C7.1 Engine

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SEBU8600-02

July 2012

Operation andMaintenance

ManualC7.1 Industrial Engine

7701-Up (Engine)

SAFETY.CAT.COM

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i03991620

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

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

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

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

The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Cat dealers have the most current information available.

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

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

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

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SEBU8600-02 3Table of Contents

Table of Contents

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

Safety Section

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

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

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

Fire Prevention and Explosion Prevention ............ 12

Crushing Prevention and Cutting Prevention ........ 15

Mounting and Dismounting ................................... 15

High Pressure Fuel Lines ..................................... 15

Before Starting Engine .......................................... 17

Engine Starting ..................................................... 17

Engine Stopping ................................................... 18

Electrical System .................................................. 18

Engine Electronics ................................................ 19

Product Information Section

Model Views ......................................................... 21

Product Identification Information ........................ 29

Operation Section

Lifting and Storage ................................................ 32

Gauges and Indicators .......................................... 36

Features and Controls .......................................... 38

Engine Diagnostics ............................................... 48

Engine Starting ..................................................... 60

Engine Operation .................................................. 63

Engine Stopping ................................................... 67

Cold Weather Operation ....................................... 69

Maintenance Section

Refill Capacities .................................................... 74

Maintenance Recommendations .......................... 79

Maintenance Interval Schedule ............................ 81

Warranty Section

Warranty Information .......................................... 127

Reference Information Section

Engine Ratings ................................................... 128

Customer Service ............................................... 129

Reference Materials ............................................ 131

Index Section

Index ................................................................... 134

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4 SEBU8600-02Foreword

Foreword

Literature Information

This manual contains safety, operation instructions,

lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.

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

Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuing

improvement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Caterpillar dealer for the latestavailable information.

Safety

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

repair on this product.

Operation

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

The operation section is a reference for operators.Photographs and illustrations guide the operator

through procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic information.

Maintenance

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

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

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

The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, aperiodic tune-up is not required. The implementation

of a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.

Maintenance Intervals

Perform maintenance on items at multiples of theoriginal requirement. Each level and/or individualitems in each level should be shifted ahead or backdepending upon your specific maintenance practices,operation and application. We recommend thatthe maintenance schedules be reproduced and

displayed near the engine as a convenient reminder.We also recommend that a maintenance record bemaintained as part of the engine's permanent record.

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

Overhaul

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

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SEBU8600-02 5Foreword

California Proposition 65 Warning

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

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

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6 SEBU8600-02Safety SectionSafety Messages

Safety Section

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Safety Messages

SMCS Code: 1000; 7405

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

Ensure that all of the warning signs are legible. Cleanthe warning signs or replace the warning signs if the words cannot be read or if the illustrations arenot visible. Use a cloth, water, and soap to cleanthe warning signs. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh

chemicals could loosen the adhesive that secures thewarning signs. The warning signs that are loosenedcould drop off the engine.

Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of theengine that is replaced, install a new warning signon the r eplacement part. Your Caterpiller dealer canprovide new warning signs.

(1) Universal Warning

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

g01154807Illustration 1

Typical example

The Universal Warning label (1) is located in twopositions. The warning labels are located on the frontright side of the valve mechanism cover and on thetop of the NOx r eduction system (NRS).

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SEBU8600-02 7Safety Section

Safety Messages


(1) Universal warning

(2) Ether

Do not use aerosol types of starting aids such asether. Such use could result in an explosion andpersonal injury.


Typical example

The ether warning label (2) is located on the top of the NOx reduction system (NRS).

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8 SEBU8600-02Safety SectionGeneral Hazard Information


(2) Ether (3) Hand (High Pressure)

(3) Hand (High Pressure)

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

structions may cause personal injury or death.


Typical example

The warning label for the Hand (High Pressure) (3) islocated on a high-pressure fuel line.

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General Hazard Information

SMCS Code: 1000; 7405


Attach a “Do Not Operate” warning tag or a similar

warning tag to the start switch or to the controlsbefore the engine is serviced or before the engine isrepaired. These warning tags (Special Instruction,SEHS7332) are available from your Caterpillar dealer. Attach the warning tags to the engine and toeach operator control station. When it is appropriate,disconnect the starting controls.

Do not allow unauthorized personnel on the engine,or around the engine when the engine is beingserviced.

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General Hazard Information

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

• Vent the engine exhaust to the outside when the

engine is operated in an enclosed area.

• If the engine is not running, do not release thesecondary brake or the parking brake systemsunless the vehicle is blocked or unless the vehicleis restrained.

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

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

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

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

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

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, perform the

maintenance under the following conditions:

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

• The pr otective locks or the controls are in theapplied position.

• Engage the secondary brakes or parking brakes.

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

• Disconnect the batteries when maintenance

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

• Disconnect the connectors for the unit injectors thatare located on the valve cover base. This will helppr event personal injury from the high voltage to theunit injectors. Do not come in contact with the unitinjector terminals while the engine is operating.

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

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

• For initial start-up of a new engine or for starting anengine that has been serviced, make provisions to

stop the engine if an overspeed occurs. This maybe accomplished by shutting off the fuel supplyand/or the air supply to the engine. Ensure thatonly the fuel supply line is shut off. Ensure that thefuel return line is open.

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

Engine exhaust contains products of combustionwhich may be harmful to your health. Always start the

engine and operate the engine in a well ventilatedarea. If the engine is in an enclosed area, vent theengine exhaust to the outside.

Cautiously remove the following parts. To helpprevent spraying or splashing of pressurized fluids,hold a rag over the part that is being removed.

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

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


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10 SEBU8600-02Safety SectionGeneral Hazard Information

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

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

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

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

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

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, performthe maintenance under the following conditions:

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

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

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

Pressurized Air and Water

Pressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

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

The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must be below275 kPa (40 psi).

Fluid Penetration

Pressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the OEMinformation for any procedures that are required to

relieve the hydraulic pressure.


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

Containing Fluid Spillage

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, “Cat Dealer Service Tool Catalog” or refer to Special Publication,PECJ0003, “Cat Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluidson Cat products.

Dispose of all fluids according to local regulations andmandates.

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Burn Prevention

Asbestos Information


Caterpillar equipment and replacement parts that areshipped f rom Caterpillar are asbestos free. Caterpillar

recommends the use of only genuine Caterpillar replacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

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

contains asbestos is generated.

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

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

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

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

• Use exhaust ventilation on permanent machining jobs.

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

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

• Obey environmental regulations for the disposalof asbestos.

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

Dispose of Waste Properly


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

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

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Burn Prevention

SMCS Code: 1000; 7405

Do not touch any part of an operating enginesystem. The engine, the exhaust, and the engineaftertreatment system can reach temperatures as

high as 650 °C (1202 °F) under normal operatingconditions. If the engine or the engine aftertreatmentsystem unexpectedly fails, the temperature of thegas at the diesel particulate fi lter (DPF) may increaseto 900°C (1652°F).

At idle engine speed and/or zero vehicle speed,an operator can request a manual regeneration.Under this condition, the exhaust gas temperaturecan reach 650 °C (1202 °F). Otherwise automaticr egeneration can produce exhaust gas temperaturesas high as 450 °C (842 °F).

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12 SEBU8600-02Safety SectionFire Prevention and Explosion Prevention

Allow the engine system to cool before anymaintenance is performed. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings, or relateditems are disconnected.

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

After the engine has stopped, you must wait for 10minutes in order to allow the fuel pressure to bepurged from the high-pressure fuel lines before anyservice or repair is performed on the engine fuel lines.

Allow the pressure to be purged in the air system, inthe hydraulic system, in the lubrication system, or in the cooling system before any lines, fittings, or related items are disconnected.

Induction System

Sulfuric Acid Burn Hazard may cause serious per-sonal injury or death.

The exhaust gas cooler may contain a smallamount of sulfuric acid. The use of fuel with sul-fur levels greater than 15 ppm may increase theamount of sulfuric acid formed. The sulfuric acidmay spill from the cooler during service of theengine. The sulfuric acid will burn the eyes, skinand clothing on contact. Always wear the appro-priate personal protective equipment (PPE) thatis noted on a material safety data sheet (MSDS)for sulfuric acid. Always follow the directions for first aid that are noted on a material safety datasheet (MSDS) for sulfuric acid.

Coolant

When the engine is at operating temperature, theengine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. The aftertreatmentregeneration device (ARD) is connected to thecoolant system and will contain hot coolant.

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

Check that the coolant level after the engine hasstopped and the engine has been allowed to cool.

Ensure that the fi ller cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly in

order to relieve pressure.

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

Oils

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

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

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Fire Prevention and ExplosionPrevention

SMCS Code: 1000; 7405


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

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

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Fire Prevention and Explosion Prevention

A flash fire may result if the covers for the enginecrankcase are removed within 15 minutes after anemergency shutdown.

Determine whether the engine will be operated in anenvironment that allows combustible gases to be

drawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.

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

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

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Store

oily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used for storing flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in a line, a tube,or a seal failure. Exhaust shields must be installedcorrectly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanks

thoroughly with a nonflammable solvent prior towelding or flame cutting.

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

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

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


After the engine has stopped, you must wait for 10minutes in order to allow the fuel pressure to bepurged from the high-pressure fuel lines before anyservice or repair is performed on the engine fuel lines.

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

Oil filters and fuel fi lters must be properly installed.The filter housings must be tightened to the proper torque.


Use caution when you are refueling an engine. Do

not smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.

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14 SEBU8600-02Safety SectionFire Prevention and Explosion Prevention


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

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

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

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

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

Fire Extinguisher

Make sure that a fire extinguisher is available. Be

familiar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Ether

Ether is flammable and poisonous.

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

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

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

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

Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strikehigh-pressure lines. Do not install any lines that arebent or damaged.

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

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

Replace the parts if any of the following conditionsare present:

• High-pressure fuel line or lines are removed.

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

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

Regeneration

The exhaust gas temperature during regeneration willbe elevated. Follow proper fire prevention instructionsand use the disable switch function when appropriate.

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Crushing Prevention and Cutting Prevention

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Crushing Prevention andCutting Prevention

SMCS Code: 1000; 7405

Support the component properly when work beneaththe component is performed.

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

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

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

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

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

i04016709

Mounting and Dismounting

SMCS Code: 1000; 7405

Do not climb on the engine or the engineaftertreatment. The engine and aftertreatment havenot been designed with mounting or dismountinglocations.

Refer to the OEM for the location of foot and handholds for your specific application.

i03550790

High Pressure Fuel Lines

SMCS Code: 1274


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16 SEBU8600-02Safety SectionHigh Pressure Fuel Lines


(1) High pressure line(2) High pressure line(3) High pressure line

(4) High pressure line(5) High pressure line(6) High pressure line

(7) High pressure fuel manifold (rail)(8) High pressure line(9) Fuel transfer line that is high pressure

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

This is because of the following items:

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

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

• The high pressure fuel lines are formed to shapeand then strengthened by a special process.

Do not step on the high pressure fuel lines. Do notdeflect the high pressure fuel lines. Do not bend or strike the high pressure fuel lines. Deformation or damage of the high pressure fuel lines may cause apoint of weakness and potential failure.

Do not check the high pressure fuel lines with theengine or the starting motor in operation. After theengine has stopped, you must wait for 10 minutes inorder to allow the fuel pressure to be purged from thehigh pressure fuel lines before any service or repair is performed on the engine fuel lines.

Do not loosen the high pressure fuel lines in order to remove air from the fuel system. This procedureis not required.

Visually inspect the high pressure fuel lines beforethe engine is started. This inspection should be eachday.

If you inspect the engine in operation, always usethe proper inspection procedure in order to avoida fluid penetration hazard. Refer to Operation andMaintenance Manual, “General hazard Information”.

• Inspect the high pressure fuel lines for damage,deformation, a nick, a cut, a crease, or a dent.

• Do not operate the engine with a fuel leak. If thereis a leak do not tighten the connection in order to stop the leak. The connection must only betightened to the recommended torque. Refer toDisassembly and Assembly, “Fuel injection lines -Remove and Fuel injection lines - Install”.

• If the high pressure fuel lines are torqued correctlyand the high pressure fuel lines are leaking thehigh pressure fuel lines must be replaced.

• Ensure that all clips on the high pressure fuel linesare in place. Do not operate the engine with clipsthat are damaged, missing or loose.

• Do not attach any other item to the high pressurefuel lines.

• Loosened high pressure fuel lines must bereplaced. Also removed high pressure fuel linesmust be replaced. Refer to Disassembly andassembly manual, “ Fuel Injection Lines - Install”.

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Before Starting Engine

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SMCS Code: 1000

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

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

outside.

Inspect the engine for potential hazards.

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

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

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

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

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

engine damage.

See the Service Manual for repairs and for adjustments.

i03635086

Engine Starting

SMCS Code: 1000

Do not use aerosol types of starting aids such asether. Such use could result in an explosion andpersonal in jury.

If a warning tag is attached to the engine start switchor to the controls DO NOT start the engine or movethe controls. Consult with the person that attachedthe warning tag before the engine is started.

All protective guards and all protective covers mustbe installed if the engine must be started in order

to perfor m service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine from the operator's compartment or from the engine start switch.

Always start the engine according to the procedurethat is described in the Operation and MaintenanceManual, “Engine Starting” topic in the OperationSection. Knowing the correct procedure will help toprevent major damage to the engine components.Knowing the procedure will also help to preventpersonal injury.

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

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

These engines are equipped with a glow plug starting

aid in each individual cylinder that heats the intake air in order to improve starting. Some Caterpillar enginesmay have a cold starting system that is controlled bythe ECM that allows a controlled flow of ether intothe engine. The ECM will disconnect the glow plugsbefore the ether is introduced. This system wouldbe installed at the factory.

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18 SEBU8600-02Safety SectionEngine Stopping

i03648639

Engine Stopping

SMCS Code: 1000

To avoid overheating of the engine and acceleratedwear of the engine components, stop the engineaccording to this Operation and Maintenance Manual,“Engine Stopping” topic (Operation Section).

Use the Emergency Stop Button (if equipped)ONLY in an emergency situation. DO NOT use theEmergency Stop Button for normal engine stopping.

After an emergency stop, DO NOT start the engineuntil the problem that caused the emergency stophas been corrected.

On the initial start-up of a new engine or an enginethat has been serviced, make provisions to stop the

engine if an overspeed condition occurs.

i04947824

Electrical System

SMCS Code: 1000; 1400

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

To help prevent sparks from igniting combustible

gases that are produced by some batteries, thenegative “−” cable should be connected last fromthe external power source to the primary position for grounding.

Check the electrical wires daily for wires thatare loose or frayed. Tighten all loose electricalconnections before the engine is started. Repair allfrayed electrical wires before the engine is started.See the Operation and Maintenance Manual for specific starting instructions.

Grounding Practices


Typical example

(1) Ground to the battery(2) Primary position for grounding(3) Ground to the starting motor

(4) Ground to the engine block

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Engine Electronics


Typical example

(5) Ground to the battery(6) Ground to the engine block(7) Primary position for grounding

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

Uncontrolled electrical circuit paths can result indamage to the crankshaft bearing journal surfacesand to aluminum components.

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

To ensure that the engine and the engine electricalsystems function correctly, an engine-to-frameground strap with a direct path to the battery must beused. This path may be provided by way of a directengine ground to the frame.

The connections for the grounds should be tight andfree of corrosion. The engine alternator must begrounded to the negative “-” battery terminal witha wire that is adequate to handle the full chargingcurrent of the alternator.

The power supply connections and the groundconnections for the engine electronics should alwaysbe from the isolator to the battery.

i03554965

Engine ElectronicsSMCS Code: 1000; 1400; 1900

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

Electrical Shock Hazard. The electronic unit injec-tors use DC voltage. The ECM sends this voltageto the electronic unit injectors. Do not come incontact with the harness connector for the elec-tronic unit injectors while the engine is operating.Failure to follow this instruction could result inpersonal injury or death.

This engine has a comprehensive, programmableEngine Monitoring System. The Electronic ControlModule (ECM) has the ability to monitor the engineoperating conditions. If any of the engine parameters

extend outside an allowable range, the ECM willinitiate an immediate action.

The following actions are available for enginemonitoring control:

• Warning

• Derate

• Shutdown

The following monitored engine operating conditionsand components have the ability to limit engine

speed and/or the engine power:

• Engine Coolant Temperature

• Engine Oil Pressure

• Engine Speed

• Intake Manifold Air Temperature

• Engine Intake Throttle Valve Fault

• Wastegate Regulator

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20 SEBU8600-02Safety SectionEngine Electronics

• Supply Voltage to Sensors

• Fuel Pressure in Manifold (Rail)

• NOx Reduction System

• Engine After treatment System

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

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

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SEBU8600-02 21Product Information Section

Model Views

Product InformationSection

Model Viewsi03913230

Model View Illustrations

SMCS Code: 1000

The following model views show typical featuresof the engine. Due to individual applications, your engine may appear different from the illustrations.

Note: Only major components are identified on thefollowing illustrations.

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22 SEBU8600-02Product Information SectionModel Views

Engine views


Typical example

(1) Rear lifting eye(2) NOx reduction system NRS(3) Front lifting eye(4) Alternator

(5) Refrigerant compressor (6) High-pressure turbocharger (7) Low-pressure turbocharger (8) Engine oil drain

(9) Flywheel housing(10) Flywheel(11) NRS cooler

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Model Views


Typical example

(12) C rankcase breather (13) Electronic control module (ECM)(14) Starting motor (15) Oil filter

(16) Oil gauge(17) Oil filler (18) Primary fuel filter (19) Secondary fuel filter

(20) In-line fuel strainer (21) Electric fuel priming pump

The location of the in-line fuel strainer (20) and thepriming pump (21) will depend on the application.

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Typical example

(22) Outlet connection to the air to air chargecooler

(23) Connection for the air inlet(24) Outlet connection for the coolant

(25) Housing for the water temperatureregulator

(26) Water pump(27) Inlet connection for the Coolant

(28) Vibration damper (29) Belt tensioner (30) Belt

Engine Aftertreatment System

The following view shows typical features of theengine aftertreatment system. Due to individualapplications, your system may appear different fromthe illustrations.

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Model Views


Typical example

(1) Diesel oxidation catalyst (DOC)(2) Securing clamp(3) Torca clamp(4) Diesel particulate fi lter (DPF)

(5) Securing clamp

(6) Torca clamp(7) Lifting eye(8) Air inlet for aftertreatment regeneration

device (ARD)

(9) Connections for Coolant manifold

(10) Lifting eye

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(11) Outlet to exhaust system(12) Aftertreatment regeneration device

(13) Lif ting eye(14) Exhaust Inlet

(15) Mounting cradle

Fuel Pump for Engine Aftertreatment

SystemNote: The fuel for the engine aftertreatment system issupplied by a designated fuel pump. The location of this pump can change depending on the application.


Typical example

(16) Fuel inlet(17) Electrical connector (18) Fuel supply line(19) Return to tank(20) Fuel inlet(21) Fuel inlet

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Model Views

i03995531

Engine Description

SMCS Code: 1000

The Caterpillar C7.1 Industrial Engine has thefollowing characteristics.

• In-line Six cylinder

• Four stroke cycle

• Series turbocharged charge cooled

Engine Specifications

Note: The f ront end of the engine is opposite theflywheel end of the engine. The left and the rightsides of the engine are determined from the flywheel

end. The number 1 cylinder is the front cylinder.


Cylinder and valve location

(A) Exhaust valves(B) Inlet valves

Table 1

C7.1 Engine Specifications

Operating Range (rpm) 900 to 2800(1)

Number of Cylinders 6 In-Line

Bore 105 mm (4.13 inch)

Stroke 135 mm (5.31495 inch)

Power 225 kW (301.72 hp)

Aspiration Turbocharged chargecooled

Compression Ratio 16.5:1

Displacement 7.01 L (428 in3)

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

Rotation (flywheel end) Counterclockwise

(1) The operating rpm is dependent on the engine rating, theapplication, and the configuration of the throttle.

Electronic Engine Features

The engine operating conditions are monitored.The Electronic Control Module (ECM) controls theresponse of the engine to these conditions and tothe demands of the operator. These conditions and

operator demands determine the precise control of fuel injection by the ECM. The electronic enginecontrol system provides the following features:

• Engine monitoring

• Engine speed governing

• Control of the injection pressure

• Cold start strategy

• Automatic air/fuel ratio control

• Torque rise shaping

• Injection timing control

• System diagnostics

• Aftertr eatment regeneration control

• NOx reduction system control

For more information on electronic engine features,refer to the Operation and Maintenance Manual,“Features and Controls” topic (Operation Section).

Engine Diagnostics

The engine has built-in diagnostics in order to ensurethat the engine systems are functioning correctly. Theoperator will be alerted to the condition by a “Stop or Warning” lamp. Under certain conditions, the enginehorsepower and the vehicle speed may be limited.The electronic service tool may be used to displaythe diagnostic codes.

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

Most of the diagnostic codes are logged and storedin the ECM. For additional information, refer tothe Operation and Maintenance Manual, “EngineDiagnostics” topic (Operation Section).

The ECM provides an electronic governor thatcontrols the injector output in order to maintain thedesired engine rpm.

Engine Cooling and Lubrication

The cooling system and lubrication system consistsof the following components:

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• Gear-driven centrifugal water pump

• Water temperature regulator which regulates theengine coolant temperature

• Gear-driven rotor type oil pump

• Oil cooler

The engine lubricating oil is supplied by a rotor typeoil pump. The engine lubricating oil is cooled and theengine lubricating oil is filtered. The bypass valvecan provide unrestricted flow of lubrication oil tothe engine if the oil filter element should becomeplugged.

Engine ef ficiency, ef ficiency of emission controls, andengine performance depend on adherence to proper operation and maintenance recommendations.Engine performance and ef ficiency also depend on

the use of recommended fuels, lubrication oils, andcoolants. Refer to this Operation and MaintenanceManual, “Maintenance Interval Schedule” for moreinformation on maintenance items.

Engine Service Life

Engine ef ficiency and maximum utilization of engineperformance depend on the adherence to proper operation and maintenance recommendations. Inaddition, use recommended fuels, coolants andlubricants. Use the Operation and MaintenanceManual as a guide for required engine maintenance.

Expected engine life is generally predicted by theaverage power that is demanded. The average power that is demanded is based on fuel consumption of the engine over a period of time. Reduced hours of operation at full throttle and/or operating at reducedthrottle settings result in a lower average power demand. Reduced hours of operation will increasethe length of operating time before an engineoverhaul is required. For more information, refer tothe Operation and Maintenance Manual, “OverhaulConsiderations” topic (Maintenance Section).

Aftermarket Products andCaterpillar Engines

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

When auxiliary devices, accessories, or consumables(filters, additives, catalysts,) which are made by other manufacturers are used on Caterpillar products, theCaterpillar warranty is not affected simply becauseof such use.

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

Aftertreatment System

The aftertreatment system is approved for use byCaterpillar. In order to be emission-compliant only theapproved Caterpillar aftertreatment system must beused on a Caterpillar engine.

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Product Identification Information

Product IdentificationInformation

i03921393

Plate Locations and FilmLocations(Engine AftertreatmentSystem)

SMCS Code: 1000


Typical example

The module arrangement exhaust plate is installedon the mounting plate (1). The location of thearrangement plate mounting plate can alter depending on the application.


Module Arrangement Exhaust Plate

Record the information that is on the plate. Thisinformation identifies the engine aftertreatmentsystem. This information will be required by your Caterpillar dealer.

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30 SEBU8600-02Product Information SectionProduct Identification Information

i03551161

Plate Locations and FilmLocations

SMCS Code: 1000


Location of the serial number plate

Serial Number Plate (1)

The engine serial number plate is located on theleft side of the cylinder block to the rear of the frontengine mounting.

Caterpiller dealers need all of these numbers in order to determine the components that were included withthe engine. This permits accurate identification of replacement part numbers.


Typical example

i03867276

Reference Numbers

SMCS Code: 1000

Information f or the following items may be needed toorder parts. Locate the information for your engine.Record the information in the appropriate space.Make a copy of this list for a record. Keep theinformation for future reference.

Record for Reference

Engine Model _______________________________________________

Engine Serial number _____________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

Primary Fuel Filter _________________________________________

Water Separator Element ________________________________

Secondary Fuel Filter Element __________________________

Lubrication Oil Filter Element ___________________________

Auxiliary Oil Filter Element _______________________________

Total Lubrication System Capacity ______ _______________

Total Cooling System Capacity _______ __________________

Air Cleaner Element _______________________________________

Drive Belt ______ ______________________________________________

Engine Aftertreatment System

Part Number ___ _____________________________________________

Serial Number ______________________________________________

i04945629

Emissions Certification Film

SMCS Code: 1000; 7405

The label for the emission is installed on the frontgear cover.

Note: A second emission label may be supplied withthe engine. If necessary, the second emission labelwill be installed on the application by the originalequipment manufacturer.

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Product Identification Information


Typical example

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SEBU8600-02 33Operation Section

Lifting and Storage

i03932110

Product Lifting(Engine)

SMCS Code: 1000; 1404; 7002


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

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

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

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

To remove the engine ONLY, use the lifting eyes thatare on the engine.

Lifting eyes are designed and installed for the specificengine arrangement. Alterations to the lifting eyesand/or the engine make the lifting eyes and the liftingfixtures obsolete. If alterations are made, ensurethat proper lifting devices are provided. Consult your Caterpillar dealer for information regarding fixturesfor proper engine lifting.

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34 SEBU8600-02Operation SectionLifting and Storage

i04161429

Product Lifting

SMCS Code: 1000; 1404; 7002


Typical example

The lifting points (1) are for the application shown. Asuitable lift truck will be required in order to lift theapplication.

The lifting eyes on the application will have blanking

devices (2) installed.


(A) Typical engine lifting eye(B) Typical CEM lifting eye

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36 SEBU8600-02Operation SectionGauges and Indicators

Gauges and Indicators

i03932253


SMCS Code: 1900; 7450

Your engine may not have the same gauges or all of the gauges that are described. For more informationabout the gauge package, see the OEM information.

