SERVICE

MANUAL
MODEL
T25K3W

Dri!tech Inc. A Tamrock Company

P.OBox 338 / Alachua, Florida 32615 USA
(904) 462.4100 / Telex 56-8441 / Fax (904) 462-3247
8/26/92 T25K3W SERVICE MANUAL S/N 731831
PAGE 1 OF 2
ALPHABETICAL. LISTING OF CONTENTS
PARTS MANUAL
NO. AND/OR PART/PAGE
VENDOR NUMBER NUMBER
ACCIDENT PREVENTION - safety precautions Page 1-13
AIR CLEANER - engine/compressor 1200-265 006307- 0
AIR FILTER - hydraulic tank 001658- 0
AIR INLET VALVE -.adjustments all models. 004320- 0
AIR PIPING SWIVEL JOINT - Chiksan 001217- 0
BUSHING - taperlock, installation instructions ' 008674- 0
CHADV - adjustment,,all feed. systema, except SP-4100 001085-
COMPRESSOR - adjUstments, dual control 008818- 0
CYLINDER - service instruction, Hydro-line 001690- 0

DRILL PIPE - tool joint,information `#12 002687- 0

DRIVELINE - Spicer Service 009739/3264 001022-
ENGINE - ,caterpillar cold weather inst. SEHS 76.59 001002- 0
ENGINE - caterpillar cold,weather operation SEBU 5898 001002-
ENGINE - caterpillar fuel specifications SEHS 7067 001002- 0
ENGINE - caterpillar lubricant SEBU 6251 001002- 0
recommendations
ENGINE - caterp4lar,3406 operation/maint. SEBU 5791 001002- 0
ENGINE - caterpillarj406 aupp.i all models SEBU `5963 001002- 0
- ETR shutdoWn system high pres-sure all HP' 006814- 2
GEARBOX - 3 pump-drive 002233/001003 00100S- 0
HYDRAULIC - schematic, T25K2 all models 006940- 0
HYDRAULIC - troublephooting/adjustments, T25K2 006914= 0
MOTOR - cooler fati,drive SFM-M4C 001011- 0
MOTOR - orbit, water:injection,' Ross MG100 009,999- 0
MOTOR - rotary head drive, overhaul 1329/2746 001329- 1B
instructions -
PLANETARY DRIVE - assembly, rotary head all models 001004- 0
PUMP - double vane, feed/accessory, T25K2 SVP-Tfi`cC 008172- 0
PUMP - oil injection, Haskel 1)07889 007037- 0
PUMP - rotation, seal install ion, 001330 001329-' 0 ;
A or C models
PUMP - vane, fan SVP-T6C
PUMP - water injection, ,20 GPO; Jop.ii Bean " 003790- 0
..-
ROTARY HEAD - overhaul instructions 009661-1/4 002153- 0
ROTARY HEAD - aleei;re:ki i: 009532- .Q
ROTARY HEAD:-4Wivel.64a1 housing packing 10-2 -001111- 0'.
TACHOMETER - instal.lationladjustme4ts*- Caterpillar engine 006269-,,0
,70P SUB - proper.itAWtion :,' 0110-
an„d'nuts 00,3657= 0
ToRps - speWicati§ne caPsrew§
11 8/26/92 T25K3W SERVICE MANUAL S/N 731831
PAGE 2 OF 2
ALPHABETICAL LISTING OF CONTENTS (CONT.)
PARTS MANUAL
NO. AND/OR PART/PAGE
VENDOR NUMBER NUMBER
VALVE - counterbalance, mast raising cylinder 001027- 0
VALVE - relief, water injection 001104- 0
WINCH - Model PD-7B, Braden PB -121 007755- 0
WIRING - engine, ETR-CAT 3406/Sullair H.P., T25K2W/WM 006859-T2A

0
0

0
FO
RC
RE
W
ME
MB
ER
S,
OP
ER
AT
ORS
AN
D OW
NE
RS
OF
DR
ILT
EC
HD
RIL
LIN
G
Po
s
(90 t Off EDu MA
CH
INE
4) ic
46 e Bo
2-4 x3 lgea S
10
0/ 38 A
Te l lo O
lex achu
56 a
-84 , Flo
41 rid
uoc.
a 32
61
5
885
ACCIDENT PREVENTION AND SAFETY PRECAUTIONS

INTRODUCTION

When operatirig equipment such as this drill the safety of the operation
crew and bystanders must be the principal concern. We have provided a
general list of potential hazards that may exist during operation and
service of this drill. All persons involved in operations or servicing
MUST read this manual, understand the safety precautions offered, and
follow them conscientiously to minimize the risk of accidents or injury.
While we believe that we have properly identified the potential hazards
that may exist certain hazards may be present in particular applications
for the drill that we have not contemplated. IT IS ULTIMATELY THE
RESPONSIBILITY OF THE DRILL OWNER OR OPERATOR TO BE CERTAIN THAT THE
DRILL IS PROPERLY EQUIPPED, SAFE TO OPERATE, AND THAT THE PROPER DRILL
SITE CONDITIONS EXIST TO ASSURE ACCIDENT FREE OPERATION.

In addition to the precautions outlined in this manual, we recommend

that owners and operators read the Portable Drill Rig Manufacturer's
Association's Drill Operator's Safety Manual, the National Water Well
Association's Manual of Recommended Safe Operation Procedures and
Guidelines for Water Well Contractors and Pump Installers and the
American Petroleum Institute's Oil and Gas Well Drilling and Servicing
Operations, API RP 54. All are excellent reference documents for
planning and establishing a viable accident prevention program and are
available from Driltech.

HAZARD SYMBOLS

A situation which is extremely hazardous

and CAN instantly result in severe
personal injury or death.

A situation which is considered to be

hazardous and COULD result in serious
personal injury or death.

A situation which is considered to be an

unsafe practice and COULD result in
personal injury, property or equipment
damage.

The above symbols are used throughout this manual; understand their
ns.
meanings and heed the accompanying instructio
2.01
 690

GENERAL

Do not operate drill in an enclosed area or building unless

exhaust fumes are routed outside. Exhaust fumes from the
diesel engine are lethal. Do not operate drill engine diesel
preheater in an enclosed area or building. Preheater exhaust
is lethal.

Do not start or attempt to operate the drill if a known unsafe condition

exists. If a known unsafe condition exists place a tag identifying this
condition on the starting controls to alert other potential users of the
drill.
Do not attempt to start, operate or service the drill unless you have
been properly trained to perform these operations and have read this
manual.
Operate this drill in compliance with all Federal, State, and local
codes, regulations, and standards.

All personnel protection devices and machinery guards must be in place

and operation properly at all times. Do not operate drill with these
devices removed or altered.

Never bypass or disconnect shutdown, warning systems, or circuits.

Serious damage to major components will result.

Eye protection, hard hats, and steel toed shoes must be worn at all
times within a minimum of 50 ft (15.25m) of the machine in operation to
minimize the risk of injury from loose objects and drilling debris. All
persons working on or around the drill must wear snug fitting clothes,
confine long hair, and avoid loose articles tied to their person to
reduce risk of injury from being caught in moving machinery.

Secure drill, remove ignition keys, and take other reasonable

precautions to prevent operation by unauthorized individuals when left
unattended. Failure to do this may result in severe damage to the drill
or personal injury.

Maintain a complete first aid kit at the drill site. At least two
members of the drilling crew or personnel in the area where the drill is
operated should be familiar with first aid and CPR practices.

2.02
1185
PREPARATION FOR TRANSPORTING TRUCK MOUNTED MACHINES

Index loader to insure drill pipe will not move laterally out of loader
pocket.

Visually inspect the rig for evidence of physical damage and cracking,
bending, or deformity of structural components.

Inspect drive train and all braking, steering, mechanical, pneumatic,

hydraulic and electrical systems to make sure they are in good operation
conditions. Test for proper operation before moving drill.

All windows and rear-view mirrors must be clean and properly adjusted
and all window 'washing, wiping, and defogging equipment must be in
serviceable condition.

Make sure tires are in good condition and inflated to the recommended
pressure for tire size and type on wheel mounted machines.

Make sure wheel studs (truck models) are torqued to the recommended
value.

Check all transport lights for proper operation and cleanliness. Clean
all reflectors as needed.

Make sure all access doors are closed and latched.

Check back-up alarm for proper operation.

Lock operator swing cab (truck models) in either operating or traveling

position. A rapid turn or quick stop will cause an unlocked cab to
swing violently and could strike personnel or other vehicles. Do not
leave cab in operation position when transporting between drill sites;
vehicle width may exceed legal limits.

See page 2.08 for Jump Starting instructions if batteries are

discharged.

PREPARATION FOR TRANSPORTING CRAWLER MOUNTED MACHINES

Index loader to insure drill pipe will not move laterally out of loader
pocket.

Visually inspect the rig for evidence of physical damage and cracking,
bending, or deformity of structural components.

Inspect crawler gearbox for proper oil level. Check to insure

sprockets, idlers, rollers and chain area is clear of mud, rocks and
debris. Check all lubrication points to insure that they have been
properly lubricated. Check propel system and brakes (one track at a
time) for proper operation before moving drill.
2.03
 691

Make sure track chains are properly adjusted and pads are secure and in
good condition.

Check back up alarm for proper operation.

Check all lights for proper operation'and cleanliness.

Insure that all access doors are closed and latched.

See page 2.08 for Jump Starting instructions if batteries are

discharged.

TRANSPORTING OF TRUCK MOUNTED MACHINES

Do not allow any condition to exist that permits the drill stem •to
rotate in the loader during transportation.

Frequently inspect the upper loader latch plate to be sure they have not
been damaged and that they will lock the drill stem properly when
rotated.

Know all measurements of your rig for traveling purposes. Watch for low
overheads and narrow side clearance. Cross railroad tracks slowly.

When transporting the drill machine long distances on the highway, stop
frequently to allow tires to cool and check wheel stud tightness.

Use seat-belts and shoulder restraints if provided. Transport at the

mobile machine manufacturer's recommended speeds. Reduce speed as
dictated by posted signs, weather and road or terrain conditions.

Avoid grades in excess of manufactures recommendations. Avoid potholes,

rocks and other obstructions and soft shoulders.or unstable terrain.

Do not permit personnel to ride in or on the machine, except in

passenger compartments provided for that purpose. The operator swing
cab on truck models is not designated as a passenger compartment.

Make sure the area behind the machine is clear of all personnel and
obstructions prior to backing.

TRANSPORTING OF CRAWLER MOUNTED MACHINES

Do not allow any condition to exist that permits the drill stem to
rotate in the loader during transportation.

2.04
691
Frequently inspect the upper loader latch plate to be sure they have not
been damaged and that they will lock the drill stem properly when
rotated.
Know all measurements of your rig for traveling purposes. Watch for low
overheads and narrow side clearance. Cross railroad tracks slowly.
When transporting the drilling machine long distances, transport by low
boy tractor and trailer.
Do not permit personnel to ride in or on the machine, except in
passenger compartments provided for that purpose.
Make sure the machine is clear of all personnel and obstructions before
moving in any direction.

2.05
 591

LOCATING, SET UP AND PARKING

Do not raise mast or operate this machine in the vicinity

of electrical power lines. Operating close to or con-
tacting a power line with any part of the machine can
result in electrocution,

Place the drill as far as possible from power lines and never work
inside the minimum perimeter set by Local, State, or Federal regulations
or those dictated by good sense.
If you have any doubts, consult a utility representative.
Treat all overhead lines as live power lines.
Slowly raise and lower the mast. If the di.stance to the line has been
misjudged, your reaction time might be too slow.
A signal person must be used to guide the machine in the vicinity of
lines. The signal person and- rig operator must be in direct visual
contact at all times.

Underground power and gas transmission lines may be

present. Know your drilling area and be sure no such lines
are present before drilling.

Do not raise the mast or attempt drilling unless the machine is fully
supported and leveled by all leveling jacks on solid footing. Failure
to level could result in the machine overturning.
Before starting machine, be sure that operator's station control panel
has been made inactive by pressing the master control panel "off" switch
prior to starting the engine and during the system warm-up period.
Switch should be in off position any time the operator leaves the
operator's station.
Promptly correct or repair any faulty operating conditions that could
cause damage to machine or personal injury. Do not operate until
repairs are made.

Keep the machine free of grease, oil, and ice to reduce risk of
personnel slipping or falling off drill or into machinery.

Before leaving the operator's station all controls must be in neutral

with all locking and safety devices set. DO NOT allow the drill to
operate unattended.

2.06
591

Park or locate the machine on level or across grade. Do not park or

locate the machine on grades exceeding the mobile machine manufacturer's
tilt ratings, never exceeding 15° (27 percent).

Park or locate the machine so the wind, if any, tends to carry the
exhaust fumes away from the operator.

Check both sides of all wheels or tracks.

Erect hazard indicators, barricades or flares (if at night) if machine

is parked on or adjacent to public roads.

Avoid entrapment and be sure that no one is inside any enclosure before
closing and latching doors. Before entering any enclosure be sure door
is secured open to prevent accidental closing while inside.

2.07
 45 591
JUMP STARTING AND BATTERY HAZARDS

Acid burn, fire, and explosion hazards exist when working around drill
and vehicle batteries. Sulfuric acid in batteries will cause severe
burns. Batteries emit hydrogen gas which will burn or explode if sparks
or flame are present.

Wear protective clothing, gloves, acid resistant apron and face shield
when servicing batteries or jump starting.

Always remove vent caps from weak batteries and cover with a cloth
before starting.

Be sure battery fluid is at the proper level.

Set parking brakes and chock wheels of both vehicles before jump
starting.
Do not smoke when jump starting or working with or near batteries.

Do not jump start if the battery fluid is frozen or slushy as the

battery may explode. The battery should be brought up to at least 40°F
(4.4°C).

Jump start only with an external power source having an electrical

system with the same voltage, ground polarity, and equipped with battery
or batteries of comparable size or larger.

Do not jump start using motor generator sets, welders, or other sources
of DC power.

Do not jump start 24V electrical systems with two 12V batteries
connected in series. The current drain will be too high on the 12V
batteries causing a possible explosion.

Do not permit metal-to-metal contact between the machine and starting

vehicle and do not allow jumper cable terminal clips to contact either
vehicle as arcing may result in fire or explosion.

Use only jumper cables that are clean, in good condition, and are heavy
enough to handle the starting current.
+ 24 VOC
JUMPER
Do not use battery terminal for CAOLE

jump starting. Arcing at battery

could result in explosion. Con-
nect jumper cables as shown at -24 VOC
JUMPER
right. CABLE

Stand as far away as possible from batteries before actual starting.

2.08
 885

COMPRESSOR AND HYDRAULIC SYSTEMS

Do not use air from the compressor for breathing. Exhaust or

other noxious gases may be drawn into the compressor intake
and pumped through the air system, making it unsafe.
Maintain and adjust the lift off relief valve pressure setting
in accordance with instructions on page 10.10 - and 10.11.
Failure to properly set the lift-off pressure could result in
upsetting the drill and possible injury or death.

BOTH COMPRESSOR AND HYDRAULIC SYSTEMS OPERATE WITH PRESSURES WHICH CAN
PRESENT DANGER TO PERSONNEL IF THE FOLLOWING PRECAUTIONS ARE NOT
OBSERVED:

0 Do not attempt to repair high pressure [250 psi (17.24 bar), 300 psi
(20.68 bar), and 350 psi (24.13 bar)] compressor minimum pressure
valves. This valve must be replaced if faulty. Refer to Service or
Parts Manual.

Do not open air/oil receiver tank while machine is running or tank is

pressurized.

Do not "horse play" with air hoses and lines.

Do not use more than 30 psi (2.07 bar) for cleaning and blowing away
debris, use appropriate regulator and use eye protection.

Do not exceed manufacturer's recommendations on rated operating

pressures for hoses, valves, fittings, filters, piping, and auxiliary
tools operated by compressed air.

Do not open hydraulic tanks or hydraulic connections while drill is

running or system is under pressure. Sudden release of lid or hose or
spray of hot oil could cause serious injury.

0 Do not attempt to locate the hydraulic leaks by using your hand.

Hydraulic oil under extreme pressure from a small opening can puncture
the skin, possibly injecting oil into the body.

Do not operate drill with leaking or damaged hoses, lines or

connections.

Keep personnel clear and away from the discharge opening of hoses, drill
pipe and bit, or any other discharge point.

Check all air pressure relief valves at least weekly. They must not be
blocked, closed, or disabled.

2.09
 n
855

Vent all internal pressures before opening any tank, breaking any
connection, or attempting to service any pressurized system.
I]
Secure hose ends by suitable chains or retainers. o
Pressure test all hoses in accordance with guidelines suggested by the
Rubber Manufacturer's Association. o
All safety guards and devices should be in place and operating properly
at all times to protect operating and maintenance personnel from injury. o
a
0
0
a
Li
u
[I
9
o
o
a
o
u
2.10
 45 591
DRILL MECHANISM AND MOVING PARTS

Do not raise mast when personnel are standing or positioned within 50

'feet to the side or behind the drill. Operator must be positioned at
the controls. Alert personnel in area before raising or lowering mast.
Use only drill pipe specifically designed for use in Driltech machines.
Do not use drill pipe which has excessive wear on the corners of the
[1 flat --Face4Tu4amtly_inspect the lower pocket flats and drill stem flats
for wear to verify that drill stem can not turn past the flats.
Do not use the drill pipe loader if lock plates are worn.
Do not use a worn hinged drill pipe pick-up mechanism.
Regularly and frequently verify that drill stem is properly secured in
the drill stem loader.
Do not operate the drill without the drill pipe retaining hoop mounted
on the mast. Some models include a "swing away" retainer hoop that may
be moved away from open side of mast for loading long casing sections.
Hoop should ALWAYS be locked in normal position over open face of mast
when drilling or loading drill pipe. For maximum personnel safety move
hoop to out position only when absolutely necessary.
Do not store hose, tools, loose drill stem or other items in the lowered
mast
Do not climb mast to perform maintenance. If climbing erect mast is
unavoidable use approved harness attached to both the mast and body at
all times
Before lowering the mast, index loader to a position such that the top
plate of the loader prevents all drill pipe from moving past the top
plate. Any pipe that is free to slide through the opening in the top
plate could be released from the loader while traveling down a steep
slope or during a fast stop. Loose pipe striking another vehicle or
persons could result in serious injury or death.
Keep hands, arms and other parts of the body, including clothes, away
from belts, pulleys, the mast, feed chain and other moving parts.
Disconnect the grounded battery connection or otherwise disable the
starter to prevent accidental operation prior to attempting repairs or
adjustments.
Do not disassemble cooler fan assembly or make adjustments to fan
blades. The u-bolts and capscrews furnished with the fan are made from
special material and should not be replaced with any other substitutes.

2.11
Q
 45 591

All parts of the body should be in operator's cab or under operator's

roof when raising or lowering mast. This will prevent operator from
being struck by mast structure or loose items falling from mast during
raising or lowering operation._ Failure to observe this warning could_
result in death or serious injury.

Before operating this drill use the check list provided in Section 13 of
the Operator's Manual. Be sure all conditions are satisfactory before
proceeding.

2.12
692
PUSH-PULL CABLE OPERATION,
. MAINTENANCE AND WARNING INFORMATION

1. Do not adjust the control cable with the engine running. Serious
injury or death could result.
2. A gradual or sudden increase in the no-load friction (cable
disconnect at both ends) of a control cable is an indication of a
pending or present performance problem. The control cable should
be replaced, 'otherwise serious injury or death may result.
3. A gradual or sudden decrease in the usable stroke, is an indication
of a pending or present performance problem. The control cable
should be replaced, otherwise serious injury or death may result.
4. Control cables which have moisture inside of them and/or have
frozen should be replaced. • Do not apply heat to thaw or dry
control cables.
5. Control cables used on Driltech machines are lubricated for the
life of the control cable. Do not remove the seals or lubricate
the control cable.
6. Do not attempt to repair control cables. They are designed to be
non-repairable.

2.13
 591

_FIRE, EXPLOSION AND BURN HAZARDS a

Do not inject ether or other starting aids into the
engine/compressor intake filter. Most Driltech models have
common engine/compressor air intakes. Ether or other aids
drawn into the compressor could cause an explosion.

Always maintain serviceable fire extinguishers near the drill. Refer to

Fire Prevention Maintenance page 2.13.

Properly train and brief the crew in what actions to take in the event
of fire on the drill. The safety of the crew and other persons in the
vicinity must be the first consideration. Untrained persons should not
attempt to extinguish a fire and, because of possible fire related
explosion, should remain at least 100 yards away from a fire.

Do not store flammable fluids on or in the immediate vicinity of the

drill. This includes, but is not limited to fuel, lubricants, coolants
and starting aids.

Do not use the drilling machine in oil, gas, or waterwell operations

unless the well head is properly equipped with blow-out preventers and
safety equipment required by law or as recommended in the American
Petroleum Institute's document API 54.

Engine oil, hydraulic fluid and compressor oil are flammable, especially
after the drill has been operating and the temperature of these oils has
been raised. Exposure of any of these oils to hot parts, flame or
sparks can result in an explosion or fire for both.
B
Do not operate this drill with leaking or worn hydraulic or air/oil
hoses or lines. Replace worn or leaking hoses and lines with only those
specified by Driltech.

When replacing hoses or lines route exactly as the original

installation.

2.14
885
ADDITIONAL TIM HAZARDS

Do not clean washable filter elements with flammable solvents, kerosene,

or gasoline.

Do not attempt welding repairs unless flammable fluid lines nearby or

combustible materials have been isolated or removed. Batteries must be
disconnected before welding on the machine.

Keep electrical wiring,• including battery terminals in good condition.

Replace any wiring that has cut, cracked, abraded, or otherwise degraded
insulation; replace terminals that are worn, discolored or corroded.
Keep all terminals clean and tight.

Keep objects, such as tools, away from exposed live electrical parts,
such as terminals, to avoid arching which might serve as a source of
ignition.

Turn off battery charge before making or breaking connections to any

battery.

Do not operate drill under low overhanging leaves or permit such objects
to contact hot exhaust system surfaces when operating the drill in
forested areas.

Ethyl ether used in diesel engine ether starting aid systems is

extremely flammable. Change cylinders or maintain or troubleshoot these
systems only in well ventilated areas away from heat, open flames, or
sparks. Do not install, store, or otherwise expose ether cylinders to
temperatures above 160°F (71°C). Remove ether cylinder when operation
in ambient temperatures above 60°F (16°C) and cap or plug the ether
injection equipment.

Antifreeze compound used in air line anti-ice systems contains methanol,

which is flammable. Use system and refill with compound only in
well-ventilated areas away from heat, open flames, or sparks. Do not
expose any part of the system or the antifreeze compound to temperatures
above 150°F (65°C). Vapors from the antifreeze compound are heavier
than air. Do not store compound or discharge treated air in confined or
unvented areas.' Do not store containers or antifreeze component in
direct sunlight.

2.15
 885
REFUELING OR SERVICING

Shut down the drill and allow to cool before refueling or servicing.
Do not refuel, add oil, add air line antifreeze, or otherwise service
with flammable liquids when the drill machine is running.
Do not attempt to add compressor oil or hydraulic fluid when the drill
machine is running.
Do not change ether injection canister or otherwise perform service to
this system when the drill machine is running.
Do not fuel or service with flammable fluids when welding operations are
in progress on or near the drill or open flame or sparks are present.
Do not smoke when servicing or fueling the drill.
Clean up spills of flammable fluids and prevent them from accumulating
on the drill. Remove and replace any installed material such as cab
insulation that has absorbed flammable fluids.
Remove all flammable fluid soaked rags from the drill.
Do not use flammable solvents for cleaning purposes.
Replace damaged fuel lines immediately rather than attempting to' weld or
otherwise repair them. Do not store or attempt to operate this drill
with any fuel leaks.
Do not open engine cooler (radiator) cap when drill is running, hot, or
overheated. Extreme burn hazard exists from high temperature coolant
under pressure. Allow system to cool then remove cap slowly allowing
pressure to be released.
Do not allow diesel engine preheater to be operated unattended.

2.16
690

FIRE PREVENTION MAINTENANCE

The following is a suggested daily maintenance outline which can help

reduce the risk of fire before starting engine.

1. Check all oil, hydraulic fluid, fuel lines

and hoses for cuts, abrasions or undue
wear. Replace as needed, don't gamble;
replace any questionable line or hose.

2. Inspect all oil, hydraulic, fuel line and

hose fittings for tightness. Remove all
residue and tighten clamps.

3. Clean vehicle of all combustible debris -

dry vegetation, particles, coal dust,
rags, etc. Also, remove any oil and fuel
drippings, particularly near and around
the engine, hydraulic pumps, motors and
cylinders.

4. Be sure that there is an adequate number

of approved fire extinguishers on hand;
check to be sure they are strategically
located, readily accessible and in good
working condition. As a minimum
requirement at least four 20-pound (9
ltr), class B:C fire extinguishers should
be on-hand.

5. Check all possible ignition points (engine

block, exhaust manifolds, turbochargers,
mufflers, etc.). Make sure oil, hydraulic
fluid, fuel lines, and hoses are not in
contact with these ignition points and all
protective covers are secured in place.

6. Check all electrical lines and connections

for tight fit, wear, abrasion or cor-
rosion. Replace any defective electrical
equipment or wiring.

2.17
I.
.. ID in on
.. aft-11R nano
nag
.• 34068 Industrial and

..
EPG Generator Set
Diesel Engines

..
6TB1-UP
2WB1-UP
4RG1-UP

..
1
iMaintenance Management Information Included
 3
Safety Section
Important Safety Information

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you
have read and understood the operation, lubrication, maintenance and repair information.

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

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"WARNING" as shown below.

A WARNING

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by Caterpillar is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged
or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information
available at the time it was written. The specifications, torques, pressures, measurements, adjustments,
illustrations, and other items can change at any time. These changes can affect the service given to
the product. Obtain the complete and most current information before starting any job. Caterpillar
dealers have the most current information available. For a list of the most current publication form
numbers available, see the Service Manual Contents Microfiche, REG1139F.
4
Safety Section
Safety

Safety

Warning Signs and Labels Use all cleaning solutions with care.

There may be several specific safety signs on your Never put maintenance fluids into glass containers
engine. Please take the time to familiarize yourself with since glass containers can break.
the safety signs.
Report all needed repairs.
Make sure that you can read all safety signs. Clean or
replace these if you cannot read the words or see the Unless Instructed Differently, Perform All
pictures. When cleaning the labels use a cloth, water Maintenance as Follows:
and soap. Do not use solvents, gasoline, etc., to clean
safety signs. The use of solvents, gasoline, etc., could • Stop the engine.
loosen the sign's adhesive and cause the sign to fall
• Ensure the protective locks or controls are in the
off.
applied position.
You must replace a label if it is damaged, missing or
cannot be read. If a label is on a part that is replaced, • Apply the secondary (emergency) and parking brakes
make sure a new label is installed on the replaced part. (if equipped).
See your Caterpillar dealer for new labels.
• Block or restrain the vehicle, if applicable before
servicing.
General Hazard Information
• Disconnect the batteries before servicing the
electrical system.

• Do not attempt repairs you do not understand.

• Use proper tools and replace or repair broken or

damaged equipment.

• When starting an engine after repairs have been

made to the fuel system, make provisions for shutting
off the engine's intake air supply, (to stop the engine),
in case there is an overspeed on start-up.

• Start the engine only from the operator's station.

Never short across the starter terminals or the
batteries as this could bypass the engine neutral-start
Attach a "DO NOT OPERATE" or similar warning tag to system as well as damage the electrical system.
start switch or controls before servicing or repairing the
engine. These tags, Form SEHS7332, are available
from your Caterpillar dealer. Pressure Air and Water
Pressure air can cause personal injury. When using
Do not allow unauthorized personnel around the engine
pressure air for cleaning, wear a protective face shield,
when it is being serviced.
protective clothing and protective shoes.
When operating the engine in a closed area, vent the
The maximum air pressure must be below 205 kPa (30
exhaust to the outside.
psi) for cleaning purposes.
Wear a hard hat, protective glasses and other
Wear eye protection at all times when cleaning the
protective equipment as required by job conditions.
cooling system. Pressurized water could cause debris
and/or hot water to be blown and result in personal
Do not wear loose clothing or jewelry that can catch on
injury.
controls or other parts of the engine.

Make certain all protective guards and covers are

secured in place.
;

Fluid Penetration
Always use a board or cardboard when checking for a
leak. Escaping fluid under pressure, even a pin-hole
size leak, can penetrate body tissue, causing serious
injury, and possible death.
If fluid is injected into your skin, it must be treated by a
doctor familiar with this type of injury immediately.
Asbestos Information
Caution should be used to avoid breathing dust that
may be generated when handling components
containing asbestos fibers. If this dust is inhaled, it can
be hazardous to your health.
Components in Caterpillar products that may contain
asbestos fibers are brake pads, brake band and lining
assemblies, clutch plates and some gaskets.
The asbestos used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous as long as airborne dust
which contains asbestos is not generated.
If dust which may contain asbestos is present, there
are several common sense guidelines that should be
followed.
• Never use compressed air for cleaning.
• Avoid brushing or grinding of asbestos containing
materials.
• For clean up, use wet methods or a vacuum
equipped with a high efficiency particulate air (HEPA)
filter.
• 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 regulations for the
work place (for example in the U.S.A., OSHA
requirements as set forth in 29 CFR 1910.1001).
• Follow environmental rules and regulations for
disposal of asbestos.
• Avoid areas where asbestos particles may be in the
air.
5
Safety Section
Safety
Lines, Tubes and Hoses
Do not bend or strike high pressure lines. Do not install
bent or damaged lines, tubes or hoses.
Repair any loose or damaged fuel and oil lines, tubes
and hoses. Leaks can cause fires.
Inspect all lines, tubes and hoses carefully. Do not use
your bare hands to check for leaks. Tighten all
connections to the recommended torque.
Check for the following:
• End fittings damaged or leaking.
• Outer covering chafed or cut and wire reinforcing
exposed.
• Outer covering ballooning locally.
• Evidence of kinking or crushing of the flexible part of
the hose.
• Armoring embedded in the outer cover.
• End fittings displaced.
Burn Prevention
Do not touch any part of an operating engine. Allow
the engine to cool before any repairs are performed on
the engine.
Relieve all pressure in air, oil, fuel or cooling systems
before any lines, fittings or related items are
disconnected or removed.
Coolant
To prevent personal injury, do not step up on engine to
remove the filler cap, if applicable. Use an adequate
ladder.
At operating temperature, the engine coolant is hot and
under pressure. The radiator and all lines to heaters or
the engine contain hot water. When pressure is relieved
rapidly, this hot water can turn into steam.
Any contact with hot water or steam can cause severe
burns.
6
Safety Section
Safety
Check the coolant level only after the engine has been
stopped and the filler cap is cool enough to remove
with your bare hand.
Remove the cooling system filler cap slowly to relieve
pressure.
Cooling system additive contains alkali. To prevent
personal injury, avoid contact with the skin and eyes
and do not drink.
Allow cooling system components to cool before
draining.
Oils
Hot oil and components can cause personal injury. Do
not allow hot oil or components to contact the skin.
Batteries
Battery electrolyte contains acid and can cause injury.
Avoid contact with the skin and eyes.
Wash hands after touching batteries and connectors.
Use of gloves is recommended.
Batteries give off flammable fumes which can explode.
Do not smoke when observing the battery electrolyte
levels.
Always wear protective glasses when working with
batteries.
Fire or Explosion Prevention
Determine whether the engine will be operated in an
environment in which combustible gases could be
drawn through the air inlet system. These gases could
cause the engine to overspeed, which in turn could
destroy the engine and result in bodily injury or
property damage.
If your application involves the presence of combustible
gases, consult your Caterpillar dealer to obtain
additional information concerning protection devices
(i.e. air inlet shutoff) suitable for the application
involved.
All fuels, most lubricants and some coolant mixtures
are flammable.
Diesel fuel is flammable. Gasoline is flammable. The
mixture of diesel and gasoline fumes are extremely
explosive.
Do not smoke while refueling or in a refueling area.
Do not smoke in areas where batteries are charged, or
where flammable materials are stored.
Keep all fuels and lubricants stored in properly marked
containers and away from all unauthorized persons.
Store all oily rags or other flammable material in a
protective container, in a safe place.
Do not weld or flame cut on pipes or tubes that contain
flammable fluids. Clean them thoroughly with
nonflammable solvent before welding or flame cutting
on them.
Remove all flammable materials such as fuel, oil and
other debris before they accumulate on the engine.
Do not expose the engine to flames, burning brush,
etc., if at all possible.
Shields, which protect hot exhaust components from oil
or fuel spray in the event of a line, tube or seal failure,
must be installed correctly.
Have a fire extinguisher available and know how to use
it. Inspect and have it serviced as recommended on its
instruction plate.
When starting from an external source, always connect
the positive (+) jumper cable to the POSITIVE (+)
terminal of the battery of the engine to be started.
To prevent potential sparks from igniting combustible
gases produced by some batteries, attach the negative
(—) boost ground cable last, to the starter NEGATIVE
(—) terminal (if equipped) or to the engine block.
See the "Operation Section" of this manual for specific
starting instructions.
Clean and tighten all electrical connections. Check
daily for loose or frayed electrical wires. Have all loose
or frayed electrical wires tightened, repaired or replaced
before operating the engine.
 1
Information Section
Table of Contents

Table of Contents

Information Section Maintenance Section

Foreword 2 Torque Specifications 36

Cooling System Specifications 38

Safety Section
Fuel Specifications 43
Important Safety Information 3
Lubricant Specifications 46
Safety 4
Warning Signs and Labels 4 Scheduled Oil Sampling (S•O•S) 48
General Hazard Information 4
Burn Prevention 5 Terminology 49
Fire or Explosion Prevention 6
Crushing or Cutting Prevention 7 Lubricant Viscosities and Refill Capacities 50
Mounting and Dismounting 7
7 Maintenance Management Schedule 51
Preparing to Start the Engine
Engine Starting 7
Daily 52

Every 125 Hours 61

General Section
Every 250 Hours 62
Specifications and Model Views 8
Every 1000 Hours 74
Engine Information 9
Every 3000 Hours 77
Serial Number, Information Plate and Reference
Numbers 10
Every 5000 Hours 86

Overhaul 90
Operation Section
11 Standby Generator Sets 96
Gauges
Preventive Maintenance Schedules 97
Engine Protection Devices 13

18 Performance Analysis 100

Dipsticks

Before Starting the Engine 19

Literature Reference Section
Engine Starting 22
Literature Reference Materials 101
Engine Operation 25
Maintenance Records 102
Engine Stopping 28
Maintenance Log 103
After Stopping the Engine 29

Value Planned Repair (Repair Before Failure) 30 Index Section

Index 104
Engine Operating Cost Analysis 31

Fuel Problems In Cold Weather Operation 32

Engine Lifting and Storage 34

2
Information Section
Foreword

Foreword

Literature Information If the Preventive Maintenance Program is followed, a

This manual contains safety, operation, lubrication and
maintenance information.
Some photographs or illustrations in this publication
show details or attachments that may be different from
your engine. Guards and covers may have been
removed for illustrative purposes.
Continuing improvement and advancement of product
design may have caused changes to your engine
which are not included in this publication. Read - study
- and keep this manual with the engine.
Whenever a question arises regarding your engine, or
this publication, please consult your Caterpillar dealer
for the latest available information.
periodic tune-up is not required. The implementation of
a Preventive Maintenance Management Program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that occurs
first.

The service interval for each item listed in the

Safety
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations of
warning labels used on the engine.
Read and understand the basic precautions listed in
the safety section before operating or performing
lubrication, maintenance and repair on this product.
Operation
"Maintenance Management Schedule" is primarily
based on the item and its relationship to either engine
speed or load.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is specified
in the "Maintenance Management Schedule" might be
necessary.
Your Caterpillar dealer can assist you in tailoring your
schedule to meet the needs of your operating
environment.

The operation section is a reference for the new

operator and a refresher for the experienced one. This Engine Description
section includes a discussion of gauges, switches and
engine controls to assist you with developing the skills
and techniques required to operate your engine more
efficiently and economically.

Photographs and illustrations guide the operator

through correct procedures of checking, starting,
operating and stopping the engine.

Operating techniques outlined in this publication are

basic. Skill and techniques develop as the operator
gains knowledge of the engine and its capabilities.

Maintenance
The engines described in this publication are 3406B
The maintenance section is a guide to equipment care. Industrial and EPG diesel engines.
The illustrated, step-by-step instructions are grouped by
maintenance intervals. Items in the "Maintenance They are designed primarily for electrical prime power
Management Schedule" are referenced to detailed generation, petroleum and auxiliary industrial
instructions that follow. applications.
The "Maintenance Management Schedule" items are
organized for a Preventive Maintenance Program.

Crushing or Cutting Prevention
Support equipment and attachments properly when
working beneath them.
Never work under a partially tilted cab unless it is
properly secured.
Never attempt adjustments while the engine is running
unless otherwise specified in this manual.
Stay clear of all rotating and moving parts. Guards
should be in place whenever maintenance is not being
performed.
Keep objects away from moving fan blades. They will
throw or cut any object or tool that falls or is pushed
into them.
Wear protective glasses when striking objects to avoid
injury to your eyes.
Chips or other debris can fly off objects when struck.
Make sure no one can be injured by flying debris
before striking any object.
Mounting and Dismounting
Do not jump off the engine. Always use steps and
handholds when mounting and dismounting.
Clean steps, handholds and areas of the engine you
will be working on or around.
Preparing to Start the Engine
Be sure all protective guards and covers are installed if
an engine must be started to make adjustments or
checks. To help prevent an accident caused by parts
in rotation, work carefully around them.
1 Do not disable or bypass automatic shutoff circuits.
They are provided to prevent personal injury and
equipment damage.
Make provisions for shutting off the air supply to stop
the engine if there is an overspeed on start-up after
servicing the engine.
Inspect engine for potential hazards.
7
Safety Section
Safety
Engine Starting
Do not start the engine or move any of the controls if
there is a warning tag attached to the controls. Check
with the person who attached the tag before starting.
Make sure no one is working on, or close to the engine
or engine driven components before starting it. Always
make an inspection of the engine before and after
starting.
Diesel engine exhaust contains products of combustion
which may be harmful to your health. Always start and
operate the engine in a well-ventilated area and, if in an
enclosed area, vent the exhaust to the outside.
Start the engine only from the operator's station. Never
short across the starter terminals as this could bypass
the engine neutral-start system as well as damage the
electrical system.
Starting Aids
Ether and other starting aids are poisonous and
flammable. Do not smoke while changing ether
cylinders.
Use ether only in well ventilated areas.
Keep ether cylinders out of the reach of unauthorized
persons.
Do not store replacement ether cylinders in living areas
or in the engine compartment or cab.
Do not store ether cylinders in direct sunlight or at
temperatures above 39°C (102°F). Discard cylinders in
a safe place. Do not puncture or burn cylinders.
8
General Section
Specifications and Model Views
I
Specifications and Model Views

Engine Model Views Engine Specifications

The Caterpillar 3406B Turbocharged (T) or
Turbocharged and Aftercooled (TA) Diesel Engine is a
14.6 L (893 cu in.) displacement, 137 mm (5.40 in)
I
bore, 165 mm (6.5 in) stroke, four stroke cycle, 6
cylinder engine. The firing order is 1-5-3-6-2-4 and the
direction of rotation is counterclockwise, as viewed
I
from the flywheel.

