PDF c7 Specifications Systems Operation Testing and Adjusting - Caterpillar

RENR7572-06
July 2006
Systems Operation
Testing and Adjusting
C7 On-hig hway Engine
On-highway
YPG1-Up (Engine)
KAL1-Up (Engine)
(Engine)
LBM1-Up (Engine
(Engine))
SAP1-Up (Engine)
(Engine)
C7T1-Up (Engine)
WAX1-Up (Engine)

i01658146
Important Safety Information

that involve product operation, maintenance and repair are caused by failure to observe
Most accidents that
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
necessary training, skills and tools to perform these functions properly.
have the necessary
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
or perform any lubrication, maintenance or repair on this product, until you have
Do not operate or
read and understood
understood the operation,
operation, lubrication, maintenance and repair informatio
information.
n.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
heeded, bodily injury or death could occur to you or to other persons.
are not heeded,
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention!! Be
Attention come Alert! Your Safety is Involved.
Become
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
that may cause product damage are identified by “NOTICE” labels on the product and in
Operations that
Operations
this publication.
Caterpillar
Caterp illar cannot anticipate every possible
possible circumstance that might involve a potent
potential
ial hazar
hazard.
d.
The warning
warnings s in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
will not be damaged or be made unsafe by the operation, lubrication, maintenance or
the product will
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
availablle at the time that the publication was written. The specifications, torques, pressures,
was availab
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
job. Caterpillar dealers have the most current information available.
start any job.
When replacemen
replacementt parts
parts are req
requir
uired
ed for this
product Caterpillar recommends using Caterpil-
lar replacementt parts
replacemen parts or parts
parts with equ
equival
ivalent
ent
specifications
specifications including,
including, but not limited to, phys-
ical dimensions, type, strength and material.
material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

RENR7572-06 3
Table of Conten
Contents
ts
Table of Contents Electric Starting System - Test ....................

Engine Oil Pressure
..............................
Pressure Sensor - Test ............
.......... 84
.......................
............. 85
Pinion Clearance - Adjust ..................................... 85
Systems
Systems Operation
Operation Section
Index Section
General Information
General Information ............
........................
........................
.......................
............. 4
Electronic Control System Components ................. 7 Index ...........
.......................
........................
........................
........................
......................
.......... 87
Fuel System .......................
...................................
........................
........................
............ 9
Air Inlet and Exhaust System ........................
........... ....................
....... 23
Lubrication
Lubric ation Sy
System
stem ............
.......................
.......................
.......................
........... 27
Cooling System
System .....................
.................................
.......................
...................
........ 30
Basic Engine ...........
.......................
........................
........................
......................
.......... 32
Rear Power Take-Off
Take-Off (RPTO) ..................................
....................
........ 35
Electrical
Electric al System
System ........................
...................................
.......................
..............
.. 35
Testing and Adjusting Section

Fuel System
Fuel System - Inspect
Inspect ........................
....................................
...................
....... 39
Air in Fuel - Test ...........
.......................
........................
........................
.................
..... 39
Engine Speed - Check ..............
.........................
.......................
.................
..... 40
Electronic
Electro nic Unit Injecto
Injectorr - Test ...........
.......................
.....................
......... 41
Finding
Findin g To
Topp Center Position for No. 1 Piston ........ 42
Fuel Quality - Test .................................
.............................................
................
.... 43
Fuel System Pressure

Fuel System -Pressu
Primere.............................................
- Test ......................... ........ 44
................................. 45
Gear Group (Front) - Time .................................... 47
Air Inlet and Exhaust System

Air Inlet and Exhaust System - Inspect ............. .................
.... 49
Turbocharg
Tur bochargerer - Inspect
Inspect ......................
..................................
....................
........ 53
Inlet Manifold Pressure
Pressure - Test .......................
...............................
........ 56
Exhaust Temperature - Test .................................. 57
Aftercooler - Test ......
..................
.........................
.........................
....................
........ 57
Engine Crankcase Pressure (Blowby) - Test ........ 60
Engine Valve
Valve Lash - Inspec
Inspect/Adjus
t/Adjustt ......................
...................... 60
Lubrication System
Engine Oil Pressure - Test ..........
......................
........................
..............
.. 63
Excessive
Excessive Bearing Wear - Inspect
Inspect ......................
........................
.. 66
Excessive
Increased
Increas Engine Oil
ed Engine Oil Tempera
TConsumption
emperature - Inspect........
ture - Inspect ....... 66
66
Cooling System
Cooling System - Check (Overheating) ................ 68
Cooling System - Inspec
Inspectt .......................
...................................
...............
... 70
Cooling System - Test ....................
................................
......................
............ 70
Water Temperature Regulator - Test ..................... 75
Waterr Pump - Test .......................
Wate ...................................
........................
.............. 75
Basic Engine
Piston Ring Groove - Inspect
Inspect .......................
................................
......... 77
Main Bearings - Inspect .......................
...................................
.................
..... 77
Cylinderr Block - Inspect .......................
Cylinde ...................................
.................
..... 77
Flywheel
Flywhe el - Inspect
Inspect ........................
....................................
........................
.............. 77
Flywheel
Flywhe el Housing
Housing - Inspec
Inspectt ..............................
...................................
..... 79
Vibration
Vibration Damper - Check ..........
.....................
.......................
...............
... 81
Electrical System
Alternator - Test ...........
.......................
........................
........................
.................
..... 82
Battery - Test ....................
................................
........................
........................
.............. 82
Charging
Chargin g System - Test ............
........................
.......................
................
..... 83

4 RENR7572-06
Systems
Systems Operation
Operation Section
Systems Operation Section

i01846472
General Information
Information
SMCS Code: 100 0
Code: 1000
g00940558
Illustration 1
Illustration
Right side view
(1) Lifting eye (4) Turbocharger (7) Oil filter
(2) Water drain plug (5) Alternator (8) Water pump
(3) Exhaust manifold (6) Bleed orifice for wastegate (if equipped) (9) Crankshaft vibration damper

RENR7572-06 5
Illustration 2 g00940561
Left side view
(10) Fuel filter (13) Inlet elbow (16) Oil filler tube
(11) Unit injector hydraulic pump (14) Air inlet heater relay (17) Air compressor
(12) Engine crankcase breather (15) Wastegate solenoid (if equipped) (18) Engine Control Module ECM
The engine is a in-line six cylinder engine. The firing The hydraulic electronic unit injector system (HEUI)
order of the engine is 1-5-3-6-2-4. The engine’s eliminates many of the mechanical components
rotation is counterclockwise when the engine is that are used in a pump-and-line system. The HEUI
viewed from the flywheel end of the engine. The also provides increased control of the timing and
engine utilizes a turbocharger and an air-to-air increased control of the fuel air mixture. The timing
aftercooler. The engines have a bore of 110 mm advance is achieved by precise control of the unit
(4.3 inch) and a stroke of 127 mm (5.0 inch). The injector timing. Engine rpm is controlled by adjusting
displacement is 7.25 L (442 in 3 ). the injection duration. A specia
speciall pulse wheel provides
information to the Engine Control Module (ECM) for
detection of cylinder position and engine rpm.

6 RENR7572-06
Systems
Systems Operation
Operation Section
The engine has built-in diagnostics in order to ensure

that all of the components
components are operating properly. In
the event of a system component failure, the operator
will be alerted to the condition via the check engine
located on the dashboard. An electronic
light that is located
service tool can be used to read the numerical code
of the faulty component or condition. Also, the cruise
switches can be used to flash the code on the
control switches
check engine light. Intermittent faults are logged and
stored in memory.
Starting The Engine

The engine’s ECM will automatically provide the
correct amount of fuel in order to start the engine.
Do not hold thet he throttle down while the engine is
cranking.
crankin g. If the engine fails to start in twenty seconds,
seconds,
release the starting switch. Allow the starting motor
to cool for two
two minutes before the starting motor is
used again.
NOTICE
ether (starting fluid) can cause piston and
Excessive ether
Excessive
ring damage. Use ether for cold weather starting pur-
poses only.
Cold Mode Operation

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

RENR7572-06 7
i01833239
Electronic Control System

Components
SMCS Code: 1900
Code: 1900
g00936714
Illustration 3
Electr onic
onic control System components (left side view)
(1) Connector for the injection actuation (5) Atmospheric pressure sensor
pressure control valve (6) Boost pressure sensor
(2) Injection actuation pressure sensor (7) Speed/Timing sensors
(3) Coolant temperature sensor (8) Engine oil level switch (if equipped)
(4) Inlet air temperature sensor (9) Oil pressure sensor (if equipped)

8 RENR7572-06
Systems
Systems Operation
Operation Section
The electronic control system is integrally designed An output component is one that is operated by a
into the engine’s
engine’s fuel system and the engine’s air controll module
contro module.. The output component receives
inlet and exhaust system in order to electronically electrical energy from the control group. The output
control the fuel delivery and the injection timing. The component uses that electrical energy in one of
control system provides
electronic control provides increased
increased timing output component can use that
two ways. The output
control and fuel air ratio control in comparison to electrical energy in order to perform work. The output
conventional
conven tional mechanical engine
engines.
s. Injection
Injection timing component can use that electrical energy in order to
is achieved byby the precise control of the injector information.
provide information.
firing time. Engine rpm is controlled by adjusting
the injection duration. The ECM energizes the unit As an example, a moving solenoid plunger will
solenoids in order to start the injection of
injector solenoids work. By performing work, the component
perform work.
fuel. Also, the ECM de-energizes the unit injector has functioned in order to regulate the vehicle.
solenoids in order to stop the injection of fuel.
example,, a dash panel light or an alarm will
As an example
Refer to Systems Operation/Testing and Adjusting, provide information to the operator of the vehicle.
“HEUI Injector Operation” for a complete
complete explanation
explanation
of the fuel injection
injection process. These electr o
onic
nic components provide the ability
to electronically control the engine operation.
The engine uses the following three types of Engines with electronic controls offer the following
components:
electronic components:
electronic advantages::
advantages
• Input component • Improvement in performance

• Control component • Improvement
Improvement in fuel consum
consumption
ption
• Output component
component • Reduction in
in emissi
emissions
ons levels
An input component is one that sends an electrical
i01902644
the ECM of the system. The signal that is
signal to the
sent varies in either of the following ways: Fuel System
• Voltage SMCS Code: 1250
Code: 1250
• Frequency
• Pulse width
variation of the signal is in response to a change
The variation
in some specific system of the vehicle. Some specific
examples of an input component are the engine
ming sensors, the coolant temperature
speed-timing
speed-ti
sensor, and the cruise control switches. The ECM
interprets the signal from the input component as
ion about the condition, environment, or
information
informat
operation of the vehicle.
control component (ECM) receives the input signals

A control component
from the input componen
components. ts. Electronic circuits inside
the control component evaluate the signals from
the input
input components.
components. These electronic circuits also
supply electrical energy to the output components of
the system. The electrical energy that is supplied to
output components is based on predetermined
the output
combinations
combina tions of input signal values.
values.

RENR7572-06 9
Introduction
g00990070
Illustration 4
Fuel System Diagram
(1) Unit injector hydraulic pump (10) Fuel supply passage (19) Boost pressure sensor
(2) Oil flow to engine (11) Fuel transfer pump (20) Engine coolant temperature sensor
(3) Oil filter (12) Secondary fuel filter (21) Engine oil pressure sensor
(4) Engine oil pump (13) Primary fuel filter/water separator (22) Inlet air temperature sensor
(5) Injectors (14) Fuel tank (23) Engine oil level switch
(6) Connector for the IAP control valve (15) Fuel pressure regulator (24) Atmospheric air pressure sensor
(7) Oil cooler (16) Back of camshaft gear (25) Wastegate control valve
(8) High pressure oil passage (17) Speed/timing sensors
(9) IAP sensor (18) ECM
The operation of the Hydraulic Electronic Unit • Fuel transfer pump (11)
Injector (HEUI) fuel system is completely different
from any other type of fuel system that is actuated • Injection
Injection Actuation Pressure
Pressure sensor (9)
mechanically. The HEUI fuel system is completely
free of adjustment. Adjustments to the components Note: The components of the HEUI fuel system
Note: The
that are mechanical can not be made. Changes in are not serviceable. These fuel system components
performance
perform ance are made by install
installing
ing different software must not be disassemble
disassembled.d. Disassembly will damage
in Engine Control Module (ECM) (18). the components. If the components have been
disassembled, Caterpillar may not allow a warranty
This fuel system consists of six basic components: claim or Caterpillar may reduce the warranty claim.
• Hydrau
Hydraulic
lic Electron
Electronic
ic Unit Injector (HEUI
(HEUI)) (5)
• Engine Control Module (ECM) (18)

• Unit injector hydraulic pump (1)

10 RENR7572-06
Systems
Systems Operation
Operation Section
Component Description Engine Control Module (ECM)
Hydraulic Electronic Unit Injector Engine Control Module (ECM) (18) is located on
the left side of the engine. The ECM is a powerful
The HEUI fuel system utilizes a hydraulically actuated computerr that
compute provides total electronic control of
that provides
electronically
electronically controlled unit inject
injector
or (5). engine performance. The ECM uses data from
engine performance that is gathered by several
All fuel systems for diesel engines use a plunger sensors.
sensor s. The n, the ECM uses this data in order
Then,
and barrel in order to pump fuel under high pressure to make adjustments to the fuel delivery, injection
into the combustion chamber. This fuel is pumped pressure and injection timing. The ECM contains
into the combustion chamber in precise amounts in program med performance maps (software) in order
programmed
order to control engine performance. The HEUI uses to define horsepower, torque curves and rpm. This
engine oil under high pressure in order to power the software
softwar e is commonly called the personality
personality module.
plunger. All other fuel systems use a fuel injection
pump camshaft lobe in order to power the plunger. The engine does not have a replaceable personality
Because the HEUI is much different, a technician module. The personality module is a permanent part
must use differ
different
ent troubleshootin
troubleshooting
g methods.
methods. of the ECM. The
The personality module for the engine
can be reprogrammed by Caterpillar Electronic
The HEUI uses engine lubrication oil that is Technician (Cat ET).
pressurized from 6 MPa (870 psi) to 28 MPa
(4050 psi) in order to pump fuel from the injector. ECM (18) logs faults of engine performance. Also,
The HEUI operates in the same way as a hydraulic the ECM is capable of running several diagnostic
cylinder in order to multiply the force of the high automatically when the ECM is used with an
tests automatically
pressure oil. By multiplying the force of the high electronic service tool such as the Cat ET or the
pressure oil, the HEUI can produce injection Electronic
Electronic Control Analyzer Programmer (ECAP).
pressures that are very high. This multiplication of
pressure
pressu re is achieved
achieved by applyin
applyingg the force of the high Unit Injector Hydraulic
Hydraulic Pump
pressure oil to a piston. The piston is larger than the
plunger by approximately six times. The piston that is
powered by engine lubrication oil under high pressure
pushes on the plunger. This engine lubrication oil
under high pressure is called the actuation pressure
of the oil. The actuation pressure of the oil generates
the injection pressure that is delivered by the unit
injector.
injector. Injection pressure is greater than actuation
actuation
pressure of the oil by approximately six times.
Low actuation pressure of the oil results in low

injection
injection pressure of the fuel. During conditions
conditions of low
speed such as idle and start, low injection
injection pressure is
utilized.
g00888330
High actuation pressure of the oil results in high Illustration 5
injection pressure of the fuel. During conditions of (1) Unit injector hydraulic pump
Unit injector
high speed such as high idle and acceleration, high
injection
injection pressure
pressure is utilize
utilized.
d. Unit injector hydraulic pump (1) (high pressure oil
is located at the left front corner of the engine.
pump) is located
There are many other operating conditions when the The unit injector hydraulic pump is a variable delivery
injection pressure is between the minimum and the piston pump. The unit injector hydraulic pump uses a
maximum. Regardless of the speed of the engine, portion
portio n of the engine lubrication oil. The unit injector
the HEUI fuel system provides infinite control of hydraulic
hydrau lic pump pressu
pressurizes
rizes the engine lubricat
lubrication
ion oil
injection pressure. to the injection actuation pressure that is required in
to power the HEUI injectors.
order to

RENR7572-06 11
Pump Pressure Regulator

Regulator Injection Actuation Pressure Sensor
(IAP)
The pump pressure regulator is internal to the unit
injector hydraulic pump. The pump pressure regulator
hi gh precision that controls pump outlet
is a valve of high
pressure (actuation pressure) by changing pump
outlet flow. The performance maps in the ECM (18)
desired actuation pressure for every engine
contain a desired
operating condition. The ECM sends a control current
to the pump pressure regulator. The control current
the actual actuation pressure equal to
should make the
the desired
desired actuation
actuation pressu
pressure.
re.
pressure regulator is an actuator that

The pump pressure
converts an electrical signal from the ECM to the
mechanical control of plunger sleeves in order to
change the pump
pump outlet flow and the pump outlet
pressure. Illustration
Illustratio n7
g00739676
(9) IAP sensor

sensor
Fuel Transf er
er Pump
IAP Sensor (9) is installed in the high pressure oil
manifold. The high pressure oil manifold supplies
actuation
actuati on oil in order to power the unit injectors. The
IAP Senso
Sensorr monitors injection actuation pressure.
The IAP Sensor sends a continuous voltage signal
back to ECM (18).(18). The ECM interprets the signal.
The ECM is aware of the injection actuation pressure
at all times.
g00888334
tion 6
Illustration
Illustra
Unit injector hydraulic pump
(1) Unit injector hydraulic pump
(11) Fuel transfer pump
Fuelinjector
unit transferhydraulic
transfer pump (11) is mounted
pump (1). Theon the
fuel back of
transfer
pump
pum p is used
used in orde
orderr to draw fuel from fuel
fuel tank
Also, the fuel transfer pump is used in order
(14). Also,
to pressurize the fuel to 450 kPa (65 psi). The
pressurized fuel is supplied to injectors (5).
The fuel transfer pump is a gear pump. The pump is

mounted on the back of the unit injector hydraulic
pump. TheThe fuel transfer pump is driven by the shaft
of the unit injector hydraulic pump. A relief valve in
the fuel transfer pump limits the outlet pressure to
kPa (100 ± 10 psi). Fuel is drawn from
689 ± 69 kPa
the tank to the inlet port of the pump. The rotation
of the gears causes the fuel to flow out of the pump
port through the secondary fuel filter (12) and
outlet port
outlet
to the er
fuel
cylinder
cylind supply passage (10) that is located in the
head.

12 RENR7572-06
Systems
Systems Operation
Operation Section
HEUI Fuel System Operation
g00935590
Illustration 8
(1) Unit injector hydraulic pump (12) Secondary fuel filter
(5) Injectors (13) Primary fuel filter/water separator
(10) Fuel supply passage (14) Fuel tank
(11) Fuel transfer pump (15) Fuel pressure regulator
Low Pressure Fuel System Fuel flows from fuel filter (12) to the inlet side of fuel
transfer pump (11). An inlet check valve in the inlet
The low pressure fuel system serves three functions. port of the fuel transfer pump opens in order to allow
The low pressure
combustion fuel system
to injectors supplies
(5). Also, fuel
the low for
pressure the flow ofthe
stopped, fuel intocheck
inlet the pump.
valve After
closestheinfuel flow
order to has
fuel system supplies excess fuel flow in order to cool prevent fuel flow out of the inlet port. Fuel flows from
the unit injectors and the low pressure fuel system the inlet port in the pump to the outlet port, which also
supplies excess fuel flow in order to remove air from has a check valve. The outlet check valve opens in
the system.
system. order to allow pressurized fuel flow out of the pump.
The outlet check valve closes in order to prevent
The low pressure fuel system consists of four basic pressurized
pressu rized fuel leakag
leakagee back through the pump.
components:
Fuel flows from the outlet port of fuel transfer pump
• Fuel tank (14) (11) to the fuel supply passage in the cylinder head.
The fuel supply passage is a drilled hole which
• Primary fuel filter/water separator(13)
separator(13) begins at the front of the cylinder head. The fuel
supply passage extends to the back of the cylinder
• Two
Two micron secondary fuel filter (12) head. This passage connects with each unit injector
bore in order to supply fuel to unit injectors (5). Fuel
• Fuel transfer pump (11) from the transfer pump flows through the cylinder
head to all of the unit injectors. Excess fuel flows out
• Fuel pressure regulator (15) of the back of the cylinder head. After the excess
flows out of the back of the cylinder head, the fuel
Fuel transfer pump (11) is mounted on the back of flows into fuel pressure regulator (15).
unit injector hydraulic pump (1).
Fuel pressure regulator (15) consists of an orifice
Fuel is drawn from fuel tank (14) and flows through and a spring loaded check valve. The orifice is a flow
a thirteen micron fuel filter/water separator (13). The restriction that pressurizes the supply fuel. The spring
primary fuel filter/water separator removes large loaded check valve opens at 35 kPa (5 psi) in order
debris from the fuel. The debris may have entered to allow the fuel which has flowed through the orifice
the fuel tank during fueling. The debris may have to return to fuel tank (14). When the engine is off and
also entered the fuel tank through the vent for the fuel no fuel pressure is present, the spring loaded check
tank. The primary filter element also separates water valve closes. The spring loaded check valve closes
from the fuel. The water is collected in the bowl at the in order to prevent the fuel in the cylinder head from
bottom of the primary fuel filter/water separato
separator.
r. draining back to the fuel tank.

