but are still within specifications. The cause of any
sudden or significant change in the gauge readings should be determined
and corrected. Consult your Caterpillar dealer for assistance as needed.
Use a hoist to remove heavy components. Lift the engine by using an
adjustable lifting beam. All of the supporting members (chains and Caterpillar Electronic engines require one lamp in addition to the gauge
cables) should be parallel to each other, and as near perpendicular as package that is normally provided.
possible to the top of the object that is being lifted.
The CHECK ENGINE/DIAGNOSTIC lamp is yellow/amber. The purpose
Some removals require the use of lifting fixtures in order to obtain proper of the CHECK ENGINE/DIAGNOSTIC (YELLOW) lamp is to communicate
balance and to provide safe handling. Lifting eyes are designed for the the status of the engine's electronic system.
arrangement as sold. Alterations to the lifting eyes and/or to the
arrangement weight make the lifting devices inadequate and deficient. If An optional red WARNING lamp is available. The purpose of the
you make alterations, you are responsible for providing adequate lifting WARNING (RED) lamp is to warn the operator of engine problems such
devices. To remove the engine, use the two lifting eyes that are on the as low oil pressure, high coolant temperature, low coolant level or high
front and the rear of the engine. inlet air temperature.
Engine Storage
NOTICE
Special precautions should be taken for engines that will remain out of If no oil pressure is indicated, STOP the engine. Engine damage can
service for prolonged time periods. result.
The lubricating oil will drain from the cylinder walls and from the piston
rings of engines that are not started for several weeks. Rust can form on yj-\\ Oil Pressure - Typical oil pressure range is 240 to 480 kPa (35
the cylinder liner surface, which will increase engine wear and may result W ^ W to 70 psi) when the engine is operating at rated engine speed,
in shorter engine service life. ^ — ^ with SAE 15W40 oil, at operating temperature. Higher oil pressure
is normal on start-up with cold oil. A lower pressure is normal at low idle
Check the cooling system for adequate protection against freezing (if
speed. Oil pressure will increase and stabilize as the engine speed
applicable). A 50/50 solution of Caterpillar (permanent-type) Antifreeze
increases.
and approved water will provide protection to -37°C (-34°F).
Refer to SEHS9031, Storage Procedures For Caterpillar Products, for more
detailed information on engine storage. Consult with your Caterpillar
dealer for instructions to prepare your engine for longer storage periods.
•ill
28 29
Operation Section Operation Section
llll Gauges 'I Engine Diagnostics
Tachometer (If Equipped) - Indicates engine speed [revolutions Check Engine/Diagnostic Lamp
per minute (rpm)]. The engine can be operated at high idle
without damage, but the engine should not be allowed to The CHECK ENGINE/DIAGNOSTIC (YELLOW) lamp on the vehicle
overspeed. Overspeeding when downshifting, going downhill, etc, can dashboard is used to communicate the status or the operation situations
result in serious damage to the engine. of the electronic engine and the control system.
Engine Oil Temperature - Measures oil temperature in the oil When the ignition key switch is turned ON, the YELLOW lamp will
pan. Higher than normal oil temperature indicates a heat problem illuminate for five seconds (as a lamp check). The lamp will also illuminate
in the lubrication system and/or the cooling system. This can and flash every five seconds whenever the ECM detects an ACTIVE fault
damage the cylinder heads, the cylinder liners, the pistons, and the or condition. If the lamp comes ON and continues to flash every five
crankshaft bearings. seconds after initial start-up, the ECM has detected a system problem.
Fuel Level - This electrically operated gauge indicates the level The YELLOW lamp is also used for the Idle Shutdown Timer. The lamp will
of fuel in the fuel tank. The fuel level gauge registers only when start to flash at a rapid rate 90 seconds before the programmed idle time
the ignition key switch is ON. expires. The engine will shut down after the 90 second interval. To disable
the Idle Shutdown Timer, the ALLOW IDLE SHUTDOWN OVERRIDE must
Fuel Pressure - Indicates fuel pressure to the unit injectors from be programmed to YES. The clutch pedal or the service brake pedal must
the fuel filter. The indicator should register in the NORMAL be depressed during the final 90 seconds while the YELLOW lamp is
(green) range. A drop in fuel pressure usually indicates dirty or flashing. A diagnostic EVENT code, Override of Idle Shutdown Timer, will
plugged fuel filters. be logged 1n the ECM.
Service Hour Meter - Indicates the total number of clock hours
that the engine has operated.
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Diagnostic Flash Code Low Engine Speed Engine Shut Down Service Schedule
Engine Service
Misfire Power Reduced Shutdown Vehicle ASAP
The Air Inlet Heater system is designed to operate prior to start-up, during 3 Turn the ignition key switch to the START position in order to crank
cranking, and after the engine has started. If the sum of the coolant the engine. The Air Inlet Heater will turn ON if the sum of the coo ant
temperature and the inlet air temperature is below 25°C (77°F), the ECM temperature and the inlet air temperature is less than 25 C {it A
allows the heater to stay on for preheating when the ignition key switch is
turned to the ON (RUN) position. The indicator lamp on the instrument DO NOT PUSH DOWN OR HOLD THE THROTTLE DOWN while
panel will turn on when the Air Inlet Heater system is functioning. The cranking the engine. The system will automatically provide the correct
electric air heater grid, the starting motor solenoid, the ECM, and sensors amount of fuel to start the engine.
are part of the engine arrangement. If the engine does not start after 15 to 20 seconds of cranking, release
he ignSPon key switch. If the sum of the coolant temperature and the inlet
Start the engine using the following procedure.
aTtemperature is less than 25°C (77°F), the Air Inlet Heater preheat cycle
1. Engage the parking brake. Place the transmission in NEUTRAL. If the will S t a r t Turn to the ignition key switch to the OFF posrtion. Allow the
vehicle is equipped with a manual transmission, depress the clutch pedal starting motor to cool for two minutes. Repeat steps 2 and 6.
in order to disengage the flywheel clutch. This reduces transmission drag
and prevents movement of the vehicle. Depressing the clutch in cold
weather can mean the difference between starting and not starting by NOTICE
reducing battery drain. Do not increase engine speed until the oil pressure gauge indicates
normal. OH pressure should raise within 15 seconds after the engine
The CHECK ENGINE/DIAGNOSTIC lamp will turn ON for five seconds as
a system lamp check when the ignition key switch is first turned on. If the ^ p r e s s u r e is not indicated on gauge within 15 seconds, do not drive
lamp fails to turn ON, notify your Caterpillar dealer. If the lamp continues the vehicle. STOP the engine, investigate and correct the cause.
to flash after the engine has started, the ECM has detected an engine
system problem. Refer to Engine Diagnostics topic.
4. Release the ignition key switch to the ON (RUN) position immediately
2. Turn the ignition key switch to the ON position. The Air Inlet Heater
after the engine starts. After the engine starts, check to make sure the
system has a preheat function to improve cold weather starting.
Snsmission is still in NEUTRAL and release the clutch pedal (manual
NOTE: The AIR INLET HEATER indicator lamp will turn ON for a minimum transmission). The vehicle may be operated at a light load and speed as
of two seconds regardless of the coolant temperature. If the AIR INLET soon^s the engine oil pressure and air pressure have reached normal
HEATER indicator lamp stays ON for more than two seconds, wait until levels.
the indicator lamp turns to OFF (approximately 30 seconds) before
After the engine has started, the Air Inlet Heater may continue to operate
attempting to start the engine. If the operator attempts to start the engine
fn a Continuous mode and/or in an On/Off cycle mode. The Continuous
before the indicator lamp goes OFF, the ECM will control the Air Inlet
mode can last for a maximum of seven minutes, followed by the On/Off
Heater for the cranking cycle. Attempting to start the engine before the
indicator lamp goes OFF could result in excessive white smoke at start- cvde mode During the On/Off cycle mode, the Air Inlet Heater cycles ON
up. and OFFfor ten seconds. The Air Inlet Heater will turn OFF when the sum
of the coolant temperature and the air inlet temperature exceeds 35 C
(95°F).
NOTICE If the engine is operated with a low load, the engine will reach .normal
Do not keep the starting motor engaged for more than 30 seconds at a operating temperature sooner than when the engine is id ed with no load
time. Allow the starting motor to cool for two minutes before trying When idling in cold weather, increase the engine speed to approximately
again. If the engine does not start after three attempts, determine the 1000 to 1200 rpm in order to warm-up the engine more quickly. Do not
cause of malfunction. Pumping the accelerator will in no way assist in race the engine in order to speed the warm-up. Limit unnecessary idle
starting the engine.
time to ten minutes.
38 39
Operation Section Operation Section
Starting the Engine Starting the Engine
Personal injury or property damage can result from alcohol or start- If the engine fuel system has been run dry, fill the fuel tank and prime the
ing fluids. Alcohol or starting fluids are highly flammable and toxic fuel system. Refer to the Priming the Fuel System topic.
and if improperly stored could result in injury or property damage. If the other problems are suspected, perform the appropriate following
When using starting fluid, carefully follow the instructions that are procedure in order to start the engine.
provided by the manufacturer of the vehicle. Use ether sparingly and
spray it only while cranking the engine. Starting From An External Electrical Source
Failure to follow these instructions could result in an explosion
and/or fire and possible personal injury. ^ WARNING
NOTICE NOTICE
The optional automatic ether injection system is the only starting fluid When jump starting an engine, follow the instructions below to properly
system that is recommended. Excessive starting fluid can cause piston start the engine. This engine may be equipped with a 12 volt or a 24 volt
and ring damage. Use starting fluid for cold starting purposes only. starting system. Use only equal voltage for boost starting. The use of
higher voltage will damage the electrical system.
When using jumper cables always connect the positive (+) cable to the
Startability will be improved at temperatures below 0°C (32°F) by the use positive (+) terminal of battery which is connected to starting motor
of an automatic ether injection system and/or use of a jacket water solenoid. Connect the negative (-) cable from the external source to
heater. This will help alleviate white smoke and misfire during cold starting motor negative (-) terminal. If NOT equipped with a starting
weather start-up. Consult your Caterpillar dealer for other means of motor negative (-) terminal, connect the negative (-) terminal to the
improving startability in cold temperatures. engine block.
An optional ether starting aid is available for use with the engine. The Do not reverse the battery cables. The alternator can be damaged.
system injects ether into the air inlet manifold AFTER the air inlet heater. Attach the ground cable last and remove the ground cable first.
Extensive damage to the engine could occur if ether is directed at the air
inlet heater element while the air inlet heater is activated.
1. Turn the ignition key switch to the OFF position. Remove the key and
If the vehicle is equipped with the ether injection system, crank the turn all electrical accessories OFF before attaching the cables.
engine, depress the ether switch, hold the ether switch for three seconds,
and release the ether switch. Additional injections may be necessary to
start and/or achieve low idle speed.
1
40 41
Operation Section Operation Section
Starting the Engine Starting the Engine
>
2. Connect one end of the positive (+) cable to the positive (+) terminal Harness/Wiring Problem
of the battery being started. Connect the other of the positive (+) cable to
the positive (+) terminal of the power source.
3. Connect one end of the negative (-) cable to the negative (-) terminal
of the power source. Connect the other end of the negative (-) cable to
the starting motor negative (-) terminal or to the engine block. This
prevents potential sparks from igniting combustible gases produced by
some batteries.
4. Allow sufficient time to partially charge the battery. The engine will not
continue to operate after the engine is started if the battery does not have
a partial charge.
5. Start the engine. After the engine starts, disconnect the negative (-)
cable from the starting motor negative (-) terminal or from the engine
block. Disconnect the other end of the negative (-) cable from the
negative (-) terminal of the power source. Locate the ECM. Two harness connectors are attached to the ECM. The
upper connector is the engine harness and the lower connector is the
6. Disconnect the positive (+) cable from the positive (+) terminal of the chassis harness. Check the connectors to be sure that the connectors
battery on the engine that is being started. Disconnect the positive (+) are secure. Perform a "tug test" on EACH wire in the lower connector.
cable from the positive (+) terminal of the power source.
1. Pull (tug) on each wire with approximately 4.5 kg (10 pounds) of force.
The wire should remain in the connector.
2. If a wire feels loose, push the wire back into the connector. Then tug
the wire again in order to ensure that the wire is locked into place.
3. Start the engine. If the engine does not start, consult the nearest
Caterpillar dealer for assistance.
A.