ENGINE SPECIFICATIONS
I
Number of Cylinders
Bore
Stroke
6 In-Line
137 mm (5.40 in)
165 mm (6.5 in)
I
Oil Filter (1), Crankcase Breather (2), Oil Filler (3), Oil Level
I
Aspiration T or TA
Gage (4) and Air Cleaner (5) Displacement 14.6 L (893 cu in)
Firing Order 1-5-3-6-2-4
Rotation (viewed from flywheel) Counterclockwise

I
1
I
Fuel Filter and Priming Pump (6), Primary Fuel Filter (7),
Governor and Fuel Pump (8) and Throttle Lever (9)
I
I
I
I
I
I
?
I
I General Section
9

Engine Information

II Engine Information
The engine can be turbocharged (T) or turbocharged
and jacket water aftercooled (TA), with direct fuel
I injection.
A full range hydramechanical governor controls the fuel
I injection pump output to maintain the engine rpm
selected by the operator.
Engine Identification
Caterpillar engines are identified with serial numbers,
fuel system setting numbers and arrangement
numbers. In some cases modification numbers are also
used. These numbers are shown on the serial number
plate mounted on the engine.

Individual injection pumps, one for each cylinder, meter Caterpillar dealers need all of these numbers to

I and pump fuel under high pressure to an injection

valve for each cylinder. Automatic timing advance
provides the best fuel injection timing over the full
range of engine speed.
determine which components were included on the
engine when it was assembled at the factory. This
permits accurate identification of replacement part
numbers.

I The cooling system consists of a gear driven

centrifugal pump, with one thermostat which regulates
the engine coolant temperature, an oil cooler and a
I radiator incorporating a shunt system.

The engine lubricating oil, which is both cooled and

filtered, is supplied by a gear-type pump. Bypass
I valves provide unrestricted flow of lubrication oil to the
engine parts when oil viscosity is high, or if either the
oil cooler or the oil filter elements should become
plugged.
I Engine efficiency, efficiency of emission controls and
engine performance depend on adherence to proper

I operation and maintenance recommendations, and the

use of recommended fuels and lubrication oils.

Follow the recommended Maintenance Management

I Schedule with emphasis on emission related
components, air cleaner, oil, oil filter, fuel and fuel filter
maintenance found in this publication.

I
I
I
I
I

I
10
General Section
Serial Number, Information Plate and Reference Numbers

Serial Number, Information Plate and Reference Numbers

Serial Number Plate Fuel Filter Element No

Lubrication Oil Filter Element No

Auxiliary Oil Filter Element No

Lubrication Oil System Capacity

CATERPILLAR CAT
SEPAL Supplemental Coolant Additive Maintenance
WAIBE P ARPANGE

E ,IGi.tf
WENT
%UMW P
Element No
MODE l
A, WA,5 GIVE all Ail/MBE PS,

Supplemental Coolant Additive Precharge Element

No

Cooling System Capacity

Air Cleaner Element No

Located on the right rear side of the cylinder block.
Fan Drive Belt Set No
Information Plate Alternator Belt No

Ordering Parts

1
CAT Quality Caterpillar replacement parts are available from
SER. NO. DATE
DELIVERED
Caterpillar dealers throughout North America and the
MODIFICATION NO. DLR world. Their parts stocks are up to date and include all
CODE
AR PERF MAX parts normally required to protect your investment in
NO. SPEC ALT
O EM Caterpillar engines.
NO.
O.
FULL LOAD FULL TORO.
STATIC FUEL STATIC FUEL When ordering parts, your order should specify the
POWER AJF RATIO
HP k
DYNAMIC quantity, part number, part name and serial number,
BARE ENG. FULL FUEL
HI IDLE LOAD TIMING arrangement number and modification number of the
RPM RPM 9L6531 13
engine for which the parts are needed. If in doubt
about the part number, please provide your dealer with
a complete description of the needed item.
Located on the valve cover.
When service is needed for your Caterpillar engine, be
prepared to give the dealer all the information that is
Reference Numbers
provided on the 9L6531 Information Plate located on
Engine Model the valve cover.

Engine Serial No. Discuss the problem with the dealer, such as; when it
occurs. what happens, etc. This will help the dealer in
Engine Arrangement No troubleshooting and solving the problem faster.

Engine Power Rating

Engine Low Idle rpm

Engine Full Load rpm

Performance Specification No

Governor Group No
;
 11
Operation Section
Gauges

Gauges

Your engine may not have the same or all of the NOTICE
gauges as shown in the illustrations. The illustrations If no pressure is indicated, stop the engine. Engine
shown are of typical gauges. damage can result.
Gauges provide a "look" inside the engine. Be sure they
are in good working order. You can determine what is
the "normal" operating range by observing your gauges
over a period of time.

Noticeable changes in gauge readings are indicative of

potential gauge or engine problems. This also applies
to gauge readings that have changed significantly but
are still within specifications. The cause of any sudden
or significant change in the readings should be
determined and corrected. Contact your Caterpillar
dealer for assistance as needed.

Jacket Water Temperature - Indicates engine

coolant temperature. It should normally
indicate between 77°C (170°F) and 99°C
(210°F). Somewhat higher temperatures may occur
under certain conditions. Maximum allowable
temperature is 107°C (225°F) with the cooling system
pressurized for Prime Power Generator Sets.

Oil Pressure - Indicates engine oil pressure.

The oil pressure should be greatest after
starting a cold engine and operate between
275 and 600 kPa (40 and 88 psi) when the engine is
running at rated engine speed, with SAE 10W30 oil, at
operating temperature. A lower pressure is normal at
low idling speed.

Ammeter - Indicates the amount of charge or

discharge in the battery charging circuit.
Normal operation of the indicator should be
slightly to the positive (right) side of "0" (zero).
1 With the engine running, during normal operation, if the
indicator is constantly to the negative (left) side of "0"
(zero) or shows excessive charge, have the charging
system checked for malfunction.
12
Operation Section
Gauges
MIM
Tachometer - Indicates engine rpm (speed).
The engine can be operated at high idle
without damage, but should not be allowed to
overspeed. Overspeeding can result in serious damage
to your engine.
Fuel Level - Indicates fuel level in the fuel
tank. Electrically operated, it registers only
when the key switch is ON.
Fuel Pressure - Indicates fuel pressure to the
injection pump. The indicator should register in
the NORMAL (green) range.
If the indicator moves to the OUT position or registers
below 140 kPa (20 psi) when equipped with a
numerical gauge. the engine will not operate properly.
In most cases this is caused by a plugged fuel filter.
Service Hour Meter - Indicates the total
number of clock hours the engine has
operated.
NOTE: The following gauge is optional and not shown
on the gauge panel. This gauge is remote mounted for
use with the Large Capacity Extended Service Oil Pan.
Oil Filter Differential Pressure - Indicates the
difference of oil pressure between the inlet
side (dirty side) and the outlet side (clean side)
of the oil filter. As the element becomes plugged, the
difference in pressure between the two sides of the
element will increase. Oil filter maximum pressure
differential is 105 kPa (15 psi).
If the indicator moves to the RED position or registers
above 105 kPa (15 psi), the engine will not operate
properly, In this case the plugged oil filter should be
replaced.
I 13
Operation Section
Engine Protection Devices

Engine Protection Devices

Alarms Cooling Timers

The alarm systems provide either an audible or visual
warning, or both, to signal to the operator an abnormal
operating condition exists.
A These conditions can be low fuel supply, low oil
pressure or high coolant temperature. The alarm will
continue until cause for condition is corrected.
I The engine can be damaged if no corrective action is
taken when an alarm is activated. To prevent this from
Cool down timers are also available which will continue
running the engine after the load is removed for up to
five minutes. After the engine has cooled, the timer will
activate the fuel shutoff to stop the engine.
When any of these components shut the engine down,
the problem causing the shutdown must be corrected
before attempting to restart the engine.

Familiarize yourself with the types and locations of the

shutoff controls, the conditions which cause each
occurring to unattended engines, engine shutoff
I devices are also used.
control to function, and the resetting procedure
required to start your engine.

I Emergency Shutoffs
Shutoff systems are either electrically or mechanically
Emergency Stop Button

operated. The operation of all electric shutoffs utilize

I components which actuate switches in a sensing unit.

They are set at critical operating temperature, pressure,
level or speed than the alarm components to protect
the engine from damage.

The switch closes the circuit to the shutoff solenoid

which moves the fuel rack to the fuel OFF position. The
particular shutoff may require resetting before the
I engine will start.

Manually or mechanically operated systems require

I resetting by pushing the RESET button until it latches.

After the engine is started, oil pressure will activate the
RESET button to the extended running position.
Emergency Stop button (if equipped)

I NOTICE
If the RESET button does not move to the extended
NOTICE
Always determine the cause of the engine shutdown.
Make necessary repairs before attempting restarting
the engine.
I position after the engine starts, the engine will NOT be
protected by this particular switch.
If the RESET button remains in the reset position, the
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use Emergency shutoff devices or
engine oil pump is not developing normal oil pressure controls for normal stopping procedure. Refer to the
I and an inspection should be made to correct the
problem.
"Engine Stopping" section of this manual for normal
stopping procedures.

I Cranking Timers
Automatic START/STOP systems use a pressure which
The Engine Protective Devices shutdown controls
should be tested every 1000 service hours by
will reset itself. authorized personnel.

There are two cranking timers which may be used on

an Automatic Start/Stop generator set engine. One
allows the engine to crank for 30 seconds and the
other cranks the engine for 10 seconds up to five
successive starting attempts. If the engine will not start
during that period, the fuel rack will shut off and an

I indicator light will illuminate to warn a starting failure.

14
Operation Section
Engine Protection Devices

Low Oil Pressure Shutoff Low Coolant Level Shutdown

The switch is mounted on the side of the engine with
oil lines connected to the switch. Low engine oil
pressure closes the switch.
The oil pressure switch senses oil pressure at the
bearing oil gallery. No resetting procedure is required.
NOTE: Switches may close at 48 to 62 kPa (7 to 9 psi)
below actual trip point.
High Water Temperature Shutoff
This shutoff is a high coolant temperature shutoff.
-1---- -4
111E___,
Typical installation
The expansion tank or radiator has a low coolant level
switch, which is used to determine when the coolant
level is below the minimum level to avoid engine
overheating or possible engine damage.
When the coolant level is near or below the LOW mark
trip setting, a shutdown will occur. Coolant must be
added to the water tank to clear or reset shutdown
condition.
NOTE: In the event of intermittent engine shutdowns,
coolant water level should be inspected and premixed
coolant water added to fill tank to within 13mm (1/2
inch) below filler neck.

Overspeed Shutoffs

The shutoff sensor is located near the coolant water

regulator housing and senses the cooling system water
temperature. Excessive water temperature closes the
switch. Maximum coolant temperature to trip shutoff is
104°C (219°F). The switch opens as the coolant cools.
No resetting procedure is required.
This is an electrical shutoff overspeed switch which
uses a magnetic pickup mounted in the flywheel
housing and works through the fuel shutoff solenoid.

NOTICE
The sensing element must be submerged in the cool-
ant to operate. Be sure to have adequate water supply
in jacket water system or engine damage could result.

Should the engine overspeed, the magnetic pickup will
close the circuit to the fuel shutoff solenoid and the fuel
rack will move to fuel OFF position.
The overspeed shutdown does have to be reset. The
overspeed switch (ESS) located in the junction box also
must be reset.
This switch is mounted either on the tachometer drive
or the governor. Excessive engine speed closes the
switch by centrifugal force.
To reset the switch, push the RESET button. The
button will remain in this position until the engine
overspeeds.
Caterpillar Generator Set Control Panel
If equipped with a Caterpillar Generator Set Control
Panel, the devices on the panel must be reset.
• Turn the Engine Automatic Control Selector switch (1)
to the OFF/RESET position. Push the Overspeed
indicator (2) button in to the reset position.
15
Operation Section
Engine Protection Devices
Alarm Switches
Alarm switches consist of a sensor and contactor. The
sensor such as magnetic pickup for detecting speed,
or pressure or temperature sensors are wired to a
contactor which activates an alarm circuit in the
Annunciator Panel.
Alarm switches and sensors are set at a less critical
temperature, pressure or level limit than the engine
shutdown controls.
The purpose of the alarm switch is to warn the
operator that an unsafe operating condition is
beginning to occur.
The Annunciator Panel has lights and an audible device
to warn the operator of a malfunction or abnormal
engine operating condition. Each alarm contactor and
switch is electrically connected to an indicator light or
audible indicator. The alarm will continue until the
condition is corrected.
When an alarm is activated, corrective measures must
be taken before the situation becomes an emergency
to avoid possible damage to the engine.
If corrective measures are not taken within a
reasonable time, engine damage could result, or if
equipped, a corresponding shutdown device will stop
the engine.
The alarm will continue until the condition is corrected
or the alarm is reset by the operator. The alarm circuits
merely warn the operator, they do not shut the engine
down to protect it from damage.
A switch may be installed in the alarm circuit for
silencing the alarm while the engine is stopped for
repairs. Before starting, be sure the switch is moved to
the closed (ON) position and the warning lights are
illuminated.
If the switch is left in the open (OFF) position when the
engine is started, the engine will not be protected.
16
Operation Section
Engine Protection Devices

Shutoff and Alarm System Testing • Operate the engine at the corresponding speed
shown in the OVERSPEED TEST RPM chart below.
NOTICE
During testing, abnormal operating conditions must be Actual
Full Load Overspeed
simulated. Perform the tests correctly to prevent pos- rpm Test rpm Overspeed
sible damage to the engine. rpm
1500 1328 1770
1800 1593 2124
The Engine Protective Devices shutdown controls and 2000 1770 2360
alarms on the engine should be tested every 1000 2200 1947 2596
service hours or twice a year for proper operation by
If the Full Load rpm listed on your engine's Information Plate is
authorized Caterpillar dealer personnel. not listed in this chart, then the Overspeed Test rpm equals the
Full Load rpm times a factor of .885.
Most control panels are equipped with a test switch.
Turn the switch to ON position to check indicator lights
for proper operation. Replace defective or burnt bulbs I
immediately.

Abnormal operating conditions must be simulated

which could cause engine damage if the tests are
performed incorrectly. Refer to the Service Manual for
the testing procedure.

The Shutoff switch can be checked for proper

operation at 75% of overspeed condition:

CAT
SER. NO. DATE • Maintain the test rpm, push and hold the VERIFY
DELIVERED
DLR button, then the engine should stop. If the engine
MODIFICATION NO. CODE
AR PERF MAX
does not stop at the specified test rpm, contact your
NO.
OEM
SPEC ALT Caterpillar dealer.
NO.
FULL LOAD FULL TORO.
STATIC FUEL STATIC FUEL
POWER HP Mw
A/F RATIO
DYNAMIC
BARE ENG. FULL FUEL
HI IDLE LOAD TIMING
RPM RPM 9L6531 13

• Determine full load rpm from the engine Information

Plate.

NOTE: As the engine stops, the yellow light (2) will

illuminate and the RESET button (1) must be pushed
before restarting the engine.

;
 19
Operation Section
Before Starting the Engine

III Before Starting the Engine

Walk-Around Inspection
For maximum service life of your engine, make a
thorough inspection before starting the engine. Look
for such items as oil or coolant leaks, loose bolts, worn
fan belts and trash build-up. Remove trash build-up
.18.1111.1k 41.1.111111.
and have repairs made as needed. 410111111111.
0•11•101..•

AIRPICirs.
Perform required periodic maintenance before starting 4411.11,..
• FIMR,••—•
.455,111.110

the engine. Make a walk-around inspection of the .solmat ..o•

414.4101011..

.Oninivos•No •••••••••..,
installation. It only takes a few minutes to make minor o/INNIP/0.
corrections. This can prevent major repairs at a later 4•01400001.
.001•00.01.
.00.00000.
date. *woo*

.1••••••••pp

• Inspect the radiator for leaks and trash build-up.

NOTICE
All valves in fuel return line must be open before and
during engine operation to prevent high fuel pressure.
High fuel pressure may cause filter housing failure or
other damage.
• Inspect the radiator hoses for cracks and loose
clamps.
• Inspect the fan and accessory drive belts for cracks,
breaks or other damage. Belts for multiple groove
pulleys are sold in matched sets.

a NOTE: Belts for multiple groove pulleys must be

replaced as matched sets. If only one belt of a two or
three belt set is replaced, it will carry more of a load
than the belts not replaced since the older belts are
stretched. The additional load on the new belt could
cause it to break.

Typical Example

• Observe the air cleaner service indicator (if

equipped). Service the air cleaner when the yellow
diaphragm enters the red zone or the red piston locks
in the visible position.

If your air cleaner is not equipped with an indicator, you

can obtain one at your Caterpillar dealer. Make sure
the air inlet piping and filter are in place.
• Inspect wiring for loose connections and worn or
• Inspect air intake system hoses and elbows for frayed wires.
cracks and loose clamps.
• Disconnect any battery chargers that are not
protected against the high current drain created when
the electric starter engages. Check electrical cables
and the battery for poor connections and corrosion.
20
Operation Section
Before Starting the Engine

Pre-Start Checks

n••••••••••••.......•

• All guards must be in place. Repair or replace all

guards that are damaged or missing.
• Measure the engine crankcase oil level. The correct
oil level is shown by the FULL RANGE zone on the
• Check the fuel supply. Keep fuel tanks full, as
Engine Stopped side of the dipstick (oil level gage).
partially filled tanks will collect moisture. Do not
overfill the fuel tank. Fuel expands in warm weather,
and may overflow. Make sure fuel lines are properly
clamped and tight. Check for loose fittings or leaks.

NOTE: If leaking is observed, find the source and

correct the leak. If leaking is suspected, check the fluid
levels more frequently than the recommended service
intervals prescribed in this publication until a leak is
found or fixed, or until the suspicion for a leak has
been proven to be unwarranted.

Two dots are used to indicate the correct level on

some earlier dipsticks. Keep the oil level between these
marks. Never use the words themselves to measure
the oil level.

If the ADD and FULL marks have not been stamped on

the dipstick, see Calibration in the previous Dipsticks
section of this manual or contact your Caterpillar dealer
for assistance.

See Refill Capacities chart for the size of your engine

• Check for lubrication leaks, such as the front and rear
crankcase.
crankshaft seals, crankcase, oil filter, oil gallery plugs,
sensors and valve covers.
 17
Operation Section
Engine Protection Devices

Engine Exerciser for Standby Units

At preset times, the exerciser will start, run and stop
the engine. This function ensures proper lubrication of
engine parts and proper equipment operation when the
standby unit is required.

Electronic Overspeed Shutoff Switch with Cranking

Termination

If equipped with Electronic Overspeed Shutoff Switch

with Cranking Termination, this control has a 75%
VERIFY button (1), a RESET button (2) and an indicator
light (3) similar to the speed switch.

The operation test of this switch is identical to the

switch described above. In addition, the Electronic
Overspeed Shutoff Switch with Cranking Termination
has a sensing circuit which prevents the starter pinion
from remaining engaged in the flywheel at excessive
rpm.

After the starting motor cranks the engine, the pinion

gear can remain engaged with the flywheel as the
engine speed increases. The magnetic pickup opens
the circuit to the starting motor at 600 rpm and allows
the pinion gear to disengage.

The circuit will remain open until the flywheel stops.

This prevents energizing the starting motor circuit
again while the flywheel is turning.
 18
Operation Section
Dipsticks
I
Dipsticks

New Dipsticks With Full Range Readings 5. Add an additional 3.8 L (4 U.S. qt) of oil to the
sump. Allow enough time for the oil to drain into the
sump. Again, check the level on the dipstick.

NOTE: If equipped with the Large Capacity Extended

Service Oil Pan, add an additional 8 L (8.5 U.S. qt) of
oil to the sump. Allow enough time for the oil to drain
into the sump. Again, check the level on the dipstick.
I
6. This is the correct FULL mark in the FULL RANGE
zone on the dipstick. If it is not, mark the new FULL
level on the dipstick.
I
NOTE: Remote mounted or auxiliary filters require
additional oil also. For all information pertaining to
auxiliary oil filters, refer to the OEM or manufacturer's
I
The crankcase oil level gauges are used with dipsticks
that have the traditional FULL mark. They can be used
for industrial applications with various installations.
instructions.

7. Start the engine and operate until it reaches normal

operating temperature. Stop the engine.
I
Calibration
Use the following procedure to calibrate the dipstick. A
8. Allow the oil to drain back to the sump for a
minimum of 10 minutes.
I
convenient time to calibrate the dipstick is at the first
oil change.

Refer to the 250 Hour interval of the Maintenance

9. Remove the dipstick. The oil level should be near
the FULL mark. If it is not, add oil until the level reaches
the FULL mark in the FULL RANGE zone on the Engine
Stopped side of the dipstick.
I
Management Schedule of this publication for the proper
oil change interval.

To verify the "ADD" mark and establish the actual

This procedure is correct for use with either the non-
spacer plate oil pan or the spacer plate oil pan. Sump
I
capacities and oil levels are the same for each oil pan.
"FULL" mark, use the following procedure:

1. Operate the engine until it reaches normal operating

Any dipstick for 3406B engines can be calibrated using
this procedure.
1
temperature.

2. Stop the engine. Drain the oil and change the oil
filter.
I
3. Fill the crankcase with 30.5 L (32 U.S. qt) of oil.
Allow the oil to drain back to the sump for a minimum
of five minutes.
1
NOTE: If equipped with the Large Capacity Extended
Service Oil Pan, fill the crankcase with 60 L (63.5 U.S.
qt) of oil. Allow the oil to drain back to the sump for a
I
minimum of five minutes.

4. Remove the dipstick. The oil level should be at the

ADD mark on the Engine Stopped side of the dipstick.
I
If it is not, mark the actual level on the dipstick. This is
now the correct ADD mark.

i
I
 21
Operation Section
Before Starting the Engine

• Check the coolant level with the engine stopped and

cold. Remove the filler cap slowly to relieve pressure.

• Maintain the coolant level to within 1/2 inch (13 mm)

of the bottom of the fill pipe. Install the filler cap.

• If equipped with a sight glass, maintain the coolant to

the proper level.

NOTICE
To prevent engine damage, never add coolant to an
ii, overheated engine. Allow the engine to cool first.
Opk

• After starting, operate the engine at slow speed until

it is at operating temperature. Check and add coolant
if necessary. Check for any obvious cooling system
leaks or loose connections. Inspect the water pump
for evidence of leaks.
22
Operation Section
Engine Starting
Engine Starting
A WARNING
Diesel engine exhaust contains products of com-
bustion which may be harmful to your health. Al-
ways start and operate the engine in a well-ventilat-
ed area and, if in an enclosed area, vent the exhaust
to the outside.
Do not start the engine or move any of the controls if
there is a "DO NOT OPERATE'. or similar warning tag
attached to the start switch or controls.
The operator must be satisfied that no one will be
endangered before starting the engine.
If the engine has not been run for several weeks, fuel
may have drained and allowed air into the filter
housing. Also, when fuel filters have been changed.
some air space will be left in the housing.
In these instances, prime the fuel system.
Refer to "Priming the Fuel System" in this publication
for more information.
For starting below —18°C (0°F), use of optional cold
weather starting aids are recommended. A coolant
heater or extra battery capacity may be required.
For temperatures below —23°C (-10°F) consult your
Caterpillar dealer.
Electric Starting
NOTE: Startability will be improved at temperatures
below 16°C (60°F) by the use of a starting aid and/or
use of a jacket water (coolant) heater or other means to
heat the crankcase oil.
Start the engine using the following procedure:
1. Place the transmission in NEUTRAL (and
disengage the flywheel clutch, if equipped), or for
Generator Sets, open the main electrical circuit breaker.
2. Move throttle to approximately half engine speed to
get the fuel rack to move to the FUEL ON position.
3. Turn the starter switch to START (or battery
disconnect switch to the ON position). Crank the
engine. At temperatures below 0°C (32°F), it may be
necessary to spray starting fluid into the air cleaner
inlet. Additional injections of ether may be required to
start and/or achieve low idle speed.
If the engine fails to start within 30 seconds, release
the starter switch and wait two minutes to allow the
starter motor to cool before using it again.
A WARNING
When using starting fluid, follow the manufactur-
er's instructions carefully, use it sparingly and
spray it only while cranking the engine. Failure to do
so, could result in an explosion and/or fire and pos-
sible personal injury.
NOTICE
Excessive ether can cause piston and ring damage.
Use ether for cold starting purposes only. Do not use
excessive starting fluid during starting or after the
engine is running.
4. As soon as the engine starts, allow the engine to
idle for 3 to 5 minutes, or until the water temperature
gauge indicator has begun to rise. The engine should
run at low idle smoothly until speed is gradually
increased to high idle.

5. Allow white smoke to clear up and proceed with
normal operation. Do not apply load to the engine or
increase engine speed until the oil pressure gauge
indicates normal. Oil pressure should raise within 15
seconds after the engine starts.
NOTICE
If oil pressure does not raise within 15 seconds after
the engine starts, stop the engine and make neces-
sary troubleshooting corrections before restarting.
6. Operate the engine at low load until all systems
reach operating temperature. Check all gauges during
the warm-up period.
Engine Starting With Jumper Cables
A WARNING
Batteries give off flammable fumes that can
explode.
Improper jumper cable connections can cause an
explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jumper cable
ends to contact each other or the engine.
Do not smoke when observing the battery electro-
lyte levels.
Always wear protective glasses when working with
batteries.
Electrolyte is an acid and can cause personal injury
if it contacts skin or eyes.
Engines installed without engine-to-frame ground straps
can be damaged by electrical discharge.
To prevent electrical discharge damage, check to make
sure the engine's electrical system has an engine-to-
frame ground strap. For engines which have the
alternator connected to an engine component, the
ground strap must connect that component to the
frame.
Some engines have starter-to-frame ground straps. But
many of these starters are not electrically grounded to
the engine. They have electrical insulation systems. For
this reason, the starter-to-frame ground strap may not
be an acceptable engine ground.
23
Operation Section
Engine Starting
When boost starting, refer to the instructions that follow
to properly start the engine.
Your engine may have a 12 or 24 volt starting system.
Use only the same voltage for boost starting. Use of a
welder or higher voltage will damage the electrical
system and is not recommended.
NOTICE
When using an external electrical source to start your
engine, turn the START switch off and remove the key
and turn off all electrical accessories before attaching
cables.
When using jumper cables always connect POSITIVE
(+) cable to POSITIVE (+) terminal of battery which is
connected to starter solenoid and NEGATIVE (—) cable
from external source to starter NEGATIVE (—) ter-
minal. If not equipped with a starter NEGATIVE ter-
minal, connect to the engine block.
Do not reverse the battery cables. The alternator can
be damaged.
Attach ground cable last and remove first.
1. Connect one end of the cable to the POSITIVE (+)
terminal of the battery being started. Connect the other
end to the POSITIVE (+) terminal of the power source.
2. Connect one end of the other cable to the
NEGATIVE (—) terminal of the power source. Connect
the other end to the starter NEGATIVE (—) terminal or
to the engine block. This prevents potential sparks
from igniting combustible gases produced by some
batteries.
3. Start the engine.
4. After the engine starts, disconnect the cable from
the starter NEGATIVE (—) terminal or engine block.
Disconnect the other end from the NEGATIVE (—)
terminal of the power source.
5. Disconnect the cable from the POSITIVE (+)
terminal of the battery on the engine being started.
Disconnect the cable from the POSITIVE (+) terminal of
the power source.
24
Operation Section
Engine Starting

Engine Starting with Air

1. Open and close the drain valve on the bottom of
the air tank to drain condensation and oil carryover.

2. Check the air supply pressure. The air starting

motor requires a minimum of 689 kPa (100 psi) air
pressure to operate properly. The maximum air
pressure must not exceed 1723 kPa (250 psi). The
normal air pressure will be 758 to 965 kPa (110 to 140
psi).

4. Push the air valve or engine start button to crank

the engine. Release the valve or button as soon as the
engine starts.

3. Check the oil level in the oiler jar. Keep the jar at
least half full and add lubricant (engine oil or diesel
fuel), if necessary.
 25
Operation Section
Engine Operation

II Engine Operation
Proper operation and maintenance are key factors in Change Engine Speed
obtaining the maximum life and economy of the
engine. Following the directions in this manual will
lower operating costs.

The time needed for the engine to reach the normal

mode of operation is usually less than the time taken
for a walk-around-inspection of the engine.

After the engine is started and the cold low idle

operation is completed, the engine can be operated at
low speed and low power. The engine will reach normal
operating temperature faster when operated at low
speed and low power demand than when idled at no
load. Typically the engine should be up to operating
temperature in a few minutes.
If equipped with a control panel, move the
RAISE/LOWER switch to the correct position.
Woodward Governors

Woodward Governors are usually electrically operated

from a control panel. The load application is usually an
EPG prime power generator set. On standby generator

r
sets the governor may be set to operate only at Full
Load speed.

NOTE: For information on Standby Generator Sets,

refer to the Mechanical Governor topic in this section.

Manually turn the adjusting knob in or out to change

engine speed.

Change Speed Droop

Loosen set screw knob (1) and move lever (2) to the
up (full travel) position for "0" speed droop. Loosen set
screw knob (1) and move lever (2) to the lowest (full
travel) position for the percentage of speed droop
required.
 26
Operation Section
Engine Operation
To adjust or change engine speed droop setting, use
the speed droop stop set screw.
Starting, Operating and Stopping Engines
Equipped with Control Panels
For all information regarding the generator control
panel used for starting, operating and stopping the
engine, refer to the publication for Caterpillar SR 4
Generators and Control Panels, form SEBU6150.
Additional information and programming instructions
are provided in the Service Manual for your specific
control panel.
Mechanical Governors
0,
This governor has a manual control lever which allows
the operator to control engine speed. The control lever
is basic equipment with the Electro-mechanical Control
Panel and a mechanical governor with 3% regulation.
4.; :
.7. A
The governor control motor is a 24V motor which
allows engine control from a remote location. This
control is used with the Electronic Modular Control
Panel (EMCP).
Driven Equipment Without Load
1. Move the governor control lever to half engine
speed.
2. To get the driven equipment in motion, engage the
clutch smoothly, with no load on the equipment. This
should result without increasing engine speed above
low idle or slipping the clutch. Interrupted starts put
excessive stress on the drive train and waste fuel.
NOTE: Begin operating the engine at low load. After
normal oil pressure is reached and the temperature
gauge begins to move, the engine may be operated at
full load.
3. Move the governor control to high idle (full load)
position.
• Check the gauges and equipment for proper
operation.
4. Apply the load to the driven equipment and check
the gauges and equipment for proper operation.
NOTE: Do not allow the engine speed (rpm) to exceed
the limit above rated rpm. DO NOT allow the engine to
overspeed.
If the load is temporarily removed, engine speed may
be reduced by manually moving the governor control
lever. However, the engine may be operated at high
idle speed without causing shortened engine life.

Driven Equipment With Load
NOTICE
Always increase engine speed before increasing load.
1. Move the governor control lever to half engine
speed.
2. Move the governor control to high idle (full load)
position.
3. Apply the load to the driven equipment and check
the gauges and equipment for proper operation.
NOTE: Do not allow the engine speed (rpm) to exceed
the limit above rated rpm. DO NOT allow the engine to
overspeed.
27
Operation Section
Engine Operation
If the load varies , or is cyclic, the governor will adjust
the engine speed as required. If a slower constant
speed is desired, move the governor control lever to
the desired speed position.
The governor control lever should remain in the full
governed position while operating at full load.
Extended operation at low idle or reduced load may
cause increased oil consumption and carbon build-up
in the cylinders and result in loss of power and/or poor
performance. At least every four hours of operation at
reduced load, the engine should be fully loaded to burn
excess carbon from the cylinders.
28
Operation Section
Engine Stopping

Engine Stopping

Prior to stopping an engine that is being operated at Mechanical Governor Control

low loads, run the engine at low idle for 30 seconds
before stopping. But, if the engine is being operated at
high load, then it should be run at low idle for five
minutes to reduce and stabilize internal engine coolant
and oil temperatures before stopping.

1. Reduce engine to speed to low idle.

2. Shift clutch into Neutral, or if equipped with

generator, open Main electrical circuit breaker, to
remove load from engine. t I

3. Move governor control to no more than half engine

speed. Idle for at least five minutes.

4. Reduce engine to speed to low idle.

• If equipped with a Mechanical Governor Control, pull
5. The engine may be stopped by one of the upward on the vernier hand grip and move the
following engine mounted controls. control to the SHUT OFF position.

Woodward Governor Control Solenoid Shutoff

• If equipped with a Woodward Governor Control, move • If equipped with a remote ON/OFF/RESET switch,
the control lever upward or forward, depending on the move the switch to the OFF position.
installation. Hold the lever to the OFF or STOP
position until the engine stops.
 29
Operation Section
After Stopping the Engine

11 After Stopping the Engine

1. Fill the fuel tank to prevent accumulation of 3. Check the crankcase oil level and maintain
moisture in the fuel. between the ADD and FULL marks in the FULL
RANGE zone on the dipstick.

4. Repair any leaks, perform minor adjustments,

tighten loose bolts, etc.

5. Observe the service meter reading. Perform

periodic maintenance as instructed in the Maintenance
Management Schedule.

. • .

2. Maintain the cooling system to 13 mm (1/2 inch)

from bottom of the fill pipe.

If below freezing temperatures are expected, allow the

engine jacket water expansion tank or radiator to cool;
then check the coolant for proper antifreeze protection.
The cooling system must be protected against freezing
to the lowest expected ambient (outside) temperature.
Add proper coolant water mixture if required.
30
Operation Section
Value Planned Repair (Repair Before Failure)
Value Planned Repair
(Repair Before Failure)
Until recently, engine maintenance and repair
management involved changing the oil when it was
convenient and repairing the engine when it was
damaged. This seemed to be the accepted way of
managing a maintenance operation.
However, due to a variety of circumstances, increasing
competition have caused users to look for ways to
prolong equipment life and lower operating costs so
that they could be competitive.
To assist Caterpillar engine users in prolonging engine
life and reducing operating costs, the Value Planned
Repair approach to engine maintenance was
developed.
The Value Planned Repair approach can be tailored for
any engine. This approach, when properly structured,
outlines every maintenance and repair service required
to support an engine from the day it enters service until
the day it is retired.
To ensure the repair is performed efficiently and
expediently, the Value Planned Repair concept
approaches a given repair in three basic steps:
1. Repair determination
2. Evaluation of repair options
3. Selection of the most appropriate option
The Value Planned Repair approach addresses:
• Services required to maintain an engine at optimum
efficiency.
• Scheduled maintenance, repairs and overhauls to
minimize unscheduled downtime.
• Preplanned repairs and overhauls that can be flat-
rated, putting you in charge of costs.
• Repair or overhaul options designed to restore the
engine to proper operating condition.
• Repair or overhaul options designed to renew the
engine if a failure has occurred.
Part of the Value Planned Repair approach is the repair
before failure concept. The objective of the repair
before failure concept is to repair the engine before a
failure takes place.
The fact that a failure has not taken place makes the
repair before failure concept more economical since a
high degree of parts such as pistons, liners, valves,
etc., and major castings such as cylinder blocks,
cylinder heads, etc., can be reused.
Also, an extensive internal cleaning of the engine,
which is labor intensive, is eliminated because a debris-
generating failure has not taken place.
The best part of the repair before failure concept is that
unscheduled downtime is minimized and in most cases
eliminated.
Because the repair or overhaul can be scheduled, it
allows the user to adjust his operation accordingly.
The overall benefit to a customer who repairs an
engine before failure is that the customer and not the
engine is in control of the repairs required.
To stress the importance of the Value Planned Repair
approach, please consider the following example that
reflects the difference in the cost of a before failure
repair versus the cost of an after failure repair.
The cost to repair a turbocharger after it fails is
approximately five times more than the cost of
repairing a turbocharger before it fails.
However, if parts from a damaged turbocharger enters
the engine, then the cost to repair your engine could
be as high as 10 times or more the cost of repairing a
turbocharger before it fails.
By subscribing to the Value Planned Repair approach,
you can avoid spending money on costly repairs that
should have been prevented and utilize the money
more profitably elsewhere.
Caterpillar strongly recommends the Value Planned
Repair approach for maintaining and overhauling your
engine.
To better illustrate what the Value Planned Repair
approach means to you in terms of dollars and cents,
please refer to the "Engine Operating Cost Analysis"
section in this publication.