RENR7572-06 13
Injection Actuation System
g00935594
Illustration 9
(1) Unit injector hydraulic pump (3) Oil filter (5) Injectors
(2) Oil flow (4) Engine oil pump (7) Oil cooler
Oil Flow
Actuation Oil into the inlet port of unit injector hydraulic
Oil flows into
pump (1) and the oil fills the pump reservoir. The
The injection actuation system serves two functions.
functions. pump reservoir provides oil to the unit injector
injection actuation system supplies high pressure
The injection pump during start-up. Also, the pump
hydraulic pump
oil in order to power HEUI injectors (5). Also, the reservoir provides oil to the unit injector hydraulic
injection actuation system controls the injection pump until the engine oil pump can increase
that is produced by the unit injectors by
pressure that pressure.
changing the actuation pressure of the oil.
The pump reservoir also provides makeup oil to the
The injection
injection actuation system consists of four basic pressure oil passage in the cylinder head. When
high pressure
components: the engine is off and the engine cools down, the oil
shrinks. A check valve in the pump allows oil to be
• Engine oil pump
oil pump (4) from the pump reservoir in order to keep the
drawn from
high pressure oil passage full.
• Engine oil filter (3)
the pump reservoir is pressurized in the unit
Oil from the
• Unit injector hydraulic pump (1) injector hydraulic
hydraulic pump (1). The oil is then pushed out
of the outlet port of the pump under high pressure.
• Injection Actuation
Injection Actuation Pressure sensor (9) then flows from the outlet port of the unit injector
Oil then flows
hydraulic pump to the high pressure oil passage in
Oil from engine oil pump (4) supplies the needs of the the cylinder head.
engine lubrication
lubrication system. Also, oil from the engine
oil pump supplies the needs of unit injector hydraulic The high pressure oil passage connects with each
pump (1) for the fuel system. The capacity of the unit injector bore in order to supply high pressure
oil pump has been increased in order to meet
engine oil on oil to the unit injectors (5). Actuation oil
actuation
actuati
the additional flow requirement that is necessary. that is under high pressure flows from unit injector
hydraulic pump (1) through the cylinder head to all of
is drawn from the sump is pressurized to the
Oil that is the injectors.
injectors. Oil is contained in the high pressure
lubrication system oil pressure by engine oil pump oil passage until the oil is used by the unit injectors.
(4). Oil flows from the engine oil pump through engine Oil that has been exhausted by the unit injectors
cooler (7), through engine oil filter (3), and then to
oil cooler expelled under the valve covers. This oil returns
is expelled
the main oil gallery. A separate circuit from the main to the crankcase through the oil drain holes in the
oil gallery directs a portion of the lubrication oil in cylinder head.
to supply the unit injector hydraulic pump (1). A
order to supply
steel tube on the left side of the engine connects the
main oil gallery with the inlet port of the unit injector
lic pump.
hydraulic
hydrau

14 RENR7572-06
Systems
Systems Operation
Operation Section
Actuation
Actuation Oil Pressu
Pressure
re Control
g00990018
Illustration 10
(1) Control valve solenoid (6) Actuator piston (11) Drive gear
(2) Poppet valve (7) Eccentric drive plate (12) Check valve
(3) Armature (8) Idler (13) Piston
(4) Actuator spring (9) Spill port
(5) Sliding sleeve (10) Pump outlet ports
The unit injector hydraulic pump is a variable delivery Changing the relative position of the sliding sleeve to
piston pump. The variable piston pump uses an the spill port changes the volume of oil in the piston.
angled drive plate which rotates. The pistons do not The location of the sliding sleeve is continuously
rotate. The pistons move in relation to the angled changing. The location of the sliding sleeve is
drive plate. The pistons move in the sliding sleeves. determined by the ECM. Changing the location of the
sliding sleeves changes the flow of the pump. The
The unit injector hydraulic pump is driven by the gear result is the amount of oil that can be pressurized.
train on the front of the engine. The drive gear on the
front of the pump turns the common shaft. The angled The pressure of the injection actuation system is
drive plate is mounted on the common shaft. The controlled
controlled by matchi
matching
ng pump outlet flow and resulti
resulting
ng
rotation of the angled drive plate causes the pump pressure to the pressure demand for the injection
piston to move in and out within the sliding sleeves. actuation system. The position of the sliding sleeves
is changed in order to control the pump outlet flow.
As the pistons move out of the sliding sleeves, oil Moving the sleeves to the left covers the spill port for
is drawn into the inside of the pistons through the a longe
longerr distanc
distance.
e. This increases effectiv
effective
e pumping
passage in the drive plate. Oil is forced out of the stroke and pump outlet flow. Moving the sleeves to
piston when the piston is pushed back into the sliding the right covers the spill ports for a shorter distance
sleeve and the ports are exposed. which reduces the effective pumping stroke. This
also reduces the pump outlet flow.

RENR7572-06 15
The sliding sleeves are connected by an idler. One • The ECM constantly changes control current to
sleeve is connected
connected to an actuator piston. Moving the pump control
control valve. This changes the pump
the actuator piston right or left causes the idler and outlet flow.
sleeves to move the same distance to the right or
to the left
left.. types of actuatio
There are two types actuation
n pressu
pressure:
re:
Control pressure is determined by the amount of • Desired actuation pressure

from the ECM to the solenoid. A small amount
current from the
of pump outlet flow goes through a small passage in • Actual actuation pressure
the actuator piston. This small amount goes out of
and into the control pressure cavity. The
an orifice and actuation pressure is the injection actuation
Desired actuation
pressure in this cavity is limited by a small poppet pressure that is required by the system for optimum
valve. The opening of the poppet valve allows a engine performance. The desired actuation pressure
the oil in the cavity to flow to drain. A
portion of the established by the performance maps in the ECM.
is established
force holds the poppet valve closed. This force on The ECM selects the desired actuation pressure. The
the poppet valve is created by a magnetic field that selection is based on the signal inputs from many
acts on an ar mature.
mature. The strength of the magnetic sensors. The ECM
The ECM is getting signal inputs from some
field determines the required pressure in order to of the following sensors: throttle position sensor,
overcome the force of the actuator spring. boost pressure sensor, speed-timing
speed-timing senso
sensors,
rs, and
coolantt tem
coolan perature sensor . The desired actuation
temperature
An increase of current to the solenoid causes an pressure is constantly changing. The change is based
increase to the following items: on various signal inputs. The changing engine speed
engine load also cause the desired actuation
and engine load
• The strength
strength of the magnetic field pressure
pressu re to chang
change.
e. The desired actuat
actuation
ion pressure
is only constant under steady state conditions (steady
• The force on
on the armature and poppet valve engine speed
speed and load).
• The control pressure which causes the actuator Actual actuation pressure is the actual system
move to a position that results in more
piston to move pressure ofof the actuation oil that is powering the
flow injectors. The ECM and the pump pressure regulator
are constantly changing the amount of pump outlet
reduction of current to the solenoid causes a
A reduction This constant changing makes the actual
flow. This
reduction to the following items: actuation pressure equal to the desired actuation
pressure.
• The strength
streng th of the magnetic field
Pump Control Valve Operation
• The force on the armature and
and poppet valve
control valve has the following three
The pump control
• The control pressure which causes the actuator stages:
piston to move to a position that results in less flow
Valve ope ration (engine off)
operation
The ECM monitors actuation pressure. The ECM •
constantly changes current to the pump control • Valve operation (cranking the engine)
order to control actuation pressure. Three
valve in order
components work together in a closed loop circuit in • Valve operation (running engine)
order to control actuation pressure:
Valve Operation
Operation (ENGINE OFF)
• ECM
When the engine is off, there is no pump outlet
• Sensor for
for the Injection Actuation Pressure (IAP) pressur e from the pump and there is no current to the
control valve solenoid from the ECM. The actuator
• Pump control valve spring pushes the actuator piston completely to the
The idler which is not shown and the sliding
left. The
The closed loop circuit works in the following
following manner: sleeves are moved to the left also. At this point, the
pump is in the position of maximum output.
• The ECM determines
d etermines a desired actuation pressure
by gathering information from sensor inputs and
software
software maps.
• The ECM monitors actual actuation pressure

through a constant signal voltage from the IAP
sensor.

16 RENR7572-06
Systems
Systems Operation
Operation Section
Valve Operation (ENGINE CRANKING) Valve Operation (RUNNING ENGINE)
During engine start-up, approximately 6 MPa Once the engine starts, the ECM controls the current
(870 psi) of injection actuation pressure is required in to the pump control valve in order to maintain the
activate the unit injector. This low injection
order to activate actuation pressure. The IAP Sensor monitors
desired actuation
actuation pressure generates a low fuel injection the actual actuation pressure in the high pressure oil
pressure of about 35 MPa (5000 psi). This low fuel passage in the cylinder head. The ECM compares
on pr essure
injection
injecti essure aids cold starting. ac tuation pressure
the actual actuation pressure to the desired actuation
pressure 67 times per second. The ECM adjusts the
In order to start the engine quickly, the injection current levels to the pump control valve when the
ion pr essure
actuation
actuat essure must rise quickly
quickly.. Because
Because the actuation pressure and the desired actuation
actual actuation
unit injector hydraulic pump is being turned at engine pressure do not match. These adjustments make
cranking speed, pump flow is very low. The ECM the actual injection actuation pressure equal to the
strong current to the control valve solenoid
sends a strong injection actuation pressure.
desired injection
in order to keep the poppet valve closed. With the
poppet valve in the closed position, all of the flow Oil Flow (ENGINE RUNNING)
to the drain is
drain is blocked. The hydraulic forces that
act on each side of the actuator piston are equal. A small amount of pump outlet flow flows through
The actuator spring holds the actuator to the left. the actuator piston and into the control pressure
produces maximum flow until the 6 MPa
The pump produces Control pressure increases and the increas
cavity. Control increased
ed
(870 psi) desired pressure is reached. Now, the ECM pressure
pressu re unseats the poppe
poppett valve
valve.. The open poppet
reduces the current to the pressure regulator solenoid valve allows flow to the drain. The ECM changes
to reduce control pressure. The reduced
in order to reduce control pr essure
essure by increasing or reducing the current
control pressure allows the actuator piston to move to the control valve solenoid and resultant force on
to the right. This reduces pump outlet flow in order to the poppet.
maintain the
maintain the 6 MPa (870 psi) desired pressure.
The following items create a closed loop system:
Note: If the engine is already warm, the pressu
Note: If pressure
re that
is requir ed
ed to start the engine may be higher than • ECM
6 MPa (870 psi). The values for the desired actuation
pressures are stored in the performance maps of the • IAP
values for desired actuation pressures
ECM. The values
vary with engine temperature. • Pressure Regulator
Once the unit
the unit injectors begin to operate, the ECM closed loop system provides infinitel
This closed infinitely
y variabl
variable
e
controls the current to the control valve. The ECM and control of pump outlet pressure. This pump outlet
the control valve solenoid will maintain the actuation pressure
pressu re has a range from 6 MPa (870 psi) to 28 MPa
pressur e at 6 MPa (870 psi) until the engine starts. psi).
(4061 psi).
The ECM monitors the actual actuation pressure
through the IAP Sensor that is located in the high
pressure
pressu re oil manifold. The ECM establishes desired
HEUI Injector
Injector (Components)
actuation
actuation pressu
pressure
re by monitoring
monitoring several
several electrical
electrical The HEUI injector serves four functions. The HEUI
input signals and the ECM sends a predetermined
injector pressurizes
pressurizes supply fuel from 450 kPa (65 psi)
currentt to the control valve solenoid. The ECM also
curren
to 175 MPa (25382 psi). The HEUI injector functions
compares the desired actuation pressure to the actual
as an atomizer by pumping high pressure fuel
actuation pressure in the high pressure oil passage.
orifice holes in the unit injector tip. The HEUI
through orifice
through
ECM adjusts the current levels to the control
The ECM
injector delivers the correct amount of atomized fuel
valve solenoid in order to make the actual actuation
into the combustion chamber and the HEUI injector
pressure
pressu re equal to the desired actuation
actuation pressure.
es the atomized fuel evenly throughout the
disperses
dispers
combustion chamber.

RENR7572-06 17
(17) Sleeve
(18) Reverse flow check valve
(19) Nozzle check
(20) Nozzle tip
Refer to Illustration 11. The HEUI injector consists

of three major parts:
• Upper end, or actuator (A)

• Middle, or pumping
pumping unit (B)
• Lower end, or nozzle

nozzle assembly (C)
The upper end (A) consists of the following items:
• Solenoid (1)
• Armature spring (2)
• Armature (3)
• Seated pin (4)
• Spool spring (5)
• Spool valve (6)
• Check ball for intensifi
intensifier
er piston (7)
The middle of the injector (B) contains the following

items:
• Intensifier piston (8)

• Return spring (9)
• Plunger (10)
• Barrel (11)
The lower
following
followin end of the injector (C) consists of the
g items:
• Nozzle case (12)

• Inlet fill check
che ck (13)
g00990075
Illustration 11 • Stop (14)
Cross section of HEUI injector
(1) Solenoid
• Nozzle spring (15)
(2) Armature spring
(3) Armature • Check piston (16)
(16)
(4) Seated pin
(5) Spool spring
(6) Spool valve
• Sleeve (17)
(7) Check ball for intensifier piston
(8) Intensifier piston • Reverse flow check valve (18)
(9)
(10)Return
Plunger spring
• Nozzle check (19)
(19)
(11) Barrel
(12) Nozzle case
(13) Inlet fill check • Nozzle tip (20)
(14) Stop
(15) Nozzle spring
(16) Check piston

18 RENR7572-06
Systems
Systems Operation
Operation Section
These components
components work together
together in order to produce
produce Pre-Injection
different rates
different rates for fuel injection. The rates for fuel
injection
injection are electronicall
electronicallyy control
controlled
led by performance
performance
software in the ECM.
HEUI Fuel Injector (Operation)

The HEUI injector operates with a split injection cycle.
The split injection cycle has five phases of injection:

• Pre-injection
• Pilot injection
injection
• Injection delay
• Main injection
• Fill
g00884256
Illustration 12
Cross section of pre-injection cycle
(2) Armature spring
(3) Armature
(4) Seated pin
(5) Spool spring
(6) Spool valve
(8) Intensifier piston
(10) Plunger
(16) Check piston
(19) Nozzle check

RENR7572-06 19
Refer to Illustration 12. The injector is in the phase Pilot Injection

Injection
of pre-injecti
pre-injection
on when the engine is running and the
injector is between firing cycles. Plunger (10) and the
intensifier piston (8) are at the top of the piston bore.
below the plunger is full of fuel.
The cavity below
In the upper end, the armature (3) and the seated pin
down by the armature spring (2). High
(4) are held down
pressure actuation oil flows into the injector. The oil
then flows around the seated pin to the top of the
piston (16). This provides a positive downward
check piston (16).
force on the nozzle check (19) at all times when fuel
is not being injected.
The spool valve (6) is held in the top of the bore

for the spool valve by the spool spring (5). In this
position, the
the spool valve blocks actuation oil from
reaching
reachi ng the intensifier
intensifier piston. Actuatio
Actuation
n pressure
pressure
is felt on both the top and bottom of the spool, so
hydraulic f orces
orces on the spool are balanced. The spool
valve is held in the up position or the closed position
by the force of the spool spring.
g00884259
Illustration 13
Cross section of pilot injection cycle
(1) Solenoid
(3) Armature
(4) Seated pin
(6) Spool valve
(10) Plunger
(15) Nozzle spring
(16) Check piston
(19) Nozzle check
(20) Nozzle tip
(21) Drain

20 RENR7572-06
Systems
Systems Operation
Operation Section
Refer to Illustration 13. Pilot injection occurs when Injection Delay

the ECM sends a control
c ontrol current to the solenoid (1).
The current creates a magnetic field which lifts the
armature (3) and the seated pin (4). The seated pin
seat and an upper seat. When the seated
has a lower seat
pin is lifted by the armature, the upper seat closes
off the flow of actuation pressure to the check. The
opens. This allows the actuation oil on top
lower seat opens.
of check piston (16) to flow to drain (21). Actuation oil
that is trapped below spool (6) will also flow to drain
actuation oil drains through a vent hole in
(21). The actuation
the side of the injector.
p ressure under the spool causes a

The drop in pressure
hydraulic difference that acts on the spool. The
spool moves into the open position when hydraulic
pressure acts
acts on the top of the spool. This hydraulic
pressure
pressu re forces the spool downwa
downward.rd. The downwa
downward rd
movement of the spool is stopped when the spool
pin force the check ball (7) for the intensifier
and the pin force
piston onto the ball seat in the closed position. This
prevents
preven ts any actuation pressure from escaping
escaping from
y
the cavity
cavit for the intensifier piston (8). This drop in
the actuation pressure also removes the downward
force on the check piston.
Actuation oil now flows past the open spool and to the
top of the intensifier piston. The downward movement
piston and plunger (10) pressurizes the fuel in
of the piston
the plunger cavity to the nozzle tip (20). Pilot injection
injection
begins when the injection pressure increases in order
overcome the force of the nozzle spring (15) which
to overcome
lifts the nozzle check (19).
Pilot in jection will continue if the following conditions

exist:
• The solenoid
sole noid is energized.
• The spool remains open.
• There is no actuation
actuation pressure on top of the check
piston.
g00884279
Illustration 14
Cross section of injection delay
(1) Solenoid
(2) Armature spring
(3) Armature
(4) Seated pin
(5) Spool spring
(6) Spool valve
(10) Plunger
(16) Check piston
(19) Nozzle check

RENR7572-06 21
Refer to Illustration 14. Injection delay begins when Main Injection

Injection
the control cur rrent
ent to the solenoid (1) stops and the
solenoid is de-energized. The armature (3) is held
in the up position by a magnetic field. When the
magnetic
magnet field is de-energized, the armature spring
ic field
(2) pushes the armature and the seated pin (4)
downward. The seated pin closes the lower seat and
pin opens the upper seat. This allows the
the seated pin
actuation pressure to flow to the top of the check
piston (16). The hydraulic force on the check piston
overcomes the injection pressure and the
quickly overcomes
nozzle check (19) closes. Injection stops at this point.
Actuation pressure increases under the spool valve

(6) that creates the balance of hydraulic force on the
top and bottom of the spool. The weak spool spring
(5) now acts on
acts on the spool. This closes the spool
very slowly. As the spool remains open, actuation
pressure continues to flow past the spool to intensifier
(8) and to plunger (10). The injection pressure
piston (8) and
in the nozzle and in the plunger cavity increases very
quickly when the nozzle check is held in the closed
position..
position
g00884292
Illustration 15
Cross section of main injection cycle
(1) Solenoid
(3) Armature
(4) Seated pin
(6) Spool valve
(16) Check piston
(19) Nozzle check
(22) Drain

22 RENR7572-06
Systems
Systems Operation
Operation Section
Refer to Illustration 15. Main injection begins when Fill

the solenoid (1) (1) is re-energized. The magnetic field
is instantly created and the force of the magnetic
field lifts the armature (3) and the seated pin (4). The
closes off the flow of actuation pressure
upper seat closes
and the upper seat opens the check piston (16) and
the bottom of the spool (6) to the drain (22). The
force that holds the nozzle check (19)
hydraulic force
closed quickly dissipates
dissipates and the injection
injection pressure
pressure
opens the nozzle check. This is the start of main
injection. A
injection. A difference in hydraulic forces on the
spool is also created
created.. This differe
difference
nce forces the spool
downward. The check ball (7) for the intensifier piston
th e closed position when the spool is in
is held in the
this position. Main injection continues if the solenoid
remains energized.
g00884309
Illustration 16
Cross section of fill cycle

RENR7572-06 23
(1) Solenoid i01902820

(2) Armature spring
(3) Armature Air Inlet and Exhaust System
(4) Seated pin
(5) Spool spring
(6) Spool valve
SMCS Code: 1050
Code: 1050
(9) Return spring
(10) Plunger
(16) Check piston
(18) Reverse flow check valve
(19) Nozzle check
Refer to Illustration 16. The fill cycle begins when the

solenoid (1) is de-energized. The armature (3) and
(4) are forced down by the armature
the seated pin (4) are
spring (2). The seated pin closes the lower seat
and the seated pin opens the upper seat. Actuation
restored to the top of the check piston
pressure is restored
(16). This closes the nozzle check (19) and injection
ends. Actuation pressure is also felt under the valve g00787037
Illustration 17
spool (6). This r estores
estores the hydraulic balance on the
spool. The valve spring (5) slowly closes the spool. Airflow schematic
This stops the flow of actuation oil to the intensifier (1) Air line
piston (8). (2) Aftercooler core
(3) Air inlet elbow
(4) Exhaust outlet from turbocharger
As the spool raises, the check ball (7) for the (5) Turbine side of turbocharger
intensi fier piston is no longer held closed. Oil in the
intensifier (6) Compressor side of turbocharger
cavity for the intensifier piston lifts the check off the (7) Air cleaner
seat and flows to the drain (22) through a vent hole in
the side of the injector.
the injector. Return spring (9) pushes up The components of the air inlet and exhaust system
plunger (10) and the intensifier piston. This pushes all control the quality of the air that is available for
of the oil out of the cavity for the intensifier piston.
piston. The combustion. These components also control the
check valve (18)(18) for the fuel inlet is taken off of the amount of the air that is available for combustion.
valve seat as the plunger lifts up. This allows supply The components of the air inlet and exhaust system
fuel to flow into the plunger cavity. The fill cycle is are listed below:
when the plunger and the piston are at the
complete when
top of the bore and the plunger cavity is full of fuel. • Air cleaner
• Turbocharger
• Aftercooler
• Cylinder head
• Valves and valve system components
• Piston and cylinder
• Exhaust manifold
Inlet air is pulled through the air cleaner. The inlet air
is then compressed and heated by the compressor
wheel of turbocharger (6) to about 150°C (300°F).
The inlet air is then pushed through air-to-air
aftercooler core (2) and the inlet air is moved to air
inlet elbow (3). The temperature of the inlet air at
air inlet elbow (3) is about 43°C (110°F). Cooling
of the inlet air increases the combus
combustion
tion efficiency
efficiency..
Increased combustion efficiency helps to lower fuel
consumption. Also, increased combustion efficiency
helps to increas
increase e horsep
horsepower
ower output.