•
1
pi
IA.
m• : 42 43
fltr '" Operation Section Operation Section
IA-* Operating the Engine Operating the Engine
if'
After the vehicle is stationary, the idle shutdown timer begins. The engine
Operating the Engine can be operating at low idle or at an idle rpm selected by the PTO
governor. The CHECK ENGINE/DIAGNOSTIC (YELLOW) lamp will flash
rapidly 90 seconds prior to shutdown. Movement of the vehicle
automatically resets the idle shutdown timer to the programmed setting.
Proper operation, driving techniques and maintenance are key factors in
obtaining the maximum service life and economy of Caterpillar engines. To override the idle shutdown timer:
Following the recommendations in this manual will lower operation costs.
For more information, ask your Caterpillar dealer for LEDT2254, CAT 1. Program the ALLOW IDLE SHUTDOWN OVERRIDE to YES.
Answers Your Questions About Truck Performance. 2. The CHECK ENGINE/DIAGNOSTIC (YELLOW) lamp will flash rapidly
90 seconds prior to shutdown. Depress the service brake or the clutch
pedal during the 90 seconds when the YELLOW lamp flashes.
Idle speed is adjustable on Caterpillar electronic engines. Consult your After an idle shutdown, the engine can be restarted without turning the
Caterpillar dealer for information. The idle speed preset to 700 rpm. ignition key switch to the OFF position.
Avoid excess idling. If the vehicle is parked for more than five minutes, The override capability is disabled If the ALLOW IDLE SHUTDOWN
STOP the engine. An engine can burn from 2.8 to 5.7 L (.7 to 1.5 US OVERRIDE is programmed to NO.
gal) of fuel per hour while idling. Excessive idling can cause excessive
carbon buildup and/or slobber, which is harmful to the engine. Cold Mode Operation
If extended idle time is required, control the engine speed to 1000 rpm or Cold mode is initiated if the sum of the coolant temperature and the air
greater and take steps to ensure that the coolant temperature exceeds inlet temperature is less than 35°C (95°F). In cold mode, the low idle is
82°C (180°F). Consult your Caterpillar dealer for assistance. increased to 1000 rpm and the engine power is limited. The cold mode
strategy provides reduced smoke emission and faster warm-up time.
Fast idle can be programmed within the range of 700 to 1600 rpm. Fast
idle requires an ON/OFF switch on the dashboard. Consult your Cold mode is deactivated when the temperature condition is met, or when
Caterpillar dealer for assistance. • the engine has been operating for 12 minutes.
After cold mode is completed, the engine should be operated at low rpm
Idle Shutdown Timer and low load until normal operating temperature is reached. The engine
The idle shutdown timer can be programmed to shut the engine down will reach normal operating temperature faster when the engine is
after a specific time period of engine idling. The idle time can be operated at low rpm and low power demand than when then engine is
programmed from 3 minutes to 1440 minutes (24 hours). If the idle idled with no load.
shutdown timer is set to 0 minutes, the idle shutdown feature is disabled.
If the timer setting is unknown, allow the engine to idle and observe how
much time elapses before the engine shuts down. The following NOTICE
conditions must be met in order to activate the idle shutdown timer. The vehicle should not be moved until the engine is out of cold mode.
Power may be noticeably reduced if the vehicle is operated while the
« The idle shutdown feature must be selected engine is in cold mode. At a speed above eight km/h (five mph), the low
• No vehicle speed is detected by ECM idle speed will be reduced to the customer programmed low idle speed,
• The engine is not under load and power will still be reduced.
• The engine is at operating temperature (NOT in Cold Mode)
44 45
Operation Section Operation Section
Operating the Engine Operating the Engine
Cold mode is disabled if the throttle, the service brake, or the clutch (if If the vehicle can be operated in a higher gear after the desired vehicle
equipped) is depressed. The cold mode operation rpm drops to the speed is reached, select the highest gear available that will pull the load.
programmed low idle speed in order to allow the transmission to be put By following this recommendation, fuel economy can be obtained. The
into gear. engine will be operating at the lowest rpm required to pull the load.
.*___
48 49
•lilR* Operation Section
Operation Section
Operating the Engine Operating the Engine
Auxiliary Engine Brakes On long downhill grades, an operator should establish a "control speed"
The "control speed" is the speed at which the force that pushes the
vehicle is equal to the retarding force that slows the vehicle, with little or
no use of the service brake.
^WARNING To maximize the benefit of the engine retarder, the engine retarder should
be used anytime that the operator wants to slow the vehicle. The engine
retarder should be left in the ON position during all normal operating
If your vehicle is equipped with an auxiliary brake, follow the instruc- conditions.
tions provided in the auxiliary brake owner's manual. Failure to
follow the instructions during wet or slippery conditions could re- The operation of any vehicle under slippery conditions requires caution.
duce vehicle control and result in personal injury or death, This is also true when operating a vehicle engine retarder. As a general
rule, start with the engine retarder OFF and ensure that the vehicle
maintains control through natural retardation. Then activate the engine
retarder at the lowest power setting and increase the power setting as the
NOTICE conditions allow.
Auxiliary brakes should not be used as a primary or service brake. The
vehicle's service brake must be used in order to bring the vehicle to a
complete stop. Operating the Engine Retarder
The engine retarder is controlled by a switch on the dashboard. Before
starting the engine, ensure that the switch is in the OFF position.
Certain auxiliary engine braking devices are approved for use on these
engines. Refer to the Truck Engine Application and Installation Guide or After the engine is started, turn the switch ON. The switch may stay ON
see your Caterpillar dealer for more information. For information on the during engine operation. The engine retarder will only activate when no
specific auxiliary engine brakes on your vehicle, refer to the information fuel is supplied to the engine. The engine retarder will help to slow the
that is provided by the OEM of the vehicle. vehicle when no pressure is applied to the throttle pedal or clutch pedal.
NOTE: The antilock braking system (ABS) of this vehicle may interrupt The engine retarder may be programmed to one of three modes.
the operation of the engine retarder (auxiliary engine brake) during the • COAST
ABS actuation. The engine retarder is a compression brake, also referred • LATCH
to as an exhaust brake. For information on the operation of the ABS, refer • MANUAL
to the literature that is provided by the OEM of the vehicle.
The COAST mode and the LATCH mode require the Cruise Control
The engine retarder provides auxiliary braking in order to slow the vehicle switch to be in the ON position. The COAST mode and the LATCH mode
and control speed on grades, curves, or at any time when the reduction do not require the Cruise Control to be active. In the COAST mode or the
of speed is necessary but a long application of the service brake is not LATCH mode, the engine retarder is activated by the service brake. Use
desired. Controlling the slowing or downhill speed of a vehicle by using of the service brake deactivates the Cruise Control, but does not turn the
the engine retarder results in reduced wear on brake linings and brake Cruise Control OFF.
drums. It helps save the service brakes for emergency stopping
requirements. In the MANUAL mode, it is not necessary to depress the service brake in
order to activate the engine retarder.
An engine retarder generates the maximum retarding power at the
engine's maximum rated rpm. As the engine rpm decreases, so does the If the Cruise Control ON/OFF switch is OFF, the engine retarder will
engine retarder performance. For maximum available retarding, the activate regardless of the service brake.
operator should select a gear which will provide the desired road speed at
the highest allowable engine rpm.
52 53
Operation Section Operation Section
Auxiliary Engine Brakes Cold Weather Operation
COAST Mode
Cold Weather Operation
If the engine retarder is programmed to COAST and the Cruise Control
switch is ON, the engine retarder will activate when the service brake is
depressed. In the COAST mode, the braking power is provided by both
the service brake and the engine retarder. Caterpillar Diesel Engines can operate effectively in cold weather.
However, engine starting and operation in cold weather is dependent on
The engine retarder will deactivate when the service brake is released. the type of fuel used, the oil viscosity, and other optional starting aids
and warm-up aids. The purpose of this section is to:
LATCH Mode
• Explain potential problems that are caused by cold weather operation
If the engine retarder is programmed to LATCH and the Cruise Control
switch is ON, the engine retarder will activate when the service brake is • Suggest steps which can be taken in order to minimize starting
depressed. problems and operation problems when the ambient air temperature is
colder than 0°C (32°F) down to -55°C (-67°F)
The engine retarder remains active (latched) when the service brake is
released. The engine retarder remains active until the throttle pedal or the NOTE: Frequent maintenance checks (more than those specified in the
clutch pedal is depressed, or the engine speed drops below 900 rpm. Maintenance Schedule) will be necessary when operating under freezing
cold conditions.
MANUAL Mode
A discussion of all of the factors that affect the operation and
If the engine retarder is programmed to MANUAL, the engine retarder will maintenance of an engine in cold weather is difficult to outline in one
activate regardless of the service brake or the Cruise Control switch publication. This is because of the differences in weather conditions,
position. The engine retarder will activate when no pressure is applied to engine applications, and the supplies that are available in different areas.
the throttle pedal or clutch pedal. These factors, along with recommendations from your Caterpillar dealer
and past proven practices should be combined with the information in
this section to provide guidelines for cold weather operation.
JA...
I 54
Operation Section
55
Operation Section
Cold Weather Operation Cold Weather Operation
• To prevent condensation on exposed fuel tank walls, fill the fuel tank There are three major differences between No.1 and No.2 diesel fuel.
when the engine will be shut off for eight hours or more. Keep the fuel No.1 diesel fuel has a lower cloud point, a lower pour point and has a
tank as full as possible. lower kJ (Btu) (heat content) rating than No.2 diesel fuel. The kj (Btu)
•Inspect the air cleaners and the air inlet daily, or as necessary, when rating indicates power, therefore No.1 grade fuel will provide less power
working in snow. and fuel economy, but is less likely to plug the fuel filters and flows better
through the fuel system. Keep in mind that No.1 grade fuel or fuel blends
will not provide as much power as No.2 grade fuel. A difference may be
A WARNING noticed.
Be aware of these fuel grades when purchasing your diesel fuel. Plan fuel
Do not store alcohol or starting fluids in the operator's compartment. purchases for cases of driving from warm climates into cold climates.
They are highly flammable and toxic. Vehicles that are fueled in one climate may not operate satisfactorily when
driven to another climate. Before troubleshooting for low power or poor
performance in winter months, check the type of fuel or blend of fuel that
is being used.
A WARNING
No.2 diesel may be blended with No.1 or kerosene in the following
DO NOT USE ETHER (starting fluids) unless specifically instructed to proportions to achieve lower temperature flow capabilities.
do so. This diesel engine is equipped with an electric air inlet heater
system to aid cold weather starting and reduce white smoke. Do not
Summer Grade No.2 Fuel Modification
spray ether into the air inlet. It will contact the heater elements. Use
starting fluid ONLY if the vehicle is equipped with the optional auto- No.2 No.1 Diesel Fuel1
Ambient Temperature Diesel Fuel1 or Kerosene
matic ether injection system or immediate engine damage and per-
sonal injury may result. Above 10°C(-14°F) 90% 10%
-10to-20°C(14to-4°F) 70% 30%
Below -20°C (-4°F) 50% 50%
• Inject starting fluid only when the engine is cranking. 1
DO NOT blend this fuel with gasoline under any circumstances.
• Air system dryers may be effective in reducing condensation and ice
formation in air systems.
• Alcohol injection may prevent moisture from freezing the air compressor
Fuel Related Components
regulator and other components of the air system. Fuel Heaters
• For jump starting with cables in cold weather, refer to the topic in this
manual. When the use of unblended No.2 diesel in the winter cannot be avoided,
a thermostatically controlled or self regulating fuel heater can be installed.
Fuel heaters are not effective for cold starts unless they are powered by
Fuel Recommendations for Cold Weather an external source (i.e. AC current). Select a fuel heater that is
mechanically simple, yet adequate for the application. Choose a fuel
The three types of diesel fuel available for your vehicle engine are
heater with as large a heating surface as practical. Small fuel heaters can
typically grades No.1, No.2 or a blend of No.1 and No.2.
be too hot for their limited surface area.
NOTE: Heat exchanger type fuel heaters should have a bypass provision
to prevent excessive heating of the fuel in warm weather operation. The
excessive heating of the fuel will cause a loss of engine power. Consult
your Caterpillar dealer for information on the fuel heaters that are available
for your engine.