II Engine Operating Cost Analysis
The term "Life Cycle Costs" can be defined as the sum
of the individual costs experienced by an engine from
the day of purchase until the day of retirement. In other
words, the total Owning and Operating Costs.
Owning Costs are fixed costs such as initial purchase
price, interest on borrowed money, depreciation and
taxes
Operating Costs are a combination of fixed and
variable costs such as fuel, oil, operator expenses,
equipment maintenance and repair, engine
maintenance and repair and downtime.
The difference between revenues generated and Life
Cycle Costs (total Owning and Operating Costs) is
profit.
Caterpillar and your Caterpillar dealer cannot guarantee
that you will make a profit. However, Caterpillar and
your Caterpillar dealer can provide you with a variety of
services that can help you reduce the costs that impact
your profits.
An Engine Operating Cost Analysis is a service
provided by your dealer that was developed by
Caterpillar to help you reduce the Life Cycle Cost of
your engine.
More specifically, an Engine Operating Cost Analysis is
a computerized program that examines current and
prospective oil, fuel, maintenance, minor repair,
overhaul and downtime costs for the period of time you
expect to own the engine. It also calculates the
operating cost per hour.
This useful tool provides your dealer with the specific
information needed to develop a customized
Maintenance Management program for your operation
which will minimize your engine's operating costs.
Before a cost analysis can be performed, your dealer
needs to gather as much information as possible about
your operation. He will need to know the length of time
you plan to keep your engine, your average cost of fuel
and oil as well as a variety of other ownership and cost
related facts and figures.
Once this information is obtained, your dealer will enter
the data into an established computerized program to
produce an Engine Operating Cost Analysis printout
reflecting your current and projected operating costs
per hour.
Current and expected cost information is reflected in
the data provided by you. These are the costs that
affect your engine's operating cost.
31
Operation Section
Engine Operating Cost Analysis
The General Information section contains basic user
data such as name, business, location, ownership,
usage per year, etc., information.
The Engine Operating Information section is divided
into eight subsections that address fuel consumption,
oil consumption, preventive maintenance, component
repairs such as water pumps, turbochargers, air
compressors, etc., before failure repairs, after failure
repairs, user's revenue rate per hour and lastly,
miscellaneous costs such as operator wages,
insurance premiums, etc.
Engine Operating Cost Summary
The Operating Cost Summary is exactly what it implies,
a summary. Here the total dollar expense and
percentage of the total operating expense is calculated
for each subsection. The individual elements are then
totaled and divided by the ownership period to yield
the cost per hour. Similar calculations are also made for
only the maintenance and repair portion of the total
operating cost.
An Engine Operating Cost Analysis is a useful tool that
can be used to:
• Project the expected operating cost of a Caterpillar
engine.
• Identify the impact of individual elements on engine
operating costs.
• Determine expected operating costs if Caterpillar
service and overhaul recommendations are followed.
• Determine the cost per hour figures that you can
obtain by having your dealer perform various levels of
preventive maintenance as recommended by
Caterpillar.
• Determine the savings to be realized if Caterpillar
repair kits, exchange components, etc., are used by
those of you who elect to perform your own
maintenance.
• Determine the proper way to realize full value of your
Caterpillar Engine by utilizing genuine Caterpillar
parts and following Caterpillar recommended
guidelines for preventive maintenance and before
failure repairs.
In conclusion, an Engine Operating Cost Analysis is a
tool that was designed to identify costly problem areas
for the purpose of helping you reduce your operating
costs.
32
Operation Section
Fuel Problems In Cold Weather Operation
Fuel Problems In Cold Weather Operation
Caterpillar Diesel Engines can operate effectively in
cold weather, however, engine operation in cold
weather is dependent on the type of fuel used and how
well the fuel moves through fuel related components.
The purpose of this section is to explain some of the
problems and steps that can be taken to minimize fuel
problems during cold weather operation when the
engine area is colder than 5°C (40°F).
Fuel and the Effect from Cold Weather
The two types of diesel fuel available for your engine
are typically grades No. 1 and No. 2. Although No. 2
diesel fuel is the most commonly used fuel, No. 1
diesel fuel is the fuel that is best suited for cold
weather operation.
During cold weather operation, it may be necessary for
you to use No. 2 diesel fuel since quantities of No. 1
diesel fuel are limited and generally are only available
during the winter months and in the colder climates.
There are two major differences between No. 1 and
No. 2 diesel fuel. No. 1 diesel fuel has a lower cloud
point and a lower pour point.
The cloud point is the temperature at which a cloud or
haze of wax crystals will begin to form in the fuel and
cause fuel filters to plug. The pour point is the
temperature which diesel fuel will begin to thicken and
be more resistant to flow through fuel pumps and lines.
Be aware of these fuel values when purchasing your
diesel fuel and anticipate the average outside (ambient)
temperature for the area your engine will be operating.
Engines fueled in one climate may not operate
satisfactorily if moved to another because of problems
that result from cold weather.
NOTE: The average No. 1 diesel fuel has a lower kJ
(BTU) (heat content) rating per unit volume of fuel than
the average No. 2 diesel fuel. When using No. 1 diesel
fuel, you may notice a drop in power and fuel
efficiency, but should not experience any other
operating effects.
Before troubleshooting for low power or poor
performance in winter months, check the type of fuel
being used.
The use of starting aids, engine oil pan heaters, engine
coolant heaters, fuel heaters and fuel line insulation
also provide a means of minimizing starting and fuel
problems in cold weather when No. 2 diesel fuel is
used.
Fuel Related Components in Cold Weather
Fuel Heaters
Fuel heaters prevent plugging of the fuel filters in cold
weather due to waxing. Non-thermostatically controlled
fuel heaters can heat the fuel in excess of 65°C
(150°F). High fuel temperatures reduce engine
performance and reliability.
A fuel heater should be installed so that the fuel is
heated before it enters the first (primary) fuel filter.
Use a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
also prevent overheating of the fuel. Choose a fuel
heater with as large a heating surface as practical.
Small heaters can be too hot in their limited surface
area.
Disconnect or deactivate the fuel heater in warm
weather. A loss of engine power can occur if the fuel
supply temperature exceeds 30°C (85°F).
NOTE: Heat exchanger-type fuel heaters should have
a bypass provision to prevent overheating of the fuel in
warm weather operation.
The following fuel heaters are recommended for use
with Caterpillar engines.
Thermoblend Cat part no. 7C3557
Hot Joint Cat part no. 7C3558
For further information on fuel heaters, contact your
Caterpillar dealer.
 . 33
Operation Section
Fuel Problem Minimizing In Cold Weather Operation

..
Fuel Filters
The use of an auxiliary primary fuel filter and/or water
separator is recommended between the fuel tank and
the engine mounted fuel filter. The micron rating and
location of a primary fuel filter is important in cold
weather operation. The primary fuel filter and its fuel
Maintain Engine Compartment Temperature
Radiator shutters and on/off fans are excellent devices
for maintaining engine area/compartment
temperatures. The radiator shutter thermostat should
open the shutters at a temperature that is 5.6°C (10°F)
higher than the opening temperature of the engine

..
supply line are the most common components affected
by cold fuel.
The micron rating of the primary fuel filter should only
be fine (low) enough to protect the fuel transfer pump.
A very fine (low micron rating) primary filter, can be
more easily plugged by wax in cold weather. A primary
thermostat.
On/off fan thermostats should open at a temperature
that is 2.8° to 5.6°C (5° to 10°F) higher than the
temperature setting of the shutters. The sequence of
these events is important to maintain engine
temperature and obtain optimum fuel economy.

.r
filter, with a micron rating as fine as a secondary filter,
can cause waxing problems. If shutters are not used, fan temperature operation is
typically 5.6° to 8.4°C (10° to 15°F) above the
NOTE: A 9M2341 Filter element is recommended as a thermostat temperature.
cold weather primary fuel filter.

The best location for the primary fuel filter is in the

engine compartment, where it will benefit from the

..
radiant heat of the engine. A filter mounted outside the
frame rails, or any location exposed to wind, can be a
persistent problem in cold weather.

..
..
1 4
34
Operation Section
Engine Lifting and Storage
Engine Lifting and Storage
Engine Lifting
NOTICE
When it is necessary to remove a component on an
angle, remember that the capacity of an eyebolt is less
as the angle between the supporting members and the
object becomes less than 90°. Eyebolts and brackets
should never be bent and should only be loaded in
tension.
Use a hoist to remove heavy components. Lift the
engine by using an adjustable lifting beam. All
supporting members (chains and cables) should be
parallel to each other, and as near perpendicular as
possible to the top of the object being lifted.
Some removals require the use of lifting fixtures to
obtain proper balance and to provide adequate
handling.
To remove the engine ONLY, use the two lifting eyes
equipped with the engine.
Lifting eyes are designed for the arrangement as sold.
Alterations to lifting eyes and/or arrangement weight
make the lifting eyes obsolete.
If you make alterations, you are responsible for
providing adequate lifting devices.
See your Caterpillar dealer for information regarding
fixtures for proper lifting of your engine package.
Engine Storage
If the engine is not started for several weeks, the
lubricating oil will drain from the cylinder walls and
piston rings. Rust can form on the cylinder liner
surface, which will increase engine wear and result in
shorter engine life.
To prevent excessive engine wear:
• Be sure all lubrication recommendations mentioned in
the Maintenance Management Schedule intervals
chart are completed.
• If freezing temperatures can be expected, check the
cooling system for adequate protection against
freezing. A 50/50 solution of Caterpillar permanent-
type antifreeze and approved water will give
protection below —37°C (-34°F).
If it will be impossible to start the engine every week,
consult your Caterpillar dealer for instructions to
prepare your engine for longer storage periods.
If an engine remains out of service and its use is not
immediately planned, special precautions should be
taken.
Refer to "Storage Procedures For Caterpillar Products,"
Form SEHS9031 for more detailed information on
engine storage.
I 35
Operation Section
Engine Lifting and Storage

i
Generator Storage Procedure 'DO NOT OPERATE, form SEHS7332 tags are available

I When a generator is in storage for any length of time,

moisture condenses in the windings. Minimize the
from your Caterpillar dealer.

To remove moisture caused by high humidity, use one

condensation by use of a dry storage space and space of the following methods to make the generator dry.

I heaters. Refer to step 2 below.

Drying may be accomplished by External Heat, Internal
Heat, A Combination of Internal and External heat, or
After Storage Circulating Current. External heat (do not exceed 75°C

I NOTE: Test the main stator windings with a

megohmmeter in the following situations:
[167°9) is the most desirable method. Insulation drying
time can vary from a few hours to several days
depending on the moisture content and the drying
process used.
I 1. Before initial startup of generator set.

2. Every 3 months* if generator is operating in a

humid environment. NOTICE

I 3. If generator has not been run under load for 3

months* or more.
Drying sometimes does not produce the required re-
sults. It may be necessary for the generator to be
dipped and baked by a qualified rebuild shop.

I * This is a guideline only. It may be necessary to

megger more frequently if environment is extremely
humid, salty, or if the last megger test was close to 1 • Energize space heaters in generator, if equipped.
megohm.

I A resistance reading of 1 megohm or less (or a 50%

reduction from the reading recorded when the unit was
• Space heaters of the same type used in marine
applications, can be installed on generators. (See the
Parts Manual.) These heaters heat the windings to
remove moisture and should be connected at all
I placed in storage) is an indication that the winding has
absorbed too much moisture. times in high humidity conditions whenever the
generator is not running.

I To Remove Moisture

A WARNING
The megohmmeter test is described in Service Manual
for SR 4 Generators, form SENR3985 or Special
Instruction, form SEHS9124, Cleaning and Drying of
Caterpillar Electric Set Generators, or contact your

I When servicing or repairing electric power genera-

tion equipment:
Caterpillar dealer.

Make sure the unit is off-line (disconnected from

I utility and/or other generators power service), and
either locked out or tagged DO NOT OPERATE1.
Remove all fuses.

I Make sure the generator engine is stopped.

Make sure all batteries are disconnected.

I Make sure all capacitors are discharged.

Failure to do so could result in personal injury or
death.
Make sure residual voltage in the rotor, stator and
the generator is discharged.

4
I
36
Maintenance Section
Torque Specifications

Torque Specifications

Torque for Standard Bolts, Nuts and NOTE: Use these standard torque values for all
Taperlock Studs fasteners unless otherwise specified in this publication
or in the Service Manual.
NOTICE
The following charts give general torques for bolts, Torque for Metric Fasteners
nuts and taperlock studs of SAE Grade 5 or better
quality.
NOTICE
Be very careful never to mix metric with customary
(SAE standard) fasteners. Mismatched or incorrect
Torques for Bolts and Nuts fasteners will cause engine damage or malfunction
With Standard Threads and may even result in personal injury.
Thread Size Standard Bolt & Nut Torque Original fasteners removed from the engine should be
Inch N•m1 lb ft saved for reassembly whenever possible. If new fas-
1/4 12 ± 4 9±3 teners are needed, they must be of the same size and
5/16 25 ± 7 18 ± 5 grade as the ones that are being replaced.
3/8 45 ± 7 33 ± 5
7/16 70 ± 15 50 ± 11
1/2 100 ± 15 75 ± 11
9/16 150 ± 20 110 ± 15
5/8 200 ± 25 150 ± 18
3/4 360 ± 50 270 ± 37
7/8 570 ± 80 420 ± 60
1 875 ± 100 640 ± 75
1 1/8 1100 ± 150 820 ± 110
1 1/4 1350 ± 175 1000 ± 130
1 3/8 1600 ± 200 1180 ± 150
1 1/2 2000 ± 275 1480 ± 200
1 1 Newton meter (N•m) is approximately the same as 0.1 mkg.
The material strength identification is usually shown on
the bolt head by numbers (8.8, 10.9, etc.). The
Torques for Taperlock Studs following chart gives general torques for bolts and nuts
Standard Taperlock Stud Torque
with Grade 10.9.
Thread Size
Inch N•ml lb ft NOTE: This product uses 10.9 Grade metric fasteners.
1/4 8±3 6±2 Use these standard torque values unless otherwise
5/16 17 + 5 13 ± 4 specified in this publication.
3/8 35 ± 5 26 ± 4
7/16 45 ± 10 33 ± 7
1/2 65 ± 10 48 ± 7
9/16 90 ± 15 65 ± 11
5/8 110 ± 15 80 ± 11
3/4 170 ± 20 125 ± 15
7/8 260 ± 30 190 ± 22
1 400 ± 40 300 ± 30
1 1/8 500 ± 40 370 ± 30
1 1/4 650 ± 50 480 ± 37
1 3/8 750 ± 50 550 ± 37
1 1/2 870 ± 50 640 ± 37
;
1 1 Newton meter (N•m) is approximately the same as 0.1 mkg.
 37
Maintenance Section
Torque Specifications

Torques for 10.9 Grade Bolts and Nuts with Torque for Constant Torque Hose Clamps
Metric Threads
A constant torque hose clamp can be used in place of
METRIC ISO2 THREAD any standard hose clamp.
Standard Torque
Thread Size

1 Metric
M6
M8
N•m1
12 ± 4
25 ± 7
lb ft
9±3
18 ± 5
Make sure the constant torque hose clamp is the same
size as the standard clamp.

Due to extreme temperature changes, hose will heat

M10 55 ± 10 41 ± 7 set. Heat setting causes hose clamps to loosen.
M12 95 ± 15 70 ± 11 Loosened hose clamps can result in leaks. There have
M14 150 ± 20 110 ± 15 been reports of component failures caused by hose
220 ± 30 160 ± 22
clamps loosening. The new, constant torque hose
M16
clamp will help prevent these failures.
M20 450 ± 70 330 ± 50
M24 775 ± 100 570 ± 75
M30 1600 ± 200 1180 ± 150 Installation
M36 2700 ± 400 2000 ± 300 Each installation application can be different depending
1 1 Newton meter (N•m) is approximately the same as 0.1 mkg. on the type of hose, fitting material and anticipated
2 ISO-International Standard Organization. expansion or contraction of the hose and fittings. A
torque wrench should be used for proper installation of
the new, constant torque hose clamps. Constant
Torque for Standard Hose Clamps-Worm torque hose clamps should be installed as follows:
Drive Band Type
To allow for maximum expansion, install clamps at 5.7
NOTICE N•m (50 lb in).
The following chart gives the torques for initial installa-
tion of hose clamps on new hose and for reassembly or To allow for equal expansion and contraction, install
tightening of hose clamps on existing hose. clamps at 10.2 N•m (90 lb in).

To allow for maximum contraction, install clamps at

14.1 N•m (125 lb in).
Initial Installation
Torque on New Hose
Clamp Width N•m1 lb in
16 mm (.625 in) 7.5 ± 0.5 65 ± 5
13.5 mm (.531 in) 4.5 ± 0.5 40 ± 5
8 mm (.312 in) 0.9 -± 0.2 8±2
Reassembly or
Retightening Torque
Clamp Width N•m1 lb in
16 mm (.625 in) 4.5 ± 0.5 40 ± 5
13.5 mm (.531 in) 3.0 ± 0.5 25 ± 5
8 mm (.312 in) 0.7 ± 0.2 6+2
1 1 Newton meter (N•m) is approximately the same as 0.1 mkg.
38
Maintenance Section
Cooling System Specifications
Cooling System Specifications
Coolant Information
Diesel engine operating temperatures have increased
to improve engine efficiency. This means proper
cooling system maintenance is especially important.
Overheating, overcooling, pitting, cavitation erosion,
cracked heads, piston seizures and plugged radiators
are classic cooling system failures. In fact, coolant is as
important as the quality of fuel and lubricating oil.
NOTICE
Caterpillar recommends that the coolant mixture con-
tain a minimum of 30% Caterpillar Antifreeze, or equiv-
alent. Liquid supplemental coolant additive must be
added, when not using Caterpillar Antifreeze, which
contains the proper additive.
Never add coolant to an overheated engine, engine
damage can result. Allow the engine to cool first.
All water is corrosive at engine operating temperature.
The cooling system should be protected with a 3% to
6% concentration of liquid supplemental coolant addi-
tive at all times, regardless of the concentration of
antifreeze.
Excessive supplemental coolant additive greater than
the recommended 6%, together with concentrations
of antifreeze greater than 60% can cause deposits to
form and can result in radiator tube blockage, over-
heating, and/or water pump seal damage.
Do not use liquid supplemental coolant additive or
elements or antifreeze with Dowtherm 209 Full-Fill
coolant. Dowtherm 209 Full-Fill coolant is not compati-
ble with other antifreeze and coolant mixtures.
Dowtherm 209 full-fill coolant will lower the water
pump cavitation temperature and coolant boiling point.
These lowered temperatures will cause overheating at
a lower ambient temperature than an ethylene glycol
and water mix. If Dowtherm is used, follow the instruc-
tions provided and use only the inhibitor package rec-
ommended by the supplier.
If the engine is to be stored in, or shipped to, an area
with freezing temperatures, the cooling system must
be protected to the lowest expected outside (ambient)
temperature.
The engine cooling system is normally protected to
—28°C (-20°F) with Caterpillar Antifreeze, when
shipped from the factory unless special requirements
are defined.
Check the specific gravity of the antifreeze solution
frequently in cold weather to ensure adequate freeze
protection.
Clean the cooling system if it is contaminated, if the
engine overheats, or if foaming is observed in the
radiator.
Coolant should be drained, the system cleaned and
new coolant added every 3000 service hours or two
years. When not using Caterpillar Antifreeze and
supplemental coolant additive as recommended, the
drain period must be shortened to 1500 service hours
or one year.
Filling at over 20 L (5 U.S. gallons) per minute can
cause air pockets in the cooling system.
After draining and refilling the cooling system, operate
the engine with the radiator cap removed until the
coolant reaches normal operating temperature and the
coolant level stabilizes. Add coolant as necessary to fill
the system to the proper level.
Never operate without a thermostat in the cooling
system. Cooling system problems can arise without a
thermostat.
Refer to "Coolant and Your Engine" form SEBD0970,
for more information.
Coolant Water
Hard water, or water with high levels of calcium and
magnesium ions, encourages the formation of insoluble
chemical compounds by combining with cooling
system additives such as silicates and phosphates.
The tendency of silicates and phosphates to precipitate
out-of-solution increases with increasing water
hardness. Hard water, or water with high levels of
calcium and magnesium ions encourages the formation
of insoluble chemicals. especially after a number of
heating and cooling cycles.
Caterpillar prefers the use of distilled water or
deionized water to reduce the potential and severity of
chemical insolubility.
I 39
Maintenance Section
Cooling System Specifications

MINIMUM ACCEPTABLE WATER Antifreeze

Water Content Limits gr/gal (ppm)
Chlorides (CI) 2.4 (40) maximum NOTICE
Sulfates (SO4) 5.9 (100) maximum Caterpillar recommends that the coolant mix contain a
minimum of 30% Caterpillar Antifreeze, or equivalent
I Total Hardness
Total Solids
pH
10 (170) maximum
20 (340) maximum
5.5 to 9.0
and acceptable water to maintain an adequate water
pump cavitation temperature for efficient water pump
performance.

I ppm = parts per million

Premix coolant solution to provide protection to the
lowest expected outside (ambient) temperature. Pure
undiluted antifreeze will freeze at —23°C (-10°F).
Using water that meets the minimum acceptable water

I requirement may not prevent drop-out of these

chemical compounds totally, but should minimize the
rate to acceptable levels.
Only use a greater concentration (above 30%) of
Caterpillar Antifreeze as needed for anticipated out-
side (ambient) temperatures. Do not exceed a coolant
mixture of 60% antifreeze to water since a concentra-
I To determine water characteristics, contact local water
dept., agricultural agent or an independent laboratory
to perform the testing service. Two companies are
tion above 60% antifreeze will reduce the engine's
freeze protection and increase the possibility of depo-
sit formation in the cooling system.
listed below, however there are others who are
I qualified to provide this service.

L.O.C.C. Corp. Use Caterpillar Antifreeze or ASTM D4985-89 (GM

905 Bayshore Drive Specification 6038-M) Antifreeze. Caterpillar Antifreeze
I Coos Bay, OR 97420
Ph. (503) 267-4904
is available through your Caterpillar dealer in quantities
that follow.

I NALCO Chemical Co.

Naperville Technical Center
One Nalco Center Part No.
CATERPILLAR ANTIFREEZE
Size
Naperville, IL 60566
I Attn: Sample Receiving
Ph. (312) 961-9500
8C3684
8C3686
3.8 Liter (1 U.S. Gallon)
208 Liter (55 U.S. Gallons)

I Most commercial antifreezes are formulated for

gasoline engine applications and will, therefore, have
high silicate content. Caterpillar Antifreeze is formulated
with a low silicate content and the proper coolant
I additives for heavy duty diesel engines.

ASTM D4985-89 (GM Specification 6038-M) is a low

I silicate antifreeze, but supplemental coolant additive

must be added.

4
I
40
Maintenance Section
Cooling System Specifications
The major advantages of Caterpillar Antifreeze are:
• Significantly reduces water pump seal leakage
problems caused by excessive concentration of
chemical additives.
• There is no need to add supplemental coolant
additive on initial fill which must be done with current
commercially available antifreezes.
• High silicate antifreezes used with a supplemental
coolant additive can cause a build-up of solids over a
period of time which can cause plugging, loss of heat
transfer, and water pump seal damage.
Make proper antifreeze additions.
Adding pure antifreeze as a makeup solution for
cooling system top-up is an unacceptable practice. It
increases the concentration of antifreeze in the cooling
system which increases the concentration of dissolved
solids and undissolved chemical inhibitors in the
cooling system. Add antifreeze mixed with water to the
same freeze protection as your cooling system.
Use the chart below to assist in determining the
concentration of Caterpillar Antifreeze to use.
ANTIFREEZE CONCENTRATIONS
Protection Temperature Concentration
Protection to -15°C (5°F)
30% antifreeze and 70% water
Protection to -23°C (-10°F) 40% antifreeze and 60% water
Protection to -37°C (-34°F) 50% antifreeze and 50% water
Protection to -51°C (-60°F) 60% antifreeze and 40% water
5P0957 Coolant Tester (°F) or 5P3514 Coolant Tester (°C)
Both are available at your Caterpillar dealer.
Check the coolant solution frequently in cold weather
for glycol concentration with the 5P0957 or 5P3514
Coolant Tester to ensure adequate protection. Both
testers are identical except temperature scale. They
give immediate, accurate readings and can be used for
antifreeze/coolants that contain ethylene or propylene
glycol.
If propylene glycol based antifreeze is used. DO NOT
allow concentration greater than a 50/50 antifreeze to
water mixture. The measurement of freeze protection
must be made with a refractive-type tester (Cat 5P0957
or 5P3514) rather than a hydrometer-type, which can
be used to test ethylene glycol based antifreeze.
Supplemental Coolant Additive
Supplemental coolant additive is necessary to prevent
rust, scale, pitting and/or corrosion of engine parts that
coolant comes in contact with. Most antifreeze
solutions DO NOT contain sufficient supplemental
coolant additive.
NOTE: If other than Caterpillar products are used as
the supplemental coolant additive, follow the
manufacturers' recommendation for cooling system
treatment and test evaluation.
DO NOT mix Caterpillar Supplemental Coolant Additive
or supplemental coolant additive elements with the
other products available; select a cooling system
treatment and use it exclusively.
Liquid supplemental coolant additive can be purchased
from your Caterpillar dealer. Follow the instructions on
the container.
;
 NOTICE
Always add supplemental coolant additive or equiva-
lent to the coolant, or install a Caterpillar supplemental
coolant additive element (if equipped). Never use cool-
ant only, except if Caterpillar Antifreeze is being used.
No supplemental coolant additive is needed on initial
fill, but is necessary on a maintenance basis.
Use supplemental coolant additive or a supplemental
coolant additive element (if equipped) to maintain a 3%
to 6% concentration in the cooling system to help
prevent corrosion.
To prevent overinhibiting the engine's cooling system,
never use both the liquid supplemental coolant addi-
tive and the supplemental coolant additive element (if
equipped) at the same time. The use of these additives
together could result in excessive concentration that
would exceed the Caterpillar recommended maximum
of 6%.
Excessive concentration of an additive can form depo-
sits on the higher temperature surfaces of the cooling
system and create a barrier that reduces the engine's
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components. Excessive concentra-
tions of additive could also accelerate water pump seal
wear.
Supplemental coolant additive is required when not
using Caterpillar Antifreeze for premixed coolant
solution.
NOTICE
The Caterpillar 8T5296 Test Kit checks for concentra-
tion of nitrates in the coolant solution. Some other
manufacturers' supplemental coolant additives (SCA)
are phosphate based and the 8T5296 Test Kit will
provide inaccurate results. If non-Caterpillar supple-
mental coolant additives (SCA) are used, Caterpillar
recommends that their test kit be used to check for
coolant solution concentration.
For maintenance of a 3% to 6% concentration of
additive, add supplemental coolant additive or install a
maintenance supplemental coolant additive element (if
equipped), every 250 service hours or oil change,
whichever occurs first.
If the engine is not equipped with spin-on element. add
.25 L (1/2 pint) of supplemental coolant additive for
each 38 L (10 U.S. gallons) of coolant capacity to
maintain the 3% to 6% concentration of additive.
LIQUID SUPPLEMENTAL COOLANT ADDITIVE
QUANTITIES AVAILABLE
Part No. Size
6V3542 0.25 Liter (0.53 Pint)
8T1589 0.47 Liter (1 Pint)
3P2044 1.00 Liter (1.05 Quart)
8C3680 18.95 Liter (5 Gallons)
5P2907 208 Liter (55 Gallons)

On initial fill (precharge) of a new or reconditioned

engine: if Caterpillar Antifreeze is not used, add 1 L (1 COOLANT ADDITIVE ELEMENTS BY CAPACITY
quart) of supplemental coolant additive, or equivalent. Cooling System Initial' 250 Hour2
for each 30 L (8 U.S. gallons) so that the cooling Capacity Precharge Maintenance
liter (gal) Element Element
system will have a 3% to 6% concentration of
supplemental coolant additive. 22-32 (6-8) 9N6123 9N3368
33-47 (9-12) 9N6123 9N3718
48-62 (13-16) 9N3366 9N3368
63-85 (17-22) 9N3367 9N3368
86-115 (23-30) 9N3367 9N3718
1 Use only when not using Caterpillar Antifreeze.
2 Do not exceeed 6% maximum concentration. Check with sup-
plemental coolant additive test kit.

Use the 8T5296 Test Kit to check for concentration.

 vvvn~ IV 1.-iy .71,111 V taG,-,111%."CA. 1.11lJI IJ

Cooling System Cleaning

Our recommended intervals for performing
maintenance on the cooling system are based on
experience and gathered data relative to the
performance characteristics of this engine and its
components. Performing maintenance on the cooling
system is important because the cooling system has a
direct effect on the operation and service life of the
engine.

Improper maintenance can result in a variety of

problems that could shorten the engine's service life or
result in poor engine performance.

When you drain, clean, flush and replace the coolant,

small particles, undesirable chemicals, scale and other
deposit formations are removed. These deposits
reduce the necessary heat transfer characteristics of
the cooling system.

Failure to clean and change the coolant as

recommended will reduce the efficiency of the cooling
system and, in some cases, result in an increase in fuel
consumption.

Disregard for performing maintenance on the cooling

system can eventually cause engine overheating
problems that could result in severe damage to the
engine and its components.

Caterpillar Cooling System Cleaners are designed to

clean the system of harmful scale and corrosion. It
dissolves mineral scale, corrosion products, light oil
contamination and sludge.

Clean the system according to the maintenance

interval chart, or whenever the coolant is dirty or
foaming.

Cooling system cleaners are available from your

Caterpillar dealer in the quantities listed below. Follow
the label directions for proper usage.

COOLING SYSTEM CLEANER

QUANTITIES AVAILABLE
Part No. Size
4C4609 0.47 Liter (1 Pint)
4C4610 0.95 Liter (1 Quart)
4C4611 3.79 Liter (1 Gallon)
4C4612 18.95 Liter (5 Gallons)
4C4613 208 Liter (55 Gallons)

;
I 43
Maintenance Section
Fuel Specifications

111 Fuel Specifications

Fuel System Information The fuel return line should deposit fuel at the top of the

I Use only fuel as recommended in this section.

tank opposite the supply connection. This allows the
engine to get warm fuel from the tank. It also allows air
to escape from the return fuel without being pulled
back into the engine. If hot fuel must return to the day

I NOTICE
Fill the fuel tank at the end of each day of operation to
drive out moist air and to prevent condensation. Main-
tank, a fuel cooler is required.

Fuel Filters

I tain a fairly constant level in the day tank (near the top)
to avoid drawing moisture into the tank as the level
decreases.
A primary fuel filter and/or water separator is
recommended and should be installed between the
fuel tank and the engine fuel inlet.
Do not fill the tank to the top. Fuel expands as it gets
I warm and may overflow.
Do not fill the fuel filters with fuel before installing
After changing the fuel filter(s), always prime the fuel
system (if equipped with a priming pump) to remove air
them. Contaminated fuel will cause accelerated wear bubbles from the system.

I to the fuel system parts.

Fuel Lines
Avoid sharp angles and use as few fittings and
I Fuel Tanks
Check the fuel level in the day tank daily by observing
the sight gauge, if equipped.
connections as possible. Moisture in the fuel will tend
to collect and freeze at low points in the fuel lines. Fuel
lines should travel the most direct route to the engine
compartment.

1I
Drain the water and sediment from any fuel storage
tank weekly, at the oil change period, and before the
fuel tank is refilled. This will help prevent water and/or
sediment from being pumped from the fuel storage
tank into the engine fuel tank.
Do not use galvanized fittings in the fuel lines. Size fuel
lines so they do not exceed maximum fuel transfer
pump inlet restriction and fuel return line restriction
specifications.

Fuel tanks should contain some provision for draining

water and sediment from the bottom of the tanks. Fuel Recommendations

The top of the fuel supply tank (or day tank) should not Caterpillar Diesel Engines are capable of burning a
be higher than the fuel injectors on the engine. wide range of distillate fuels. The use of clean, stable

I Some fuel tanks use supply pipes that allow water and
sediment to settle below the end of the fuel supply
blends of distillate fuel which meet the following
requirements will provide quality engine service life.

I pipe. This water and sediment should be drained at

each oil change. Do not use fuel tanks with supply
lines that take fuel directly from the bottom of the tank.
Fuel supply connections to the engine must be at least
DISTILLATE FUEL RECOMMENDATIONS-DIESEL ENGINES
Specifications Requirements1

I
Aromantics (ASTM D1319) 35% Max.
75 mm (3 in.) above the bottom of fuel tank. Ash (ASTM D482) 0.02% Weight Max.
Cetane Number 35 Min. for PC Engines
If there is a fuel return line from the engine, it should 40 Min. for DI Engines
(ASTM D613)
return excess, hot fuel to the tank from which it was

I taken. Do not return fuel to the day tank (if equipped),

as fuel overheating could cause a decline in engine
performance.
Cloud Point (ASTM D97)

Gravity API (ASTM D287)

Not Above Lowest Expected
Ambient Temperature
30 Min. and 45 Max.

I Pour Point (ASTM D97)

Sulfur (ASTM D2788,

D3605 or D1552)
6°C (10°F) Below
Ambient Min.
0.5% Max.
(See Sulfur Topic)

i Viscosity, Kinematic @
38°C (100°F) (ASTM D445)
Water & Sediment
(ASTM D1796)
20.0 c5t Max.
1.4 cSt Min.
0.01% Max.

I ' As delivered to fuel system

44
Maintenance Section
Fuel Specifications

WORLDWIDE FUEL SPECIFICATIONS-DIESEL ENGINES Pour Point

Specifications Fuel Designation The pour point of the fuel should be at least 6°C (10°F)
AMERICAN STANDARDS below the lowest ambient temperature at which the
ASTM D975 No.1-D & No.2-D diesel engines must start and operate. The lower pour point
fuel oil of No.1 or No.1-D fuel may be necessary in extremely
ASTM D396 No.1 & No.2 fuel oils
ASTM D2880 No.1-GT & No.2-GT gas cold weather.
turbine fuels
BRITISH STANDARDS
BS 2869 Classes Al, A2 & B1
Cloud Point
engine fuels The cloud point should be below the lowest ambient
BS 2869 Classes C2 & D
burner fuels
temperature at which the engines must start and
operate to prevent the fuel filter elements from plugging
WEST GERMAN STANDARDS
DIN 51601 Diesel Fuel with wax crystals.
DIN 51603 Heating Oil El
AUSTRALIAN STANDARD
NOTE: Refer to topic, Fuel Problems in Cold Weather
AS 3570 Automotive Operation, for additional information.
diesel fuel
JAPANESE STANDARD
JIS K2204 Types 1(spl), 1, 2, 3 Sulfur
& 3(spl) gas oil
Fuels containing 0.5% or less sulfur may be used with
U.S. GOVERNMENT normal crankcase oil drain intervals using API CD or CE
W-F-800C DF-1,DF-2 conus & DF-20
performance oils. With sulfur above the 0.5% level, use
conus diesel fuel
W-F-815C FS-1 & FS-2 burner API CD or CE oils with an ASTM D-2896 Total Base
fuel oil Number (TBN) of 20 times the fuel sulfur for normal oil
U.S. MILITARY drain intervals.
MIL-L-16884G Marine Oil
Regular oil analysis (S•O•S) will provide information to
monitor oil properties and engine wear metals to
The fuels recommended for use in Caterpillar engines maintain successful engine protection and establish oil
are normally No.2-D diesel fuel and No.2 fuel oil, drain intervals. Refer to the topic, Fuel Sulfur Content,
although No.1 grades are acceptable. The following for additional information regarding fuel sulfur, its
fuel specifications are some of the worldwide fuels effects on oil, etc.
which also meet the requirements.

The following fuel characteristics should be considered Viscosity

when procuring fuel for use in Caterpillar diesel
engines.
Cetane Number
The minimum cetane number required for average
starting conditions for the direct injection engine is 40.
A higher cetane value may be required for high altitude
operation or cold weather starting.
Filterability
Clean fuels should have no more than 0.1 % of
sediment and water. Storage of fuel for extended
periods of time can cause fuel oxidation with solids
forming, causing filtering problems.
The viscosity of any fluid is a measure of resistance to
flow. Fuel viscosity is important because it provides
lubrication for fuel system components and also its
effects on fuel atomization. The viscosity limits have
been provided to meet both of these effects.
Additives
Fuel additives are generally not recommended nor
needed for the specified fuels listed previously. Cetane
improvers can be used as necessary for the direct
injection engine requirements. Biocides may be needed
to eliminate microorganism growth in storage tanks. In
cold conditions. treatment for entrained water may also
be necessary.
I 45
Maintenance Section
Fuel Specifications

i
Consult your fuel supplier about the use of additives to

I prevent incompatibility among additives already in the

fuel and the additives to be used.

NOTE: Other fuel types may be burned in the engine

I when economics or fuel availability dictate. Consult

your Caterpillar dealer for more information and advice
on any specific fuel.

I For more information on fuel selection and fuel

properties, refer to "Diesel Fuels and Your Engine,"
form SEBD0717 or contact your Caterpillar dealer.

I Fuel Sulfur Content

I The percentage of sulfur in the fuel will affect the

engine oil recommendations. Fuel sulfur is chemically
changed during combustion to form both sulfurous and
sulfuric acid. These acids chemically attack metal

I surfaces and cause corrosive wear.

Certain additives used in lubricating oils contain

alkaline compounds that are formulated to neutralize

I these acids. The measure of this reserve alkalinity in a

lubricating oil is known as its Total Base Number (TBN).
TBN values are essential to neutralize the acids from
combustion gases and to minimize corrosive wear.
I Any API classification performance oil should have
sufficient TBN for fuels with less than 0.5% sulfur. For

I fuels with 0.5% to 1.5% sulfur by weight, new engine

oil must have a TBN of 20 times the percentage of fuel
sulfur as measured by the ASTM (American Society of
Testing Materials) D-2896 method. (ASTM D-2896 can

I normally be found at your local technological society,

library or college.)

For fuel with sulfur exceeding 1.5% by weight, use an

I oil with a TBN of 30 and reduce the oil change interval

by one half.

Caterpillar recommends infrared analysis (in

I conjunction with wear metal analysis) of used oil in
determining the effectiveness of oil TBN and acid
neutralization. The Caterpillar dealer S•O•S program

I provides this information.

Periodically request fuel sulfur content information from

your fuel supplier. Fuel sulfur content can change with
each bulk delivery.

For more information on oil, fuel sulfur content, etc.,

4 refer to "Oil and Your Engine," form SEBD0640 or

contact your Caterpillar dealer.

I
46
Maintenance Section
Lubricant Specifications
Lubricant Specifications
Lubricant Information
Certain abbreviations follow S.A.E. J754 nomenclature
and some classifications follow S.A.E. J183
abbreviations. The MIL specifications are U.S.A. Military
Specifications. The definitions other than Caterpillar's
will be of assistance in purchasing lubricants. The
recommended oil viscosities can be found in the
"Lubricant Viscosities' chart in this publication.
Engine Oils
Caterpillar has two oil formulations to provide maximum
performance and life in your engine.
Diesel Engine Oil (DEO)
• Cat Diesel Engine Oil (DEO)
Cat Diesel Engine Oil is specially formulated for
Caterpillar Diesel Engines, to reduce piston and ring
deposits and thus provide longer engine life and stable
oil control.
CAT Diesel Engine Oil (DEO) is blended with a diesel
engine type additive with 14 TBN (Total Base Number)
and 1.8% sulfated ash level.
Engine Oil (EO)
• Cat Engine Oil (EO)
CAT Engine Oil (EO) is a lubricant meeting the industry
standards for both gasoline and diesel requirements.
This oil has 10 TBN and a 1.2% sulfated ash level.
If an oil other than DEO is to be used, use the following
guideline:
• API specifications CD/SE, CD/SF or CD/SG
If an oil other than EO is to be used, use the following
guideline:
• API specifications CE, CE/SF, or CE/SG
Oil with these specifications may require shortened oil
change periods as determined by close monitoring of
oil condition with Scheduled Oil Sampling (S•0•S) and
infrared analysis.
NOTE: The percentage of sulfur in the fuel will affect
the engine oil recommendations. For fuel sulfur effects,
the Infrared Analysis and the ASTM D2896 procedure
can be used to evaluate the residual neutralization
properties of an engine oil. The sulfur products
formation depends on the fuel sulfur content, oil
formulation. crankcase blowby, engine operating
conditions and ambient temperature.
The Caterpillar 20 times rule for TBN versus fuel sulfur
is a general requirement, but it can be modified by
used oil analysis. The effectiveness of an oil
formulation will depend on the additive package. A
balanced additive package oil of a lower TBN can be
as effective in fuel sulfur neutralization and overall
performance as some oils with higher TBN values
which have additives just for increased TBN. The used
oil analysis can show these results.
For more information on oil and fuel sulfur content,
refer to "Oil and Your Engine," form SEBD0640 and
"EMA Lubricating Oils Data Book," form SEBU6310.
NOTICE
Failure to follow these recommendations can cause
shortened engine life due to carbon deposits or exces-
sive wear.
Always consult with your Caterpillar dealer for the latest
lubrication recommendations.
Anti-Seize Compound (ASC)
Use 5P3931 Anti-Seize Compound (ASC) or equivalent.
 47
Maintenance Section
Lubricant Specifications

Cat Lubricating Grease

Caterpillar has greases for all applications.