24 RENR7572-06
Systems
Systems Operation
Operation Section
Aftercooler core (2) is a separate cooler core. • Exhaust stroke

Aftercooler co
core
re (2) is installed in front of the core
(standard) of the engine radiator on the machine. Exhaust gases from exhaust manifold (11) enter the
Air that is ambient temperature is moved across the turbine side of turbocharger (5) in order to turn the
oler core by the engine fan. This cools the
aftercooler
afterco wheel. The turbine wheel is connected to a
turbine wheel.
turbocharged inlet air. shaft which drives the compressor wheel. Exhaust
gases from the turbocharger pass through the
aftercooler core (2), the air is forced into the
From aftercooler exhaustt outl
exhaus et pipe, the muffler and the exhaust
outlet
cylinder head in order to fill the inlet ports. Air flow stack.
from the inlet port into the cylinder is controlled by
valves.
the inlet valves.
Turbocharger
g00805952
Illustration 18
Air inlet and exhaust system
(2) Aftercooler core
(4) Exhaust outlet from turbocharger
(5) Turbine side of turbocharger
(6) Compressor side of turbocharger
(8) Exhaust valve
(9) Inlet valve
g00294193
(10) Air inlet Illustration 19
(11) Exhaust manifold
Turbocharger
(1) Air inle
inlett
There are two inlet valves and one exhaust valve (2) Compressor housing
for each cylinder. Inlet valves open when the piston (3) Compressor wheel
moves down on the inlet stroke. When the inlet valves (4) Bearing
open, cooled compressed air from the inlet port is (5) Oil inlet port
(6) Bearing
pulled into the cylinder.
cylinder. The inlet valves close and the
piston begins to move up on the compression stroke. (7)
(8) Turbine
Turbine housing
wheel
The air in the cylinder is compressed. When the (9) Exhaust outlet
piston is near the top of the compression stroke, fuel (10) Oil outlet port
is injected into the cylinder. The fuel mixes with the (11) Exhaust inlet
air and combustion starts. During the power stroke,
the combustion force pushes the piston downward.
downward. The turbocharger is installed on the center section
After the power stroke is complete, the piston moves of the exhaust manifold. All the exhaust gases
upward. This upward movement is the exhaust from the engine go through the turbocharger. The
stroke. During the exhaust stroke, the exhaust valve compressor side of the turbocharger is connected to
opens, and the exhaust gases are pushed through the aftercooler by a pipe.
the exhaust port into the exhaust manifold. After the
piston completes the exhaust stroke, the exhaust The exhaust gases go into turbine housing (7)
valve closes and the cycle starts again. The complete through exhaust inlet (11). The exhaus
exhaustt gases then
cycle consists of four stages: push the blades of turbine wheel (8). The turbine
wheel is connected by a shaft to compressor wheel
• Inlet stroke (3).
• Compression stroke
• Power stroke

RENR7572-06 25
Clean air from the air cleaners is pulled through

compressor housing
housing air inlet (1) by the rotation of
compressor wheel (3). The action of the compressor
wheel blades causes a compression of the inlet air.
compression gives the engine more power by
This compression
allowing the engine to burn more air and more fuel
during combustion.
When the load on the engine increases, more fuel is

injected into the cylinders. The combustion of this
nal f uel
additional
additio uel produces more exhaust gases. The
additional exhaust gases cause the turbine and the
compressor
compre ssor wheels of the turbocharge
turbochargerr to turn faster.
faster.
As the compr essor
essor wheel turns faster, more air is
forced into the cylinders. The increased flow of air g00943241
gives the engine more power by allowing the engine Illustration 21
to burn the additional
additional fuel with greater efficiency. (16) Inlet manifold
(17) Wastegate solenoid
Bearings (4) and (6) for the turbocharger use engine
oil under pr essure
essure for lubrication. The oil comes in Wastegate solenoid (17) allows the engine ECM to
through oil inlet port (5). The oil then goes through more precisely regulate the boost pressure to the
passages in the center section in order to lubricate engine. By closing or partially closing the wastegate
bearings. Oil from the turbocharger goes out
the bearings. solenoid, the ECM can increase the boost pressure.
through oil outlet port (10) in the bottom of the Typical wastegates will limit boost pressure to a
center section. The oil then goes back to the engine preset limit. Wastegate solenoid (17) blocks air
lubrication
lubricat ion system. from reaching the wastegate and this allows boost
pressure to increase. Air is routed from inlet manifold
(16) to wastegate solenoid (17). The wastegate
solenoid (17) senses the air pressure of the inlet air
and the wastegate solenoid adjusts the wastegate
accordingly. Bleed orifice (15) allows air to escape
from the line (boost pressure) when the pressure is
too high.
As the boost pressure through line (14) increases

against the diaphragm in canister (13), the valve
of the wastegate is opened. When the valve of the
wastegate is opened, the rpm of the turbocharger
is limited by bypassing a portion of the exhaust
gases. The exhaust gases are routed through the
wastegate which bypasses the turbine wheel of the
Illustration 20 g00943240 turbocharger.
Turbocharger with wastegate
Note: The turbocharger with a wastegate is preset at
Note: The
(12) Actuating lever
(13) Canister
the factory and no adjustment can be made.
(14) Line (boost pressure)
(15) Bleed orifice • When the wastegate solenoid
solenoid is deactiv
deactivated,
ated, the
wastegate is closed. This allows the engine to
When the engine is operating under conditions of low obtain the maximum boost in pressure.
boost, a spring pushes on a diaphragm in canister
(13). This action moves actuating lever (12) in order • When the wastegate solenoid is activated, the
to close the valve of the wastegate. Closing the valve wastegate is open. This allows the engine to
of the wastegate allows the turbocharger to operate control the boost of the pressure.
at maximum performance.
performance.

26 RENR7572-06
Systems
Systems Operation
Operation Section
Valve System Components Heater

Air Inlet Heater
The engines are equipped with an electric heater
located behind the air inlet elbow. The electric
that is located behind
heater has two functions:
• Aid in starting
• Aid in white smoke cleanup
cleanup during start-up
Under the proper conditions, the ECM turns on

the electric heater. The following conditions are
prior to activating the electric heater:
evaluated prior
• Jacket water coolant

coolant temperature
• Inlet manifold air temperature

• Ignition switch
switch position
• Duration of time
The system is capable of delivering heat for 30
seconds prior to start-up and during cranking of the
After the engine has started, the system is
engine.. After
engine
capable
capabl e of delive
delivering
ring heat consta
constantly
ntly for 7 minutes, or
the system can cycle the heat for 13 minutes. During
heating cycle, the heat is on for ten seconds and
the heating cycle,
the heat is off for ten seconds.
g00294195
Illustration 22
Valve system components in let heater malfunctions, the engine will still
If the air inlet
start and the engine will still run. There may be a
(1) Rocker arms
(2) Bridge concern regarding the amount of white smoke that is
(3) Spring present.. Al
present so, there may be a concern regarding the
Also,
(4) Pushrods need for an alternative starting aid.
(5) Exhaust valve
(6) Inlet valves
(7) Lifter Components
System Components
(8) Camshaft lobe
The system of the air inlet heater consists of the
The valve system components control the flow of following basic components:
following
inlet air into

The valve the cylinders
system duringalso
components engine operation.
control the flow • Relay of the air inlet heater
of exhaust gases out of the cylinders during engine
operation. • Heater element
The crankshaft gear drives the camshaft gear through • Coolant temperature
temperature sensor
an idler gear. The camshaft must be timed to the
crankshaft
cranks haft in order to get the correct relation between • Inlet air temperature sensor
the piston movement and the valve movement.
• ECM
The camshaft has two camshaft lobes for each
cylinder. The lobes operate the inlet and exhaust • Indicator lamp
lamp
valves. As the camshaft turns, lobes on the camshaft
cause lifters (7) to move pushrods (4) up and down. The air inlet heater relay turns the 12 V heater ON
Upward movement of the pushrods against rocker and OFF in r eesponse
sponse to signals from the ECM (5).
arms (1) results in downward movement (opening) of
valves (5) and (6). The airThe heater

cover. inlet
The heaterelement
heater (3) is a has
component ofstrap
a ground the air
(2)inlet
that
Each cylinder has two inlet valves and one exhaust must be connected to the engine.
valve. Valve springs (3) close the valves when the
lifters move down.

RENR7572-06 27
There are three conditions that would cause the air Under the proper condition, the heater will
inlet heater to
to be activated: be reactivated.
reactivated. When the sum of the coolant
temperature and the inlet manifold air temperature
• Powerup and Mode of Preheat has dropped below 25°C (109°F), the heater will be
This condition could exist after a warm
reactivated. This
reactivated.
Regardless of temperature, the heater and the lamp engine has cooled and the operator attempts to start
of the heater should come on for two seconds when the engine.
first powered (lamp check). When the
the ECM is first
sum of the coolant temperature plus the inlet manifold When the sum of the coolant temperature and the
air temperature is less than 25°C (109°F), the ECM inlet manifold air temperature does not attain 35°C
t he heater and the lamp for 30 seconds.
will turn on the the heater will be activated. The heater can
(127°F), the heater
This is a cycle of preheat. be activated no longer than 20 minutes (maximum).
The ECM will turn off the heater after the 20 minute
then turn off the heater and the lamp.
The ECM will then time limit.
When the operator attempts to start the engine prior
to the completion of preheat, the ECM proceeds into For additional information
information on the air inlet heater
heater,, refer
the mode of cr anking
anking for heater control. to Troubleshooting
Troubleshooting,, “Air Inlet Heater Circuit - Test”.
• Mode of cranking
i01903000
During engine cranking, when the sum of the coolant

temperature plus the inlet manifold air temperature
Lubrication
Lubrication System
than 25°C (109°F), the ECM will turn on the
is less than 25°C SMCS Code: 1300
Code: 1300
heater. The heater will remain on during engine
cranking. If the engine fails to start, the ECM reverts
to preheat.
preheat. Reverting to preheat will activate the
heater for another 30 seconds.
• Running of the
the engine
After the engine has started, the same combination

manifold air temperature and coolant
of inlet manifold
temperature will determine the state of the heater.
The cycle has two strategies.
The two strategies are continuous and intermittent.

During the continuous strategy, the heater will remain
ma ximum of 7 minutes after starting. If the
on for a maximum
same conditions exist, the ECM will activate the
intermittent strategy. During the intermittent strategy,
heater is cycled for a maximum of 13 minutes.
the heater
During this cycle, the heater is turned on for 10
seconds and the heater is turned off for 10 seconds.
the 13 minute time limit, the heater is shut off.
After the
When one of the temperature sensors fails, the

will operate in the following manner:
system will
• Coolant temperature sensor

When the coolant temperature sensor has an open
circuit or a short circuit, the coolant temperature
has failed. During this condition, the heater will
sensor has
sensor
be activated when the inlet manifold air temperature
is less than 10°C (50°F).
Inlet air temperature sensor

•
When the the inlet air temperature sensor has an open
circuit or a short circuit, the inlet air temperature
sensor has failed. During this condition, the heater
be activated when the coolant temperature is less
will be activated
than 40°C (104°F).

28 RENR7572-06
Systems
Systems Operation
Operation Section
g00990983
Illustration 23
Lubrication system schematic
(1) Unit injector hydraulic pump (9) Cylinder head gallery (19) Passage to camshaft idler gear bearing
(2) High pressure relief valve (10) Passage to pushrod lifters (20) Passage
(3) Passage to the rocker arms (11) Main bearing (21) Engine oil filter
(4) High pressure oil line (12) Camshaft bearing (22) Oil cooler bypass valve
(5) High pressure oil manifold (13) Passage to engine oil pan (23) Engine oil cooler
(6) Passage from high pressure oil manifold (14) Main oil gallery (24) Engine oil pump
to injector (15) Turbocharger oil supply line (25) Oil pump bypass valve
(7) Oil supply line for unit injector hydraulic (16) Passage to front housing (26) Auxiliary engine oil filter (if equipped)
pump (17) Passage to oil pump idler gear bearing (27) Engine oil pan
(8) Piston cooling jets (18) Oil filter bypass valve

RENR7572-06 29
Engine oil pump (24) is mounted to the bottom of the The high pressure oil system provide
provides
s actuation oil to
cylinder
cylind er block
block inside
inside the engine oil pan (27). The the unit injector.
injector. The high pressure circuit operates in
engine oil pump (24) pulls oil from engine oil pan a pressure range typically between 6 MPa (870 psi)
(27). The engine oil pump pushes the oil through the and 28 MPa (4050 psi). This high pressure oil flows
the engine oil cooler (23). Oil then flows
passage to the engine line into the cylinder head. The cylinder
through a line into
through engine oil filter (21). The filtered oil then head stores the oil at actuation pressure. The oil is
enters the turbocharger oil supply line (15) and main ready to actuate the unit injector. Oil is discharged
(14).
oil gallery (14). unit injector under the valve cover so that no
from the unit injector
return lines are required.
The main oil gallery (14) distributes oil to main
(11), piston cooling jets (8), and camshaft
bearings (11), lubrication oil’s work is done, the lubrication
After the lubrication
bearing (12). Oil from main oil gallery (14) exits the oil returns to the engine oil pan.
front of the block. The oil then enters a groove that is
front housing (16).
cast in front bypass valve (25) limits the pressure
The oil pump bypass
of the oil that is coming from the engine oil pump
Oil enters the crankshaft through holes in the (24). The engine oil pump (24) can pump more than
bearing sur faces
faces (journals) for the main bearing into the system. When there is more than
enough oil into
(11). Passages connect the bearing surface (journal) enough oil, the oil pressure increases. When the oil
for the main bearing (11) with the bearing surface pressure increases, the oil pump bypass valve (25)
(journal) f or
or the connecting rod. This allows the oil that is not needed to go
will open. This
back to the suction side of the engine oil pump (24).
The passage in front housing (16) sends the oil flow
directions. At the upper end of the passage,
in two directions. bypass valves (22) and (18) will open when
The bypass valves
oil is directed back into the block and up to cylinder the engine is cold (starting conditions). Opening
head gallery (9) through passage (3) to the rocker the bypas
bypass s valve
valvess achiev
achieves
es immediate lubrica
lubrication
tion
arm mechanism.
mechanism. A passage (17) sends oil to the oil of all components
components.. Immediate lubricat
lubrication
ion is critica
criticall
pump idler gear bearing. when cold oil with high viscosity causes a restriction
to the oil flow through engine oil cooler (23) and
the front main bearing enters a passage (19)
Oil from the oil filter (21). The engine oil pump (24) sends
engine oil
to the camshaft idler gear bearing. Oil passages in the cold oil through the bypass valves around the
the crankshaft send oil from all the main bearings engine oil cooler (23) and engine oil filter (21) to the
through the connecting rods to the connecting
(11) through rger oil supply line (15) and the main oil
turbocharger
turbocha
rod bearings. gallery (14) in the cylinder block.
The passages
passages send oil from the camshaft bearing When the oil
the oil gets warm, the pressure difference
(12) to an oil passage in the side covers. The oil then in the bypass valves decreases and the bypass
enters a hole in the shafts to pushrod lifters (10). The valves close.
close. After the bypass valves close, there is a
oil lubr icates
icates the bearings of the lifter. normal f low
low of oil through the engine oil cooler and
the engine oil filter.
Note: Engines that are equipped with an auxiliary oil
Note: Engines
(26) will receive oil at a port. The filtered oil will
filter (26) bypass valves will also open when there is a
The bypass
be returned to engine oil pan (27). restriction in the engine oil cooler (23) or engine
oil filter (21). This design allows the engine to be
unit injector hydraulic pump (1) is a gear-driven
The unit injector ated even though engine oil cooler (23) or
lubricated
lubric
axial piston pump. The unit injector hydraulic pump engine oil filter (21) are restricted.
raises the engine oil pressure from the typical
ing oil pressure to the actuation pressure
operating
operat engine oil cooler bypass valve is also activated
The engine
that is required by the unit injectors. The injection by pressure. If the oil pressure differential across the
actuation
actuat ion pressu
pressurere control valve (5) electronically
electronically engine oil cooler reaches 125 ± 30 kPa (18 ± 4.5 psi),
controls
contro ls the output pressure of the unit injector valve will open. Opening the valve allows the oil
the valve
hydraulic pump (1). flow to bypass the engine oil cooler (23).
oil circuit consists of a low pressure circuit and

The oil
a high pressure circuit. The low pressure circuit
typically operates at a pressure of 240 kPa (35 psi) to
kPa (70 psi). The low pressure circuit provides
480 kPa
engine oil that has been filtered to the unit injector
hydraulic pump (1). Also, the low pressure circuit
des engine oil that has been filtered to the
provides
provi
lubricating system of the engine. Oil is drawn from
the engine oil pan (27). Oil is supplied through the
ne oil cooler (23) and engine oil filter (21) to both
engine
engi
the engine and the unit injector hydraulic pump (1).

30 RENR7572-06
Systems
Systems Operation
Operation Section
The main oil flow now reaches the main engine oil A pressure type cooling system offers two
filter (21). When
When the oil pressure differential across advantages:
the oil filter bypass valve (18) reaches 125 ± 30 kPa
(18 ± 4.5 psi), the valve opens in order to allow • The cooling system can operate safely at a
to go around the oil filter (21). The
the oil flow to temperature that is higher than the normal boiling
temperature
oil flow continues in order to lubricate the engine point of water.
components. When the oil is cold, an oil pressure
difference inin the bypass valve also causes the valve • The cooling system
system prevents cavitation
cavitation in the water
to open. This bypass valve then provides immediate pump.
lubrication to all the engine components when cold
hig h viscosity causes a restriction to the oil
oil with high Cavitation is
Cavitation the sudden formation of low pressure
is the
flow through the engine oil filter (21). The bypass bubbles in liquids by mechanical forces. The
valve will also open when there is a restriction in the formation of air or steam pockets is more difficult
engine oil f ilter
ilter (21). This design allows the engine pressure type cooling system.
within a pressure
to be lubricated even though engine oil filter (21) is
restricted. The shunt line preven
prevents
ts cavitation by the water pump.
The shunt line
line provides a constant head pressure
Note: Refer to Specifications, “Engine Oil Filter
Note: Refer at the water pump inlet.
Base”.
coolant mixture must be a minimum
Note: The coolant
Note: The
Filtered oil flows through the main oil gallery (14) in of 30 percent ethylene glycol base antifreeze for
the cylinder block. Oil is supplied from the main oil efficient water pump performance for air to air after
(14) to the following components:
gallery (14) engines. The mixture keeps the cavitation
cooled engines.
temperature range of the coolant high enough for
• Piston cooling jets (8) efficient performance.
• Valve mechanism
• Camshaft bearing
bearing (12)
• Crankshaft main bearings

• Turbocharger cartridge
cooling chamber is formed by the lip that is
An oil cooling
forged at the top of the skirt of the piston and the
cavity that is behind the ring grooves in the crown.
Oil flow f or
or the piston cooling jet enters the cooling
chamber through a drilled passage in the skirt. Oil
flow from the piston cooling jet returns to the engine
g00293080
(27) through the clearance gap between the
oil pan (27) Illustration
Illustra tion 24
crown and the skirt. Four holes that are drilled from Cooling system schematic
the piston oil ring groove to the interior of the piston (1) Cylinder head
excess oil from the oil ring.
drain excess (2) Water temperature regulator housing
(3) Expansion tank
The breather allows engine blowby to escape from (4) Shunt line (expansion tank to water pump)
(5) Bypass hose
crankcase. The engine blowby is discharged
the crankcase. (6) Radiator
through a hose into the atmosphere. This prevents (7) Cylinder block
pressure from building up that could cause seals or (8) Oil cooler
gaskets to
gaskets to leak. (9) Water pump
pump (9) is located on the right side of the

Water pump (9)
i01903111 cylinder block. The water pump is belt driven from
the crankshaft pulley. Coolant can enter the water
Cooling System pump in thr ee
ee places:
SMCS Code: 1350
Code: 1350
• Inlet at the bottom of the water pump
This engine has a pressure type cooling system that
is equipped with a shunt line.
• Bypass hose
hose (5) into the top of the water pump
• Shunt line (4)
line (4) into the top of the water pump

RENR7572-06 31
Coolant from the bottom of the radiator is pulled into Water temperature regulator (11) controls the
the bottom inlet
inlet of the pump by impeller rotation. The direction of flow.
flow. When the coolant temperature is
coolant exits the back of the pump directly into the oil below the normal operating temperature, the water
cooler cavity of the block. temperature regulator is closed. The coolant is
through bypass hose (5) and into the top inlet
directed through
All of the coolant passes through the core of the of the water pump. When the coolant temperature
oil cooler and the coolant enters the internal water reaches the normal operating temperature, water
manifold
manifol d of the cylinder block. The manifold disperses temperature regulator (11) opens. When the water
the coolant to water jackets around the cylinder walls. temperature regulator is open, the bypass is closed.
Most of the coolant goes through outlet (10) to the
for cooling. The remainder flows through
radiator for
bypass hose (5) and into the water pump.
coolant systems may contain two water

Note: Some coolant
Note: Some
temperature regulators.
The shunt line

line (4) extends from the top of the water
pump to an expansion tank. The shunt line must be
routed properly in order to avoid trapping any air.
By providing a constant head pressure to the water
providin
pump, the shunt line can provide a constant flow of
coolant to the water pump. This prevents cavitation
water pump.
by the water
Note: Water temperature regulator (11) is an

Note: Water
important part of the cooling system. The water
temperature
tempera ture regulator divides coola
coolant
nt flow betwee
between
n
the radiator and the bypass in order to maintain
normal operating temperature. If the water
the normal
temperature regulator is not installed in the system,
there is no mechanical control, and most of the
will travel the path of least resistance through
coolant will
the bypass. This will cause the engine to overheat
in hot weather and the engine will not reach normal
operating
operati ng temperature in cold weather.
Note: Air vent valve (12) will allow the air to escape
Note: Air
g00293081
Illustration 25 the water temperature regulator from the cooling
past the water
Lines Group
Water Lines system while the radiator is being filled. During
normal operation, the air vent valve will be closed
(1) Cylinder head
order to prevent coolant flow past the water
in order
(2)
(5) Water
Bypasstemperature
hose regulator housing temperature regulator.
(9) Water pump
(10) Outlet to radiator
(11) Water temperature regulator Coolant For Air Compressor (If
(12) Air vent valve in thermostat
ed)
Equipped)
Equipp
From the cylinder block, the coolant flows into
passages in the cylinder head. The passages send If the engine is equipped with an air compressor the
coolantt for the air compressor is supplied from the
coolan
the flow ar ound
ound the unit injector sleeves and the inlet
and the exhaust passages. The coolant now enters water temperature regulator housing through the
water temperature regulator housing (2) at the front coolant supply line. The coolant is circulated through
air compressor and the coolant is returned to the
the air
side of the cylinder head.
right side
cooling system through the coolant return line into
the cylinder head.
Coolant
Coolant Conditioner
Conditioner (If Equipped)
Equipped)
Some conditions of operation can cause pitting. This
pitting is caused by corrosion or by cavitation erosion.
A cor rosion
rosion inhibitor is a chemical that provides
a reduction in pitting. The addition of a corrosion
inhibitor can keep this type of damage to a minimum.