56
57
Operation Section
Operation Section
Cold Weather Operation Cold Weather Operation
Disconnect or deactivate the fuel heater in warm weather in order to Jacket Water Heater
prevent excessive heating of fuel and possible engine power loss. A
gradual loss of engine power occurs as the temperature of the fuel A jacket water heater can improve the startability and reduce warm up
increases. Electronic engines will correct for higher fuel temperatures to a time by heating the coolant that surrounds the combustion chambers. An
limit. Consult your Caterpillar engine dealer for information. electric jacket water heater can be activated as soon as the engine is
stopped. Use of a jacket water heater reduces the temperature at which
ether is required. An effective jacket water heater is typically a 1250/1500
Fuel Filters W unit. Consult your vehicle dealer for more information.
A primary fuel filter and/or water separator is installed between the fuel
tank and the engine mounted fuel filter. The location of the primary fuel Cold Weather Starting Recommendations
filter is important in cold weather operation. The primary fuel filter and the
fuel supply line are commonly affected by cold fuel. The best location for Batteries
the primary fuel filter is in the engine compartment, where the primary
fuel filter will benefit from the radiant heat of the engine. A primary fuel Batteries must provide sufficient amperage needed to start and operate
filter that is mounted outside the frame rails, or in any location that is the engine at the coldest expected temperatures.
exposed to wind, can be a persistent problem in cold weather. Maintain the proper battery electrolyte level. Keep all batteries fully
charged (to a corrected specific gravity of 1.250 or above). Keep the
Engine Lubrication Oil Viscosity batteries warm. The temperature of the battery has a considerable effect
on the available power. If the battery is too cold, the battery will not have
Proper engine oil viscosity is essential to ensure engine starting at cold enough power to crank and start the engine, even if the engine is warm.
ambient temperatures. Refer to the Lubricant Viscosity chart for Batteries typically have only fifty percent of the capability at -10°C (14°F)
recommended oil viscosities to use at various operating temperature versus 27°C (80°F). At -35°C (-31 °F), only ten percent of the original
ranges. power is available. To maximize the battery power, heat the battery
compartment or store the battery in a warm location.
Oil Pan Heater
Oil pan heaters are useful devices to assist in reducing the cranking Inlet Air Heater/Ether Start System
amperage that is needed to start the engine. Oil pan heaters improve the As temperatures drop below 0°C (32°F), starting a cold engine requires
flow of oil at start-up and reduce the time that is needed to warm the assistance in the form of ether starting aids or inlet air heaters. An
engine up. Oil pan heaters also increase the service life of bearings. Oil automatic metered ether injection system is preferred over a manual
pan heaters can reduce the normal minimum ambient temperatures system. An automatic ether injection system reduces the risk of engine
-20°C (-5°F) at which multi-grade API CG-4 oil can be used. Consult damage by minimizing the operator's responsibility to correctly determine
your vehicle dealer for more information. how much ether is required. Excessive ether will damage the engine and
void the manufacturer's warranty.
Coolant Recommendations An alternative to ether is an inlet air heater. The preheated inlet air
Engine coolant should offer the correct mixture of glycol and water for the considerably improves the engine's cold starting ability at very low
lowest minimum ambient temperature expected. Refer to the Coolant temperatures and ensures smooth engine operation within a shorter
Specifications. period of time.
Engine Idling For this reason, any time the engine is started, run the engine until the
coolant temperature is 71 °C (160°F) minimum. This will keep carbon
When idling after startup in cold weather, increase the engine speed to deposits on the valve stems at a minimum and maintain free operation of
1000 to 1200 rpm in order to warm up the engine more quickly. Do not the valves and valve components.
race the engine to speed the warm-up.
In addition, operating the engine until the engine is thoroughly warm will
When idling, the application of a light (parasitic) load will assist in keep the other engine parts in better condition and generally extend the
maintaining the minimum operating temperature of 71 °C (160°F). The service life of the engine. Lubrication will be improved, with less acid and
installation of a hand throttle will make it easier to maintain an elevated sludge in the oil. This will provide longer service life for the engine
low idle speed for extended periods. An idle speed of 1000 rpm is bearings, piston rings, and other parts. However, limit unnecessary idle
preferred for all engines. time to ten minutes. Engine wear is greatest at low idle and unnecessary
idling wastes fuel.
Exhaust Restrictor
Exhaust restrictors apply a load to the engine in order to reduce warm-up On/Off Fan Clutch
time and white smoke at start-up. When extended idling periods are For better control of fan operation, an ON/OFF fan clutch may be used.
unavoidable, the exhaust restrictor can help maintain acceptable coolant ON/OFF fan clutches can help prevent excessive cooling in cold weather.
temperatures above 71 °C (160°F). Exhaust restrictors for the engines can Viscous fans often rotate continuously in cold weather. Fan clutches that
also be obtained from other companies. keep the fan stationary in the OFF position reduce unnecessary air
movement in order to help maintain adequate engine operating
Coolant Warm Up temperatures.
Recommended Options
Purge Valve/Insulated Heater Lines
If a vehicle has been parked long enough for some of the systems to cool
To help prevent excessive cooling of the engine during lightly loaded
much below normal operating temperatures, the systems should be
periods of operation, the coolant must be made to bypass the radiator.
warmed up before returning the engine to full operation. Damage to
Coolant passing through the radiator must be minimized in order to
engine valve components during operation in very cold temperature
maintain the engine operating temperature in cold weather.
conditions can result from engine operation for short intervals. This can
happen if the engine is started and stopped many times, but does not run Valves that allow air flow but prevent coolant flow (often called "jiggle"
long enough to become completely warm. valves) can help prevent excessive cooling. These valves prevent
unnecessary coolant flow which may divert around the water temperature
During the interval of time that the engine operates at temperatures below regulator to the radiator.
normal, fuel and oil are not completely burned in the combustion
chambers. This fuel and oil causes soft carbon deposits on the valve Insulated cab heater lines for very cold climates are also beneficial.
stems. Generally, these deposits do not cause problems because they Insulated cab heater lines provide more available heat from the coolant to
are burned off during operation at normal engine temperatures. the cab with less heat lost to the outside air.
When the engine is started and stopped frequently (short interval trips)
and the engine operating temperature is seldom or never up to normal, Air Inlet and Cab Insulation
the carbon deposits become thicker. This will prevent free operation of
When temperatures below -18°C (0°F) will be frequently encountered, an
the valves and can stick valves, bend push rods or result in other
under-the-hood air cleaner inlet may be specified. This is sometimes
damage to valve train components.
referred to as a "Snow Valve". An under-the-hood air cleaner inlet may
also minimize the packing of snow into the air cleaner. Heat rejected by
the engine through convection can warm the inlet air.
•i
ill.' 60 61
Operation Section Operation Section
Cold Weather Operation Cold Weather Operation
Additional heat can be retained around the engine by specifying The following charts were designed to assist dealers and customers
additional insulation for the cab and the hood when the vehicle is ordered equip and operate their Caterpillar diesel engine effectively in frigid
This will improve the comfort level of the operator, particularly while idlinq weather. Starting aids should be selected that allow the engine to start at
overnight. the various temperature ranges without the need for extended cranking
periods. If extended idling periods are unavoidable, some or all of the idle
Winter Front/Shutters temperature and coolant warmup devices should be considered based
on the maximum temperatures expected. The goal is to maintain a
With the introduction of air-to-air aftercooling, the use of winter fronts or minimum engine coolant temperature of 160°F (71 °C).
shutters for normal operating conditions above freezing requires caution
in order to avoid high inlet and exhaust temperatures. The restriction in air
flow can cause higher exhaust temperatures, power loss, excessive fan Cold Weather Recommendation Charts
usage, and a reduction in fuel economy.
Cold Weather Operation Recommendations
Caterpillar Medium Duty Vehicle Engines
However, winter fronts or shutters are useful in maintaining minimum
engine coolant temperatures when the outside air temperatures drop Starting Aids
below freezing. If the engine coolant temperature is above the minimum Expected
of 160°F (71 °C), a winter front is not needed no matter how cold the Coldest Ether 1 Block Larger Inlet 1
Temperature Aid Heater Alt/Battery Air Heater
ambient temperature. The water (coolant) temperature should be
monitored with the dash gauges so the engine does not overheat when Above 20°F Available Available Available Standard
the winter front is used. (-7°C)
20 to 0°F Available Available Available Standard
The following guidelines apply if a winter front or shutter is used. (-7to-18°C)
0 to -20°F Recom'd Required Recom'd Standard
(-18to-28°C)
NOTICE -20 to -40°F Recom'd Required Required Standard
Failure to open the winter fronts with the engine under load could cause (-28 to -40°C)
engine damage and/or loss of fuel economy. Below -40°F 2 Required Required Required Standard
(-40°C)
1
Use ONLY the automatic ether injection system if the engine is equipped with an inlet
• 1 °C (34°F) or higher - Open or remove the winter front air heater.
2
Consult the factory.
• -18 to 0°C (0 to 32°F) - Use a winter front with circular or diamond
shaped opening directly in line with the fan hub. Use a minimum
opening of 385 cm2 (60 inch2).
• -292 to -18°C2 (-20 to 0°F) - Use a winter front with an openinq a
of 192 5
cm (30 inch ).
• -34 to -29°C (-30 to -20°F) - Use a winter front with opening of 102
cm2 (16 inch2). Position the opening directly in line with the fan hub
• Below -34°C (-30°F) - Completely close the winter front.
• Overnight Idling - Completely close the winter front.
Winter fronts are generally less expensive than radiator shutters. If radiator
shutters are installed, the shutter thermostat (if automatic) should open the
shutters at a temperature that is 6°C (10°F) lower than the opening
temperature of the engine thermostat.
62 63
Operation Section Operation Section
Cold Weather Operation Stopping the Engine
- —• — «.._*.»_. M u n i u i I U C I I l U U U .
2
Not available from the factory. Consult your Caterpillar dealer
' b e t o w - 2 0 / ° F t f - 2 9 ° n t / S h U t t e r t 0 P i C '" t h i S " " ^ ^ W ' n t e r f r o n t / s h u t t e r s are
required
4
Consult your Caterpillar dealer.
5
Or low speed viscous fan clutch. Required below -20°F (-29°C).
64 65
Maintenance Section Maintenance Section
Torque Specifications Torque Specifications
Terminology
Some abbreviations follow the Society of Automotive Engineers (SAE)
J754 nomenclature. Some classifications follow the SAE J183
abbreviations. The definitions other than Caterpillar's will be of assistance
in selecting lubricants.
"A
II
Grease
The National Lubricating Grease Institute (NLGI) classifies grease, based
on the American Society for Testing Materials (ASTM) D217-68 Worked
E00999
Penetration characteristics. Grease characteristics are given a defined
consistency number.
Due to significant variations in the quality and in the performance of API CG-4 oils are preferred for Caterpillar on-highway diesel engines
commercially available oils, Caterpillar recommends: because the oils provide improved deposit control and additional soot
dispersancy. Also, API CG-4 is the only oil category that evaluates oils
Caterpillar Diesel Engine Oil (DEO) 15W40- with engine tests utilizing 0.05 percent sulfur diesel fuel. Since October 1,
Caterpillar Diesel Engine Oil (DEO) 10W30 1993, all USA on-highway vehicle diesel fuel has been regulated to a
maximum of 0.05 percent sulfur.
Caterpillar recommends the use of multigrade oils in all on-highway
vehicle engines. Caterpillar multigrade DEO is formulated with detergents, The following explanations of these API categories can be used to make
dispersants, and sufficient alkalinity to provide superior performance in the proper choice of a commercial oil.
Caterpillar Diesel Engines. Multigrade DEO is blended in two viscosity
grades: SAE 10W30 and SAE 15W40. Refer to the Lubricant Viscosities CG-4: CG-4 is the newest heavy duty diesel oil category. CG-4 oils can
For Ambient Temperatures chart to choose the correct viscosity grade be used in all Caterpillar on-highway diesel engines where CF-4 oils are
based on ambient temperatures. Multigrade oils provide the correct recommended. Compared to CF-4 oils, CG-4 oils provide improved piston
viscosity for a broad range of operating temperatures and for cold engine cleanliness, improved viscosity control, and improved crankcase
starts. Multigrade oils are also effective in maintaining low oil consumption cleanliness, especially in applications where oil soot is a problem.
and low levels of piston deposits. Although CG-4 oils were primarily developed for diesel engines operating
on 0.05 percent sulfur diesel fuel, CG-4 oils can be used with higher
Caterpillar multigrade DEO is also qualified for use in other diesel engines sulfur fuels. The new oil Total Base Number (TBN) determines the
and in gasoline engines. Refer to the engine manufacturer's guide for the maximum fuel sulfur level for CG-4 and CF-4 oils. Refer to the TBN and
recommended specifications. Compare the recommendations to the Fuel Sulfur topics in this publication.
specifications of Caterpillar multigrade DEO. The current Caterpillar
multigrade DEO industry specifications are listed on the product labels CG-4 oils are the first oils to pass industry tests for foam control and
and on the product data sheets. viscosity shear loss. CG-4 oils must also pass recently developed tests for
metals corrosion and wear.