• Cat Multipurpose Molybdenum Grease (MPGM)

Use MPGM for heavily loaded bearings and joints

where an extreme pressure grease will maximize the
life of Caterpillar equipment. This NLGI No. 2 grade is
suitable for most temperatures.

If MPGM is not available, use a multipurpose type

grease which contains 3 to 5% molybdenum.

• Cat Multipurpose Lithium Grease (MPGL) (non-

extreme pressure)

This NLGI No. 2 grade is recommended for light duty

automotive type applications where a high temperature
[up to 175°C (350°F)] is required. This grease offers
excellent mechanical stability, high resistance to
oxidation, good rust protection and excellent
breakaway torque.

If this grease is not available, use a similar

multipurpose grease.

• Cat Special Purpose Grease (SPG)

This grease is recommended for high temperature anti-

friction bearings in such applications as electric
motors, alternators, starters and generators. The
grease is a NLGI No. 2 grade.

This NLGI No. 2 grade is suitable for most temperatures

[-28°C to +149°C (-18°F to +300°F)]. Use NLGI No. 1
or No. 0 grade for extremely low temperature.

If this grease is not available, use a similar

multipurpose grease suitable for anti-friction bearings.
48
Maintenance Section
Scheduled Oil Sampling (S•O•S)
Scheduled Oil Sampling (S•O•S)
Caterpillar's Scheduled Oil Sampling (S•O•S) is the
best indicator for determining what is happening inside
your engine.
S•O•S is a diagnostic tool used to determine oil
performance and component wear rates with a series
of tests designed to identify and measure
contamination such as soot, sulfur, etc. and
degradation such as the presence of fuel, water and
antifreeze in a sample of oil.
The tests also determine the amount of wear metals
present in the oil sample, which is compared to
established Caterpillar norms to determine
acceptability. To be effective as an indicator, S•O•S
must be performed on a continuing basis. Intermittent
sampling will not allow wear rate trend lines to be
established.
S•O•S INTERVAL CHART
Compartment
Engine Oil
Interval
Every 250 Hour or at Oil
Change
S•O•S Sampling Valve (if equipped)
Obtain Every 250 Hour Interval.
Obtain S•O•S samples at regularly scheduled intervals
to monitor the condition and maintenance requirements
of your engine. Each oil sample should be taken when
the oil is warm and well mixed to ensure that the
sample is representative of the oil in the engine
crankcase.
Consult your Caterpillar dealer for complete information
and assistance in establishing an S•O•S program for
your engine(s).
I
S•O•S Analysis
S•O•S is composed of three basic tests: I
• Wear Analysis
• Chemical and Physical Tests
• Oil Condition Analysis I
Wear analysis is performed with an atomic absorption
spectrophotometer to monitor component wear by
identifying and measuring concentrations, in parts per
million, of wear elements present in the oil. Based on
I
known normal concentration data, maximum limits of
wear elements are established. Impending failures can
be identified when test results deviate from
concentration levels established as acceptable, based
I
on normal wear.
Chemical and physical tests detect the presence of
I
water, fuel and glycol (antifreeze) in the oil and
determine whether or not their concentrations exceed
established maximum limits. I
Oil condition is evaluated with infrared analysis. This
test determines the presence and measures the
amount of contaminants such as soot, sulfur products,
oxidation, and nitration products in the oil. Infrared
I
analysis can also assist in customizing (reducing,
maintaining or extending) oil change intervals for
particular conditions and applications. I
Infrared analysis should always be accompanied by
wear element analysis and chemical and physical tests
to assure accurate diagnosis.
I
NOTE: Infrared analysis must be used to determine oil
change intervals. S•O•S must include Infrared (IR) in
the analysis.
I
The test results of the oil samples will then be used as
a basis for determining the oil change interval for your
engine, giving you the ultimate time between oil
I
changes without the risk of engine damage.
I
I
I
p
I

III Terminology
Adjust - to conform and correspond to specifications.
Check - to observe for satisfactory conditions,
accuracy, safety or performance.
Exchange - to trade a worn or failing component for a
remanufactured or rebuilt component.
Inspect - to examine closely, in critical appraisal, while
testing or evaluating components or systems.
Inspect/Rebuild or Exchange - to examine closely;
then making the decision on repair option (i.e. Rebuild
or Exchange).
Lubricate - to apply a lubricant (oil, grease, etc.) as
specified for reducing friction, heat and wear between
solid surfaces.
Protective Devices - indicators such as gauges, lights,
emergency shutoffs, etc., that alert an operator that a
potential problem may exist. Failure to respond to these
indicators in a timely manner could result in serious
engine damage.
Rebuild - to repair a worn or failing component with
new parts, components and/or remanufactured
components.
Replace - to install something new, remanufactured or
rebuilt in place of an existing worn or failing
component.
Service Hours (Electrical) - records the time (clock
hours) the engine is actually running but does not
reflect variations in speed, load, etc.
NOTE: The Maintenance Management Schedules are
developed for clock hours or fuel consumption. For
most users, clock hours are the standard interval for
maintenance. However, Caterpillar recommends that
fuel consumption be used as the preferred method of
determining intervals rather than clock hours.
49
Maintenance Section
Terminology
Interval Terminology
Engine components can generally be grouped into
"speed sensitive" and "load sensitive" categories.
Therefore, the maintenance interval for each item listed
in the "Maintenance Management Schedule" is primarily
based on the item and its relationship to either engine
speed or load.
Speed sensitive items such as water pumps, air
compressors, etc., are not primarily affected by the
load on your engine during operation. The load on an
engine will not significantly accelerate the repair or
replacement cycle for speed sensitive items.
Therefore, the maintenance intervals established for
speed sensitive items are based on service hours.
Load sensitive items such as piston rings, cylinder
liners, etc., are affected by the load on your engine
during operation. Generally speaking, the lower the
load, the longer the engine life and conversely, the
higher the load, the shorter the engine life. A heavy
load on an engine will accelerate the repair or
replacement cycle for load sensitive items.
Load sensitive items are normally internal engine
components. The amount of fuel consumed is directly
related to the load on your engine.
Therefore, the maintenance interval for load sensitive
items also includes quantity of fuel used, since the
amount of fuel consumed is directly related to the load
on your engine.
Since the amount of fuel consumed is a better indicator
of performing an maintenance than service hours,
Caterpillar recommends performing maintenance on
these items at the specified maintenance interval
based on the quantity of fuel consumed.
NOTE: The Maintenance Management chart follows.
Ensure that the chart is adhered to.
50
Maintenance Section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities and Refill Capacities

Lubricant Viscosities Refill Capacities

The proper SAE grade of oil to select is determined by
NOTICE
the outside temperature at which the engine is started
In order to properly maintain the cooling system, Total
and the maximum outside temperature in which the
Cooling System capacity must be known. The chart is
engine will be operating. See chart for recommended
blank and should be filled in by the customer to deter-
viscosity and temperature range.
mine the Total Cooling System Capacity for this en-
To determine if the oil in the crankcase will flow in cold gine and application.
weather, remove the oil dipstick before starting. If the
oil will flow off, the oil is fluid enough to circulate
properly. REFILL CAPACITIES - (APPROXIMATE)
Compartment U.S. Imperial
or System Liters Quarts Quarts
LUBRICANT VISCOSITIES
FOR AMBIENT (OUTSIDE) TEMPERATURES 3406B ENGINE 34.0 36.0 30.0
CRANKCASE Including
Compartment °C °F Filters (Shallow Pan )1
0111
or System Viscosities Min Max Min Max 3406B ENGINE 68.0 72.0 60.0
Engine SPC SAE 5W20 -30 +10 -22 +50 CRANKCASE (Including
Crankcase Filters) (Deep Pan)'
SAE 5W20 -25 +10 -13 +50
3406B COOLING 23.0 24.0 20.0
SAE 10W2 -20 +10 -4 +50 SYSTEM (Engine Only)
SAE 10W30 -20 +40 -4 +104 COOLING SYSTEM
SAE 15W40 -15 +50 +5 +122 (Radiator Only)2
SAE 302 0 +40 +32 +104 TOTAL COOLING
SYSTEM (with Radiator)3
SAE 402 +5 +50 +41 +122
Optional bypass filters supplied by Caterpillar require additional
Select oil viscosity based on maximum expected operating
oil. Additional oil is required with the use of auxiliary filters.
temperature. Engine start-up at lower than specified ambient
Make sure to add enough oil to fill auxiliary oil circuit. Refer to
temperature requires caution. Start-up at very low ambient
OEM manufacturers' specifications regarding auxiliary filter
temperatures may require auxiliary oil heaters or other methods
capacity.
to increase the engine crankcase and surrounding
2 Refer to Caterpillar or the OEM manufacturers' specifications
temperatures.
regarding cooling equipment capacity and enter capacity in this
2 Oil viscosity grades which meet the API CE performance
column.
category are limited somewhat to multigrades (SAE 15W40 and
3 Add ENGINE ONLY and appropriate RADIATOR ONLY capacity
10W30). If single viscosity grades are selected, confirm with
for TOTAL COOLING SYSTEM capacity for your engine and
your oil supplier that the oil does meet the API CE rating
requirement. application.

The Total Cooling System capacity will vary. depending

1
Air Starting Motor Oiler: Use SAE 10W engine oil in
all temperatures. on the radiator type and capacity provided by
Caterpillar or the OEM manufacturer.
 51
Maintenance Section
Maintenance Management Schedule

Maintenance Management Schedule

Use fuel consumption, calendar interval or service Every 3000 Hours or Two Years or
hours, whichever occurs first. 114 000 L (30,000 gal) of Fuel*

NOTE: Experience has shown that maintenance Thermostat - Replace 77

intervals are most accurately scheduled on the basis of Cooling System - Clean/Flush coolant 79
fuel consumed rather than service hours. Valve Lash - Check/Adjust 81
Fuel Ratio Control - Check/Adjust 83
Governor Set Point and Low Idle Speed -
Daily Check/Adjust 83
Turbocharger - Inspect for proper operation 84
Walk-Around Inspection - Inspect engine for Engine Mounts - Inspect 84
leaks and loose connections 52 Damper Inspect 85
Engine Crankcase - Check oil level 54
Cooling System - Check coolant level 55
Clutch Shift Collar and PTO Main Shaft2 - Every 5000 Hours or 190 000 L
Lubricate 56 (50,000 gal) of Fuel*
Air Starter (if equipped) - Check lubricator level 56
Air Tank (if equipped) - Drain water 57 Fuel Injection Nozzles - Test/Exchange 86
Engine Air Cleaner Indicator - Check service SR 4 Generator (If Equipped) - Lubricate bearing 87
indicator 58 Water Pump - Rebuild or Exchange 87
Turbocharger - Rebuild or Exchange 87
Alternator - Rebuild or Exchange 87
Every 125 Hours or 4200 L (1000 gal) of Fuel* Electric Starting Motor - Rebuild or Exchange 87

Pilot Bearings (if equipped) and Shift Levert -

Lubricate 61 OVERHAUL Every 10,000 hours or
380 000 L (100,000 gal) of Fuel*

Every 250 Hours or 9500 L (2500 gal) of Fuel* Cylinder Head Assembly, Cylinder Packs, Oil
Pump, Fuel Transfer Pump and Timing Advance,
Scheduled Oil Sampling (S•O•S) Analysis - Fuel Ratio Control and Spacer Plate - Rebuild or
Obtain 62 Exchange 92
Engine Oil and Filters1 - Change 63 Crankshaft Bearings, Valve Rotators and
Crankcase Breather - Clean 65 Crankshaft Seals Install new 92
Valve Lash (At First Oil Change Only) - Fuel Injection Nozzles and Fuel Injection Pump -
Check/Adjust 66 Test or Exchange 92
Cooling System - Test for concentration of Crankshaft, Camshaft, Camshaft Followers and
supplemental coolant additive 66 Bearings, Damper, Fuel Rack and Governor,
Fuel Filters - Replace final filter/Clean primary Gear Train Gears and Bushings, and Driven Unit
filter 68 Alignment Inspect 93
Fuel Tank - Drain water & sediment 70 Oil Cooler and Aftercooler Core Clean/Test 93
Belts and Hoses - Inspect/Replace 70 Coolant Analysis - Obtain 94
Clutch - Check/Adjust 72
Fan Drive Bearing - Lubricate 72 "First Perform Previous Service Hour Items
Batteries - Clean/Check electrolyte level 73
' Maximum fuel usage for engine oil change interval
equipped with 500 hour oil pan (large sump) is 19 000
Every 1000 Hours or 38 000 L L (5,000 gal). Refer to 4W6412 Oil Cooler decal for oil
(10,000 gal) of Fuel* change recommendations based on fuel consumption.
2 Or as shown on the clutch or PTO mounted
Engine Protection Devices - Inspect for proper Information Plate.
operation 74 • To prevent crankshaft and/or bearing damage, crank
Woodward Governor and Tachometer Drive - engine to fill all filters before starting engine.
Lubricate 76 • Remote mounted or auxiliary filters require additional
oil. When changing oil, overfill crankcase by amount
needed for auxiliary system (if equipped).
52
Maintenance Section
Daily

Daily

You must read and understand the warnings

and instructions contained in the Safety section
of this manual, before performing any operation
or maintenance procedures.

Walk-Around Inspection
Inspect Engine for Leaks and Loose
Connections
A walk-around inspection should only take a few
minutes of your time. By taking the time to make these
checks, costly repairs and accidents can be avoided
and your equipment will be ready to run should the • Inspect the fan and alternator drive belts for cracks,
need arise. breaks or other damage.

For maximum service life of your engine(s), make a
thorough inspection before starting the engine. Look
for such items as oil or coolant leaks, loose bolts, worn
fan belts, loose connections and trash build-up.
Remove trash build-up and have repairs made as
needed.
Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt of a 2 or 3 belt set is
replaced, it will carry more of a load than the belts not
replaced since the older belts are stretched. The
additional load on the new belt could cause it to break.

Keep a close watch for leaks. If leaking is observed,

find the source and correct the leak. If leaking is
suspected or observed, check the fluid levels more
frequently than the recommended service intervals
prescribed in this publication until a leak is found and
fixed. Or, until the suspicion for a leak has been proven
to be unwarranted.

• Wipe all fittings, caps and plugs before servicing to

keep dirt and debris from entering engine
components.

• Inspect the water pump for leaks.

• Check the engine, cooling system, aftercooler and

generator (if equipped) for dirt and debris. Inspect the
radiator (if equipped) for leaks and trash build-up.

• Inspect the cooling system hoses for cracks and • Inspect the engine for oil leaks, such as front and rear
loose clamps. crankshaft seals, oil pan, oil filters and valve covers.
 53
Maintenance Section
Daily

• Inspect air intake system hoses and elbows for

cracks and loose clamps.

• Inspect the fuel system for leaks, loose fuel line

clamps and fittings and loose or worn hoses.

• All guards must be in place. Repair or replace missing

or damaged guards.

• Disconnect any battery chargers that are not

protected against the starter current drain. Check
condition of batteries and the level of electrolyte.

• Drain water and sediment from fuel storage and day • Inspect engine-to-frame ground strap for good
tanks on a daily basis to ensure clean fuel only enters connection and condition.
the fuel system.

• Inspect wiring for loose connections and worn or

frayed wires.
54
Maintenance Section I
Daily

Engine Crankcase
Check Oil Level

NOTICE
Make sure you read and understand the information in
the "Lubricant Specifications" section of this manual
before you proceed with maintenance of the oil
I
system.
I
3. Remove the oil filler cap and add oil if necessary.
See "Refill Capacities" for the size of your engine
crankcase.

NOTE: Remote mounted or auxiliary filters require

additional oil. For all information pertaining to auxiliary
I
filters, refer to the OEM filter manufacturer's
instructions. 1
1. Check the oil level with the engine stopped. is
I
I
I
I
2. Maintain the oil level between the ADD and FULL
RANGE marks on the "ENGINE STOPPED" side of the
dipstick. Do not fill the crankcase above the FULL
I
RANGE mark.

NOTE: Operating your engine when the oil level is

above the FULL RANGE mark could cause your
I
crankshaft to dip into the oil. If this happens, the air
bubbles created from the crankshaft dipping into the oil
will reduce the lubricating characteristics of your oil
and would result in the loss of power.

;
I
 55
Maintenance Section
Daily

Cooling System
Check Coolant Level

NOTICE
Make sure you read and understand the information in
the "Cooling System Specifications" section of this
manual before you proceed with maintenance of the
cooling system.

4. Inspect the filler cap. Replace the cap if gaskets

are damaged. Install the filler cap.

1. Check the coolant level with the engine stopped

and cool.

2. Remove the filler cap slowly to relieve any

pressure.

5. Inspect and clean the radiator fins of dirt and

debris.

44.14.40444—.

,. ...,:, ,N;:ii:;:,i:iii:iii ?.::::,:::::::::::::::::::•;:.;.:.: ..:,.......x.:.:;.x.,.:i

,:•:,.•:•:•!•2..X.:•:•:.
.,......,.........,,,,
......MIS
A :::: ::::::::::•:•:•:•:,:•:•:•:•:•:•:. ......,.......................-.• ••••••••••••••••••••••••••••••••••••
": :::::::::::::::::. Is.. O.

3. Maintain the coolant level within 13 mm (1/2 inch)

below the bottom of the fill pipe or to the proper level
on the sight glass, if equipped.
56
Maintenance Section
Daily

Clutch Shift Collar and PTO Main Air Starter (if equipped)
Shaft
Check Lubricator Level
Lubricate with MPGL Grease
NOTICE
Never allow the lubricator jar to become empty. The
111113111111111 r
rood NO
starting motor will be damaged by lack of proper
FigmughmAx SPEED I °Pr 14.1.11 lubrication.
10.11.11Ee mg aloe RN Rai Vial nut saw a mom
arm um aims MRS CM CAN! SAW
061010.180. BOY sio. OAR OE ONDI •01011 O1I0ER460 PARTS Never reuse diesel fuel or engine oil from the collector
riaraci=CLU101 M OMOMIL OE WHO UEM mILTIT HT& t HACH
TI CLUTO4 OEri THO PULL. HILFOI, OF. memo.. 1r
S
jar to refill the motor oiler, use clean lubricant.
IfifiniCroova T101 run. meow* wawa ow a rum mu...moo
0 report r—i— o
wME
1 TO 1.11,7 I COMM 0
MOT TO PM TO 1010,010 a.uno. paor CLUTCH MOD ROM MEOW &MOT
WWI FOR MA.
,AMMOMON. NOT" AMICK ITH Kau wow aul. won OF MOO oe04 Tvoir
OHM
FM TT HMO OF ormarnors 10 001R T1gp HTTH011
amrir ea moo. or ororrwom Two omegas
111A4URCTURED FOR
CAIERPILUVI
BY
TIMM DISC
■ NOCHPONOTOD
MACE MYEA TIOCIPOL up. limo ORM

Instruction Plate

Refer to Instruction Plate on your clutch for correct

lubrication information.

The vanes of the starting motor are lubricated with a

fine mist of diesel fuel or engine oil from the motor
lubricator while operating.

• When the lubricator jar becomes half empty, remove

the filler plug and fill the jar with clean lubricant.

Lubricate fittings with one grease gun shot each with

MPGL or 2S3230 grease. Do not over grease.

The collector jar must be emptied when it becomes half

full. The jar collects both the lubricant, after it has
lubricated the starting motor vanes, and moisture
condensation from the compressed air.

;

Oiler Feed Adjustment
If necessary, adjust the lubricator to release
approximately four drops of fluid per minute into the
starting motor air stream.
• Be sure there is NO fuel supply to the engine.
• Push on the air start control lever to crank the engine.
• Count the drops of fluid per minute that is released
into the air stream. Turn the needle valve knob (1) on
top of lubricator counterclockwise to increase flow
and clockwise to decrease flow of fluid into the air
stream.
57
Maintenance Section
Daily
Air Tank (If Equipped)
Drain Water
Open the drain valve on the bottom of the air tank to
drain condensation and oil carryover and close when
oil is free from water condensation.
Check the air supply pressure. The air starting motor
requires a minimum of 620 kPa (90 psi) air pressure to
operate properly. The maximum air pressure must not
exceed 1723 kPa (250 psi). The normal air pressure will
be 758 kPa (110 psi) to 965 kPa (140 psi).
58
Maintenance Section
Daily

Engine Air Cleaner Single Stage Air Cleaner Elements

Check Air Cleaner Service Indicator If your air cleaner element becomes plugged, the air
can split the element filter material. This allows
unfiltered air into the engine which would drastically
accelerate internal engine wear.

Your Caterpillar dealer has air filter elements to

maintain the air induction system. Contact your
Caterpillar dealer for the correct filter element to fit your
engine and application.

Typical air cleaner indicator shown.

Your engine may be equipped with a different indicator.

A service indicator (if equipped) may be mounted on

the air cleaner or in a remote location. A colored piston
showing in the window indicates the need for servicing
the air cleaner.

Observe the air cleaner service indicator. Clean or

• Remove the air cleaner cover and element, and cover
replace the air cleaner when the yellow diaphragm
the turbocharger compressor inlet.
enters the red zone or the red piston locks in the visible
position. • Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
As the air cleaner element becomes plugged, the
difference of air pressure between the inlet side (dirty
• Inspect the replacement element for damage, dirt or
side) and the engine side (clean side) will increase.
debris.
If the air cleaner indicator shows red at any time, clean
• Remove the covering from the turbocharger
the filter element or install a new air cleaner element.
compressor inlet and install a clean, undamaged
element.

NOTICE • Install the air cleaner housing cover and reset the
Never service the air cleaner with the engine running service indicator.
since this will allow dirt to enter the engine.
If equipped with a Two Stage Air Cleaner Element,
clean the dust collector/precleaner (if equipped) to
remove any dirt and debris as needed.
The primary element (Caterpillar air filters) can be
cleaned several times before replacement. The
element, when cleaned, should be thoroughly checked
for rips or tears in the filter material. Replace the
primary element at least every year regardless of
operating hours it has accumulated.
 59
Maintenance Section
Daily

Two Stage Air Cleaner Elements Air Cleaner Element-Standby Gen Set
Remove and Install Air Cleaner Elements NOTICE
Never service the air cleaners with the engine running,
since this will allow dirt to enter the engine.

1. Loosen the retaining bolt on the lower body and

remove the end cover on the air cleaner housing.
Remove and empty the dust collector cup.
The standard air cleaner element is NOT serviceable
(washable). This air cleaner element is intended for use
of up to 50 hours of operation unless environmental
conditions require more frequent replacement. Check
the air cleaner element for dirt and damage. Replace
the element if necessary.

Replace the Standard Air Cleaner Element

2. Loosen the clamping bolt on the upper body

retainer and remove the lower body to clean the tubes
on both ends.

3. Inspect seals between the lower body and the dust

collector cup. Inspect seals between the lower and
upper bodies and install new seals if necessary.

4. Install lower body to upper body and tighten 1. Loosen the clamp fastening the air cleaner to the
retaining clamp. air intake, and remove the dirty element.

5. Install dust cup and tighten retaining clamp. 2. Remove the clamp from the dirty element.

3. Install the clamp on a new element.

4. Install the new element and tighten the clamp.

60
Maintenance Section
Daily
I

Optional Heavy Duty Air Cleaners Only

Service the air cleaner using the air cleaner indicator as
the basis for determining the condition of the elements.
l
i
I
If the air cleaner element becomes plugged, the air can
split the element filter material. This allows unfiltered air
into the engine which would drastically accelerate
engine wear. I
If the air cleaner element becomes plugged, but does
not split, engine performance will deteriorate and
output power will be reduced. I
Keep spare filter elements on hand for replacement.

For the procedure to clean or replace the optional
heavy duty air cleaner elements, refer to the topic
Cleaning Air Cleaner Elements.
Cleaning Air Cleaner Elements
1. Direct air or water along the pleats inside and I
outside of filter element.
The element can be washed in warm water and
nonsudsing household detergent. Rinse inside and
I
outside the pleats and air dry fully.

NOTICE
Do not clean the filter elements by bumping or tapping
2. Inspect the filter elements after cleaning. Do not
use a filter element with damaged pleats, gaskets or
I
them. Engine damage could result. seals.

Do not use filter elements with damaged pleats, gas-

kets or seals.
3. Wrap and store the clean filter elements in a clean,
dry place.
I
NOTE: Most air cleaner filter elements can be cleaned
For more information on air cleaner element cleaning,
refer to "Guideline for Reusable Parts-Cleaning and
Inspection of Air Filters," form SEBF8062.
I
with air, water or detergent. Have spare elements on
hand to use while cleaning used elements.

Filter elements can be cleaned with pressure air - 205

I
kPa (30 psi) maximum, pressure water - 280 kPa (40
psi) maximum, or detergent washing.
I
I
I
I

;
I
 61
Maintenance Section
Every 125 Hours

111 Every 125 Hours

You must read and understand the warnings

and instructions contained in the Safety section
of this manual, before performing any operation
or maintenance procedures.

Before proceeding with Every 125 Hour maintenance,

perform Daily maintenance requirements.

Pilot Bearings (If Equipped)

and Shift Lever
Lubricate the fittings with MPGL.
Clutch Pilot Bearings (1) and Shift Lever (2) fittings.

811.11101.
r Lubricate fitting on rear of PTO shaft with MPGL or
rillaniAL7 POMP WOE Off mixtNo 2S3230 grease.
iihx. vim IUUM

mom ir f - 111r Men IS fun was

mar on weft Nos cm um awni
nut am
SNOW NO I Sao NO. S*T n OMIDI VANN oftersas Purrs
a momps
Lubricate two fittings; one fitting on each side of the
wMEM Cur.C14 4 014EN114010 i1E mile. LEW" i441 Mt, memeat
IF ow,. 0041 NOT 441. FOAM OM OPEAAnd 9
Amin 010T ADAMITIMPF,a 44.4114144F
clutch housing with MPGL.
ZMPAI TM. MIL044f4.011 tf.aullO M. fl.ow F4As6ne14 0
IBMVE wuf
TO LLTT OPBMONG
TO NOR I -
2t FO INMAN :aura. wra cum. IN IN
IF4r, F04- arwm.t wousr
rpm mio 4444.
..impicAnok APR, 44410( Ms 10.4 OMAN OM 11141F) OF MEW A.
fb .4.444 OF OPIIMMOOFF TO 4414
• INeIr. M mOuPill OF opownopt To now rem PiT17414
MAAUFOCTUPIED RDA
CaT_SPILLAR
WY
TWPOI IltSC
MEXIMPOMATED
14.01 44 USA IWC•11- FM. IOW own

Refer to the Instruction Plate on the clutch for

lubrication information. Some earlier clutches have pilot
bearing fittings that need lubrication, whereas the later
clutches have pilot bearings that are sealed-for-life.
62
Maintenance Section
I
Every 250 Hours

Every 250 Hours

You must read and understand the warnings

and instructions contained in the Safety section
of this manual, before performing any operation
If either of these methods are not possible, then use a
drain stream method when changing the oil.
I
I
I
or maintenance procedures. NOTE: When using the drain stream to obtain the oil
sample, do not sample from the beginning or end of
Before proceeding with this maintenance, perform
previous maintenance interval requirements.
drain stream. The oil at the beginning or end of the
drain stream is not mixed well enough to be
representative of the oil in the crankcase.
I
Scheduled Oil Sampling
(S.O.S) Analysis S•O•S INTERVAL CHART
I
Compartment Interval
To compliment a good preventive maintenance
program, Caterpillar recommends using S•O•S at
regular scheduled intervals to monitor the condition of
Engine Oil

Engine Oil
Every 250 Hours
(shallow pan)
Every 500 Hours
I
the engine oil and maintenance requirements of your (deep pan)
engine.

Consult your Caterpillar dealer for complete information

I
Obtain Sample
Each oil sample should be taken when the oil is warm
or assistance in establishing an S•O•S program for
your engine. I
and well mixed to ensure that the sample is
representative of the oil in the crankcase. There are
two methods recommended to obtain S•O•S samples
from the 3406B engines.
Oil Drain Intervals
It is essential that an S•O•S analysis be performed to
analyze oil condition before oil change period
■
adjustment is considered.

If the engine crankcase oil has reached its condemning

I
limits as established by the oil analysis program, refer
to the topic, Engine Oil and Filter(s), in this publication
for the procedure to change the crankcase oil and oil
filters.
I
Due to manufacturing tolerances, engine application
and maintenance variation, all engines do not consume
fuel and oil at the same rate. Some history of fuel and
I
oil consumed for each engine (or group of engines) in
a similar application must be established. I
For a group of engines, determine the average fuel
• Use the sampling valve installed on the engine for
samples.
• Use a sampling gun inserted into the sump.
consumption and add oil rate. This is performed by
multiplying the total quantity of fuel consumed by the
operating (service) hours of the engines.
I
The sample valve should be flushed with oil from the
engine to rinse the dirt and debris from the valve.
For more information on adjusting oil change intervals
for specific applications, see your Caterpillar dealer. I
Refer to "How to Take a Good Oil Sample," Form
PEHP6001 for a step-by-step explanation if using this
method of sampling crankcase oil.

Caterpillar recommends using one of the methods.

;
I

Engine Oil and Filter(s)
Change Oil
NOTICE
Refer to the "Lubricant Specifications" section of this
manual for the recommended oil to use for this engine.
NOTE: Drain the crankcase with the engine stopped
and the oil warm to allow for the draining of waste
particles that are suspended in the oil.
Failure to follow this recommended procedure would
result in these waste particles being recirculated
through your engine lubrication system with the new
oil. As the oil cools, suspended waste particles will
settle on the bottom of the crankcase or oil pan and
will not be removed with the draining oil.
1. Remove the crankcase drain lines plug (or oil pan
drain plug) and allow the oil to drain. If equipped with
drain lines, turn knob on valve counterclockwise (CCW)
to drain oil.
I 2. Install the crankcase drain lines plug. If equipped
with oil pan drain plug, tighten it to 70 ± 14 N•m (50 ±
10 lb ft).
63
Maintenance Section
Every 250 Hours
Change Filter(s)
3. Use a 2P8250 Filter Wrench to remove the oil filter
and optional bypass oil filter, if equipped.
Element with debris.
Use a 6V7905 Service Tool to cut the oil filter element
open. Spread pleats apart and inspect the element for
metal debris. An excessive amount of debris in the oil
filter element may be indicative of a pending failure.
Use a magnet to differentiate between the ferrous and
non-ferrous metals found in your oil filter element.
Ferrous metals may indicate wear on the steel and cast
iron parts of your engine.
Non-ferrous metals may indicate wear on the aluminum
parts of your engine, such as main and rod bearings,
turbocharger bearings and cylinder head wear.
Due to normal wear, friction, etc., it is not uncommon
to find small amounts of debris in your oil filter element.
Consult your Caterpillar dealer to arrange for further
analysis if an excessive amount of debris is found in
your oil filter element.
64
Maintenance Section
Every 250 Hours

7. Replace the bypass filter (if equipped).

NOTE: The Caterpillar bypass filter will require an

additional 2.5 L (2.6 U.S. qts) of oil.

4. Wipe the sealing surface of the filter element

mounting base. Make sure all of the old gasket is
removed.

NOTE: Make sure to use the correct Caterpillar oil

filter element(s) for your engine arrangement.
Your Caterpillar oil filter element was built to Caterpillar
specifications to ensure you receive a quality part at a
competitive price. Caterpillar oil filter elements are
inspected as part of an inspection program that was
developed to ensure compliance with established
quality standards.
8. Remove the oil filler cap to fill the crankcase. See
"Lubricant Viscosities and Refill Capacities" for the
proper oil and quantity to use.
NOTE: If equipped with an auxiliary oil filter, extra oil
must be added when filling the crankcase. Follow the
OEM filter manufacturer's recommendations.

Use of an oil filter element not recommended by
Caterpillar could result in severe engine damage to
your engine bearings, crankshaft, etc., as a result of
the larger debris particles or unfiltered oil entering your
engine.
If the extra oil is not added, the engine may starve for
oil.
NOTICE
In some applications FULL RANGE dipsticks are used.
It may be necessary to calibrate FULL RANGE dip-
sticks by referring to the Before Starting the Engine
and Dipsticks sections of this manual for proper oil
level information for this engine.
Either underfilling or overfilling of engine crankcase oil
can cause engine damage.

5. Apply a small amount of clean engine oil to the

new filter element gasket.

6. Install the new filter element until the gasket

contacts the base. Tighten the filter 3/4 of a turn more
by hand. Do not overtighten.
 65
Maintenance Section
Every 250 Hours

Crankcase Breather
Clean

9. Before starting the engine, ensure your oil level is

within the correct operating range on the "ENGINE
STOPPED" side of the dipstick.

1. Loosen breather retaining clamp (1) on breather.

NOTICE
To prevent crankshaft or bearing damage, crank en- 2. Loosen hose clamp (2) and remove breather
gine with fuel OFF to fill all filters BEFORE starting. Do assembly.
Not crank engine for more than 30 seconds.
3. Wash breather in clean, nonflammable solvent and
allow to dry.

10. Start and run the engine at LOW IDLE for two 4. Install new breather assembly seal.
minutes. Inspect for oil leaks. Stop the engine.
5. Assemble breather and install in reverse order of
removal.

6. Tighten all hose clamps (2) to 3.0 ± 0.5 N•rn (27 ±

4.5 lb in).

Refer to the "Torque Specifications" section of this

manual for Worm Drive Band Type hose clamps for
more information.

11. Wait 10 minutes to allow the oil to drain back into

the crankcase. Check the oil level again. Maintain the
oil level to the FULL or (FULL RANGE) mark on the
"ENGINE STOPPED" side of the dipstick.
66
Maintenance Section
Every 250 Hours

Valve Lash Cooling System

Check/Adjust
Initial valve lash adjustment on new, rebuilt or
remanufactured engines is recommended at the first
scheduled oil change interval due to initial wear and
seating of valve train components. Subsequent
adjustments should be made at Every 3000 Hour
interval.
NOTICE
Make sure you read and understand the information in
the Cooling System Specifications section of this man-
ual before you proceed with maintenance of the cool-
ing system.
Refer to the Cooling System Specifications section of
this manual for all cooling system requirements before
performing this maintenance procedure.

0 0 0 0
Test for Concentration
• O •O •O •O •O •O
6 5 4 3 2 1 ■
• O •O •O •O •O 110

0 •
INTAKE EXHAUST
0.38mm ( .015") 0.76mm ( .030" )

3406B Valve Locations

See topics in the Every 3000 Hour maintenance interval

for additional information and adjustment procedures.

Refer to the Service Manual or your Caterpillar dealer

for the complete valve adjustment procedure. Use the 8T5296 Coolant Conditioner Test Kit to check
for concentration.

Clean/Flush the cooling system before the

recommended 3000 Hour or Two Year maintenance
interval if:

• Coolant is heavily contaminated.

• The engine overheats frequently.
• Foaming is observed in the radiator or expansion
tank.
• The oil cooler has failed allowing oil in the cooling
system and contaminated the coolant.
• Fuel has entered the cooling system and
contaminated the coolant.

Add Supplemental Coolant Additive
1. Loosen the radiator filler cap slowly to relieve
pressure and remove the cap.
2. It may be necessary to drain enough coolant from
the radiator to allow for the addition of the
supplemental coolant additive.
3. Add 0.25 L (1/2 U.S. pint) of coolant additive for
every 38 L (10 U.S. gal) of cooling system capacity.
Refer to the Refill Capacities chart in this publication
for the cooling system capacity for your engine.
4. Inspect the radiator filler cap gaskets. Replace the
cap if the gaskets are damaged.
5. Install the filler cap.
67
Maintenance Section
Every 250 Hours
Replace Coolant Additive Element (If Equipped)
NOTICE
DO NOT mix coolant additive and additive elements or
use together. Use one method or the other exclusively.
1. Close coolant additive element inlet valve (1) and
outlet valve (2). Remove and discard coolant additive
element (3).
2. Clean the element mounting base. Make sure all of
the old gasket is removed.
3. Replace with a new Caterpillar maintenance
element.
4. Coat the gasket of a new supplemental coolant
maintenance element with a thin film of engine oil.
68
Maintenance Section
Every 250 Hours

5. Install and tighten the element until the seal Fuel Filters
contacts the base, then tighten 3/4 turn more by hand.
Do not overtighten. Clean/Replace Filters
6. Open the inlet valve (1) and the outlet valve (2). • Stop the engine.

• Shut off the fuel tank supply valve.

• Turn the start switch OFF or disconnect the battery

when changing fuel filters.

Clean Primary Filter (If Equipped)

7. Remove the radiator filler cap.

8. Start the engine and check for leaks. Allow the

coolant level to stabilize.

1. Loosen bolt (1) on the filter housing and remove

filter case (3).

2. Remove element (2) and wash it in clean,

nonflammable solvent.

• 3. Install element (2) and case (3). Tighten bolt (1) to

•• ••• ....V.V.:V., •
a torque of 24 ± 4 N•rn (18 ± 3 lb ft).

Replace Final Fuel Filter

9. Add premixed coolant water, if necessary, to bring

the coolant to within 1/2 inch (13 mm) below the
bottom of the fill pipe or to the proper level on the sight
glass, if equipped.

1. Remove and discard the fuel filter element.

 69
Maintenance Section
Every 250 Hours

2. Push the plunger in and tighten by hand.

3. Start the engine. If the engine will not start, or once

started continues to misfire or smoke, further priming is
necessary.

4. If the engine starts, but runs rough, continue

running the engine at low idle until the engine runs
smoothly.

2. Clean the gasket sealing surface of the filter base.

Make sure all of the old gasket is removed.

3. Apply clean diesel fuel to the new fuel filter gasket.

NOTICE
Do not fill the fuel filters with fuel before installing
them. This fuel would not be filtered and could be
contaminated. Contaminated fuel will cause accelerat-
ed wear to the fuel system parts. 5. If the engine will not start, loosen the fuel line nuts
at the cylinder head.