32 RENR7572-06
Systems
Systems Operation
Operation Section
The coolant conditioner element is a spin-on element element The camshaft is accessible through the covers
that is similar to
to the fuel filter and to the oil filter on the left side of the cylinder block. These side
elements.
element s. The coolant conditioner
conditioner element attaches
attaches covers support the pushrod lifters. The camshaft
to the coolant conditioner base that is mounted on is supported by bearings that are pressed into the
the engine. Coolant flows from the water
the front of the block. There are seven camshaft bearings.
cylinder block.
pump to the coolant conditioner base and back to the
cylinder
cylind er block. Coolant constantly flows through the The cylinder
cylinder head is separa
separated
ted fro
from
m the cylinder
cylinder block
conditioner element when the valves are in
coolantt conditioner
coolan nonasbestos fiber gasket with a steel backing.
by a nonasbestos
the OPEN position. Coolant flows out of the cylinder block through gasket
openings
openin gs and into the cylinder head. This gasket also
The element has has a specific amount of inhibitor for oil supply and drain passages between the
seals the oil supply
acceptable
accept able cooling system protection.
protection. As the coolant
coolant cylinder block and the cylinder head.
flows through the element, the corrosion inhibitor
th e solution. The corrosion inhibitor is a dry
goes into the inlet ports are on the left side of the cylinder
The air inlet ports
solution, so the inhibitor dissolves. The corrosion head, while the exhaust ports are located on the right
inhibitor then mixes to the correct concentration. side of the cylinder head. There are two inlet valves
Two basic types
types of elements are used for the and one exhaust
exhaust valve for each cylinder. Replaceable
cooling system. The two elements are the precharge valve guides are pressed into the cylinder head.
elements and the maintenance elements. Each The hydraulically actuated electronically controlled
element has a specific use. The elements
type of element injector is located between the three valves.
unit injector
must be used correctly in order to get the necessary Fuel is injected directly into the cylinders at very
concentration for cooling system protection. The high pressure. A pushrod valve system controls the
elements also contain a filter. The coolant conditioner
elements also valves.
elements should remain in the system after the
conditioner
conditioner material has dissolved.
dissolved.
Piston, Rings
Rings And Connecting
The precharge element contains more than the Rods
normal amount of inhibit
inhibitor.
or. The precharge element is
when a system is first filled with new coolant.
used when a One-piece aluminum pistons are used in most
This element must add enough inhibitor in order to applications.
applic ations. Engines with higher cylinder pressures
bring the complete cooling system up to the correct one-piece steel pistons. Refer to the Parts
require one-piece
ration.
concentration.
concent Manual in order to obtain information about the type
of pistons that are used in a specific engine.
The maintenance elements have a normal amount
of inhibitor
inhibitor.. The maintenance elements are installed
installed Aluminum
Aluminum and Steel One-Piece
One-Piece Pistons
at the first change interval. A sufficient amount of
inhibitor is provided by the maintenance elements The aluminum
aluminum and steel pistons have an iron band
order to maintain the corrosion protection at an
in order for the compression ring. This helps to reduce wear
acceptable level. After the first change interval, on the compression ring groove. The pistons have
only maintenance elements are installed. In order rings:
three rings:
provide the cooling system with protection,
to provide
maintenance elements are installed at specific • Compression ring
intervals.
• Intermediate ring
i02099085
i02099085
• Oil ring
Basic Engine
All of the rings are located above the piston pin
SMCS Code: 1200
Code: 1200 The compression ring is a Keystone ring.
bore. The
Keystone rings have a tapered shape. The action
of the ring in the piston groove that is tapered helps
Cylinder Block And Head preventt seizure of the rings. Seizure of the rings is
preven
caused by deposits of carbon. The intermediate ring
cylinder block has seven main bearings. The
The cylinder is rectangular with a sharp lower edge. The oil ring
main bearing caps are fastened to the cylinder block standard type of ring or a conventional type of
is a standard
with two bolts for each cap. ring. Oil returns to the crankcase through slots in the
Removal of the oil pan allows access to the bottom of the groove.
crankshaft, the main bearing caps, the piston cooling
and the oil pump.
jets, and
jets,

RENR7572-06 33
Oil from the piston cooling jets sprays the underside

of the pistons. The
pistons. The spray lubricates the pistons and
the spray cools the pistons. The spray also improves
the piston’s life and the spray also improves
improves the ring’s
aluminum pistons use a single jet. The steel
life. The aluminum
pistons use two jets. Refer to the Specifications,
“Piston Cooling Jets” for more information.
The connecting rod has a taper on the pin bore

end. This taper gives the connecting rod and the
strength. The additional strength is
piston more strength.
concentrated in the areas with the most load. Two
bolts hold the connecting rod cap to the connecting
design keeps the connecting rod width to a
rod. This design
minimum, so that the connecting rod can be removed g00293227
through the cylinder. You must keep the rod and the Illustration 26
original cap
cap together. Schematic of oil passages In crankshaft
(1) Oil gallery
(2) Main bearings
Crankshaft (3) Connecting rod bearings
The crankshaft
crankshaft changes
changes the combustion forces in the Pressure oil is supplied to all main bearings through
cylinder into usable rotating torque which powers the
cylinder drilled holes in the webs of the cylinder block. The oil
vehicle. A vibration damper is used at the front of the then flows through drilled holes in the crankshaft in
crankshaft
cranks haft to reduce torsional vibratio
vibrations
ns (twist on the order to provide oil to the connecting rod bearings.
crankshaf t)
t) that can cause damage to the engine. The crankshaft is held in place by seven main
bearings. A thrust bearing next to the rear main
The crankshaft drives a group of gears on the front bearing controls the end play of the crankshaft.
engine. The gear group drives the following
of the engine.
devices:
Vibration Damper
• Oil pump
The force from combustion in the cylinders will
cause the crankshaft to twist. This is called torsional
• Camshaft
vibration. If the vibration is too great, the crankshaft
• Unit injector hydraulic pump will be damaged. The vibration damper limits the
torsional vibrations to an acceptable amount in order
• Gear-driven
Gear-driven air compressor to prevent damage to the crankshaft.
• Power steering pump
In addition, belt pulleys on the front of the crankshaft

drive the following
following compon
components:
ents:
• Radiator fan
• Water pump
pump
• Alternator
• Refrigerant compressor
Hydrodynamic seals are used at both ends of the
Hydrodynamic
crankshaft
cranks haft to control
control oil leakag
leakage.
e. The hydrodynamic
grooves in the seal lip move lubrication oil back into
crankcase as the crankshaft turns. The front
the crankcase
seal is located in the front housing. The rear seal is
installed in the flywheel housing.

34 RENR7572-06
Systems
Systems Operation
Operation Section
Rubber Vibration
Vibration Damper (If Equipped)
Equipped) Viscous Vibration Damper (If Equipped)
g00293231 g00293230
Illustration 27 Illustration 28
Rubber vibration damper Cross section of viscous vibration damper
(1) Crankshaft (1) Crankshaft
(2) Ring (2) Weight
(3) Rubber ring (3) Case
(4) Hub
(5) Alignment marks
The viscous vibration damper is installed on the front
of crankshaft (1). The viscous vibration damper has
The rubber vibration damper is installed on the a weight (2) in a case (3). The space between the
front of crankshaft (1) . The hub (4) and ring (2) are weight and the case is filled with a viscous fluid.
isolated by a rubber ring (3). The rubber vibration The weight moves in the case in order to limit the
damper has alignment marks (5) on the hub and the torsional vibration.
ring. These marks give an indication of the condition
of the rubber vibration damper.
Camshaft
The camshaft is located in the upper left side of the
cylinder block. The camshaft is driven by gears at
the front of the engine. Seven bearings support the
camshaft. A thrust plate is mounted between the
camshaft drive gear and a shoulder of the camshaft
in order to control the end play of the camshaft.
The camshaft is driven by an idler gear which is

driven by the crankshaft gear. The camshaft rotates in
the same direction as the crankshaft. The crankshaft
rotates in the counterclockwise direction when the
engine is viewed from the flywheel end of the engine.
There are timing marks on the crankshaft gear, the
idler gear, and the camshaft gear in order to ensure
the correct camshaft timing to the crankshaft for
proper valve operati
operation.
on.

RENR7572-06 35
As the camshaft turns, each lobe moves a lifter

assembly. Ther e are two lifter assemblies for each
cylinder. Each lifter assembly moves a pushrod.
Each pushrod moves a valve (exhaust) or a set of
(inlet). The camshaft must be in time with
valves (inlet).
the crankshaft. The relation of the camshaft lobes
to the crankshaft position causes the valves in each
operate at the correct time.
cylinder to operate
i02099146
Rear Power Take-Off (RPTO)

SMCS Code: 1165-RE
Code: 1165-RE
The Rear Power Take-Off (RPTO) is an integral part

of the flywheel housing. The rear power take-off is
positioned on the rear of the engine at approximately
one o’clock. The rear power take-off provides
continuous power through a series of three direct
drive gears, the crankshaft gear, the idler gear,
g00864026
and the output shaft gear. These gears are driven Illustration 29
off the rear of the crankshaft. The RPTO turns Grounding Stud To Battery Ground (“−”)
1.2 revolutions for each revolution of the engine
crankshaft.
direction as The output crankshaft.
the engine shaft rotatesAll
inbearings
the sameand
all thrust surfaces are internally lubricated. The
RPTO requires no additional maintenance.
i02099630
Electrical System
SMCS Code: 1400;
Code: 1400; 1550; 1900
Grounding Practices
Proper grounding for the vehicle electrical system
and the engine electrical systems is necessary for
proper vehicle
grounding performance
will result and reliability.
in unreliable electricalImproper
circuit
paths and uncont
uncontrolled
rolled electrical circuit paths.
Uncontrolled engine electrical circuit paths can result

Uncontrolled g00864027
g00864027
in damage to main bearings, crankshaft bearing Illustration 30
journal surfaces, and aluminum components. Alternat e Groundin g Stud To Battery Ground (“−”)
Uncontrolled electrical circuit paths can cause engine must have a wire ground to the battery.
The engine
electrical noise which may degrade the vehicle and
radio performance. Ground wires or ground straps should be combined
at ground
ground studs that are only for ground use. You
To ensure proper functioning of the vehicle and need to periodically check that the grounds are tight
engine electrical systems, an engine-to-frame ground and grounds are free of corrosion.
strap with a direct path to the battery must be used.
This may be provided by a starting motor ground, by The engine alternator should be battery ground
a
toframe
enginetoground.
startingAn
motor ground, or byground
engine-to-frame a directstrap
frame with a ng
wire
charging
chargi size that
current is capable
of the of managing the full
alternator.
must be used in order to connect the grounding stud
of the engine to the frame of the vehicle and to the
negative
negati ve battery post.

36 RENR7572-06
Systems
Systems Operation
Operation Section
Both the low amperage circuit and the charging circuit

NOTICE are connected to to the same side of the ammeter. The
When jump starting an engine, the instructions in Op- starting circuit is connected to the opposite side of
Maintenance Manual, “Starting with Jump
eration and Maintenance the ammeter.
Start Cables” should be followed in order to properly
start the engine. NOTICE
the alternator without the battery in the
Never operate the
This engine may be equipped with a 12 volt starting circuit. Making or breaking an alternator connection
syst
system
for em orstarting
jump a 24
start volt
voshould
ing lt sta
starti
rting
ng
besyste
system.
m.The
used. Only
Onluse
y eq
equa
uala
of l volta
vo ltage
ge
higher with heavyor
the regulat load
.
regulator on the circuit can cause damage to
voltage will damage the electrical system.
Control Module (ECM) must be discon-

The Engine Control Charging
Chargi System Components
ng System
nected at the J1/P1 and J2/P2 locations before weld-
ing on the vehicle. Alternator
Engine Electrical System

The electrical system has three separate circuits:
• Charging cir cuit
cuit
• Starting circuit
• Low amperage circuit
electrical system components are used
Some of the electrical
in more than one circuit. The following components
are used in each of the three circuits:
• Battery
• Circuit breaker
breaker
• Ammeter
g00293544
Illustration 31
• Battery cables
Alternat or component s
charging circuit is in operation when the engine
The charging (1) Brush holder
(2) Rear frame
is running.circuit.
charging An alternator generates
A voltage regulatorelectricity for the
in the circuit (3) Rotor
(4) Stator
the electrical output in order to keep the
controls the (5) Drive end frame
battery at full charge. (6) Fan assembly
(7) Slip rings
(8) Rectifier
NOTICE
disconnect switch, if equipped, must be in the ON
The disconnect The alterna
alternator
tor has three-phase, full-wave, rectified
position in order to let the electrical system function. output. The alternator uses brushes to generate
There will be damage to some of the charging circuit electricity.
components
component s if the engine is running with the discon-
nect switch in the OFF position. The alternator is an electrical component and a
mechanical component that is driven by a belt from
If the vehicle has a disconnect switch, the starting engine rotation. The alternator is used to charge
circuit can operate only after the disconnect switch the storage battery during engine operation. The
is put in the ON position. alternator is cooled by a fan that is a part of the
alternator. The fan pulls air through holes in the
The starting circuit is in operation only when the start back of the alternator. The air exits the front of the
switch is activated. alternator and the air cools the alternator in the
process.

RENR7572-06 37
The alternator converts mechanical energy and

magnetic energy
energy into alternating current (AC)
and voltage. This process is done by rotating an
electromagnetic field (rotor) that is direct current
t hree-phase stator. The alternating
(DC) inside a three-phase
current and the voltage that is generated by the
stator are changed to direct current. This change is
accomplished
accomplishe d by a system that uses three-phase,
full-wave, rectified outputs. The three-phase,
full-wave, rectified outputs have been converted
rectifier diodes that are made of silicon. The
by six rectifier
alternator also has a diode trio. A diode trio is an
assembly that is made up of three exciter diodes.
The diode tr ioio rectifies field current that is needed to
start the charging process. Direct current flows to the g00285112
alternator
alterna tor output terminal. Illustration 32
Solenoid
A solid-state regulator is installed in the back of the
alternator. Two brushes conduct the current through The solenoid has windings (one set or two sets)
rings to the field coil on the rotor.
two slip rings around a hollow cylinder. A plunger with a spring
loaded device is inside of the cylinder. The plunger
Also, a capacitor is mounted in the back of the can move forward and backward. When the start
r. The capacitor protects the rectifier from
alternator.
alternato switch is closed and electricity is sent through the
high voltages. The capacitor also suppresses radio windings, a magnetic field is created. The magnetic
noise sources
sources.. field pulls the plunger forward in the cylinder. This
moves the shift lever in order to engage the pinion
The voltage regulator is a solid-state electronic drive gear with the ring gear. The front end of the
switch that controls the alternator
alternator output. The voltage
voltage plunger then makes contact across the battery and
regulatorr limits the alternator voltage to a preset
regulato the motor terminals of the solenoid. After the contact
value by controlling the field current. The voltage is made, the starting motor begins to turn the flywheel
regulator feels the voltage in the system. The voltage of the engine.
regulatorr switches ON and OFF many times per
regulato
second in order to control the field current for the When the start switch is opened, current no longer
alternator. The alternator uses the field current in flows through the windings. The spring now pushes
order to generate
to generate the required
required voltage output. the plunger back to the original position. At the same
time, the spring moves the pinion gear away from
Note: Refer to Service Manual, SENR3862 for
Note: Refer the flywhe
flywheel.
el.
detailed
detaile d service information for the Delco Remy 27
SI Series Alternator.
Alternator. When two sets of solenoid windings are used, the
windings are called the hold-in winding and the
the alternator is connected to an engine
Note: If the
Note: If pull-in winding. Both sets of windings have the same
component, the ground strap must connect that number of turns around the cylinder, but the pull-in
engine component to the frame or to the battery winding uses a wire with a larger diameter. The wire
ground..
ground with a larger diameter produces a greater magnetic
field. When the start switch is closed, part of the
current flows from the battery through the hold-in
Starti ng System Components
Starting windings. The rest of the current flows through the
pull-in windings to the motor terminal. The current
Starting Solenoid then flows through the motor to ground. The solenoid
is fully activated when the connection across the
A solenoid is a magnetic switch that does two basic battery and the motor terminal is complete. When
operations: the solenoid is fully activated, the current is shut
off through the pull-in windings. At this point, only
• The solenoid closes
closes the high current starting motor the smaller hold-in windings are in operation. The
circuit with a low current start switch circuit. hold-in windings operate for the duration of time that
is required in order to start the engine. The solenoid
• The solenoid engages
engages the starter motor pinion with will now draw less current from the battery, and the
the ring gear. heat that is generated by the solenoid will be kept at
an accept
acceptable
able level.

38 RENR7572-06
Systems
Systems Operation
Operation Section
Starting
Starting Motor When the ignition switch is released from the START
position, the starting
starting motor solenoid is deactivated.
The starting motor solenoid is deactivated when
current no longer flows through the windings. The
pushes the plunger back to the original
spring now pushes
position of the plunger. At the same time, the spring
moves the pinion gear away from the flywheel ring
gear.
g00293548
Illustration 33
Starting motor (typical example)
assembly
(1) Brush assembly
windings
(2) Field windings
(3) Solenoid
(4) Clutch
(5) Pinion
(6) Armature
The starting motor is used to turn the engine flywheel

w ill allow the engine to start running.
at a rate that will
Note: Some starting motors have ground straps

Note: Some
the starting motor to the frame, but
that connect the
many of these starting motors are not grounded to
the engine. These starting motors have electrical
tion systems. For this reason, the ground strap
insulation
insula
that connects the starting motor to the frame may not
be an acceptable
acceptable engine ground. Starting motors that
installed as original equipment are grounded to
were installed
the engine. These starting motors have a ground wire
from the starting motor to the negative terminal of
battery. When a starting motor must be changed,
the battery.
consultt an authorized dealer for the proper grounding
consul grounding
practices
practic es for that starting motor.
The starting motor has a solenoid. When the ignition

switch is turned to the START position, the starting
solenoid will be activated electrically. The
motor solenoid
solenoid plunger will now move a mechanical linkage.
The mechanical linkage will push the starter motor
order to engage with the flywheel ring gear.
pinion in order
The starter motor pinion will engage with the ring
gear before the electric contacts in the solenoid close
circuit between the battery and the starting
the circuit starting motor.
When the circuit between the battery and the starting
motor is complete, the pinion will turn the engine
l. A clutch gives protection for the starting
flywheel.
flywhee
motor so that the engine cannot turn the starting
motor too fast.