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

Noticeable changes in gauge readings indicatepotential gauge or engine problems. Problems may

also be indicated by gauge readings that changeeven if the readings are within specifications.Determine and correct the cause of any significantchange in the readings. Consult your Caterpillar dealer f or assistance.

Some engine applications are equipped with Indicator Lamps. Indicator lamps can be used as a diagnosticaid. There are two lamps. One lamp has an orangelens and the other lamp has a red lens.

These indicator lamps can be used in two ways:

• The indicator lamps can be used to identify the

current operational status of the engine. Theindicator lamps can also indicate that the enginehas a f ault. This system is automatically operatedvia the ignition switch.

• The indicator lamps can be used to identify activediagnostic codes. This system is activated bypressing the Flash Code button.

Refer to the Troubleshooting Guide, “Indicator Lamps” for further information.

NOTICEIf no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOPthe engine. Engine damage can result.

Engine Oil Pressure – The oil pressureshould be greatest after a cold engine isstarted. The typical engine oil pressure with

SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) at ratedrpm.

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

1. Remove the load.

2. Stop the engine.

3. Check and maintain the oil level.

Jacket Water Coolant Temperature –Typical temperature range is 82° to 94°C(179.6° to 169.2°F). This temperature range

will vary according to engine load and the ambienttemperature.

A 100 kPa (14.5 psi) radiator cap must be installedon the cooling system. The maximum temperaturefor the cooling system is 108° C (226.4° F). Thistemperature is measured at the outlet for thewater temperature regulator. The engine coolanttemperature is regulated by the engine sensorsand the engine ECM. This programming cannot bealtered. Derates can occur if the maximum enginecoolant temperature is exceeded.

If the engine is operating above the normal range,reduce the engine load. If high coolant temperaturesare a frequent event, perform the followingprocedures:

1. Reduce the load on the engine.

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

3. Inspect the cooling system for leaks. If necessary,consult your Caterpillar dealer for assistance.

Tachometer – This gauge indicates enginespeed (rpm). When the throttle control lever is moved to the full throttle position without

load, the engine is running at high idle. The engine isrunning at the full load rpm when the throttle controllever is at the full throttle position with maximumrated load.

NOTICETo help prevent engine damage, never exceed thehigh idle rpm. Overspeeding can result in serious

damage to the engine. Operation at speeds exceed-ing high idle rpm should be kept to a minimum.

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

indicator should be to the “+” side of “0” (zero).

Fuel Level – This gauge indicates the fuellevel in the fuel tank. The fuel level gaugeoperates when the “START/STOP” switch

is in the “on” position.

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Service Hour Meter – The gauge indicatestotal operating hours of the engine.

Indicator Lamps• Shutdown lamp

• Warning lamp

• Wait to star t lamp

• Low oil pressure lamp

For information, refer to this manual, “MonitoringSystem (Table for the Indicator Lamps)” for thesequence of operation of the shutdown lamp and thewarning lamp.

The function of the wait to start lamp is automaticallycontrolled at engine start-up.

The function of the low oil pressure lamp is controlledby the engine ECM. If low oil pressure is detected,the lamp will be illuminated. The reason for theillumination of the low-pressure lamp should beinvestigated immediately.

All lamps will illuminate for 2 seconds in order tocheck that the lamps are functioning when thekeyswitch is turned to the ON position. If any of thelamps stay illuminated, the reason for illumination

should be investigated immediately.

Aftertreatment Lamps

For information on the aftertreatment lamp, refer tothis Operation and Maintenance Manual, “DieselParticulate Filter Regeneration”.

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38 SEBU8600-02Operation SectionFeatures and Controls

Features and Controls

i03921355

Monitoring System

(Engine)SMCS Code: 1900; 7400; 7402; 7450; 7451

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

necessary.

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

The following parameters are monitored:

• Coolant temperature

• Intake manifold air temperature

• Intake manifold air pressure

• Oil pressure

• Pressure in the fuel rail

• Fuel fi lter differential pressure

• Fuel temperature

• Water in fuel

• Engine speed/timing

• Atmospheric pressure (Barometric pressure)

• The Inlet pressure of the NOx reduction system

• The differential pressure within the NOx reductionsystem

• Temperature of the NOx reduction system

• The amount of soot in the Diesel particulate fi lter

Programmable Options andSystems Operation

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

The engine can be programmed to the followingmodes:

“Warning”

The “Warning” lamp and the warning signal (orangelamp) turn “ON” and the warning signal is activated

continuously in order to alert the operator that one or more of the engine parameters is not within normaloperating range.

“Warning/Derate”

The “Diagnostic” lamp turns “ON” and the warningsignal (red lamp) is activated. After the warning, theengine power will be derated. The warning lamp willbegin to flash when the derating occurs.

The engine will be derated if the engine exceedspreset operational limits. The engine derate isachieved by restricting the amount of fuel that isavailable for each injection. The amount of thisreduction of fuel is dependent on the severity of the fault that has caused the engine derate. Thisreduction in fuel results in a predetermined reductionin engine power.

“Warning/Derate/Shutdown”

The “Diagnostic” lamp turns “ON” and the warningsignal (red lamp) is activated. After the warning,the engine power will be derated. The engine willcontinue at the rpm of the set derate until a shutdownof the engine occurs. The engine can be restarted

after a shutdown for use in an emergency.

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

If there is a signal for low oil pressure or for coolanttemperature, there will be a two second delay inorder to verify the condition.

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For each of the programmed modes, refer toTroubleshooting Guide, “Indicator Lamps” for moreinformation on Indicator Lamps.

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

Instrument panels and Displays

In order to monitor the engine a wide verity of instrument panels are available. These instrumentpanels can contain the aftertreatment lamps and theindicator lamps and the gauges for the application.The regeneration switch can be incorporate withinthe panel.

Also available are mini power displays andperformance monitors. These displays and monitorscan show the operator the following engine

information.

• The system configuration parameters

• The customer specified parameters

• Diagnostic codes

• Event codes

• Coolant temperature

• Oil temperature

• Oil pressure

• Intake temperature

• Intake pressure

• Atmospheric pressure

• Fuel temperature

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i03552521

Monitoring System(Engine)

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

Table 2

WarningLamp

ShutdownLamp

LampStatus

Description of Lamp Status Engine Status

ON ONLamp check When the engine start switch is turned to the

“ON” position both lamps will illuminate for 2seconds only.

The engine has not beenstarted.

OFF OFF No faults There are no active diagnostic faults. The engine is running

normally.

ON OFF Activediagnosticfault

An active diagnostic fault has been detected. The engine is runningnormally.

ON FLASHING Activediagnosticfault

A serious active diagnostic fault has beendetected and an engine derate has been invoked.

The engine is runningbut the engine has beenderated.

FLASHING OFFDerate andwarning

One or more of the engine protection values hasbeen exceeded.

The engine is runningbut the engine has beenderated.

FLASHING ONEngineshutdown

One or more of the engine protection values hasbeen exceeded or a serious active diagnosticfault has been detected.

The engine is shutdownor shutdown is imminent.

i03928178

Sensors and ElectricalComponents(Aftertreatment)

SMCS Code: 1439; 1900; 7400

The following view shows typical features of theengine aftertreatment system. Due to individualapplications, your system may appear different fromthe illustrations.

• Glossary

• ARD Aftertreatment Regeneration Device

• DOC Diesel Oxidation Catalyst

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Typical example

(1) Soot sensor connection(2) Spark plug lead(3) ARD air pressure sensor (4) DOC pressure sensor (5) Pressure differential sensor

(6) Relay(7) Soot sensor connection(8) DOC Temperature sensor (not shown)(9) Harness connector (10) Main fuel valve (If equipped)(11) Pilot fuel valve(12) Fuel pressure sensor (if equipped)(13) Fuel pressure sensor (pilot)(14) Aftertreatment device ID(15) Coil for spark plug(16) ARD air control valve(17) Location of spark plug(18) ARD exhaust gas temperature sensor

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i03915130

Sensors and ElectricalComponents(Engine)

SMCS Code: 1439; 1900; 7400

Sensor Locations

The Illustration within the section shows the typicallocations of the sensors for a C7.1 Industrial Engine.Specific engines may appear different from theillustration due to differences in applications.


(1) Engine Intake Throttle Valve(2) Wastegate Regulator (3) Control Valve for the NOx Reduction

System (NRS)(4) Temperature Sensor for the NOx

Reduction System(5) Intake Pressure Sensor for the NOx

Reduction System (NRS)(6) Differential Pressure Sensor for the NOx

Reduction System (NRS)

(7) Fuel Pressure Sensor (Fuel RailPressure Sensor)

(8) Intake Manifold Air Temperature Sensor (9) Intake Manifold Pressure Sensor (10) Electronic Control Module (ECM)(11) Atmospheric Pressure Sensor

(Barometric Pressure Sensor)(12) Primary Speed/Timing Sensor (13) Starting Motor (14) Oil Pressure Sensor

(15) Oil level Switch ( if Equipped)(16) Diagnostic Connector (17) Fuel Temperature Sensor (18) Solenoid for the High Pressure Fuel

Pump(19) Coolant Temperature Sensor

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The location of the fuel fi lters will depend on the application.

(20) Differential Pressure Switch for theSecondary Fuel Filter

(21) Water in Fuel Switch

(22) Secondary Speed/Timing Sensor (23) Fuel Priming Pump(24) Alternator

(25) Refrigerant Compressor (if equipped)

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(16) Diagnostic Connector (17) Fuel Temperature Sensor

(18) Solenoid for the High Pressure FuelPump

(19) Coolant Temperature Sensor


(20) Differential Pressure Switch for the

Secondary Fuel Filter

(21) Water in Fuel Switch

(22) Secondary Speed/Timing Sensor

(23) Fuel Priming Pump

Programmable Monitoring System(PMS)

The Programmable Monitoring System determinesthe level of action that is taken by the Engine ControlModule (ECM) (10). In response to a conditionthat can damage the engine. These conditions areidentified by the ECM from the signals that areproduced from the following sensors.

• Coolant Temperature Sensor

• Intake Manifold Air Temperature Sensor

• Intake Manifold Pressure Sensor

• Fuel Pressure Sensor

• Engine Oil Pressure Sensor

• Primary Speed/Timing Sensor

• Secondary Speed/Timing Sensor

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• Fuel Temperature Sensor

• Temperature Sensor for the NRS

• Intake Pressure Sensor for the NRS

• Differential Pressure Sensor for the NRS

i03928179

Engine Shutoffs and EngineAlarms

SMCS Code: 1900; 7400; 7418

Shutoffs

The shutoffs are electrically operated or mechanicallyoperated. The electrically operated shutoffs arecontrolled by the ECM.

Shutoffs are set at critical levels for the followingitems:

• Operating temperature

• Operating pressure

• Operating level

• Operating rpm

The particular shutoff may need to be reset beforethe engine will start.

NOTICE Always determine the cause of the engine shutdown.Make necessary repairs before attempting to restartthe engine.

Be familiar with the following items:

• Types and locations of shutoff

• Conditions which cause each shutoff to function

• The resetting procedure that is required to restartthe engine

Alarms

The alarms are electrically operated. The operationsof the alarms are controlled by the ECM.

The alarm is operated by a sensor or by a switch.When the sensor or the switch is activated, a signalis sent to the ECM. An event code is created bythe ECM. The ECM will send a signal in order toilluminate the lamp.

Your engine may be equipped with the followingsensors or switches:

Coolant temperature – The coolant temperaturesensor indicates high jacket water coolanttemperature.

Intake manifold air temperature – The intakemanifold air temperature sensor indicates high intakeair temperature.

Intake manifold pressure – The intake manifoldpressure sensor checks the rated pressure in theengine manifold.

Fuel rail pressure – The fuel rail pressure sensor checks for high pressure or low pressure in the fuelrail.

Engine oil pressure – The engine oil pressure

sensor indicates when oil pressure drops below ratedsystem pr essure, at a set engine speed.

Engine overspeed – If, the engine rpm exceeds theoverspeed setting the alarm will be activated.

Air filter restriction – The switch checks the air filter when the engine is operating.

User-defined switch – This switch can shut downthe engine remotely.

Water in fuel switch – This switch checks for water in the primary fuel filter when the engine is operating.

Fuel temperature – The fuel temperature sensor monitors the pressurized fuel in the high-pressurefuel pump.

Fuel differential pressure – This switch checks thepressure across the fuel filter.

Note: The sensing element of the coolanttemperature switch must be submerged in coolantin order to operate.

Engines may be equipped with alarms in order to alert the operator when undesirable operating

conditions occur.

NOTICEWhen an alarm is activated, corrective measures mustbe taken before the situation becomes an emergencyin order to avoid possible engine damage.

If corrective measures are not taken within ar easonable time, engine damage could result. Thealarm will continue until the condition is corrected.The alarm may need to be reset.

8/10/2019 C7.1 Engine




Note: If installed, the coolant level switch and theoil level switch are indicators. Both switches operatewhen the application is on level ground and theengine RPM at zero.

Testing

Turning the keyswitch to the ON position will checkthe indicator lights on the control panel. All theindicator lights will be illuminated for 2 seconds after the keyswitch is operated. Replace suspect bulbsimmediately.

Refer to Troubleshooting, KENR9106 for moreinformation.

i03554501

Overspeed

SMCS Code: 1900; 1907; 1912; 7427

• ECM ______________________ Electronic Control Module

• RPM ____ ____________________ Revolutions Per Minute

An overspeed is detected by the speed/timingsensors.

The default setting for an overspeed is 3000 rpm.The ECM will cut the power to the electronic unitinjectors, until the rpm drops below 200 rpm of theoverspeed setting. A diagnostic fault code will be

logged into the ECM memory and a warning lamp willindicate a diagnostic fault code.

An overspeed can be set from 2600 rpm to 3000 rpm.This setting depends on the application.

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48 SEBU8600-02Operation SectionEngine Diagnostics

Engine Diagnostics

i01796959

Self-Diagnostics

SMCS Code: 1000; 1900; 1901; 1902

Caterpillar Electronic Engines have the capability toperform a self-diagnostics test. When the systemdetects an active problem, a diagnostic lampis activated. Diagnostic codes will be stored inpermanent memory in the Electronic Control Module(ECM). The diagnostic codes can be retrieved byusing Caterpillar electronic service tools.

Some installations have electronic displays thatprovide direct readouts of the engine diagnosticcodes. Refer to the manual that is provided by the

OEM for more information on retrieving enginediagnostic codes.

Active codes represent problems that currently exist.These problems should be investigated first.

Logged codes represent the following items:

• Intermittent problems

• Recorded events

• Performance history

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

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

i03554520

Diagnostic Lamp

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

A diagnostic lamp is used to indicate the existenceof an active fault. A fault diagnostic code will remainactive until the problem is repaired. The diagnosticcode may be retrieved by using the electronic servicetool.

i04036139

Diagnostic Flash CodeRetrieval

SMCS Code: 1000; 1900; 1901; 1902

In order to read the diagnostic flash codes throughthe diagnostic lamp, cycle the key switch from off toon twice within 3 seconds.

The codes will be flashing in sequence. For exampleif the flash code equals 133, the diagnostic lamp willflash once, pause, flash three times, pause, and flashthree times.

After the complete code has flashed, a 3 secondpause will take place before the next code will beginto flash (if another code is present).

Note: For more information refer toTroubleshootingmanual.

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Engine Diagnostics

Table 3

CDL Code Description J1939

CodeFlashCode

N/A No Diagnostic Code Detected N/A 551

1-2 Cylinder #1 Injector data incorrect 651-2

1-5 Cylinder #1 Injector current below normal 651-5

1-6 Cylinder #1 Injector current above normal 651-6

111




112




113




114




115




116

18-5 Fuel Control Valve current below normal 1076-5 -

18-6 Fuel Control Valve current above normal 1076-6 -

41-3 8 Volt DC Supply voltage above normal 678-3

41-4 8 Volt DC Supply voltage below normal 678-4517

91-2 Throttle Position Sensor erratic, intermittent, or incorrect 91-2

91-3 Throttle Position Sensor voltage above normal 91-3

91-4 Throttle Position Sensor voltage below normal 91-4

91-8 Throttle Position Sensor abnormal frequency, pulse width, or period 91-08

154

100-3 Engine Oil Pressure Sensor voltage above normal 100-3

100-4 Engine Oil Pressure Sensor voltage below normal 100-4

100-21 Engine Oil Pressure Sensor data drifted low 100-21

157

110-3 Engine Coolant Temperature Sensor voltage above normal 110-3

110-4 Engine Coolant Temperature Sensor voltage below normal 110-4168

168-2 Electrical System Voltage erratic, intermittent, or incorrect 168-2

168-3 Electrical System Voltage voltage above normal 168-3

168-4 Electrical System Voltage voltage Below normal 168-4

511

172-3 Intake Manifold Air Temperature Sensor voltage above normal 105-3

172-4 Intake Manifold Air Temperature Sensor voltage below normal 105-4133

(continued)

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(Table 3, contd)


CodeFlashCode

174-3 Fuel Temperature Sensor voltage above normal 174-3

174-4 Fuel Temperature Sensor voltage below normal 174-4165

190-8 Engine Speed Sensor abnormal frequency, pulse width, or period 190-8 141

247-9 SAE J1939 Data Link abnormal update rate - 514

253-2 Personality Module erratic, intermittent, or incorrect 631-2 415

261-11 Engine Timing Offset fault 637-11 143

262-3 5 Volt Sensor DC Power Supply voltage above normal 3509-3

262-4 5 Volt Sensor DC Power Supply voltage below normal 3509-4516

268-2 Programmed Parameter Fault erratic, intermittent, or incorrect 630-2 527

274-3 Atmospheric Pressure Sensor voltage above normal 108-3

274-4 Atmospheric Pressure Sensor voltage below normal 108-4

274-13 Atmospheric Pressure Sensor calibration required 108-13

274-21 Atmospheric Pressure Sensor data drifted low 108-21

152

342-8 Secondary Engine Speed Sensor abnormal frequency, pulse width, or period 723-8 142

526-5 Turbo Wastegate Drive current below normal 1188-5

526-6 Turbo Wastegate Drive current above normal 1188-6177

535-3 Exhaust Temperature Sensor voltage above normal 3241-3

535-4 Exhaust Temperature Sensor voltage below normal 3241-4185

774-2 Secondary Throttle Position Sensor erratic, intermittent, or incorrect 29-2

774-3 Secondary Throttle Position Sensor voltage above normal 29-3

774-4 Secondary Throttle Position Sensor voltage below normal 29-4

774-8 Secondary Throttle Position Sensor abnormal frequency, pulse width, or period 29-8

155

993-2 DPF Active Regeneration Inhibited Due to Inhibit Switch 3703-31 -

1262-2 Engine Throttle Actuator 1 Control Command not responding properly 3464-7 -

1634-2 Idle Validation Switch #1 erratic, intermittent or incorrect 558-2 245

1635-2 Idle Validation Switch #2 erratic, intermittent or incorrect 2970-2

1639-9 Machine Security System Module abnormal update rate 1196-9246

1743-2 Engine Operation Mode Selector Switch erratic, intermittent, or incorrect 2882-2 144

1785-3 Intake Manifold Pressure Sensor voltage above normal 3563-3

1785-4 Intake Manifold Pressure Sensor voltage below normal 3563-41785-13 Intake Manifold Pressure Sensor calibration required 3563-13

1785-21 Intake Manifold Pressure Sensor data drifted low 3563-21

197

1797-3 Fuel Rail Pressure Sensor voltage above normal 157-3

1797-4 Fuel Rail Pressure Sensor voltage below normal 157-4

1797-7 Fuel Rail Pressure Sensor not responding properly 157-7

159

1834-2 Ignition Key Switch loss of signal 158-2 429

2131-3 5 Volt Sensor DC Power Supply #2 voltage above normal 3510-3

2131-4 5 Volt Sensor DC Power Supply #2 voltage below normal 3510-4528

(continued)

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Engine Diagnostics

(Table 3, contd)


CodeFlashCode

2246-6 Glow Plug Start Aid Relay current above normal 676-6 199

2417-5 Ether Injection Control Solenoid current below normal 626-5

2417-6 Ether Injection Control Solenoid current above normal 626-6

233233

2452-3 DPF #1 Intake Temperature Sensor voltage above normal 3242-3 224

2452-4 DPF #1 Intake Temperature Sensor voltage below normal 3242-4 224

2458-3 DPF #1 Differential Pressure Sensor : voltage above normal 3251-3 222

2458-4 DPF #1 Differential Pressure Sensor : voltage below normal 3251-4 222

2460-3 ARD Fuel Pressure #1 Sensor voltage above normal 3480-3 219

2460-4 ARD Fuel Pressure #1 Sensor voltage below normal 3480-4 219

2461-5 ARD Fuel Pressure #1 Control current below normal 3479-5

2461-6 ARD Fuel Pressure #1 Control current above normal 3479-6216

2465-5 Aftertreatment #1 Ignition Transformer Primary current below normal 3484-5

2465-6 Aftertreatment #1 Ignition Transformer Primary current above normal 3484-6243

2489-5 ARD Air Pressure Control Actuator current below normal 3487-5

2489-6 ARD Air Pressure Control Actuator current above normal 3487-6211

2490-3 ARD Air Pressure Control Actuator Position Sensor voltage above normal 3488-3

2490-4 ARD Air Pressure Control Actuator Position Sensor voltage below normal 3488-4212

2498-3 ARD Supply Air Pressure Sensor voltage above normal 3837-3 -

2498-4 ARD Supply Air Pressure Sensor voltage below normal 3837-4 -

2498-13 ARD Supply Air Pressure Sensor calibration required 3837-13 -

2498-21 ARD Supply Air Pressure Sensor data drifted low 3837-21 -

2526-3 Air Inlet Temperature Sensor voltage above normal 172-3 232

2526-4 Air Inlet Temperature Sensor voltage below normal 172-4 232

3180-5 Aftertreatment #1 Ignition Transformer Secondary current below normal 4265-5

3180-6 Aftertreatment #1 Ignition Transformer Secondary current above normal 4265-6244

3182-5 Aftertreatment #1 Fuel Injector #1 Heater current below normal 5425-5

3182-6 Aftertreatment #1 Fuel Injector #1 Heater current above normal 5425-6215

3385-3 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage above

normal 3358-3

3385-4 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage below normal 3358-4

3385-13 Engine Exhaust Gas Recirculation Intake Pressure Sensor calibration required 3358-13

3385-21 Engine Exhaust Gas Recirculation Intake Pressure Sensor data drifted low 3358-21

231

3386-3 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage above

normal 412-3

3386-4 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage below normal 412-4

227

(continued)

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(Table 3, contd)


CodeFlashCode

3397-2 DPF #1 Soot Loading Sensor : Erratic, Intermittent, or Incorrect 4783-2

3397-3 DPF #1 Soot Loading Sensor : Voltage Above Normal 4783-3

3397-4 DPF #1 Soot Loading Sensor : Voltage Below Normal 4783-4

3397-9 DPF #1 Soot Loading Sensor abnormal update rate 4783-9

3397-12 DPF #1 Soot Loading Sensor failure 4783-12

3397-13 DPF #1 Soot Loading Sensor calibration required 4783-13

3397-19 DPF #1 Soot Loading Sensor data error 4783-19

3397-21 DPF #1 Soot Loading Sensor data drifted low 4783-21

226

3405-5 Engine Exhaust Gas Recirculation Valve Control current below normal 2791-5

3405-6 Engine Exhaust Gas Recirculation Valve Control current above normal 2791-6228

3407-3 Engine Exhaust Gas Recirculation Valve Position Sensor voltage above normal 27-3

3407-4 Engine Exhaust Gas Recirculation Valve Position Sensor voltage below normal 27-4 229

3427-5 Aftertreatment Fuel Pump Relay current below normal 5423-5 218

3427-6 Aftertreatment Fuel Pump Relay current above normal 5423-6 218

3464-3 DPF #1 Intake Pressure Sensor voltage above normal 3609-3

3464-4 DPF #1 Intake Pressure Sensor voltage below normal 3609-4

3464-13 DPF #1 Intake Pressure Sensor calibration required 3609-13

3464-21 DPF #1 Intake Pressure Sensor data drifted low 3609-21

223

3468-2 Aftertreatment #1 Identification Number Module erratic, intermittent, or incorrect 5576-2 -

3468-8 Aftertreatment #1 Identification Number Module abnormal frequency, pulse

width, or period 5576-8 -

3468-14 Aftertreatment #1 Identification Number Module special instruction 5576-14 -

3511-3 Engine Exhaust Gas Recirculation Outlet Pressure Sensor voltage above

normal 5019-3

3511-4 Engine Exhaust Gas Recirculation Outlet Pressure Sensor voltage below normal 5019-4

3511-13 Engine Exhaust Gas Recirculation Outlet Pressure Sensor calibration required 5019-13

3511-21 Engine Exhaust Gas Recirculation Outlet Pressure Sensor data drifted low 5019-21

247

3514-5 Engine Throttle Actuator Control Command current below normal 3464-5 -

3514-6 Engine Throttle Actuator Control Command current above normal 3464-6 -

3515-3 Engine Throttle Valve Position Sensor voltage above normal 51-3

3515-4 Engine Throttle Valve Position Sensor voltage below normal 51-4

252

Event Codes

E172-1 High Air Filter Restriction - Warning 107-15 151

E232-1 High Fuel/Water Separator Water Level - Warning 97-17 -

E360-1 Low Engine Oil Pressure - Warning 100-17

E360-3 Low Engine Oil Pressure - Shutdown 100-01157

(continued)

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Engine Diagnostics

(Table 3, contd)


CodeFlashCode

E361-1 High Engine Coolant Temperature - Warning 110-15

E361-2 High Engine Coolant Temperature - Derate 110-16

E361-3 High Engine Coolant Temperature - Shutdown 110-0

168

E362-1 Engine Overspeed - Warning 190-15 141

E363-1 High Fuel Supply Temperature - Warning 174-15

E363-2 High Fuel Supply Temperature - Derate 174-16165

E396-2 High Fuel Rail Pressure - Warning 157-16

E398-2 Low Fuel Rail Pressure - Warning 157-18

E499-3 Fuel Rail #1 Pressure Leak - Shutdown 1239-0

159

E539-1 High Intake Manifold Air Temperature - Warning 105-15

E539-2 High Intake Manifold Air Temperature - Derate 105-16133

E593-2 Aftertreatment Insuf ficient Temperature to Complete Regeneration - Derate 3711-31 214

E991-3 DPF Active Regeneration Inhibited Due to Permanent System Lockout -

Shutdown 3715-31 -

E992-3 DPF Active Regeneration Inhibited Due to Temporary System Lockout -

Shutdown 3714-31 -

E995-2 High DPF #1 Soot Loading - Derate 3719-16

E995-3 High DPF #1 Soot Loading - Shutdown 3719-0226

E997-1 High DPF #1 Ash Loading - Warning 3720-15 -

E997-2 High DPF #1 Ash Loading - Derate 3720-16 -

E1008-2 High DPF #1 Intake Temperature - Derate 3242-16 224

E1014-2 Low DPF #1 Intake Temperature - Derate 3242-18 224

E1022-1 Low ARD Fuel Pressure #1 - Warning 3480-17

E1022-2 Low ARD Fuel Pressure #1 - Derate 3480-18219

E1025-2 Aftertreatment #1 Loss of Ignition - Derate 3473-31 244

E1026-2 Aftertreatment #1 Loss of Combustion - Derate 3474-31 -

E1041-2 ARD Air Pressure Control Actuator Not Responding To Command - Derate 3487-7 211

E1044-2 High Intake Manifold Pressure - Derate 102-16

E1045-2 Low Intake Manifold Pressure - Derate 102-18197

E1050-1 High Aftertreatment #1 Fuel Pressure #1 - Warning 3480-15

E1050-2 High Aftertreatment #1 Fuel Pressure #1 - Derate 3480-16

219

E1070-1 Aftertreatment Fuel Injector #1 not responding - Warning 3556-7 -

E1092-1 High Engine Exhaust Gas Recirculation Temperature - Warning 412-15 227

E1092-2 High Engine Exhaust Gas Recirculation Temperature - Derate 412-16 227

E1121-2 Engine Exhaust Gas Recirculation Valve Control Not Responding to Command

- Derate 2791-7 228

E1154-2 Low DPF #1 Intake Pressure - Warning 3609-18

E1156-1 High DPF #1 Intake Pressure - Warning 3609-15223

E1170-2 Low Aftertreatment #1 Secondary Air Pressure - Derate 3837-18 -

(continued)

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(Table 3, contd)


CodeFlashCode

E1264-3 High Pressure Common Rail Fuel Pressure Relief Valve Active - Shutdown 5571-0 159

E1305-1 Initial Assembly Aftertreatment #1 Regeneration Required - Warning 3483-11 -

E1319-2 Engine Exhaust Gas Recirculation Mass Flow Rate Not Responding - Derate 2659-7 -

E2143-3 Low Engine Coolant Level - Shutdown 111-01 169

i03554529

Fault Logging

SMCS Code: 1000; 1900; 1901; 1902

The system provides the capability of Fault Logging.When the Electronic Control Module (ECM)generates an active diagnostic code, the code will be

logged in the memory of the ECM. The codes thathave been logged in the memory of the ECM canbe retrieved with electronic service tools. The codesthat have been logged can be cleared with electronicservice tools. The codes that have been logged in thememory of the ECM will be automatically cleared fromthe memory after 100 hours. The following faults cannot be cleared from the memory of the ECM withoutusing a factory password: overspeed, low engine oilpressure, and high engine coolant temperature.

i03554534

Engine Operation with ActiveDiagnostic Codes

SMCS Code: 1000; 1900; 1901; 1902

If a diagnostic lamp illuminates during normal engine

operation, the system has identifi

ed a situation thatis not within the specification. Use electronic servicetools to check the active diagnostic codes.