4. Install the new filter until the filter gasket contacts 6. Crank the engine until the fuel flows free of air
the base. Tighten the filter 3/4 turn more by hand. Do bubbles. If the engine starts, then run the engine until
not over tighten. fuel flows free of air bubbles.

After changing the fuel filters, prime (purge) the fuel 7. Tighten the fuel line nuts to 40 ± 7 N•m
system to remove air bubbles from the system. (30 ± 5 lb ft).

NOTE: DO NOT remove the plug in the fuel filter base

Priming the System (for the fuel pressure sending unit if equipped) to
release air from the fuel system while priming. Periodic
removal of the plug will result in increased wear of the
threads in the fuel filter base and lead to fuel leakage.

1
1. Unlock and operate the priming pump plunger until
a resistance is felt.
70
Maintenance Section
Every 250 Hours

Fuel Tank Belts and Hoses

Drain Water & Sediment Inspect/Replace Alternator, Fan and
Accessory Drive Belts

Inspect all drive belts for wear and replace if they show
any signs of wear.

If one belt in a set requires replacement, always install

a new matched set of belts. Never replace just the
worn belt. If only the worn belt is replaced, the new
belt will carry all the load, as it will not be stretched as
much as the older belts. All the belts will fail in rapid
succession.

If belts are too loose, they vibrate enough to cause

unnecessary wear on the belts and pulleys.

If belts are too tight, unnecessary stresses are placed

This maintenance item should be performed daily (or
upon the pulley bearings and belts which might
as necessary) to remove water and sediment. Water in
shorten the life of both.
the fuel system could freeze, damage internal parts or
cause the fuel system to malfunction.

Open the drain valve to remove water and sediment

from the fuel tank (day tank). Refer to Fuel
Specifications and Fuel Problem Minimizing in Cold
Weather sections of this manual for additional
information on fuel tanks and fuel lines.

1. Inspect the condition and adjustment of alternator

belts and fan drive belts.

2. To check the belt tension, apply 110 Newton (25

Ibs) of force midway between the pulleys. Correctly
adjusted belts will deflect 13 to 19 mm (1/2 to 3/4
inch).
I 71
Maintenance Section
Every 250 Hours

i
Adjust Alternator Belts Before Replacing Hoses

I
I
I
I
1. To adjust the alternator drive belts, loosen
mounting nut (1) and adjusting bracket nut(s) (2).

2. Adjust the alternator in or out by either tightening

1. Loosen the radiator filler cap slowly to relieve any
pressure and remove the cap.

2. Drain the coolant from the cooling system to a

I
or loosening adjusting nut(s) (2), as required, to obtain
the correct adjustment.

3. Tighten nuts (1) and (2).

level below the hose being replaced.

3. Remove the hose clamps, disconnect the old hose

and replace with a new hose.

I 4. If new belts are installed, check belt adjustment

again after 30 minutes of engine operation. Replace
belts in matched sets only.
4. Install hose clamps. See the Torque Specifications
section for the appropriate torque.

I Adjust Fan Drive Belts

After Replacing Hoses
1. Add coolant/water mixture to the cooling system.

I 1. To adjust the fan drive belts, loosen mounting

bolts and adjust with adjusting bolt.

2. Move the fan drive up or down as required to

Bring it to the proper level by mixing a solution of
acceptable water and Caterpillar Antifreeze. Add
supplemental coolant additive if NOT using Caterpillar
Antifreeze or, if equipped with a coolant additive

1 obtain the correct adjustment. Tighten mounting bolts.

3. If new belts are installed, check belt adjustment

element, install the appropriate element.

2. Install the filler cap.

again after 30 minutes of engine operation.

I Inspect/Replace Hoses and Clamps

3. Start the engine and inspect for leaks.

4. Check water temperature gauge for proper

I
operating temperature.
Hose replacement prior to failure is cost effective and a
good preventive maintenance practice. Replacing a
hose before it fails saves you money and reduces the

I chances for unscheduled downtime. By replacing a

hose that is cracked, soft or leaking, you will avoid
major repairs that could result in a severe engine
overheating problem.

I Inspect all hoses for leaks due to cracking, softness

and loose clamps. Replace hoses that are cracked or
soft and tighten loose clamps.

I
I
72
Maintenance Section
Every 250 Hours

Clutch (if equipped) Fan Drive Bearing (if equipped)

The clutch should engage with a firm push of the lever Lubricate the Fitting
and a distinct snap. If the engagement is soft or slow,
adjust the clutch.

Check/Adjust
1. Stop the engine and remove the inspection cover
from the housing.
2. Turn the clutch manually until the lock pin
(engaged in the locking ring) is visible.
3. Pull the lock pin OUT and rotate the locking ring
clockwise (CW) until the lock pin slips into the next
notch.
NOTE: To test the clutch adjustment, engage clutch
with a torque wrench to 296 to 393 N•m (218 to 289 lb
ft). If torque is still low, rotate the locking ring (CW) until
lock pin slips into next notch. If the adjustment is too
tight, turn the locking ring back (CCW) one to the
previous notch.
1111 1
1I
I
Lubricate one fitting with SPG grease.
I
Use Special Purpose-type Grease (SPG) suitable for
taper roller bearings which operate at high speeds and
temperatures for lubricating engine fan drive bearing.
This grease conforms to MIL-M-7866, and contains a
suitable corrosion inhibitor. NLGI No. 2 Grade is
suitable for most temperatures.
Use NLGI No. 1 or No. 0 Grade for extremely low
temperatures. Caterpillar part number 2S3230
(standard cartridge) meets these specifications. It is
acceptable for temperatures from —35°C (-30°F) to
160°C (325°F).

4. Install the inspection cover.

 73
Maintenance Section
Every 250 Hours

Batteries Check Battery Charger (if equipped)

Clean/Check Electrolyte Level (if equipped)

BATTERY ELECTROLYTE CHART

Battery Interval
Conventional 100 Hour
Low Maintenance 250 Hours
Maintenance Free None Required

1. Remove fill caps. Maintain electrolyte to bottom on

fill plug openings.

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

Check the battery charger for proper operation. If
distilled water is not available use clean water that is
batteries are properly charged, ammeter reading should
low in minerals. Do not use artificially softened water.
be very near zero.
At proper charging rate, batteries should not require
All batteries should be kept charged to a corrected
more than 30 cc (1 ounce) water per cell per week.
specific gravity of 1.250 or above. The batteries should
be kept warm, if possible.
2. Keep batteries clean.
The battery temperature affects the cranking power. If
the battery is too cold, it will not crank the engine, even
if the engine is warm.

When the engine is not run for long periods of time or

is run for short periods, the batteries may not fully
recharge. Ensure a full charge to help prevent the
battery from freezing.

Battery, Battery Cable or Disconnect Switch

Replacement
NOTE: When replacing batteries, battery cables, or the
disconnect switch, use the following procedure:

1. Turn off the start switch and all electrical loads.

3. Loosen and remove cable clamps from all battery
terminals.
4. Clean all battery terminals.
5. Clean all cable clamps.
6. Install and tighten cable clamps to battery
terminals.
7. Coat cable clamps and terminals with 5N5561
Silicone Lubricant, petroleum jelly or MPGM grease.
2. Turn off (open) the disconnect switch and remove
the key.
3. Disconnect the cable that goes to the frame at the
disconnect switch (one cable connects to frame and
one to battery negative). Be sure the disconnect cable
cannot contact the switch stud where it was just
removed.
4. Disconnect the negative battery cable terminal at
the battery(s) that goes to the disconnect switch.
Where four 12 volt batteries are involved, the negative
side of two batteries must be disconnected.

5. Proceed with necessary system repairs.

6. Reverse steps two through five.

74
Maintenance Section
Every 1000 Hours

Every 1000 Hours

You must read and understand the warnings

NOTICE
and instructions contained in the Safety section If oil pressure fails to raise within 15 seconds after the
of this manual, before performing any operation engine starts, stop the engine and make necessary
or maintenance procedures. repairs.

Before proceeding with Every 1000 Hour maintenance.

perform all previous maintenance interval requirements.

Engine Protection Devices

Inspect for Proper Operation

Check Gauges

• Oil Pressure - Check for proper operating oil pressure.

The pressure will be greatest after starting a cold
engine. Oil pressure will decrease as the engine
warms while idling. As the engine speed is increased
to full load speed, oil pressure will increase and
stabilize. Minimum oil pressure is 240 kPa (35 psi) at
rated speed.

Check the condition of all gauges. Repair or replace Inspect Generator and Control Panel
any broken gauge before it becomes a problem. (if equipped)
While operating, frequently observe all gauges,
especially the engine oil pressure gauge and the fuel
pressure gauge.

Caterpillar Control Panel

Visually inspect the generator and control panel. Check

• Fuel Pressure - Check for proper operating fuel
pressure. Minimum fuel pressure is 140 kPa (20 psi)
at rated speed.
for loose, broken, or damaged wiring or components.
The inspection only takes a few minutes and could
avert a potential problem that could cause your
generator set to fail.
 75
Maintenance Section
Every 1000 Hours

Operational Checks Automatic Switches (if equipped)

Start the engine. Use the starting procedure found in
the SR 4 Generators and Control Panels Operation and
Maintenance Manual, form SEBU6150.

The following operational checks are intended to check

the generator operation and the engine starting,
lubricating and fuel systems as well as overall
operation. The checks should take no longer than five
minutes to complete. Longer periods of operation are
not required. A more thorough Performance Analysis
should be performed every 3000 hours with the engine

1 operating under load.

Check and Record Readings from Check that all switches are in proper position for
Frequency (rpm) and Generated Voltage automatic start.

The shutoff controls must be checked so that they

function properly when they are required. To prevent
damage to the engine while performing the test, only
authorized personnel or your Caterpillar dealer should
perform the checks.

Refer to the Engine Protection Devices section of this

publication for additional information.

Refer to the SR 4 Generators and Control Panels

Operation and Maintenance Manual, form SEBU6150
for additional information.

Check and record the frequency and voltage readings.

NOTE: The operating voltage of a cold (just started)

generator will be slightly higher than the operating
voltage of a generator that has been under load and
warm. The full load voltage of an SR 4 Generator will
decrease a maximum of 1% when this generator
stabilizes at 100°C (212°F).

Most of the voltage decrease occurs in about 30

minutes. Generally, they stabilize within two hours.
76
Maintenance Section
Every 1000 Hours

Woodward Governor and

Tachometer Drive
Lubricate fittings
Check/Lubricate Linkages
Check and adjust if necessary, all linkages.

Tachometer Drive

Lubricate one fitting with MPGL.

Woodward PSG Governor with Remote Motor Control

Lubricate two fittings on the governor linkage with

MPGL.
 I 77
Maintenance Section
Every 3000 Hours

Every 3000 Hours

You must read and understand the warnings Remove Thermostat

I and instructions contained in the Safety section

of this manual, before performing any operation
or maintenance procedures.
1. Stop the engine and allow to cool.

2. Loosen the coolant filler cap slowly to relieve any

pressure and remove the cap.
I Before proceeding with Every 3000 Hour
maintenance, perform previous maintenance
maintenance requirements.
3. Drain the coolant from the cooling system to a
level below the thermostat housing.

I Thermostat
I Replace Thermostat, Gaskets and Seal
Replacing your thermostat prior to failure is a
recommended preventive maintenance practice

I because it reduces your chances for unscheduled

downtime.

I NOTICE
Failure to replace your thermostat on a regularly
scheduled basis could cause severe engine damage.

I Since Caterpillar engines incorporate a shunt design

4. Remove six bolts (1) that fasten the thermostat
housing to the cylinder head.

I cooling system, it is mandatory to always operate the

engine with a thermostat.
5. Remove thermostat housing (2) and gaskets.

If your thermostat fails in the closed position, it will

I cause excessive overheating. Excessive overheating

could result in cylinder head cracking or piston seizure
problems.

I If your thermostat fails in the open position, it will cause

the engine operating temperature to be too low during
partial load operation. Low engine operating
temperatures during partial loads could cause an
I excessive carbon build-up inside the cylinder. This
excessive carbon build-up could result in accelerated
ring and liner wear.

I Depending on load, a thermostat that fails in a partially

opened position will cause either an overheating or an 6. Remove thermostat (3) from the housing.
overcooling condition.

I Caterpillar recommends the replacement of your

thermostat on a regularly scheduled basis to be the
most cost effective way to operate your engine.
I NOTE: All tools shown or mentioned in the
disassembly and assembly of thermostats are available
through any Caterpillar dealer.
i
I
78
Maintenance Section
Every 3000 Hours

NOTE: The thermostats can be reused if they are

tested and meet the test specifications below and are NOTICE
If the thermostat is installed wrong, it will cause the
not damaged or have excessive buildup of deposits.
engine to overheat.
Thermostats should begin to open and be fully open as
indicated in the following chart:

Rated Thermostat Beginning Opening1 Fully Open

°C °F °C °F °C °F
82 180 81 to 84 178 to 183 92 198
88 190 87 to 89 189 to 192 98 208
1 Bench test in atmospheric pressure.

10. Install thermostat (3) in the housing (2) as shown.

7. Remove lip-type seal from the housing. Use tooling

[Slide Hammer Puller (1P0074), Bearing Cup Puller
Attachment (8B7554) and Leg (7S7786)] to remove
seal from the housing.

8. Replace thermostat, gaskets and seal.

11. Put the new gaskets in position between the

Install Thermostat cylinder head and the thermostat housing. Install
thermostat housing (2).

NOTE: Before proceeding with following steps (12 &

13), perform Hose replacement and Cooling System
clean/flush procedures, unless replacing thermostats
ONLY before this 3000 Hour interval.

12. Add coolant to. the cooling system to bring it to

the proper level by mixing a solution of acceptable
water, Caterpillar Antifreeze (or equivalent) and
supplemental coolant additive, or if equipped, install a
coolant additive element.

Refer to the Cooling System Specifications section of

9. Install lip-type seal in housing with tooling (A)
[Driver Group (1P0510)]. Install the seal with the lip of
the seal away from the thermostat.
this publication for information about the appropriate
maintenance of the cooling system or contact your
Caterpillar dealer for assistance. ;
13. Start the engine and inspect for leaks and proper
operating temperature.
 79
Maintenance Section
Every 3000 Hours

Cooling System
1 Clean/Flush Coolant

NOTICE
Do not change the coolant until you read and under-
stand the material in the "Cooling System Specifica-
tions" section.
This procedure is to be used for normal maintenance
of cooling system surfaces to return to "like new"
condition.
For heavy build-up of scale and deposits, a severe acid
type commercial cleaner or mechanical cleaning will be Right Side View
required.
3. Remove the block drain plugs from both sides of
the engine. Allow coolant to drain.

With the recent shortage and higher cost of new

antifreeze and the disposal problems of used engine
coolant, the interest in recycling the used engine
coolant has sharply increased. Various methods have
been proposed to reclaim used coolant for reuse in
engine cooling systems.
...WO .1.111•1116
411111.111111110 .1.1111111.
411111111.11M .111111111111111.
Filtering methods for reclaiming the used engine
.111.04.
4.1Mwthot
.11411111.111. coolant do not reduce the level of chemicals in the
NSW.,
.11.10.1611,
OMSK. water.
.1111.06.
WIWPIP#4.
.119•MPOW.
ameormillIk AilliumeMM
vimormIIIM
011••••001 0011.511001s
The full distillation procedure is the only method
MOW..
acceptable by Caterpillar to reclaim the used coolant.
Typical Example The ethylene glycol and water obtained from this
process can be treated with new chemical corrosion
1. Remove the radiator filler cap slowly to relieve inhibitors to provide a like-new coolant.
pressure.
Commercial units are available to do this distillation
process. Contact Caterpillar Service Technology Group:

Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

Refer to Service Magazine article dated November 13,

1989 and/or Engine News article dated November
1989 for information regarding disposal and recycling
of used coolant.

4. Clean and install all drain plugs or close the drain

valve.

2. Remove the drain plug or open the drain valve on

bottom of cooling water system radiator or expansion
tank.
80
Maintenance Section
Every 3000 Hours
.
5. Refill the cooling system with clean water mixed
with a 6 to 10 percent concentration of Caterpillar
Cooling System Cleaner. Install radiator filler cap.
10. Fill the cooling system with the coolant solution at
20 L (5 U.S. gal) per minute or less to avoid air locks.
I.I
See Refill Capacities chart in this publication for the
NOTE: A 33-47 L (9-12 gal) cooling system capacity capacity of your engine's system.
requires 3.8 L (1 gal) of Caterpillar Cooling System
Cleaner to accommodate the 6-10 percent
concentration.
11. Start and run the engine with the filler cap
removed. Allow the coolant to warm, the thermostat to
I
open and the coolant level to stabilize.
Caterpillar Cooling System Cleaner is available through
your Caterpillar dealer.
NOTICE
I
6. Start and run the engine to circulate fluid in the
cooling system for 1 1/2 hours.

7. Stop the engine, remove radiator filler cap and

To prevent engine damage, never add coolant to an
overheated engine. Allow the engine to cool first. I
cooling system drain plugs.

8. Drain the cleaning solution. Flush the cooling

system with clean water until draining water is clear.
12. Add coolant mixture if necessary to bring the
coolant to within 13 mm (1/2 inch) below the bottom of
I
the fill tube or the correct level on the sight glass, if
Clean and install all drain plugs and/or close the drain
valve.
equipped.
I
9. Mix a solution of acceptable water and Caterpillar
Antifreeze (which contains supplemental coolant NOTICE
additive).

When NOT using Caterpillar Antifreeze, add 1 L (1 U.S.

In cold weather, frequently check the specific gravity
of the coolant solution to ensure adequate protection. 1
If the engine is to be stored in, or shipped to an area
qt) of Caterpillar Supplemental Coolant Additive for
every 30 L (8 U.S. gal) of cooling system capacity OR
change coolant additive maintenance element only (if
with freezing temperatures, the cooling system must
be either protected to the lowest expected outside
temperature or drained completely to prevent damage.
I
equipped).

NOTE: Caterpillar Supplemental Coolant Additive or a

coolant additive element (if equipped) should only be
Always check your cooling system before operating
your engine. I
Since Caterpillar engines incorporate a shunt design
used when NOT using Caterpillar Antifreeze.

Refer to the Cooling System Specifications in this

publication for all information pertaining to water,
cooling system, it is mandatory to always operate the
engine with a thermostat. Depending on load, failure to
operate with a thermostat could result in either an
I
overheating or an overcooling condition.
antifreeze and supplemental coolant additive
requirements. I
13. Check the condition of the filler cap gasket. If the
gasket is damaged, discard the old filler cap and install
a new filler cap. I
If the gasket is not damaged, use a 9S8140 Service
Tool to pressure test the filler cap. This tool is available
from your Caterpillar dealer. I
The correct filler cap pressure is stamped on the face
of the filler cap. If the filler cap does not hold the
correct pressure, install a new filler cap.
I
14. Stop the engine and check the coolant to ensure
it is at the proper level. I
I
 81
Maintenance Section
Every 3000 Hours

.1
Valve Lash
Check/Adjust 0 D 0
A WARNING • o •0 •o
6 4 3
•0 •o
2 1
• 0 •50 •0 •0 00 50
To prevent possible injury, do not use the starter
motor to turn the flywheel.
0 •
Hot engine components can cause burns. Allow INTAKE EXHAUST
additional time for the engine to cool before mea- 0.38mm ( .015") 0.76mm (.030")
suring valve clearance.
Operation of Caterpillar engines with improper 3406B Engine
valve adjustments will reduce engine efficiency.
This reduced efficiency could result in excessive

1 fuel usage and/or shortened engine component

life.
Measure the valve lash for the valves shown in the
Compression Stroke and Exhaust Stroke column in the
following charts for the engine being maintained.

CRANKSHAFT POSITIONS FOR INJECTOR TIMING

NOTE: Initial valve lash adjustment on new, or rebuilt AND VALVE CLEARANCE SETTING
engines is recommended at the first scheduled oil
Check/Adjust With No. 1 Piston on:1
change interval due to initial wear and seating of valve
train components. 3406B TC TC
Engine Compression Stroke Exhaust Stroke
SAE Standard (Counterclockwise) Rotation Engines -
as Viewed from Flywheel End
NOTICE 1-2-4 3-5-6
Intake Valves
Measure the valve lash with the engine stopped. To
Exhaust Valves 1-3-5 2-4-6
obtain an accurate measurement, allow at least 20
minutes for the valves to cool to engine cylinder head Firing Order 1-5-3-6-2-4
and block temperature. 1 Put No. 1 piston at top center (TC) position and make identifica-
tion for the correct stroke. After top center position for a partic-
ular stroke is found and adjustments are made for the correct
cylinders, remove the timing bolt and turn the flywheel 360° in
Set the clearance to within ± 0.08 mm (± 0.003 in.) of the direction of normal engine rotation. This will put No. 1 pis-
ton at top center (TC) position on the other stroke. Install the
the valve setting given in the Valve Clearance Setting timing bolt in the flywheel and complete the adjustments for the
chart shown. cylinders that remain.

VALVE CLEARANCE SETTING

Intake 0.38 mm (0.015 inch) Refer to the Service Manual or your Caterpillar dealer
Exhaust 0.76 mm (0.030 inch) for the complete valve adjustment procedure.

NOTE: Rotate the engine crankshaft 360° in the

normal crankshaft rotation direction before any
adjustments are made.
82
Maintenance Section
Every 3000 Hours
Observe Rotation of Valves With Engine Idling
After Setting the Valve Clearances
A WARNING
When inspecting the valve rotators, protective
glasses or face shield and protective clothing must
be worn, to prevent being burned by hot oil spray.
NOTICE
If a damaged rotator is not replaced, valve face gutter-
ing could result in pieces of the valve to fall into the
cylinder. This can cause piston and cylinder head
damage.
After setting all valve clearances and before installing
the valve cover:
1. Start the engine.
2. Move the governor control to LOW IDLE position.
3. Watch the top surface on each valve rotator. Each
valve rotator should turn slightly each time the valve
opens and closes. If a valve fails to rotate, contact your
Caterpillar dealer.
.
NOTE: Caterpillar recommends replacement of
..
improperly operating valve rotators. An improperly
operating valve rotator will shorten valve life through
accelerated valve face and valve seat wear. If a
damaged rotator is not replaced, valve face guttering
could result in pieces of the valve falling into the
cylinder and causing piston and cylinder head damage.
4. Stop the engine and inspect the valve cover
..
gasket to ensure it is not damaged. Use a new gasket
if the gasket is not in good, usable condition.
5. Install the valve cover and torque the bolts to 11 ±
3 N•m (8 ± 2 lb ft).
Refer to the Service Manual or your Caterpillar dealer
.I
for the complete valve adjustment procedure.
..
..
..
;1

Fuel Ratio Control
Check Setting - Adjust if Necessary
Slow engine response and low power may indicate a
need for adjustment or repair. This adjustment should
not be attempted by untrained personnel. Your
Caterpillar dealer is equipped with the necessary tools,
personnel and procedures to perform this service.
Inspect the fuel ratio control diaphragm for any sign of
leaking. Check for any cracking or deterioration of the
diaphragm.
83
Maintenance Section
Every 3000 Hours
Governor Set Point
and Low Idle Speed
Check/Adjust
The only on-engine adjustment to the governor is the
low idle setting. All other governor adjustments are to
be made during bench (off engine) testing.
NOTE: Refer to the Special Instruction SEHS8024 and
SEHS7795 for procedures and tooling required for
bench testing the governor.
NOTICE
These adjustments are to be made only by a
Caterpillar dealer or a mechanic that has the correct
training. A governor set point that is incorrectly adjust-
ed could result in excessive fuel consumption or pre-
mature engine component wear.
Your Caterpillar dealer has all of the necessary
equipment to check and adjust your governor.
The Low Idle screw is normally set during the bench
test procedure. However, if the low idle setting is not
satisfactory, use 1U6672 Wrench to loosen the locknut
and adjust screw to the desired low idle speed. Tighten
the locknut and recheck the low idle setting.
NOTE: Refer to the Fuel Setting And Related
Information Fiche for the correct low idle speed for your
engine. This information can be obtained from your
Caterpillar dealer.
84
Maintenance Section I
Every 3000 Hours

Turbocharger Engine Mounts

Inspect for Proper Operation Inspect I
I
I
I
1. Remove the exhaust outlet piping and inlet piping
Front engine mount shown.
I
from the turbocharger.

2. Turn the turbine and compressor wheel by hand.

Caterpillar recommends checking the engine mounts
for deterioration and proper bolt torque. This will
prevent excessive engine vibration caused from
I
improper mounting. See your Service Manual or
3. The assembly should turn freely.

4. Inspect the turbine wheel and compressor wheel

for contact with the turbocharger housing.
Caterpillar dealer for recommended torque values.
I
5. There should NOT be any visible signs of contact
between the turbine wheel or compressor wheel and
I
the turbocharger housing.

NOTE: When installing or replacing V-band clamp, I

position the gap (tightening screw) down if possible so
any water will drain away.

6. Visually check for oil leaks. I

NOTE: If maintenance is required, refer to Every 5000
Hour interval in this publication for turbocharger service
options. I
I
I
I

I
I
I 85
Maintenance Section
Every 3000 Hours

Damper
I Inspect

I
I
I
I Damage to, or failure of, the damper will increase
torsional vibrations and result in damage to the
I crankshaft and other engine components. A failing
vibration damper will cause more gear train noise at
variable points in the speed range.

I The vibration damper can have a visual wobble

(movement to the front and rear when in rotation). This
does not mean a replacement is necessary since some

I wobble is normal. To see if the amount of wobble is

acceptable, or replacement is necessary, check the
damper with the procedure in the Testing and
Adjusting section of the Service Manual.

I
I
I
I
I
I
I
I
86
Maintenance Section .
Every 5000 Hours

Every 5000 Hours

You must read and understand the warnings
and instructions contained in the Safety section
of this manual, before performing any operation
or maintenance procedures.
Before proceeding with Every 5000 Hour maintenance,
perform previous maintenance interval requirements.
3. When a cylinder is found where the loosened fuel
line nut does not make a difference in engine
performance or smoking, have that cylinder fuel nozzle
tested to determine whether the fuel nozzle can be
cleaned and used again or exchanged for a new
nozzle.

4. Stop the engine.

I
Fuel Injection Nozzles
Test/Exchange
To Remove and Install Fuel Nozzles
Refer to the Service Manual for your engine to remove
I
Whenever the engine performs in such a manner that a
fuel injection nozzle is suspected of causing irregular
running, smoking or knocking, isolate each fuel
and install fuel nozzles.

NOTE: For complete fuel injection nozzle test

information, refer to Special Instruction Form SEHS7292
I
injection nozzle, one at a time, to determine the
malfunctioning nozzle.
or consult your Caterpillar dealer.

This Special Instruction contains information and

I
1. Start the engine. procedures to test the fuel nozzle for:

NOTICE
• Pressure Loss
• Valve Opening Pressure (VOP)
I
• Tip and Bleed Screw Leakage
Do not loosen nuts at the top of fuel nozzles. The nozzles
will be damaged if the top of the nozzle turns in the body
when the fuel lines are loosened. The engine will be
damaged if a defective fuel injection nozzle is used be-
• Spray Pattern from Orifice Restriction
• Flushing Procedure I
cause of the shape of fuel (spray pattern) that comes out
of the nozzles will be incorrect.
NOTE: Do not use a fuel nozzle in the engine unless
the nozzle has been tested for the items listed above
and all test results are within test specifications.
I
Your Caterpillar dealer has the necessary equipment to
perform this maintenance. I
I
I
I
2. Loosen the fuel injection line nut at the fuel pump,
one at a time, with the engine running. Be sure to
tighten each fuel line nut after the test, before the next
fuel line nut is loosened.
I
I
I
I
 87
Maintenance Section
Every 5000 Hours

SR 4 Generator Water Pump, Turbocharger,

(if equipped) Alternator and Electric
Lubricate Bearing
Starting Motor
Inspect/Rebuild or Exchange

Note: Some engines equipped with generators may be

equipped with a sealed prelubed bearing. These Water Pump
generator set bearings will not require lubrication every
5000 service hours.

Lubricate small frame generators with a hand held

grease gun using two pumps of MPGM grease.

Use Multipurpose-type Grease (MPGM) which contains

3% to 5% molybdenum disulfide. NLGI No. 2 Grade is
suitable for most temperatures. Use NLGI No. 1 or 0
Grade for extremely low temperatures.

Wipe fitting of excess grease. Start the engine and run

at low idle. Engage driven equipment and allow the
grease to expand.
Turbocharger

Alternator
88
Maintenance Section
Every 5000 Hours
Electric Starting Motor
One unscheduled failure caused by any of these
components will cost more in downtime than
maintaining them before failure. The cost incurred to
maintain these components before failure as
recommended, could be significantly less than if the
component fails.
The belief that it is more costly to maintain components
before failure than it is to operate the engine until the
component fails, is false.
By maintaining these components before failure,
unscheduled downtime will be minimized and the
chances for potential damage to other engine parts
reduced. The prevention of unscheduled downtime
saves money and lowers operating costs.
If the engine is operated until the component(s) fails, it
could cause additional damage to the engine. For
example: A failed water pump might cause severe
engine overheating problems that could result in cracks
in the cylinder head, a piston seizure or other potential
damage to the engine; severe damage to the
turbocharger compressor wheel could cause parts from
the compressor wheel to enter the engine cylinder and
cause additional damage to the piston, valve and
cylinder head.
If the engine is operated until the water pump fails, the
repair costs could be as much as twenty-five times or
more the repair before failure cost. This excessive cost
is due to the additional engine damage that could have
been prevented.
Our recommended intervals for performing preventive
maintenance on these components are based on
experience and gathered data relative to the expectant
life of the engine and its components. These
maintenance intervals were developed as a service for
the owner's use to minimize unexpected and costly
repairs as well as to serve as an aid to lowering
operating costs.
Failure to follow the recommendations could result in
unexpected, costly repairs and unscheduled downtime.
Caterpillar recommends that the most cost effective
method of operation for these components is to inspect
the unit before it fails and make the decision to rebuild
or exchange the components.
Maintenance Options
New Parts - Genuine Caterpillar parts are constantly
tested and modified to incorporate the latest design
advances. Your Caterpillar dealer can provide the parts
needed for rebuilding the components. Your benefit:
Long-lasting replacement parts at competitive prices.
Repair Kits - These useful kits can be obtained from
your Caterpillar dealer. These kits include all the
necessary parts and instructions to repair the
components, in either the owner's maintenance shop
or at a Caterpillar servicing dealer's facility. Repair kits
simplify parts ordering, help speed repairs and reduce
parts cost.
Remanufactured - This process uses manufacturing
techniques and procedures to restore the components
to like-new performance capability. This process
always involves an end product which conforms to the
manufacturer's "original" functional specifications.
Remanufactured parts may not be available in your
area. Contact your Caterpillar dealer for information.
I 89
Maintenance Section
Every 5000 Hours

New Components — Replace worn or failing

components with new components.
I Before deciding which method is best, make sure all of
the options and costs associated with repair have been

I considered. Some considerations are:

• The costs associated with using separate parts from

inventory versus the cost of a repair kit.

I • Downtime costs while the product is being rebuilt or

repaired.

• Total parts and labor costs for repairs versus the

actual Remanufactured cost.

• Remanufactured components from Caterpillar (if

I available) are covered by a standard, factory

warranty.

I Caterpillar Recommendation
To minimize downtime, Caterpillar recommends that
the use of Remanufactured components (subject to

I availability) is the most cost effective option.

NOTE: There are two levels of pricing for

I Remanufactured turbochargers. The first level is

primarily based on damage to the turbocharger before
failure. The second level is primarily based on damage
to the turbocharger after failure.

I Removal and Installation

I Refer to the established procedure in the Service

Manual for this engine to remove and install these
components or contact your Caterpillar dealer for
assistance.
I
I
I

4
I
90
Maintenance Section
Overhaul
I
Overhaul

You must read and understand the warnings As an example, consider the following graph.
and instructions contained in the Safety section
of this manual, before performing any operation
or maintenance procedures. 1
II
I
1I
Overhaul the 3406B diesel engine(s) at the fuel OVERHAUL
I I
I I
I

R HOUR
consumption or hour interval specified in the I I
I I
Maintenance Management Schedule. / I

AVIRA01 COST►!
I
BEFORE FAILURE -- I I
According to the Maintenance Management Schedule, AFTER FAILURE — — — I 1
I I
it's time to have your engine(s) overhauled. However, I I
i
with the exception of burning a little oil and A
I
i p
experiencing a slight increase in fuel consumption, you
are not having any other problems with your engine.

The overhaul interval in the Maintenance Management

/
\
Ne'
I /
I /
i I
I
• • • • •
Schedule gives Caterpillar's recommendation for doing 1 2 3 4 S ;I 7 $ 9 to

an overhaul. The interval is expressed in total amount SERVICE HOURS :1000

of fuel consumed as well as Service Hours. The best

figure to use is total fuel consumed, even if this figure • The solid line shows the maintenance and repair
is estimated. Fuel consumption more closely follows
the load upon the engine.
costs for an owner who followed the maintenance
and repair recommendations for inspection, repair or
exchange for components and for overhauls. The
I
The hours figure is an average value for a reasonable peaks represent the years in which overhauls
load factor. The hours figure will be too high if the
engine is run at high load and too low if the engine is
lightly loaded.
occurred.

• The dotted line represents another user operating

I
Use the fuel consumption or service hour figure only as
a guideline. Other factors, such as how conscientiously
preventive maintenance has been performed, fuel
identically except he has chosen to operate beyond
the Caterpillar recommended intervals. His peaks also
represent years with overhauls.
I
quality, operating conditions, S•O•S results, etc., are
important in deciding when to perform an overhaul, as
well as some important economic points to keep in
mind.
Notice that in the early years, the "repair-after-failure"
philosophy is a little less expensive and also that the
first overhaul was delayed one year. The graph also
I
illustrates that the peaks are significantly higher than
Caterpillar has determined the recommended overhaul
interval with total operating costs in mind.
the peaks for the customer using the "repair-before-
failure" philosophy. I
The higher peaks result from two key factors. First,
waiting until a component fails or wears out means
more likelihood of a catastrophic (expensive) failure,
requiring more parts, labor and cleanup. Second,
I
excessive wear means less components will be
reusable, or at least will need more labor to salvage or
repair.
I
IN THIS EXAMPLE, EXTENDING OVERHAUL PERIODS
2000 HOURS RESULTED IN TOTAL MAINTENANCE
AND REPAIR COSTS INCREASING BY ALMOST 30%.
I

;
I

There is very little reasoning which can justify running
the engine beyond recommended maintenance and
overhaul intervals.
Note that the 30% increase does not consider the cost
of any additional downtime that resulted from time to
repair the worn out engine, or the additional revenue
lost during the repair period.
The choice to continue running, or to overhaul the
engine at the recommended service interval is yours.
Maybe there won't be a failure within a reasonable
amount of time, but more parts will require replacement
and you will have to do the overhaul sooner or later.
By NOT performing an overhaul, you risk the chance of
seizing a piston, breaking a rod, fatiguing a bearing or
causing other severe damage to your engine. The cost
to repair this damage could range from U.S. $5000 to
$9000 and the amount of downtime encountered would
exceed the amount of downtime required for a
scheduled overhaul.
Why increase repair costs unnecessarily and risk
component and/or failure? The longer you wait, the
greater your risks, your costs and your downtime.
Most users will save money by overhauling at the
intervals recommended in the Maintenance
Management Schedule. It is virtually NEVER CHEAPER
to wait for the engine to show signs of excessive wear
or failure. "REPAIR-BEFORE-FAILURE" is the least
expensive alternative for most components and
engines, when all costs are accounted for.
Caterpillar strongly recommends that you overhaul your
engine before failure.
Overhaul Programs
Your Caterpillar dealer may be offering a variety of
options regarding overhaul programs and Caterpillar
recommends that an Overhaul be performed at this
maintenance interval.
91
Maintenance Section
Overhaul
Overhaul Before Failure
A planned overhaul may be your best value, because
you can:
• Avoid costly unplanned downtime
• Reuse as many original parts as standards permit
• Extend your engine's service life without the risk of a
major catastrophe had you continued to operate to
failure
• Get the best cost/value relationship per hour of
extended life
The cost of a scheduled, before failure overhaul is
usually 20-25% of the cost of a new engine.
Flat Rate Overhaul
To further control your overhaul costs, Caterpillar
recommends that you contact your dealer for
information regarding the availability of a Flat Rate
Overhaul.
A Flat Rate Overhaul is not really a type of overhaul but
a program that guarantees the maximum price you will
pay for an overhaul. Flat Rate Overhauls will help you
control your costs.
Flat rate prices on preventive maintenance programs or
major repair options are available from many servicing
dealers for all Caterpillar engine models.
Overhaul Options
Caterpillar Dealer - Contact your Caterpillar dealer to
schedule a Before Failure Overhaul.
Overhaul Kit - This useful kit was developed for those
users that prefer to perform their own overhaul. This kit
includes a combination of new, reused and
remanufactured parts. Also included is a step-by-step
instruction regarding how to perform an overhaul. An
Overhaul Kit simplifies parts ordering, helps speed
repairs and reduces parts costs.
Contact your local Caterpillar dealer for information
regarding the Overhaul Kit.
92
Maintenance Section
Overhaul
Before Failure Overhaul
To minimize downtime and provide you with the lowest
cost and highest value, Caterpillar recommends that
the engine be Overhauled Before Failure by scheduling
an overhaul with your Caterpillar dealer.
NOTE: Overhaul programs vary from dealer to dealer.
Therefore. Caterpillar recommends that you confer with
your dealer to obtain specific information regarding the
types of programs offered and overhaul services
provided for extending the life of your engine.
Overhaul Instructions
If you elect to perform an overhaul yourself, without
having a Caterpillar dealer perform the overhaul for you,
or without using an overhaul kit, then you should be
aware of the following:
Rebuild or Exchange
Cylinder Head Assembly, Cylinder Packs, Oil Pump
and Fuel Transfer Pump, Timing Advance and Fuel
Ratio Control, and Spacer Plate.
These components should be inspected according to
the instructions found in various Caterpillar reusability
publications. Refer to the Index Of Publications On
Reusability Or Salvage Of Used Parts section of the
"Guideline For Reusable Parts and Salvage
Operations," form SEBF8029 to determine the
reusability publications needed for inspecting your
parts.
The "Guideline For Reusable Parts and Salvage
Operations" is part of an established Caterpillar parts
reusability program. These guidelines were developed
to assist Caterpillar dealers and customers reduce
costs by avoiding unnecessary expenditures for new
parts when existing parts can be used as is, repaired
or salvaged.
If your parts comply with the established visual,
dimensional, etc., inspection specifications expressed
in the reusable parts guideline, then they should be
reused.
• Spacer Plate - Inspect the spacer plate for excessive
wear or warping.
NOTE: Parts complying with the specifications
outlined in the reusable parts guideline will give an
additional service life.
If your parts are not within specification, then they
should be salvaged, repaired or replaced. Failure to
salvage, repair or replace out-of-spec parts will result in
unscheduled downtime and could result in costly
repairs caused by potential damage to other engine
parts.
Furthermore, the use of out-of-spec parts can reduce
your engine's efficiency and increase fuel
consumption. Reduced engine efficiency and
increased fuel consumption translates into higher
operating costs for you. Therefore, Caterpillar
1
recommends that you salvage, repair or replace your
out-of-spec parts.
Install New
Crankshaft Bearings, Valve Rotators and
Crankshaft Seals.
In most probability, your crankshaft bearings, valve
rotators and crankshaft seals will not last until your
second overhaul. Therefore, Caterpillar recommends
the installation of new components at each overhaul
period.
Test or Exchange
Fuel Injection Nozzles and Fuel Injection Pump.
Have your Caterpillar dealer check your these
components for proper operation and correct settings.
He can rebuild or furnish an exchange components.
The cost of diesel fuel can be 80 to 85% of the total
cost to own and operate your engine. Therefore,
Caterpillar recommends that your fuel injection nozzles
and pump be tested at this overhaul period to ensure
your engine is operating at peak efficiency.
Your Caterpillar dealer can provide these services and
components for you and ensure that they are operating
within the appropriate specifications.