RENR7572-06 39
Testing and Adjust
Adjusting
ing Section
Testing and Adj usting

Adjusting Inspection of the Fuel System
during Engine Operation
Section
Either too much fuel for combustion or not enough
fuel for combustion can be the cause of a problem in
Fuel System the fuel system. Finding the source of the problem
can be difficult, especially when you have smoke that
rises from the exhaust. Therefore, work is often done
i02270984 on the fuel system when the problem is really with
some other part of the engine.
Fuel System - Inspect
When noticeable smoke rises from the exhaust, this
SMCS Code: 1250-040
Code: 1250-040 problem can be caused by a damaged unit injector.
This unusual smoke can also be caused by one or
Initia
Initiall Inspect
Inspection
ion of the Fuel
Fuel Syste
System
m more of the reasons that follow:
A problem with the components that send fuel to • Not enough air for good combustion
the engine can cause low fuel pressure. This can
decrease engine performance. • An overload at high altitude
1. Check the fuel level in the fuel tank. Inspect the • Oil leakage into combustion
combustion chamber
cap for the fuel tank. Ensure that the vent in the
fuel cap is not filled with dirt. • Altitude
2. Check all fuel lines for fuel leakage. The fuel lines • Air inlet and exhaust leaks
must be free from restrictions and faulty bends.
Verify that the fuel return line is not collapsed. Note: Refer to Trou
Note: Refer Troubleshoo
bleshooting
ting for more information
on the fuel system.
3. Clean the screen inside the inlet fitting of the fuel
transferr pump.
transfe Checking The Operation Of
4. Operate the hand priming pump (if equipped).
Individual Cylinders
If excessive resistance is felt, inspect the fuel
Low temperature at an exhaust manifold port is an
pressure regulating valve. Make sure that the
indication of no fuel to the cylinder. This can possibly
pressure regulator is installed correctly, and
be an indication of an injector with a defect. An extra
make sure that the pressure regulator functions
high temperature at an exhaust manifold port can be
correctly.
an indication of too much fuel to the cylinder. High
temperatures may also be caused by an injector with
5. Install a new fuel filter.
a defect.
6. Cut the old filter open with the 175-7546 Oi
Oill
Refer to Testing And Adjusting, “Exhaust
Filter Cutter Gp. Inspect the filter for excess
Temperature - Test” for the procedure for checking
contamination. Determine the source of the
the temperatures in the exhaust manifold port.
contamination. Make the necessary repairs.
7. Service the primary fuel filter (if equipped). i02486845
8. Operate the hand priming pump (if equipped). If Air in Fuel - Test
uneven resistance is felt, test for air in the fuel.
Refer to Testing and Adjusting, “Air in Fuel - Test” SMCS Code: 1280-081
Code: 1280-081
for more information.
This procedure checks for air in the fuel. This
9. Remove any air that may be in the fuel system. procedure
procedu re also assist
assists
s in finding the source of the air.
Refer to Testing and Adjusting, “Fuel System -
Prime”. 1. Examine the fuel system for leaks. Ensure that
the fuel line fittings are properly tightened. Check
the fuel level in the fuel tank. Air can enter the
fuel system on the suction side between the fuel
transfer pump and the fuel tank.

40 RENR7572-06
Adjusting Section
2. Install a 2P-8278 Tube As (SIGHT GAUGE) in If excessive air is not seen at the inlet to the fuel
the fuel return line.
return line. When possible,
possible, install the sight transfer pump, the
pump, the air is entering the system after
gauge in a straight section of the fuel line that is the fuel transfer pump. Proceed to Step 6.
at least 304.8 mm (12 inches) long. Do not install
gauge near the following devices that
the sight gauge a ir is seen at the inlet to the fuel
If excessive air
create turbulence: transfer pump, air is entering through the suction
side of the fuel system.
• Elbows
• Relief valves
To avoi
avoid
d personal
personal inj
injur
ury
y, alw
alway
ays
s we
wear
ar eye
eye and fac
face
e
• Check valves protection when using pressurized air.
Observe the f ueluel flow during engine cranking.
Look for air bubbles in the fuel. If there is no fuel NOTICE
in the sight gauge, prime the fuel system. Refer To avoid damage, do not use more than 55 kPa (8 psi)
to Testing and
and Adjusting, “Fuel System - Prime” to pressurize the fuel tank.
for more information. If the engine starts, check
for air in the fuel at varying engine speeds. When
operate the engine under the conditions
possible, operate 4. Pressurize the fuel tank to 35 kPa (5 psi). Do
which have been suspect of air in the fuel. not use more than 55 kPa (8 psi) in order to
damage to the fuel tank. Check for leaks in
avoid damage to
the fuel lines between the fuel tank and the fuel
transfer pump. Repair any leaks that are found.
fu el pressure in order to ensure that
Check the fuel
the fuel transfer pump is operating properly. For
information
informa tion about check
checking
ing the fuel pressure, see
and Adjusting, “Fuel System Pressure -
Testing and Adjusting,
Test”.
source of the air is not found, disconnect

5. If the source
the supply line from the fuel tank and connect an
external fuel supply to the inlet of the fuel transfer
pump. If this
th is corrects the problem, repair the fuel
tank or the stand pipe in the fuel tank.
injector sleeve is worn or damaged,

6. If the injector
combustion gases may be leaking into the fuel
system. Also, if the O-rings on the injector sleeves
worn, missing, or damaged, combustion gases
are worn, missing,
may leak into the fuel system.
g01096678
Illustration 34 i02276736
2P-8278 Tube As (SIGHT GAUGE)
(1) A steady stream of small bubbles with a diameter of
Engine Speed - Check
approximately 1.60 mm (0.063 inch) is an acceptable amount
of air in the fuel. SMCS Code: 1000
Code: 1000
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch)
are also acceptable if there is two seconds to three seconds Table 1
intervals between bubbles.
(3) Excessive air bubbles in the fuel are not acceptable. To
Tools
ols Needed
Part Name
Part Name Quantity
3. If excessive air is seen in the sight gauge in the Number
fuel return line, install a second sight gauge at the
inlet to the fuel transfer pump. If a second sight 1U-6602 Photo-Tachometer (1) 1
gauge is not available, move the sight gauge from or or
9U-7400 Multitach Tool Gp
the fuel return line and install the sight gauge
at the inlet to the fuel transfer pump. Observe (1) This unit is a hand-held service tool.
the fuel flow during engine cranking. Look for air
bubbles in the fuel. If the engine starts, check for Note: Caterpillar Electronic Technician (ET) can also
Note: Caterpillar
air in the fuel at varying engine speeds. be used.

RENR7572-06 41
Testing and Adjust
Adjusting
ing Section
You can observe the engine rpm, which is displayed i02180482

on the status screen
screen of Cat ET.
Electronic Unit Injector - Test
SMCS Code: 1290 -081
Code: 1290-081
This procedure assists in identifying the cause for

misfiring. Perform this procedure only
an injector misfiring.
after performing the Cylinder Cutout Test. Refer to
Troubleshooting, “Injector Solenoid Circuit - Test” for
information.
more information.
1. Check for air in the fuel, if this procedure has not

performed. Refer to Testing and
already been performed.
Adjusting, “Air in Fuel - Test”.
g00286276
Illustration 35
9U-7400 Multitach Tool Gp
Electrical
Electrical shock hazar
hazard.
d. The electro
electronic
nic unit injec-
uses 90-120 volts.
tor system uses
The 9U-7400 Multitach Tool Gp can measure engine
rpm from a magnetic pickup. This magnetic pickup is
located in the flywheel housing. The multitach also 2. Remove the valve covecoverr and look for broken parts.
uses the ability to measure engine rpm from visual Repair any br oken
oken parts or replace any broken
engine parts that are rotating. parts that are found. Inspect all wiring for the
solenoids. Look for loose connections. Also look
Note: Refer to Special Instruction, NEHS0605 that
Note: Refer wires or broken wires. Ensure that the
for frayed wires
is with the 9U-7400 Multitach Tool Gp. This manual connector for the unit injector solenoid is properly
gives instructions for the test procedure. connected. Perform a pull test on each of the
Inspect the posts of the solenoid for arcing.
wires. Inspect
Refer to Disassembly and Assembly Manual, “Unit
Injector - Install”.
3. Look for signs of fuel leakage. Investigate the

source of the leaking fuel. Remedy the cause of
le ak.
the fuel leak.
4. Check the valve lash setting for the cylinder of

the suspect
suspect unit injector. Refer to Testing and
Adjusting, “Engine Valve Lash - Inspect/Adjust”.
that the bolts that hold the unit injector

5. Ensure that
are tightened to the proper torque. In order to
check the torque, loosen the bolts that hold the
g00296064
g00296064
Illustration 36 injector. Tighten the bolts to a torque of
unit injector.
1U-6602 Photo-Tachometer 12 ± 1 N·m (9.0 ± 1.0 lb ft). Refer to Disassembly
and Assembly Manual , “Unit Injector - Install” for
The 1U-66
1U-660202 Photo-Tachometer is a phototach tightening procedure.
the tightening
for general use. This tachometer can only register
the basic input frequency on any rotating part that
visible. The basic input frequency is 1 pulse per
is visible.
revolution per piece of reflective tape.
fer to Special Instruction, SEHS8854 that is

Note: Refer
Note: Re
with this group. This manual provides instructions for
using this tool.
Note: The measurement of engine rpm can be set

Note: The
with the Cat ET. Refer to the Troubleshooting manual.

42 RENR7572-06
Adjusting Section
6. Remove the suspect unit injector and check the

unit injector f o
orr signs of exposure to coolant.
Exposure to coolant will cause rust to form on
the injector. If the unit injector shows signs of
coolant, remove the injector sleeve
exposure to coolant,
and inspect the injector sleeve. Replace the
injector sleeve if the injector sleeve is damaged.
Check the unitunit injector for an excessive brown
discoloration that extends beyond the injector
tip. If excessive discoloration is found, check
quality of the fuel. Refer to Testing and
the quality of
Adjusting, “Fuel Quality - Test”. Replace the seals
on the injector and reinstall the injector. Refer to
Disassembly
Disassembl y and Assembly Manual, “Unit Injector
- Install”. Also refer to Disassembly and Assembly g01072227
Manual, “Unit Injector Sleeve - Install”. Inspect Illustration 37
the injector
injector for deposits of soot that are above Flywheel housing (A)
the surface of the seat of the injector. Deposits of (1) Bolts
soot indicate combustion gas leakage. The source (2) Cover
leak should be found, and the source of
of the leak should (3) Timing hole
the leak should be remedied. The injector will not
need to be replaced if combustion gas leakage
was the pr oblem.
oblem.
7. If the problem is not resolved, replace

replace the suspect
suspect
injector with
with a new injector. In order to verify that
the new injector is working properly, perform
the Cylinder Cutout Test. Use the Caterpillar
nic Technician (ET).
Electronic
Electro
i02100106
Finding Top Center Position

for No. 1 Piston
SMCS Code:
Code: 1105-531
Table 2
Required Tools
Tool Part Part Name Qty Illustration 38

g01070212
Number
Flywheel housing (B)
A 139-7063 Timing Pin Adapter 1
(3) Timing hole
B 178-8615 Engine Turning Tool 1
1. Only perform this step if you have flywheel
C 214-7340 Reverse Ratchet 1
housing (A). Remove two bolts (1) and remove
D 632
136-4632
136-4 Timing Pin 1 cover (2) from flywheel housing (A) in order to
open the turning hole.
E 208-0888 Engine Turning Tool 1

RENR7572-06 43
Testing and Adjust
Adjusting
ing Section
2. Remove the plug from timing hole (3) and install i02486888
Tool (D) in the timing
t iming hole on flywheel housing
(A) and flywheel housing (B). The timing hole Fuel Quality - Test
(3) is located above the turning hole on flywheel
housing (A). UseUse Tool (B) and Tool (C) to turn the SMCS Code: 1280 -081
Code: 1280-081
engine flywheel for flywheel housing (A). Tool (E)
can be used for turning the flywheel on flywheel This test checks for problems regarding fuel quality.
housing
housin g (B). Turn the flywheel in the direction of
(B). Turn Diesel Fuels and Your Engine, SEBD0717
Refer to Diesel Fuels
engine rotation. The direction of engine rotation is for additio
additional
nal details.
counterclockwise, as the engine is viewed from
flywheel end. Turn the flywheel until the timing
the flywheel following procedure to test for problems
Use the following
pin engages with the threaded hole in the flywheel. regarding
regarding fuel qualit
quality:
y:
the flywheel is turned beyond the point of

Note: If the flywheel
Note: If water and/or contaminants are
1. Determine if water
engagement, the flywheel must be turned in the present in the fuel. Check the water separator (if
direction that is reverse of normal engine rotation. equipped). If a water separator is not present,
Turn the flywheel
flywheel by approximately 30 degrees. Then Step 2. Drain the water separator, if
proceed to Step
turn the flywheel in the direction of normal rotation necessary. A full fuel tank minimizes the potential
until the timing pin engages with the threaded hole. for overnight condensation.
procedure eliminates the backlash from the
This procedure
gears when the No. 1 piston is at the top center Note: A water separator can appear to be full of fuel
Note: A
position. when the water separator is actually full of water.
3. Remove the front valve mechanism cover from 2. Determine if contaminants are present in the
the engine.
engine. fuel. Remove a sample of fuel from the bottom
of the fuel tank.
t ank. Visually inspect the fuel sample
4. The inlet and exhaust valves for the No. 1 for contaminants. The color of the fuel is not
cylinder are fully closed if No. 1 piston is on the necessarily an indication of fuel quality. However,
compression
compress ion stroke and the rocker arms can be is black, brown, and/or similar to sludge
fuel that is black,
moved by hand. If the rocker arms cannot be can be an indication of the growth of bacteria or
moved and the valves are slightly open, the No. 1 oil contamination. In cold temperatures, cloudy
is on the exhaust stroke.
piston is on indicates that the fuel may not be suitable for
fuel indicates
operating
operati ng conditi
conditions.
ons. The followi
following
ng method
methodss can
Note: When the actual stroke position is identified,
Note: When be used to prevent wax from clogging the fuel
and the other
other stroke position is needed, remove the filter:
timing bolt from the flywheel. Then turn the flywheel
by 360 degrees in the direction of normal engine • Fuel heaters
rotation
rotatio n and reinstall the timing bolt.
• Blending fuel with additives
Calibrate the Electronic Injection
Calibrate • Utilizing
Utilizing fuel with a low cloud point such as
Timing With the Electronic Service kerosene
Tool Operation
Refer to Operatio n and Mainten
Maintenance
ance Manual,
SEBU6251,
SEBU625 1, “Caterp
“Caterpillar
illar Commercial
Commercial Diesel
to Electronic Troubleshooting, “PC-32: Engine
Refer to Engine Fluids Recommendations”, “Fuel
Speed/Timin
Speed/ Timingg Calibration”
Calibration” for the proper procedure
procedure dations”” for more informat
Recommendations
Recommen information.
ion.
to calibrate the electronic injection timing.
3. Check fuel API with a 9U-7840 Fluid and Fuel
This timing calibration should be performed when the ion Gp for low power complaints. The
Calibration
Calibrat
following conditions exist: acceptable range of the fuel API is 30 to 45 when
the API is measured at 15 °C (60 °F), but there is
• Replaced ECM a signif icant
icant difference
difference in energy within this range.
Refer to Tool Operating Manual, NEHS0607
NEHS0607 for
• Front gear
gear changes API correction factors when a low power problem
present and API is high.
is present
• Replaced major engine components
Note: A
Note: A correction
correction factor that is greater than 1 may be
The timing calibration should also be performed when cause of low power and/or poor fuel consumption.
the cause
you are unable to communicate with the old ECM
the ECM has been replaced.
and the

44 RENR7572-06
Adjusting Section
4. If fuel quality is still suspected as a possible Note: The fuel system does not need to be primed
Note: The
cause to problems
problems regarding
regarding engine performance,
performance, after changing
changing only
only the fuel filter. The engine will
disconnect the fuel inlet line, and temporarily remain running after starting with a dry filter.
operate the engine from a separate source of
known to be good. This will determine
fuel that is known NOTICE
if the problem is caused by fuel quality. If fuel
Do not allow dir t to enter the fuel system. Thoroughly
quality is determined to be the problem, drain the clean the area around a fuel system component that
fuel system andand replace the fuel filters. Engine will be discon
disconnecte
nected.d. Fit a suitable cover over discon-
performance can be affected by the following
characteristics: nected fuel system
system component.
• Cetane number of the fuel 1. After fuel is added to the fuel tank, remove plug
(1).
• Air in the fuel
fue l
NOTICE
• Other fuel characteristics Use a suitable container to catch any fuel that might
up any spilled fuel immedia
spill. Clean up immediately
tely..
i02241691
Fuel System - Prime 2. Unlock and operate hand priming pump (2) in
order to pump f uel
uel into the fuel system. This will
SMCS Code: 1258-548
Code: 1258-548 also purge air from the fuel syste
system.
m. Stop operat
operating
ing
the hand priming pump when fuel appears at the
port.
3. Install plug (1). Clean up any spilled fuel

Fuel leaked or spilled onto hot surfaces or elec- immediately.
immediatel y.
trical components can cause a fire. To help pre-
possible injury, turn the start switch off when
vent possible 4. Operate the hand priming pump until a strong
changing fuel filters or water separator elements. pressure
pressu re is felt on the pump and you hear a click
is felt
Clean up fuel spills immediately
immediately.. from the fuel filter base. This pressurizes the
system with approximately 345 kPa (50 psi). This
reduces the cranking time that is needed
greatly reduces
to start the engine.
and hand tighten the priming pump

5. Push in and hand
plunger.
NOTICE
Do not cran
crankk the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
6. Crank the engine as soon as possible after

pressurizing the system. The engine should start
seconds.
within 15 seconds.
If the engine does not start after 30 seconds, stop

the engine. Repeat Steps 4 through 6.
cranking the
cranking
g01129836
Illustration 39
(1) Plug
(2) Priming pump
If the fuel system runs out of fuel or if air is introduced

into the fuel system the following procedure may be
followed.

RENR7572-06 45
Testing and Adjust
Adjusting
ing Section
i02100313
Fuel System Pressure - Test

SMCS Code: 1250 -081; 1256-081
Code: 1250-081;
Table 3
Required Tools
Tool Part Part Name Qty

Number
Engine Pressure
1U-5470 Test Group
A or or 1
198-4240 Digital Pressure
Indicator g00284796
Illustration 40
B 3Y-2888 Connector 1 1U-5470 Engine Pressure Test Group

(1) Pressure indicators
C 3J-1907 O-Ring Seal 1 (2) Zero adjustment screw
(3) Pressure indicator
(4) Pressure tap
Use Tooling (A) in order to check the engine’s fuel (5) Pressure indicator
pr essures.
essures.
Tooling (A) conta
contains
ins several pressu
pressure
re gauges that
Note: It may be necessary to use Tooling (B) and (C)
Note: It are used for measuring engine pressures.
order to adapt to the correct fitting size.
in
Reference: Refer to Special Instruction, SEHS8907
Reference: Refer
for information that relates to the operation and
maintenance of the tool group.
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. Clean up fuel Low Fuel Pressure
spills immediately.
spills
Low fuel pressure can cause low engine power. Low
fuel pressure can also cause cavitation of the fuel
NOTICE which can damage the fuel injectors. The following
Keep all parts clean from contaminants. conditions can cause low fuel pressure:
Contaminants may cause rapid wear and shortened
component life.
• Plugged fuel filters
• Debris in the check valves for the fuel priming
pump (if equipped)
Ca
Care
re mu
mustst be ta
take
ken n to eNOTICE
ens
nsure
ure that
that fluids
fluids ar
are
e cont
contain
ained
ed
during performance of inspec inspection,
tion, maintenance, test- • Sticking
Sticking or worn fuel pressu
pressure
re regulating valv
valve
e in
ing,
ing, ad
adju
just
sting
ing an
andd repa
repair ir of th
the
e pr
prod
oduc
uct.
t. Be pre
prepar
pared
ed to the fuel transfer pump
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- • Severe wear on return fuel pressure regulating
nent contai
containing
ning fluids
fluids.. valve at the rear of the cylinder head
Refer to Special Publication,

Publication, NENG2500, “Caterpillar • Worn gears in the fuel transfer
transfer pump
Tools
ools an
andd Shop
Shop Pro
Produc
ducts
ts Guid
Guide”
e” for to
tools
ols an
and
d supp
supplie
liess
suitabl
suitable
e to collec
collectt and contain
contain fluids on Cate
Caterpil
rpillar
lar • Pinched
Pinched fuel lines or unders
undersized
ized fuel lines
products.
• Old fuel lines that have a reduced interior diameter
diameter
Dispose of all fluids according to local regulations and that was caused by swelling
mandates.
• Fuel lines with deteriorating
deteriorating interior surfaces
• Pinched fuel line fittings or undersized fuel line

fittings
• Debris in the fuel tank, fuel lines, or fuel system

components
components that create restrictions

46 RENR7572-06
Adjusting Section
Pressure
High Fuel Pressure Type II Fuel System
Excessive fuel pressure can cause fuel filter gaskets
The following conditions can cause high
to rupture. The following
fuel press
pressure:
ure:
• Plugged orifices
orifices in the fuel pressure regulating
valve
• Stuck fuel pressure

pre ssure relief valve in the fuel transfer
pump
• Restricted fuel
fuel return line
System
Type I Fuel System
g01010186
Illustration 43
Fuel lines gr o
oupup
(6) Fuel hose (fuel transfer pump to fuel filter)
(7) Tube assembly (fuel filter to fuel supply passage)
(8) Pressure regulator
g00872953
Illustration 41
Fuel lines group
(6) Tube assembly (fuel transfer pump to fuel filter)
(7) Tube assembly (fuel filter to fuel supply passage)
(8) Pressure regulator
g01010184
Illustration 44
Pressure tap locations
filter base
(9) Fuel filter
for the unfiltered fuel pressure
(10) Line for
(11) Tap for the
the filtered fuel pressure
During normal operating conditions and load

conditions,, the fuel system should maintain the
conditions
following pressure:
• 400 to 525 kkP