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

The active diagnostic code should be investigated.The cause of the problem should be corrected as

soon as possible. If the cause of the active diagnosticcode is repaired and there is only one activediagnostic code, the diagnostic lamp will turn off.

Operation of the engine and performance of theengine can be limited as a result of the activediagnostic code that is generated. Accelerationrates may be significantly slower. Refer to theTroubleshooting Guide for more information on therelationship between these active diagnostic codesand engine performance.

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Engine Diagnostics

i01797063

Engine Operation withIntermittent Diagnostic Codes

SMCS Code: 1000; 1900; 1901; 1902

If a diagnostic lamp illuminates during normal engineoperation and the diagnostic lamp shuts off, anintermittent fault may have occurred. If a fault hasoccurred, the fault will be logged into the memory of the Electronic Control Module (ECM).

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

• Low power

• Limits of the engine speed

• Excessive smoke, etc

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

i03905586

Configuration Parameters

SMCS Code: 1000; 1900; 1901; 1902

The engine electronic control module (ECM) hastwo types of configuration parameters. The systemconfiguration parameters and the customer specifiedparameters.

The electronic service tool is required in order to alter the configuration parameters.

System Configuration Parameters

System configuration parameters affect the emissionsof the engine or the power of the engine. Systemconfiguration parameters are programmed at thefactory. Normally, system configuration parameterswould never require changing through the lifeof the engine. System configuration parametersmust be reprogrammed if an ECM is replaced.System configuration parameters do not requirereprogrammed if the ECM software is changed.Factory passwords are required to change theseparameters.

8/10/2019 C7.1 Engine



Table 4

System Configuration Parameters

Configuration Parameters Record

Engine Serial Number

Delayed Engine Shutdown

Factory Installed Aftertreatment #1 Identification Number

DPF #1 Soot Loading Sensing System Configuration Code

Limp Home Engine Speed Ramp Rate

System Operating Voltage Configuration

Rating Number

CAN Communication Protocol Write Security

Customer Specified Parameters

Customer specified parameters allow the engine tobe configured to the exact needs of the application.

The electronic service tool is required in order to alter the customer configuration parameters.

Customer parameters may be changed repeatedly asoperational requirements change.

Table 5

Customer Specified Parameters

Specified Parameters Record

Throttle Type Channel 1

Throttle Type Channel 2

Continuous Position Throttle Configuration 1

Continuous Position Throttle Configuration 2

Multi Position Throttle Switch Configuration

Throttle Arbitration

Equipment ID

Low Idle Speed

Ether Solenoid Configuration

Engine Idle Shutdown Minimum Ambient Air Temperature

Engine Idle Shutdown Maximum Ambient Air Temperature

Engine Idle Shutdown Enable Status

Engine Idle Shutdown Delay Time

Engine Idle Shutdown Ambient Temperature Override Enable Status

Delayed Engine Shutdown Maximum Time

High Soot Load Aftertreatment Protection Enable Status

Key off regen enable status

Key Off Aftertreatment Regeneration Maximum Time

(continued)

8/10/2019 C7.1 Engine



Engine Diagnostics

(Table 5, contd)

Multiple Engines on J1939

Air Shutoff

ARD Auto Regeneration Enable Status

Throttle Lock Feature Installation Status

PTO Mode

Throttle Lock Engine Set Speed #1

Throttle Lock Engine Set Speed #2

Throttle Lock Increment Speed Ramp Rate

Throttle Lock Decrement Speed Ramp Rate

Throttle Lock Engine Set Speed Increment

Throttle Lock Engine Set Speed Decrement

Monitoring Mode Shutdowns

Monitoring Mode Derates

Limp Home Desired Engine Speed

Engine Acceleration Rate

Engine Speed Decelerating Ramp Rate

Intermediate Engine Speed

Fan

Engine Fan Control

Engine Fan Type Configuration

Engine Cooling Fan Pulley Ratio

Engine Cooling Fan Temperature Error Increasing Hysteresis

Engine Cooling Fan Temperature Error Decreasing Hysteresis

Engine Cooling Fan Current Ramp Rate

Engine Cooling Fan Speed

Top Engine Fan Speed

Minimum Desired Engine Cooling Fan Speed

Engine Cooling Fan Solenoid Minimum Current

Engine Cooling Fan Solenoid Maximum Current

Engine cooling Fan solenoid Dither Frequency

Engine Cooling Fan Solenoid Dither Amplitude

Fan Temperatures

Engine Fan Control Charge Air Cooler Outlet Temperature InputEnable

Engine Cooling Fan Maximum Air Flow Charge Air Cooler OutletTemperature

Engine Cooling Fan Minimum Air Flow Charge Air Cooler OutletTemperature

Engine Cooling Fan Control Coolant Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Coolant Temperature

(continued)

8/10/2019 C7.1 Engine



(Table 5, contd)

Engine Cooling Fan Minimum Air Flow Coolant Temperature

Engine Cooling Fan Control Transmission Oil Temperature InputEnable Status

Engine Cooling Fan Maximum Air Flow Transmission Oil Temperature

Engine Cooling Fan Minimum Air Flow Transmission Oil Temperature

Engine Cooling Fan Control Hydraulic Oil Temperature Input EnableStatus

Engine Cooling Fan Maximum Air Flow Hydraulic Oil Temperature

Engine Cooling Fan Minimum Air Flow Hydraulic Oil Temperature

Engine Cooling Fan Control Auxiliary #1 Temperature Input EnableStatus

Engine Cooling Fan Maximum Air Flow Auxiliary #1 Temperature

Engine Cooling Fan Minimum Air Flow Auxiliary #1 Temperature

Engine Cooling Fan Control Auxiliary #2 Temperature Input Enable

Status

Engine Cooling Fan Maximum Air Flow Auxiliary #2 Temperature

Engine Cooling Fan Minimum Air Flow Auxiliary #2 Temperature

Reversing Fan

Engine Fan Reversing Feature

Engine Fan Reverse Operation Early Termination Enable Status

Engine Fan Manual Purge

Engine Fan Suspend Purge

Engine Fan Purge Cycle Interval

Engine Fan Purge Cycle DurationOther Parameters

Maintenance Indicator Mode

Maintenance Level 1 Cycle Interval Hours

Coolant Level Sensor

Air Filter Restriction Switch Installation Status

Air Filter Restriction Switch Configuration

Fuel/Water Separator Switch Installation Status

User Defined Switch Installation Status

Auxiliary Temperature Sensor Installation Status

Auxiliary Pressure Sensor Installation Status

Engine Overspeed Setpoint

Fuel Filter Differential Pressure Switch Config

Diesel Particulate Filter Regeneration Force/ Inhibit Switch Installation

Diesel Particulate Filter Regeneration Inhibit Indicator Installation

Diesel Particulate Filter Soot Loading Indicator Installation

High Exhaust System Temperature Indicator Installation

Auxiliary Temp #2

(continued)

8/10/2019 C7.1 Engine



Engine Diagnostics

(Table 5, contd)

Remote Torque Speed Control Enable Status

Number of Engine Operating Mode Switches

Engine Operating Mode Configuration

8/10/2019 C7.1 Engine


60 SEBU8600-02Operation SectionEngine Starting

Engine Starting

i03648917


SMCS Code: 1000; 1400; 1450

Perform the required daily maintenance and other periodic maintenance before the engine is started.Inspect the engine compartment. This inspection canhelp prevent major repairs at a later date. Refer to theOperation and Maintenance Manual, “MaintenanceInterval Schedule” for more information.

• Ensure that the engine has an adequate fuelsupply.

• Open the fuel supply valve (if equipped).

NOTICE All valves in the fuel return line must be open and fuelsupply lines must be open. Damage to the fuel systemcan occure if fuel lines are closed with the engine inoperation.

If the engine has not been started for several weeks,fuel may have drained from the fuel system. Air may have entered the fi lter housing. Also, when fuelfilters have been changed, some air pockets will betrapped in the engine. In these instances, prime thefuel system. Refer to the Operation and Maintenance

Manual, “Fuel System - Prime” for more informationon priming the fuel system. Also, check that the fuelspecification is correct and that the fuel conditionis correct. Refer to the Operation and MaintenanceManual, “Fuel Recommendations”.

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

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

• Reset all of the shutoffs or alarm components.

• Ensure that any driven equipment has beendisengaged. Minimize electrical loads or removeany electrical loads.

i02322203

Starting the Engine

SMCS Code: 1000; 1450

Note: Do not ad just the engine speed control duringstart-up. The electronic control module (ECM) willcontrol the engine speed during start-up.

Starting the Engine

1. Disengage any equipment that is driven by theengine.

2. Turn the keyswitch to the RUN position. Leave thekeyswitch in the RUN position until the warninglight for the glow plugs is extinguished.

3. When the warning light for the glow plugs is

extinguished turn the keyswitch to the STARTposition in order to engage the electric startingmotor and crank the engine.

Note: The operating period of the warning light for the glow plugs will change due to the temperatureof the engine.

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

If the engine fails to start within 30 seconds, release

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

4. Allow the keyswitch to return to the RUN positionafter the engine starts.

5. Repeat step 2 through step 4 if the engine failsto start.

i03586430

Cold Weather Starting

SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900


Startability will be improved at temperatures below−18 °C (0 °F) from the use of a jacket water heater or extra battery capacity.

8/10/2019 C7.1 Engine



Engine Starting

When Group 2 diesel fuel is used, the following itemsprovide a means of minimizing starting problemsand fuel problems in cold weather: Engine oil panheaters, jacket water heaters, fuel heaters, andfuel line insulation. For more information, refer toCommercial Diesel Engine Fluids Recommendations

, SEBU6251.

Use the procedure that follows for cold weather starting.

Note: Do not adjust the engine speed control duringstart-up. The electronic control module (ECM) willcontrol the engine speed during start-up.

1. Disengage any driven equipment.

2. Turn the keyswitch to the RUN position. Leave thekeyswitch in the RUN position until the warninglight for the glow plugs is extinguished.

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

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

3. When the warning light for the glow plugs isextinguished turn the keyswitch to the STARTposition in order to engage the electric starting

motor and crank the engine.

Note: The operating period of the warning light for the glow plugs will change due to the temperatureof the engine.

4. Allow the keyswitch to return to the RUN positionafter the engine starts.

5. Repeat step 2 through step 4 if the engine failsto start.

Note: The engine should not be “raced” in order tospeed up the warm up process.

6. Allow the engine to idle for three to five minutes, or allow the engine to idle until the water temperatureindicator begins to rise. When idling after theengine has started in cold weather, increase theengine rpm from 1000 to 1200 rpm. This willwarm up the engine more quickly. Maintainingan elevated low idle speed for extended periodswill be easier with the installation of a handthrottle. Allow the white smoke to disperse beforeproceeding with normal operation.

7. Operate the engine at low load until all systemsreach operating temperature. Check the gaugesduring the warm-up period.

i03653722

Starting with Jump StartCables

SMCS Code: 1000; 1401; 1402; 1900

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

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jump start

cable ends to contact each other or the engine.

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

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

Many batteries which are considered unusable arestill r echargeable. After jump starting, the alternator may not be able to fully recharge batteries thatare severely discharged. The batteries must be

charged to the proper voltage with a battery charger.For information on testing and charging, refer tothe Special Instruction, SEHS7633, “Battery TestProcedure”.

NOTICEUsing a battery source with the same voltage as theelectric starting motor. Use ONLY equal voltage for

jump starting. The use of higher voltage will damagethe electrical system.

Do not reverse the battery cables. The alternator canbe damaged. Attach ground cable last and removefi

rst.

When using an external electrical source to start theengine, turn the generator set control switch to the“OFF” position. Turn all electrical accessories OFF be-fore attaching the jump start cables.

Ensure that the main power switch is in the OFF posi-tion before attaching the jump start cables to the en-gine being started.

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

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62 SEBU8600-02Operation SectionEngine Starting

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

3. Connect one negative end of the jump start cableto the negative cable terminal of the electricalsource. Connect the other negative end of the

jump start cable to the engine block or to thechassis ground. This procedure helps to preventpotential sparks from igniting the combustiblegases that are produced by some batteries.

Note: The engine ECM must be powered before thestarting motor is operated or damage can occur.

4. Start the engine in the normal operating procedure.Refer to this Operation and Maintenance Manual,“Starting the Engine”.

5. Immediately after the engine is started, disconnectthe jump start cables in reverse order.

After jump starting, the alternator may not be able tofully recharge batteries that are severely discharged.The batteries must be replaced or charged to theproper voltage with a battery charger after the engineis stopped. Many batteries which are consideredunusable are still rechargeable. Refer to Operationand Maintenance Manual, “Battery - Replace” andTesting and Adjusting Manual, “Battery - Test”.

Refer to the Electrical Schematic for your engine.

Consult your Caterpillar dealer for more information.

i02330138

After Starting Engine

SMCS Code: 1000

Note: In ambient temperatures from 0 to 60°C(32 to 140°F), the warm-up time is approximatelythree minutes. In temperatures below 0°C (32°F),additional warm-up time may be required.

When the engine idles during warm-up, observe thefollowing conditions:

Do not check the high pressure fuel lines with theengine or the starting motor in operation. If youinspect the engine in operation, always use theproper inspection procedure in order to avoid afluid penetration hazard. Refer to Operation andMaintenance Manual, “General hazard Information”.

• Check for any fluid or for any air leaks at idle rpmand at one-half full rpm (no load on the engine)before operating the engine under load. This is notpossible in some applications.

• Allow the engine to idle for three to five minutes, or allow the engine to idle until the water temperatureindicator begins to rise. Check all gauges duringthe warm-up period.

Note: Gauge readings should be observed andthe data should be recorded frequently while theengine is operating. Comparing the data over time

will help to determine normal readings for eachgauge. Comparing data over time will also helpdetect abnormal operating developments. Significantchanges in the readings should be investigated.

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SEBU8600-02 63Operation SectionEngine Operation

Engine Operation

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Engine Operation

SMCS Code: 1000

Proper oper ation and maintenance are key factorsin obtaining the maximum life and economy of the engine. If the directions in the Operation andMaintenance Manual are followed, costs can beminimized and engine service life can be maximized.

The time that is needed for the engine to reachnormal operating temperature can be less than thetime taken for a walk-around inspection of the engine.

The engine can be operated at the rated rpm after

the engine is started and after the engine reachesoperating temperature. The engine will reach normaloperating temperature sooner during a low enginespeed (rpm) and during a low-power demand. Thisprocedure is more effective than idling the engineat no load. The engine should reach operatingtemperature in a few minutes.

Avoid excess idling. Excessive idling causes carbonbuildup, engine slobber, and soot loading of theDiesel Particulate Filter (DPF). This is harmful to theengine.

Gauge readings should be observed and the data

should be recorded frequently while the engineis operating. Comparing the data over time willhelp to determine normal readings for each gauge.Comparing data over time will also help detectabnormal operating developments. Significantchanges in the readings should be investigated.

Reduction of Particulate Emissions

The Diesel Particulate Filter (DPF) and the Aftertreatment Regeneration Device (ARD) worktogether in order to reduce particulate emissions. TheDPF collects the soot and any ash that is produced by

the combustion in the engine. During regeneration,the soot is converted into a gas which is released intothe atmosphere. The Ash remains in the DPF untilthe ash is cleaned out of the DPF.

The temperature of the DPF must be above aparticular value in order for regeneration to occur.The exhaust gas provides heat for the regenerationprocess. There are two types of regeneration:

Passive Regeneration – Is a chemical reactionwithin the system and the engine provides suf ficientexhaust gas temperature for regeneration.

Active Regener ation – The engines duty cycledoes not provide suf ficient exhaust temperature for passive regeneration. The ARD operates in order toraise the temperature of the exhaust gas. When theregeneration process is complete, the ARD turns off.

The operator will receive information on the status of the ARD from dash lamps and the driver will be ableto request a regeneration by using a switch. Refer tothis Operation and Maintenance Manual, “MonitoringSystem” for more information.

Engine Operation and ActiveRegeneration

Your ARD may perform an active regeneration whileyour engine is at idle. During this active regenerationof the DPF, the engine may operate at idle for periodslonger than 5 minutes.

i04945862

Diesel Particulate Filter Regeneration

SMCS Code: 108F

Regeneration

Regeneration is the removal of soot from the DieselParticulate Filter (DPF). The Caterpillar RegenerationSystem (CRS) is used to regenerate the DPF. TheDPF traps both soot and ash. The ash is removedthrough a cleaning process. Refer to Operation andMaintenance Manual, “Diesel Particulate Filter -Clean/Replace” for more information on the serviceof the DPF.

Regeneration Indicators

Regeneration Active – This indicator willilluminate in order to show that the CRS isactive. This indicator shows that elevated

emission temperatures are possible. This indicator will turn off when regeneration is complete.

DPF – This indicator will illuminate in order to show that a regeneration is needed. Thisindicator will illuminate when the soot level

reaches 90%.

Regeneration Disabled – This indicator will illuminate in order to show that aregeneration has been disabled.

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64 SEBU8600-02Operation SectionEngine Operation

Regeneration Switch

Force Regeneration – Press in the top of the switch for 2 seconds in order to beginregeneration.

Disable Regeneration – Press in thebottom of the switch for 2 seconds in order to disable regeneration.

Note: The MIDDLE position of the regenerationswitch is the default position for automaticregeneration.

Note: You may return to normal operation at anypoint during a regeneration.

Note: To re-enable automatic regeneration, cyclethe engine start switch key or press and hold down

the force regeneration switch for 2 seconds. If thesoot level is above 15%, regeneration will begin if theapplication is at low idle and the engine interlocksare enabled.

Note: If the engine start switch key is cycled while theregeneration system is disabled through the disableregeneration switch, press and hold the disableregeneration switch for 2 seconds to reinitiate thedisable regeneration.

Soot Level Monitoring


The soot level monitor indicates the level of soot thathas accumulated within the DPF. The five marks onthe monitor represent a percentage of soot withinthe DPF. The first mark indicates 0% soot level. Thesecond mark indicates 25% soot level. The middle

mark indicates 50% soot level. The fourth markindicates 75% soot level. The last mark indicates100% soot level. The soot level monitor can be usedto optimize DPF regenerations based upon the workcycle of your application. If application conditions donot allow for an automatic regeneration, a manualregeneration should be performed before the sootlevel gauge indicates 100%.

Modes of Regeneration

Automatic: The engine ECM uses multipleinputs from the engine and the application todetermine the best time to perform an automaticregeneration. Automatic regenerations can take place

throughout the operating cycle of the engine. Theregeneration active indicator will be illuminated whena regeneration is being performed. Interruptions of the regeneration are acceptable. If a regeneration isin progress and needs to be stopped for any reason,it is permissible to press the disable regenerationswitch or turn off the engine.

Note: Automatic adjustments of engine speed maybe noticed during automatic regenerations. If aregeneration is taking place and the engine is takento low idle, the engine speed may remain elevated inorder to maintain the regeneration.

Note: If an automatic regeneration is started while theengine is at low idle and the application is taken backto work, this may stop the regeneration. The engineECM will continue to monitor inputs to determine thebest time to restart the regeneration.

Manual: A manual regeneration is initiated bypressing the force regeneration switch. A manualregeneration is allowed when the soot level is equalto or greater than 15%. The application must bestationary, the engine interlocks must be applied, andthe engine must be at low idle in order to performa manual regeneration.

Disabled: When the regeneration system is indisabled mode, automatic regenerations will not beperformed.

Regeneration System WarningIndicators


Indicator will illuminate when DPF soot load is greater than 90%

Regeneration should be performed as soon aspossible. The operation of the application maynot allow an automatic regeneration to take place.A manual regeneration should be performed assoon as possible.

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SEBU8600-02 65Operation SectionEngine Operation

Indicator will turn off once DPF regeneration hasstarted.

Note: In some situations, the DPF indicator may stayilluminated when the soot load is below 90%. Theilluminated DPF indicator indicates that a complete

regeneration has not been performed. A completeregeneration is when the soot level is reduced to0%. If the DPF indicator stays illuminated, perform aregeneration without interruption until the soot levelis reduced to 0%. A complete regeneration will resetthe DPF indicator.


If the amount of soot collected in the DPF hasreached a level that a regeneration is required, theDPF indicator and an action lamp will illuminate. Stopthe application and apply the engine interlocks. Withthe engine at low idle, initiate a manual regeneration.Engine power will be slightly derated if the applicationcontinues to operate.


After a certain period, if no action is taken toregenerate an action alarm will activate. After 5minutes with the action alarm active, the engine willautomatically be taken to low idle.

A manual regeneration is required at this time. Acomplete regeneration will unlock the forced low idlespeed. Cycling the engine start switch key will unlock

the forced low idle speed.

Once the engine has been in the forced low idlestrategy for approximately 10 minutes, regenerationwill be locked out. At this time, a regeneration canonly be done through the electronic service tool, byan authorized Caterpillar dealer.

After a certain amount of time, engine willautomatically shut down. Engine can be restartedbut will only run for 30 seconds before shutting downagain.

Finally, if the engine is still allowed to run throughmultiple forced engine shutdowns, all types of regenerations are locked out. The DPF must bereplaced. Consult your local Caterpillar dealer if theDPF needs to be replaced.

i01646335

Engaging the DrivenEquipment

SMCS Code: 1000

1. Operate the engine at one-half of the rated rpm,when possible.

2. Engage the driven equipment without a load onthe equipment, when possible.

Interrupted starts put excessive stress on the drivetrain. Interrupted starts also waste fuel. To get thedriven equipment in motion, engage the clutchsmoothly with no load on the equipment. Thismethod should produce a start that is smooth andeasy. The engine rpm should not increase and theclutch should not slip.

3. Ensure that the ranges of the gauges are normalwhen the engine is operating at one-half of the rated rpm. Ensure that all gauges operateproperly.

4. Increase the engine rpm to the rated rpm. Always

increase the engine rpm to the rated rpm beforethe load is applied.

5. Apply the load. Begin operating the engine at lowload. Check the gauges and equipment for proper oper ation. After normal oil pressure is reachedand the temperature gauge begins to move,the engine may be operated at full load. Checkthe gauges and equipment frequently when theengine is operated under load.

Extended operation at low idle or at reduced loadmay cause increased oil consumption and carbonbuildup in the cylinders. This carbon buildup

results in a loss of power and/or poor performance.

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66 SEBU8600-02Operation SectionEngine Operation

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Fuel Conservation Practices

SMCS Code: 1000; 1250

The ef fi

ciency of the engine can affect the fueleconomy. Caterpillar's design and technology inmanufacturing provides maximum fuel ef ficiency inall applications. Follow the recommended proceduresin order to attain optimum performance for the lifeof the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuelmay over flow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed.