Consult your Caterpillar dealer for part numbers and available container
CF-4 oils service a wide variety of modern diesel engines. This oil
sizes.
classification was developed with 0.40 percent sulfur diesel fuel. The fuel
used in the CF-4 category represents the type of diesel fuels commonly
Commercial Diesel Engine Oils available world wide. CF-4 oils provide improved piston deposit control
and improved oil control when compared to the other category oils.
The performance of commercial diesel engine oils is based on API
categories. API categories are developed to provide commercial
lubricants for a wide variety of diesel engines that operate in various NOTICE
conditions. Failure to follow these oil recommendations can cause shortened engine
If Caterpillar multigrade DEO is not used, the following commercial oils are service life due to deposits and/or excessive wear.
recommended.
• Preferred API CG-4 (multigrade)
• Acceptable API CF-4 (multigrade) NOTICE
Single grade oils must not be used in Caterpillar on-highway diesel
engines, regardless of the API specification.
71
Maintenance Section Maintenance Section
Lubricant Specifications Lubricant Specifications
Some synthetic base stock oils have performance characteristics that Because the number of lubricants acceptable for use in Arctic conditions
enhance the useful service life of the oil. However, Caterpillar does NOT is limited, Caterpillar has special recommendations for these situations.
recommend the "automatic" extension of oil change intervals for any oil, Caterpillar recommends the following engine oils, in order of preference,
including synthetic base stock oils. For Caterpillar diesel engines, oil for use in Arctic conditions:
change intervals can only be adjusted through an oil analysis program
that contains the following elements: oil condition and wear metals • First Choice: API CG-4 or CF-4 oils with an SAE 0W20, 0W30, 5W30, or
(Caterpillar's S*0«S Oil Analysis preferred), trend analysis, fuel 5W40 viscosity grade
consumption, and oil consumption.
• Second Choice: Oils with a CG-4 or CF-4 type additive package and an
SAE 0W20, 0W30, 5W30, or 5W40 viscosity grade
Re-Refined Base Stock Oils
Re-refined base stock oils are acceptable for use in Caterpillar engines if NOTICE
these oils meet the performance requirements specified by Caterpillar. Shortened engine service life could result if second choice oils are used.
Re-refined oils can be used exclusively in a finished oil or in combination
with new base stocks. The US Military and other heavy equipment
manufacturers have also accepted the use of re-refined base stock oils After-Market Oil Additives
with the same criteria.
Caterpillar does NOT recommend the use of after-market oil additives.
The re-refining process should be adequate to remove all wear metals After-market oil additives are not necessary to achieve service life
and oil additives that were present in the used oil. This type of re-refining predictions or to achieve rated performance. Fully formulated finished oils
is generally accomplished by vacuum distillation and hydrotreating the are made up of base stocks and commercial additive packages. The
used oil. Filtering alone is inadequate for producing a high quality re- additive packages are blended into the base stocks at precise
refined base stock from used oil. percentages to produce finished oils with performance characteristics that
meet lubricant industry standards.
Total Base Number (TBN) and Fuel Sulfur Levels For NOTICE
Caterpillar Dl Diesel Engines Operating with fuel sulfur levels over 1.0 percent may require shortened
oil change intervals in order to maintain adequate wear protection.
Most diesel fuel contains some sulfur. Byproducts of sulfur include
corrosive sulfurous and sulfuric acids. Additives in the lubricating oil
contain alkaline compounds which are formulated to neutralize the acids.
The measure of this alkalinity in an oil is known as TBN. Lubricant Viscosity
The TBN required in a new oil depends on the sulfur level of the fuel The proper SAE viscosity grade oil is determined by the minimum outside
used For direct injection engines running on distillate diesel fuel the temperature at cold engine start-up, and the maximum outside
minimum new oil TBN (by ASTM D2896) should be 10 times he fuel temperature during engine operation. Use the minimum temperature
sulfur level, and the minimum TBN is 5 regardless of a low fuel sulfur column on the chart to determine the oil viscosity required for starting a
"cold soaked" engine. Use the maximum temperature column on the chart
level- refer to the following graph. to select the viscosity for operation at the highest temperature anticipated.
In general, use the highest viscosity oil available that still meets the start-
up temperature requirements.
Lubricating Grease MPGM is recommended for heavily loaded pin joints, journal bearings,
heavy duty automotive, agricultural, industrial, steel mill, mining, and off
Caterpillar provides grease for a variety of applications and extreme road equipment. MPGM meets NLGI GC-LB certification. Normal ambient
temperature conditions. The descriptions of these products follow. temperatures for this product are from -28 to 149°C (-18 to 300°F) for
the NLGI No.O and from -18 to 149°C (0 to 300°F) for the MPGM NLGI
Consult your Caterpillar dealer for part numbers and available container No.2.
sizes.'
NOTE: If MPGM is not available, use a multipurpose type grease that
NOTE: One grease may be incompatible with another grease. When contains three to five percent molybdenum.
using commercial grease, make sure the grease is compatible with the
grease used in your system, or make sure to purge the system. Consult
your supplier regarding grease compatibility questions. Special Purpose Grease
Bearing Lubricant
Multipurpose Grease Bearing Lubricant is a NLGI No.2 lubricating grease with a polyurea
Multipurpose Lithium Complex Grease (MPG) thickener. Bearing Lubricant is recommended for high temperature
antifriction bearings in applications such as electric motors, alternators,
MPG is a general purpose lithium complex grease for light to medium fan drives, starting motors, and generators. Bearing Lubricant has an
duty applications. MPG has good high temperature characteristics, with a effective operating range from -29 to 177°C (-20 to 350°F).
minimum dropping point of 260°C (500°F). MPG contains unleaded
extreme pressure additives and antiwear and corrosion inhibitors to Water and Temperature Resistant Grease (WTR)
provide extra protection in a variety of construction, agricultural and
automotive applications. WTR grease is designed for applications where water washout, sever
corrosion, or higher operating temperatures are a concern. WTR is an
MPG meets the requirements for extended service intervals of automotive environmentally friendly grease that provides extreme pressure, antiwear,
chassis points and wheel bearings with disc brakes, particularly in oxidation and corrosion protection without using barium, zinc, antimony,
passenger cars, vans, light trucks and taxi fleets. MPG meets NLGI GC- phosphorous, lead, or sulfur additives. WTR is very shear stable and
LB certification. MPG is available in NLGI No.2. Normal operating resists breakdown in the presence of water.
temperatures range from -28 to 149°C (-18 to 300°F). MPG is also
available as a white lithium complex grease. WTR grease performs extremely well in marine, automotive, agricultural,
and industrial applications, in construction equipment, and in washer
Multipurpose Lithium Complex Grease With Molybdenum (MPGM) equipment bearings. WTR meets NLGI GC-LB certification. WTR normal
operating temperatures range from -40 to 204°C (-40 to 400°F).
MPGM is a general purpose lithium complex grease for light to medium
duty applications. MPGM is fortified with molybdenum disulfide and
polymer for extra lubricity and protection. MPGM contains unleaded
additives and antiwear and oxidation/corrosion inhibitors for protection
and lubrication in many environments. MPGM is formulated with a high
viscosity base fluid and contains polymer additive to help protect against
water washout, enhance retention, and withstand heavy loads.
77
Maintenance Section
Maintenance Section .
Fuel Specifications
Lubricant Specifications
Ash (D482)
0.02% Weight Maximum General Coolant Information
1.05% Weight Maximum
Carbon Residue Many engine failures are related to the cooling system. Problems such as
On 10% Bottoms (D524) overheating, water pump leaking, plugged radiators, and cylinder liner
35 Minimum (PC Engines)
Cetane Number (D613)
40 Minimum (Dl Engines) pitting can be avoided with proper cooling system maintenance. Cooling
system maintenance is as important as fuel and lubricating system
Maximum Not Above Lowest
Cloud Point (D97) Expected Ambient Temperature maintenance. Coolant quality is as important as the quality of fuel and
lubricating oil.
Copper Strip Corrosion
No. 3 Maximum
(D130) Coolant is normally composed of three elements:
10% At 282°C (540°F) Maximum
Distillation (D86) 90% At 360°C (680°F) Maximum • Water
Flash Point (D93)
Legal Minimum • Additives
30 Minimum/45 Maximum • Glycol
AP! Gravity (D287)
6°C (10°F) Minimum
Pour Point (D97) Below Ambient Temperature
Water
Sulfur1 (D3605 or D1552) 3% Maximum
1.4 cSt Minimum NOTICE
Viscosity2 (D445)
Kinematic at 40°C(104°F) 20.0 cSt Maximum Never use water alone without Supplemental Coolant Additives (SCA) or
0.1% Maximum without inhibited coolant. Water alone is corrosive at engine operating
Water and Sediment (D1796)
0.1 % Maximum temperatures. Water alone does not provide adequate freeze or boil
Water (D1744) protection.
0.05% Weight Maximum
Sediment (D473)
10 mg/100 ml Maximum
Gums & Resins (D381)
(5.8 grains/US gal) Maximum
Distilled or deionized water is recommended for use in engine cooling
1 caterpillar fuel systems and engine components can operate or, higtJ su'to fuels
systems. DO NOT use hard tap water or salt softened tap water in engine
Howeve", fuel sulfur .evels effect exhaust part.ou^e^missions On J994 and newer
cooling systems. If distilled or deionized water is not available, use water
that meets the minimum acceptable requirements listed in the following
chart.
additional information.
81
Maintenance Section
Maintenance Section
Coolant Specifications
Coolant Specifications
Consult your Caterpillar dealer for part numbers and available container ELC Cooling System Cleaning
sizes.
N0TE
- C L f A N W A T E R i s t h e on|V s V s t e m cleaning/flushing aqent
NOTE: The Caterpillar EC-1 Specification is an industry standard required when ELC is drained from the cooling system.
developed by Caterpillar. The EC-1 specification defines all of the
performance requirements that an engine coolant must meet in order to ELC can be recycled. The drained coolant mixture can be "distilled" to
be sold as an extended life coolant for Caterpillar engines. Caterpillar ELC remove the ethylene glycol and water for reuse. Consult your Caferp l l
can be used in most OEM diesel, gasoline, and natural gas engines. dealer for more information. ^cuw.p.ndr
Caterpillar ELC meets the industry performance requirements of ASTM
D4985 and D5345 for heavy duty low silicate coolant/antifreezes. TlJ'l?9 a n d r e f i " i n g t h e C 0 0 l i n 9 s y s t e m - °P e r a t e the engine with the
Caterpillar ELC also meets the industry performance requirements of radiator filler cap removed until the coolant reaches normal operating
ASTM D3306 and D4656 for automotive applications. temperature and the coolant level stabilizes. Add ELC mixture as
necessary to fill the system to the proper level.
I the ELC service life. The cooling system should be treated with Extender
at 483 000 km (300,000 miles) or one half of the ELC service life. Use the
1. Drain the cooling system.
chart below to determine the proper amount of Caterpillar Extender 2. Flush the system with clean water to remove any debris.
required.
3. Clean the cooling system with Caterpillar Cooling System Cleaner
Consult your Caterpillar dealer for part numbers and available container Follow the instructions on the label. ^'^ner.
sizes.
4. Flush the cooling system with clean water. It is very important to
remove all of the cleaning agent.
Caterpillar ELC Extender Additions
By Cooling System Capacity 5. Fill the cooling system with clean water. Operate the engine until the
Cooling System Capacity Extender Addition cooling system temperature is 49 to 66°C (120 to 150°F).
22 to 30 L (6 to 8 US gal) 0.57 L (20 fl oz)
6. Drain the cooling system. Flush the cooling system with clean water.
31 to 38 L(9 to 10 US gal) 0.71 L (24 fl oz)
39 to 49 L (11 to 13 US gal) 0.95 L (32 fl oz) L R e p e t ? f Bpf 5 a n d 6 ' C o n t i n u e t 0 f l u s h ^ e cooling system with clean
50 to 64 L(14 to 17 US gal) 1.18L(40floz) water until the draining water is also clean.