Pa (58 to 76 psi)
At low idle, the fuel system should maintain the

pressure:
following pressure:
g00872950
Illustration 42
Pressure tap locations
• 400 to 435 kPa (58 to 63 psi)
(9) Fuel filter base The pressure diffe
differential
rential is the difference between
(10) Tap for the unfiltered fuel pressure
(11) Tap for the filtered fuel pressure
filtered fuel pressure and unfiltered
unfiltered fuel pressu
pressure.
re.
With a new filter, the pressure differential across the

fuel filter will be the following amount:
• 35 kPa (5 psi)

RENR7572-06 47
Testing and Adjust
Adjusting
ing Section
As abrasive particles collect in the fuel filter, the Tests for the HEUI Fuel System
pressure differential
differential across the filter will increase.
When a filter becomes plugged, fuel supply Injection Actuation Pressure Control
pressure may drop as low as 69 kPa (10 psi)
significant power loss is detected by the
before a significant
System
operator.
operato r. Low fuel pressure will cause cavitatio
cavitationn and
Reference: Refer to Troubleshooting, “Injection
Reference: Refer
internal damage to the unit injectors. The
injectors. The pressure
Actuation Pressure Control Valve Circuit - Test” in
differentiall across the fuel filter should not
differentia
order to test for the correct operation of the injection
exceed 69 kPa (10 psi).
actuation
actuation pressu
pressure
re control system.
regulator (8) is mounted directly in the rear
Pressure regulator
Pressure
Reference: Refer
of the cylinder head. The regulator is located at the
Actuation Pressure Sensor - Test” in order to test
fuel return port toward the rear end of the fuel supply
e orifice maintains fuel pressure at low for the correct operation of the injection actuation
passage.
passag e. Th
The
pressure sensor.
engine rpm. The regulator contains a check valve
that prevents fuel from draining out of the cylinder
head and back
back to the tank during engine shutdown. Unit Injector Hydraulic
Hydraulic Pump
In order to check the unfiltered fuel pressure (fuel Reference: Refer

transferr pu
transfe mp pressure),
pump pressure), follow this procedure: Actuation Pressure - Test” in order to test the unit
injector hydraulic pump for problems that relate to
1. Install the pressure test group onto the engine. mechanical operation and hydraulic operation.
a. For type I fuel systems that contain a fuel

i02237153
pressurethetap
fuel(10)
port of the fuel that
filter is installed
base, remove inthethe inlet
plug from Gear Group (Front) - Time
the pressure tap. Install Tooling (B) and Tooling
(C) on the fuel pressure tap (10). Code: 1206-531
SMCS Code: 1206-531
Install Tooling (A) in order to measure the fuel

pressure.
b. For type II fuel systems without a pressure tap,

install a t-fitting in the fuel line for the unfiltered
fuel pressure
pressure (10). If necessary, install Tooling
(B) and Tooling (C) on the t-fitting.
Tooling (A) in order to measure the fuel

Install Tooling
pressure.
2. Start the engine and record the unfiltered fuel

the engine
pressure.
check the filtered fuel pressure,

To check the pressure, follow these steps:
1. Remove the plug from fuel pressure tap (11).
2. Install Tooling (B), and Tooling (C) to fuel pressure

tap (11).
Note: Install Tooling (A) in order to measure the fuel

Note: Install
pressure.
3. Start the engine and record the unfiltered fuel

pressure.
g01134615
g01134615
Illustration 45
Front gear group
Camshaft gear and timing reference gear
(1) Camshaft
Idler gear
(2) Idler
(3) Timing
Tim ing marks
Crankshaft gear
(4) Crankshaft

48 RENR7572-06
Adjusting Section
Correct fuel injection timing and correct valve

mechanism oper a ation
tion is determined by the timing
reference gear and the alignment of the front gear
group. The timing reference gear is located on the
camshaft gear . The timing reference gear is used to
measure
measur e crankshaft
crankshaft rotation.
rotation. During installatio
installation
n of
the front gear, timing marks (3) on idler gear (2) must
alignment with the timing marks on crankshaft
be in alignment
gear (4) and the timing marks on camshaft gear (1).
teeth on the timing reference gear. The

Check the teeth
teeth should not be defaced. The teeth should have
sharp clean edges and the teeth should be free of
ts.
contaminants.
contaminan
Note: The electronic injection timing must be

calibrated after
calibrated after reassembly of the front gear train.
Refer to Troubleshooting, “Engine Speed/Timing
Sensor - Calibrate”.

RENR7572-06 49
Testing and Adjust
Adjusting
ing Section
Air Inlet and Ex haust

Exhaust 3. Che
Check
ck for dirt trac
tracks
engine air cleaner
ks on the clea
cleann side of the
cleaner element, the air inlet hose,
System and the clamps. If dirt tracks are observed,
contaminants are flowing past the engine air
cleanerr eleme
cleane nt, the seal for the air cleaner,
element,
i02399810 and/or the air inlet hose.
Air Inlet and Exhaust System engine air cleaner element. Replace
4. Inspect the engine
a dirty engine air cleaner element with a clean
- Inspect engine air cleaner element.
SMCS Code: 1050-040
Code: 1050-040
Air Inlet Restriction

Hot eng
Hot engin
ine componen
e compo nents
ts can cau
cause
se inju
injury
ry fro
from
m
There will be a reduction in the performance of the burns.
burns. Bef
Before
ore per
perfor
forming
ming main
mainten
tenance
ance on the
engine if there is an excess restriction in the air inlet engine, allow the engine and the components to
system or the exhaust system. cool.
Table 4
Required Tools
Part Making contact with a running engine can cause
Part Name Quantity
Number burns from hot parts and can cause injury from
1U-5470 Engine Pressure Group 1 rotating
rotating parts.
or or
198-4240 Pressure Indicator Tool Gp When working on an engine that is running, avoid
contact with hot parts and rotating parts.
5. Use the differential pressure gauge of the

1U-5470 Engine Pressure Group or the
198-4240 Pressure Indicator Tool Gp.
g00293196
Illustration 46
1U-5470 Engine Pressure Group
Refer to Special Instruction, SEHS8907, “Using

the 1U-5470 Engine Pressure Group” for the
instructions that are needed to use the 1U-5470
Engine Pressure Group. Refer to Operation Manual,
NEHS0818, “Using the 198-4240 Pressure Indicator
Tool Gp” for the instructions that are needed to use
the 198-4240 Pressure Indicator Tool Gp.
1. Check the Air Filter Change Indicator Gp on the g01176673

Illustration 47
air inlet for a reading of the restriction.
Air inlet system (typical example)
2. Inspect (1)
(2) Turbocharger
in orderthe enginethat
to ensure air cleaner inlet and ducting
the passageway is not Air Inlet Piping
(3) Test location
blocked
blocke d or collap
collapsed.
sed. (4) Air cleaner

50 RENR7572-06
Adjusting Section
a. Connect the vacuum port of the differential

pressure
pressu re gauge to
gauge to test location (3). Test
location (3) can be located anywhere along air
Hot engi
engine
ne comp
compone
onents
nts can cause inju
injury
ry from
inlet piping (2) after engine air cleaner (4) but
burns.
burns. Bef
Before
ore per
perfor
forming
ming main
mainten
tenance
ance on the
turbocharger (1).
before turbocharger
engine, allow the engine and the components to
cool.
The air flow through a new engine air cleaner element
have a system restriction of more than the
must not have a
following amount:
Maximum
Maximum restriction ..... 3.7 kPa
restriction kPa (15 inch of H2O)
Making contact with a running engine can cause
The air flow through a used engine air cleaner may burns from hot parts and can cause injury from
additional restriction. The air flow through a
have an additional rotating
rotating parts.
parts.
plugged engine air cleaner will be restricted to some
magnitude. In either case, the restriction must not be When working on an engine that is running, avoid
the following amount:
more than the contactt with
contac hot parts and rotating parts.
with hot
Maximum
Maximum restriction ..... 6.2 kPa (25 inch of H2O)
If the exhaust is not equipped with a back pressure
following procedure may be use in order to
tap, the following
Exhaust Restriction install a pressure tap. Refer to Truck Engine News,
SEBD6729,
SEBD67 29, “Measu
“Measuring
ring Exhaust Back Pressure”
measuring the back pressure at a proper test
for measuring
location.
The muff
muffler
ler,, cataly
catalytic
tic con
conver
verter
ter/muf
/muffler
fler,, and diesel
diesel Use the diff erential
erential pressure gauge of the 1U-5470
particulate filter will become extremely hot during
engine oper ation.
ation. A hot muffler, catalytic convert
convert-- Engine Pressure Group or the 198-4240 Pressure
er/muffler and diesel particulate filter can cause Indicator Tool Gp in order to measure back pressure
serious
serious bur
burns.
ns. Allo
Alloww ade
adequa
quate
te cooling
cooling time befo
before
re exhaust. Use the following procedure in
from the exhaust.
on or near the muffler, catalytic convert-
working on or order to measure back pressure from the exhaust:
er/muffler and diesel particulate filter.
(Plugging) Test
High Idle (Plugging)
Excessive idling can cause the muffler, the catalytic
Excessive idling
converter/muffler, or the diesel particulate filter
to plug. A plugged muffler, a plugged catalytic
converter /muffler,
/muffler, or a plugged diesel particulate
particulate filter
will lead to an increase in exhaust back pressure.
Operating the engine in extremely cold conditions
cause the muffler, the catalytic converter/muffler
may cause the
, or the diesel particulate filter to plug. One indication
of a plugged muffler, catalytic converter, or diesel
ate filter is poor engine response.
particulate
particul
Back Pressure for Mufflers

Exhaust Back
and Catalytic Converters
Back pressure is the difference in the pressure
between
between the exhaust and the atmospheric air.
Table 5
Tools Needed
Needed
Part Illustration 48
g01176674
Part Name Quantity
Number
Exhaust system (typical example)
1U-5470
or Engine Pressure Group
or 1 (1) Turbocharger
(6) Test location
198-4240 Pressure Indicator Tool Gp (7) Muffler
(8) Exhaust piping

RENR7572-06 51
Testing and Adjust
Adjusting
ing Section
Note: Do not try to burn out a plugged muffler. The

Note: Do 4. The back pressure for the catalytic
muffler can become
become severely overheated. This will converter/muf ffler
ler is at 15.0 kPa (60 inch of H2O).
cause other system components to fail.
5. Replac
Replace
e any compon
components
ents that have been proven
system components for any noticeable
1. Inspect the system damaged.
damage that would cause a restriction.
2. Connect the pr essure

essure port of the differential
Exhaust Back Pressure
Pressure for Diesel
pressure gauge
Engine News, to test location.
SEBD67
SEBD6729, Refer
ngto
29, “Measuring
“Measuri Truckt
Exhaust
Exhaus Particulate
Particulate Filters (If Equipped)
Equipped)
Back Pressur e”
e” for measuring the back pressure High Idle (Plugging) Test
at a proper test location.
vac uum port of the differential pressure

3. Leave the vacuum
gauge open to the atmosphere.
4. Start the engine.

eng ine. Run the engine in the no-load
condition at high idle until the engine reaches
normal operatin
operatingg temperature.
temperature.
5. Record the value.
6. Multiply th
thee value from Step 5 by 1.8.
7. Compare
follows. the result from Step 6 to the value that
g01176677
Illustration 49
Back pressure from the exhaust must not be more particulate filter (typical example)
Diesel particulate
following amount:
than the following
(9) Inlet section
(10) Catalyst section
Maximum back pressure for engines with a (11) Filter section
standard
standa muffler ............. 10 kPa (40 inch of H 2O)
rd muffler (12) Outlet section
(13) Test location
Maximum back pressure for engines with a (14) Tee fitting
converter/muf
catalytic converter/muffler
fler ........................
........................ 15 kPa (15) Copper tubing
(60 inch of H2O) (16) Thermocouple
maximum back pressure is within the allowable

If the maximum Note: Limit the idle time of the engine to 20 minutes.
Note: Limit
limits, refer to Troubleshoo
Troubleshooting,
ting, “Low/Power/Poor
“Low/Power/Poor or If large quantities of soot are accumulated in the
No Response to Throttle”. particulate filter, running the engine can
diesel particulate
permanently damage the filter and other components.
If the back pressure exceeds 15 kPa (60 inch of H2O), Avoid continuous idle time of the engine by using the
replace the muffler. shutdown timer.
idle shutdown timer. Refer to Troublesh
Troubleshooting,
ooting, “Idle
Shutdown Timer - Test” for using the idle shutdown
timer.
Full Load Test
Note: Do not test the exhaust back pressure if the
Note: Do
not try to burn out a plugged muffler. The
Note: Do not
Note: Do
red warning light has been activated. Clean the
muffler can become severely overheated. This will
particulate filter immediately.
Diesel particulate
cause other system components to fail.
Note: Refer to Special Instruction, REHS1807,
Note: Refer
1. Check the arrangement
arrangement number of the engine and
“Installation
“Installa tion Guide for Diesel Particulate Filters” for
verify that all components are correct.
properly
properl y cleani
cleaning
ng the diesel particulat
particulate
e filter
filter..
Note: Run the vehicle on a dyno up to 30 minutes in
Note: Run
the system compon
1. Inspect the components
ents for any noticeable
order to reach operating temperature. Monitor all of
damage that would cause a restriction.
engine components for any signs of overheating.
the engine
2. Measure the back pressure at a full load and full 2. Connect the
the pressure port of the differential
pressure gauge to test location. Refer to Truck
speed.
Engine News, SEBD67
SEBD6729, 29, “Measu
“Measuring
ring Exhaus
Exhaustt
Pressure” for measuring the back pressure
Back Pressure”
3. Record the results.
at a proper test location.

52 RENR7572-06
Adjusting Section
3. Leave the vacuum port of the differe

differential
ntial pressure
pressure
gauge open to the
the atmosphere.
4. Start the engine. Run the engine in the no-load

high idle until the engine reaches
condition at high
normal operatin
operating
g temperature.
temperature.
5. Record the val ue.

value.
6. Multiply the value from Step 5 by 1.8.
7. Compare the test result to the value that follows.
diesel particulate filter if the back pressure

Clean the diesel
exceeds the following value.
pressure for engines with a Diesel

Maximum back pressure
Particulate Filter ........... 25 kPa (100 inch of H 2O)
Full Load Test

Limit the idle time of the engine to 20 minutes. If
quantities of soot are accumulated in the diesel
large quantities
particulate
particu late filter, running the engine can permanently
damage the filter

idle
continuous idle
continuous andofother
time components.
the engine Avoid
by using the idle
shutdown timer. Refer to Troubleshooting, “Idle
Shutdown Timer - Test” for using the idle shutdown
timer.
Note: Do not test the exhaust back pressure if the

Note: Do
warning light has been activated. Clean the diesel
red warning light
particulate filter immediately.
Note: Refer to
Note: Refer to Special Instruction, REHS1807,
“Installation Guide for Diesel Particulate Filters” for
properly
properl y cleaning
cleaning the diesel particulat
particulate
e filter.
filter.
1. Check the arrangement

arrangement number of the engine and
verify that all components are correct.
Note: Run the vehicle on a dyno up to 30 minutes in

Note: Run
order to reach operating temperature. Monitor all of
engine components for any signs of overheating.
the engine components overheating.
2. Measure the back pressure at a full load and full

speed.
3. Record the results.
4. The back pressure for the diesel particulate filter

is at 25 kPa (100 inch of H2O).
5. Replace
Replace any components that cannot be cleaned.
Replace
Replace any components that are proven faulty.
faulty.

RENR7572-06 53
Testing and Adjust
Adjusting
ing Section
Data Sheet for Testing Catalytic

Diesel Particulate Filter
Converters or Diesel
Hot engi
engine
ne comp
compone
onents
nts can cause inju
injury
ry from
S/N ______ _______________________________________________________ burns.
burns. Bef
Before
ore per
perfor
forming
ming main
mainten
tenance
ance on the
engine, allow the engine and the components to
Miles __________________________________________________________ cool.
Date ________ __________________________________________________
Type of pressure gauge ________ ___________________________

Personal injury can result from rotating and mov-
Mark the pressure test location with an “X” on the ing parts.
Illustration.
Stay clear of all rotating and moving parts.
Never attempt adjustments while the machine is

moving or the engine is running unless otherwis
otherwise
e
specified.
The machine must be parked on a level surface

and the engine stopped.
NOTICE
Keep all parts clean from contaminants.
component
component life.
NOTICE
Ca
Care
re mus
mustt be tak
taken
en to ensu
ensure re tha
thatt flu
fluid
ids s are cont
contain
ained
ed
during performance of inspection,
inspection, maintenance
maintenance,, test-
ing,, adjus
ing adjusti
ting
ng and
and repa
repairir of the produ
product ct.. Be prepa
prepared
red to
ing any compartment or disassembling any compo-
nent contain
containing
ing fluids.
Refer to Specia
Speciall Publication,
Publication, NENG2500, “Caterpillar
Tools
ools and
and Shop
Shop Pro
Produc
ducts
ts Gui
Guide
de”” fo
forr too
tools
ls and
and supp
supplie
lies
s
g01183535 suitab
suitable
le to coll
products. collect
ect and cont
contain
ain flui
fluids
ds on Cate
Caterpil
rpillar
lar
Illustration 50
Engine speed
speed _ __ ___ ___________________________________ rpm
___ rpm Dispose of all fluids according to local regulations and
mandates.
Engine load _ __ ___ _________________________________ percent
Before you begin inspection of the turbocharger,
Back pressure __ __
____
__ __ _______
_________________ inches
_____ inches of water be sure that the inlet air restriction is within the
specifications for your engine. Be sure that the
i02100383
exhaustt system restrictio
exhaus restriction
n is within the specifications
specifications
for your engine. Refer to Systems Operation/Testing
Turbocharger - Inspect
Turbocharger and Adjusting, “Air Inlet and Exhaust System -
Inspect”.
SMCS Code: 1052-040
Code: 1052-040
The condition of the turbocharger will have definite
effects on engine performance. Use the following
inspections and procedures to determine the
condition of the turbocharger.
Disconnect batteries before performance of any
work.
service work.
service
• Inspection
Inspection of the Compres
Compressor
sor and the Compre
Compressor
ssor
Housing

54 RENR7572-06
Adjusting Section
• Inspection
Inspection of the Turbine
Turbine Wheel and the Turbine Inspection of the Turbine Wheel
Housing
and the Turbine Housing
• Inspection of the Wastegate Remove the air piping from the turbine outlet casing.
Inspection of the Compressor and 1. Inspec

Inspectt the turbine for damage by a foreign object.
If there is damage, determine the source of the
the Compressor Housing foreign object. Replace the turbocharger. If there
piping from the compressor inlet.
Remove air piping is no damage, go to Step 2.
2. Inspec
Inspectt the turbine wheel for buildup of carbon and
1. Inspect the compressor wheel for damage from a
other foreign material. Inspect the turbine housing
object. If there is damage, determine the
foreign object.
for buildup of carbon and foreign material. Clean
source of the foreign object. As required, clean
the turbine wheel and clean the turbine housing
the inlet system and repair the intake system.
if you find buildup of carbon or foreign material. If
t urbocharger. If there is no damage,
Replace the turbocharger.
there is no buildup of carbon or foreign material,
go to Step 3.
go to Step 3.
compressor wheel and clean the
2. Clean the compressor
3. Turn the rotating assembly by hand. While you
compressor housing if you find buildup of foreign
turn the assembly, push the assembly sideways.
material. If there is no buildup of foreign material,
The assembly should turn freely. The turbine
go to Step 3.
wheel should not rub the turbine wheel housing.
Replace the turbocharger if the turbine wheel rubs
3. Turn the rotating assembly by hand. While you
the turbine wheel housing. If there is no rubbing or
turn
The the assembly,
assembly,
assembly push
should the
turn assembly
freely. sideways .
The compressor scraping, go to Step 4.
wheel should not rub the compressor housing.
4. Inspect the turbine and the turbine wheel housing
the turbocharger if the compressor wheel
Replace the
for oil leakage. Inspect the turbine and the turbine
rubs the compressor wheel housing. If there is no
wheel housing for oil coking. Some oil coking
rubbing or scraping, go to Step 4.
may be cleaned. Heavy oil coking may require
replacement of the turbocharger. If the oil is
4. Inspect the compressor and the compressor
coming from the turbocharger center housing go
wheel housing for oil leakage. An oil leak from
to Step 4.a. Otherwise go to “Inspection of the
compressor may deposit oil in the aftercooler.
the compressor
Wastegate”.
Drain and clean the aftercooler if you find oil in
the aftercooler.
a. Remove the oil drain line for the turbocharger.
Inspect the drain opening. Inspect the area
a. Check the oil level in the crankcase. If the oil
between the bearings of the rotating assembly
level is too high, adjust the oil level.
shaft. Look for oil sludge. Inspect the oil drain
hole for oil sludge. Inspect the oil drain line
b. Inspect
Inspec t theisair
restriction cleaner
found, element
correct for restricti
restriction.
the problem. on. If for oil sludge. If necessary, clean the rotating
assembly shaft. If necessary, clean the drain
opening. If necessary, clean the drain line.
c. Inspect the engine crankcase breather. Clean
the engine crankcase breather or replace
b. If crankcase pressure is high, or if the oil drain
engine crankcase breather if the engine
the engine
is restricted, pressure in the center housing
crankcase
crankcase breather is plugged.
plugged.
may be greater than the pressure of the turbine
housing. Oil flow may be forced in the wrong
d. Remove the the oil drain line for the turbocharger.
direction and the oil may not drain. Check the
Inspect the drain opening. Inspect the oil drain
crankcase
crankc ase pressure and correct any proble
problems.
ms.
line. Inspect the area between the bearings of
rotating assembly shaft. Look for oil sludge.
the rotating
c. If the oil drain line is damaged, replace the oil
Inspect the oil drain hole for oil sludge. Inspect
drain line.
the oil drain line for oil sludge in the drain
If necessary, clean the rotating assembly
line. If
d. Check the routing of the oil drain line. Eliminate
shaft. If necessary, clean the oil drain hole. If
any sharp restrictive bends. Make sure that
necessary, clean the oil drain line. the oil drain line is not too close to the engine
exhaust manifold.
e. If Steps 4.a through 4.d did not reveal the
source of the oil leakage, the turbocharger has
al damage. Replace the turbocharger.
internal
intern