• Be aware of the properties of the different fuels.

Use only the recommended fuels. Refer to theOperations and Maintenance Manual, “FuelRecommendations”for further information.

• Avoid unnecessary idling.

Shut off the engine rather than idle for long periods of time.

• Observe the service indicator frequently. Keep theair cleaner elements clean.

• Ensure that the turbocharger is operating correctly.For mor e information refer to this Operation and

Maintenance Manual, “Turbocharger - Inspect”.

• Maintain a good electrical system.

One faulty battery cell will overwork the alternator.This f ault will consume excess power and excessfuel.

• The belt should be in good condition. Refer to theSystems Operation, Testing and Adjusting, “V -Belt Test” for further information.

• Ensure that all of the connections of the hoses aretight. The connections should not leak.

• Ensure that the driven equipment is in goodworking order.

• Cold engines consume excess fuel. Utilize heatfrom the jacket water system and the exhaustsystem, when possible. Keep cooling systemcomponents clean and keep cooling systemcomponents in good repair. Never operate theengine without water temperature regulators.

All of these items will help maintain operatingtemperatures.

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Engine Stopping

Engine Stopping

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Stopping the Engine

SMCS Code: 1000; 7000

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

Avoid accelerating the engine prior to shutting it down.

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

Note: Individual applications will have differentcontrol systems. Ensure that the shutoff proceduresare understood. Use the following general guidelinesin order to stop the engine.

1. Remove the load from the engine. Reduce theengine speed (rpm) to low idle. Allow the engineto idle for five minutes in order to cool the engine.

2. Stop the engine after the cool down periodaccording to the shutoff system on the engine andturn the ignition key switch to the OFF position.If necessary, refer to the instructions that areprovided by the OEM.

i03554860

Emergency Stopping

SMCS Code: 1000; 7418

NOTICEEmergency shutoff controls are for EMERGENCY useONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure.

Ensure that any components for the external systemthat support the engine operation are secured after the engine is stopped.

Emergency Stop Button


Typical emergency stop button

The emergency stop button is in the OUT position for normal engine operation. Push the emergency stopbutton. The engine will not start when the button islocked. Turn the button clockwise in order to reset.

Refer to Operation and Maintenance Manual,“Features and Controls” for the location and theoperation of the emergency stop button.

i03648931

After Stopping Engine

SMCS Code: 1000

Note: Before you check the engine oil, do not operatethe engine for at least 10 minutes in order to allowthe engine oil to return to the oil pan.

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68 SEBU8600-02Operation SectionEngine Stopping


• After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure tobe purged from the high pressure fuel lines beforeany service or repair is performed on the enginefuel lines. If necessary, perform minor adjustments.Repair any leaks from the low pressure fuelsystem and from the cooling, lubrication or air systems. Replace any high pressure fuel line thathas leaked. Refer to Disassembly and assemblyManual, “Fuel Injection Lines - Install”.

• Check the crankcase oil level. Maintain the oil levelbetween the “MIN” mark and the “MAX” mark onthe engine oil level gauge.

• If the engine is equipped with a service hour meter,note the reading. Perform the maintenance thatis in the Operation and Maintenance Manual,“Maintenance Interval Schedule”.

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

NOTICEOnly use antifreeze/coolant mixtures recommended inthe Refill Capacities and Recommendations topic thatis in this Operation and Maintenance Manual. Failureto do so can cause engine damage.

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-

sur e.

• Allow the engine to cool. Check the coolant level.

• Check the coolant for correct antifreeze protectionand the correct corrosion protection. Add thecorrect coolant/water mixture, if necessary.

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

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Cold Weather Operation


i04224330


SMCS Code: 1000; 1250

Caterpillar Diesel Engines can operate effectively incold weather. During cold weather, the starting andthe operation of the diesel engine is dependent onthe following items:

• The type of fuel that is used

• The viscosity of the engine oil

• The operation of the glow plugs

• Optional Cold starting aid

• Battery condition

Refer to Special Publication, SEBU5898, “ColdWeather Recommendations for Caterpillar Machines”.

This section will cover the following information:

• Potential problems that are caused by cold-weather operation

• Suggest steps which can be taken in order to

minimize starting problems and operating problemswhen the ambient air temperature is between“0° to −40 °C (32° to -40 °F)”.

The operation and maintenance of an engine infreezing temperatures is complex . This complexity isbecause of the following conditions:

• Weather conditions

• Engine applications

Recommendations from your Caterpillar dealer arebased on past proven practices. The information that

is contained in this section provides guidelines for cold-weather operation.

Hints for Cold Weather Operation

• If the engine will start, operate the engine until aminimum operating temperature of 80° C (176° F)is achieved. Achieving operating temperature willhelp prevent the intake valves and exhaust valvesfrom sticking.

• The cooling system and the lubrication systemfor the engine do not lose heat immediately uponshutdown. This means that an engine can be shutdown for a period and the engine can still startreadily.

• Install the correct specification of engine lubricantbefore the beginning of cold weather.

• Check all rubber parts (hoses, fan drive belts)weekly.

• Check all electrical wiring and connections for anyfraying or damaged insulation.

• Keep all batteries fully charged and warm.

• Fill the fuel tank at the end of each shift.

• Drain the water from the fuel system. Refer to this

Operation and Maintenance Manual, “Fuel SystemPrimary Filter/Water Separator - Drain”.

• Check the air cleaners and the air intake daily.Check the air intake more often when you operatein snow.

• Ensure that the glow plugs are in working order.Refer to Troubleshooting , “Glow Plug Starting Aid- Test”.

Personal injury or property damage can resultfrom alcohol or starting fluids.

Alcohol or startingfluids are highlyflammable andtoxic and if improperlystored could result in injuryor property damage.


• For jump starting with cables in cold weather,refer to the Operation and Maintenance Manual,“Starting with Jump Start Cables.” for instructions.

Viscosity of the Engine LubricationOil

Correct engine oil viscosity is essential. Oil viscosityaffects the amount of torque that is needed tocrank the engine. Refer to this Operation andMaintenance Manual, “Fluid Recommendations” for the recommended viscosity of oil.

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70 SEBU8600-02Operation SectionCold Weather Operation

Recommendations for the Coolant

Provide cooling system protection for the lowestexpected outside temperature. Refer to this Operationand Maintenance Manual, “Fluid Recommendations”for the recommended coolant mixture.

In cold weather, check the coolant often for thecorrect glycol concentration in order to ensureadequate freeze protection.

Engine Block Heaters

Engine block heaters (if equipped) heat theengine jacket water that surrounds the combustionchambers. This heat provides the following functions:

• Startability is improved.

• Warm up time is reduced.

An electric block heater can be activated once theengine is stopped. A block heater can be 110V dcor 240V dc. The output can be 750/1000W. Consultyour Caterpillar dealer for more information.

Idling the Engine

When idling after the engine is started in coldweather, increase the engine rpm from 1000 to1200 rpm. This increase in RPM will warm up theengine more quickly. Maintaining an elevated low idlespeed for extended periods will be easier with the

installation of a hand throttle. The engine should notbe “raced” in order to speed up the warm-up process.

While the engine is idling, the application of a lightload (parasitic load) will assist in achieving theminimum operating temperature. The minimumoperating temperature is 80° C (176° F).

Recommendations for CoolantWarm Up

Warm up an engine that has cooled below normaloperating temperatures due to inactivity. This

procedure should be performed before the engine isreturned to full operation. During operation in verycold temperature conditions, damage to enginevalve mechanisms can result from engine operationfor short intervals. This damage can happen if theengine is started and the engine is stopped manytimes without being operated in order to warm upcompletely.

When the engine is operated below normal operatingtemperatures, fuel and oil are not completely burnedin the combustion chamber. This fuel and oil causessoft carbon deposits to form on the valve stems.Generally, the deposits do not cause problems andthe deposits are burned off during operation at

normal engine operating temperatures.

When the engine is started and the engine is stoppedmany times without being operated in order to warmup completely, the carbon deposits become thicker.This carbon can cause the following problems:

• Free operation of the valves is prevented.

• Valves become stuck.

• Pushrods may become bent.

• Other damage to valve train components can

result.

For this reason, when the engine is started,the engine must be operated until the coolanttemperature is 80° C (176° F) minimum. Carbondeposits on the valve stems will be kept at a minimumand the free operation of the valves and the valvecomponents will be maintained.

The engine must be thoroughly warmed in order tokeep other engine parts in better condition. Also, theservice life of the engine will be generally extended.Lubrication will be improved. There will be less acidand less sludge in the oil. This improvement will

provide longer service life for the engine bearings,the piston rings, and other parts. However, limitunnecessary idle time to 10 minutes in order toreduce wear and unnecessary fuel consumption.

The Water Temperature Regulator andInsulated Heater Lines

The engine is equipped with a water temperatureregulator. When the engine coolant is below thecorrect operating temperature, jacket water circulatesthrough the engine cylinder block and into theengine cylinder head. The coolant then returns to the

cylinder block via an internal passage that bypassesthe valve of the coolant temperature regulator. Thisensures that coolant flows around the engine under cold operating conditions. The water temperatureregulator begins to open when the engine jacketwater has reached the correct minimum operatingtemperature. As the jacket water coolant temperaturerises above the minimum operating temperature thewater temperature regulator opens further allowingmore coolant through the radiator to dissipate excessheat.

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The progressive opening of the water temperatureregulator operates the progressive closing of thebypass passage between the cylinder block andhead. This process ensures maximum coolant flowto the radiator in order to achieve maximum heatdissipation.

Note: Do not restrict the air flow. Restriction to theair flow can damage the fuel system. Caterpillar strongly discourages the use of all air flow restrictiondevices such as radiator shutters. Restriction of theair flow can result in the following: high exhausttemperatur es, power loss, excessive fan usage, andreduction in fuel economy.

A cab heater is beneficial in very cold weather. Thefeed from the engine and the return lines from thecab should be insulated in order to reduce heat lossto the outside air.

Insulating the Air Inlet and EngineCompartment

When temperatures below −18 °C (−0 °F) will befrequently encountered, an air cleaner inlet thatis located in the engine compartment may bespecified. An air cleaner that is located in the enginecompartment may also minimize the entry of snowinto the air cleaner. Also, heat that is rejected by theengine helps to warm the intake air.

Additional heat can be retained around the engine byinsulating the engine compartment.

Recommendation for Crankcase Breather

Protection

Crankcase ventilation gases contain a large quantityof water vapor. This water vapor can freeze incold ambient conditions and can plug or damagethe crankcase ventilation system. If the engine isoperated in temperatures below −25° C (−13° F),measures must be taken to prevent freezing andplugging of the breather system. Insulated hoses anda heated canister assembly should be installed.

Consult with your Caterpillar dealer for therecommended breather components for operationfrom −25° to -40°C (−13° to -40.°F).

i04156663

Radiator Restrictions

SMCS Code: 1353; 1396

Caterpillar discourages the use of air fl

ow restrictiondevices that are mounted in front of radiators. Air flowrestriction can cause the following conditions:

• High exhaust temperatures

• Power loss

• Excessive fan usage

• Reduction in fuel economy

Reducing air flow over components will alsoaffect under hood temperatures. Reducing air

flow can increase surface temperatures duringan aftertreatment regeneration and could affectcomponent reliability.

Reducing air flow can increase surface temperaturesduring an aftertreatment regeneration and couldaffect component reliability.

If an air flow restriction device must be used, thedevice should have a permanent opening directlyin line with the fan hub. The device must have aminimum opening dimension of at least 770 cm2

(120 in2).

A centered opening that is directly in line with the fanhub is specified in order to prevent an interruptedair flow on the fan blades. Interrupted air flow on thefan blades could cause a fan failure.

Cater pillar recommends a warning device for theinlet manifold temperature and/or the installation of an inlet air temperature gauge. The warning devicefor the inlet manifold temperature should be set at75 °C (167 °F). The inlet manifold air temperatureshould not exceed 75 °C (167 °F). Temperatures thatexceed this limit can cause power loss and potentialengine damage.

i02237624

Fuel and the Effect from ColdWeather

SMCS Code: 1000; 1250

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

• No. 1

• No. 2

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72 SEBU8600-02Operation SectionCold Weather Operation

• Blend of No. 1 and No. 2

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

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

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

• Lower cloud point

• Lower pour point

• Lower rating of kJ (BTU) per unit volume of fuel

When No. 1 diesel fuel is used, a decrease in power and in fuel ef ficiency may be noticed. Other operatingeffects should not be experienced.

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

Be awar e of these values when diesel fuel is

purchased. Anticipate the average ambienttemperature of the area. Engines that are fueled inone climate may not operate well if the engines aremoved to another climate. Problems can result dueto changes in temperature.

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

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

• Starting aids

• Engine oil pan heaters

• Engine coolant heaters

• Fuel heaters

• Fuel line insulation

For more information on cold weather operation,see Special Publication, SEBU5898, “Cold Weather Recommendations”.

i04004437

Fuel Related Components inCold Weather

SMCS Code: 1000; 1250

Fuel Tanks

Condensation can form in partially filled fuel tanks.Top off the fuel tanks after you operate the engine.

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

Some fuel tanks use supply lines that take fuel

directly from the bottom of the tank. If the engine isequipped with this system, regular maintenance of the fuel system fi lter is important.

Drain the water and sediment from any fuel storagetank at the following intervals: weekly, serviceintervals, and refueling of the fuel tank. Thisprocedure will help prevent water and/or sedimentfrom being pumped from the fuel storage tank andinto the engine fuel tank.

Fuel Filters

After you change the fuel fi lter, always prime the fuelsystem in order to remove air bubbles from the fuelsystem. Refer to the Operation and MaintenanceManual in the Maintenance Section for moreinformation on priming the fuel system.

The micron rating and the location of a primary fuelfilter is important in cold-weather operation. Theprimary fuel filter and the fuel supply line are the mostcommon components that are affected by cold fuel.

NOTICEIn or der to maximize fuel system life and preventpremature wear out from abrasive particles in the

fuel, a four micron[c] absolute high ef ficiency fuel filter is r equired for all Caterpillar Electronic Unit Injectors.Caterpillar High Ef ficiency Fuel Filters meet theserequirements. Consult your Caterpillar dealer for thepr oper part numbers.

Fuel Heaters

Fuel heaters help to prevent fuel filters from pluggingin cold weather due to waxing. A fuel heater shouldbe installed in the fuel system before the primaryfuel filter.

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For further inf ormation on fuel heaters, consult your Caterpillar dealer.

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74 SEBU8600-02Maintenance SectionRefill Capacities

Maintenance Section

Refill Capacities

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Refill Capacities andRecommendations

SMCS Code: 1348; 1395; 7560

Engine Oil

NOTICEThese recommendations are subject to change with-out notice. Contact your local Caterpillar dealer for the

most up-to-date fluids recommendations.

• EMA ___ _________ Engine Manufacturers Association

• API _____________________ American Petroleum Institute

• SAE ___________________________________________ Society Of Automotive Engineers Inc.

• DEO-ULS _______________________________________ DieselEngine Oil-Ultra Low Sulfur

Cat DEO-ULS

Cat DEO-ULS is developed and tested in order to provide superior protection and life for your Caterpillar engines.

• Better Detergents

• Advanced Additive Package

• Enhanced Dispersants

• Improved Protection from Thermal breakdown andOxidation Breakdown

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

• Cat DEO-ULS (SAE 10W-30)

• Cat DEO-ULS (SAE 15W-40)

Cat DEO-ULS Multigrade oil is available in variousviscosity grades that include SAE 10W-30 and SAE15W-40. To choose the correct viscosity grade for theambient temperature, see illustration 45. Multigradeoils provide the correct viscosity for a broad rangeof operating temperatures. Multigrade oils are also

effective in maintaining low oil consumption and lowlevels of piston deposits.

Consult your Caterpillar dealer for part numbers andfor available sizes of containers.

Note: Cat DEO-ULS in SAE 15W-40 passes thefollowing proprietary tests: sticking of the piston ring,oil control tests, wear tests, and soot tests. Proprietarytests help ensure that Caterpillar multigrade oilprovides superior performance in Caterpillar DieselEngines. In addition, Cat DEO-ULS Multigrade oilexceeds many of the performance requirements of other manufacturers of diesel engines. Therefore,

this oil is an excellent choice for many mixed fleets.True high performance oil is produced with acombination of the following factors: industrystandard tests, proprietary tests, field tests,and prior experience with similar formulations.The design and the development of Caterpillar lubricants that are both high performance andhigh quality are based on these factors.

Commercial Oils

Note: Non-Caterpillar commercial oils are secondchoice oils.

NOTICECater pillar require the use of the following specifica-tion of engine oil. Failure to use the appropriate spec-ification of engine oil will reduce the life of your en-gine. Failure to use the correct specification of enginewill also reduce the life and the effectiveness of your aftertreatment system.

Table 6

API Classifications for the Industrial Engine

Oil Specification

ECF-3CJ-4 AECA E9

NOTICEFailure to follow these oil recommendations can causeshortened engine service life due to deposits and/or excessive wear.

Note: Refer to Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engine FluidsRecommendations” for additional information thatrelates to lubrication for your engine.

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SEBU8600-02 75Maintenance Section

Refill Capacities

Lubricant Viscosity Recommendations

The proper SAE viscosity grade of oil is determinedby the minimum ambient temperature duringcold engine start-up, and the maximum ambienttemperature during engine operation.

Refer to illustration 45 (minimum temperature) inorder to determine the required oil viscosity for starting a cold engine.

Refer to illustration 45 (maximum temperature) inorder to select the oil viscosity for engine operation atthe highest ambient temperature that is anticipated.

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

If ambient temperature conditions at engine start-up

require the use of multigrade SAE 0W oil, SAE0W-40 viscosity grade is preferred over SAE 0W-20or SAE 0W-30.


Supplemental heat is recommended for cold soaked starts belowthe minimum ambient temperature. Supplemental heat may berequired for cold soaked starts that are above the minimumtemperature that is stated, depending on the parasitic load andother factors. Cold soaked starts occur when the engine has notbeen operated for a period of time. This will allow the oil to becomemore viscous due to cooler ambient temperatures.

S·O·S Oil Analysis

Caterpillar has developed a tool for maintenancemanagement that evaluates oil degradation and thetool also detects the early signs of wear on internalcomponents. The Caterpillar tool for oil analysis iscalled S·O·S Oil Analysis and the tool is part of theS·O·S Services program. S·O·S Oil Analysis dividesoil analysis into three categories:

• Wear Analysis

• Oil condition

• Additional tests

The wear analysis monitors metal particles, some oiladditives, and some contaminants.

Oil condition uses infrared (IR) analysis to evaluatethe chemistry of the oil. Infrared analysis is also usedto detect certain types of contamination.

Additional tests are used to measure contaminationlevels from water, fuel, or coolant. Oil viscosity andcorrosion protection can be evaluated, as needed.

Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations”or contact your local Caterpillar dealer for additional

information concerning the S·O·S Oil Analysisprogram.

Lubrication System

The refill capacities for the engine crankcase reflectthe approximate capacity of the crankcase or sumpplus standard oil filters. Auxiliary oil fi lter systems willrequire additional oil. Refer to the OEM specificationsin order to find the capacity of the auxiliary oil fi lter.

Table 7

Engine

Refi

ll CapacitiesCompartmentor System

Minimum Maximum

Crankcase OilSump(1)

13.5 L (14.3 qt) 16.5 L (17.4 qt)

(1) These values are the approximate capacities for the crankcaseoil sump (aluminum) which includes the standard factoryinstalled oil fi lters. Engines with auxiliary oil fi lters will requireadditional oil. Refer to the OEM specifications for the capacityof the auxiliary oil fi lter. The design of the oil pan can changethe oil capacity of the oil pan.

Lubricating Grease

Caterpillar provides a range of moderate greasesto extremely high performance greases in order toservice the entire line of Caterpillar products thatoperate throughout the wide variety of climates. Youwill always be able to find a grease that will meetyour machines requirements for a certain application.Caterpillar grease products often exceed Caterpillar specifications.

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Before selecting a grease products for anyapplication, the performance requirements must bedetermined. Consult the grease recommendationsthat are made by the OEM for the equipment whenthe equipment is operated in the expected conditions.Then, consult with your Caterpillar dealer for a list of

greases and the following related characteristics.

• Performance specifications

• Available sizes of containers

• Part number s

Always choose a grease that meets therecommendations that are specified by theequipment manufacturer for the application, or choose a grease that exceeds the recommendationsthat are specified by the equipment manufacturer for the application.

If it is necessary to choose a single grease for useon all of the equipment at one site, always choosea grease that meets the requirements of the mostdemanding application. A product that barely meetsthe minimum performance requirements will shortenthe life of the part. Use the grease that yields the leasttotal operating cost. Base this cost on an analysisthat includes the costs of the parts, the labor, thedowntime, and the cost of the grease that is used.

Some greases are not chemically compatible.Consult your supplier in order to determine if two or more gr eases are compatible.

Purge the grease from a joint at the following times:

• Switching from one grease to another grease

• Switching from one supplier to another supplier

Note: All Caterpillar brand name greases arecompatible with each other.

Note: Refer to Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engine FluidsRecommendations” for additional information thatrelates to lubrication for your engine.

Fuel

Refer to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations”for the Caterpillar Specification for distillate fuel andfor additional information that relates to fuel for your engine.

Ultra low Sulfur Diesel (ULSD)

Your Caterpillar Diesel Engine must use ultralow sulfur diesel fuel. This fuel complies with theemissions regulations that are prescribed by theEnvironmental Protection Agency of the UnitedStates.

Engines that are manufactured by Caterpillar arecertified with the fuel that is prescribed by the UnitedStates Environmental Protection Agency. Enginesthat are manufactured by Caterpillar are certifiedwith the fuel that is prescribed by the EuropeanCertification. Caterpillar does not certify dieselengines on any other fuel.

Note: The owner and the operator of the engine hasthe responsibility of using the fuel that is prescribedby the United States Environmental Protection

Agency and other appropriate regulatory agencies.

Fuel tank inlet labels are installed in order to ensure

that the correct fuels are used. Illustration 46 is anexample of one of the labels designs that will beinstalled.


Typical example

Fuel Additives

Many types of fuel additives are available. Caterpillar does not generally recommend the use of fueladditives.

In special circumstances, Caterpillar recognizes theneed for fuel additives. Fuel additives need to be usedwith caution. The additive may not be compatible withthe fuel. Some additives may precipitate. This actioncauses deposits in the fuel system. The deposits maycause seizure. Some additives may be corrosive andsome additives may be harmful to the elastomersin the fuel system.

Some additives may damage emission controlsystems. Some additives may cause the amount of sulfur in the fuel to be greater than 15 ppm.

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Refill Capacities

Contact your fuel supplier for those circumstanceswhen fuel additives are required. Your fuel supplier can recommend the best additives for your application and for the proper level of treatment.

Note: For the best results, your fuel supplier should

treat the fuel when additives are necessary.

Coolant

The following two coolants are used in Caterpillar diesel engines:

Preferred – Cat ELC (Extended Life Coolant) or a commercial extended life coolant that meets theCaterpillar EC-1 specification

Acceptable – A Cat DEAC (Diesel Engine Antifreeze/Coolant) or a commercial heavy-duty

antifreeze that meets “ASTM D6210” specifi

cations

NOTICEThe Caterpillar industrial engine must be operatedwith a 1:1 mixture of water and glycol. This con-centration allows the NOx reduction system to op-erate correctly at high ambient temperatures.

NOTICEDo not use a commercial coolant/antifreeze that onlymeets the ASTM “D3306” or equivalent specification.This type of coolant/antifreeze is made for light dutyautomotive applications.

Use only the coolant/antifreeze that is recommended.

Caterpillar recommends a 1:1 mixture of water andglycol. This mixture of water and glycol will provideoptimum heavy-duty performance as an antifreeze.

Note: Cat DEAC does not require a treatment withan SCA at the initial fill. Commercial heavy-dutyantifreeze that meets “ASTM D6210” specificationsMAY require a treatment with an SCA at the initial fill.Read the label or the instructions that are providedby the OEM of the product.

In stationary engine applications that do notrequire anti-boil protection or freeze protection, amixture of SCA and water is acceptable. Caterpillar recommends a 6 percent to 8 percent concentrationof SCA in those cooling systems. Distilled water or deionized water is preferred. Water which has therecommended properties may be used.

Table 8

Coolant Service Life

Coolant Type Service Life (1)

Cat ELC 12000 Service Hours or

Six Years(2)

Commercial coolant thatmeets the Caterpillar

EC-1 Specification

6000 Service Hours or Six Years(3)

Cat DEAC 3000 Service Hours or

Three Years

Commercial Heavy-DutyCoolant/Antifreeze thatmeets “ASTM D6210”

3000 Service Hours or Two Years

(1) Use the interval that occurs first. The cooling system mustalso be flushed out at this time.

(2) Cat ELC Extender must be added at 6000 service hours or onehalf of the service life of the Cat ELC. Refer to your machineOperation and Maintenance Manual for exceptions.

(3) An ex tender must be a dded at 3000 serv ice hours or one half of the service life of the coolant.

Note: Refer to Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engine FluidsRecommendations” for additional information thatrelates to coolant for your engine.

S·O·S Coolant Analysis

Table 9

Recommended Interval

Type of Coolant Level 1 Level 2

DEAC Every 250 Hours

(1) Yearly(1)

ELC Optional (1) Yearly

(1) The Level 2 Coolant Analysis should be performed sooner if aproblem is identified by a Level 1 Coolant Analysis.

S·O·S Coolant Analysis (Level 1)

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

The following properties of the coolant are tested:

• Glycol concentration for freeze protection and boilprotection

• Ability to protect from erosion and corrosion

• pH

• Conductivity

• Visual analysis

• Odor analysis

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The results are reported, and appropriaterecommendations are made.

Refer to the Maintenance Interval Schedule in thisOperation and Maintenance Manual in order to findthe maintenance interval for collecting the coolant

samples.


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

The S·O·S Coolant Analysis has the followingfeatures:

• Full coolant analysis (Level 1)

• Identification of the source of metal corrosion andof contaminants

• Water hardness

• Identification of buildup of the impurities that causecorrosion

• Identification of buildup of the impurities that causescaling

The results are reported, and appropriaterecommendations are made.