Inspect
Crankshaft, Camshaft, Camshaft Followers and
Bearings, Damper, Gear Train Gears and Bushings,
Fuel Rack and Governor, and Driven Unit Alignment.
The ideal time for inspecting these items is while your
engine is disassembled for overhaul. Inspect each
component for potential damage as follows:
• Crankshaft - Inspect for deflection, journal damage
and bearing material seized to the journal. At the
same time, check the taper and profile of the
crankshaft journals by interpreting your main and rod
bearing wear patterns.
NOTE: If the crankshaft is removed for any reason,
use the magnetic particle inspection process to check
the crankshaft for cracks.
• Camshaft - Inspect the camshaft for journal damage
and lobe damage.
NOTE: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check the
camshaft for cracks.
• Camshaft Followers and Bearings - Inspect the cam
bearings for fatigue and wear.
• Damper - It is our recommendation to replace the
damper for any of the reasons that follow.
1. The engine has had a failure because of a broken
crankshaft.
2. The crankshaft front bearing is badly worn.
3. There is a large amount of gear train wear that is
not caused by a lack of oil.
If none of the above conditions is found, dampers can
be used again at overhaul, providing the damper is not
damaged.
• Gear Train Gears and Bushings - Inspect for worn
gear teeth, unusual fits and unusual wear.
• Driven Unit Alignment - Upon reassembly of the drive
line and driven unit, check alignment as outlined in
the following publications.
• LEBX6213-Building Services Application and
Installation Guide
93
Maintenance Section
Overhaul
• LEBH9324-Agricultural and Material Handling
Application and Installation Guide
• SEHS7654-Alignment-General Instructions
NOTE: For additional information regarding these
items, contact your local Caterpillar dealer for
assistance.
Clean/Test
Oil Cooler Core and Aftercooler Core.
Caterpillar recommends that the oil cooler core and the
water-to-air aftercooler core be cleaned and pressure
tested at each overhaul. For additional specifications
and/or pressure test information, contact your local
Caterpillar dealer.
Cleaning Procedure for Oil Cooler or
Aftercooler Core
Caterpillar recommends that the oil cooler and
aftercooler cores be removed, cleaned, and tested at
overhaul time or if a turbocharger failure has occurred
or if at any time the turbocharger develops an oil leak.
To clean the oil cooler or aftercooler system:
1. Remove the core. Turn the core upside down to
remove debris from the inlet tank.
NOTICE
Do not use caustic cleaners to clean the cores. Caustic
cleaners will attack the internal metals of the core and
cause leakage.
2. Back flush internally with a solvent to loosen foreign
substances and to remove oil.
Caterpillar recommends the use of Caterpillar
Hydrosolv 4165 or Hydrosolv 100 Liquid Cleaners.
Part No. Description Size
8T7570 Hydrosolv 4165 208L (55 U.S. Gal.) Drum
8T7571 Hydrosolv 100 208L (55 U.S. Gal.) Drum
For more information see "General Instructions and
Application Guide" Form LEHO6101 or contact your
Caterpillar dealer.
94
Maintenance Section
Overhaul
3. Shake the core vigorously to eliminate any trapped
debris.
4. Wash the core with hot, soapy water. Rinse
thoroughly with clean water.
5. Dry the core with compressed air. Blow air in
reverse direction of normal flow. Use all necessary
safety equipment while using compressed air.
6. Inspect the system to ensure cleanliness and install
the core.
Obtain Coolant Analysis
There are two types of coolant analysis that can be
performed. First, the concentration of coolant additives
(inhibitor) should be checked regularly for over or under
concentration. The intervals recommended for re-
charging with coolant additive should be adequate for
many users, but it is a good idea to periodically check
the concentration.
For checking the concentration of coolant additive,
Caterpillar offers an 8T5296 Test Kit.
At overhaul time a further coolant analysis may be
desirable. For example, suppose considerable deposits
are found in the water jacket areas on the external
cooling system, yet coolant additive concentrations
were carefully maintained. Chances are that the
coolant water had minerals which deposited on the
engine over time. One way to verify the water
condition, or to be sure of new water at fill time, is to
have a water analysis conducted.
.
Full water analysis can sometimes be obtained locally
..
by contacting your local water utility company or an
agricultural agent. Private laboratories are also
available. Refer to the Cooling System Specifications
for additional information.
To analyze a water sample, most laboratories need
approximately 250 ml (1/2 pint) of water. Check the lab
..
you use for details about labeling and shipping.
Caterpillar Recommendation
The "Repair Before Failure" concept makes sense. It
saves you money, lowers your operating cost and
minimizes your downtime.
.I
As previously illustrated, it is not cheaper to operate
your engine until a component fails, since failing
components may effect your fuel costs and upon
failure, could damage other engine parts. The money
that would be wasted, is money that could be used
more profitably elsewhere. The choice is yours.
..
Caterpillar strongly recommends that you subscribe to
the "Repair Before Failure" concept.
..
..
;
 95
Maintenance Section
Overhaul

After Failure Overhaul The following is a list of (R) Remanufactured

components currently being offered by Caterpillar* in
If you experience a major engine failure which requires many countries:
removal of the engine, there are also many After
Failure Overhaul options available. • Short block
• Cylinder pack '
• Cylinder head - bare
After Failure Recommendations • Cylinder head - assembly and group
• Crankshaft - undersized
An overhaul should be performed if your block or • Crankshaft - upgrade to new
crankshaft needs to be repaired. • Complete turbocharger
• Turbocharger cartridges
If the block and/or crankshaft is repairable, then the • Water pump
cost of an overhaul should be between 40 and 50% of • Oil pump
the cost of a new engine (with like exchange core). • Oil cooler core
• Connecting rods
This lower cost can be attributed to Caterpillar • Compressors
"designed-in" features that include: • Alternator
• Electric Starting motor
• Regrindable crankshaft • Governor and fuel pump group
• Undersize bearings • Fuel Nozzles
• Cat dealer and Caterpillar Remanufactured exchange
components NOTE: If the component you need is not listed here,
contact your Caterpillar dealer to see if it is offered
Dealer Exchange Components - This cost cutting under a dealer exchange component program (* X).
service permits you to exchange worn engine
components for quality Cat dealer rebuilt components • The current parts book will asterisk a part number
on an over-the-counter basis. When you need them, when a (R) Remanufactured unit is offered by
these parts are ready for a substantial savings in both Caterpillar.
time and money.
' Caterpillar cylinder packs contain both
Caterpillar Remanufactured Components - remanufactured and new pistons, connecting rods,
Manufacturing techniques and processes are used to cylinder liners, wrist pins, snap rings and new piston
restore your components to "like-new" performance rings. Caterpillar cylinder packs can be removed and
capabilities and are exchanged for your existing parts. installed as one unit.
The processes used result in an end product that
conforms to the manufacturer's original functional
specifications. Caterpillar Recommendation
To further control your overhaul costs, Caterpillar
recommends that you contact your dealer for
information regarding the availability of a Flat Rate After
Failure Overhaul.
96
Maintenance Section
Standby Generator Sets
Standby Generator Sets
Recommended Preventive
Maintenance
The objective of this information is to assist users in
establishing a Preventive Maintenance Program for
Standby Generator Sets or as an aid in evaluating their
present programs.
Standby Generator Sets may not be needed very often,
but when they are, it is usually under emergency
conditions. Maintenance of these standby units is very
important. They must always be in excellent operating
condition, ready to work under load at any time.
Establishing a Preventive Maintenance Program will
provide maximum availability of a standby generator
set when needed, longer engine and generator life, and
a minimum of expensive repairs.
The recommended weekly maintenance checks can be
performed by an operator. All yearly and three year
maintenance should be performed by an authorized
mechanic or your Caterpillar dealer.
These guidelines are to be used with the information
contained in the Operation and Maintenance Sections
of this manual. The Operation and Maintenance
sections of the manual will provide the necessary
information on how to perform the checks and routine
maintenance. Additional information can be obtained
from the Generator and Engine Service Manuals, or
contact your Caterpillar dealer for assistance.
Inspection and Maintenance Agreements
Your Caterpillar dealer can establish an Inspection and
Preventive Maintenance Program for your generator set
to provide maximum reliability, increased engine and
generator life, and minimize expensive repairs. Contact
your Caterpillar dealer for details.
Safety
Always make repairs with the engine stopped and the
starting system disabled. When servicing the
generator, make sure that switch gear and automatic
transfer switches will not present a shock hazard. Lock
them out on the generator being serviced.
Record keeping
Maintain a log or record keeping system to document
all gauge readings, problems, repairs, and
maintenance performed on the equipment.
Space Heaters
Moisture is a natural enemy of generators and all
electrical equipment. Every effort must be made to
keep the generator as dry as possible. Space heaters
should be operated inside the generator when it is not
in use to maintain integrity of the generator windings.
A WARNING
Failure to comply with the following could result in
personal injury or death.
The Stop-Manual-Automatic switch on the cranking
panel must be at "STOP" position when performing
maintenance or repair work on a standby generator
set. This prevents the unit from starting if a power
failure or voltage drop should occur while working
on the unit.
To prevent personal injury due to accidental start-
ing of the engine, disconnect the batteries or disa-
ble the starting system before doing maintenance
or repair work.
Lock out all switch gear and automatic transfer
switches associated with the generator while per-
forming maintenance or repairs. Make sure no
shock hazard exists.
I 97
Maintenance Section
Preventive Maintenance Schedule

Preventive Maintenance Schedule

Refer to the Maintenance Management Schedule in this Weekly: With Engine Running

I
publication for the topics listed to find information
regarding details and maintenance procedures.
Operational Checks - Start the engine. The following
operational checks are intended to check the generator
operation and the engine starting, lubricating and fuel

I
Weekly: Before Starting the Engine
To Be Performed By An Authorized Operator
systems as well as overall operation. The checks
should take no longer than five (5) minutes to
complete. Longer periods of operation are not required.
A more beneficial test will be performed annually with

I
Walk-Around Inspection - Check the engine, radiator
and generator for debris, foreign objects, loose or
broken fittings, guards and components. Repair as
the engine operating under load.
Engine Crankcase - Check and maintain oil level.
Frequency (rpm) and Generated Voltage - Check
necessary.

I
Engine Crankcase - Check and maintain oil level.
Cooling System - Maintain coolant level.
Block Heater - Check for proper operation. Maintain
and record readings.
Leaks and Noises - Check for leaks and unusual
noises. NOTE: Engine must be stopped before making
necessary repairs.

I
32°C (90°F) minimum coolant temperature in block at
all times.
Fuel System - Check for leaks. Keep fuel tank full.
Air Cleaner (Standard) - The standard air cleaner is
Weekly: After Stopping the Engine

I
non serviceable and is intended for a maximum of 50
service hours of use, unless operating in a severe
environment. Check the air cleaner for cleanliness and
damage such as rips and tears.
Automatic Switches (If Equipped) - Check that all
switches are in proper position for automatic start.
Fuel Level - Check the fuel level; refill when below
three-fourths full.

I
Air Cleaner Indicator (If Equipped) - Check the
indicator (Equipped with optional heavy duty air
cleaners only). Change the air cleaner elements when
Battery Charger - Record charging amperage
reading.
Malfunctions - Report any malfunction and make

I
the indicator diaphragm remains locked. necessary repairs.
Belts - Inspect for worn, broken or loose belts
(alternator, fan, drive, etc.).
Battery Charger - Check for proper operation.

I
Batteries - Maintain electrolyte level, clean batteries if
necessary, check connections.
Gauges - Check the condition of all gauges. Repair or
replace any broken gauge.

I
Generator and Control Panel - Visual inspection,
check for loose, broken, or damaged wiring or
components.

I
I
I
I
I
I
98
Maintenance Section
Preventive Maintenance Schedule
Yearly: Before Starting the Engine
To Be Performed By An Authorized Mechanic
Walk-Around Inspection - Perform all Weekly Before
Starting the Engine Preventive Maintenance
Procedures. Check the engine, radiator, and generator
for debris, foreign objects, loose or broken fittings,
guards and components. Repair as necessary.
Cooling System - Check for leaks. Add supplemental
coolant additive (if required).
Fuel System - Drain water and sediment from tank.
Change fuel filters.
Air Cleaner Element - All standard (50 hour service)
air cleaner elements are to be replaced. Inspect; clean
or replace all optional heavy duty air cleaners only.
Engine Crankcase - Check and maintain oil level.
Engine Crankcase Breather - Clean.
Valve Lash - Check/Adjust if necessary.
Linkages - Check and adjust all linkages if necessary.
Lubricate all linkage fittings.
Alarms and Shutdown Devices - Check; test for
proper operation.
Batteries - Check electrolyte level, clean terminals and
connections.
Engine - Clean.
Generator - Lubricate bearing; Vacuum clean, and
check wiring of the regulator, exciter, and stator. Check
generator windings with megohmmeter and record
readings for reference. Check operation of space
heaters.
NOTE: Refer to the Generator Service Manual for
information relating to use of the megohmmeter and
low resistance readings.
Yearly: With Engine Running
Operational Checks - Start the Engine. Check all
gauges, oil pressure, fuel pressure, rpm (frequency),
generated voltage and engine jacket water
temperature, for correct readings.
Engine crankcase - Check and maintain oil level.
Leaks and Noises - Check for leaks and unusual
noises. NOTE: Engine must be stopped before making
necessary repairs.
Load Test - Load the engine to minimum of 30% of
rated load. Operate at this level for a minimum of two
hours.
Gauge Readings - After approximately one hour,
record the readings of all gauges: oil pressure, fuel
pressure, oil level, rpm (frequency), generated voltage,
service meter, engine jacket water temperature, and
exhaust temperature (if equipped).
Yearly: After Stopping the Engine
Repair or Adjust - Make any repairs or adjustments to
the engine and generator set as necessary.
Scheduled Oil Sampling (S•O•S) - Obtain sample for
analysis.
Engine Crankcase - Change oil; Change filters, cut
old filter(s) open and inspect for foreign material.
Fuel Level - Record the fuel tank level. Fill if below
three-fourths full.
Battery Charger - Record charging amperage
reading.
Automatic Switches (If Equipped) - Check that all
switches are in proper position for automatic start.
 . 99
Maintenance Section
Preventive Maintenance Schedule

..
Every Three Years: Before Starting the Engine

To Be Performed By An Authorized Mechanic

Walk-Around Inspection — Before starting the engine,

perform all Weekly and Yearly Before Starting the
Engine Preventive Maintenance procedures.

..
Cooling System — Drain, clean and flush the cooling
system. Replace thermostat. Refill with coolant solution
and coolant additive.
Rubber Hoses and Belts — It is recommended that all
hoses and belts be replaced at this time to minimize
downtime and additional repair cost of component
failures caused by these items.

.r
Batteries — Replace.
Turbocharger — Inspect for proper operation. Check
the end play and radial clearance on the turbine wheel
and shaft.
Engine — Perform a complete engine adjustment and
tune-up.

..
Every Three Years With Engine Running

Operational Checks — Perform all Yearly With Engine

Running Preventive Maintenance Procedures.
Exhaust System — Check for Leaks. Repair or replace
defective components with engine stopped.

.1
Every Three Years With Engine Stopped

Repair or Adjust — After stopping, and perform all

Yearly After Stopping the Engine Preventive
Maintenance Procedures.

..
1
4
100
Maintenance Section
Performance Analysis
.
Performance Analysis

Approximately 80 to 85% of your engine's operation

and maintenance cost is the cost of the fuel. Therefore,
substantial cost reductions can be achieved by
keeping your engine operating at peak efficiency. The
fuel economy and performance of the engine is
affected by the application and specifications, how it is
operated and the condition of the engine. Each plays
an important part in minimizing your overall owning
I
and operating cost.

Caterpillar recommends a regularly scheduled analysis

to monitor the condition and maintenance requirements
I
of your engine and to ensure your engine is operating
at peak efficiency. I
Potential problems can be identified early, thus
preventing unnecessary repair costs and unscheduled
downtime. Consult your Caterpillar dealer for complete
information and assistance in conducting a
I
performance analysis of your engine.

Tests normally conducted by your Caterpillar dealer

can:
I
• confirm your engine is operating efficiently and within
specification. I
• identify potential problems.

• determine components or systems that should be

adjusted, replaced, etc.
I
Fuel rate and boost are the primary indicators of your
engine's performance and the analysis of this data will
I
help pinpoint potential problems faster.

Regular performance testing on your engine can be

cost effective to help lower fuel costs and lower costs
I
associated with maintenance, repairs and overhauls.

I
I
I
I
I
I
 101
Literature Reference Section
Literature Reference Materials

Literature Reference Materials

Caterpillar Reference Material SEHS8024, "Governor Adjusting Tool Group"

The following literature can be obtained through any SEHS8094, "Use of Nozzle Puller Group"
Caterpillar dealer.
SEHS9124, "Cleaning and Drying of Caterpillar Electric
SEBD0518, "Know Your Cooling System" Set Generators"

SEBD0970, "Coolant and Your Engine"
SEBD0717, "Diesel Fuels and Your Engine"
SEBU6310, "EMA Lubricating Oils Data Book" for
engines
SEBU6150, "SR 4 Generators and Control Panels
Operation and Maintenance Manual"
LEBX6213, "Building Services Application and
Installation Guide"
LEBH9324, "Agricultural and Material Handling
Application and Installation Guide"
PEHP7504, "CAT Engine Oil Spec Sheets"
PEHP7505, "CAT Diesel Engine Oil Spec Sheets"

SEBD0640, "Oil and Your Engine" All of the above publications are available through your
Caterpillar dealer.
SENR2557, Service Manual (2WB1-UP, 4RG1-UP)

SENR3023, Service Manual (6TB1-UP) Additional Reference Material

SEBP1436, Parts Manual (2WB1-UP) ASTM D2896 TBN Measurements

SEBP1532, Parts Manual (2WB1-UP Package ASTM D217-68 - Worked Penetration

Generator Set)
ASTM Specs can normally be obtained from your local
SEBP1258, Parts Manual (2WB1-UP Floor-standing technological society, library or college.
Switch Gear)
SAE J313 Diesel Fuels
SEBP1340, Parts Manual (2WB1-UP Automatic Transfer
Switch) SAE J754 Nomenclature

SEBP1765, Parts Manual (2WB1-UP EMCP) SAE J183 Classification

SEBP1804, Parts Manual (4RG1-UP) SAE Specs can be found in your SAE handbook or can
be obtained from your local library, college or
SEBP1800, Parts Manual (4RG1-UP equipped with technological society.
9Y1300 or 9Y1400 Control Panel)

SEBP1434, Parts Manual (6TB1-UP)

SEHS7654, "Alignment-General Instructions"

SEHS9031, "Storage Procedure for Caterpillar Products"

SEBF8029, "Guideline For Reusable Parts and Salvage

Operations" (An index of publications on reusability or
salvage of used parts.)

SEBF8062, "Guideline for Reusable Parts - Cleaning

and Inspection of Air Filters"

SEHS7292, "Use of 5P4150 Nozzle Testing Group"

SEHS7795, "Use of Pump & Governor Tool Group"

102
Literature Reference Section
Maintenance Records
.
Maintenance Records

Maintenance records are a key element of a well

managed maintenance program. With accurate
maintenance records your Caterpillar dealer can help
you fine tune the recommended maintenance intervals
to meet your specific operating situation. This should
result in a lower engine operating cost.

The key elements to keep records on are:

I
• Liters (Gallons) of Fuel Consumed

This is essential for determining when load-sensitive

I
items should be inspected or repaired, and for
determining overhaul intervals.

• Service Hours
I
This is essential for determining when revolution-
sensitive items should be inspected or repaired.
I
• Documents

The following types of documents should be kept as

I
proof of maintenance or repair for warranty and should
not be difficult to obtain and keep in the engine history
file. All documents should show date, service hours,
liters (gallons) of fuel consumed, unit number and
engine serial number. If the engine is sold, transfer the
I
records with the engine.

1. Dealer work orders and itemized bills

I
2. Owner's repair orders.

3. Owner's receipts.
I
4. Maintenance log (see following example).
I
I
I
I
I
il
I
I 103
Literature Reference Section
Maintenance Log

11 Maintenance Log

Engine Model Customer Identifier

I Serial Number Arrangement Number

I Service
Hours
Quantity
Of Fuel Item Serviced
By
Date Initials

I
I
I
I
0
I
I
I
I
I
I

I
104
Index Section
I
Index

Index

A Cooling System 79

Additional Reference Material

After Failure Overhaul
97
95
Clean/Flush Coolant
Cooling System Cleaning
Cooling System Specifications
79
42
38
I
After Failure Recommendations 95 Crankcase Breather 65
Caterpillar Recommendation 95 Clean 65
After Stopping the Engine 29 Crushing or Cutting Prevention 7 I
Air Compressor 87
Caterpillar Recommendation 89
Inspect/Rebuild or Exchange
Maintenance Options
87
88
D

Daily 52
I
Removal and Installation 89
Air Starter (if equipped) 56 Damper 85
Check Lubricator Level
Air Tank (If Equipped)
56
57
Inspect
Dipsticks
85
18 I
Drain Water 57
Alarm Switches
Alarms
Alternator
15
13
87
E I
Electric Starting 22
Caterpillar Recommendation 89
Inspect/Rebuild or Exchange
Maintenance Options
Removal and Installation
87
88
89
Electric Starting Motor
Caterpillar Recommendation
Inspect/Rebuild or Exchange
87
89
87
I
Maintenance Options 88
Anti-Seize Compound (ASC) 46
Removal and Installation 89
Antifreeze 39
Emergency Shutoffs 13 111
Engine Air Cleaner 58
B Air Cleaner Element-Standby 59

Batteries 73
Check Air Cleaner Service Indicator
Cleaning Air Cleaner Elements
Single Stage Air Cleaner Elements
58
60
58
I
Clean/Check Electrolyte Level (if equipped) 73
Two Stage Air Cleaner Elements 59
Before Failure Overhaul
Caterpillar Recommendation
Overhaul Instructions
92
94
92
Engine Crankcase
Check Oil Level
54
54
I
Before Starting the Engine 19 Engine Description 2
Belts and Hoses 70 Engine Exerciser for Standby Units 17
Inspect/Replace Alternator, Fan and Accessory Engine Identification 9
Drive Belts 70 Engine Information 9
Inspect/Replace Hoses and Clamps 71 Engine Lifting 34
Burn Prevention 5 Engine Lifting and Storage 34
Engine Model Views 8
Engine Mounts 84
C Inspect 84
Engine Oil and Filter(s)
Cat Lubricating Grease 47 Change Filter(s) 63
Caterpillar Reference Material 97 Change Oil 63
Clutch (If Equipped) 72 Engine Oils 46
Check/Adjust 72 Engine Operating Cost Analysis 31
Clutch Shift Collar and PTO Main Shaft 56 Engine Operating Cost Summary 31
Lubricate with MPGL Grease 56 Engine Operation 25
Coolant Information 38 Engine Protection Devices 13
Coolant Water 38 Engine Protection Devices 74
Cooling System 55 Inspect for Proper Operation 74
Check Coolant Level 55 Engine Specifications 8
Cooling System 66 Engine Starting 7
Test for Concentration 66 Engine Starting 22
Engine Starting with Air ,..
iiiiiiiii itilii111111111111111111111111111124

Engine Starting With Jumper Cables 23

I
I 105
Index Section
Index

II 28 M
Engine Stopping

I Engine Storage
Engine Storage
Every 125 Hours
2
34
61
Maintenance
Maintenance Log
2
99
Every 250 Hours 62 Maintenance Management Schedule 51

I Every 1000 Hours

Every 3000 Hours
Every 5000 Hours
74
77
86
Maintenance Records
Maintenance Section
Mechanical Governor Control
98
36
28
Mechanical Governors 26

I F
Mounting and Dismounting 7

Fan Drive Bearing (If Equipped) 72 N

I Lubricate the Fitting
Fire or Explosion Prevention
Foreword
72
6
2
New Dipsticks With Full Range Readings 18

I Fuel and the Effect from Cold Weather

Fuel Filters
Clean/Replace Filters
32
68
68
0

Operation 2
Fuel Injection Nozzles 86
Operation Section 11
I Test/Exchange
Fuel Problems In Cold Weather Operation
Fuel Ratio Control
86
32
83
Overhaul
Overhaul Options
90
91
91
83 Overhaul Programs
Check Setting - Adjust if necessary

I Fuel Recommendations
Fuel Related Components in Cold Weather
Fuel Specifications
43
32
43
P
45
I Fuel Sulfur Content
Fuel System Information
Fuel Tank
43
70
Performance Analysis
Pilot Bearings (If Equipped) and Shift Lever
Lubricate the fittings with MPGL.
96
61
61
Drain Water & Sediment 70 Preparing to Start the Engine 7

I G R

I Gauges
General Hazard Information
General Section
11
4
8
Reference Numbers
Ref ill Capacities
10
50

Generator Storage Procedure 34

I Governor Set Point Speed and Low Idle

Check/Adjust
83
83
S

Safety 2
Safety 4
I I

Important Safety Information 3

Safety Section
Scheduled Oil Sampling (S•O•S)
Scheduled Oil Sampling (S•O•S) Analysis
3
48
62
10
I Information Plate
Information Section
Interval Terminology
1
49
Obtain Sample
Oil Drain Intervals
Serial Number Plate
62
62
10
Serial Number, Information Plate and Reference
Numbers 10
L Shutoff and Alarm System Testing 16
Solenoid Shutoff 28
Literature Reference Materials 97
97 Specifications and Model Views 8
Literature Reference Section
4' Lubricant Information
Lubricant Specifications
46
46
SR 4 Generator Bearing (if equipped)
Lubricate with MPGM
87
87
40
50 Supplemental Coolant Additive
Lubricant Viscosities 48
I Lubricant Viscosities and Refill Capacities 50 S•O•S Analysis
106
.
Ii
Index Section
Index

..
T

Terminology 49
Thermostat 77
Replace Thermostat, Gaskets and Seal 77
Torque for Constant Torque Hose Clamps 37
Torque for Metric Fasteners 36

1.
Torque for Standard Bolts, Nuts and Taperlock
Studs 36
Torque for Standard Hose Clamps-Worm Drive
Band Type 37
Torque Specifications 36
Turbocharger 84
Inspect for Proper Operation 84
Turbocharger (if equipped)

.1
87
Caterpillar Recommendation 89
Inspect/Rebuild or Exchange 87
Maintenance Options 88
Removal and Installation 89

..
Value Planned Repair (Repair Before Failure) 30
Valve Lash 66
Check/Adjust 66
Valve Lash 81
Check/Adjust 81

..
w
Walk-Around Inspection 19
Walk-Around Inspection 52
Inspect Engine for Leaks and Loose
Connections 52
Water Pump 87

..
Caterpillar Recommendation 89
Inspect/Rebuild or Exchange 87
Maintenance Options 88
Removal and Installation 89
Warning Signs and Labels 4
Woodward Governor and Tachometer Drive 76
Lubricate fittings with MPGL 76
Woodward Governor Control 28
Woodward Governors 25

;1
 SEBU6103-03
CATERPILLAR' November 1989

ElniR nEing
EIR g 17-iiiR
Ogh d.Rd
Industrial and EPG
Diesel Engines

001966- 0
001002- 0
003021- 0
(PAGES 1 THRU 43)
 1
Information Section
Table of Contents

Table of Contents

Information Section 3508 Industrial and EPG Diesel Engines

(Rated Up to 1300 rpm) 23
Foreword 2
3508 Industrial and EPG Diesel Engines
Maintenance Management 3 (Rated 1301 to 1600 rpm) 24
Customized Maintenance Management Program 5 3508 Industrial and EPG Diesel Engines
(Rated 1601 to 1800 rpm) 25
Scheduled Oil Sampling (S•O•S) 6
3512 Industrial and EPG Diesel Engines
Caterpillar Reference Materials 8 (Rated Up to 1300 rpm) 26
Maintenance Records 9 3512 Industrial and EPG Diesel Engines
(Rated 1301 to 1600 rpm) 27
Maintenance Log 10
3512 Industrial and EPG Diesel Engines
Terminology Used in the Maintenance (Rated 1601 to 1800 rpm) 28
Management Schedules 11
3516 Industrial and EPG Diesel Engines
(Rated Up to 1300 rpm) 29
Maintenance Section
3516 Industrial and EPG Diesel Engines
3114 Industrial and EPG Prime Power Diesel
(Rated 1301 to 1600 rpm) 30
Engines (All Rated rpm's) 13
3516 Industrial and EPG Diesel Engines
3116 Industrial and EPG Prime Power Diesel
(Rated 1601 to 1800 rpm) 31
Engines (All Rated rpm's) 14
3606 Industrial and EPG Diesel Engines
3204 Industrial and EPG Diesel Engines
(Rated to 1000 rpm) 32
(All Rated rpm's) 15
3608 Industrial and EPG Diesel Engines
3208 Industrial and EPG Diesel Engines (Rated to 1000 rpm) 34
(All Rated rpm's) 16
3612 Industrial and EPG Diesel Engines
3304 Industrial and EPG Diesel Engines (Rated to 1000 rpm) 36
(All Rated rpm's) 17
3616 Industrial and EPG Diesel Engines
3306 Industrial and EPG Diesel Engines (Rated to 1000 rpm) 38
(All Rated rpm's) 18
D353 Industrial and EPG Diesel Engines
3406 Industrial and EPG Diesel Engines (All Rated rpm's) 40
(All Rated rpm's) 19
D379 Industrial and EPG Diesel Engines
3408 Industrial and EPG Diesel Engines (All Rated rpm's) 42
(All Rated rpm's) 20
D398 Industrial and EPG Diesel Engines
3412 Industrial and EPG Diesel Engines (All Rated rpm's) 44
(All Rated rpm's) 21
D399 Industrial and EPG Diesel Engines
3412 Industrial and EPG Diesel Engines (All Rated rpm's) 46
Extreme Service (Oil Well Servicing) 22

Index Section
Index 48
2
Information Section
Foreword

Foreword

The maintenance schedules included in this

publication
are also included in the Operation and
Maintenance/Owners Manuals. Refer to the
Manual for
illustrations and further information to acco
mplish each
maintenance operation.

Maintenance Management
1
This publication contains lubrication and maintenance
management information. The lubrication and
maintenance items are organized for managing an
effective preventive maintenance program. The
implementation of a well-managed lubrication and
maintenance program should:
• Minimize downtime.
• Reduce engine operating costs.
• Increase engine life.
The items in the Maintenance Schedules fall into one of
the following three categories:
Preventive Maintenance Items
These items must be performed at the hour intervals
shown on the schedule. If these items are not
performed as recommended, engine life and
performance will be affected.
Revolution-Sensitive Items
Revolution-sensitive items include items such as water
pumps, alternators, fuel transfer pumps, and oil
pumps. The intervals for revolution-sensitive items are
based on hours of operation. These items are not
affected by the load on the engine during operation.
1 Instead, the faster and longer the engine runs, the
faster the component wears.
Load-Sensitive Items
Load-sensitive items include items such as cylinder
liners, cylinder heads, connecting rods, pistons, piston
rings, main and connecting rod bearings, and valve
train components. The basis for establishing service
intervals for load-sensitive items includes liters (gallons)
1 of fuel used, as well as service hours.
The best indicator for determining service intervals for
load-sensitive items is total fuel consumed. Liters
(gallons) of fuel used varies with the load on the engine
during operation. In general, the lower the load, the
longer the engine life.
3
Information Section
Maintenance Management
The intervals for inspecting, rebuilding, replacing, or
servicing items in the maintenance schedules were
very carefully selected to minimize the total cost of
maintenance and repair for most users. If an item is
inspected at the interval recommended in the
maintenance schedules, component wear should not
be excessive.
Items can be repaired/adjusted/resealed/etc., at least
expense. Even if wear is excessive, the repair cost will
be minimized because a failure has not taken place.
This will prevent unexpected downtime and minimize
operating cost.
Caterpillar has determined that it is almost always more
expensive to let a component or engine fail than to
repair it before failure. This is especially true even when
repairs before failure are performed at the
recommended conservative intervals. There are several
reasons for this:
• Cost of the repair or replacement of failed item versus
minimal rebuild cost if it has not failed.
• Cost of related damage, caused by the failure.
• Cost of additional labor to repair the failure and the
related damage, and to clean up the engine.
• Cost of (unscheduled) downtime and lost productivity
while the repair is done.
• Cost of additional worn or damaged parts that would
have otherwise been reusable.
If excessive wear is identified at the recommended
interval, contact your Caterpillar dealer. He will review
your maintenance practices and operating conditions
to help you to establish before failure repair intervals, to
meet your specific operating situation. Also, if your
wear is minimal at the recommended
inspection/maintenance interval, your dealer can
advise you whether longer intervals are recommended.
 4
Information Section
Maintenance Management

Revolution-Sensitive Comp
on ents In most applications, engine
load fluctuates, making it
difficult to establish a precise
hour interval for servicing
load-sensitive items. Therefo
re, Caterpillar strongly
recommends that accurate fue
l consumption records
be maintained to ensure that
inspection or repair of
load-sensitive items is perform
ed at the recommended
interval.

NOTE: In both situations an

occasional failure can
occur before the indicated inte
rval. The maintenance
intervals have not been set so
conservatively as to
eliminate the possibility of a
component not reaching
the maintenance interval.

The point marked "X" on the

curve marks the point in
time that the maintenance sch
edules recommend an
inspection, repair or replaceme
nt. If components are
serviced at this point, the risk
of a failure is minimized
for most users. If the compon
ent needs repair, but is
operated longer, the risk of failu
re increases rapidly as
shown by the rising curve. Ma
ny users will exceed the
limits of the hour intervals as
shown in the schedules,
but by doing so, they assum
e a higher risk of
component failure and unnece
ssary expense.

Load-Sensitive Component
s
The wear rate of a load-sens
itive item is a function of
gallons of fuel consumed. An
engine operating at
100% load takes less time to
consume the same
amount of fuel as an engine
operating at 50% load.

High Low
Fuol Rat* Fu•I Rate
100% Load 50 9
• Load

A aim• momb
41Momp mom

TIME— HOURS

As you can see by the "X's"

on graph B, it takes less
time for an engine operating
at 100% load (high fuel
rate) to wear the same amoun
t as an engine operating
at a 50% load (low fuel rate).
-
 5
Information Section
Customized Maintenance Management Program

Customized Maintenance Management Program

Your authorized Caterpillar dealer can assist you in Ask your Caterpillar dealer for more details on the
tailoring the maintenance management schedules to Engine Investment Analysis (EIA) Program.
meet the needs of your operating environment and
economic goals through a Customized Maintenance Your Caterpillar dealer has all the elements of a
Management (CMM) Program consisting of: complete maintenance management program that can
help reduce your engine operating costs. He wants to
help you realize full value from your investment.
Maintenance Scheduling
Let your Caterpillar dealer schedule your maintenance,
component repairs, and overhauls using his computer.
A good scheduling program helps ensure that service
is performed at the recommended intervals which helps
minimize unexpected downtime and keeps your
operation running smoothly.

Flat-Rated Repairs
The cost of most scheduled maintena - -e and repairs
can be predetermined, allowing you to accurately
budget for these expenses. (When an engine is run to
failure, these "flat rate" or "firm" prices are subject to
additional charges for failed parts, cleaning, machining,
etc.)

Repair Options
Your Caterpillar dealer can offer you several choices for
mc't maintenance and repair needs, including:

• Genuine Caterpillar Replacement Components

• Caterpillar Remanufactured Components

• Caterpillar Dealer Exchange Components

• Caterpillar Dealer Rebuild Using Genuine Caterpillar

Parts

You may be pleasantly surprised at your dealer's

prices for these options, compared to your own total
costs to do the repairs yourself.