RENR7572-06 55
Testing and Adjust
Adjusting
ing Section
e. If Steps 4.a through 4.d did not reveal the When the external supply of air that is connected to
source of the oil
oil leakage, the turbocharger has line (3) reaches
reaches the corresponding pressure for the
internal damage. Replace the turbocharger. wastegate valve, the actuating lever should move by
0.50 ± 0.25 mm (0.020 ± 0.010 inch). If the actuating
NOT move by this amount, replace the
lever does NOT move
Inspection of the Wastegate turbine’s
turbine’ s housing assembly of the turbocharger
turbocharger.. This
housing
housin g assemb
assemblyly includes the wastegate valve. If
The turbochar ger
ger senses boost pressure which
necessary, r eplace
eplace the complete turbocharger.
actuates the wastegate valve. The wastegate valve
controls the amount of exhaust gas that is allowed Note: The housing assembly for the wastegate
Note: The
the turbine side of the turbocharger.
to bypass the turbine
turbine is pr eset
eset at the factory and no adjustments
Regulating the amount of exhaust gas that enters the
can be made.
turbocharger
turbocharger regulates the rpm of the turbocharger.
turbocharger.
wastegate valve can be checked by applying the
The wastegate
pressure that is given in Table 6. Refer to Table 6
for the amount of lift of the wastegate valve that will
occur at the given
the given pressur
pressure.e.
Table 6
Amount of Pressure That is Required to

Check the Wastegate Valve
Engine
Pressure Lift
Horsepower
≤ 230 130 kPa (18.9 psi) 0.5 mm

(0.02 inch)
0.5 mm
g00942619 ≥ 250 142 kPa (20.6 psi)
Illustration 51 (0.02 inch)
(1) Actuating rod
(2) Canister
(3) Line NOTICE
If the high idle rpm or the engine rating is higher than
When the engine operates in conditions of low giv
given
en in the Techechnic
nical
al Mark
Marketi
eting
ng Info
Informa
rmation
tion (TMI
(TMI))
boost (lug), a spring presses against a diaphragm in for the height above sea level at which the engine is
canister (2). This moves actuating rod (1) in order to operated, there can be damage to engine or to tur-
close the wastegate valve. Then, the turbocharger bocharger parts. Damage will result when increased
can operate at maximum performance. heat and/or friction due to the higher engine output
goes beyond the engine cooling and lubrication sys-
As the boost pressure increases against the tem’s abilitie
abilities.
s.
diaphragm in canister (2), the wastegate valve opens.
The rpm of the turbocharger becomes limited. This The boost pressure controls the maximum rpm of the
limitation occurs because a portion of the exhaust turbocharger
turbocharger,, becaus
becausee the boost pressure controls
gases bypass the turbine wheel of the turbocharger.
turbocharger. the position of the wastegate. The following factors
also affect the maximum rpm of the turbocharger:
The following levels of boost pressure indicate a
problem with the wastegate valve: • Engine rating
• Too high at full load condition
conditions
s • Horsepower demand on the engine
• Too low at all lug conditions • High idle rpm
The Technical Marketing Information (TMI) provides • Height above sea level for engine operation
operation
the correct pressure for the inlet manifold.
• Inlet air restriction
To check the operation of the wastegate valve, verify
the correct pressure for the wastegate valve. Refer • Exhaust system restriction
to Table 6 for the correct pressure.
Remove the air line, and slowly apply the
corresponding
corresponding amount of pressu
pressure
re to the canister.
canister.
DO NOT EXCEED 200 kPa (29 psi).

56 RENR7572-06
Adjusting Section
i02438865
Inlet Manifold Pressure - Test

Code: 1058-081
The efficiency of an engine can be checked by

making a compar ison
ison of the pressure in the inlet
manifold
manifol d with the informa
information
tion given in the Technica
Technicall
Marketing Information (TMI). This test is used when
there is a decr ease
ease of horsepower from the engine,
yet there is no real sign of a problem with the engine.
The correct pr essure

essure for the inlet manifold is listed
in the TMI. Development of this information is
g00293196
performed
perform ed under the followi
following
ng conditions:
conditions: Illustration 52
• 96 kPa (28.8 in Hg) dry barometric pressure
pressure
Refer to Special Instruction, SEHS8907, “Using
• 25 °C (77 °F) outside
o utside air tempera
temperature
ture the 1U-5470 Engine Pressure Group” for the
instructions that are needed to use the 1U-5470
• 35 API rated fuel Engine Pressure Group. Refer to Operation Manual,
NEHS0818,
NEHS081 8, “Using the 198-4240 Pressure Indicator
Any change from these conditions can change the Tool GP” for the instructions that are needed to use
pressure in the inlet manifold. The outside air may the 198-4240 Digital Pressure Indicator.
higher temperature and a lower barometric
have a higher
pressure than the values that are given above.
This will cause a lower inlet manifold pressure
measurementt than the pressure in the TMI. Outside
measuremen
air that has both a lower temperature and a higher
barometric
baromet ric pressure will cause a higher inlet manifold
measurement.
pressure measurement.
A difference in fuel density will change horsepower

(stall speed)
speed) and boost. If the fuel is rated above 35
API, the pressure in the inlet manifold can be less
than the pressure that appears in the TMI. If the
rated below 35 API, the pressure in the inlet
fuel is rated
manifold can be more than the pressure that appears
in the TMI.
g01134338
Illustration 53
Note: Be sure that the air inlet or the exhaust does
Note: Be test location
Pressure test
Pressure
not have a restriction when you are checking the (1) Plug
pressure..
pressure
Use the following procedure in order to measure the
Note: The Caterpillar Electronic Technician (ET) may
Note: The inlet manifold
manifold press
pressure:
ure:
to check the pressure in the inlet manifold.
be used to check
Table 7
1. Remove plug (1) from the air inlet cover.
Tools Needed 2. Connect thethe 1U-5470 Engine Pressure Group to

Part Number Part Description Qty the air inlet cover at the pressure test location.
1U-5470 Engine Pressure Group Note: A

Note: te e fitting or some other plumbing component
A tee
or or 1 will be necessary to allow the boost pressure sensor
198-4240 Digital Pressure Indicator to be connected with a test location.

4. Compare the
the value that was recorded in Step 3 to
the pressure that is given in the TMI.

RENR7572-06 57
Testing and Adjust
Adjusting
ing Section
i02100926
Exhaust Temperature - Test

Pressurized air can cause personal injury. When
Code: 1088-081 pressurized air is used for cleaning, wear a pro-
tective face shield, protective clothing, and pro-
Table 8 tective shoes.
Tools Needed
Part Part Name Quantity Ensure

tightenedthat
to the
the constant torqueCheck
correct torque. hose clamps are
the welded
Number
joints for cracks. Ensure that the brackets are
164-3310 Infrared Thermometer 1 tightened in the correct positions. Ensure that the
brackets are in good condition. Use compressed air
When the engine runs at low idle, the temperature of to clean any debris or any dust from the aftercooler
an exhaust manifold port can indicate the condition core assembly. Inspect the cooler core fins for the
of a unit injector: following conditions:
A low temperature indicates that no fuel is flowing to • Damage

the cylinder. An inoperative unit injector pump could
cause this low temperature. • Debris
A very high temperature can indicate that too much • Corrosion

fuel is flowing to the cylinder. A malfunctioning unit
injectorr could cause this very high temperature.
injecto temperature. Use a stainless steel brush to remove any corrosion.
Ensure that you use soap and water.
Use the 164-3310 Infrared Thermometer to check
this exhaust temperature. You can find operating Note: When parts of the air-to-air aftercooler system
Note: When
instructions
instructions and maintenance
maintenance instructions inside the are repaired, a leak test is recommended. When
Operator’s
Operato r’s Manual, NEHS0630. parts of the air-to-air afterco
aftercooler
oler system are replaced
replaced,,
a leak test is recommended.
i02277538 The use of winter fronts or shutters is discouraged

with air-to-ai
air-to-airr aftercooled
aftercooled systems.
Aftercooler - Test
SMCS Code: 1063-081
Code: 1063-081 Inlet Manifold Pressure
Pressure
Table 9 Normal inlet manifold pressure with high exhaust

temperature can be caused by blockage of the fins of
Required Tools the aftercooler core. Clean the fins of the aftercooler
Part core. Refer to “Visual Inspection” for the cleaning
Number Part Name Quantity procedure.
Low inlet manifold pressure and high exhaust
or or 1
198-4240 Digital Pressure Indicator manifold temperature can be caused by any of the
following conditions:
FT-1984 Aftercooler Testing Group 1
FT-1438 After
Aftercool
cooler
er Gp 1
Plugged air
air cleane
cleanerr – Clean the air cleaner or
(DYNAMOMETER TEST) replace the air cleaner, as required. Refer to the
Operation and Maintenance Manual, “Engine Air
Cleaner Element - Clean/R
Clean/Replace
eplace”.
”.
Visual Inspection
Blockage in the air llines
Blockage ines – Blockage in the air lines
Inspect the following parts at each oil change: between the air cleaner and the turbocharger must
be removed.
• Air lines
oler core leakage – Aftercooler core
Aftercooler
Afterco
• Hoses leakage should be pressure tested. Refer to
“Aftercooler Core Leakage” topic for the testing
• Gasket joints procedure.
Leakage of the induction sy

Leakage stem – Any leakage
system
from the pressu
pressure
re side of the induct
induction
ion system should
be repaire
repaired.
d.
58 RENR7572-06
Adjusting Section
Inlet manifold
manifold le
leak
ak – An inlet manifold leak can be
caused by the following
following conditions:
conditions: loose fittings and NOTICE
plugs, missing fittings and plugs, damaged fittings Remove all air leaks from the system to prevent en-
and plugs, and leaking inlet manifold gasket. gine damage. In some operating conditions, the en-
gine can pull a manifold vacuum for short periods of
Aftercooler Core Leakage time. A leak in the aftercooler or air lines can let dirt
foreign material into the engine and cause
and other foreign
rapid wear and/or damage to engine parts.
A large leak of the

the aftercooler core can often be
found by making a visual inspection. To check for
smaller leaks, use the following procedure:
1. Disconnect the air pipes from the inlet and outlet

side of the aftercooler core.
Dust plug chains must be installed to the after-

cooler core oror to the radiator brackets to prevent
possible
possib le injury while you are test
testing.
ing. Do not stand
in front of the dust plugs while you are testing.
2. Install couplers (5) on each side of the aftercooler

core. Also, install dust plugs (7) and (8). These
items are included
included with the FT-1984 Aftercooler
Testing Group.
llation of additional hose clamps on the

Note: Installation
Note: Insta
hump hoses is recommended in order to prevent
the hoses from bulging while the aftercooler core is
pressurized.
being pressurized.
23
g01134323
g011343
Illustration 54
NOTICE
FT-1984 Aftercooler Testing Group
Do not use more than 240 kPa (35 psi) of air pressure
Regulator and valve assembly
(1) Regulator to the aftercooler core can be the result.
or damage to
Nipple
(2) Nipple
(3) Relief
Relief valve
(4) Tee
3. Install the regulato
regulatorr and valve assem
assembly
bly (1) on the
(5) Coupler
Coupler side of the aftercooler core assembly. Also,
outlet side
(6) Aftercooler
Aftercooler
plug
(7) Dust plug attach the air supply.
plug
(8) Dust plug
(9) Chain air valve and pressurize the aftercooler
4. Open the air
to 205 kPa (30 psi). Shut off the air supply.
A low power problem in the engine can be the result
aftercooler leakage. Aftercoo
of aftercooler Aftercooler
ler system leakage alll connection points for air leakage.
5. Inspect al
can result in the following problems:
6. The aftercooler system’s pressure should not drop
• Low power more than 35
than 35 kPa (5 psi) in 15 seconds.
• Low boost pressure 7. If the pressure drop is more than the specified
use a solution of soap and water to check
amount, use
• Black smoke all areas for leakage. Look for air bubbles that will
identify possible leaks. Replace the aftercooler
aftercooler
• High exhaust
exhau st temperature
temperature
core, or r e
epair
pair the aftercooler core, as needed.

RENR7572-06 59
Testing and Adjust
Adjusting
ing Section
• Clean
To help
help preve
prevent
nt pe
pers
rson
onal
al injur
injury
y when
when th
the
e toolin
tooling
g is • Repair
removed, relieve all pressure in the system slowly
by using an air regulator and a valve assembly. • Replacement
8. After the testing, remove the FT-1984 Aftercooler

Turbocharger Failure
Failure
Testing
sides of Group. Reconnect
the aftercooler corethe air pipes
assembly
assemb ly.. on both
Air System Restriction Personal injury can result from air pressure.
injury can result without following prop-

Personal injury
er pr
proc
oced
edur
ure.
e. Whe
Whenn using
using pr
pres
essu
sure
re air
air,, wea
wearr a pr
pro-
o-
tective face shield and protect
protective
ive clothing.
Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.
If a turbocharger failure occurs, remove the air-to-air

aftercooler core. Internally flush the air-to-air
core with a solvent that removes oil
aftercooler core
aftercooler
and other foreign substances. Shake the air-to-air
aftercooler core in order to eliminate any trapped
Wash the aftercooler with hot, soapy water.
debris. Wash
Thoroughly
Thoroug hly rinse the aftercooler with clean water and
blow dry the aftercooler with compressed air. Blow
assembly in the reverse direction of normal
dry the assembly
air flow. To
To make sure that the whole system is clean,
carefully inspect the system.
NOTICE
g00581364
Illustration 55 Do not use caustic cleaners to clean the air-to-air af-
tercooler
tercooler core.
Pressure measurements should be taken at the inlet
manifold (1) and at the turbocharger outlet (2). Caustic cleaners will attack the internal metals of the
core and cause leakage.
Use the differential pressure gauge of the 1U-5470
Engine Pressure Group or use the 198-4240 Digital
Pressure Indicator. Use the following procedure in Dynamometer Test
order to measure the restriction of the aftercooler:
In hot ambient tempera
temperatures,
tures, chassis dynamometer
1. Connect the vacuum port of the differential tests for models with an air-to-air aftercooler can
pressure gauge to port (1). greater heat load to the jacket water cooling
add a greater
system. Therefore,
Therefore, the jacket water coolin
cooling
g system’
system’s
s
2. Connect the pressure port of the differential temperature must be monitored. The following
pressure gauge to port (2). measurements
measurem ents may also need a power correction
factor:
• Inlet air temperature
The air lines and the cooler core must be inspected
for internal restriction when both of the following • Fuel API rating
conditions are met:
• Fuel temperature
• Air flow is at a maximum level.
• Barometr ic
ic pressu
pressure
re
• Total air pressure drop of the charged system
exceeds 16.9 kPa (5 in Hg). With dynamometer tests for engines, use the
A ftercooler
FT-1438 Aftercool er Gp (DYNAMO
(DYNAMOMETER
METER TEST).
If a restriction is discovered, proceed with the This tool provides a water cooled aftercooler in order
following
following tasks, as required:
required: to control the inlet air temperature to 43 °C (110 °F).
60 RENR7572-06
Adjusting Section
i01281928 i02277566
Engine Crankcase Pressure Engine Valve Lash -

(Blowby) - Test Inspect/Adjust
SMCS Code: 1215;
Code: 1215; 1317 SMCS Code:
Code: 1102-025
Table 10
Tools Needed
Part To prevent possible injury, do not use the starter
Part Name Quantity to turn the flywheel.
Number
8T-2700 Blowby/Air Flow Indicator 1 Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
Damaged pistons or damaged rings can cause too valve clearance.
suring valve clearance.
much pressure in the crankcase. This condition
will cause the engine to run rough. There will be
more than the normal amount of fumes (blowby)
rising from the crankcase breather.
breather. The breather can
then become restricted in a very short time. This This engine uses high voltage to control the fuel
condition can cause oil leakage at gaskets and seals injectors.
that would not normally have leakage. Blowby can
also be caused by worn valve guides or by a failed Disconnect electronic fuel injector enable circuit
connector to prevent personal injury.
turbocharger seal.
Note: The
Note: The electronic service tool can be used to Do not come in contact with the fuel injector ter-
measure crankcase pressure. minals while the engine is running.
Note: Valve lash is measured between the rocker

Note: Valve
arm and the bridge for the inlet valves. Valve lash
is measured between the rocker arm and the valve
stem for the exhaust valve. All of the clearance
measurements and the adjustments must be made
with the engine stopped. The valves must be fully
closed.
Valve Lash Check

An adjustment is not necessary if the measurement
of the valve lash is in the acceptable range. Adjust
the valve lash while the engine is stopped. The range
g00286269 is specified in Table 11.
Illustration 56
8T-2700 Blowby/Air Flow Indicator
The 8T-2700 Blowby/Air Flow Indicator is used

to check the amount of blowby. Refer to Special
Instruction, SEHS8712, “Using the 8T-2700
Blowby/Air Flow Indicator” for the test procedure for
checking the blowby.

RENR7572-06 61
Testing and Adjust
Adjusting
ing Section
Table 11 Valve Lash and Valve Bridge

Valve
Inle
Inlett Val
alve
ves
s Ex
Exha
haus
ustt Val
alve
ves
s Adjustment
Valve Lash
0.38 ± 0.08 mm 0.64 ± 0.08 mm
Check
(0.015 ± 0.003 (0.025 ± 0.003
(Stopped
inch) inch)
Engine)
TC
Compression
Stroke 1-2-4 1-3-5
TC Exhaust
3-5-6 2-4-6
Stroke(1)
Firing Order 1-5-3-6-2-4(2)

(1) 360° from TC compression stroke
(2) The No. 1 cylinder is at the front of the engine.
If the measurement
measurement is
is not within this range
range adjustment
adjustment
is necessary. See Testing And Adjusting, “Valve Lash
And Valve Bridge Adjustment”.
g01109236
Illustration 58
(1) Exhaust rocker arm
(2) Inlet valve bridge
(3) Rocker arm adjustment screw locknut for the exhaust rocker
arm
(4) Rocker arm adjustment screw for the exhaust rocker arm
Table 12
Valve Lash
Valves Dimension of Gauge
Inlet 0.38 ± 0.
0.0
08 mm (0.
0.0
015 ± 0.003 inch)
g01105757
Illustration 57
Exh
xhau
aus
st 0.
0.64±
64± 0.
0.08mm
08mm (0
(0..025
025 ± 0.0
.003in
03inc
ch)
Cylinder and Valve Location
(A) Exhaust valve
(B) Inlet valves
Adjust the valve lash while the engine is stopped.
1. Put the No. 1 piston at the top center position

on the compression stroke. Refer to Testing and
Adjusting, “Finding Top Center Position for No.
1 Piston”.
Table 13
TC
Compression Inle
Inlett Val
alve
ves
s Exha
Exhaus
ustt Val
alve
ves
s
Stroke
0.38 ± 0.08 mm 0.64 ± 0.08 mm
Valve lash (0.015 ± 0.003 (0.025 ± 0.003
inch) inch)
Cylinders 1-2-4 1-3-5
2. Adjust the valve lash according to Ta

Table
ble 13.
a. Ligh
Lightly
tly tap the rocker arm at the top of the
adjustment screw with a soft mallet. This will
ensure that the lifter roller seats against the
camshaft’s base circle.