Refer to the Maintenance Interval Schedule inthis Operation and Maintenance Manual, “CoolingSystem Coolant Sample (Level 2) - Obtain” for the maintenance interval for collecting the coolantsamples.

Testing the engine coolant is important to ensure thatthe engine is protected from internal cavitation andfrom corrosion. The analysis also tests the ability of the coolant to protect the engine from boiling andfrom freezing. The S·O·S Coolant Analysis can bedone at your Caterpillar dealer. Caterpillar S·O·SCoolant Analysis is the best way to monitor thecondition of your coolant and your cooling system.

S·O·S Coolant Analysis is a program that is basedon periodic samples.

Ref er to Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Recommendations”for additional information.

Refill Capacity

Table 10

EngineRefill Capacities

Compartment or System Liters

Engine Only 15 L

(3.96 US gal)

External System Per OEM(1)

(1) The External System includes a radiator or an expansiontank with the following components: heat exchanger andpiping. Refer to the OEM specifications. Enter the value for thecapacity of the External System in this row.

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Maintenance Recommendations

MaintenanceRecommendations

i03648938

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

Coolant System

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

The engine can have the ability to auto start. Ensurethat the power supply is isolated before any serviceor repair is performed.

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

Fuel System

To relieve the pressure from the fuel system, turn off

the engine.



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

This is because of the following differences:

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

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

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

1. Stop the engine.

2. Wait for 10 minutes.

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

Engine Oil

To relieve pressure from the lubricating system, turnoff the engine.

i04103075

Welding on Engines with

Electronic ControlsSMCS Code: 1000

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

Proper welding procedures are necessary in order to avoid damage to the engines ECM, sensors, andassociated components. When possible, remove

the component from the unit and then weld thecomponent. If removal of the component is notpossible, the following procedure must be followedwhen you weld on a unit equipped with an ElectronicEngine. The following procedure is considered to bethe safest procedure to weld on a component. Thisprocedure should provide a minimum risk of damageto electronic components.

NOTICEDo not ground the welder to electrical componentssuch as the ECM or sensors. Improper grounding cancause damage to the drive train bearings, hydraulic

components, electrical components, and other com-ponents.

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

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

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

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80 SEBU8600-02Maintenance SectionMaintenance Recommendations

2. Ensure that the fuel supply to the engine is turnedoff.

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

4. Disconnect all electronic components fromthe wiring harnesses. Include the followingcomponents:

• Electronic components for the driven equipment

• ECM

• Sensors

• Electronically controlled valves

• Relays

• Aftertreatment ID module

NOTICEDo not use electrical components (ECM or ECM sen-sors) or electronic component grounding points for grounding the welder.


Use the example above. The current flow from the welder tothe ground clamp of the welder will not damage any associatedcomponents.

(1) Engine(2) Welding electrode

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

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

5. Connect the welding ground cable directly tothe part that will be welded. Place the groundcable as close as possible to the weld in order toreduce the possibility of welding current damageto the following components. Bearings, hydraulic

components, electrical components, and groundstraps.

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

6. Pr otect the wiring harness from welding debrisand spatter.

7. Use standard welding practices to weld thematerials.

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Maintenance Interval Schedule

i04946918

Maintenance Interval Schedule

SMCS Code: 1000; 7500

When RequiredBattery - Replace .................................................. 84Battery or Battery Cable - Disconnect .................. 85Engine - Clean ...................................................... 97Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 97Engine Air Cleaner Element (Single Element) -

Inspect/Replace ................................................ 100Engine Air Cleaner Element (Single Element) -

Replace ............................................................. 101Fuel System - Prime ............................................ 111Severe Service Application - Check ................... 121

DailyCooling System Coolant Level - Check ................ 92Driven Equipment - Check .................................... 96Engine Air Cleaner Service Indicator - Inspect ... 101Engine Air Precleaner - Check/Clean ................. 102Engine Oil Level - Check .................................... 106Fuel System Primary Filter/Water Separator -

Drain .................................................................. 114Walk-Ar ound Inspection ...................................... 124

Every Week

Hoses and Clamps - Inspect/Replace ................. 116

Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................ 116

Every 250 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ................................................................. 93

Engine Oil Sample - Obtain ................................ 106

Ever y 500 Service Hours

Belt - Inspect ......................................................... 86Engine Oil and Filter - Change ........................... 107

Fan Clearance - Check ....................................... 109Fuel Filter (In-Line) - Replace .............................. 110

Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 85Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 94Crankshaft Vibration Damper - Inspect ................. 95Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 97Engine Air Cleaner Element (Single Element) -

Inspect/Replace ................................................ 100

Engine Air Cleaner Element (Single Element) -Replace ............................................................. 101

Fuel System Primary Filter (Water Separator)Element - Replace ............................................. 112

Fuel System Secondary Filter - Replace ............. 114Radiator - Clean .................................................. 120


Alternator - Inspect ............................................... 84Belt Tensioner - Inspect ........................................ 86Water Pump - Inspect ......................................... 125


Engine Crankcase Breather Element - Replace .. 102


Aftercooler Core - Inspect ..................................... 83

Engine Mounts - Inspect ..................................... 105Starting Motor - Inspect ...................................... 122Turbocharger - Inspect ........................................ 122

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ................................................................. 94


Alternator and Fan Belts - Replace ....................... 84Radiator Pressure Cap - Clean/Replace ............ 121

Every 3000 Service Hours or 2 Years

Cooling System Coolant (DEAC) - Change .......... 87


After cooler Core - Clean/Test ............................... 83


ARD Spark Plug - Clean/Inspect/Replace ............ 83


Diesel Particulate Filter - Clean ............................ 96

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 91

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 89

Overhaul

Overhaul Considerations ..................................... 117

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82 SEBU8600-02Maintenance SectionMaintenance Interval Schedule

Commissioning

Fan Clearance - Check ....................................... 109

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ARD Spark Plug - Clean/Inspect/Replace

i03907823

ARD Spark Plug -Clean/Inspect/Replace

SMCS Code: 1555-040; 1555-070; 1555-510

• ARD Aftertreatment Regeneration Device

NOTICEIf the engine is running, or the keyswitch is in the ONposition the ARD spark plug will continue to fire. Turnthe keyswitch to the OFF position before servicing the

ARD spark plug.


1. Ensure that the power is in the “OFF” position andthe engine has stopped. Remove any dirt or debrisfrom the area around the spark plug. Remove wireharness (2) from spark plug (1).

2. Use a 342-9516 Socket in order to remove thespark plug. Loosen the spark plug and use thesocket to remove the spark plug by hand in order to detect problems with the threads. Discard the

spark plug.


3. Use 305-2389 Plug Bore Brush in order to cleanthe ground electrode (3).

4. Install the new spark plug by hand. Tighten thespark plug to a torque of 47 N·m (34 lb ft).

5. Connect the wiring harness (2).

i01807350

Aftercooler Core - Clean/Test(Air-To-Air Aftercooler)

SMCS Code: 1064-070; 1064-081

The air-to-air aftercooler is OEM installed in manyapplications. Please refer to the OEM specificationsfor information that is related to the aftercooler.

i04380914

Aftercooler Core - Inspect

SMCS Code: 1064-040

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

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

For air-to-air aftercoolers, use the same methods thatare used for cleaning radiators.

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84 SEBU8600-02Maintenance Section

Alternator - Inspect

Personal injury can result from air pressure.

Personal injury can result without following prop-er procedure. When using pressure air, wear a pro-tective face shield and protective clothing.

Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the fans air flow. Hold the nozzle approximately6 mm (.25 inch) away from the fins. Slowly movethe air nozzle in a direction that is parallel with thetubes. The pressurized air will remove debris that isbetween the tubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

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

After cleaning, start the engine and accelerate theengine to high idle rpm. This will help in the removalof debris and drying of the core. Stop the engine.

Use a light bulb behind the core in order to inspectthe core for cleanliness. Repeat the cleaning, if necessary.

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

Note: If parts of the aftercooler system are repairedor replaced, a leak test is highly recommended. For more information, refer to OEM specification for theaftercooler.

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

i03641972

Alternator - Inspect

SMCS Code: 1405-040

Caterpillar r ecommends a scheduled inspectionof the alternator. Inspect the alternator for looseconnections and proper battery charging. Inspect theammeter (if equipped) during engine operation inorder to ensure proper battery performance and/or proper performance of the electrical system. Makerepairs, as required.

Check the alternator and the battery charger for proper operation. If the batteries are properlycharged, the ammeter reading should be very near zero. All batteries should be kept charged. Thebatteries should be kept warm because temperatureaffects the cranking power of the battery. If the battery

is too cold, the battery will not crank the engine.

When the engine is not run for long periods of timeor if the engine is run for short periods, the batteriesmay not fully charge. A battery with a low charge willfreeze more easily than a battery with a full charge.

i02320208

Alternator and Fan Belts -Replace

SMCS Code: 1357-510

Refer to Disassembly and Assembly Manual , “ Alternator Belt - Remove and Install”.

i03559623

Battery - Replace

SMCS Code: 1401-510

Batteries give off combustible gases which can

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

Ensure proper ventilation for batteries that are inan enclosure. Follow the proper procedures in or-der to help prevent electrical arcs and/or sparksnear batteries. Do not smoke when batteries areserviced.

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Battery Electrolyte Level - Check

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

1. Switch the engine to the OFF position. Removeall electrical loads.

2. Turn off any battery chargers. Disconnect anybattery chargers.

3. Ensure that the battery disconnect switch is in theOFF position.

4. Disconnect the NEGATIVE “-” cable from theNEGATIVE “-” battery terminal.

5. Disconnect the POSITIVE “+” cable from thePOSITIVE “+” battery terminal.

Note: Always recycle a battery. Never discard abattery. Dispose of used batteries to an appropriaterecycling facility.

6. Remove the used battery.

7. Install the new battery.

Note: Before the cables are connected, ensure thatthe battery disconnect switch is in the OFF position.

8. Connect the POSITIVE “+” cable to the POSITIVE“+” battery terminal.

9. Connect the NEGATIVE “-” cable to the NEGATIVE“-” battery terminal.

10. Turn the battery disconnect switch to the ONposition.

i02724529

Battery Electrolyte Level -Check

SMCS Code: 1401-535

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

All lead-acid batteries contain sulfuric acid whichcan burn the skin and clothing. Always wear a faceshield and protective clothing when working on or near batteries.

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

If the addition of water is necessary, use distilledwater. If distilled water is not available use cleanwater that is low in minerals. Do not use artificiallysoftened water.

2. Check the condition of the electrolyte with the245-5829 Coolant Battery Tester Refractometer.

3. Keep the batteries clean.

Clean the battery case with one of the followingcleaning solutions:

• Use a solution of 0.1 kg (0.2 lb) baking sodaand 1 L (1 qt) of clean water.

• Use a solution of ammonium hydroxide.

Thoroughly rinse the battery case with clean water.

Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOT

remove material excessively. Excessive removalof material can cause the clamps to not fit properly.Coat the clamps and the terminals with 5N-5561Silicone Lubricant, petroleum jelly or MPGM.

i02323088

Battery or Battery Cable -Disconnect

SMCS Code: 1402-029

The battery cables or the batteries should not beremoved with the battery cover in place. The bat-tery cover should be removed before any servic-ing is attempted.

Removing the battery cables or the batteries withthe cover in place may cause a battery explosionresulting in personal injury.

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

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86 SEBU8600-02Maintenance SectionBelt - Inspect

2. Disconnect the negative battery terminal. Ensurethat the cable cannot contact the terminal. Whenfour 12 volt batteries are involved, two negativeconnection must be disconnected.

3. Remove the positive connection.

4. Clean all disconnected connection and batteryterminals.

5. Use a fine grade of sandpaper to clean theterminals and the cable clamps. Clean the itemsuntil the surfaces are bright or shiny. DO NOTremove material excessively. Excessive removalof material can cause the clamps to not fitcorrectly. Coat the clamps and the terminals witha suitable silicone lubricant or petroleum jelly.

6. Tape the cable connections in order to helpprevent accidental starting.

7. Proceed with necessary system repairs.

8. In order to connect the battery, connect thepositive connection before the negative connector.

i03973719

Belt - Inspect

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

NOTICE

Ensur e that the engine is stopped before any servicingor repair is performed.


Typical example

To maximize the engine performance, inspect the belt(1) for wear and for cracking. Replace the belt if thebelt is worn or damaged.

• Inspect the belt for cracks, splits, glazing, grease,displacement of the cord and evidence of fluid

contamination.

The belt must be replaced if the following conditionsare present.

• The belt has a crack in more than one rib.

• More than one section of the belt is displaced inone rib of a maximum length of 50.8 mm (2 inch).

To replace the belt, refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”.If necessary, replace the belt tensioner. Refer to Disassembly and Assembly, “Alternator Belt -

Remove and Install” for the correct procedure.

i03557440

Belt Tensioner - Inspect

SMCS Code: 1358-040


Typical example

Remove the belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”.

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Cooling System Coolant (DEAC) - Change

Ensure that the belt tensioner is securely installed.Visually inspect the belt tensioner (1) for damage.Check that the pulley on the tensioner rotates freelyand that the bearing is not loose. Some engineshave a idler pulley (2). Ensure that the idler pulley issecurely installed. Visually inspect the idler pulley

for damage. Ensure that the idler pulley can rotatefreely and that the bearing is not loose. If necessary,replace damaged components.

Install the belt. Refer to Disassembly and Assembly,“Alternator Belt - Remove and Install”.

i04155953

Cooling System Coolant(DEAC) - Change

SMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and thecoolant is contaminated.

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

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

NOTICEWhen any servicing or repair of the engine coolingsystem is performed the procedure must be performedwith the engine on level ground. Level ground will al-low you to accurately check thecoolant level. This pro-cedure will also help in avoiding the risk of introducing

an air lock into the coolant system.

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

Drain

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

Note: Refer to Operation and Maintenance Manual,“General Hazard Information” for information onContaining Fluid Spillage.


Typical example

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88 SEBU8600-02Maintenance SectionCooling System Coolant (DEAC) - Change


Typical example

2. Open the drain cock or remove the drain plug (1)on the engine. Also remove the drain plug (2).Open the drain cock or remove the drain plug onthe radiator.

Allow the coolant to drain into a suitable container.

3. Properly dispose of the drained material. Obeylocal regulations for the disposal of the material.

NOTICEDispose of used engine coolant properly or recycle.Various methods have been proposed to reclaim usedcoolant for reuse in engine cooling systems. The fulldistillation procedure is the only method acceptable byCaterpillar to reclaim the used coolant.

Flush

1. Flush the cooling system with clean water in order to remove any debris.

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to TorqueSpecifications, SENR3130 for more informationon the correct torques.

NOTICEDo not fill the cooling system faster than 5 L(1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per 15 L(4 US gal) of the cooling system capacity. Installthe cooling system filler cap.

4. Start and run the engine at low idle for a minimumof 30 minutes. The coolant temperature should beat least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve (if equipped). Clean the drain plugs. Install the drainplugs. Refer to Torque Specifications, SENR3130for more information on the correct torques.

Cooling Systems with Heavy

Deposits or PluggingNote: For the following procedure to be effective,there must be some active flow through the coolingsystem components.

1. Flush the cooling system with clean water in order to remove any debris.

2. Close the drain valve (if equipped). Clean thedrain plugs. Install the drain plugs. Refer to TorqueSpecifications, SENR3130 for more informationon the correct torques.



3. Fill the cooling system with a mixture of cleanwater and Caterpillar Fast Acting Cooling SystemCleaner. Add 0.5 L (1 pint) of cleaner per 3.8 to 7.6 L (1 to 2 US gal) of the cooling systemcapacity. Install the cooling system filler cap.

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Cooling System Coolant (ELC) - Change

4. Start and run the engine at low idle for a minimumof 90 minutes. The coolant temperature should beat least 82 °C (180 °F).

NOTICEImproper or incomplete rinsing of the cooling systemcan result in damage to copper and other metal com-ponents.

To avoid damage to the cooling system, make sureto completely flush the cooling system with clear wa-ter. Continue to flush the system until all signs of thecleaning agent are gone.

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling system drain

plugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve (if equipped). Clean the drain plugs. Install the drainplugs. Refer to Torque Specifications, SENR3130for more information on the correct torques.

Fill



1. Fill the cooling system with the coolant/antifreeze.Refer to this Operation and Maintenance Manual,“Refill Capacities and Recommendations” topic(Maintenance Section) for more information oncooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increasethe engine rpm to high idle. Operate the enginein order to open the engine thermostat. This willallow any air in the system to be purged. Decreasethe engine speed to low idle. Stop the engine.

3. Maintain the coolant level at the maximum markthat is correct for your application.

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system fi ller cap. If the gasket that is on the cooling system filler capis damaged, discard the old cooling system filler cap and install a new cooling system filler cap.If the gasket that is on the cooling system filler

cap is not damaged, perform a pressure test. A9S-8140 Pressurizing Pump is used to performthe pressure test. The correct pressure for thecooling system fi ller cap is stamped on the face of the cooling system fi ller cap. If the cooling systemfiller cap does not retain the correct pressure,install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system for leaks and f or the correct operating temperature.

i04155958

Cooling System Coolant (ELC)- Change

SMCS Code: 1350-070; 1395-044

Clean the cooling system and flush the coolingsystem before the recommended maintenanceinterval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and the

coolant is contaminated.

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

Note: When the cooling system is cleaned, onlyclean water is needed when the ELC is drained andreplaced.

Note: Inspect the water pump and the water temperature regulator after the cooling system hasbeen drained. Replace the water pump, the water temperature regulator, and the hoses, if necessary.

NOTICEService or repair of the engine cooling system must beperformed on level ground. The engine must be levelin order to check the coolant level. The engine mustbe level in order to avoid the risk of introducing an air lock into the coolant system.

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Cooling System Coolant Extender (ELC) - Add

3. Fill the cooling system with clean water. Install thecooling system filler cap.

4. Start and run the engine at low idle until thetemperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowlyin order to relieve any pressure. Remove thecooling system filler cap. Open the drain valve(if equipped) or remove the cooling system drainplugs. Allow the water to drain. Flush the coolingsystem with clean water. Close the drain valve (if equipped). Clean the drain plugs. Install the drainplugs. Refer to Torque Specifications, SENR3130for more information on the correct torques.

Fill



1. Fill the cooling system with Extended Life Coolant(ELC). Refer to this Operation and MaintenanceManual, “Refill Capacities and Recommendations”topic (Maintenance Section) for more informationon cooling system specifications. Do not install thecooling system filler cap.

2. Start and run the engine at low idle. Increase theengine rpm to high idle. Operate the engine inorder to open the engine thermostat. An openthermostat will allow any air in the system to bepurged. Decrease the engine speed to low idle.Stop the engine.

3. Maintain the coolant level at the maximum markthat is correct for your application.

4. Clean the cooling system filler cap. Inspect thegasket that is on the cooling system filler cap. If the gasket that is on the cooling system fi ller capis damaged, discard the old cooling system fi ller

cap and install a new cooling system fi

ller cap. If the gasket that is on the cooling system filler cap isnot damaged, use a 9S-8140 Pressurizing Pumpin order to pressure test the cooling system filler cap. The correct pressure for the cooling systemfiller cap is stamped on the face of the coolingsystem filler cap. If the cooling system filler capdoes not retain the correct pressure, install a newcooling system filler cap.

5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.

i04403146

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352-045; 1395-081

Cat ELC (Extended Life Coolant) does not requirethe frequent additions of any supplemental coolingadditives which are associated with the presentconventional coolants. The Cat ELC Extender onlyneeds adding once.

NOTICEUse only Cat Extended Life Coolant (ELC) Extender with Cat ELC.

Do NOT use conventional supplemental coolant addi-tive (SCA) with Cat ELC. Mixing Cat ELC with conven-

tional coolants and/or conventional SCA reduces theCat ELC service life.

Check the cooling system only when the engine isstopped and cool.

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all lines

to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

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92 SEBU8600-02Maintenance SectionCooling System Coolant Level - Check

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers before

opening any compartment or disassembling any com-ponent containing fluids.

Refer to Cat Hand Tools and Shop Supplies for suit-able contains use on Cat products.


NOTICEWhen any servicing or repair of the engine cool-ing system is performed, the procedure must beperformed with the engine on level ground. This pro-

cedure will allow you to check accurately the coolantlevel. This procedure will also help in avoiding the riskof introducing an air lock into the coolant system.

1. Loosen the cooling system filler cap slowly inorder to relieve pressure. Remove the coolingsystem filler cap.

2. If necessary, drain enough coolant from thecooling system in order to add the Cat ELCExtender.

3. Add Cat ELC Extender according to the

requirements for your engines cooling systemcapacity. Refer to the Operation and MaintenanceManual, “Refill Capacities and Recommendations”article for more information.

4. Clean the cooling system filler cap. Inspect thegaskets on the cooling system fi ller cap. Replacethe cooling system filler cap if the gaskets aredamaged. Install the cooling system fi ller cap.

i04403158

Cooling System Coolant Level

- CheckSMCS Code: 1395-082

Check the coolant level when the engine is stoppedand cool.


Cooling system filler cap


NOTICEWhen any servicing or repair of the engine cool-ing system is performed, the procedure must beperformed with the engine on level ground. This pro-cedure will allow you to check accurately the coolantlevel. This procedure will also help in avoiding the riskof introducing an air lock into the coolant system.

1. Remove the cooling system filler cap slowly inorder to relieve pressure.

2. Maintain the coolant level at the maximum markthat is correct for your application. If the engine isequipped with a sight glass, maintain the coolantlevel to the correct level in the sight glass.

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Cooling System Coolant Sample (Level 1) - Obtain


Typical filler cap gaskets

3. Clean the cooling system filler cap and check thecondition of the filler cap gaskets. Replace thecooling system filler cap if the filler cap gaskets aredamaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

i04035949

Cooling System CoolantSample (Level 1) - Obtain

SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Obtaining a Coolant Sample (Level 1) isoptional if the cooling system is filled with CatELC (Extended Life Coolant). Cooling systems filledwith Cat ELC should have a Coolant Sample (Level2) that is obtained at the recommended interval asstated in the maintenance interval schedule.

Note: Obtain a Coolant Sample (Level 1) if the

cooling system is fi

lled with any other coolantinstead of Cat ELC including the followingcoolants:

• Commercial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze

Table 11

Recommended Interval

Type of Coolant Level 1 Level 2

Cat DEAC

Conventionalheavy duty-

coolant

Commercialcoolant thatmeets the

requirementsof the Caterpillar

EC-1 standard

Every 250service hours

Every year (1)

Cat ELC or conventionalEC-1 coolant

Optional Every year (1)

(1) The Level 2 Coolant Analysis should be performed sooner if aproblem is suspected or identified.

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

Note: Level 1 results may indicate a need for Level 2 Analysis.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In order toreceive the full effect of S·O·S analysis, establisha consistent trend of data. In order to establisha pertinent history of data, perform consistentsamplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer.

Use the following guidelines for proper sampling of the coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

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94 SEBU8600-02Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain

• Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis,see this Operation and Maintenance Manual, “RefillCapacities and Recommendations” or consult your Caterpillar dealer.

i04051750

Cooling System CoolantSample (Level 2) - Obtain

SMCS Code: 1350-008; 1395-008; 1395-554; 7542

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

NOTICE

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

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

Dispose of all fluids according to local regulations and

mandates.

Refer to Operation and Maintenance Manual,“Cooling System Coolant Sample (Level 1) - Obtain”f or the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.

For additional information about coolantanalysis, see Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engines FluidsRecommendations” or consult your Caterpillar dealer.

i03644817

Cooling System SupplementalCoolant Additive (SCA) -Test/Add

SMCS Code: 1352-045; 1395-081

Cooling system coolant additive contains alkali.To help prevent personal injury, avoid contact withthe skin and the eyes. Do not drink cooling systemcoolant additive.

Note: Test the concentration of the SupplementalCoolant Additive (SCA) or test the SCA concentrationas part of an S·O·S Coolant Analysis.

Test for SCA Concentration

Coolant and SCA

NOTICEDo not exceed the recommended six percent supple-mental coolant additive concentration.

Use the 8T-5296 Coolant Conditioner Test Kitor use the 4C-9301 Coolant Conditioner Test Kitin order to check the concentration of the SCA.Refer to this Operation and Maintenance Manual,“Refill Capacities and Recommendations” for moreinformation.

Water and SCA

NOTICEDo not exceed the recommended eight percent sup-plemental coolant additive concentration.

Test the concentration of the SCA with the 8T-5296Coolant Conditioner Test Kit. Refer to the SpecialPublication, SEBU6251, “Caterpillar Commercial

Diesel Engine Fluids Recommendations” for moreinformation.

S·O·S Coolant Analysis

S·O·S coolant samples can be analyzed at your Caterpillar dealer. S·O·S Coolant Analysis is aprogram that is based on periodic samples.

Level 1

Level 1 is a basic analysis of the coolant. Thefollowing items are tested:

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Crankshaft Vibration Damper - Inspect

• Glycol Concentration

• Concentration of SCA

• pH

• Conductivity

The results are reported, and recommendationsare made according to the results. Consult your Caterpillar dealer for information on the benefits of managing your equipment with an S·O·S Coolant

Analysis.

Level 2

This level coolant analysis is recommended when theengine is overhauled. Refer to this Operations andMaintenance Manual, “Overhaul Considerations” for further information.

Add the SCA, If Necessary

NOTICEDo not exceed the recommended amount of sup-plemental coolant additive concentration. Excessivesupplemental coolant additive concentration can formdeposits on the higher temperature surfaces of thecooling system, reducing the engine's heat transfer characteristics. Reduced heat transfer could causecracking of the cylinder head and other high temper-ature components. Excessive supplemental coolantadditive concentration could also result in radiator tube blockage, overheating, and/or accelerated water pump seal wear. Never use both liquid supplementalcoolant additive and the spin-on element (if equipped)at the same time. The use of those additives together could result in supplemental coolant additive concen-tration exceeding the recommended maximum.

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling system

components are cool. Loosen the cooling systempressure cap slowly in order to relieve the pres-sure.