Financial Analysis
Let your Caterpillar dealer show you the savings that
can be realized by following a Customized
Maintenance Management Program. A computer
program is used to show you fuel, oil, preventive
maintenance, component repair, and overhaul costs
over the life of your engine. This allows you to more
effectively budget for your total engire operating cost.
 6
Information Section
Scheduled Oil Sampling (S•O•S)
Scheduled Oil Sampling (S•O•S)
Caterpillar s Scheduled Oil Sampling (S•O•S) Program
is a series of diagnostic tests designed to identify and
measure contamination and condition of oil in an
engine's crankcase S•O•S is also used to determine
oil performance anL.1 component wear rates.
Caterpillar's Scheduled Oil Sampling (S•O•S) is the
best indicate,- for determining what is happening inside
your engine
S•O•S is a series tests designed to identify and
measure contam.- ::on such as soot, sulfur, etc. and
degradation Such _s the presence of fuel, water and
antifreeze in a sample of oil.
A test can be performed to determine the amount of
wear metals present in the oil sample, which is
compared to established Caterpillar norms to determine
acceptability. To be effective as an indicator, S•O•S
must be performed on a continuing basis.
Intermittent sampling will not allow wear rate trend lines
to be established.
Obtain S•O•S samples at regularly scheduled intervals
to monitor the condition and maintenance requirements
of your engine. Each oil sample should be taken when
the oil is warm and well mixed to ensure that the
sample is representative of the oil in the engine
crankcase and oil pan.
Refer to Every 250 Service Hour interval or consult your
Caterpillar dealer for complete information and
assistance in establishing an S•O•S program for your
engine(s).
S•0•S INTERVAL CHART
Compartment Interval
Engine Oil Every 250 Hours or at Oil
Change
S•O•S Analysis
S•O•S is composed of three basic tests:
• Wear Analysis
• Chemical and Physical Tests
• Oil Condition Analysis
WEAR ANALYSIS is performed with an atomic
absorption spectrophotometer. The test monitors a
given.component's wear by identifying and measuring
concentrations of wear elements in oil. These wear
particles are then compared against established
Caterpillar norms to determine acceptability.
Based on known normal noncentration data, maximum
limits of wear elements are established. Imperiling
failure can be identified when test results devia:e from
the established norm.
CHEMICAL and PHYSICAL TESTS which detect the
presence of water, fuel and antifreeze in the oil and
determine whether or not their concentrations exceed
established maximum limits.
The oil samples should then be tested using Infrared as
well as the standard chemical and physical tests to
determine its condemning limits.
OIL CONDITION ANALYSIS Infrared Analysis
identifies and measures the amount of contaminants
such as soot, sulfur, oxidation and nitration products.
NOTE: S•O•S must include Infrared (IR) in the
analysis. Infrared analysis must be used to determine
oil change intervals.
This test can also be used tc- customize (reduce,
extend or maintain) oil change intervals.
The test results of the oil samples will then be used as
a basis for determining the oil change interval for your
engine, giving you the ultimate time between oil
changes without the risk of engine damage.
Caterpillar's S•O•S Program is the best indicator to
identify what's taking place inside the engine structure.
Early warning of unacceptable oil contamination can
save considerable expense in engine repairs. To be
effective as an indicator, S•O•S must be performed on
a continuing basis. Intermittent sampling will not allow
wear rate trend lines to be established for a particular
engine, which makes identifying the best time to
overhaul an engine virtually impossible. Consult your
Caterpillar dealer for complete information and
assistance in establishing an S•O•S Program for your
engine.
 7
Information Section
Scheduled Oil Sampling (S•O•S
)

Infrared Analysis
3600 S•O•S Requirements
NOTE. S•O•S must include (Inf
rared) IR in the
analysis Oil should be changed when
the sample shows
condemning limits have reache
d. The following
The oil samples should then be guidelines for condemning limi
tested using Infrared as ts:
well as the standard chemical
and physical tests to
determine its condemning limits. • The TBN value should not
be less than 50% of new
using ASTM D 2896. with TBN
value of 5 minimum 3 .
The test results of the samples will then be used as • The maximum permissible
amount of pentane
a basis for determining the oil insolubles (soot, dirt, oxidized
change interval for your products) is 3% and
engine, giving you the ultimate the maximum permissible amo
time between oil unt of toluene
changes without the risk of eng insolubles (soot, dirt) is 2% usin
ine damage. g infrared scan or
ASTM D 893.
NOTE: Infrared analysis must • The maximum permissible
be used to determine oil amount of water is 0.5%
change intervals. maximum using the "sputter test
".
• The viscosity of used oil mea
Use S•O•S at regular scheduled sured in centistokes
intervals to mori'-)r (cSt) at 100°C should not incr
the condition and maintenance ease more than 3 cSt
requirements of your above the viscosity when the oil
engine. was new using
ASTM D 445 2 .
• The oil must not have any
Each oil sa..-ole should be take ethylene glycol content
n when the oil is warm using ASTM D 2982B.
and well mixed to ensure that • The maximum fuel dilution is
the sample is 3% using ASTM D 3828.
representative of the oil in the
compartment.
If oil analysis cannot be used
Consult your Caterpillar dealer and no other means of
for complete information analysis is available, the oil cha
and assistance in establishing nge interval residual
an S•O•S program for (blended or heavy) fuel and for
your engine. Refer to the Every distillate fuel is 1000
250 Service Hour hours maximum.
interval for more information.
I Oil is placed on a 110°C (230°F
) hot plate; water
bubbles formed during this pro
cedure are compared to
oils with a known water content
.
2 Minimum API clas
sification CD or MIL-L-2104D plus
an acceptable induction time on
the Micro-oxidation
Test. An SAE 40 oil is recomm
ended, SAE 30 or SAE
15W40 and 20W40 multi-grade
oils are acceptable for
low ambient temperature operatio
n. Refer to the
applicable Operation and Mainten
ance Manual for
viscosity and ambient temperatur
e information or your
Caterpillar dealer for information
on the Micro-oxidation
Test.

3 The TBN value of

new oil must be 20 times the
percentage of fuel sulphur with
a TBN value of 10
minimum.
8
Information Section
Caterpillar Reference Materials

Caterpillar Reference Materials

SEBD0518 ...... Know Your Cooling System Additional Reference Material

SEHS7067 Fuels for Caterpillar Diesel Engines ASTM D 445 -Viscosity

SEBD0717 Diesel Fuels and Your Engine ASTM D 893 -Insolubles

SEBD0970 Coolant and Your Engine ASTM D 2896 -TBN Measurements

SE3J5898 Cold Weather Recommendations ASTM D 2982B -Ethylene Glycol Content

Operation and Maintenance Manual
SEBU6310 EMA Lubricating Oils Data Book
SEHS7067 Fuels for Caterpillar Diesel Engines
ASTM D 3828 -Fuel Dilution
ASTM Specs can normally be obtained from your local
technological society, library or college.

SEBD0640 Oil and Your Engine SAE J313 -Diesel Fuels

SEHS7392 . Storage Procedure for Gas and Diesel SAE J754 -Nomenclature
Engines, Generators, and Marine Transmissions
SAE J183 -Classification
SEBF8029 .. Index to Guidelines for Reusable Parts
and Salvage Operations SAE Specs can be found in your SAE handbook or can
be obtained from your local library, college or
LEBM8295 Worldwide %.a.rine Directory technological society.

XXXXXXXX ... Operation and Maintenance/Owners Your Caterpillar dealer can provide any literature
Manual (Appropriate for your Engine Model) required to maintain your engine.

XXXXXXXX .. Service Manual (Appropriate for your

Engine Model)

XXXXXXXX Engine Application and Installation

Guide (Apprdpriate for our Application)

SEHS9031 7torage Procedure for Caterpillar Products

PEHP7505 CXP or CAT Diesel Engine Oil Spec Sheets

All of the above publications are available through your

Caterpillar dealer.
 9
Information Section
Maintenance Records

Maintenance Records

Maintenance records are a key element of a well

managed maintenance program. With accurate
maintenance records your Caterpillar dealer can help
you fine tune the recommended maintenance intervals
to meet your specific operating situation. This should
result in a lower engine operating cost.

The key elements to keep records on are:

Fuel Consumption

This is essential for determining when load-sensitive

items should be inspected or repaired, and for
determining overhaul intervals.

Service Hours

This is essential for determining when revolution-

sensitive items should be inspected or repaired.

Documents

The following types of documents should be kept as

proof of maintenance or repair for warranty and should
not be difficult to obtain and keep in the engine history
file. All documents should show date, service hours,
fuel consumption, unit number and engine serial
number. If the engine is sold, transfer the records with
the engine.

1. Dealer work orders and itemized bills.

2. Owner's repair orders.

3. Owner's receipts.

4. Owner's log (see following example).

10
Information Section
Maintenance Log

Maintenance Log

Engine Model Customer Identifier

Serial Number Arrangement Number

Service j Quantity By
Hours Of Fuel Item Serviced Date Initials
 11
Information Section
Terminology Used in the Maintenance Management Schedules

Terminology Used in the Maintenance Management

Schedules
Maintenance Terminology • Short Block
• Cylinder Pack (Piston, Rod. Piston Pin, and Cylinder
Check - To observe for satisfactory conditions, Liner)
accuracy, safety and performance. • Cylinder Head (Bare)
• Cylinder Head (Assembled)
Inspect - To examine closely in critical appraisal while • Crankshaft (Undersized)
testing or evaluating components or systems. • Crankshaft (Upgrade to New)
• Complete Turbocharger
Protective Devices - Engine shutdown safety switches • Turbocharger . artridge
such as oil presure, coolant temperature, overspeed,
• Water Pump
etc., as well as indicators such as gauges, lights, etc.,
• Oil Pump
that alert an operator that a potential problem may
• Connecting Rods
exist. Failure to respond to these indicators in a timely • Fuel Injection Nozzles/Injectors
manner could result in engine failure. • Tune-up Kits
• Fuel Ratio Control
Lubricate - To apply a lubricant (oil, grease. etc.) as
• Alternator
specified for reducing friction, heat and wear between
• Electric Starter
solid surfaces.
Usually Caterpillar Remanufactured Components have
Replace - To install something new, remanufactured
a warranty dentical to that of a new part.
or rebuilt in place of an existing worn or failing
component. • NOTE: If the component you need is not listed here,
contact your Caterpillar dealer to see if it is offered
Adjust - Return to service manual specifications.
under his Dealer Exchange Component Program.
Inspect/Rebuild or Exchange - Inspect to determine
NOTE: Because engines may be equipped with
the component's condition; select the service option
various optional components, the charts may
depending on the component's condition, dealer's
recommend maintenance for items not installed on
capability, and most importantly, the customer's
your engine. Simply disregard reference to any
satisfaction.
extraneous items. If unsure of any item, consult your
Caterpillar dealer.
Maintenance Options

Rebuild With New Parts - Genuine Caterpillar parts Maintenance Intervals

are constantly tested and modified to incorporate the
Because engines may be equipped with various
latest design advancements. Your Caterpillar dealer
optional components, the charts may recommend
can rebuild or provide the parts needed for overhauling
maintenance for items not installed on your engine.
your engine. Your benefit - long lasting replacement
Simply disregard reference to any extraneous items. If
parts at competitive prices.
unsure of any item, consult your Caterpillar dealer.
Exchange - This cost-cutting service permits you to
The following charts give maintenance intervals in
exchange worn engine components for quality
hours or total (accumulated) amount of fuel consumed.
Caterpillar Remanufactured or Caterpillar dealer rebuilt
components on an over-the-;counter basis. When you Hours are expressed in clock hours, not service meter
need them, these parts are ready for a substantial units (unless the service meter is a clock hour device).
savings in both time and money. For some older models, intervals are in SMU's (see the
headings on each chart). Hours of operation include
Caterpillar Factory Remanufactured Components -
only the time that the engine is running. An electric
The latest remanufacturing techniques and procedures
clock device should be connected so it is "OFF when
are used to restore components to Caterpillar's original
the engine is not running.
functional specifications. The following is a list of
Remanufactured Components currently being offered
by Caterpillar for many engine models.
 12
Information Section
Terminology Used in the Maintenance Management Schedules

TOP END Interval
Ore interval for some engines .s abeled TOP END
because it involves removal. inspection. and rework of
the cylinder head components. This interval is
dependent on load-sensitive items/total amount of fuel
consumed.
OVERHAUL Interval
The last interval in each chart lists the components
inspected, rebuilt, exchanged or replaced at overhaul.
OVERHAUL is defined as the interval at which the
major wear items in the engine should be replaced. The
Overhaul interval represents overhaul of a non-failed
engine. In other words, the engine is being rebuilt with
certain new parts replacing WORN parts. The major
wear items include piston rings, engine rod and main
bearings, valves and valve seats.. etc.
• The TOP END and OVERHAUL intervals assume that
regular maintenance recommendations in the rest of
the Chart have been carefully followed.
• Some users may obtain significantly longer or shorter
life than the chart recommends between overhauls,
but if the - ecommended intervals are followed,
OVERI-AuLS will occur BEFORE actual FAILURE, and
the total COST of operation will be MINIMIZED.
Although most users will obtain more life between
overhauls than the chart recommends, Caterpillar has
determined that these limits are the best (least cost) for
the vast majority of our engine users. Extend the
intervals to overhaul only if your experience shows
strong evidence that the intervals are too short for your
situation and maintenance practices.

Incidental to the replacement of these relatively few

parts is the complete inspection of all other parts that
are visible during the overhaul of the engine. The
disassembly required to do an overhaul means that
disturbed seals and gaskets, etc., will be replaced, and
the internal passages of the engine and block be
cleaned.

The most important criteria for TOP END and

OVERHAUL is Fuel Consumption. The hours criteria is
mainly for reference. To obtain a better estimate of
Hours to overhaul, use the following formula:

OVERHAUL Interval (Hours) equals Total Fuel

Consumption divided by 'Actual Average Fuel
Consumption per Hour.

'Use actual fuel records or estimate load factor. Actual

will be less than the specification sheet, because an
engine does not run at 100% load factor 100% of the
time.
1
I
I
I
I
I
I
I
I
a
I
I
I
1
I
I
I
I
1
 16
Information Section
3208 Industrial and EPG Diesel Engines (All Rated rpm's)
3208 Industrial and EPG Diesel Engines (All Rated rpm
's)
Use service hours, time interval or fuel consumption,
whichever occurs first. See the 'information Section"
of this manual for information relating to
OVERHAUL.
Daily
Engine Crankcase - Check oil level
Cooling System - Check coolant level
Water Separator (If Equipped) - Drain
Leaks and Loose Connections - Inspect engine
Air Cleaner Indicator - Check
Clutch - Check/Adjust
Every 100 Hours or Two Weeks
or 1900 L (500 gal) of Fuel'
Clutch Control Lever - Adjust/lubricate two fittings
with MPGM
Pilot Bearing and Flywheel Clutch (Standard) -
Lubricate with MPGM
Flywheel Clutch (Heavy Duty) - Check level
Every 200 Hours or 3 Months or 3800 L
(1000 gal) of Fuel' (NA ONLY)
Scheduled Oil Sampling (S•0•S)** - Obtain
Engine Oil and Filter— - Replace
Fuel Filter - Replace
Primary Fuel Filter - Clean
Cooling System - Replace supplemental coolant
element if equipped or add supplemental coolant
additive (conditioner)
Radiator Fins - Inspect/Clean
Air Cleaner - Clean/Replace element
Batteries - Clean/Check electrolyte level
Hoses and Belts - Inspect/Replace
Valve Lash and Injector Fuel Timing— (At First Oil
Change Only) - Check/Adjust
Every 300 Hours or 3 Months or 5700 L
(1500 gal) of Fuel' (T ONLY)
Scheduled Oil Sampling (S•O•S)•' - Obtain
Engine Oil and Filter— - Replace
Fuel Filter - Replace
Primary Fuel Filter - Clean
Cooling System - Replace supplemental coolant
element if equipped or add supplemental coolant
additive (conditioner)
Radiator Fins - Inspect/Clean
Hoses and Belts - Inspect/Replace
Air Cleaner - Clean/Replace element
Batteries - Clean/Check electrolyte level
Valve Lash and Injector Fuel Timing— (At First Oil
Change Only) - Check/Adjust
Every 1200 Hours or One Year or
22 700 L (6000 gal) of Fuel'
Engine Protective Devices. Engine Mounts,
Turbocharger and Vibration Damper - Inspect/Check
Valve Lash - Check/Adjust
Water Separator Element - Inspect/Replace
PCV Valve - Check/Clean
Flywheel Clutch (Heavy Duty) - Replace oil
Every 2400 Hours or Two Years or
45 500 L (12,000 gal) of Fuel*
Fuel Nozzles - Test
Set Point and Low Idle - Check/Adjust
Fuel Pump/Governor Housing - Drain water
Every 3000 Hours or Two Years or
57 000 L (15,000 gal) of Fuel'
Cooling System - Clean and flush
Thermostat and Coolant Hoses - Replace
Every 3600 Hours or 68 000 L
(18,000 gal) of Fuel*
Air Compressor, Starter, Turbocharger and Water
Pump - Inspect/Rebuild or Exchange
Flywheel Ring Gear, Fan Drive and Belt Tightener
Assembly - Inspect/Check
Every 4000 Hours or 76 000 L
(20,000 gal) of Fuel`
SR 4 Generator Bearing (If Equipped) - Lubricate
with MPGM
OVERHAUL Every 6000 Hours or
114 000 L (30,000 gal) of Fuel'
Alternator, Cylinder Heads, Connecting Rods,
Pistons, Turbocharger, Oil Pump, Oil Pump Relief
Valve, Cam Followers, Fuel Pump and Governor,
Fuel Ratio Control and Timing Advance -
Inspect/Rebuild or Exchange
Piston Rings and Main and Rod Bearings- Replace
Crankshaft, Camshaft, Cam Bearings, Damper and
Cylinder Block - Inspect
Fuel Nozzles - Test
Oil Cooler and Aftercooler Core - Clean/Test
Coolant Analysis - Obtain
'First Perform Previous Service Hour Items
"Refer to the Operation and Maintenance Manual
for the correct oil change interval for your specific
engine.
 17
Maintenanc e Sec tion
al and EPG Die sel Eng ines (All Rated rpm's)
3304 Industri

es (All Rated rpm's)

3304 Industrial and EPG Diesel Engin
consumption, Every 1000 Hours or 22 500 L
Use service hours, time interval or fuel (6000 gal) of Fuel"
rmation Section"
whichever occurs first. See the "Info
ting to Check
of this manual for information rela Engine Protective Devices - Inspect/
with MPGM
OVERHAUL. Woodward Governor - Lubricate
te with MPG M
Tachometer Drive - Lubrica
Daily
Every 2000 Hours or 45 000 L
Engine Crankcase - Check oil level (12,000 gal) of Fuel'
l
Cooling System - Check coolant leve
ck leve l Point and Low
Air Starter Lub rica tor Oil - Che Valve Lash, Fuel Ratio Control, Set
Air Tan k - Dra in wate r Idle - Check/Adjust
ect engine
Leaks and Loose Connections - Insp Fuel Nozzles - Test
ck per and Valve
Air Cleaner Indicato r - Che
M Turbocharger, Engine Mounts, Dam
Clutch Shift Collar - Lubricate with MPG Rotators - Inspect/ Che ck

gal) of Fuel'
Every 50 Hours or 1100 L (300 Every 3000 Hours or Two Years
or
68 220 L (18,000 gal) of Fue l'
Dust Collector - Clean
Cooling System - Clean and flush
gal) of Fuel' Thermostat - Replace
Every 125 Hours or 2800 L (750 Coolant Hoses - Replace
t Bearings -
PTO Main Shaft, Shift Lever and Pilo
Lubricate with MPGM Every 4000 Hours or 90 000 L
Clutch - Check/Adjust (24,000 gal) of Fuel'
and
0 gal) of Fuel" Air Compressor, Water Pump, Starter
Every 250 Hours or 5600 L (150 Turboch arge r - Insp ect/ Reb uild or Exc han ge
(If Equ ippe d) - Lub ricate
SR 4 Generator Bearing
S•O•S Analysis (T Only)"• - Obtain with MPGM
lace
Engine Oil and Filters (T Only)•" - Rep ary filter
/Cle an prim
Fuel Filters - Replace final filter
ck
Fuel Pressure Gauge - Che
l coolant Every 6000 Hours or 135 000 L
Cooling System - Replace supplementa (36,000 gal) of Fuel"
ntal coolant
element if equipped or add suppleme
ge
additive (conditioner) Alternator - Inspect/Rebuild or Exchan
n
Crankcase Breather (T Only)" - Clea
Clea n/Ch eck elec troly te leve l
Batteries - Check or
Radiator Fins, Belts and Hoses - Insp ect/ OVERHAUL Every 10,000 hours
r 227 000 L (60 ,000 gal ) of Fue l'
Fuel Tank - Drain wate
y) (T Only)" -
Valve Lash (At First Oil Change Onl ons, Cylinder
Check/Adjust Cylinder Head, Connecting Rods, Pist
Spa cer Plate, Fuel
Fan Drive - Lubricate with MPGM Liners, Turbocharger, Oil Pump,
rs, Fue l Tran sfer Pump
Ratio Control, Cam Followe
e -Ins pec t/Re build or Exchange
and Timing Advanc
ring s, Valve
Every 500 Hours or 11 250 L Piston Rings, Main Bearings, Rod Bea
- Inst all new
(3000 gal) of Fuel' Rotators and Crankshaft Seals
Governor -
Fuel Nozzles, Fuel Injection Pump and
S-O.S Analysis (NA Only)" - Obtain Test
Replace s, Damper,
Engine Oil and Filters (NA Only)" - Crankshaft, Camshaft, Cam Bearing
nge Onl y) (NA Only)" - Fuel Rack -
Valve Lash (At First Oil Cha Governor, Fuel Pump Camshaft and
Check/ Adjust Inspect
n
Crankcase Breather (NA Only)"• - Clea Oil Cooler and Aftercooler Core - Clea
n/Test
Coolant Analysis - Obt ain
ance Manual
"Refer to the Operation and Mainten
your specific
for the correct oil change interval for 'First Perform Previous Service Hou
r Items
enaine.
18
Information Section
3306 Industrial and EPG Diesel Engines (All Rated rpm's)
3306 Industrial and EPG Diesel Engines (All Rated rpm's)
Use service hours, time interval or fuel consumption,
whichever occurs first. See the "Information Section"
of this manual for information relating to
OVERHAUL.
Daily
Engine Crankcase - Check oil level
Cooling System - Check level
Air Starter Lubricator Oil - Check level
Air Tank - Drain water
Leaks and Lbose Connections - Inspect engine
Air Cleaner Indicator - Check
Clutch Shift Collar - Lubricate with MPGM
Every 50 Hours or 1900 L (500 gal) of Fuel'
Dust Collector - Clean
Every 125 Hours or 4250 L (1100 gal) of Fuel`
PTO Main Shaft, Shift Lever and Pilot Bearings -
Lubricate with MPGM
Clutch - Check/Adjust
Every 250 Hours or 8500 L (2200 gal) of Fuel'
S.O.S Analysis (T Only)" - Obtain
Engine Oil and Filters (T Only)" - Replace
Fuel Filters - Replace final filter/Clean primary filter
Cooling System - Replace supplemental coolant
element if equipped or add supplemental coolant
additive (conditioner)
Crankcase Breather (T Only)" - Clean
Batteries - Clean/Check electrolyte level
Radiator Fins, Belts and Hoses - Inspect/Check
Fuel Tank - Drain water
Valve Lash (At First Oil Change Only) (T Only)" -
Check/Adjust
Fan Drive - Lubricate with MPGM
Every 500 Hours or 17 000 L
(4500 gal) of Fuel'
S-0•S Analysis (NA Only)" - Obtain
Engine Oil and Filters (NA Only)" - Replace
Valve Lash (At First Oil Change Only) (NA Only)" -
Check/ Adjust
Crankcase Breather (NA Only)" - Clean
"Refer to the Operation and Maintenance Manual
for the correct oil change interval for your specific
engine.
Every 1000 Hours or 34 000 L
(9000 gal) of Fuel'
Engine Protective Devices - Inspect/Check
Woodward Governor - Lubricate with MPGM
Tachometer Drive - Lubricate with MPGM
Every 2000 Hours or 67 000 L
(18,000 gal) of Fuel'
Valve Lash, Fuel Ratio Control, Set Point and Low
Idle - Check/Adjust
Fuel Nozzles - Test
Turbocharger, Engine Mounts, Damper and Valve
Rotators - Inspect/Check
Every 3000 Hours or Two Years or
91 000 L (24,000 gal) of Fuel'
Cooling System - Clean and flush
Thermostat - Replace
Coolant Hoses - Replace
Every 4000 Hours or 136 000 L
(36,000 gal) of Fuel'
Air Compressor, Water Pump, Starter and
Turbocharger - Inspect/Rebuild or Exchange
SR 4 Generator Bearing (If Equipped) - Lubricate
with MPGM
Every 6000 Hours or 204 000 L
(54,000 gal) of Fuel'
Alternator - Inspect/Rebuild or Exchange
OVERHAUL Every 10,000 hours or
340 000 L (90,000 gal) of Fuel'
Cylinder Head, Connecting Rods, Pistons, Cylinder
Liners, Turbocharger, Oil Pump, Spacer Plate, Fuel
Ratio Control, Cam Followers, Fuel Transfer Pump
and Timing Advance - Inspect/Rebuild or Exchange
Piston Rings, Main Bearings, Rod Bearings, Valve
Rotators and Crankshaft Seals - Install new
Fuel Nozzles, Fuel Injection Pump and Governor -
Test
Crankshaft, Camshaft, Cam Bearings, Damper,
Governor, Fuel Pump Camshaft and Fuel Rack -
Inspect
Oil Cooler - Clean/Test
Aftercooler Core - Clean/Test
Coolant Analysis - Obtain
'First Perform Previous Service Hour Items
 19
Information Section
3406 Industrial and EPG Diesel Engines (All Rated rpm's)

3406 Industrial and EPG Diesel Engines

(All Rated rpm's)
Use service hours, time interval or fuel consumption, Every 3000 Hours or Two Years
whichever occurs first. See the "Information Section" 114 0000 L (30,000 gal) of Fuel'
of this manual for information relating to
OVERHAUL. Valve Lash, Fuel Ratio Control, Set Point and Low
Idle - Check/Adjust
Turbocharger, Engine Mounts, Damper and Valve
Daily Rotators - Inspect/Check
Cooling System - Clean/Flush
Engine Crankcase - Check oil level Thermostat - Replace
Cooling System - Check level
Air Starter Lubricator Oil - Check level
Air Tank - Drain water Every 5000 Hours or 190 000 L
Leaks and Loose Connections - Inspect Engine (50,000 gal) of Fuel'
Air Cleaner Indicator - Check
Clutch Shift Collar - Lubricate with MPGM Fuel Nozzles - Test or Exchange
Alternator, Air Compressor, Water Pump, Starter
and Turbocharger - Inspect/Rebuild or Exchange
1 Every 125 Hours or 4750 L SR 4 Generator Bearing (If Equipped) - LubriCate
(1250 gal) of Fuel' with MPGM

PTO Main Shaft, Shift Lever and Pilot Bearings -

Lubricate with MPGM OVERHAUL Every 10,000 Hours or
380 000 L (100,000 gal) of Fuel'

Every 250 Hours or 9500 L (2500 gal) of Fuel` Cylinder Head, Connecting Rods, Pistons, Cylinder
Liners, Turbocharger, Oil Pump, Spacer Plate, Fuel
S•O•S Analysis - Obtain Ratio Control, Cam Followers, Fuel Transfer Pump
Engine Oil and Filters - Replace and Timing Advance - Inspect/Rebuild or Exchange
Fuel Filter - Replace final filter/Clean primary filter Piston Rings, Main Bearings, Rod Bearings, Valve
Cooling System - Replace supplemental coolant Rotators and Crankshaft Seals - Install new
element if equipped or add supplemental coolant Fuel Nozzles - Test or Exchange
additive (conditioner) Fuel Injection Pump - Test
Crankcase Breather (Turbocharger Only) - Clean Crankshaft, Camshaft, Cam Bearings, Damper,
Batteries - Clean/Inspect electrolyte level Governor, Fuel Pump Camshaft and Fuel Rack -
Radiator Fins - Inspect/Check Inspect
Clutch - Check/Adjust Oil Cooler - Clean/Test
Belts - Inspect/Check Aftercooler Core - Clean/Test
Hoses - Inspect/Check Coolant Analysis - Obtain
Fuel Tank - Drain water
Valve Lash (At First Oil Change Only) - Check/Adjust •First Perform Previous Service Hour Items
Fan Drive - Lubricate with MPGM
1 Or as shown on lubrication information plate affixed
to the clutch or PTO.
Every 1000 Hours or 38 000 L
(10,000 gal) of Fuel` '

Engine Protective Devices - Inspect/Check

Woodward Governor - Lubricate with MPGM
Tachometer Drive - Lubricate with MPGM
 20
Information Section
3408 Industrial and EPG Diesel Engines (All Rated rpm's)

3408 Industrial and EPG Diesel Engines

(All Rated rpm's)
Use service hours, time interval or fuel consumption, Every 3000 Hours or Two Years
whichever occurs first. See the "Information Section" 153 500 L (40,500 gal) of Fuel'
of this manual for information relating to
OVERHAUL. Valve Lash, Fuel Ratio Control, Set Point and Low
Idle - Check/Adjust
Turbocharger, Engine Mounts, Damper and Valve
Daily Rotators - Inspect/Check
Cooling System - Clean/Flush
Engine Crankcase - Check oil level
Thermostat - Replace
Cooling System - Check level
Air Starter Lubricator Oil - Check level
Air Tank - Drain water Every 5000 Hours or 256 000 L
Leaks and Loose Connections - Inspect Engine (67,500 gal) of Fuel'
Air Cleaner Indicator - Check
Clutch Shift Collar - Lubricate with MPGM Fuel Nozzles - Test or Exchange
Alternator, Air Compressor, Water Pump, Starter
and Turbocharger - Inspect/Rebuild or Exchange .
1 Every 125 Hours or 6500 L
SR 4 Generator Bearing (If Equipped) - Lubricate
(1700 gal) of Fuel'
with MPGM
PTO Main Shaft, Shift Lever and Pilot Bearings -
Lubricate with MPGM OVERHAUL Every 10,000 Hours or
500 000 L (135,000 gal) of Fuel'
Every 250 Hours or 13 000 L
Cylinder Head, Connecting Rods, Pistons, Cylinder
(3400 gal) of Fuel*
Liners, Turbocharger, Oil Pump, Spacer Plates, Fuel
Ratio Control, Cam Followers, Fuel Transfer Pump
S•O•S Analysis - Obtain
and Timing Advance - Inspect/Rebuild or Exchange
Engine Oil and Filters - Replace
Piston Rings, Main Bearings, Rod Bearings, Valve
Fuel Filter - Replace final filter/Clean primary filter
Rotators, and Crankshaft Seals - Install new
Cooling System - Replace supplemental coolant
Fuel Nozzles - Test
element if equipped or add supplemental coolant
Fuel Injection Pump - Test
additive (conditioner)
Crankshaft, Camshaft, Cam Bearings, Damper,
Crankcase Breather - Clean
Clutch - Check/Adjust Governor, Fuel Pump Camshaft and Fuel Racks -
Inspect
Batteries - Clean/Check electrolyte level
Oil Cooler - Clean/Test
Radiator Fins - Inspect/Check
Aftercooler Core - Clean/Test
Belts - Inspect/Check
Coolant Analysis - Obtain
Hoses - Inspect/Check
Fuel Tank - Drain water
*First Perform Previous Service Hour Items
Valve Lash (At First Oil Change Only) - Check/Adjust
Fan Drive - Lubricate with MPGM 1 Or as shown on lubrication information plate affixed
to the clutch or PTO.
Every 1000 Hours or 51 0001
(13,500 gal) of Fuel'

Engine Protective Devices - Inspect/Check

Woodward Governor - Lubricate with MPGM
Tachometer Drive - Lubricate with MPGM
 21
Informa tion Sect ion
stria l and EPG Dies el Engines (All Rated rpm's)
3412 Indu

es
3412 Industrial and EPG Diesel Engin
(All Rated rpm's)
consumption, Every 3000 Hours or Two Years
Use service hours, time interval or fuel 227 500 L (60,000 gal) of Fuel'
first. See the "Inf orma tion Section"
whichever occurs
infor mati on relat ing to t and Low
of this man ual for Valve Lash, Fuel Ratio Control, Set Poin
OVERHAUL. Idle - Check/Adjust
and Valve
Turbocharger, Engine Mounts, Damper
Rotators - Inspect/Check
Daily Cooling System - Clean/Flush
Thermostat - Replace
Engine Crankcase - Check oil level
Cooling System - Check level
Air Starter Lubricator Oil - Check level Every 5000 Hours or 379 000 L
Air Tank - Drain water (100,000 gal) of Fuel'
Engine
Leaks and Loose Connections - Inspect
- Chec k
Air Cleaner Indicator Fuel Nozzles - Test or Exchange
MPGM
Clutch Shift Collar - Lubricate with Alternator, Air Compressor, Water Pum
p, Starter
ect/R ebuil d or Exch ange
and Turbocharger - Insp
Bear ing (If Equi pped ) - Lubr icate
SR 4 Generator
1 Every 125 Hours or 9500 L
• with MPGM
(250 0 gal) of Fuel'
Bearings -
PTO Main Shaft, Shift Lever and Pilot OVERHAUL Every 10,000 Hours or
Lubricate with MPGM 758 000 L (200,000 gal) of Fuel`
ns, Cylinder
Cylinder Head, Connecting Rods, Pisto
Every 250 Hours or 19 000 L Liners, Turbocha rger , Oil Pum p, Spac er Plates, Fuel
(5000 gal) of Fuel` rol, Cam Follo wers , Fuel Tran sfer Pump
Ratio Cont
build or Exchange
and Timing Advance - Inspect/Re
S-0•S Analysis - Obtain Rod Bear ings, Valve
Piston Rings, Main Bearings,
Engine Oil and Filters - Replace ksha ft Seal s - Insta ll new
n primary filter Rotators, and Cran
Fuel Filter - Replace final filter/Clea
leme ntal coolant Fuel Nozzles - Test
Cooling System - Replace supp Fuel Injection Pump - Test
equipped or add supp leme ntal coolant
element if Crankshaft, Camshaft, Cam Bearings,
Damper,
additive (conditioner) Governor , Fuel Pum p Cam shaft and Fuel Racks -
Clutch - Check/Adjust Inspect
Crankcase Breather - Clean Oil Cooler - Clean/Test
e level
Batteries - Clean/Check electrolyt Aftercooler Core - Clean/Test
Radiator Fins - Inspect/Check Coolant Analysis - Obtain
Belts - Inspect/Check
Hoses - Inspect/Check `First Perform Previous Service Hour Item
s
Fuel Tank - Drain water
- Check/Adjust
Valve Lash (At First Oil Change Only) ' Or as shown on lubrication information plate
affixed
Fan Drive - Lubricate with MPG M
to the clutch or PTO.

Every 1000 Hours or 76 000 L

(20,000 gal) of Fuel'
heck
Engine Protective Devices - Inspect/C
icate with MPG M
Woodward Governor - Lubr
e - Lubr icate with MPG M
Tachometer Driv
22
Information Section
3412 Industrial and EPG Diesel Engines Extreme Service1
3412 Industrial and EPG Diesel Engines
Extreme Service1
Use service hours, time interval or fuel consumption,
whichever occurs first. See the "Information Section"
of this manual for information relating to
OVERHAUL.
Use service hours or fuel consumption, whichever
occurs first. Experience has shown that
maintenance intervals are most accurately
scheduled on the basis of fuel consumed. Rated
engine speed and load factor are also important for
some components.
Daily
Walk-Around Inspection - Check for leaks and loose
connections and air intake system
Air Starter - Maintain motor oiler
Engine Crankcase - Check oil level
Cooling System - Check coolant level
Every 125 Service Hours or 18 950 L
(5000 gal) of Fuel'
Scheduled Oil Sampling (S•O•S) Analysis'• - Obtain
sample
Engine Oil and Filter(s)•• - Change oil & filter(s)
Crankcase Breathers - Clean
Hoses and Clamps - Inspect/Replace if necessary
Belts - Inspect/Adjust
Fuel Tank - Drain Water
Fuel Filters - Replace final filter, Clean primary filter
Valve Lash (At First Oil Change Only)" -
Check/Adjust
Every 250 Service Hours or 37 900 L
(10,000 gal) of Fuel'
Cooling System - Add supplemental coolant additive
(conditioner) or replace supplemental coolant
conditioner element (if equipped)
Every 1000 Service Hours or 151 600 L
(40,000 gal) of Fuel`
Engine Mounts - Inspect
Viscous Dampers - Inspect
Valve Lash - Check/Adjust
Valve Rotators - Check
Engine Protection Devices - Check for proper
operation
Fuel Injection Nozzles - Test or Exchange
Turbochargers - Rebuild or Exchange
Water Pump - Rebuild or Exchange
Every 2250 Service Hours or 341 100 L
(90,000 gal) of Fuel'
Connecting Rod Bearings - Replace
Every 3000 Service Hours or Two Years or
454 800 L (120,000 gal) of Fuel'
Cooling System - Clean/Flush
Thermostats - Replace
OVERHAUL Every 4500 Service Hours or
682 200 L (180,000 gal) of Fuel`
Cylinder Head, Connecting Rods, Pistons, Cylinder
Liners, Turbocharger, Oil Pump, Spacer Plates, Fuel
Ratio Control, Cam Followers, Fuel Transfer Pump
and Timing Advance - Inspect/Rebuild or Exchange
Piston Rings, Main Bearings, Rod Bearings, Valve
Rotators, and Crankshaft Seals - Install new
Fuel Nozzles - Test
Fuel Injection Pump - Test
Crankshaft, Camshaft, Cam Bearings, Damper,
Governor, Fuel Pump Camshaft and Fuel Racks -
Inspect
Oil Cooler - Clean/Test
Aftercooler Core - Clean/Test
Coolant Analysis - Obtain
• First. Perform Previous Service Hour Items
• The oil change interval is based on fuel
consumption. The sump capacity of 68 liters (72 U.S.
quarts) will allow the maximum consumption of 18 950
liters (5000 gallons) of fuel by the engine. This would
be an average fuel consumption of 151 L/hr (40 gal/hr).
Therefore, use fuel consumption as the best indicator
of oil change interval.
Confirm the recommended interval with Scheduled Oil
Analysis (S•O•S) at your local Caterpillar dealer.
1 The following operating conditions are examples of
Extreme Service:
• Extended operation at or above 2100 rpm
• Extended operation at high load factor; 90 L (24 gal)
per hour or more
• Marginal lubrication operation; excessive cold starts,
etc.
• Excessive metal debris in oil filter
• Excessive lubrication oil sooting
• Oil Well Servicing (9XF1-UP)
 CATERPILLAR

CIAL, INVRUCTION

• RECOMMENDATIONS FOR COLD WEATHER STARTING OF ENGINES EQUIPPED

TO OPERATE AIR COMPRESSORS AND DRILLS 1000
1450

Air compressor and drill engines with connected driven loads are difficult to start in cold weather.
Starting of the engine is even more difficult in high altitudes.

The following recommendations are given in the order of their importance.

• AUXILIARY HEATING AIDS

For cold weather operation of Diesel Engines, auxiliary heating equipment is necessary. Know the type
of application, expected low temperature, and make plans for auxiliary heaters before cold weather has
started. To help find the level of auxiliary heaters needed, use the information below as a guide.