65 to 83 L (18 to 22 US gal) 1.60 L (54 fl oz) 8. Fill the cooling system with Caterpillar ELC.
84 to 114 L (23 to 30 US gal) 2.15L(72floz)
115 to 163 L(31 to 43 US gal) 3.00L(100floz) 9. Attach a label to the cooling system to indicate the system has been
ueen
mm switched over to Caterpillar ELC.
164 to 242 L (44 to 64 US gal) 4.40L(148floz)
mm
87
86 Maintenance Section
Maintenance Section
Coolant Specifications
Coolant Specifications
The foiiowing chart lists part numbers and quantities for Caterpillar SCA.
S-O-S Oil Analysis
Caterpillar Liquid SCA
Part Number Quantity
Caterpillar's S»0«S Oil Analysis is the best indicator for determining what
6V-3542 .24 L (8 oz) is happening inside your engine.
111-2372 .36 L(12oz)
.47L(16oz) S«0*S Oil Analysis is a diagnostic tool used to determine oil performance
8T-1589
and component wear rates. S»0»S Oil Analysis uses a series of tests
3P-2044 .94 L (32 oz)
designed to identify and measure contamination such as:
5P-2907 208 L (55 US gal) • soot, sulfur, etc.
• degradation such as the presence of fuel, water and antifreeze in a
sample of oil
NOTE: Due to specific engine applications, maintenance practices may • the amount of wear metals present in the oil sample
need periodic evaluation in order to properly maintain the engine's cooling
system. Wear metals present in the oil sample are compared to established
Caterpillar norms to determine acceptability. S»0»S Oil Analysis must be
Heavy Duty Coolant/Antifreeze Cooling System Cleaning performed on a continuing basis to be effective as an indicator.
Intermittent sampling does not allow wear rate trend lines to be
Caterpillar Cooling System Cleaners are designed to clean the cooling established.
system of harmful scale and corrosion. Caterpillar cleaners dissolve
mineral scale, corrosion products, light oil contamination, and sludge.
S-O'S Interval Chart
Clean the cooling system: Compartment Interval
• after draining used coolant and before filling the cooling system with Engine Crankcase Every 250 Service Hours
new coolant
• whenever the coolant is dirty or foaming
Obtain An Oil Sample Every 250 Service Hours.
Obtain S»0»S oil samples at regularly scheduled intervals to monitor the
condition and maintenance requirements of your engine. Each oil sample
should be taken when the oil is warm and well mixed to ensure that the
sample is representative of the oil in the engine crankcase.
Consult your Caterpillar dealer for complete information and assistance in
establishing an S«0»S analysis program for your engine(s).
S»0«S Oil Analysis is composed of three basic tests:
llplf
ti • Wear Analysis
• Chemical and Physical Tests
• Oil Condition Analysis
92 93
Maintenance Section Maintenance Section
S»OS Oil Analysis % S°0«S Coolant Analysis
NOTE: Infrared analysis must be used to determine oil change intervals. Level I: Basic Coolant Maintenance Check
S'0»S Oil Analysis must include Infrared (IR) in the analysis.
Checks for correct chemical balance for proper heat and corrosion
The test results of the oil samples will then be used as a basis for control. Tests for:
determining the oil change interval for your engine, giving you the ultimate
time between oil changes without the risk of engine damage. • glycol
• SCA concentrations
Refer to PEDP1129, Listen To Your Oil, for information and benefits of ®pH
S«0*S Oil Analysis. • conductivity
S»0»S Coolant Analysis reports results and makes recommendations,
usually within 24 hours.
The concentration of SCA should be checked regularly for
overconcentration or underconcentration. This should be done with test
kits, or S»0»S Coolant Analysis (Level I) Every 250 Service Hours.
Further coolant analysis is recommended at twice a year or Every 1000
Service Hours.
For example, suppose considerable deposits are found in the water jacket
areas on the external cooling system, yet coolant additive concentrations
were carefully maintained. Chances are that the coolant water had
minerals which deposited on the engine over time.
94 95
Maintenance Section Maintenance Section
S»0«S Coolant Analysis Terminology
A,.
One way to verify the water condition, or to be sure of new water at fill
time, is to have a coolant analysis conducted. Full water analysis can Terminology
sometimes be obtained locally from your local water utility company or an
agricultural agent. Private laboratories are also available.
Caterpillar recommends S°0*S Level II Coolant Analysis. Adjust - to conform and correspond to specifications.
Check - to observe for satisfactory conditions, accuracy, safety or
performance.
Level II: Comprehensive Cooling System Analysis Inspect - to examine closely, in critical appraisal, while testing or
evaluating components or systems.
Completely analyzes coolant and coolant effects on the cooling system.
Inspect/Rebuild or Exchange - to examine closely; then making the
Level I! Analysis provides: decision on repair option (Rebuild or Exchange).
• full Level I analysis Lubricate - to apply a lubricant (oil, grease, etc) as specified for reducing
• visual properties inspection friction, heat and wear between solid surfaces.
• metal corrosion and contaminant identification Rebuild - to trade or repair a worn or failing component with new parts,
• identification of built up impurities that point to corrosion and scaling components and/or for a remanufactured or rebuilt component.
problems BEFORE they lead to costly repairs. Replace - to install something new, remanufactured or rebuilt in place of
an existing worn or failing component.
Level 11 Analysis provides a simple, clear report of results, and makes Service Hours (Electrical) - the time that the engine is actually operating.
recommendations for the lowest cost corrective options. Service hours do not reflect variations in speed, load, etc.
For more information on coolant analysis and how it can help you
manage your equipment, see your Caterpillar dealer. Consult your Maintenance Intervals
Caterpillar dealer for complete information and assistance in establishing
The Maintenance Schedule requires all previous interval maintenance
an S°0«S analysis program for your engine(s). items to be performed first. For example, if the PM Level 1 maintenance is
being done, then the Daily maintenance items must be completed
BEFORE performing PM Level 1 maintenance.
Engines may be equipped with various optional components. The
maintenance charts may recommend maintenance for items not installed
on your engine. Simply disregard reference to any unrelated items. If
unsure of any item, consult your Caterpillar dealer.
Overhaul Interval
Overhaul is defined as the interval at which the major wear items in the
engine should be replaced. The Overhaul interval represents the planned
replacement of work components with new or rebuilt components. In
other words, the engine is being rebuilt with certain new parts replacing
worn parts such as piston rings, engine rod and main bearings, valves
and valve seats, etc.
NOTE: The Maintenance Schedules follow in this manual. Ensure that the
recommendations are adhered to.
96 97
Maintenance Section Maintenance Section
Maintenance Schedule Recommendations
Refill Capacities A...
'initial 9660 km (6000 miles) Or 3800 L (1000 US gal) Of Fuel Every Two Years Or 322 000 km (200,000 Miles)
Or 250 Service Hours Or Six Months
Cooling System Coolant (DEAC) - Change 111
Engine Valve Lash - Check/Adjust (At the first oil change) 133
Every 483 000 km (300,000 Miles)
PH Level 1 - Every 9660 km (6000 miles) Or 3800 L (1000 US
gaS) Of Fuel Or 250 Service Hours Or Six Months Cooling System Coolant (ELC) Extender- Add 116
Air Compressor Air Filter (If Equipped) - Replace 103 Every Six Years Or 966 000 km (600,000 Miles)
Air-To-Air-Aftercooler - Inspect 105
Battery - Clean/Check 106 Cooling System Coolant (ELC) - Change 114
Belts - Inspect 107
Cooling System Coolant (DEAC) Supplemental Coolant Additive
Every 113 000 L (30,000 US gal) of Fuel
(SCA) - Test/Add 118
Cylinder Head Ground Stud - Inspect 121 Overhaul - Evaluate 140
Engine Crankcase Breather - Clean 125
Engine Oil and Oil Filter - Change 127
Fan Drive Bearing - Lubricate/Inspect 134
Fuel System Primary Filter (If Equipped) - Clean 135
Fuel System Secondary Fuel Filter - Replace 135
Fuel Tank Water and Sediment - Drain 139
Hoses and Clamps - Inspect 139
Radiator - Inspect 141
S'0*S Oil Analysis (Recommended) - Obtain 142
100 101
Maintenance Section Maintenance Section
Maintenance Schedule - Engines with a Deep Oil Sump Maintenance Schedule - Engines with a Deep Oil Sump
.i#^
Do not disconnect the air line from the air compressor governor
without purging the air brake and auxiliary air systems. Failure to
purge the air brake and auxiliary air systems before removing the air
compressor and/or air lines couid cause personal injury.
^WARNING
I
it The function of the air compressor pressure relief valve is to bypass air Air-To-Air Aftercooler
when there is a malfunction in the air compressor system. The pressure
relief valve releases air pressure at 1723 kPa (250 psi). It is very important Inspect
that all personnel stand clear of the pressure relief valve when
Depending on your findings and operating environment, the maintenance
compressed air is released. All personnel should also stand clear of the
interval for cleaning the air-to-air aftercooler may be more frequent.
general vicinity of the air compressor when the engine is operating and
the hood is raised.
NOTICE
Air Compressor Air Filter - Clean/Replace A hose failure or significant system leak will cause a large drop in boost
pressure and power. The engine can be operated at this power level long
One of the single most important aspects of air compressor preventative enough to reach a stop area. Sustained operation under this condition
maintenance is the induction of clean air. The type of maintenance that is should be avoided as loss of boost pressure raises exhaust temperature
required for the air compressor and the maintenance interval depends and dirt can enter the air stream.
upon the type of air induction system that is used. More frequent
maintenance will be required for operation in dusty or dirty environments.
Refer to the Service Manual for the type of air compressor that is installed A reduction in power or response, or an increase in exhaust temperature,
on your engine. Follow the maintenance recommendations that are may indicate an air leak in the charge air cooler core, a gasket failure, a
provided by the OEM of the air compressor. duct failure, or a leak in the piping.
• Check the front of the aftercooler for insects, dirt and other debris.
Inspect the Air Compressor Clean the front of the aftercooler when required with a stainless steel
brush and soapy water. Clean dirt and debris from between the
Refer to the Service Manual for the type of air compressor that is installed aftercooler and radiator.
on your engine. Visually check for fluid leaks and listen for air leaks. • Inspect all of the air ducting and the gasket connections at each oil
Inspect the air compressor as instructed by the literature provided by the change. Constant torque hose clamps should be used to secure the
OEM of the air compressor. For more information on how to check the air
ducting.
compressor, refer to the Service Manual. Consult your Caterpillar dealer
• Check all of the welds for cracks. Check the mounting brackets to
for assistance. ensure the mounting brackets are secure and in good condition.
• Examine fins for external damage, dirt, debris, salt corrosion, etc. Use a
firm stainless steel brush to remove dirt, debris, salt, etc.
• Use compressed air to clean core blockage due to dirt and debris.
NOTE: Whenever air-to-air aftercooler parts are repaired and/or replaced,
a leak test is highly recommended. Refer to SEHS8622, Using the
FT-1984 Air-To-Air Aftercooler Leak Test Group, or consult your Caterpillar
dealer for assistance.
107
Maintenance Section Maintenance Section
Alternator - Inspect zy^
Belts
1. Remove the fill caps. Maintain the electrolyte level to the bottom of the
Alternator - Inspect fill cap openings.
Inspect the alternator for loose connections and proper battery charging. If the addition of water is necessary, use distilled water. If distilled water is
Inspect the ammeter gauge during engine operation to ensure the not available use clean water that is low in minerals. Do not use artificially
batteries and/or electrical system is performing correctly. Make repairs as softened water.
necessary. Refer to the Service Manual.
At the proper charging rate, the batteries should not require more than 30
Check the alternator and battery charger for proper operation. If the cc (1 oz) of water per cell per week.
batteries are properly charged, ammeter reading should be very near
zero. All batteries should be kept charged. The batteries should be kept 2. Keep the batteries clean.
warm because temperature affects the cranking power. If the battery is
too cold, it will not crank the engine, even if the engine is warm. When 3. Remove the cable terminals from the battery.
the engine is not run for long periods of time or run for short periods, the
batteries may not fully recharge. Ensure the alternator performs properly 4. Clean the battery terminals and the cable terminals.
to charge the battery and to help prevent the battery from freezing. 5. Attach the cable terminals to the battery terminals. Tighten the cable
terminals.
Battery 6. Coat the cable terminals and the battery terminals with petroleum jelly
or MPGM.