NOTICEWhen any servicing or repair of the engine coolingsystem is performed the procedure must be performedwith the engine on level ground. This will allow you toaccurately check the coolant level. This will also helpin avoiding the risk of introducing an air lock into thecoolant system.

1. Slowly loosen the cooling system filler cap inorder to relieve the pressure. Remove the coolingsystem filler cap.

Note: Always discard drained fluids according tolocal regulations.

2. If necessary, drain some coolant from the coolingsystem into a suitable container in order to allowspace for the extra SCA.

3. Add the proper amount of SCA. Refer to the Special Publication, SEBU6251,“Caterpillar Commercial Diesel Engines FluidsRecommendations” for more information on SCArequirements.

4. Clean the cooling system filler cap. Inspect thegaskets of the cooling system filler cap. If thegaskets are damaged, replace the old cooling

system fi ller cap with a new cooling system fi ller cap. Install the cooling system fi ller cap.

i03634651

Crankshaft Vibration Damper - Inspect

SMCS Code: 1205-040

Viscous Damper

The viscous damper has a inertia weight that islocated inside a fluid fi lled case. The inertia weightmoves in the case in order to limit torsional vibration.

Visually inspect the crankshaft damper. Ensure thatthe cooling fins (1) on the crankshaft damper areclean and free from dirt.

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96 SEBU8600-02Maintenance SectionDiesel Particulate Filter - Clean


Typical example

Inspect the damper and replace the damper for anyof the following reasons:

• The damper is dented, cracked, or leaking.

For information on removal of the crankshaft damper,refer to Disassembly and Assembly, “VibrationDamper and Pulley - Remove and Install”.

i04083930

Diesel Particulate Filter - Clean

SMCS Code: 108F-070

Wear goggles, gloves, protective clothing, anda National Institute for Occupational Safety andHealth (NIOSH) approved P95 or N95 half-facerespirator when handling a used Diesel Particu-late Filter or Catalytic Converter Muf fler. Failure

to do so could result in personal injury.

The muf fler, catalytic converter/muf fler, and dieselparticulate filter will become extremely hot duringengine operation. A hot muf fler, catalytic convert-er/muf fler and diesel particulate filter can causeserious burns. Allow adequate cooling time beforeworking on or near the muf fler, catalytic convert-er/muf fler and diesel particulate filter.


Typical example

• DPF __________________________ Diesel Particulate Filter

Note: Caterpillar recommends the use of theCaterpillar ash service tool. Caterpillar does notendorse the use of non-Caterpillar ash service tools.Improper cleaning or repair of the DPF can damagethe DPF and the engine aftertreatment system.Contact your Caterpillar dealer for more information.

Before the DPF can be removed for cleaning, youmust perform a service regeneration in order toremove the soot from the DPF. The DPF will needto cool before removal. New torca clamps (1) mustbe installed on the DPF.

For information on removal of the DPF, refer toDisassembly and Assembly, “DPF - Remove”. Also,refer to System Operation Testing and Adjusting,“Diesel Particulate Filter- Clean”.

Only ultra low sufur diesel fuel can be used in anapplication that has an engine aftertreatment system.The use of other fuel will damage your engine system.

Caterpillar recommend the use of Cat DEO-ULSengine oil.

i00174798

Driven Equipment - Check

SMCS Code: 3279-535

Refer to the OEM specifications for more informationon the following maintenance recommendations for the driven equipment:

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Engine - Clean

• Inspection

• Adjustment

• Lubrication

• Other maintenance recommendations

Perform any maintenance for the driven equipmentwhich is recommended by the OEM.

i04947820

Engine - Clean

SMCS Code: 1000-070

Personal injury or death can result from high volt-age.

Moisture can create paths of electrical conductiv-ity.

Make sure that the electrical system is OFF. Lockout the starting controls and tag the controls “DONOT OPERATE”.

NOTICE Accumulated grease and oil on an engine is a fire haz-ard. Keep the engine clean. Remove debris and fluid

spills whenever a significant quantity accumulates onthe engine.

Periodic cleaning of the engine is recommended.Steam cleaning the engine will remove accumulatedoil and grease. A clean engine provides the followingbenefits:

• Easy detection of fluid leaks

• Maximum heat transfer characteristics

• Ease of maintenance

Note: Caution must be used in order to preventelectrical components from being damaged byexcessive water when the engine is cleaned.Pressure washers and steam cleaners should not bedirected at any electrical connectors or the junction of cables into the rear of the connectors. Avoid electricalcomponents such as the alternator, the starter, andthe ECM. Protect the fuel injection pump from fluidsin order to wash the engine.

Aftertreatment System

During the engine cleaning process, ensurethat water or cleaning fluids cannot enter theaftertreatment system. If cleaning fluids enters theaftertreatment system, damage could occur.

i04404720

Engine Air Cleaner Element(Dual Element) - Clean/Replace

SMCS Code: 1054-037; 1054-510

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering theengine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.

NOTICENever service the air cleaner element with the enginerunning since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air can split the material of the air cleaner element.Unfiltered air will drastically accelerate internal enginewear. Your Caterpillar dealer has the proper air cleaner elements for your application. Consult your Caterpillar dealer for the correct air cleaner element.

• Check the precleaner (if equipped) daily for accumulation of dirt and debris. Remove any dirtand debris, as needed.

• Operating conditions (dust, dirt, and debris) mayrequire more frequent service of the air cleaner element.

• The air cleaner element may be cleaned up to

six times if the element is properly cleaned andinspected.

• The air cleaner element should be replaced at leastone time per year. This replacement should beperformed regardless of the number of cleanings.

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98 SEBU8600-02Maintenance SectionEngine Air Cleaner Element (Dual Element) - Clean/Replace

Replace the dir ty paper air cleaner elements withclean air cleaner elements. Before installation, theair cleaner elements should be thoroughly checkedfor tears and/or holes in the filter material. Inspectthe gasket or the seal of the air cleaner element for damage. Maintain a supply of suitable air cleaner

elements for replacement purposes.

Dual Element Air Cleaners

The dual element air cleaner contains a primaryair cleaner element and a secondary air cleaner element. The primary air cleaner element can beused up to six times if the element is properly cleanedand inspected. The primary air cleaner elementshould be r eplaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

The secondary air cleaner element is not serviceableor washable. The secondary air cleaner elementshould be removed and discarded for every threecleanings of the primary air cleaner element. Whenthe engine is operating in environments that aredusty or dirty, air cleaner elements may require morefrequent replacement.


(1) Cover (2) Primary air cleaner element(3) Secondary air cleaner element(4) Turbocharger air inlet

1. Remove the cover. Remove the primary air

cleaner element.

2. The secondary air cleaner element should beremoved and discarded for every three cleaningsof the primary air cleaner element.

Note: Refer to “Cleaning the Primary Air Cleaner Elements”.

3. Cover the turbocharger air inlet with tape in order to keep out dirt.

4. Clean the inside of the air cleaner cover and bodywith a clean, dry cloth.

5. Remove the tape for the turbocharger air inlet.Install the secondary air cleaner element. Install aprimary air cleaner element that is new or cleaned.

6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.

Cleaning the Primary Air Cleaner Elements

NOTICECaterpillar recommends certified air filter cleaning ser-vices that are available at Cat dealers. The Cat clean-ing process uses proven procedures to assure consis-tent quality and suf ficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filter element. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage toengine components.

The primary air cleaner element can be used upto six times if the element is properly cleaned andinspected. When the primary air cleaner element iscleaned, check for rips or tears in the fi lter material.The primary air cleaner element should be replacedat least one time per year. This replacement shouldbe performed regardless of the number of cleanings.

Use clean primary air cleaner elements while dirtyelements are being cleaned.

NOTICEDo not clean the air cleaner elements by bumping or tapping. This could damage the seals. Do not use el-ements with damaged pleats, gaskets or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air cleaner elementsbefore cleaning. Inspect the air cleaner elements for damage to the seal, the gaskets, and the outer cover.Discard any damaged air cleaner elements.

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Engine Air Cleaner Element (Dual Element) - Clean/Replace

There are two common methods that are used toclean primary air cleaner elements:

• Pressurized air

• Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean primary air cleaner elements that have not been cleaned morethan two times. Pressurized air will not removedeposits of carbon and oil. Use fi ltered, dry air with amaximum pressure of 207 kPa (30 psi).


Note: When the primary air cleaner elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the streamof air directly at the primary air cleaner element. Dirtcould be forced further into the pleats.

Note: Refer to “Inspecting the Primary Air Cleaner Elements”.

Vacuum Cleaning

Vacuum cleaning is a good method for cleaningprimary air cleaner elements which require dailycleaning because of a dry, dusty environment.Cleaning with pressurized air is recommended prior to vacuum cleaning. Vacuum cleaning will not removedeposits of carbon and oil.

Note: Refer to “Inspecting the Primary Air Cleaner Elements”.

Inspecting the Primary Air Cleaner

Elements


Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air cleaner element. Rotate the primary air cleaner element.Inspect the primary air cleaner element for tearsand/or holes. Inspect the primary air cleaner elementfor light that may show through the fi lter material. If itis necessary in order to confirm the result, comparethe primary air cleaner element to a new primary air cleaner element that has the same part number.

Do not use a primary air cleaner element that hasany tears and/or holes in the fi lter material. Do notuse a primary air cleaner element with damagedpleats, gaskets, or seals. Discard damaged primary

air cleaner elements.

Storing Primary Air Cleaner Elements

If a primary air cleaner element that passes inspectionwill not be used, the primary air cleaner element canbe stored for future use.

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100 SEBU8600-02Maintenance SectionEngine Air Cleaner Element (Single Element) - Inspect/Replace


Typical example

Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An air flow restrictionmay result. To protect against dirt and damage, wrapthe primary air cleaner elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary air cleaner element into a boxfor storage. For identification, mark the outside of the box and mark the primary air cleaner element.

Include the following information:

• Date of cleaning

• Number of cleanings

Store the box in a dry location.

i01432811

Engine Air Cleaner Element (Single Element) -Inspect/Replace

SMCS Code: 1054-040; 1054-510

Perform the Operation and Maintenance Manual,“Engine Air Cleaner Service Indicator-Inspect”procedure and perform the Operation andMaintenance Manual, “Engine Air Precleaner Check/Clean” procedure (if equipped) beforeperforming the following procedure.

NOTICENever run the engine without an air cleaner elementinstalled. Never run the engine with a damaged air cleaner element. Do not use air cleaner elements withdamaged pleats, gaskets or seals. Dirt entering the

engine causes premature wear and damage to enginecomponents. Air cleaner elements help to prevent air-borne debris from entering the air inlet.



(1) Air cleaner cover (2) Air filter element(3) Air inlet

1. Remove air cleaner cover (1) and remove air fi lter element (2).

2. Cover air inlet (3) with tape or a clean cloth so thatdebris cannot enter the air inlet.

3. Clean the inside of air cleaner cover (1). Clean thebody that holds the air cleaner element.

4. Inspect the replacement element for the followingitems:damage, dirt, and debris.

5. Remove the seal from the opening of the air inlet.

6. Install a clean, undamaged air filter element (2).

7. Install air cleaner cover (1).

8. Reset the air cleaner service indicator.

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Engine Air Cleaner Element (Single Element) - Replace

i02242500

Engine Air Cleaner Element(Single Element) - Replace

SMCS Code: 1051; 1054-510



(1) Air cleaner element. (2) Clamp.

1. Loosen clamp (2) which fastens air cleaner element (1) to the air inlet. Remove the dirty air cleaner element and clamp.

2. Install clamp (2) on new air cleaner element (1).

3. Install new air cleaner element (1) to the air inlet and tighten clamp (2). Refer to TorqueSpecifications, SENR3130 for the correct torque.

i02335405

Engine Air Cleaner ServiceIndicator - Inspect

SMCS Code: 7452-040

Some engines may be equipped with a differentservice indicator.

Some engines are equipped with a differential gaugefor inlet air pressure. The differential gauge for inletair pressure displays the difference in the pressurethat is measured before the air cleaner element andthe pressure that is measured after the air cleaner element. As the air cleaner element becomes dirty,the pressure differential rises. If your engine isequipped with a different type of service indicator,follow the OEM recommendations in order to servicethe air cleaner service indicator.

The service indicator may be mounted on the air cleaner element or in a remote location.


Typical service indicator

Observe the service indicator. The air cleaner element should be cleaned or the air cleaner elementshould be replaced when one of the followingconditions occur:

• The yellow diaphragm enters the red zone.

• The red piston locks in the visible position.

Test the Service Indicator

Service indicators are important instruments.

• Check for ease of resetting. The service indicator should reset in less than three pushes.

• Check the movement of the yellow core whenthe engine is accelerated to the engine ratedspeed. The yellow core should latch at the greatestvacuum that is attained.

If the service indicator does not reset easily, or if theyellow core does not latch at the greatest vacuum,the service indicator should be replaced. If the newservice indicator will not reset, the hole for the serviceindicator may be restricted.

The service indicator may need to be replacedfrequently in environments that are severely dusty.

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102 SEBU8600-02Maintenance SectionEngine Air Precleaner - Check/Clean

i02927289

Engine Air Precleaner -Check/Clean

SMCS Code: 1055-070; 1055-535


Typical engine air precleaner

(1) Wing nut(2) Cover (3) Body

Remove wing nut (1) and cover (2). Check for anaccumulation of dirt and debris in body (3). Clean thebody, if necessary.

After cleaning the precleaner, install cover (2) andwing nut (1).

Note: When the engine is operated in dustyapplications, more frequent cleaning is required.

i04946934

Engine Crankcase Breather Element - Replace

SMCS Code: 1317-510-FQ

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

NOTICEEnsure that the engine is stopped before any servicingor repair is performed.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers before

opening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, “Cat Dealer Service Tool Catalog” or refer to Special Publication,PECJ0003, “Cat Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and contain fluidson Cat products.


The crankcase breather is a very important

component in order to keep your engine emissionscompliant.

• The filter element within the crankcase breather must be serviced at the prescribed service interval.

• The correct filter element must be installed beforethe engine is operated.

• The installation of the filter element is veryimportant.

• The quality of the filter element that is installed isvery important.

For information on aftermarket products, refer to Operation and Maintenance Manual, “EngineDescr iption”. Within that section, refer to the title“Aftermarket Products and Caterpillar engines”.

The breather element can be serviced from the topposition or the breather element can be serviced fromthe bottom position.

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Engine Crankcase Breather Element - Replace

Top Service


Typical example

1. Ensure that dirt cannot enter the breather assembly. Ensure that the outside body of thebreather assembly is clean and free from damage.Place a container under the breather assembly.

2. Rotate the top cap (1) counterclockwise into theunlocked position. Remove the top cap from thebody of the breather (3) and remove the filter element (2).


Typical example

3. Remove the old seal (4) and install a new seal.

Note: The cut away from section (5) in the top capallows access to the seal.


(A) Alignment position(B) Alignment position

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104 SEBU8600-02Maintenance SectionEngine Crankcase Breather Element - Replace

4. Install a new filter element into the breather body(3). Ensure the correct position of the element,refer to illustration 70. Align position (A) on the topcap to position (B) on the fi lter element.


Typical example

5. Install the top cap (1). Rotate the top cap by handclockwise until the top cap locks into the lockedposition (C) on the breather body.

6. Remove the container.

Bottom Service

Ensure that dirt cannot enter the breather assembly.


Typical example

(X) Alignment mark(Y) Alignment mark

1. Ensure that the outside body of the breather assembly is clean and free from damage. Placea container under the breather.

2. Remove the tube connection (1). Ensure thatdirt cannot enter the tube connection. Note theposition of the alignment marks (X and Y). Rotate

the bottom cap (2) counterclockwise in order torelease the cap and the fi lter element (4) from thebreather body (3).

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Engine Mounts - Inspect


Typical example

(A) Alignment postion(B) Alignment postion

3. Remove the filter element (4). Remove the seal

(5).

Note: The bottom cap has a section that allowsaccess in order to remove the seal.

4. Install a new seal (5). Install a new fi lter elementinto the bottom cap (2).

5. Align position (A) on the top cap to position (B) onthe fi lter element. Refer to illustration 73.

6. Install the assembly of the filter element and thebottom cap (2). Rotate the bottom cap by handclockwise until the bottom cap locks into the

locked position on the breather body. Ensurethat the alignment marks (X and Y) are correctlyaligned. Refer to illustration 72.

7. Install tube connection (1). Ensure that theretaining clips on the tube connection are correctlyengaged. Remove the container.

Check the System


Typical example

Inspect the breather tube (1) for damage. Ensure thatthe outlet (2) is clean and free from any obstructions.Ice can cause obstructions in adverse weather conditions.

i02456872

Engine Mounts - Inspect

SMCS Code: 1152-040

Inspect the engine mounts for deterioration and for proper bolt torque. Engine vibration can be causedby the following conditions:

• Improper mounting of the engine

• Deterioration of the engine mounts

Any engine mount that shows deterioration should bereplaced. Refer to Special Publication, SENR3130,“Torque Specifications” for the recommendedtorques. Refer to the OEM recommendations for more information.

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106 SEBU8600-02Maintenance SectionEngine Oil Level - Check

i04947803

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.

g02173847Illustr ation 75

“L” Low

“H” High

NOTICEPerform this maintenance with the engine stopped.

Note: Ensure that the engine is either level or thatthe engine is in the normal operating position in order to obtain a true level indication.

Note: After the engine has been switched OFF, waitfor 10 minutes in order to allow the engine oil to drainto the oil pan before checking the oil level.

1. Maintain the oil level between the mark (L) andthe mark (H) on the engine oil dipstick. Do not fillthe crankcase above the “H”.

NOTICE

Operating your engine when the oil level is above the“FULL” mark could cause your crankshaft to dip intothe oil. The air bubbles created from the crankshaftdipping into the oil reduces the oil's lubricating char-acteristics and could result in the loss of power.

2. Remove the oil fi ller cap and add oil, if necessary.Clean the oil fi ller cap. Install the oil fi ller cap.

If an increase in the oil level is noticed, refer toTroubleshooting, “Oil Contains Fuel”.

i04237495

Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1348-554-SM;7542-554-OC, SM

In addition to a good preventive maintenanceprogram, Caterpillar recommends using S·O·S oilanalysis at r egularly scheduled intervals. S·O·S oilanalysis provides infrared analysis, which is requiredfor determining nitration and oxidation levels.

Obtain the Sample and the Analysis

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components to

contact the skin.

Before you take the oil sample, complete the Label,PEEP5031 for identification of the sample. In order to help obtain the most accurate analysis, providethe following information:

• Engine model

• Service hours on the engine

• The number of hours that have accumulated sincethe last oil change

• The amount of oil that has been added since thelast oil change

To ensure that the sample is representative of the oilin the crankcase, obtain a warm, mixed oil sample.

To avoid contamination of the oil samples, the toolsand the supplies that are used for obtaining oilsamples must be clean.

Caterpillar recommends using the sampling valvein order to obtain oil samples. The quality and theconsistency of the samples are better when the

sampling valve is used. The location of the samplingvalve allows oil that is flowing under pressure to beobtained during normal engine operation.

The 169-8373 Fluid Sampling Bottle isrecommended for use with the sampling valve. Thefluid sampling bottle includes the parts that areneeded for obtaining oil samples. Instructions arealso provided.

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Engine Oil and Filter - Change

NOTICE Always use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. This

contaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

If the engine is not equipped with a sampling valve,use the 1U-5718 Vacuum Pump. The pump isdesigned to accept sampling bottles. Disposabletubing must be attached to the pump for insertioninto the sump.

For instructions, see Special Publication, PEGJ0047,“How To Take A Good S·O·S Oil Sample”. Consultyour Cat dealer for complete information and

assistance in establishing an S·O·S program for your engine.

i03996035

Engine Oil and Filter - Change

SMCS Code: 1318-510; 1348-044

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components to

contact the skin.

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


NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Do not drain the engine lubricating oil when theengine is cold. As the engine lubricating oil cools,suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed withdraining cold oil. Drain the oil pan with the enginestopped. Drain the oil pan with the oil warm. This

draining method allows the waste particles that aresuspended in the oil to be drained properly.

Failure to f ollow this recommended procedure willcause the waste particles to be recirculated throughthe engine lubrication system with the new oil.

Drain the Engine Lubricating Oil

Note: Ensure that the vessel that will be used is largeenough to collect the waste oil.

After the engine has been run at the normal operating

temperature, stop the engine. Use one of thefollowing methods to drain the engine oil pan:


Typical example

• If the engine is equipped with a drain valve, turn thedrain valve knob counterclockwise in order to drainthe oil. After the oil has drained, turn the drain valveknob clockwise in order to close the drain valve.

• If the engine is not equipped with a drain valve,remove oil drain plug (1) in order to allow the oil todrain. If the engine is equipped with a shallow oilpan, remove the bottom oil drain plugs from bothends of the oil pan.

After the oil has drained, the oil drain plugs should becleaned and installed. If necessary, replace the Oring seal. Tighten the drain plug to 34 N·m (25 lb ft).

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108 SEBU8600-02Maintenance SectionEngine Oil and Filter - Change

Replace the Oil Filter

NOTICECaterpillar oil filters are manufactured to Caterpillar specifications. Use of an oil filter that is not recom-mended by Caterpillar could result in severe damageto the engine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil fi lters rec-ommended by Caterpillar.

1. Remove the oil filter with a 1U-8760 ChainWrench.

Note: The following actions can be carried out aspart of the preventive maintenance program.


Element with debris

2. Cut the oil filter open with a 175-7546 Oil Filter Cutter . Break apart the pleats and inspect theoil filter for metal debris. An excessive amountof metal debris in the oil filter may indicate earlywear or a pending failure.

Use a magnet to differentiate between the ferrousmetals and the nonferrous metals that are found inthe oil fi lter element. Ferrous metals may indicatewear on the steel and cast iron parts of the engine.

Nonferrous metals may indicate wear on thealuminum parts, brass parts or bronze parts of the engine. Parts that may be affected includethe following items: main bearings, rod bearings,turbocharger bearings, and cylinder heads.

Due to normal wear and friction, it is notuncommon to find small amounts of debris in theoil filter. Consult your Caterpillar dealer in order to arrange for a further analysis if an excessiveamount of debris is found in the oil fi lter.


Typical example

3. Clean the sealing surface of the oil fi lter base (2).

4. Apply clean engine oil to the O ring seal (3) for the new oil filter.

NOTICEDo not fill the oil fi lters with oil before installing them.This oil would not be filtered and could be contaminat-ed. Contaminated oil can cause accelerated wear toengine components.

5. Install the engine oil filter. Spin on the oil fi lter untilthe O ring seal contacts the oil filter base. Rotatethe oil fi lter ¾ of a full turn.

Fill the Oil Pan

1. Remove the oil filler cap. Refer to thisOperation and Maintenance Manual, “FluidRecommendations” for more information onsuitable oils. Fill the oil pan with the correctamount of new engine lubricating oil. Refer to this Operation and Maintenance Manual,“Refill Capacities” for more information on refillcapacities.

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Fan Clearance - Check

NOTICEIf equipped with an auxiliary oil filter system or a re-mote filter system, follow the OEM or the filter manu-factures recommendations. Under filling or over fillingthe crankcase with oil can cause engine damage.

2. Start the engine and run the engine at “LOWIDLE” for 2 minutes. Perform this procedure inorder to ensure that the lubrication system hasoil and that the oil filters are filled. Inspect the oilfilter for oil leaks.

3. Stop the engine and allow the oil to drain back tothe oil pan for a minimum of 10 minutes.


“L” Low

“H” High

4. Remove the engine oil level gauge in order tocheck the oil level. Maintain the oil level betweenthe “L” and “H” marks on the engine oil levelgauge. Do not fi ll the crankcase above the “H”mark.

i03926370

Fan Clearance - Check

SMCS Code: 1356; 1359; 1360

There are different types of cooling systems. Refer tothe OEM for information on clearance for the fan.

Ensure that the engine is stopped. Ensure that thebattery disconnect switch is in the OFF position.Ensure that the cooling system is full. The clearancebetween the cover (1) and the fan (2) will requirechecking. The gap (A) between the edge of the cover and the tip of the fan blade must be checked in four equally spaced positions.

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110 SEBU8600-02Maintenance SectionFuel Filter (In-Line) - Replace


Adjustment of the cover will change the clearance(gap) between the edge of the cover and the tip of the fan blade. Ensure that the cover is centralized tothe fan.

The clearance (A) must be 11 ± 2 mm(0.43307 ± 0.07874 inch).

i04945626

Fuel Filter (In-Line) - Replace

SMCS Code: 1261-510; 1261

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. To help pre-vent possible injury, turn the start switch off whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.

Note: Refer to Systems Operation, Testing,and Adjusting, “Cleanliness of Fuel SystemComponents” for detailed information on thestandards of cleanliness that must be observedduring ALL work on the fuel system.


The location of the in-line fuel fi

lter will depend on theapplication that the engine has been installed.

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SEBU8600-02 111Maintenance SectionFuel System - Prime


Typical example

1. Turn the fuel supply valve (if equipped) to the OFFposition. Remove any brackets that hold the in-linefuel fi lter (1) in place, refer to OEM information.

2. Release the hose clips (3) and remove the hoselines from the in-line fuel fi lter. Remove the in-linefilter.

3. Install a new in-line filter and secure, refer to OEM

information. Ensure that the arrow mark (2) isaligned to the direction of fuel flow from the tankto the fuel pump.

4. Install the fuel hose lines and install the hose clips(3). Turn the fuel supply valve (if equipped) to theON position.

5. The in-line fuel filter must be changed with theprimary fi lter and the secondary fuel fi lter.

i03906114

Fuel System - Prime

SMCS Code: 1258-548


Ensure that all adjustments and repairs are performedby authorized personnel that have had the correcttraining.

NOTICEDo not crank the engine continuously for more than30 seconds. Allow the starting motor to cool for twominutes before cranking the engine again.

If air enters the fuel system, the air must be purgedfrom the fuel system before the engine can bestarted. Air can enter the fuel system when thefollowing events occur:

• The fuel tank is empty or the fuel tank has beenpartially drained.

• The low-pr essure fuel lines are disconnected.