Different starting temperatures need different levels of engine preparation before starting. This
guide is given for an engine that has been given correct regular maintenance. Given below are five
temperature levels

• Level (1) +50°F to +32°F (+10°C to 0°C)

• Level (2) +32°F to +10°F (0°C to -12°C)

• Level (3) +10°F to -15°F (-12°C to -25°C)

• Level (4) -16°F to -40°F (-26°C to -40°C)

• Level (5) below -40°F (-40°C)

PRINTED IN U.S.A.
CATERPILLAR FUNDAMENTAL ENGLISH
FORM SEHS7659
 •The following procedures of engine preparation for starting, are the recommendations at the five
temperature levels.
LEVE

(1)
+50°F to +32°F
a) Use of glow plugs on precombustion chamber engines.
(+10°C to 0°C)

(2)
b) Use of glow plugs and/or starting fluid needed. Coolant heater plus out- +32°F to +10°F
side power supply or heated batteries may be necessary if the driven (0°C to -12°C)
}
load on the engine is heavy during startup.

c) Normal practical procedure is to run the engine at idle speed instead of (3)
shut down at temperatures below -15°F (-26°C). Glow plugs and/or starting +10°F to -15°F
fluid, preheating of coolant, and outside power supply for batteries with (-12°C to -25°C)
permanent leads and/or heaters are needed. }

d) Run the engine at idle speed or keep it in a heated area, because starting
cannot be sure at these temperatures. If this recommendation is not fol-
lowed, preheating of the coolant and oil for from 4 to 8 hours will be
necessary to give a water outlet, battery cell and oil temperature of no
less than 0°F (-18°C) before starting. A heated battery compartment or an
outside power supply will be needed. If enough preheat is used, very lit- (4) and (5)
tle or no ether will be needed. Even if the engine starts because the -16°F to -40°F
coolant and oil are preheated, it must be remembered that the other com- (-26°C to -40°C)
partments are cold and have fluids which permit pumping at starting tem- below -40°F (-50°C)
peratures. Operate the unit for one hour before starting normal operation.
This procedure is acceptable if engine and the battery compartment are
closed and heated. On a unit without such protection, the wind can make
the unit cold faster than the heater can make it warm. When canvas covers
are used, do not install them near exhaust systems. Keep the starting
fluid at room temperature.

"'FUEL HEATERS
a) Waxing of fuel and freezing water are the most common causes of difficult starting. A change of
fuel filters and thoroughly priming the system can correct the waxing problem. Make sure water is
kept out of the fuel; this is important. Fuel heaters can also be used.

Suppliers of fuel heaters are: (See page 8 for complete addresses)

411J/McQ Fuel Heater - Water Separator
•Phillips Temro, Inc.
•Webb Enterprises, Inc.
•South Wind Division of. Stewart Warner Corporation

2
 • TYPES OF AUXILIARY HEATING AIDS

• ELECTRIC

If 110 or 220 volt (50 or 60 Hz) current is available, electric heaters can be used. There are two
types of electric water heaters for engines:

!Immersion Water Heaters

a) The in-block immersion water heaters are available from Caterpillar dealer parts departments. They
are made to keep an engine warm after it has been shut down. Normal procedure is to put the unit
near an electrical power supply to keep the engine warm until it is started again. These heaters
are not made to heat a cold engine. They are installed in the cylinder block core plugs or oil cool-
er connections.

I
b) The chart below gives engine displacement, weight, thermostat opening temperature and water volume
that should be sent to suppliers when heaters are ordered.

DRY ENGINE ENGINE WATER IN

WEIGHT DISPLACEMENT TEMPERATURE THERMOSTATS JACKET
MODEL lbs. (KG) IN (LITER) START TO OPEN ° F (°C) QUART (LITER)

3412 4,620 lbs. (2,005) 1,649 in 3 (27) 175°F (79°C) 60 qts. (227)

3408 1,099 in 3 (18) 175°F (79°C) 44 qts. (166)

3,365 lbs. (1,515)

3406 2,960 lbs. (1,345) 893 in 3 (14.6) 175°F (79°C) 34 qts. (128)

3306 2,160 lbs. (980) 638 in 3 (10.5) 175°F (79° C) 21 qts. (79)

3304 1,655 lbs. (750) 425 in 3 (6.9) 175°F (79°C) 18 qts. (68)

3208 1,350 lbs. (615) 636 in 3 (10.4) 175°F (79°C) 25 qts. (94)

3
 •Available heaters from Caterpillar dealers are:
Wattage at 120 volt

3208 Engine (see Special Instruction Form SEHS7299)

9N5753 Heater Group - Jacket Water
750
7N7957 Element Assembly - Jacket Water Heater
(part of 9N5753 Heater Group)

3300 Series Engines

4N3586 Heater Group - Jacket Water
2P8841 Element Assembly - Jacket Water Heater 1,500
(part of 4N3586 Heater Group)

3406 Engine
4N730 Heater Group - Jacket Water
4N4334 Element Assembly - Jacket Water Heater 1,500
(part of 4N730 Heater Group)

3408 and 3412 Engines

7N37 Heater Group - Jacket Water
2-4N4337 Element Assemblies - Jacket Water Heater 3,000
(part of 7N37 Heater Group)
7N210 Adapter - Jacket Water Heater
(part of 7N37 Heater Group)

b) Other suppliers of immersion heaters are: (see page 8 for complete addresses)
• Phillips Temro Inc.
• Kim Hotstart Manufacturing Co.

4
•The pictures below give the element installation location for in-block immersion water heaters.

a) Right side location for 3208 Engine. b) Left side location for 3208 Engine.

NOTE: Do not damage the bore when the core plug is removed.

c) Element location for 3300 Series Engine. d) Element location for 3406 Engine.

e) Right side location for 3408 and 3412 Engines. f) Left side location for 3408 and 3412 Engines.

NOTE: Remove the cover and install a

7N210 Adapter.

5
OTANKWATER HEATERS

a) Tank water heaters use a location outside the engine and need electrical power. The differenc
e in
temperature moves the water from the tank and through the engine. Thermosta
ts control water temper-
ature. Always install the heater so that cold water comes in at the bottom
of the heater.

b) These heaters can be added to the engines; see your Caterpillar dealer for details.
Other suppliers
of tank heaters are: (see page 8 for complete addresses)
•Kim Hotstart Manufacturing Co.
•Phillips Temro, Inc.

•NON-ELECTRIC HEATERS

a) When electricity is not available from an outside power supply or auxiliary

generators, water heaters
that burn diesel fuel, gasoline, propane, etc., can be used. Use the engine
specification chart on
page 4 to give similar capacity information in a letter to the following
suppliers: (see page 8 for
complete addresses)
•Phillips Temro, Inc.
•South Wind Division of Stewart Warner Corporation
41Webasto North American._

6
 ONINc) PROTECTION
a) Remember that the effect of wind chill (cold) factor is importan
t to maintenance of a minimum
operating temperature and to hold the heat from jacket water heaters.
Keep engine coolant tempera-
ture above 170°F )77°C) during operation and keep oil sump temperat
ure above 200°F (93°C).
b) Flexible covers can be used to completely cover the radiator, for
protection of radiator coolant in
engines not in operation, and can also be used over part of the radiator
during engine operation, to
keep the coolant at the necessary minimum temperature.

• BATTERY HEATERS

a) Battery heaters can increase cool cranking amperage. If battery heaters

are used, make an enclosure
from styrofoam or other insulation to keep in the heat. CAUTION: Battery
gases must be ventilated
(let out) through the enclosure. Suppliers of battery heaters are:
(see page 8 for complete ad-
dresses)
•Kim Hotstart Manufacturing Co.
•Phillips Temro, Inc.

• OIL HEATERS

a) The use of immersion oil heaters is not a Caterpillar recommendation. Use of

multi-viscosity or
synthetic oil is our recommendation.

7
 •Below is a list of some suppliers of heaters and other cold weather starting aids.
41J/McQ Fuel Heaters •Sinus B.V.
1212 Classen Drive P.O. Box 192
Oklahoma City, OK USA 73118 Van Reenenivey 63
(405) 528-1434 Zirst - The Netherlands
Telephone: 0304-20504
•Kim Hotstart Manufacturing Co. Telex: 47218
West 917 Broadway
Box 42 •South Wind Division
Spokane, WA USA 99210 Stewart Warner Corporation
(509) 534-6171 1514 Drover Street
Indianapoliis, IN USA 46221
•Motor-Mate Sales Division (317) 632-8411
Hay-May TWX: 810-341-3319
Box 128 Telex: 27389
Bendena, KS USA 66008 Cable: Southwind Indianapolis Indiana
(913) 988-4417
•Webasto North American
•Phillips Temro, Inc. (Zero Start) 71 Part Street
8200 Grand Avenue South Troy, MI USA 48084
Minneapolis, MN USA 55420 (313) 585-5880
(612) 888-4105
•Webb Enterprises, Inc.
2605 S. Rivershore Drive
Moorhead, MN USA 56560
(701) 232-8946

"'OPERATING CONTROLS

a) Check the engine and drill controls on the operator's panel to make sure that full travel is
possible and that the controls are correctly engaged. Read and understand the machine Operation
Guide for correct starting instructions and procedures.

b) Some hydraulic pumps can be destroked (put the pump in a neutral or by-pass condition). Also, it
is the recommendation of some OEM's that pumps be destroked at shutdown to remove the oil from
pump sections which would not normally drain.

c) Put the start-run switches on the air compressor in the start position to decrease compression
resistance.

d) To decrease driven loads on equipment when starting the engine, use all available adjustments or
unloading valves.

e) Make sure that low pressure and high temperature shut-down equipment operates correctly and can be
by-passed for start-up.

8
"'STARTING AIDS

a) Starting aids are needed in cold weather for both precombustion chamber and direct injection type
Caterpillar engines.

PRECOMBUSTION CHAMBER ENGINES

b) Glow plugs are necessary when the engine is started at less than 60°F (15°C). If the temperature is
below +10°F (-12°C), ether starting aids can also be used.

• DIRECT INJECTION ENGINES

c) If the temperature is less than 60°F (15°C), ether starting aids must be used to help start the
engine.

d) Ether Starting Aid Kits must be compatible (work together correctly) with your engine. For details
of nozzle location, amount of ether and nozzle size see your Caterpillar Dealer, OEM Dealer or
Caterpillar Tractor Co.

e) Glow plugs are not available on direct injection type engines.

• BASICMAINtENANCE

The need for basic maintenance becomes more important as ambient temperatures decrease or at higher
altitudes.

A) FUEL
1. Check a fuel sample for waxing or cloudiness.
2. Drain the water from the fuel tank and water separators every day after shutdown.
3. Make sure fuel pressure is at minimum cranking pressure [replacement of plugged (full of
restriction) fuel filters is necessary].
4. Prime the fuel system after the water is drained from the fuel tanks and water separators.
5. Make sure that all fuel line connections are tight on the suction line; this will keep air
out of the fuel system.

B) OIL
1 Use the correct viscosity oil in the engine and driven equipment for the lowest expected
ambient temperature.

C) ELECTRIC
1. Check for loose battery and starter connections.
2. Keep the batteries in good condition.

D) INTAKE AND EXHAUST

1 . Snow and ice can cause a restriction in the engine inlet, exhaust and breather; check to
make sure these are not plugged.

9
CATERPILLAR' SEBU5898-05
July 1990

[iniR HEM
ERRild
Cold Weather Recommendations

For Caterpillar Machines

 1
Information Section
Table of Contents

Table of Contents

Information Section

Introaucticr

Cold Weatner Hints

3

Operation Section

Starting Recommendations
5
Operation Recommendations
9
Parking Recommendations
11

Maintenance Section

Cool - -I System r:.,,ecifications

12
Fuel Specifications
16
Lubrication Recommendations
21
Lubricant Viscosities
.... 23
Battery Recommendations
24
Tire Inflation Information
25

Index Section

no•ex
26
 2
Information Section
Introduction

Introduction

The information ,n this manual is an aid to the

operation and maintenance of Caterpillar built
machines operating .n temperatures from 0°C to —55°C
i32°F to —67°F)

NOTE. When operating in temperatures above 0°C

(32°F), refer to the particular product Operation &
Maintenance Manual.

This manual is a supplement to the information

furnished with the machine and the recommendations
from your Caterpilia' dealer. Use the Lubricant
Viscosities chart a :n aid to determine proper SAE
viscosity oil to use. Remember that this chart reflects
the useful temperature range of the oil indicated.
Temperature range is used since there is considerable
variation in daily cold weather temperatures.

The operation and maintenance of a machine in

freezing temperatures is difficult to outline in a general
publication. This is due to the vast differences in
weather conditions, application and the supplies
available in your area. These varying factors,
recommendations from your Caterpillar dealer and past
proven practices should be combined with the
information in this manual to provide the best
guidelines possible.
 3
Information Section
Cold Weather Hints

Cold Weather Hints

NOTICE Check the air cleaners and the air intak

Fluids contained in new machines perm e daily or as
it operation to necessary. when working in snow.
the temperature limits given in the follo
wing chart. If a
new machine is shipped to an area Keep all starting fluid at room temperatu
with the outside re. Inject it only
temperatures below these limits all when the engine is cranking.
fluids must be
changed. If fluids are not changed, the engine
should not oe started, unless the Steering response on equipment with
fluids are pre- hydraulic steering
warmed. may become very slow at very low temp
eratures. This
can happen even if the correct oils are
used.
If the engine is started. without the engi
ne actually
TEMPERATURE LIMITS FOR operating iintil full warm-up is achieved,
FACTORY FILL OIL FOR COLD WEATHER run the engine
until it reacnes operating temperature. This
will help
Compartment 'C °F
Prevent valve sticking.
Oil
or System Viscosities Min Max Min Max Air Compressors. Use alcohol
Engine SAE 10W-30 -20 . +40 injectior :0 prevent
-4 .1 22 moisture from freezing in the air system.
Hydraulic SAE 10W -20 +40 -4 +122
Transmission SAE 30 0 -35 +32 , +95
ansmission SAE 10W
iz,nai Drives SAE 50
-20
0 +50
0 -4
+32
+50
+122
A WARNING
Do not store alcohol in the operator's
compartment.
Prepare the machine by using heaters. Alcohol is highly flammable and toxic
compartment .
enclosures and storage facilities as requ
ired for the
climatic conditions anticipated.
The cooling system and the lubrication
Install the correct lubricant in each com system of the
partment before engine do not lose their heat immediate
the beginning of cold weather. ly upon shut-
down. The transmission and the hydraulic
system lose
heat more rapidly becau'se of more expo
Provide cooling system protection for the sed areas.
lowest Gear cases cool off rapidly. since they
expected outside temperature. do not operate
as warm as other compartments.
Premix •he antifreeze solution for the cooli This means an engine can be shut down
ng system. for a few
The frieze protection of the solution shou hours and still start readily. The other syste
ld equal or ms
exceed the system protection requirem however, have lost heat more rapidly, so
ents. it is necessary
to exercise the equipment upon starting.
Check all rubber parts (hoses, tie s. fan belts If it is shut
) weekly. down for 16 hours or more, it should be
considered
cooled to outside temperature.
Check ail electrical wiring and connectio
ns for any
frays or damaged insulation.

To assist in warm-up. block the rad►ator to restr

ict fan
air.

Keep ail batteries fully charged and warm

.
Fill the foci tank at the end of each shift.
4
Information Section
Cold Weather Hints
SAE lOW lubricants may be used successfully, when
operating at outside temperatures below the pour point
of the oil. by iea,..ing the engine running at idle. This
helps keep lubricants and compartments warm. This
apples to transmission and engine compartments.
However , t will not keer --/draulic systems warm.
The outer wrapper on hydraulic hoses can crack when
they flex in cold temperatures. This does not mean they
have failed. They will still carry oil under pressure.
Condition the hydraulic hoses on the equipment before
the temperqtures go below —40°C (-40°F).
To condition hoses on the machine: Operate at 66°C
(150°F) hydraulic oil temperature for at least 1 hour.
Use an oil that has a pour point of —54°C (-65°F),
before exposing the hoses to temperatures below
—40°C (-40°F).
Conditioning usual.. 3 accomplished during normal
operation, if Arctic fluids have been put in the system
before cold weather begins.
Condition new replacement hose if installation is
required at ambient temperatures below -40°C (-40°F)
To condition replacement hose before installation. fill
hose assembly (with couplings attached) with kerosene
or winter grade diesel fuel for a minimum of 8 hours at
22°C (72°F). Hose assemblies should be installed
within 30 days once conditioned
Check to be sure that the voltage of electric heaters on
the machine will work with the local power source.
Do not get the cab too warm. It is best to keep it under
0°C (+32°F) to prevent perspiring. If the engine stops.
and the operator is perspiring, it will lessen his chances
for survival.
Correct track tension is especially important during
cold weather operation in snow. Refer to the Operation
& Maintenance Manual for the machine. for adjustment
procedures.
For jump starting with cables in cold weather. refer to
the machine Operation & Maintenance Manual for jump
starting.
 5
Operation Section
Starting Recommendations

Starting Recommendations

before Starting
NOTICE
not remove the air cleaner element when snow
packing occurs. This could cause severe engine dam-
age. Instead, rework the air intake so air is taken in
under the hood.
Do not use a torch to heat a compartment. This causes
fires, burns wiring, gaskets and seals, or melts the
battery case.
When using canvas covers, do not install them near
exhaust systems. This helps prevent fires.
The fluids in all compartments must nave a pour point
below the outside starting temperature
CATEGORY 1 0°C to -12°C ,:+32°F to +10°F)
The use of glow plugs on eectric start engines. .f
equipped. is required !Normally a Cateroi!iar direct
injection diesel engine will not require any starting alas
in this temperature range.;
NOTE. Leave the ether start switch in the AUTOMATIC
position machines equipped with Caterpillar 3500
series en.. es ana an automatic ether start system.
Ether \will ce iniected automatically whenever the ,acket
water s oe!ow 13:0 ;55°F)

Check the air cleaner daily before starting. When
operating in snow. attach a burlap sack to the
precleaner. loose enough to flop around and clean
itself. See that it does not get near any heated parts.
such as exhaust piping. or moving parts.
Keep starting fluid at room temperature.
To assist in warm-up. block the radiator to restrict fan
air. Coolant and block heaters. tents. additional
batteries. etc . may be required.
Before getting into the operator's station. inspect the
condition of all hydraulic hose. tires and fan belts for
cuts. cracks and worn spots. Check all electrical wiring
and connections for any frays or damaged insulation.
Machines equipped with Caterpillar 3500 series
engines. but not equipped with an ether starting
system. should use an alternate system such as a
jacket water heater
CATEGORY 2: -12°C to -26°C (+10°F to -15°F)
The use of glow plugs and coolant heaters Is required
(starting fluid may be required) on electric start
engines. An external starting power source will be
required if the battery is not fully charged. The use of
glow plugs or starting fluid is required for engines
equipped with a gasoline starting engine. Operate
equipment for 15 minutes. with no load, before starting
normal operation.
CATEGORY 3: -26°C to -40°C (-15°F to -40°F)

Gasoline Start Fuel System Idle the engine rather than shutting it off when the
outside temperatures are under -23°C (-20°F)
Check the aasoline tank sediment bowl for mois _,re or
Starting fluid, glow plugs (if equipped) and preheating
dirt every 50 service hours.
of coolant are required.

An external power source or a heated battery

Starting Considerations
compartment will be required if the battery is not fully
Cold Weather Categories charged. Where an external power source is used.
provide permanent jumper cables to prevent arcing at
Temperature the battery terminals. Operate equipment for 30
Category Range minutes, with no load, before starting normal operation
CATEGORY 1 0°C to -12°C
(+32°F to +10°F) CATEGORY 4: Below -40°C (-40°F)

CATEGORY 2 - 12°C to -26°C It is necessary that the engine be idled. or kept in a

(+10°F to -15°F) heated area. since starting cannot be assured at these
- 26°C to -40°C temperatures. If this is not done. preheat the coolant
CATEGORY 3
(-15°F to -40°F) and oil for 4 to 8 hours to provide a water outlet
temperature, a battery cell temperature and an oil
Below -40°C
CATEGORY 4 temperature of at least -18°C (0°F; before trying to
(-40°F)
start. A heated battery compartment or an external
power source will be required
6
Operation Section
Starting Recommendations
If enough preneat.-.g is used, very little or no ether will
be needed. Even though the engine may start, all other
compartments are cold and must have fluids which can
be pumped at starting temperature. Otherwise. the
machine must be tented or heated.
Operate the equipment for one hour. with no load,
before starting normal operation.
This applies if the engine and battery compartment are
closed and heated. On an unprotected machine, the
wind can chill it faster than the heater can heat it.
Starting the Engine
A WARNING
Ether is poisonous and flammable.
Breathing ether vapors or repeated contact of ether
with skin can cause personal injury.
Use ether only in well ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living
reas or in the operator's compartment.
Do not store ether cylinders in direct sunlight or at
temperatures above 39°C (102°F).
Discard cylinders in a safe place. Do not puncture or
burn cylinders.
Keep ether cylinders out of the reach of unauthor-
ized personnel.
To avoid possible personal injury, be sure the
brakes are applied and all controls are in HOLD or
NEUTRAL.
Jumper Start Cables
Use a Jumper cable with a type of connector that will
mate with the receptacle .
The 8S2632 plug assembly is 10 feet long and has
connectors for a receptacle on the machine and spade
terminals for a battery cart on the other end.
The 9S3664 plug assembly is 15 feet long and has
machine receptacle connectors on both ends. This
assembly permits starting a machine with a Jump from
another machine, ..:nen both have starting receptacles.
Contact your Caterpillar dealer for the appropriate
Jumper cables.
NOTE: For machines not equipped with a starting
receptacle. refer to the Operation & Maintenance
Manual for your individual machine. for jump starting
instructions.
Diesel Engines Equipped With Gasoline
Starting Engines
1. '''ace the compression release lever in START
2. Move the governor control to the shut-o'' pcs
3. Start cranking the diesel engine with the starting
engine transmission in LOW.
4. After the diesel engine turns freely. disengage the
starting engine clutch. Shift the starting engine
transmission to HIGH. Then engage the starting engine
clutch. Crank the diesel engine several minutes to.
warm the engine, and bring the oil pressure and the
diesel fuel pressure to NORMAL on the gauges.
5. Move the compression release giver to RUN. Move
the diesel engine governor control iever to the high idle
position.
NOTICE
Start the diesel engine with the starting engine trans-
mission in HIGH only.
6. After the diesel engine starts, reduce its' speed.
Disengage the starting engine clutch. Turn the fuel to
the starting engine off. Continue to run the starting
engine until its carburetor bowl is dry.
Starting Aids
Diesel Engines Equipped With Gasoline
Starting Engines and Glow Plugs
1. Place the compression release lever in START
2. Move the governor control to the shut-off position.
3. Start cranking the diesel engine with the starting
engine transmission in LOW.

4. hen tne engine ,s turning. disengage the
starting clutch St-Lft the starting engine transmission to
HIGH Then engage the starting engine clutch. Crank
the desei engine se\,erai 'es to warm t. and bring
the oli pressure and the dies uel pressure to
NORMAL on the gauges
5. Disengage the starting engine clutch. but keep -le
starting engine •
6. Turn the glow plug heat switch to the HEAT
position for 2 to 5 minutes but do not crank tile diesel
engine.
7. Move the compression release lever to RUN. and
engage the starting engine clutch again .
8. With the heat switch ON, allow the starting engine
to turn the diesel engine until normal cranking speed is
obtained.
NOTICE
Start the diesel engine with the starting erigine trans-
mission in HIGH only.
9. While cranking the engine with the heat switch ON.
move the governor control lever to the high idle
position.
10. Hold the heat switch on until the diesel engine
starts and runs smoothly. Reduce the engine speed
after it starts.
NOTICE
Do not turn the heat-start switch to HEAT if the engine
is warm and running. Engine damage could result.
11. Disengage the starting engine clutch. Turn the
fuel to the starting engine off. Continue to run the
starting engine until its carburetor bowl is dry.
7
Operation Section
Starting Recommendations
Diesel Engines Equipped with (Manual Only)
Metered Ether Injection System
At temperatures above 0°C (32°F t fs normally not
necessary to use ether At temperatures between 0°C
(32°F) and -18°C (0°F), it will take 1 to 6 injections of
ether. depending upon the engine type and cranking
speed.
When starting below - 1 8°C i0°F) use a fresh
container of ether starting fluid to make sure there is
er lelivery pressure
NOTICE
Inject ether starting fluid only while cranking.
At temp., -es below -18°C (0°F). it will take 3 to 6
injections .:they to get the engine to start. After the
engine starts. and cranking is stopped. continue to
inject ether until the engine runs smoothly and/or the
white exhaust smoke stops. This may take 10 to 12
injections of ether.
Diesel Engines Equipped with Automatic
Metered Ether Injection System
Start the engine with the ether starting aid switch in the
AUTOMATIC position.
Once the engine has started, move the ether starting
aid switch to the MANUAL position and hold it there
until the engine runs smoothly and/or the white exhaust
smoke stops.
NOTE: Ether will not be injected regardless of the
switch position if the jacket water temperature is 13°C
(55°F) or above.
Allow the engine to warm up at low idle for a minimum
of five minutes before operating the machine.
8
Operation Section
Starting Recommendations

Diesel Engines Equipped With Glow Plugs

Starting Aid Ci)art

Starting Glow Plug
Temperature Heat Time
Above 16°C (60°F) None
16°C to 0°C
1 Minute
(60°F to 32°F)
0°C to -18°C
2 Minutes
(32°F to 0°F)
Below -18°C (0°F) 3 Minutes

1. Move the governor to full throttle position.

2. Turn the heat-start switch to HEAT position for the

time indicated in the chart.

3. Turn the heat-start switch to START position and

spray starting fluid into air intake, if required, while
cranking only.

NOTICE
Never operate electric starter for more than 20
seconds at a time without allowing 2 minutes for cool-
ing before using it again.
Do not turn the heat-start switch to the HEAT or the
START position with the engine warm and running.
Engine damage could result.
Use ether sparingly, spray ether into the air intake for
Dproximately 1 second. Then wait approximately 2
seconds before spraying again. Spray only while
cranking the engine. Follow instructions on the con-
tainer carefully.

4. When the engine starts, return the governor to the

low idle position. Run the engine at a speed at which it
runs smoothly. Return the heat-start switch to HEAT
until the engine runs smoothly.

When the engine is stopped, turn the disconnect

switch off to prevent battery discharge.

Operation Recommendations
After Starting
If a machine has been parked long enough for some of
the systems to cool much below normal operating
temperatures. the systems should be warmed up
before returning the equipment to full operation.
Damage to engine valve components during operation
in very cold temperature conditions can result from
engine operation for short intervals. This can happen if
the engine is started and stopped many times but
does not run long enough to become completely warm.
During the interval of time that the engine operates at
temperatures below normal, fuel and oil are not
completely burned in the combustion chambers. This
fuel and oil causes soft carbon deposits on tr,e valve
stems. Generally, these deposits do not cause
problems because they are bined off during operation
at normal engine temperatures.
When the engine is started and stopped at short
intervals, and the engine temperature is never up to
normal. the carbon deposits become thicker until they
prevent free operation of the valves. This can cause
burnt valves. bent push rods. or other damage to valve
components.
For this reason, any time the engine is started, the
recommendation is to run the engine until the coolant
temperature is 66°C (150°F) or higher. This will keep
carbon deposits on the valve stems at a minimum.
In addition, operation of the engine until it is thoroughly
warm will keep the other engine parts in better
condition and generally extend the service life
engine. Lubrication will be improved, with less acid and
sludge in the oil. This will give longer service life for
engine bearings, piston rings, and other parts.
9
Operation Section
Operation Recommendations
Installation of the 9N3771 Cetane Injection Group on
3208 Diesel Engines will keep white smoke at a
minimum when the engine is started during cold
temperatures. See your Caterpillar dealer for more
information.
After the engine is warm, warm up the other systems
Start with the hydraulics. With the engine running at
less than 1/3 throttle, slowly move the control lever to
lift the attachment. Lift the attachment only a few
centimeters (inches) the first time. Lower it slowly
Continue the raise, lower, extend and retract sequence.
Extend the travel during each cycle. Do this for all
hydraulic circuits. Alternate between all of the
attachments.
Exercise the transmission and power train. Apply the
parking brake or brake pedal if transmission selector
can not be moved. Run the engine slightly above low
idle. Shift to first forward, then to first reverse speed.
several times.
Release the brake and move the equipment forward
and backward several meters (feet) for several minutes.
To reduce the total warm-up time, start exercising the
entire machine near the end of the hydraulic exercise
time.
Operate under light load until the systems reach normal
operating temperatus.
the
10
Operation Section
Operation Recommendations

Do not get the cab too warm. it .s best to keep it under

0°C (+32°F} to prevent perspiring If tre engine stops,
and the operator is perspiring. it will lessen the
chances for survival.

If the engine temperature is not high enough. enclose

the engine and block the radiator. A higner opening
thermostat will not increase the engine temperature
when the engine is rot being worked.

To prevent seal ana gasket damage, keep the engine

crankcase breather pipe clear of obstructions.

In extreme conditions, use a heat tent over the engine

compartment. and a space heater. This will aid in
starting the engine. To provide initial warm-up, the tent
may be extended to cover hydraulic components.

SAE 101N lubricants may be used successfully, when

operating at outside temperatures below the pour point
of the oil, by leaving the engine running at low idle. This
helps keep lubricants and compartments warm. This
applies to transmission and engine compartments.
However, it will not keep hydraulic systems warm.

Cold weather operations require more time for

completion than others. The extra time spent in caring
for the equipment properly. can prolong the life of
equipment and make these difficult operations more
cost-effective.
 11
Operation Section
Parking Recommendations

Parking Recommendations

Always cark tne machine ,n the proper area.

Park it on
wooden planks to avoid a creeze-down to the
ground.
Before parking a track-type machine, opera
te it in
forward and reverse. on hard. dry material. Trave
l in
2nd and 3rd speed. 15 to 20 meters (40 to
60 feet)
each direction. This will help ensure that the
track parts
are free.

Clean the roller frames and the track area of

debris.
Support the attachments on wooden blocks
to avoid
freeze-down also.

Follow the recommendations for stopping and

parking
in the Operation & Maintenance Manual for
the
particular c
 12
Maintenance Section
Cooling System Specifications

Cooling System Specifications

Cooling System General Information

The tendency of silicates and phosphates to
precipitate
out-of-solution increases with increasing water
NOTICE hardness Hard water or water with high levels
of
Never add coolant to an overheated engin calcium and magnesium ions encourages the
e. engine formation
damage can result. Allow the engine to cool of insoluble chemicals. espec ; after a numb
first. er of
heating and cooling cycles
If the machine is to be stored in, or shipped
to. an area
with freezing temperatures. the cooling syste
m must Caterpillar prefers the use stilled water or
be protected to the lowest expected outside deionized water to reduce the potential and
(ambient) severity of
temperature. chemical insolubility
The engine cooling system is normally prote
cted to
— 28°C ( -20°F) with Caterpillar Antifreeze. whe
n
shipped from the factory unless special requi MINIMUM ACCEPTABLE WATER
rements
are defined. Water Content Limits gr/gal (ppm)
Chlorides (CI) 2.4 (40) maximum
Sulfates (SO4) 5.9 (100) maximum
Check the specific gravity of the coolant solut Total Hardness
ion 10 (170) maximum
frequently in cold weather to ensure adequate Total Solids 20 (340) maximum
protection.
pH
5.5 to 9.0
Clean the cooling system if it is contaminated, ppm = parts per million
if the
engine 0'. ,
-- -heats or if foaming is observed in the
radiator.
Using water that meets the minimum acceptabl
e water
Filling at over 20 liters (5 U.S. gallons) per minu requirement may not prevent drop-out of these
te can chemical compounds totally. but should minim
cause air pockets in the cooling system. ize the
rate to acceptable levels.
After draining and refilling the cooling syste
m. operate
the engine with the radiator cap removed until
the Cooling System Information for Gasoline
coolant reaches normal operating temperatu Pnd
re and the Liquefied Petroleum Gas Engines Only
coolant level stabilizes. Add coolant as nece
ssary to fill
the system to the proper level.
Caterpillar recommends that the coola- -nix
contain
Never opu: ate without a thermostat in the coolin 50% commercially available automotive antifr
g eeze. or
system. Cooling system problems can arise equivalent and acceptable water
without a
thermostat.
The engine cooling system is protected with
a
Refer '1^ow Your Cooling System," form SEBDOF commercially available automotive antifreeze
. when
" shipped from the factory.
and -C .it and Your Engine," form SEBD0970. for
more detailed specifications.
The cooling system should be drained and
cleaned.
and new coolant should be added as recom
mended by
-oolant Water the commercially available automotive antifr
eeze being
used.
hard water, or water with high levels of calciu
m and The use of a supplemental coolant additive
magnesium ions, encourages the formation is not
of insoluble required when using commercially available
:hernical compounds by combining with coolin automotive
g antifreeze.
system additives such as silicates and phos
phates
 13
Maintenance Section
Cooling System Specificatio
ns

Cooling System Information

for Diesel
Engines Only Coolant should be drained. tne
system cleaned and
new coolant added every 3000
service hours or tivo
Diesel ergire operating !empera years. whichever comes first Wh
tures have increased en not using
to improve engine efficiency. This Caterpillar Antifreeze and supplem
means proper ental coolant
cooling system maintenance is additive as recommended. the drai
especially important. n period must ce
Overheating. overcooling. pitting. shortened to 1500 service'hours
cavitation erosion. or one year
on -ed heads. piston seizures.
and plugged radiators Refer to -Dowtherm 209 Full-Fill
are classic cooling system failures. Coolant.- form
In fact, coolant is as LEKQ6333. for more detailed info
important as the quality of fuel and rmation on Dowtherm
lubricating oil 209 Full-Fill Coolant.

NOTICE Antifreeze
All water is corrosive at engine
operating temperature.
The cooling system should be
protected with a 3% to NOTICE
6% concentration of liquid supplem Caterpillar recommends that the
ental coolant addi- coolant mix contain a
tive at all times. regardless of minimum of 30% Caterpillar Ant
the concentration of ifreeze, or equivalent
antifreeze. and acceptable water to mainta
in an adequate water
Excessive supplemental coolant pump cavitation temperature for
additive greater than efficient water pump
the recommended 6%, togeth performance.
er with concentrations
of antifreeze greater than 60% Premix coolant solution to pro
can cause deposits to vide protection to the
form and can result in radiato lowest expected outside (ambien
r tube blockage. over- t) temperature. Pure
heating. and/or water pump sea 'undiluted antifreeze will freeze
l damage. at -23°C (-10°F).
Caterpillar recommends that the Only use a greater concentrat
coolant m contain a ion (above 30%) of
minimum of 30°/0 Caterpillar Ant Caterpillar Antifreeze as needed
ifreeze or antifreeze for anticipated out-
meeting GM 6038-M specificatio side (ambient) temperatures. Do
ns, and acceptable not exceed a coolant
water to maintain an adequate mixture of 60% antifreeze to wat
water pump cavitation er since a concentra-
temperature for efficient water tion above 60% antifreeze will
pump performance. reduce the engine's
Do not use liquid supplementa freeze protection and increase
l coolant additive or the possibility of depo-
elements or antifreeze with Dow sit formation in the cooling sys
therm 209 Full-Fill tem.
coolant. Dowtherm 209 Full-Fill
coolant is not compati-
ble with other antifreeze and coo
lant mixtures.
Dowtherm 209 full-fill coolan Use Caterpillar Antifreeze or GM
t will lower the water Specification 6038-M
pump cavitation temperature and Antifreeze. Caterpillar Antifreeze
coolant boiling point. is available through
These lowered temperatures will your Caterpillar dealer in quantiti
cause overheating at es that follow
a lower ambient temperature tha
n an ethylene glycol
and water mix. If Dowtherm is use
d, follow the instruc-
tions provided and use only the CATERPILLAR ANTIFREEZE
inhibitor package rec-
ommended by the supplier. Part No.
Size
8C3684
Do not use Caterpillar liquid sup 3 8 Liter (1 U.S.Galion)
plemental coolant ad- 8C3686
ditive, coolant additive eleme 208 Liter (55 U S. Gallons)
nts or antifreeze with
Dowtherm 209 Full-Fill coolant.
Dowtherm 209 Full-Fill
coolant is not compatible with
other antifreezes and Most commercial antifreezes are
coolant mixtures. formulated for
gasoline engine applications and
The engine cooling system will. therefore nave
is protected to -28°C high silicate content. Caterpillar
(-20°F) with Caterpillar Antifre Antifreeze is formulated
eze, ;en oed with a low silicate content and the
from the factory. proper coolant
additives for heavy duty diesel eng
ines.
GM Specification 6038-M is a low
silicate antifreeze
but supplemental coolant additive
must be aaciec
14
Maintenance Section
Cooling System Specifications
The major advantages c: - aterpillar Antifreeze are .
• Significantly reduces water pump seal leakage
problems caused by excessive concentration of
chemical additives.
• There is no need to add supplemental coolant
additive on initial fill which must be done with current
commercially available antifreezes.
• High silicate antifreezes used with a supplemental
coolant additive can cause a build-up of solids over a
period of, time which can cause plugging, loss of heat
transfer. and water pump seal damage.
Make proper antifreeze additions.
Adding pure antifreeze as a makeup solution for
cooling system top-up is an unacceptable practice. It
increases the concentration of antifreeze in the cooling
system which increases the concentration of dissolved
solids and undissolved chemical inhibitors in the
cooling • stem. Add antifreeze mixed with water to the
same freeze protection as your cooling system.
Use the chart below to assist in determining the
concsrIration of Caterpillar Antifreeze to use.
ANTIFREEZE CONCENTRATIONS
Protection Temperature Concentration
Protection to -15°C (5°F) 30% antifreeze and 70% water
Protection to -23°C (-10°F) 40% antifreeze and 60% water
Protection to -37°C (-34°F) 50% antifreeze and 50% water
Protection to -51°C (-60°F) 60% antifreeze and 40% water
Supplemental Coolant Additive
Supplemental coolant additive is necessary to prevent
rust scale. pitting and/or corrosion of engine parts :hat
coolant comes in contact with. Most antifreeze
solutions DO NOT contain sufficient supplemental
coolant additive.
NOTICE
Always add supplemental coolant additive or equiva-
lent to the coolant. or install a Caterpillar supplemental
coolant additive element (if equipped). Never use cool-
ant only, except if Caterpillar Antifreeze is being used
which contains the additive. In this case. no supple-
mental coolant additive is needed on initial fill, but is
necessary on a maintenance basis.
Use supplemental coolant additive or a supplemental
coolant additive element (if equipped). This will provide
a 3% to 6% concentration in the cooling system to help
prevent corrosion.
To prevent overinhibiting the engine.s cooling system.
never use both the liquid supplemental coolant addi-
tive and the supplemental coolant additive element (if
equipped) at the same time. The use of these additives
together could result in excessive concentration that
would exceed the Caterpillar recommended maximum
of 6%.
Excessive concentratiorof an additive can form den -
sits on the higher temperature surfaces of the cool g
system and create a barrier that reduces the engine s
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components. Excessive concentra-
tions of additive could also accelerate water pump seal
wear.
Supplemental coolant additive is needed when not
using Caterpillar Antifreeze for premixed coolant
solution.
Liquid supplemental coolant additive can be purchased
from your Caterpillar dealer. Follow the instructions on
the container.
1