& WARNING
Belts - Inspect
Battery electrolyte contains acid and can cause injury. Avoid contact
with the skin and eyes. Always wear protective glasses when work- Inspect the belts when the engine is stopped.
ing with batteries. Wash hands after touching batteries and connec-
tors. Use of gloves is recommended. Batteries give off flammable Inspect the condition and the adjustment of the alternator belt and the
fumes which can explode. Ensure there is proper ventilation for accessory drive belt. Examine the belts for wear. Replace the belts if the
batteries which are located in an enclosure. Do not smoke when belts show any signs of wear. Loose or worn pulley grooves cause belt
servicing the batteries. slippage and low accessory drive speed. If belts are too loose, the belts
vibrate enough to cause unnecessary wear on the belts and pulleys and
possibly slip enough to cause overheating.
Clean/Check Electrolyte Level If belts are too tight, unnecessary stresses are placed upon the pulley
bearings and on the belts which might shorten the service life of both.
Battery Electrolyte Chart
Battery Interval If one belt in a set requires replacement, always install a new matched set
125 Hour of belts. Never replace just the worn belt. If only the worn belt is replaced,
Conventional
250 Hours
the new belt will carry all the load, as it will not be stretched as much as
Low Maintenance the older belts. All the belts will fail in rapid succession.
Maintenance Free None Required
ill.
109
/laintenance Section Maintenance Section
Salts Belts
D48389
Beit tensioner.
• If the engine is equipped with a freon compressor (air conditioner), the (1) Adjusting bolt. (2) Mounting bolt.
belt for the fan drive, the alternator, and the accessories will have an
automatic belt tensioner. 1 . Slightly loosen mounting bolts (2) and adjusting bolt (1).
• If the engine is NOT equipped with a freon compressor, the alternator is 2 . Move the pulley to adjust the belt tension.
used to adjust the belt tension. 3. Tighten adjusting bolt (1). Tighten mounting bolts (2).
Remove the belt guard. Inspect the condition and adjustment of alternator 4. Install the belt guard.
belts and accessory drive belts (if equipped).
If a new belt is installed, check the belt adjustment again after 30 minutes
To check the belt tension, apply 110 Newton (25 lb) of force, of engine operation at rated speed.
perpendicular to the belt, midway between the pulleys. Measure the belt
deflection. Correctly adjusted belts will deflect 9 to 15 mm (% to % inch).
If the belt does not require replacement or adjustment, install the belt
guard. If the belt requires adjustment or replacement, perform the
following procedure to adjust the belt tension.
111
/laintenance Section Maintenance Section
Cooling System Coolant (DEAC) - Change
Jelt Tensioner - Inspect
4. Start and run the engine for a minimum of 30 minutes with the coolant
Drain the Coolant temperature at a minimum of 82°C (180°F). Stop the engine and allow the
1. Stop the engine and allow the engine to cool. Loosen the radiator filler engine to cool.
c^p slowly to relieve any pressure. Remove the radiator filler cap. 5. Loosen the radiator filler cap slowly to relieve any pressure. Remove
2 Remove the cooling system drain plug(s) or open the drain valva the radiator filler cap. Remove the cooling system drain plug(s) or open
OnenThe cab heater valve to drain coolant from the cab heater. Remove the drain valve(s). Allow the cleaning solution to drain. Flush the cooling
fhe draki plug from the bottom of the water pump housing. Remov.the system with clean water until the draining water is clear. Clean and install
drain Slue, from the bottom of the radiator. Allow the coolant to dram. all drain plugs and/or close the drain valve(s).
3 Fill the cooling system with a mixture of clean water and Caterpillar
^ Acting Cooling System Cleaner. Add .5 L (1 pt) of cleaner per 15 L
(4 US S of cooling system capacity. Install the radiator filler cap.
115
Maintenance Section
Maintenance Section Cooling System Coolant (ELC) - Change
Cooling System Coolant (ELC) - Change
Only clean water is needed in order to clean and flush the cooling system
Flush the Cooling System
when ELC is drained and replaced.
1. Flush the cooling system with clean water to remove any debris.
2. Clean and install the drain plugs. Close the drain valve.
3. Fill the cooling system with clean water. Install the radiator filler cap.
Operate the engine until the jacket water temperature reaches 49 to 66°C
(150to120°F).
4. Stop the engine and allow the engine to cool. Loosen the radiator filler
cap slowly to relieve any pressure. Remove the radiator filler cap. Remove
IlL the cooling system drain plugs. Open the drain valve. Allow the water to
drain. Flush the cooling system with clean water.
5. Repeat steps 3 and 4.
I 116
Maintenance Section Maintenance Section
117
Cooling System Coolant Extender - Add Cooling System Coolant Level - Check
Fill the Cooling System 2. It may be necessary to drain enough coolant from the cooling system
to allow for the addition of the Extender.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid 3. Add Extender according to the requirements for your engine's cooling
air locks. system capacity. Refer to the Refill Capacities chart for the cooling
system capacity for your engine. Refer to the Coolant Specifications for
the Caterpillar ELC Extender Additions chart.
1. Install the drain plugs. Close the drain valve. Fill the cooling system 4. Install the radiator filler cap. Start the engine and inspect for coolant
with ELC. Refer to the Refill Capacities chart for the amount of ELC leaks. Stop the engine.
needed to refill the cooling system.
•If 2. Start and run the engine with the radiator filler cap removed. Allow the
5. Check the coolant level. Add coolant if necessary. Clean the radiator
filler cap. Inspect the radiator filler cap. If the gaskets are damaged,
ELC to warm, the water temperature regulator to open, and the coolant replace the old radiator filler cap with a new radiator filler cap. Install the
level to stabilize. Add ELC if necessary in order to bring the coolant to the radiator filler cap.
proper level.
3. Check the condition of the radiator filler cap. If the gaskets are Cooling System Coolant Lewel - Check
damaged, replace the old radiator filler cap with a new radiator filler cap.
If the gaskets are not damaged, pressure test the radiator filler cap with a Check the coolant level with the engine stopped and cool.
9S-8140 Pressurized Pump Group (available from your Caterpillar dealer).
The correct pressure is stamped on the face of the radiator filler cap. If 1. Remove the radiator filler cap slowly in order to relieve any pressure.
the radiator filler cap does not hold the correct pressure, install a new 2. Maintain the coolant level within 13 mm {Vz inch) below the bottom of
radiator filler cap. the fill pipe or to the proper level on the sight glass, if equipped.
4. Start the engine. Inspect for coolant leaks and proper operating
3. Clean up any coolant that has spilled or dripped. Install the radiator
temperature. filler cap.
ill 1. Loosen the radiator filler cap slowly in order to relieve pressure.
Remove the radiator filler cap.
119
118
Maintenance Section
Maintenance Section
Cooling System Coolant (DEAC) Cooling System Coolant (DEAC)
Supplemental Coolant Additive (SCA) - Test/Add Supplemental Coolant Additive (SCA) - Test/Add
1
It Use the 4C-9301 Test Kit or use the 8T-5296 Test Kit to check for SCA
Cooling System Coolant (DEAC) Supplemental
pi Coolant Additiwe (SCA) - Test/Add
concentration. Add SCA if the concentration is too low. If the SCA
concentration is excessive, drain half the coolant, and replace with the
I NOTE- Before performing this maintenance, determine the type of
proper water/antifreeze mixture.
coolant that is being used. This maintenance applies ONLY to cooling NOTE: You may test your coolant SCA concentration OR have the SCA
systems that are filled with conventional heavy duty coolant/antifreeze concentration tested as part of a S«0«S Coolant Analysis (Level I).
such ad Caterpillar Diesel Engine Antifreeze/Coolant (DEAC).
Obtain Level I Analysis
Test for SCA Or Obtain Level I Analysis
S°0*S Coolant Analysis is an excellent way to monitor the condition of
your coolant and your cooling system.
^piiRNlNG
Level I: Basic Coolant Maintenance Check
Coolant additive contains alkali. To prevent personal injury, avoid Checks for correct chemical balance for proper heat and corrosion
contact with the skin and eyes. Do not drink coolant. control. Tests for:
• glycol
Check the cooling system only after the engine is stopped and cool. • SCA concentrations
Remove the filler cap slowly to relieve pressure. To prevent engine • pH
damage, never add cooling system products to an overheated engine. • conductivity
Allow the engine to cool first.
S-0*S Coolant Analysis results and recommendations are usually made
The use of Caterpillar SCA will prevent internal damage to the engine, within 24 hours. Consult with your Caterpillar dealer for more information.
such as liner or block pitting. If the SCA concentration is too low, pitting ot
the cylinder wall may occur, which can lead to costly engine damage. Add Liquid Supplemental Coolant Additive (SCA)
If the SCA concentration is too high, sludge and mud-like deposits may
form in the cooling system. This adversely affects engine performance NOTICE
and can also lead to costly repairs of the engine and cooling system. ONLY add SCA if required by test results.
NOTICE 1. Loosen the radiator filler cap slowly in order to relieve any pressure.
The overconcentration of a supplemental coolant additive will result in Remove the radiator filler cap.
deposits on the higher temperature surfaces of the cooling system and
create a barrier that reduces the engine's heat transfer characteristics. 2. It may be necessary to drain enough coolant from the radiator to allow
fjif for the addition of the liquid SCA.
ten Reduced heat transfer could cause cracking of the cylinder head and
other high temperature components. Excessive concentrations of addi- 3. Add liquid SCA according to the requirements for your cooling system
tive could also accelerate water pump seal wear. Do not exceed the capacity. Refer to the Caterpillar SCA Requirements For Heavy Duty
recommended six percent SCA concentration. Coolant/Antifreeze chart in the Coolant Specifications.
121
Maintenance Section Maintenance Section
Crankshaft Vibration Damper - Inspect Cylinder Head Ground Stud - Inspect
4. Install the radiator filler cap. Start the engine and inspect for coolant Cylinder Head Ground Stud - Inspect
leaks. Stop the engine.
5. Check the coolant level. Add coolant if necessary. Clean the radiator
filler cap. Inspect the radiator filler cap. If the gaskets are damaged,
replace the old radiator filler cap with a new radiator filler cap. Install the
HIS radiator filler cap.
• Clean the cylinder head ground stud and strap terminals with a clean
cloth.
• Keep the cylinder head ground stud and the ground strap clean and
coated with petroleum jelly or MPGM.
122 123
Maintenance Section Maintenance Section
Engine - Clean Engine Air Cleaner Service Indicator - Inspect
Engine - Clean Your Caterpillar dealer has air cleaner filter elements to fit most popular
makes of vehicles.
NOTICE
Accumulated grease and oil on an engine is a fire hazard. Keep your Engine Air Cleaner Service Indicator - Inspect
•ill engine clean. Remove debris and fluid spills each time a significant
This engine may be equipped with a service indicator, mounted between
quantity accumulates on the engine.
the air cleaner and the air inlet manifold. The engine may be equipped
with a different indicator.
Steam cleaning the engine provides for easy detection of fluid leaks. An air cleaner differential pressure gauge may be located in the on the
•p. Repairing an oil or coolant leak upon detection may save money by gauge panel. The air cleaner differential pressure gauge indicates the
avoiding major repairs that could result from low oil or coolant levels. difference of air pressure between the inlet (dirty) side and the engine
Steam cleaning the engine as recommended will also improve the (clean) side of the filter element. The pressure difference between the two
engine's heat transfer characteristics. sides increases as the filter element becomes plugged.
If your air cleaner filter element becomes plugged, the air can split the
element material. Unfiltered air will drastically accelerate internal engine
wear.
• Service the air cleaner when required by the air cleaner service
indicator. After servicing the air cleaner, reset the service indicator by
pushing on the piston plunger. Typical service indicator.
• Check the precleaner (if equipped) daily for accumulation of dirt and Observe the service indicator. A colored piston showing in the window
debris. Remove any dirt and debris as needed. indicates the need for servicing the air cleaner. Clean or replace the filter
• Operating conditions (dust, dirt and debris) may require more frequent element when the yellow diaphragm enters the red zone or the red piston
air cleaner element maintenance. locks in the visible position. If the service indicator shows red at any time,
Replace dirty paper elements with new ones. Keep spare filter elements clean the filter element or install a new filter element.
on hand for replacement. The element should be thoroughly checked for Inspect the service indicator daily for cracks, holes, or loose fittings. If any
rips or tears in the filter material. Check for air cleaner seal/gasket of these conditions are present, repair or replace the service indicator.
damage, and replace the filter element at least every year.