• A leak exists in the low-pressure fuel system.

• The fuel filter has been replaced.

Use the following procedures in order to remove air from the fuel system:

1. Ensure that the fuel system is in working order.Check that the fuel supply valve (if equipped) is inthe “ON” position.

2. Turn the keyswitch to the “RUN” position.

3. The keyswitch will allow the electric priming pumpto operate. Operate the electric priming pump.The ECM will stop the pump after 2 minutes.

4. Turn the keyswitch to the “OFF” position. The fuelsystem should now be primed and the engineshould be able to start.

5. Operate the engine starter and crank the engine. After the engine has started, operate the engine atlow idle for a minimum of 5 minutes. Ensure thatthe fuel system is free from leaks.

Note: Operating the engine for this period will helpensure that the fuel system is free of air. DO NOTloosen the high-pressure fuel lines in order topurge air from the fuel system. This procedure isnot required.

After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure tobe purged from the high-pressure fuel lines beforeany service or repair is performed on the enginefuel lines. If necessary, perform minor adjustments.Repair any leaks from the low-pressure fuel systemand from the cooling, lubrication, or air systems.Replace any high-pressure fuel line that has leaked.Refer to Disassembly and Assembly Manual, “FuelInjection Lines - Install”.

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112 SEBU8600-02Maintenance SectionFuel System Primary Filter (Water Separator) Element - Replace


If the engine will not start, refer to Troubleshooting,

“Engine Cranks but will not Start”.

i04946947

Fuel System Primary Filter (Water Separator) Element -Replace

SMCS Code: 1260-510-FQ; 1263-510-FQ



NOTICE

Ensure that the engine is stopped before any servicingor repair is performed.

Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFFposition before performing this maintenance.

2. Place a suitable container under the water separator in order to catch any fuel that might spill.Clean up any spilled fuel. Clean the outside bodyof the filter assembly.


Typical example

3. Install a suitable tube onto drain (3). Openthe drain valve (2). Rotate the drain valvecounterclockwise. Two full turns are required.

4. Loosen the vent screw (1).

5. Allow the fuel to drain into the container. Removethe tube from the drain valve.

6. Tighten the vent screw (1) securely . Remove thewiring harness from connection (4).

7. Rotate filter bowl (6) counterclockwise andremove the filter bowl from assembly. Refer toyour caterpillar dealer for the correct tool.

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Fuel System Primary Filter (Water Separator) Element - Replace


Typical example

8. Rotate the filter element (5) counterclockwise andremove the filter element . Clean the fi lter bowl.

Install the New Filter Element


Typical example

1. Locate the thread in the new filter element (8)onto the threads (9). Spin on the fi lter element and

tighten the drain valve (2) securely.

2. Lubricate the O ring seal (7) with clean engine oil.Do NOT fi ll the bowl with fuel before the assemblyis installed.

3. Do not use a tool in order to install the filter assembly. Tighten the filter bowl (6) by hand.Install the filter bowl (6). Turn the filter bowlclockwise until the filter bowl locks into positionagainst the stops.

4. Remove the container and dispose of the fuel ina saf e place.

5. The secondary filter element must be replaced atthe same time as the primary fi lter element. Refer to the Operation and Maintenance Manual, “FuelSystem Secondary Filter - Replace”.

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114 SEBU8600-02Maintenance SectionFuel System Primary Filter/Water Separator - Drain

i04947017

Fuel System PrimaryFilter/Water Separator - Drain

SMCS Code: 1260-543; 1263-543



NOTICEThe water separator can be under suction during nor-mal engine operation. Ensure that the drain valve istightened securely to help prevent air from enteringthe fuel system.

1. Place a suitable container under the water separator in order to catch any fluid that mightspill. Clean up any spilled fluid.

2. Ensure that the outer body of the filter assembly isclean and free from dirt.


Typical example

3. Install a suitable tube onto drain (3). Openthe drain valve (2). Rotate the drain valvecounterclockwise. Two full turns are required.Loosen vent screw (1).

4. Allow the fluid to drain into the container.

5. Tighten the drain valve clockwise by handpressure only. Remove the tube and remove thecontainer.

6. Tighten the vent screw securely.

i04947024

Fuel System Secondary Filter -Replace

SMCS Code: 1261-510-SE



Refer to Systems Operation, Testing, andAdjusting, “Cleanliness of Fuel SystemComponents” for detailed information on thestandards of cleanliness that must be observedduring ALL work on the fuel system.

Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFFposition before performing this maintenance.

2. Place a suitable container under the fuel filter inorder to catch any fuel that might spill. Clean upany spilled fuel. Clean the outside body of the filter assembly.

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Fuel System Secondary Filter - Replace


Typical example

3. Install a suitable tube onto drain (4). Openthe drain valve (3). Rotate the drain valvecounterclockwise. Two full turns are required.Loosen vent screw (1).

4. Allow the fuel to drain into the container andremove the tube.

5. Tighten the vent screw (1) securely.

6. Remove the filter bowl (2). Rotate the filter assembly counterclockwise in order to remove theassembly. Refer to your caterpillar dealer for thecorrect tool number.


Typical example

7. Rotate the fi lter element (5) counterclockwise andremove the fi lter element. Clean the fi lter bowl.

Install the Element


Typical example

1. Locate the thread (7) in the fi lter element onto thethreads (8). Spin on the element and tighten thedrain valve (3) by hand.

2. Lubricate the O ring seal (6) with clean engine oil.

Do NOT fi ll the filter bowl (2) with fuel before thefilter assembly is installed.

3. Do not use a tool in order to install the filter assembly. Tighten the assembly by hand. Installthe filter bowl (2). Turn the filter bowl clockwiseuntil the filter bowl locks into position against thestops.

4. Turn the fuel supply valve to the ON position.

5. The primary fuel filter and the secondary fuelfilter must be replaced at the same time. Refer to the Operation and Maintenance Manual ,

“Fuel System Primary Filter (Water Separator)Element - Replace”. Also, the in-line fuel must bereplaced when the primary and secondary filtersare replaced. Refer to Operation and MaintenanceManual , “Fuel Filter (In-Line) - Replace”

6. Prime the fuel system. Refer to the Operation andMaintenance Manual, “Fuel System - Prime” for more information.

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116 SEBU8600-02Maintenance SectionFuel Tank Water and Sediment - Drain

i02348492

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.


Fuel TankFuel quality is critical to the performance and to theservice life of the engine. Water in the fuel can causeexcessive wear to the fuel system.

Water can be introduced into the fuel tank when thefuel tank is being filled.

Condensation occurs during the heating and coolingof fuel. The condensation occurs as the fuel passesthrough the fuel system and the fuel returns to thefuel tank. This causes water to accumulate in fueltanks. Draining the fuel tank regularly and obtaining

fuel from reliable sources can help to eliminate water in the fuel.

Drain the Water and the Sediment

Fuel tanks should contain some provision for drainingwater and draining sediment from the bottom of thefuel tanks.

Open the drain valve on the bottom of the fuel tankin order to drain the water and the sediment. Closethe drain valve.

Check the fuel daily. Allow five minutes after the

fuel tank has been filled before draining water andsediment from the fuel tank.

Fill the fuel tank after operating the engine inorder to drive out moist air. This will help preventcondensation. Do not fill the tank to the top. Thefuel expands as the fuel gets warm. The tank mayover flow.

Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuelsupply pipe. Some fuel tanks use supply lines thattake fuel directly from the bottom of the tank. If the engine is equipped with this system, regular maintenance of the fuel system fi lter is important.

Fuel Storage Tanks

Drain the water and the sediment from the fuelstorage tank at the following intervals:

• Weekly

• Service intervals

• Refill of the tank

This will help prevent water or sediment from being

pumped from the storage tank into the engine fueltank.

If a bulk storage tank has been refilled or movedrecently, allow adequate time for the sediment tosettle before filling the engine fuel tank. Internalbaf fles in the bulk storage tank will also help trapsediment. Filtering fuel that is pumped from thestorage tank helps to ensure the quality of the fuel.When possible, water separators should be used.

i02518232

Hoses and Clamps -

Inspect/Replace

SMCS Code: 7554-040; 7554-510



Inspect all hoses for leaks that are caused by thefollowing conditions:

• Cracking

• Softness

• Loose clamps

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Overhaul Considerations

Replace hoses that are cracked or soft. Tighten anyloose clamps.

Check for the f ollowing conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wir e that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

• Armoring that is embedded in the outer covering

A constant torque hose clamp can be used in placeof any standard hose clamp. Ensure that the constanttorque hose clamp is the same size as the standard

clamp.

Due to extreme temperature changes, the hose willharden. Hardening of the hoses will cause hoseclamps to loosen. This can result in leaks. A constanttorque hose clamp will help to prevent loose hoseclamps.

Each installation application can be different. Thedifferences depend on the following factors:

• Type of hose

• Type of fitting material

• Anticipated expansion and contraction of the hose

• Anticipated expansion and contraction of thefittings

Replace the Hoses and the Clamps

Refer to the OEM information for further informationon removing and replacing fuel hoses (if equipped).

The following text describes a typical methodof replacing coolant hoses. Refer to the OEM

inf ormation for further information on the coolantsystem and the hoses for the coolant system.

Pressurized System: Hot coolant can cause seri-ous burns. To open the cooling system filler cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempr essure cap slowly in order to relieve the pres-sure.

1. Stop the engine. Allow the engine to cool.

2. Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the coolingsystem filler cap.

Note: Drain the coolant into a suitable, cleancontainer. The coolant can be reused.

3. Drain the coolant from the cooling system to alevel that is below the hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: For the correct coolant, see this Operation andMaintenance Manual, “Fluid Recommendations”.

8. Refill the cooling system. Refer to the OEMinformation for further information on refilling thecooling system.

9. Clean the cooling system filler cap. Inspect thecooling system filler cap's seals. Replace thecooling system fi ller cap if the seals are damaged.Install the cooling system fi ller cap.

10. Start the engine. Inspect the cooling system for leaks.

i04224312


SMCS Code: 7595-043

Reduced hours of operation at full load will result in alower average power demand. A decreased averagepower demand should increase both the engineservice life and the overhaul interval.

The need for an overhaul is indicated by increasedfuel consumption, increased oil consumption,excessive engine blowby, and reduced power. Arctic

temperatures, extreme high temperatures, corrosiveenvironments, or extreme dusty conditions contributeto premature wear and the need for an overhaul.

The following factors are important when a decisionis being made on the proper time for an engineoverhaul:

• The need for preventive maintenance

• The quality of the fuel that is being used

• The operating conditions

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118 SEBU8600-02Maintenance SectionOverhaul Considerations

• The results of the S·O·S analysis

Oil Consumption as an OverhaulIndicator

Oil consumption, fuel consumption, and maintenanceinformation can be used to estimate the totaloperating cost for your Caterpillar engine. Oilconsumption can also be used to estimate therequired capacity of a makeup oil tank that is suitablefor the maintenance intervals.

Oil consumption is in proportion to the percentageof the rated engine load. As the percentage of theengine load is increased, the amount of oil that isconsumed per hour also increases.

The oil consumption rate (brake-specific oilconsumption) is measured in grams per kW/h (lb per

bhp). The brake-specific oil consumption (BSOC)depends on the engine load. Consult your Caterpillar dealer for assistance in determining the typical oilconsumption rate for your engine.

When an engines oil consumption has risen to threetimes the original oil consumption rate due to normalwear, an engine overhaul should be scheduled.There may be a corresponding increase in blowbyand a slight increase in fuel consumption.

Overhaul Options

Before Failure Overhaul

A planned overhaul before failure may be the bestvalue for the following reasons:

• Costly unplanned downtime can be avoided.

• Many original parts can be reused according to thestandards for reusable parts.

• The engines service life can be extended withoutthe r isk of a major catastrophe due to enginefailure.

• The best cost/value relationship per hour of

extended life can be attained.

After Failure Overhaul

If a major engine failure occurs and the enginemust be removed, many options are available. Anoverhaul should be performed if the engine block or the crankshaft needs to be repaired.

If the engine block is repairable and/or the crankshaftis repairable, the overhaul cost will be less than thecost of a new engine with a similar exchange core.

This lower cost can be attributed to three aspects:

• Specially designed Caterpillar engine features

• Caterpillar dealer exchange components

• Caterpillar Inc. remanufactured exchangecomponents

Overhaul Recommendation

To minimize downtime, Caterpillar Inc. recommends ascheduled engine overhaul by your Caterpillar dealer before the engine fails. This process will provide youwith the best cost/value relationship.

Note: Overhaul programs vary according to theengine application and according to the dealer thatperforms the overhaul. Consult your Caterpillar

dealer for specifi

c information about the availableoverhaul programs and about overhaul services for extending the engine life.

Aftertreatment

The aftertreatment system can be expected tofunction properly for the useful life of the engine(emissions durability period), as defined byregulation, subject to prescribed maintenancerequirements being followed.

Rebuild or Exchange

If an overhaul is performed without overhaul servicefrom your Caterpillar dealer, be aware of the followingmaintenance recommendations.

Cylinder Head Assembly, Oil Pump, and FuelTransfer Pump

These components should be inspected according tothe instructions that are found in various Caterpillar reusability publications. The Special Publication,SEBF8029 lists the reusability publications that areneeded for inspecting the engine parts.

If the parts comply with the established inspection

specifications that are expressed in the reusableparts guideline, the parts should be reused.

Par ts that are not within the established inspectionspecifications should be dealt with in one of thefollowing manners:

• Salvaging

• Repairing

• Replacing

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Using out-of-spec parts can result in the followingproblems:

• Unscheduled downtime

• Costly repairs

• Damage to other engine parts

• Reduced engine ef ficiency

• Increased fuel consumption

Reduced engine ef ficiency and increased fuelconsumption translates into higher operating costs.Therefore, Caterpillar Inc. recommends repairingout-of-spec parts or replacing out-of-spec parts.

Inspection and/or Replacement

Crankshaft Bearings Crankshaft Seals andPistons

The following components may not last until thesecond overhaul.

• Thrust bearings

• Main bearings

• Rod bearings

• Crankshaft seals

• Piston assembly

Cater pillar Inc. recommends the installation of newparts at each overhaul period.

Inspect these parts while the engine is disassembledfor an overhaul.

Inspect the crankshaft for any of the followingconditions:

• Deflection

• Damage to the journals

• Bearing material that has seized to the journals

Check the journal taper and the profile of thecrankshaft journals. If the wear patterns on the rodbearing or the main bearing show a problem, thecr ankshaft will need to be measured with specialistequipment.

Inspect the camshaft for damage to the journals andto the lobes.

Note: If the camshaft is removed for any reason, usethe magnetic particle inspection process to check for cracks in the camshaft.

Inspect the following components for signs of wear or for signs of scuf fing:

• Camshaft bearings

• Lifters

Caterpillar Inc. recommends replacing the crankshaftvibration damper.

Oil Cooler Core

During an overhaul, Caterpillar Inc. recommends theremoval of the oil cooler core. Clean the oil cooler core. Then, pressure test the oil cooler core.

NOTICEDo not use caustic cleaners to clean the core.

Caustic cleaners can attack the internal metals of thecore and cause leakage.

Note: Use this cleaning procedure to clean the oilcooler core.

1. Remove the oil cooler core.

2. Remove any debris from the oil cooler core. Toremove debris from the oil cooler core, turn the oil

cooler core onto one end.

3. Flush the oil cooler core internally with cleaner inorder to loosen foreign substances. This flushingwill also help to remove oil from the oil cooler core.

Note: Caterpillar Inc. recommends the use of Hydrosolv Liquid Cleaners. Table 12 lists theHydrosolv Liquid Cleaners that are available fromyour Caterpillar dealer.

Table 12

HydrosolvLiquid Cleaners

PartNumber

Description Size

1U-8812 4 L (1 US gallon)

1U-5490 19 L (5 US gallon)

8T-7570

Hydrosolv4165

208 L (55 US gallon)

1U-8804 4 L (1 US gallon)

1U-5492 19 L (5 US gallon)

8T-5571

Hydrosolv100

208 L (55 US gallon)

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120 SEBU8600-02Maintenance SectionRadiator - Clean

4. Use steam to clean the oil cooler core. Thesteam will remove any remaining residue fromthe cleaner. Flush the fins of the oil cooler core.Remove any other trapped debris.

5. Wash the oil cooler core with hot, soapy water.

Rinse the oil cooler core thoroughly with cleanwater.



Maximum air pressure at the nozzle must be lessthan 205 kPa (30 psi) for cleaning purposes.

6. Dry the oil cooler core with compressed air. Directthe air in the reverse direction of the normal flow.

7. Inspect the components in order to ensurecleanliness. The oil cooler core should bepressur e tested. Repair the oil cooler core, if necessary. Install the oil cooler core.

For mor e information about cleaning the cores,consult your Caterpillar dealer.

Obtain Coolant Analysis

The concentration of supplemental coolant additive(SCA) should be checked regularly with test kitsor with S·O·S Coolant Analysis (Level 1). Further coolant analysis is recommended when the engineis overhauled.

For example, considerable deposits are found in thewater jacket areas on the external cooling system,but the concentrations of coolant additives werecarefully maintained. The coolant probably containedminerals that were deposited on the engine over time.

A coolant analysis can be conducted in order to verify

the condition of the water that is being used in thecooling system. A full water analysis can be obtainedby consulting your local water utility company or an agricultural agent. Private laboratories are alsoavailable for water analysis.

Caterpillar Inc. recommends an S·O·S Coolant Analysis (Level 2).


An S·O·S Coolant Analysis (Level 2) is acomprehensive coolant analysis which completelyanalyzes the coolant and the effects on the coolingsystem. An S·O·S Coolant Analysis (Level 2) provides

the following information:

• Complete S·O·S Coolant Analysis (Level 1)

• Visual inspection of properties

• Identification of metal corrosion

• Identification of contaminants

• Identification of built up impurities (corrosion andscale)

S·O·S Coolant Analysis (Level 2) provides a report of

the results of both the analysis and the maintenancerecommendations.

For more information about coolant analysis, seeyour Caterpillar dealer.

i04248509

Radiator - Clean

SMCS Code: 1353-070

Note: Some applications will require a fuel cooler

to be installed. The fuel cooler is a type of radiator that uses air to cool the fuel and the fuel cooler willrequire cleaning.

Note: Adjust the frequency of cleaning according tothe effects of the operating environment.

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



The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the air nozzle is deadheaded.

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Radiator Pressure Cap - Clean/Replace

Pressurized air is the preferred method for removingloose debris. Direct the air in the opposite directionof the air flow. Hold the nozzle approximately 6 mm(0.25 inch) away from the fins. Slowly move the air nozzle in a direction that is parallel with the tubes.This movement will remove debris that is between

the tubes.

Pressurized water may also be used for cleaning.The maximum water pressure for cleaning purposesmust be less than 275 kPa (40 psi). Use pressurizedwater in order to soften mud. Clean the core fromboth sides.

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

After cleaning, start the engine and accelerate the

engine to high idle rpm. This procedure will help inthe removal of debris and drying of the core. Stop theengine. Use a light bulb behind the core in order toinspect the core for cleanliness. Repeat the cleaning,if necessary.

Inspect the fins for damage. Bent fins may be openedwith a “comb”. Inspect these items for good condition:welds, mounting brackets, air lines, connections,clamps, and seals. Make repairs, if necessary.

i03639888

Radiator Pressure Cap -Clean/Replace

SMCS Code: 1353-Z2


NOTICEWhen any servicing or repair of the engine coolingsystem is performed the procedure must be performedwith the engine on level ground. This will allow you toaccurately check the coolant level. This will also helpin avoiding the risk of introducing an air lock into thecoolant system.

1. Stop the engine and allow the engine to cool.Loosen the cooling system filler cap slowly inorder to relieve any pressure. Remove the radiator pressure cap.

2. Check coolant level. Refer to Operation andMaintenance Manual, “Cooling System CoolantLevel - Check”.

3. Install new radiator pressure cap.

i00151038

Severe Service Application -Check

SMCS Code: 1000-535

Severe service is an application of an engine thatexceeds current published standards for that engine.Caterpillar maintains standards for the followingengine parameters:

• Performance (power range, speed range, and fuel

consumption)

• Fuel quality

• Altitude range

• Maintenance intervals

• Oil selection and maintenance

• Coolant selection and maintenance

• Environmental qualities

• Installation

Refer to the standards for the engine or consult withyour Caterpillar dealer in order to determine if theengine is operating within the defined parameters.

Severe service operation can accelerate componentwear. Engines that operate under severe conditionsmay need more frequent maintenance intervals inorder to ensure maximum reliability and retention of full service life.

Due to individual applications, it is not possible toidentify all of the factors which can contribute to

severe service operation. Consult your Caterpillar dealer for the unique maintenance that is necessaryfor the engine.

The operating environment, improper operatingprocedures and improper maintenance procedurescan be factors which contribute to severe serviceconditions.

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122 SEBU8600-02Maintenance SectionStarting Motor - Inspect

Environmental Factors

Ambient temperatures – The engine may beexposed to extended operation in extremelycold environments or hot environments. Valvecomponents can be damaged by carbon buildup if

the engine is frequently started and stopped in verycold temperatures. Extremely hot inlet air reducesengine performance.

Air Quality – The engine may be exposed toextended operation in an environment that is dirtyor dusty, unless the equipment is cleaned regularly.Mud, dirt and dust can encase components.Maintenance can be very dif ficult. The buildup cancontain corrosive chemicals.

Buildup – Compounds, elements, corrosivechemicals and salt can damage some components.

Altitude – Problems can arise when the engine isoperated at altitudes that are higher than the intendedsettings for that application. Necessary adjustmentsshould be made.

Improper Operating Procedures

• Extended operation at low idle

• Frequent hot shutdowns

• Operating at excessive loads

• Operating at excessive speeds

• Operating outside the intended application

Improper Maintenance Procedures

• Extending the maintenance intervals

• Failure to use recommended fuel, lubricants andcoolant/antifreeze

i02348493

Star ting Motor - InspectSMCS Code: 1451-040; 1453-040

Caterpillar recommends a scheduled inspection of the starting motor. If the starting motor fails, theengine may not start in an emergency situation.

Check the starting motor for correct operation. Checkthe electrical connections and clean the electricalconnections. Refer to the Systems Operation, Testingand Adjusting Manual, “Electric Starting System -Test” for more information on the checking procedureand for specifications or consult your Caterpillar

dealer for assistance.

i04103131

Turbocharger - Inspect(High Pressure and LowPressure Turbochargers)

SMCS Code: 1052-040; 1052


Typical example

Hot engine components can cause injury fromburns. Before performing maintenance on theengine, allow the engine and the components tocool.

The engine is equipped with a high-pressureturbocharger (1) and a low-pressure turbocharger (4).

A regular visual inspection of both turbochargers isrecommended. If the turbocharger fails during engineoperation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to theturbocharger compressor wheel can cause additionaldamage to the pistons, the valves, and the cylinder head.

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Turbocharger - Inspect

NOTICETurbocharger bearing failures can cause large quanti-ties of oil to enter the air intake and exhaust systems.Loss of engine lubricant can result in serious enginedamage.

Minor leakage of oil into a turbocharger under extend-ed low idle operation should not cause problems aslong as a turbocharger bearing failure has not oc-cured.

When a turbocharger bearing failure is accompaniedby a significant engine performance loss (exhaustsmoke or engine rpm up at no load), do not continueengine operation until the turbocharger is renewed.

A visual inspection of the turbochargers can minimizeunscheduled downtime. A visual inspection of

the turbochargers can also reduce the chance for potential damage to other engine parts. Do notinspect the engine with the engine in operation.

Removal and Installation

Refer to the Disassembly and Assembly Manual,“Turbocharger - Remove and Turbocharger Install”for further information.

Inspecting

NOTICEThe compressor housing for the turbocharger mustnot be removed from the turbocharger for inspectionor removed for the cleaning of the compressor.

1. Ensure that the turbocharger is clean and free fromdirt before removing components for inspection.

2. Remove the pipe from the high-pressuretur bocharger exhaust outlet and remove the air intake pipe to the turbocharger. Visually inspectthe piping for the presence of oil. Clean the interior of the pipes in order to prevent dirt from enteringduring reassembly.

3. Remove bolt (3).

4. Remove air duct (2) and check for the presenceof engine oil.

5. Check for any loose bolts or any missing bolts.Check for damage to the oil supply line and the oildrain line. Check for cracks in the housing of theturbocharger. Ensure that the compressor wheelcan rotate freely.

6. Check for the pr esence of oil. If oil is leaking fromthe back side of the compressor wheel, there is apossibility of a failed turbocharger oil seal.

The presence of oil may be the result of extendedengine operation at low idle. The presence of oil

may also be the result of a restriction of the linefor the intake air (clogged air filters), which causesthe turbocharger to slobber.

7. If engine oil is found in the system, the cause canbe the engine operating condition.

a. Ensure that the air duct (2) is clean and freefrom dirt. Install air duct (2). Install bolt (3).Ensure that the air intake is not clogged.

b. Operate the engine for 15 minutes at amoderate high load condition.

c. Allow the engine to cool. Remove air duct andcheck for the presence of engine oil. If thedeposits of wet engine oil have been removed,the air duct can be installed and the engine canoperate normally. For more information, refer to Systems Operation, Testing and Adjusting,“Turbocharger - Inspect”.

8. Inspect the bore of the housing of the turbineoutlet for corrosion.

9. Fasten the air intake pipe and the exhaust outletpipe to the turbocharger housing. Ensure that allclamps are installed correctly and that all clamps

are tightened securely.

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124 SEBU8600-02Maintenance SectionWalk-Around Inspection

i04156725

Walk-Around Inspection

SMCS Code: 1000-040

Inspect the Tube of the CrankcaseBreather


Typical example

Inspect the breather tube (1) for damage. Ensure thatthe outlet (2) is clean and free from any obstructions.Ice can cause obstructions in adverse weather conditions.

Inspect the Engine for Leaks andfor Loose Connections

A walk-around inspection should only take a fewminutes. When the time is taken to perform thesechecks, costly repairs and accidents can be avoided.