1 124
Maintenance Section 125
Maintenance Section
IP Engine Air Cleaner Service Indicator - Inspect
Engine Crankcase Breather - Clean
:f
Test Service Indicator
Engine Crankcase Breather - Clean
Service indicators are inexpensive but important instruments.
Perform this maintenance at every other oil change interval (500
Check for ease of resetting. The service indicator should reset in less than Service Hours), or more often if needed.
three pushes.
If the service indicator does not reset easily, the service indicator should
be replaced. If the new service indicator will not reset, the indicator sensor NOTICE
hole may be plugged. If the crankcase breather is not maintained on a regular basis the
crankcase breather will become plugged. A plugged crankcase breather
Severely dusty environments may require frequent service indicator can cause excessive crankcase pressure that may cause leaks.
replacements. Replace the service indicator yearly, regardless of
operating conditions. Replace the service indicator at Overhaul, and
whenever major engine components are replaced.
NOTE: When you install a new service indicator, excessive force may
crack the top of the service indicator. Tighten the service indicator to a
torque of 2 N«m (18 lb in).
NOTICE
Always stop the engine to service the air cleaner. Never service the air
cleaner with the engine running since this will allow dirt to enter the
engine.
(1) Hose clamp. (2) Hose. (3) Bolt. (4) Breather.
If your filter element becomes plugged, the air can split the filter element 1. Loosen hose clamp (1). Slide hose (2) from breather (4).
material. Unfiltered air will drastically accelerate internal engine wear.
2. Loosen bolt (3). Remove breather (4) and O-ring seal.
• Service the air cleaner when required by the service indicator. After
servicing the air cleaner, reset the service indicator by pushing on the 3. Wash breather (4) in clean, nonflammable solvent. Allow the breather
piston plunger. to dry.
• Check the precleaner (if equipped) daily for accumulation of dirt and 4. Install a new O-ring seal.
debris. Remove any dirt and debris as needed.
• Operating conditions (dust, dirt and debris) may require more frequent 5. Install the breather in reverse order of removal. Tiqhten bolt (3) to 7 +
W
filter element maintenance. 2 N-m (62 ± 1 8 lb in).
Replace dirty paper elements with new ones. Keep spare filter elements 6. Slide hose (2) on to breather (4). Tighten hose clamp (1) Refer to the
on hand for replacement. The filter element should be thoroughly checked Torque Specifications.
for rips or tears in the filter material. Check for air cleaner seal/gasket
damage, and replace the filter element at least every year.
126 127
Maintenance Section Maintenance Section
Engine Mounts - Inspect Engine Oil and Oil Filter - Change
•
111
017664
(1) Oil filler. (2) Oil level gauge. (1) Shallow oil sump.
(2) Deep oil sump.
1. Observe the oil level on the ENGINE STOPPED side of the oil level
gauge. Maintain the oil level between the ADD and FULL marks on the The scheduled oil change interval depends on the size of the oil sump.
ENGINE STOPPED side of the oil level gauge. For the scheduled oil change interval, refer to "Maintenance Schedule -
Engines with Shallow Oil Sump" or refer to "Maintenance Schedule -
Engines with a Deep Oil Sump".
NOTICE
Operating your engine when the oil level is above the FULL mark could
cause your crankshaft to dip into the oil. The air bubbles created from the
crankshaft dipping into the oil reduce the lubricating characteristics of
the oil and could result in the loss of power.
Jii
IIP
2. Remove the oil filler cap and add oil if necessary. Do not fill the
crankcase above the FULL mark. Clean up any oil that has spilled or
IllPl
dripped, install the oil filler cap.
128 129
Maintenance Section Maintenance Section
Engine Oil and Oil Filter - Change Engine Oil and Oil Filter - Change
Do not drain the oil when the engine is cold. As oil cools, suspended
waste particles settle on the bottom of the crankcase or oil pan. The
waste particles are not removed with the draining cold oil. Drain the
crankcase with the engine stopped and the oil warm. This allows for the
draining of the waste particles that are suspended in the oil.
Failure to follow this recommended procedure would result in these waste
particles being recirculated through your engine lubrication system with
the new oil.
After the engine has been operating at normal operating temperature,
stop the engine. Attach a DO NOT OPERATE or a similar warning tag to
the ignition key switch. Catch the oil in a suitable container. Have the
used oil recycled, or dispose of the used oil properly.
Element with debris.
1. Remove the oil drain plug. Allow the oil to drain.
Cut the oil filter case open with a 4C-5084 Oil Filter Cutter Inspect the
2. Clean the oil drain plug. Install the oil drain plug. Tighten the oil drain
plug to 25 ± 5 NTTI (18 ± 4 lb ft).
S S S l 0 1 ' ^ e l T n t S p r e a d t h e o i l f i l t e r e|ement pleats apart and
nspect the oil filter element for metal debris. Due to normal wear and
fnction ,t ,s not uncommon to find small amounts of debris in "he dl filter
Replace OiS Filter p . ? 6 " N ' f T f C e S S i V e a m o u n t o f d e b r i s i s P res ent consult your
Caterpillar dealer to arrange for further analysis.
NOTE: Change the oil filter at every oil change. Make sure to use the
correct Caterpillar oil filter for your engine arrangement.
NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an oil
filter not recommended by Caterpillar could result in severe damage to
your engine bearings, crankshaft, etc, as a result of the larger debris
particles from unfiltered oil entering your engine lubricating system.
?n ? t a n t ! f S 6 f n ° S u r f a c e o f t h e oil f i l t e r
mounting base. Ensure that
all of +the old gasket is removed.
mmu&m0msmmmmm
132 133
Maintenance Section Maintenance Schedule
Engine Oil and Oil Filter Change Engine Valve Lash - Check/Adjust
Example: An oil capacity of 31 L (33 qt) was determined, along with fuel Engine Vaiwe Lash - Check/Adjust
with 0.5 percent sulfur. The oil change interval is approximately every
8855 km (5500 mi) or 220 Service Hours. The same engine, if using fuel Initial valve lash adjustment on new, rebuilt or remanufactured Caterpillar
with less than 0.5 percent sulfur, has an oil change interval at every engines is scheduled at the first oil change interval due to initial wear and
16 100 km (10,000 miles) or 420 Service Hours. seating of valve train components. Perform subsequent engine valve lash
check/adjustment at the PM Level 2 interval.
Oil Change Interval Graph This maintenance is recommended by Caterpillar as part of a preventive
maintenance schedule to provide maximum engine service life.
j ^ WARNING
NOTICE
Perform the procedures for engine valve lash according to the informa-
tion in the Service Manual.
Fan Driwe Bearing - Lubricate/Inspect Fuel System Primary Fuel Filter - Clean
A WARNING
Fuel leaked or spilled onto hot surfaces or electrical components can
cause a fire. To prevent possible injury, turn the start switch OFF
when changing fuel filters or water separator elements. Clean up fuel
spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a suitable
cover over any disconnected fuel system components.
(1) Grease fitting.
Lubricate grease fitting (1) with Bearing Lubricant.
For information on maintenance for the primary fuel filter, refer to the
literature that is provided by the OEM of the vehicle or the OEM of the
Inspect primary fuel filter.
Inspect the fan drive pulley assembly. It should be difficult to detect
movement of the shaft in the bearing. If the shaft is loose, an inspection Fuel System Secondary Fuel Filter - Replace
of the internal components should be made.
If the assembly should require disassembly, refer to the Service Manual A WARNING
for the procedure. Consult your Caterpillar dealer for assistance.
Fuel leaked or spilled onto hot surfaces or electrical components can
cause a fire. To prevent possible injury, turn the start switch OFF
when changing fuel filters or water separator elements. Clean up fuel
spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a suitable
cover over any disconnected fuel system components.
1. Stop the engine. Turn the ignition/start switch OFF or disconnect the
m battery. Shut off the fuel supply valve (if equipped).
ft
It
It
136 137
Maintenance Section Maintenance Section
Fuel System - Prime Fuel System - Prime
2. Remove and discard the used fuel filter. Engines Equipped With A Fuel Priming Pump
3. Clean the gasket sealing surface of the fuel filter base. Make sure all NOTICE
IMF of the old gasket is removed. Do NOT loosen the fuel lines at the fuel manifold. The fittings may be
4. Apply clean diesel fuel to the new fuel filter gasket. damaged and/or a loss of priming pressure may occur when the fuel lines
are loosened.
NOTICE
Do NOT fill the fuel filters with fuel before installing them. The fuel would 1. Unlock and operate the priming pump until a resistance is felt. A
PIP not be filtered and could be contaminated. Contaminated fuel will cause considerable number of pump strokes may be required.
jji accelerated wear to fuel system parts. 2. Push in and lock the priming pump.
llllll
5 Install the new fuel filter onto the fuel filter base until the gasket NOTICE
contacts the base. Tighten the fuel filter one full turn (360 degrees) more Do not crank the engine for more than 30 seconds. Allow the starter
by hand. Do not overtighten. motor to cool for two minutes before cranking again.
§. Open the fuel supply valve. Prime the fuel system. Start the engine
and inspect for fuel leaks.
3. Promptly start the engine. If the engine runs rough, continue to
•11 operate the engine at low idle until the engine operates smoothly.
NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow NOTE: If the engine will not start, or once started, continues to misfire or
smoke, further priming may be necessary.
the starting motor to cool for two minutes before cranking again.
j||
138
139
Maintenance Section Maintenance Section
Fuel System - Prime Fuel Tank Water and Sediment - Drain
ll§
140 141
Maintenance Section Maintenance Section
Overhaul - Evaluate Radiator - Inspect
it NOTICE
Do not overtighten the fuel line clamps. Overtightening causes the
Inspect the water pump for leaks. The water pump seal is lubricated by
coolant in the cooling system. It is normal for a small amount of leakage
to occur as the engine cools down and parts contract.
clamps to deform, which results in low clamping force, fuel line vibration, Removal and Installation
and eventual failure.
Refer to the Service Manual for the procedure to remove and install the
water pump, or consult your Caterpillar dealer for assistance.
• Inspect the engine wiring and the wiring harnesses for loose
connections and worn or frayed wires. Water Pump Pulley Bearing - Inspect
• Inspect the engine electrical ground for good connection and condition. Inspect the water pump pulley for unusual noise, excessive looseness
and/or wobbling of the bearings.
NOTE: Some vehicles may use a starting motor to battery ground strap.
If a starting motor change is made, consult an authorized Caterpillar Refer to the Service Manual for the procedure to remove and install the
dealer to make sure that the proper grounding procedures are followed water pump pulley, or consult your Caterpillar dealer for assistance.
for that starting motor.
• All guards must be in place. Repair or replace any guard that is
damaged or missing.
• Check the condition of the battery and the level of electrolyte, unless
equipped with a maintenance free battery. Refer to the maintenance
information that is provided by the vehicle Owner's Manual or by the
OEM of the battery.
iii
•Ill
148
Maintenance Section
149
Maintenance Section
Water Separator
Water Temperature Regulator - inspect/Replace
Water Separator
NOTICE
Drain Water and Sediment The water separator is under suction during normal engine operation.
Ensure that the drain valve is tightened securely in order to prevent air
from entering the fuel system.
A WARNING
Fuel leaked or spilled onto hot surfaces or electrical components can 2. Close drain valve (1).
cause a fire. To prevent possible injury, turn the start switch OFF
when changing fuel filters or water separator elements. Clean up fuel
spills immediately. Water Temperature Regulator -
Inspect/Replace
Remove the water temperature regulator according to the instructions that
NOTICE are in the Service Manual. Inspect the water temperature regulator for
The water separator is not a filter. The water separator separates water good condition. Ensure that the water temperature regulator operates
from the fuel. The engine should never be allowed to run with the water properly according to the test procedure that is in the Service Manual.
separator more than Vz full- engine damage may result.
Replacing the water temperature regulator prior to failure is a
recommended preventive maintenance practice because it reduces the
A water separator is recommended and should be installed between the chances for unscheduled downtime.
fuel tank and the engine fuel inlet. Drain the water and sediment from the
water separator on a daily basis. Depending on load, a water temperature regulator that fails in a partially
opened position will cause either an overheating or an overcooling
condition.
If the water temperature regulator fails in the closed position, it will cause
excessive overheating. Excessive overheating could result in cylinder
head cracking or piston seizure problems.
If the water temperature regulator fails in the open position, it will cause
the engine operating temperature to be too low during partial load
operation. Low engine operating temperatures during partial loads could
cause an excessive carbon buildup inside the cylinder. This excessive
carbon buildup could result in accelerated ring and liner wear.
D19661
(1) Drain valve.
1 . Open drain valve (1). Catch the draining water in a suitable container
and dispose of properly.
150 151
Maintenance Section Maintenance Section
Water Temperature Regulator - Inspect/Replace Severe Service Application
Caterpillar recommends that accurate maintenance records be Engine Model _ Vehicle Make.
maintained. Accurate maintenance records can be used for determining Serial Number. Vehicle Serial No..
operating costs, establishing maintenance schedules for other engines
being operated in the same environment, and for a variety of other related
business decisions.
Miles Service Quantity
or km Hours Of Fuel By
Accurate maintenance records can also be used to show compliance Item Serviced Date Initials
with the required maintenance practices and intervals. Documents such
as dealer work orders, itemized bills, owner's repair orders, receipts and
owner's vehicle log are generally accepted as proof of maintenance or
repair for warranty. Documents must show the date of the maintenance
performed, kilometers (mileage), vehicle and/or engine serial number.
If the vehicle is sold within the warranty period, transfer the records with
the vehicle.
?i
Hi
I
154
Warranty Section
Federal Emission Control Warranty
155
Warranty Section
Federal Emission Control Warranty
Limitations
Caterpillar Inc. is not responsible for resultant damages to an emission
California Emission Control Warranty
related part or component resulting from: Statement
• Any application or installation Caterpillar Inc. deems improper. Owner Warranty Rights
• Attachments, accessory items or parts not sold nor approved by
Caterpillar Inc. and Obligations
• Improper truck engine maintenance, repair or abuse. The California Air Resources Board (CARB) and Caterpillar Inc. are
• Owner's unreasonable delay in making the product available after being pleased to explain the emission control system warranty on your 1995 or
notified of a potential product problem. later truck engine.
This warranty is in addition to Caterpillar Inc. standard warranty,
In California, new motor vehicle engines must be designed, built and
applicable to the truck engine product involved.
equipped to meet the state's stringent anti-smog standards. Caterpillar
Remedies under this warranty are limited to the provision of material and Inc. must warrant the emission control system on your truck engine for
services as specified herein. Caterpillar Inc. is not responsible for the duration of time listed below provided there has not been any abuse
incidental or consequential damages. neglect or improper maintenance of your truck engine.
Your emission control system may include parts such as the fuel injection
system and engine computer, if equipped. Also included may be hoses
connectors, clamps and other emission-related components.
Where a warrantable condition exists, Caterpillar Inc. will repair the truck
engine at no cost to the owner including diagnosis, parts and labor.
•ill Any replacement part may be used for maintenance or repairs. The owner
should ensure that such parts are equivalent in design and durability to
• Costs to investigate complaints which are not caused by a defect in
Caterpillar Inc. material or workmanship.
genuine Caterpillar parts. Use of non-genuine Caterpillar parts does not
invalidate the warranty. However, Caterpillar Inc. is not liable for parts • Providing timely notice of a warrantable failure and promptly making the
Hi which are not genuine Caterpillar parts. product available for repair.
1!
Limitations
These warranties are subject to the following: Caterpillar Inc. is not responsible for resultant damages to an emission
related part or component resulting from:
Caterpillar Inc. Responsibilities • Any application or installation Caterpillar Inc. deems improper as
During the emission warranty period, if a defect in material or explained in the Operation and Maintenance Manual.
iii workmanship of a warranted part or component is found, Caterpillar Inc.
will provide:
• Attachments, accessory items or parts not authorized for use by
Caterpillar Inc.
•III • New, Remanufactured or repaired parts and/or components required to • Improper truck engine maintenance, repair or abuse.
correct the defect.
•111
if NOTE: Items replaced under this warranty become the property of
Caterpillar Inc.
• Owner's unreasonable delay in making the product available after being
notified of a potential product problem.
This warranty is in addition to Caterpillar Inc. standard warranty,
• Labor, during normal working hours, required to make the warranty applicable to the truck engine product involved.
repair. This includes diagnosis and labor to remove and install the
engine, if necessary. Remedies under this warranty are limited to the provision of material and
•It services as specified herein. Caterpillar Inc. is not responsible for
incidental or consequential damages such as downtime or loss-of-use of
truck.
lliitf
in
• H
•Iii
162 163
Warranty Section Warranty Section
Emissions Warranty Information Emissions Warranty Information
n Maintenance Recommendations
Inspect, test and replace if necessary. Unit injectors can be tested by an
authorized Caterpillar truck engine dealer.
Iii Caterpillar Inc. truck engines are certified by the United States TURBOCHARGER - Check for any unusual sound or vibration in the
Environmental Protection Agency (EPA) to comply with smoke and turbocharger. Inspect inlet and exhaust piping and connections. Check
.fin
•ill bearing condition and perform maintenance as described in the
gaseous emission standards prescribed by Federal laws at the time of
manufacture. Maintenance Schedule.
ill
V Efficiency of emission control and engine performance depends on AIR/FUEL RATIO CONTROL - This component is a device to control
I adherence to proper operation and maintenance recommendations AND
use of recommended fuels and lubricating oils. It is recommended that
the black smoke emission of an engine during its operation when low inlet
manifold pressure exists.
major adjustments and repair be made by your authorized Caterpillar Slow engine response and low power may indicate a need for adjustment
dealer. or repair. Your Caterpillar dealer is equipped with the necessary tools,
• Various chemical fuel additives which claim to reduce visible smoke are personnel and procedures to perform this service.
available commercially. Although additives have been used by individuals
Owner is encouraged to keep adequate maintenance records, but the
to solve some isolated smoke problems in the field, they are not
absence of such, in and of itself, will not invalidate the warranty.
recommended for general use. Federal smoke regulations require that
111
engines be certified without smoke depressants. The vehicle owner may perform routine maintenance, repairs and other
non warranty work or have it done at any repair facility. Such non
m The corrective steps taken immediately on discovery of worn parts, which
may affect emission levels, will help assure proper operation of emission
warranty work need not be performed at a designated warranty station in
order for the warranty to remain in force.
control systems. The use of genuine Caterpillar parts is recommended.
iiii. Suppliers of non-Caterpillar parts must assure the owner that the use of iP
such parts will not adversely affect emission levels.
Regular maintenance intervals, along with special emphasis on the
following items, are necessary to keep exhaust emissions within
acceptable limits for the useful life of the engine. Refer to the
Maintenance Section of this manual. If the engine is operating under
severe conditions, adjust the maintenance schedule accordingly. See
your authorized Caterpillar dealer to help analyze your specific
application, operating environment and maintenance schedule
adjustments.
The following is an explanation of maintenance for emission-related
components. See the Maintenance Schedule for the specific interval for
the following items.
164
Warranty Section 165
Emissions Warranty Information Warranty Section
Engine Protection Plans
• w
166
Reference Information Section
Customer Assistance
J Reference Informal
Customer
Customer Assistance Outside of the USA and of Canada
japan
Shin Caterpillar Mitsubishi Ltd. z?w
3700, Tana, Sagamihara-shi
Kanagawa-ken, 229
Japan
Phone: Sagamihara 81-427-62-2112
Fax:81-427-62-8542
Japan
Caterpillar Power Systems, Inc.
Japan Branch Sanno Grand Bldg.
2-14-2 Nagatacho
Chiyoda-ku, Tokyo, 100
Japan
Phone:81-335-93-3237
Fax: 81-335-93-3238
•111
ill
warn:
170 171
Reference Information Section Reference Information Section
Ordering Replacement Parts Reference Materials
Quality Caterpillar replacement parts are available from Caterpillar dealers Caterpillar Reference Material
throughout the world. Their parts stocks are up to date and include all of
the parts that are normally required to protect your Caterpillar engine Lubricants
investment. PEHP5026, Data Sheet- Caterpillar Diesel Engine Oils (DEO) (CG4/CF-4)
• When ordering parts, the order should specify the part number, the part (North America and selected International)
name and the quantity of the parts that are needed. The order should PEHP1026, Data Sheet- Caterpillar Diesel Engine Oil (DEO) (CF-4)
specify the serial number, the arrangement number and the modification (International only)
number of the engine for which the parts are needed. If there is a doubt PEHP0003, Data Sheet- Multipurpose Lithium Complex Grease (MPG)
about the part number, please provide the dealer with a complete PEHP0002, Data Sheet- Multipurpose Lithium Complex Grease with
description of the item that is needed. Molybdenum (MPGM)
PEHP0017, Data Sheet- Special Purpose Grease (SPG) Bearing Lubricant
• When maintenance or repair is needed for a Caterpillar engine, be PECP4025, One Safe Source
prepared to give the dealer all of the information that is provided on the SEBD0640, Oil and Your Engine
engine's Information Film. SEBU5898, Cold Weather Recommendations
PEHP6001, How to Take a Good Oil Sample
• Discuss the problem with the dealer, such as when the problem occurs, PEDP1129, Listen To Your Oil
what happens, etc. This will help the dealer to troubleshoot and solve
the problem faster.
Fuels
SEBD0717, Diesel Fuels and Your Engine
Coolants
PEHP4036, Data Sheet- Caterpillar Coolant
PEHP5033, S'O'S Coolant Analysis
PECP4025, One Safe Source
SEBD0518, Know Your Cooling System
SEBD0970, Coolant and Your Engine
Special Instructions
The following Special Instructions pertain to the operation and
maintenance of your Caterpillar engine. Some of these publications
will be included with tool kits, others will be available from your
Caterpillar dealer.
SEHS8622, Using the FT-1984 Air-To-Air Aftercooler Test Group
SEHS9031, Storage Procedure for Caterpillar Products
SEHS7332, Tag - DO NOT OPERATE
172 173
Reference Information Section Reference Information Section
Reference Materials Reference Materials
i
Idle/PTO Governor Mode 48
Idling 42
Important Safety Information 5
Information Film 22
Information Section 1
178 179
Index Section Index Section
Index Index
R
ntenance 3
Maintenance Intervals 95 Radiator - Inspect -\^
Ma ntenance Log ••••• 153 Reduced Maintenance Intervals 97
Maintenance Recommendations 162 Re-Refined Base Stock Oils ............... 70
Maintenance Records 152 Reference Information Section 166
Mai ntenance Schedule - Engines with a Shallow Oil Sump 98 Reference Materials -\j-\
Mai ntenance Schedule - Engines with a Deep Oil Sump 100 Reference Numbers and Ordering Parts 23
Mai ntenance Schedule Recommendations 97
Refill Capacities ' 95
Mai ntenance Section 64
Ma ntenance Section 96
Model Views 16 S
Mounting and Dismounting 12 Safety 3 g
Safety Section '5
Self-Diagnostics "29
Serial Number Plate ]["[[[[['.'.".'.'.'.'. 21
Notes 102 Severe Service Application 15-1
Standard Torque for Hose Clamps-Worm Drive Band Type 64
Starting From An External Electrical Source 39
Starting Motor - Inspect ......143
Operating the Engine 42 Starting Problems " 39
Operation 3 Starting the Engine 35
Operation Section 27 Stopping the Engine 53
Operation With Active Diagnostic Codes 32 Synthetic Base Stock Oils 70
Operation With Intermittent Diagnostic Codes 32 S»0*S Coolant Analysis 93
Ordering Replacement Parts 170 S»0«S Oil Analysis (Recommended) - Obtain 142
Overhaul 4 S"0»S Oil Analysis g-|
180
Index Section
Index
95
Terminology RC.
Torque for Constant Torque Hose Clamps ®y
Torque Specifications .',;'""A',
Total Base Number (TBN) and Fuel Sulfur Levels For Caterpillar Dl
Diesel Engines •
14ci
Turbocharger - Inspect
U
Under-the-Hood Inspection 35
49
Uphill Operation
¥
45
Vehicle Efficiency
W
-MR
Walk-Around Inspection '"~
Inspect Engine for Leaks and Loose Connections 14b
Warning Signs and Labels -_°
Warranty Section XO
Water Pump Pulley Bearing - Inspect ™/
Water Pump - Inspect Yv
Replace the Water Pump Seal, If Necessary 14/
Water Separator Yo
Drain Water and Sediment ™B
Water Temperature Regulator - Inspect/Replace 149
Welding and Caterpillar Electronic Engines ^u
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