For maximum engine service life, make a thoroughinspection of the engine compartment before startingthe engine. Look for items such as oil leaks or coolantleaks, loose bolts, worn belts, loose connections, andtrash buildup. Make repairs, as needed:

• The guards must be in the correct place. Repair damaged guards or replace missing guards.

• Wipe all caps and plugs before the engine isserviced in order to reduce the chance of systemcontamination.

NOTICEFor any type of leak (coolant, lube, or fuel) clean up thefluid. If leaking is observed, find the source and correctthe leak. If leaking is suspected, check the fluid levelsmore often than recommended until the leak is found

or fixed, or until the suspicion of a leak is proved to beunwarranted.

NOTICE Accumulated grease and/or oil on an engine is a firehazard. Remove the accumulated grease and oil. Re-fer to this Operation and Maintenance Manual, “En-gine - Clean” for more information.

• Ensure that the cooling system hoses are correctlyclamped and that the cooling system hoses aretight. Check for leaks. Check the condition of allpipes.

• Inspect the water pump for coolant leaks.

Note: The water pump seal is lubricated by thecoolant in the cooling system. It is normal for a smallamount of leakage to occur as the engine cools downand the parts contract.

Excessive coolant leakage may indicate the need toreplace the water pump. Remove the water pump.Refer to Disassembly and Assembly , “Water Pump -Remove and Install”. For more information, consultyour Caterpillar dealer.

• Inspect the lubrication system for leaks at the frontcrankshaft seal, the rear crankshaft seal, the oilpan, the oil fi lters, and the rocker cover.

• Inspect the piping for the air intake system and theelbows for cracks and for loose clamps. Ensurethat hoses and tubes are not contacting other hoses, tubes, wiring harnesses, etc.

• Ensure that the areas around the rotating parts areclear.

• Inspect the alternator belts and any accessory

drive belts for cracks, breaks, or other damage.

• Inspect the wiring harness for damage.

Belts for multiple groove pulleys must be replaced asmatched sets. If only one belt is replaced, the belt willcarry more load than the belts that are not replaced.The older belts are stretched. The additional load onthe new belt could cause the belt to break.

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Water Pump - Inspect


Contact with high pressure fuel may cause fluid

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

After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure tobe purged from the high-pressure fuel lines beforeany service or repair is performed on the enginefuel lines. If necessary, perform minor adjustments.Repair any leaks from the low-pressure fuel systemand from the cooling, lubrication, or air systems.Replace any high-pressure fuel line that has leaked.Refer to Disassembly and Assembly Manual, “FuelInjection Lines - Install”.


Visually inspect the high-pressure fuel lines for damage or signs of fuel leakage. Replace anydamaged high-pressure fuel lines or high-pressurefuel lines that have leaked.

Ensure that all clips on the high-pressure fuel linesare in place and that the clips are not loose.

• Inspect the rest of the fuel system for leaks. Lookfor loose fuel line clamps.

• Drain the water and the sediment from the fueltank on a daily basis in order to ensure that onlyclean fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayedwires. Check for any loose tie-wraps or missingtie-wraps.

• Inspect the ground strap for a good connection andfor good condition.

• Disconnect any battery chargers that are notpr otected against the current drain of the startingmotor. Check the condition and the electrolyte levelof the batteries, unless the engine is equipped witha maintenance free battery.

• Check the condition of the gauges. Replace anygauges that are cracked. Replace any gauge thatcannot be calibrated.

i03570653

Water Pump - Inspect

SMCS Code: 1361-040; 1361

A failed water pump may cause severe engineoverheating problems that could result in the followingconditions:

• Cracks in the cylinder head

• A piston seizure

• Other potential damage to the engine


(A) Weep hole(B) Vent hole

Note: The water pump seals are lubricated by the

coolant in the cooling system. It is normal for a smallamount of leakage to occur. Refer to illustration 91for the position of the weep hole and the vent hole.

Visually inspect the water pump for leaks.

Note: If engine coolant enters the engine lubricatingsystem the lubricating oil and the engine oil filter mustbe replaced. This will remove any contamination thatis caused by the coolant and this will prevent anyirregular oil samples.

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126 SEBU8600-02Maintenance SectionWater Pump - Inspect

The water pump is not a serviceable item. In order toinstall a new water pump, refer to the Disassemblyand Assembly Manual, “Water Pump - Remove andInstall”.

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SEBU8600-02 127Warranty Section

Warranty Information

Warranty Section

Warranty Information

i01087950

Emissions WarrantyInformation

SMCS Code: 1000

This engine may be certified to comply with exhaustemission standards and gaseous emission standardsthat are pr escribed by law at the time of manufacture,and this engine may be covered by an EmissionsWarranty. A detailed explanation of the EmissionsWarranty that is applicable to emissions certified

engines is found in Supplement, SEBU6981, “FederalEmissions Control Warranty Information”. Consultyour authorized Caterpillar dealer to determine if your engine is emissions certified and if your engine issubject to an Emissions Warranty.

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128 SEBU8600-02Reference Information SectionEngine Ratings

Reference InformationSection

Engine Ratingsi03579032

Engine Rating Conditions

SMCS Code: 1000

It is important to know the use of the engine sothat the rating will match the operating profile. Theproper rating selection is also important so that thecustomer's perception of price and value is realized.

In selecting a rating for a specific application, the

most important consideration is the time that is spentat full throttle. The rating definitions identify thepercent of time at full throttle. The definitions alsoidentify the corresponding times below rated rpm.

Note: For an exact determination of the appropriaterating, follow the OEM specifications or consult your Caterpillar dealer.

There are five ratings from A to E. The rating for theC7.1 industrial engine is C.

C – Intermittent service in conjunction with maximum

power and/or speed are cyclic. The engine at full loadshould not exceed 50 percent of the duty cycle.

NOTICEOperating engines above the rating definitions can re-sult in shorter service life before overhaul.

i04650089

Engine Rating Definitions

SMCS Code: 1000

All engine ratings are in compliance with the followingstandard ambient air conditions of “ISO14396:2002”:

• 100 kPa (29.3 Inches Hg)

• 30 percent relative humidity

• A temperature of 25 °C (77 °F)

The engine ratings are based on the following fuelspecifications:

• The Low Heat Value (LHV) of the fuel at 29 °C(84.2 °F) at 42780 kJ/kg (18390 Btu/lb)

• Specific gravity of .833 - 837 at 15 °C (60 °F)

The engine ratings are gross output ratings.

Gross Output Ratings – The total output capabilityof the engine that is equipped with standard

accessories.

Standard accessories include the followingcomponents:

• Oil pumps

• Fuel pumps

• Water pumps

Subtract the power that is required to drive auxiliarycomponents from the gross output. This processwill produce the net power that is available for the

external load (flywheel).

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SEBU8600-02 129Reference Information Section

Customer Service

Customer Service

i03996951

Customer Assistance

SMCS Code: 1000

USA and Canada

When a problem arises concerning the operation or the service of an engine, the problem will normally bemanaged by the dealer in your area.

Outside of the USA and of Canada

If a problem arises outside the USA and outsideCanada, and if the problem cannot be resolved at the

dealer level, consult the appropriate Caterpillar of fi

ce.

Latin America, Mexico, CarribeanCaterpillar Americas Co.701 Waterford Way, Suite 200Miami, FL 33126-4670USAPhone: 305-476-6800Fax: 305-476-6801

Europe, Africa, and Middle EastCaterpillar Overseas S.A.76 Route de FrontenexP.O. Box 6000

CH-1211 Geneva 6SwitzerlandPhone: 22-849-4444Fax: 22-849-4544

Far EastCaterpillar Asia Pte. Ltd.7 Tractor RoadJurong, Singapore 627968Republic of SingaporePhone: 65-662-8333Fax: 65-662-8302

China

Caterpillar China Ltd.37/F., The Lee Gardens33 Hysan AvenueCauseway BayG.P.O. Box 3069Hong KongPhone: 852-2848-0333Fax: 852-2848-0440

JapanShin Caterpillar Mitsubishi Ltd.SBS Tower 10-1, Yoga 4-ChomeSetagaya-Ku, Tokyo 158-8530Japan

Phone: 81-3-5717-1150Fax: 81-3-5717-1177

JapanCaterpillar Power Systems, Inc.SBS Tower (14th floor)4-10-1, YogaSetagaya-Ku, Tokyo 158-0097Phone: 81-3-5797-4300Fax: 81-3-5797-4359

Australia and New ZealandCaterpillar of Australia Ltd.1 Caterpillar Drive

Private Mail Bag 4Tullamar ine, Victoria 3043

AustraliaPhone: 03-9953-9333Fax: 03-9335-3366

i03655027

Ordering Replacement Parts

SMCS Code: 7567

When replacement parts are required for thisproduct Caterpillar recommends using Caterpillar replacement parts or parts with equivalent spec-ifications including, but not limited to, physicaldimensions, type, strength and material.

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

Quality Caterpillar replacement parts are availablefrom Caterpillar dealers throughout the world.

Caterpillar dealers' parts inventories are up-to-date.The parts stocks include all of the parts that arenormally needed to protect your Caterpillar engineinvestment.

When you order parts, please specify the followinginformation:

• When a Caterpillar engine requires maintenanceand/or repair, provide the dealer with all theinformation that is stamped on the InformationPlate. Refer to this Operation and MaintenanceManual, “Plate Locations and Film Locations”.

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130 SEBU8600-02Reference Information SectionCustomer Service

• Part number

• Part name

• Quantity

If there is a question concerning the part number,please provide your dealer with a completedescription of the needed item.

Discuss the problem with the dealer. Inform thedealer about the conditions of the problem and thenature of the problem. Inform the dealer about whenthe problem occurs. This will help the dealer introubleshooting the problem and solving the problemfaster.

8/10/2019 C7.1 Engine



Reference Materials

Reference Materials

i03975270

Reference Material

SMCS Code: 1000

The following literature can be obtained through anyCaterpillar dealer.

Lubricants

• Special Publication, PEHP8038, “Data Sheet -Caterpillar Diesel Engine Oils (DEO) (CH-4) (North

America)”

• Special Publication, PEHP9536, “Data Sheet- Caterpillar Diesel Engine Oil (DEO) (CF-4)

(International only)”

• Special Publication, NEDG6022, “Cat LubricatingGrease”

• Special Publication, PEHP0002, “Data Sheet -Molybdenum (MPGM) Grease”

• Special Publication, NEHP6015, “Data Sheet -Caterpillar Special Purpose Grease (SPG)”

• Operation and Maintenance Manual, SEBU5898,“Cold Weather Recommendations”

• Operation and Maintenance Manual, SEBU6251,“Caterpillar Commercial Diesel Engine FluidsRecommendations”

• Special Publication, PEHP6001, “How To Take AGood Oil Sample”

Coolants

• Special Publication, PEHP4036, “Data Sheet -Extended Life Coolant”

• Special Publication, PEHP7057, “Data Sheet -

S·O·S Coolant Analysis”

• Special Publication, SEBD0518, “Know Your Cooling System”

• Label, PEEP5027, “Extended Life Coolant/ Antifreeze”

Miscellaneous

• Service Manual, REG1139F, “Service ManualContents Microfiche”

• Service Manual, UERN0603, “C7.1 IndustrialEngines”

• Troubleshooting, KENR9106, “C7.1 IndustrialEngines”

• Systems Oper ation, Testing, and Adjusting,KENR9104, “C7.1 Industrial Engines”

• Specifications, KENR9103, “C7.1 IndustrialEngines.”

• Disassembly and Assembly, KENR9105, “C7.1Industrial Engines”

• Specifications, SENR3130, “Torque Specifications”

• Special Publication, PECP9067, “One SafeSource” English language for use in NACD

• Special Publication, LEDM5615, “Caterpillar Marine Parts and Service Locations Directory”

• Special Publication, SEBF8029, “Index toGuidelines for Reusable Parts and SalvageOperations”

• Special Publication, SEBF8062, “Procedure toInspect and Clean Air Filters”

• Special Instruction, SEHS9031, “StorageProcedure for Caterpillar Products”

• Special Publication, NEHS0526, “Service

Technician Application Guide”

• Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine FluidsRecommendations”

• Special Instruction, SEHS7633, “Battery TestProcedure”

• Label, SEHS7332, “Danger Do Not Operate”

Emissions Warranty

This engine may be Certified and this enginemay be covered by an Emissions Warranty. Adetailed explanation of the Emissions Warrantythat is applicable to Certified engines is foundin Supplement, SMBU6981, “Emissions ControlWarranty Information”. The engine is Certified if the engine has a special label that verifies thecertification. A Caterpillar dealer can also inform youif the engine is certified.

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132 SEBU8600-02Reference Information SectionReference Materials

i02780825

Additional Reference Material

SMCS Code: 1000

The “Society of Automotive Engineers (SAE)Specifications” can be found in your SAE handbook.This publication can also be obtained from thefollowing locations: local technological society, locallibrary, and local college. If necessary, consult SAEat the following address:

SAE International400 Commonwealth DriveWarrendale, PA, USA 15096-0001Telephone: (724) 776-4841

The “American Petroleum Institute Publication No.1509” can be obtained from the following locations:

local technological society, local library, and localcollege. If necessary, consult API at the followingaddress:

American Petroleum Institute1220 L St. N.W.Washington, DC, USA 20005Telephone: (202) 682-8000

The International Organization for Standardization(ISO) of fers information and customer serviceregarding international standards and standardizingactivities. ISO can also supply information on thefollowing subjects that are not controlled by ISO:

national standards, regional standards, regulations,certification, and related activities. Consult themember of ISO in your country.

International Organization for Standardization(ISO)1, rue de VarembéCase postale 56CH-1211 Genève 20SwitzerlandTelephone: +41 22 749 01 11Facsimile: +41 22 733 34 30E-mail: [email protected] site: http://www.iso.ch

European classifications are established by theCounseil International Des Machines a Combustion(CIMAC) (International Council on CombustionEngines).

CIMAC Central SecretariatLyoner Strasse 1860528 FrankfurtGermanyTelephone: +49 69 6603 1567Facsimile: +49 69 6603 1566

i00912149

Maintenance Records

SMCS Code: 1000

Caterpillar Inc. recommends the retention of accuratemaintenance records. Accurate maintenance recordscan be used for the following purposes:

• Determine operating costs.

• Establish maintenance schedules for other enginesthat are operated in the same environment.

• Show compliance with the required maintenancepractices and maintenance intervals.

Maintenance records can be used for a variety of other business decisions that are related to engine

maintenance.

Maintenance records are a key element of amaintenance program that is well managed. Accuratemaintenance records can help your Caterpillar dealer to fine tune the recommended maintenance intervalsin order to meet the specific operating situation. Thisshould r esult in a lower engine operating cost.

Records should be kept for the following items:

Fuel Consumption – A record of fuel consumptionis essential in order to determine when the loadsensitive components should be inspected or

repaired. Fuel consumption also determines overhaulintervals.

Service Hours – A record of service hours isessential to determine when the speed sensitivecomponents should be inspected or repaired.

Documents – These items should be easy toobtain, and these items should be kept in the enginehistory file. All of the documents should show thisinformation: date, service hours, fuel consumption,unit number, and engine serial number. The followingtypes of documents should be kept as proof of maintenance or repair for warranty:

Keep the following types of documents as proof of maintenance for warranty. Also, keep these types of documents as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owner's repair costs

• Owner's receipts

• Maintenance log

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Reference Materials

i01176304

Maintenance Log

SMCS Code: 1000

Table 13

Engine Model Customer Identifier

Serial Number Arrangement Number

ServiceHours

QuantityOf Fuel

Service Item Date Authorization

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134 SEBU8600-02Index Section

Index

A

Additional Reference Material ............................. 132

After Starting Engine ............................................. 62 After Stopping Engine............................................ 67 Aftercooler Core - Clean/Test (Air-To-Air

Aftercooler) .......................................................... 83 Aftercooler Core - Inspect...................................... 83 Alternator - Inspect ................................................ 84 Alternator and Fan Belts - Replace ....................... 84 ARD Spark Plug - Clean/Inspect/Replace ............. 83

B

Battery - Replace................................................... 84Battery Electrolyte Level - Check .......................... 85Battery or Battery Cable - Disconnect ................... 85Before Starting Engine .................................... 17, 60Belt - Inspect.......................................................... 86Belt Tensioner - Inspect ......................................... 86Burn Prevention...................................................... 11

Batteries............................................................. 12Coolant............................................................... 12Induction System ............................................... 12Oils..................................................................... 12

C

Cold Weather Operation........................................ 69Hints for Cold Weather Operation...................... 69Idling the Engine ................................................ 70Recommendations for Coolant Warm Up .......... 70Recommendations for the Coolant .................... 70Viscosity of the Engine Lubrication Oil............... 69

Cold Weather Starting ........................................... 60Configuration Parameters...................................... 55

Customer Specified Parameters........................ 56System Configuration Parameters..................... 55

Cooling System Coolant (DEAC) - Change........... 87Cooling Systems with Heavy Deposits or

Plugging ........................................................... 88Drain .................................................................. 87

Fill ...................................................................... 89Flush .................................................................. 88Cooling System Coolant (ELC) - Change.............. 89

Drain .................................................................. 90Fill ...................................................................... 91Flush .................................................................. 90

Cooling System Coolant Extender (ELC) - Add..... 91Cooling System Coolant Level - Check................. 92Cooling System Coolant Sample (Level 1) -

Obtain .................................................................. 93Cooling System Coolant Sample (Level 2) -

Obtain .................................................................. 94

Cooling System Supplemental Coolant Additive(SCA) - Test/Add.................................................. 94 Add the SCA, If Necessary ................................ 95

S·O·S Coolant Analysis...................................... 94Test for SCA Concentration ............................... 94

Crankshaft Vibration Damper - Inspect ................. 95Viscous Damper................................................. 95

Crushing Prevention and Cutting Prevention ........ 15Customer Assistance........................................... 129

Outside of the USA and of Canada.................. 129USA and Canada............................................. 129

Customer Service................................................ 129

D

Diagnostic Flash Code Retrieval ........................... 48Diagnostic Lamp.................................................... 48Diesel Particulate Filter - Clean............................. 96Diesel Particulate Filter Regeneration................... 63

Modes of Regeneration...................................... 64Regeneration ..................................................... 63Regeneration Indicators..................................... 63Regener ation Switch.......................................... 64Regeneration System Warning Indicators ......... 64Soot Level Monitoring ........................................ 64

Driven Equipment - Check..................................... 96

E

Electrical System................................................... 18Grounding Practices .......................................... 18

Emergency Stopping ............................................. 67Emergency Stop Button..................................... 67

Emissions Certification Film .................................. 30Emissions Warranty Information.......................... 127Engaging the Driven Equipment............................ 65Engine - Clean....................................................... 97

Aftertreatment System ....................................... 97Engine Air Cleaner Element (Dual Element) -

Clean/Replace ..................................................... 97Cleaning the Primary Air Cleaner Elements ...... 98Servicing the Air Cleaner Elements ................... 97

Engine Air Cleaner Element (Single Element) -Inspect/Replace................................................. 100Engine Air Cleaner Element (Single Element) -

Replace.............................................................. 101Engine Air Cleaner Service Indicator - Inspect.... 101

Test the Service Indicator................................. 101Engine Air Precleaner - Check/Clean.................. 102Engine Crankcase Breather Element - Replace.. 102

Bottom Service................................................. 104Check the System............................................ 105Top Service ...................................................... 103

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SEBU8600-02 135Index Section

Engine Description ................................................ 27 Aftermarket Products and Caterpillar Engines... 28 Aftertreatment System ....................................... 28Electronic Engine Features................................ 27Engine Cooling and Lubrication......................... 27Engine Diagnostics ............................................ 27

Engine Service Life ............................................ 28Engine Specifications......................................... 27

Engine Diagnostics................................................ 48Engine Electronics................................................. 19Engine Mounts - Inspect...................................... 105Engine Oil and Filter - Change ............................ 107

Drain the Engine Lubricating Oil ...................... 107Fill the Oil Pan.................................................. 108Replace the Oil Filter ....................................... 108

Engine Oil Level - Check..................................... 106Engine Oil Sample - Obtain................................. 106

Obtain the Sample and the Analysis................ 106Engine Operation................................................... 63

Engine Operation and Active Regeneration....... 63

Reduction of Particulate Emissions ................... 63Engine Operation with Active Diagnostic Codes ... 54Engine Operation with Intermittent Diagnostic

Codes .................................................................. 55Engine Rating Conditions.................................... 128Engine Rating Definitions .................................... 128Engine Ratings .................................................... 128Engine Shutoffs and Engine Alarms...................... 46

Alarms................................................................ 46Shutoffs.............................................................. 46Testing................................................................ 47

Engine Starting................................................ 17, 60Engine Stopping .............................................. 18, 67

F

Fan Clearance - Check........................................ 109Fault Logging......................................................... 54Features and Controls ........................................... 38Fire Prevention and Explosion Prevention ............ 12

Ether .................................................................. 14Fire Extinguisher................................................ 14Lines, Tubes, and Hoses ................................... 14Regeneration ..................................................... 14

Foreword ................................................................. 5California Proposition 65 Warning ....................... 5Literature Information........................................... 4

Maintenance ........................................................ 4Maintenance Intervals.......................................... 4Operation ............................................................. 4Overhaul .............................................................. 4Safety................................................................... 4

Fuel and the Effect from Cold Weather ................. 71Fuel Conservation Practices.................................. 66Fuel Filter (In-Line) - Replace............................... 110Fuel Related Components in Cold Weather .......... 72

Fuel Filters ......................................................... 72Fuel Heaters ...................................................... 72Fuel Tanks.......................................................... 72

Fuel System - Prime............................................. 111

Fuel System Primary Filter (Water Separator)Element - Replace .............................................. 112

Install the New Filter Element ........................... 113Remove the Element ........................................ 112

Fuel System Primary Filter/Water Separator -Drain ................................................................... 114

Fuel System Secondary Filter - Replace.............. 114Install the Element ............................................ 115Remove the Element ........................................ 114

Fuel Tank Water and Sediment - Drain ................ 116Drain the Water and the Sediment.................... 116Fuel Storage Tanks........................................... 116Fuel Tank .......................................................... 116

G

Gauges and Indicators .......................................... 36 Aftertreatment Lamps ........................................ 37Indicator Lamps ................................................. 37

General Hazard Information .................................... 8 Asbestos Information .......................................... 11Containing Fluid Spillage ................................... 10Dispose of Waste Properly ................................. 11Fluid Penetration................................................ 10Pressurized Air and Water ................................. 10

H

High Pressure Fuel Lines ...................................... 15Hoses and Clamps - Inspect/Replace .................. 116

Replace the Hoses and the Clamps ................. 117

I

Important Safety Information ................................... 2

L

Lifting and Storage ................................................ 32

M

Maintenance Interval Schedule ............................. 81

Maintenance Log................................................. 133Maintenance Recommendations ........................... 79Maintenance Records.......................................... 132Maintenance Section............................................. 74Model View Illustrations......................................... 21

Engine Aftertreatment System ........................... 24Engine views...................................................... 22

Model Views .......................................................... 21Monitoring System (Engine) ............................ 38, 40

Instrument panels and Displays......................... 39Programmable Options and Systems

Operation ......................................................... 38Mounting and Dismounting.................................... 15

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136 SEBU8600-02Index Section

O

Operation Section.................................................. 32Ordering Replacement Parts............................... 129Overhaul Considerations...................................... 117

Oil Consumption as an Overhaul Indicator ....... 118

Overhaul Recommendation .............................. 118Overspeed............................................................. 47

P

Plate Locations and Film Locations....................... 30Serial Number Plate (1) ..................................... 30

Plate Locations and Film Locations (Engine Aftertreatment System)........................................ 29

Product Identification Information.......................... 29Product Information Section .................................. 21Product Lifting........................................................ 34Product Lifting (Clean Emission Module) .............. 32

Product Lifting (Engine)......................................... 33Product Storage..................................................... 35

R

Radiator - Clean .................................................. 120Radiator Pressure Cap - Clean/Replace ............. 121Radiator Restrictions ............................................. 71Reference Information Section ............................ 128Reference Material .............................................. 131

Coolants........................................................... 131Emissions Warranty ......................................... 131Lubricants ........................................................ 131

Miscellaneous .................................................. 131Reference Materials ............................................ 131Refer ence Numbers .............................................. 30

Record for Reference......................................... 30Refill Capacities..................................................... 74Refill Capacities and Recommendations............... 74

Coolant............................................................... 77Engine Oil .......................................................... 74Fuel .................................................................... 76Lubricating Grease............................................. 75S·O·S Coolant Analysis...................................... 77

S

Safety Messages ..................................................... 6(1) Universal Warning .......................................... 6(2) Ether............................................................... 7(3) Hand (High Pressure)..................................... 8

Safety Section ......................................................... 6Self-Diagnostics..................................................... 48Sensors and Electrical Components

(Aftertreatment).................................................... 40Sensors and Electrical Components (Engine)....... 42

Programmable Monitoring System (PMS) ......... 45Sensor Locations ............................................... 42

Severe Service Application - Check .................... 121Environmental Factors ..................................... 122Improper Maintenance Procedures.................. 122Improper Oper ating Procedures ...................... 122

Starting Motor - Inspect ....................................... 122Starting the Engine................................................ 60

Starting the Engine ............................................ 60Starting with Jump Start Cables ............................ 61Stopping the Engine .............................................. 67System Pressure Release..................................... 79

Coolant System.................................................. 79Engine Oil .......................................................... 79Fuel System ....................................................... 79

T

Table of Contents..................................................... 3Turbochar ger - Inspect (High Pressure and Low

Pressure Turbochargers)................................... 122

Inspecting......................................................... 123Removal and Installation.................................. 123

W

Walk-Around Inspection ...................................... 124High Pressure Fuel Lines................................. 125Inspect the Engine for Leaks and for Loose

Connections ................................................... 124Inspect the Tube of the Crankcase Breather ... 124

Warranty Information ........................................... 127Warranty Section................................................. 127Water Pump - Inspect .......................................... 125

Welding on Engines with Electronic Controls ........ 79

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Product and Dealer Information

Note: For product identification plate locations, see the section “Product Identification Information” in the Operationand Maintenance Manual.

Delivery Date:

Product Information

Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information

Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:

8/10/2019 C7.1 Engine