62 RENR7572-06
Adjusting Section
b. Loosen the adjustment locknut.

locknut.
c. Place the appropriate feeler gauge between

rocker arm and the valve bridge. Then, turn
adjustment screw in a clockwise direction.
the adjustment
Slide the feeler gauge between the rocker arm
and the valve bridge. Continue turning the
ment screw until a slight drag is felt on
adjustment
adjust
the feeler gauge. Remove the feeler gauge.
a djustment locknut to a torque
d. Tighten the adjustment
of 30 ± 7 N·m (22 ± 5 lb ft). Do not allow
the adjustment screw to turn while you are
ing the adjustment
tightening
tighten adjustment locknut
locknut.. Rechec
Recheck
k
the valve lash after tightening the adjustment
locknut.
3. Remove the timing bolt and turn the flywheel by

360 degrees in the direction of engine rotation.
put the No. 6 piston at the top center
This will put
position on the compression stroke. Install the
timing bolt in the flywheel.
Table 14
TC Exhaust Inle
Inlett Val
alve
ves
s Exha
Exhaus
ustt Val
alve
ves
s
Stroke(3)
0.38 ± 0.08 mm 0.64 ± 0.08 mm
Valve lash (0.015 ± 0.003 (0.025 ± 0.003
inch) inch)
Cylinders 3-5-6 2-4-6
(3) Position for No. 1 cylinder
4. Adjust the valve lash according to Table

Table 14.
a. Lightly tap the rocker arm at the top of the

adjustment screw with a soft mallet. This will
ensure that the lifter roller seats against the
camshaft’s base circle.
b. Loosen the adjustment locknut.

locknut.
c. Place the appropriate feeler gauge between

rocker arm and the valve bridge. Then, turn
the adjustment screw in a clockwise direction.
Slide the feeler gauge between the rocker arm
and the valve bridge. Continue turning the
adjustment screw until a slight drag is felt on
the feeler gauge. Remove the feeler gauge.
d. Tighten the adjustment locknut to a torque

of 30 ± 7 N·m (22 ± 5 lb ft). Do not allow
the adjustment screw to turn while you are
tightening
tightening the adjustment locknut. Rechec
Recheck
k
the valve lash after tightening the adjustment
locknut.
5. Remove the timing bolt from the flywheel after all

adjustments to the valve lash have been made.
Reinstallll the timing cover.
Reinsta

RENR7572-06 63
Testing and Adjust
Adjusting
ing Section
Lubrication System
i01849289
Engine Oil Pressure - Test

SMCS Code: 130 4-081
Code: 1304-081
Measuring
Measuring Engine Oil Pressure
Engine
Work carefully around an engine that is running. g00296486

En
Engin
gine
e parts
parts th
that
at ar
are
e hot,
hot, or pa
part
rts
s that
that are
are movin
moving,
g, Illustration 59
can cause per sonal
sonal injury. 1U-5470 Engine Pressure Group
The 1U-5470 Engine Pressure Group measures

measures the
NOTICE oil pressure in the system. This engine tool group can
Keep all parts clean from contaminants. read the oil pressure inside the oil manifold.
Contaminants may cause rapid wear and shortened Note: Refer to Special Instruction, SEHS8907, “Using
Note: Refer
component life. the 1U-5470 Engine Pressure Group” for more
1U-5470
information on the
information Engine Pressure Group.
NOTICE Note: The
Note: The electronic service tool can measure engine
Ca
Care
re mu
mustst be ta
take
ken n to eens
nsure
ure that
that fluids
fluids ar
are
e cont
contain
ained
ed oil pressure.
pressure. Refer to Trou
Troublesho
bleshooting
oting for information
information
during performance of inspec inspection,
tion, maintenance, test- on the use of the electronic technician.
ing,
ing, ad
adju
just
sting
ing an
andd repa
repair ir of th
the
e pr
prod
oduc
uct.
t. Be pre
prepar
pared
ed to
nent contai
containing
ning fluids
fluids..
Refer to Special Publication,

Tools
ools an
andd Shop
Shop Pro
Produc
ducts
ts Guid
Guide”
e” for to
tools
ols an
and
d supp
supplie
liess
suitabl
suitable
e to collec
collectt and contain
contain fluids on Cate
Caterpil
rpillar
lar
products.
Dispose of all fluids according to local regulations and

mandates.
Table 15
Required Tools g00941945

Illustration 60
Part Number Part Name Quantity Oil galle ry plug
gallery
1U-5470 Engine Pressure Group (1) Plug

or or 1
198-4240 Digital Pr essure
essure Indicator 1. Install the 1U-5470 Engine Pressure Group into
oil gallery plug (1).
8J-7844 Adapter Fitting 1
3K-0360 O-Ring Seal 1 Note: Engine oil pressure to the camshaft and main
Note: Engine
bearings should be checked on each side of the
4M-5317 Terminal Bushing
cylinder block
block at oil gallery plug (1).
or or 1
5P-2720 Probe Adapter
2. Start the engine. Run the engine with SAE
10W30 or S AE
S AE 15W40 oil. The information in the
engine oil pressure graph is invalid for other oil
viscosities.
viscosities. Refer to Operati
Operation
on and Maintena
Maintenance
nce
“Engine Oil” for the recommendations of
Manual, “Engine
Manual,
engine oil.

64 RENR7572-06
Adjusting Section
Note: Allow the engine to reach operating 7. An engine oil pressure indicator that has a defect
temperature before
before you perform the pressure test. or an engine oil pressure
oil pressure sensor that has a defect
can give a false indication of a low oil pressure or
Note: The engine oil temperature should not exceed
Note: The a high oil pressure. If there is a notable difference
(239°F).
115°C (239°F). engine oil pressure readings make
between the engine
necessary repairs.
3. Record the value of the engine oil pressure when
has reached operating temperature.
the engine has 8. If low engine oil pressure is determined, refer to
engine oil
4. Locate the point that intersects the lines for the “Reasons for Low Engine Oil Pressure”.
and for the oil pressure on the engine
engine rpm and for engine oil pressure is determined, refer to
9. If high engine
oil pressure graph. “Reason for High Engine Oil Pressure”.
Reasons for Low Engine Oil

Pressure
NOTICE
parts clean from contaminants.
Keep all parts

life.
component life.
Care mu
Care st be take
must aken NOTICE
n to ens
ensure
ure that
that fluids
fluids are
are con
contain
tained
ed
during performance of inspection,
inspection, maintenance
maintenance,, test-
ing,, adjus
ing adjusti
ting
ng and
and repa
productct.. Be prepa
prepared
red to
collect the f luid
luid with suitable containers before open-
nent contain
containing
ing fluids.
Refer to Specia
Speciall Publication,
g00866125 Tools
ools and
and Shop
Shop ProProduc
ducts
ts Gui
Guide
de”” fo
forr too
tools
ls and
and supp
supplie
liess
Illustration 61
e to collect
suitable
suitabl collect and cont
contain
ain flui
fluids
ds on Cate
Caterpil
rpillar
lar
Engine Oil Pressure Graph products.
5. The results must fall within the “ACCEPTABLE” Dispose of all

all fluids according to local regulations and
range on the chart. A problem exists when the mandates.
results fall within the “NOT ACCEPTABLE” range
on the chart. The problem needs to be corrected.
Engine failure or a reduction in engine life can be • Engine oil level is low.
low. Refer to Step 1.
the result if engine operation is continued with oil
manifold
manifo ld pressu
pressurere outside this range. • Engine oil is contaminated.
contaminated. Refe
Referr to Step 2.
Note: A record of engine oil pressure can be used as

Note: A • The engine oil
engine oil bypass valves are open. Refer to
an indication of possible engine problems or damage. Step 3.
A possible problem could exist if the oil pressure
suddenly
sudde nly increases or decreases 70 kPa (10 psi) and • The engine lubrication
engine lubrication system is open. Refer to
the oil pressure is in the “ACCEPTABLE” range. The Step 4.
engine should be inspected and the problem should
be corrected.
corrected. • The oil suction
suction tube has a leak or a restricted inlet
screen. Refer to Step 5.
6. Compare the recorded engine oil pressure with
the oil pressure indicators on the instrument panel • The engine oil
engine oil pump is faulty. Refer to Step 6.
and the engine oil pressure that is displayed on
the electronic service tool. • Engine Bearings have excessive clearance. Refer
to Step 7.

RENR7572-06 65
Testing and Adjust
Adjusting
ing Section
1. Check the engine oil level in the crankcase. The 5. The inlet screen of the oil suction tube for the
oil level can possibly
possibly be too far below the oil pump engine oil pump can
pump can have a restriction. This
supply tube. This will cause the oil pump not to restriction will cause cavitation and a loss of
have the ability to supply enough lubrication to the engine oil pressure. Check the inlet screen on
components. If the engine oil level is low
engine components. pickup tube and remove any material that
the oil pickup tube
add engine oil in order to obtain the correct engine may be restricting engine oil flow. Low engine oil
oil level. Refer to Operation and Maintenance pressure may also be the result of the oil pickup
“Engine Oil” for the recommendations of
Manual,, “Engine
Manual d rawing in air. Check the joints of the
tube that is drawing
engine oil. oil pickup
seal. tubethe
Remove for engine
cracks or
oil apan
damaged
in orderO-ring
to gain
that is contaminated with fuel or
2. Engine oil that access to the
th e oil pickup tube and the oil screen.
coolant will cause low engine oil pressure. Refer to Disassembly and Assembly, “Engine Oil
High engine oil level in the crankcase can be Pan - Remove and Install” for more information.
indication of contamination. Determine the
an indication
reason for contamination of the engine oil and 6. Check the following problems that may occur to
make the necessary repairs. Replace the engine the engine oil pump.
oil with the approved
the approved grade of engine oil. Also
replace the engine oil filter. Refer to Operation a. Air leakage in the supply side of the oil pump
and Maintenance Manual, “Engine Oil” for the will also cause cavitation and loss of oil
ations of engine oil.
recommendations
recommend Check the supply side of the oil pump
pressure. Check
and make necessary repairs. For information
NOTICE on the repair of the engine oil pump, refer to
Caterpillar
Caterpil lar oil filt
filters
ers are built
built to Caterp
Caterpilla
illarr speci-
speci- Disassembly
Disassemb ly and Assembly, “Engine Oil Pump
- Remove”.
fications.. Use
fications Use of an oil oil filter
filter not recomm
recommenendededd by
Caterpillar could result in severe engine damage to gears that have too much wear will
b. Oil pump gears
the engine bearings, crankshaft, etc., as a result of
cause a reduction in oil pressure. Repair the
the larger waste
waste particles from unfiltered oil entering
the eng
engine
ine lub
lubrica
ricating
ting system.
system. Only use oil filt filters
ers engine oil pump. For information on the repair
recommended
recomme nded by Caterpillar.
Caterpillar. engine oil pump, refer to Disassembly
of the engine
and Assembly, “Engine Oil Pump - Remove”.
3. If the engine oil bypass valves are held in the Excessive clearance at engine bearings will
7. Excessive
open position, a reduction in the oil pressure can cause low engine oil pressure. Check the
result. This may be due to debris in the
be the result. engine components
components that have excessi
excessive
ve bearin
bearing
g
engine oil. If the engine oil bypass valves are clearance
clearan ce and make the necessary repairs.
stuck in the open position, remove each engine
bypass valve and clean each bypass valve in
oil bypass
order to correct this problem. You must also clean
Reason f or
or High Engine Oil
each bypass valve bore. Install new engine oil Pressure
filters.. For information on the repair of the engine
filters
oil bypass valves, refer to Disassembly and NOTICE
Assembly, “Engine Oil Filter Base - Disassemble”. Keep all parts clean from contaminants.
4. An oil line or an oil passage that is open, broken, Contaminants may cause rapid wear and shortened
or disconnected will cause low engine oil pressure. component
component life.
open lubrication system could be caused by a
An open lubrication
piston cooling jet that is missing or damaged.
NOTICE
Note: T
Note: he piston cooling jets direct engine oil toward
The Ca
Care
re mus
mustt be tak
taken
en to ensu
ensure re tha
thatt flu
fluid
ids s are cont
contain
ained
ed
the bottom of the piston in order to cool the piston. performance
during performan ce of inspect
inspection,
ion, maintenance, test-
This also provides lubrication for the piston pin. ing,, adjus
ing adjusti
ting
ng and
and repa
product ct.. Be prepa
prepared
red to
age, a restriction, or incorrect installation of the
Breakage,
Break collect the fluid with suitable containers before open-
piston cooling jets will cause seizure of the piston. compartment or disassembling any compo-
ing any compartment
nent contain
containing
ing fluids.
to Special Publication, NENG2500, “Caterpillar

Refer to
Tools
ools and
and Shop
Shop Pro
Produc
ducts
ts Gui
Guide
de”” fo
forr too
tools
ls and
and supp
supplie
liess
suitab
suitable
le to coll
collect
ect and cont
contain
ain flui
fluids
ds on Cate
Caterpil
rpillar
lar
ts.
products.
produc
Dispose of all fluids according to local regulations and

es.
mandates.
mandat

66 RENR7572-06
Adjusting Section
Engine oil pressure will be high if the engine oil i01282970

bypass valves become
become stuck in the closed position
and the engine oil flow is restricted. Foreign matter Excessive Engine Oil
in the engine oil system could be the cause for the Consumption - Inspect
ion of the oil flow and the movement of the
restriction
restrict
engine oil bypass valves. If the engine oil bypass SMCS Code: 1348-040
Code: 1348-040
valves are stuck in the closed position, remove
valve and clean each bypass valve in
each bypass valve
order to correct
each bypass this bore.
valve problem. You
Install must
new also clean
engine oil Oil Leakage On Outside Of Engine
New engine oil filters will prevent more debris
filters. New leakage at the seals at each end of the
Check for leakage
from causing this problem. For information on the crankshaft.
cranks haft. Look for leakage at the oil pan gasket and
repair of the engine oil filter bypass valve, refer to all lubrication system connections. Look for any oil
Disassembly
Disassembl y and Assembly, “Engine Oil Filter Base - leaking from the crankcase breather. This
that may be leaking
Disassemble”. can be caused by combustion gas leakage around
the pistons. A dirty crankcase breather will cause
high pressu
pressur r e in the crankcase. A dirty crankcase
NOTICE
breather will cause the gaskets and the seals to leak.
Caterpillar
Caterpil lar oil filt
filters
ers are built
built to Caterp
Caterpilla
illarr speci-
speci-
fications. Use of an oil oil filter
filter not re
reco
comm
mmenendededd by
Caterpillar could result in severe engine damage to Oil Leakage Into Combustion Area
the engine bearings, crankshaft, etc., as a result of Of Cylinders
the larger waste
waste particles from unfiltered oil entering
the eng
engine
ine lub
lubrica
ricating
ting system.
system. Only use oil filt filters
ers Oil leakage into the combustion area of the cylinders
recommended
recomme nded by Caterpillar.
Caterpillar. can be the cause
cause of blue smoke. There are four
possible ways for oil leakage into the combustion
area of the cylinders:
i01126690
Excessive Bearing Wear - • Oil leakage between

between worn valve guides and valve
stems
Inspect
• Worn components or damaged components
Code: 1203-040; 1211-040; 1219-040
SMCS Code: 1203-040; (pistons, piston rings, or dirty oil return holes)
When some components of the engine show bearing • Incorrect installation of the compression ring and/or
wear in a short time, the cause can be a restriction in the intermediate ring
passage.
an oil passage.
• Oil leakage past the seal
seal rings in the impeller end
An engine oil pressure indicator may show that there of the turbocharger shaft
enough oil pressure, but a component is worn
is enough oil
Excessive oil consumption can also be the result if
duepassage
the to a lack for
of lubrication. In such
the oil supply to theacomponent.
case, look at oil with the wrong viscosity is used. Oil with a thin
A restri
restriction
ction in an oil supply passage will not allow viscosity
viscosit y can be caused by fuel leakage into the
enough lubrication to reach a component. This will crankcase
crankc ase or by increas
increased
ed engine temperatu
temperature.
re.
result in early wear.
i01283115
Increased Engine Oil

Temperature - Inspect
SMCS Code: 1348-040
Code: 1348-040
When the engine is at operating temperature

and you are using SAE 10W30 oil, the maximum
oil temperature is 115 °C (239 °F). This is the
temperature of the oil after passing through the oil
cooler.

RENR7572-06 67
Testing and Adjust
Adjusting
ing Section
Look for a restriction in the oil passages of the oil

cooler. The oil temperature
oil temperature may be higher than
normal when the engine is operating. In such a case,
the oil cooler may have a restriction. A restriction in
the oil cooler will
will not cause low oil pressure in the
engine.
e if the
Determine
Determin the oil cooler bypass valve is held in the
open position.
through Thisinstead
the valve condition willoil
of the allow the oil
cooler. Thetooil
pass
will increase.
temperature will
temperature

68 RENR7572-06
Adjusting Section
Cooling System 4. Check for air in the cooling system. Air can enter
the cooling system
system in differ
different
ent ways. The followi
following
ng
items are some of the most common causes for
i01389751 air in the cooling system:
Cooling System - Check • Filling the cooling syste

system
m incorrectly
(Overheating)
• Combustion gas
gas leakage into the cooling system
SMCS Code: 1350-535
Code: 1350-535
• Loose hose clamp
Above normal coolant temperatures can be caused
by many conditions. Use the following procedure Combustion gas can get into the system through
to determine the cause of above normal coolant the following conditions: inside cracks
cracks,, damage
damaged
d
temperatures:
temperature s: head, and damaged cylinder head gasket.
cylinder head,
A loose hose clamp can allow air into the cooling
system during the cooldown period. Air in the
cooling system
system causes a reduction in the cooling
capacity of the coolant.
Personal injury can result from escaping fluid un-
Personal
der pressure. fan drive system. A fan drive system
5. Check the fan drive
that is not turning at the correct speed can cause
If a pressure indication is shown on the indicator, improper air speed across the radiator core. The
push the release valve in order to relieve pressure proper air flow across the radiator core
lack of proper
before removing any hose from the radiator.
radiator. can cause the coolant not to cool to the proper
temperature differential.
1. Check the coolant level in the cooling system.
6. Check the water temperature gauge. A water
Refer to Operation and Maintenance Manual,
temperature gauge which does not work correctly
“Cooling System Coolant Level - Check”. If the
show the correct temperature. Refer to
will not show
coolant level is too low, air will get into the cooling
Testing and Adjusting, “Cooling System - Test”.
system. Air in the cooling system will cause a
reduction in coolant flow and bubbles in the
s ending unit. In some conditions, the
7. Check the sending
coolant. Air bubbles cause a reduction in the
temperature sensor in the engine sends signals
cooling of engine parts.
to a sending unit. The sending unit converts these
signals
signal to an electrical impulse which is used by a
s to an
2. Check the quality of the coolant. The coolant
mounted gauge. If the sending unit malfunctions,
should have the following
following properties:
properties:
the gauge can show an incorrect reading. Also if
electric wire breaks or if the electr
the electric electric
ic wire shorts
• Color that is similar
similar to new coolant
out, the gauge can show an incorrect reading.
• Odor that is similar to new coolant
coolant
8. Check the radiator.
the radiator.
• Free from dirt and debris a. Check the radiator for a restriction to coolant
Check the radiator for debris, for dirt, or
flow. Check
If the coolant does not have these properties,
for deposits on the inside of the radiator core.
drain the system and flush the system. Refill
Debris, dirt, or deposits will restrict the flow of
the cooling system with the correct mixture of
through the radiator.
coolant through
coolant
water, antifreeze, and coolant conditioner. Refer
to Operation
Operation and Maintenance Manual, “General
b. Check for debris or for damage between
Coolant Information”.
the fins of
fins of the radiator core. Debris between
the fins of the radiator core restricts air flow
3. Check the coolant mixture of antifreeze and
through the radiator core. Refer to Testing and
water. The mixture should be approximately 50
ing, “Cooling System - Inspect”.
Adjusting,
Adjust
percent water and 50 percent antifreeze with
3 to 6 percent coolant conditioner. Refer to
c. Check for missing radiator baffles or for
Operation
Operati on and Maintenance Manual, “General
damaged
damage d radiator baffles. Radiator baffles
Coolant Information”. If the coolant mixture is
incorrect, drain the cooling system and flush the prevent recirculation of air around the sides
of the radiator. A missing radiator baffle or a
cooling system. Refill the cooling system with the
damaged
damage d radiator baffle raises the temperature
correct mixture of water, antifreeze, and coolant
of the air that goes through the radiator.
conditioner.

RENR7572-06 69
Testing and Adjust
Adjusting
ing Section
d. Ensure that the radiator size is according to 13. Check for a restriction in the air inlet system.
the OEM specifications.
specifications. An undersized radiator A restriction of the air that is coming into the
does not have enough area for the effective engine can cause high cylinder temperatures.
release of heat. This may cause the engine to High cylinder temperatures
temperatures can cause higher than
run at a temper ature
ature that is higher than normal. normal temper atures
atures in the cooling system. Refer
The normal temperature is dependent on the to Testing and Adjusting, “Air Inlet and Exhaust
ambient temperature. System - Inspect”.
9. Check
radiatorthe
canfiller cap.the
cause A pressure drop
boiling point to in
bethe
lower. a. Ifmaximu
the measured
maximum restriction
m permiss
permissible is higher
ible restriction, than the
remove the
cause the cooling system to boil. Refer
This can cause material from the engine air cleaner
foreign material
to Testing and Adjusting, “Cooling System - Test”. element or install a new engine air cleaner
element. Refer to Operation and Maintenance
fan and/or the fan shroud.
10. Check the fan and/or “Engine Air Cleaner Element -
Manual, “Engine
Clean/Replace”.
a. Ensure that the fan is installed correctly.
Improper installation
installation of the fan can cause airr inlet system for a restriction
b. Check the ai
engine overheating. again.
must be large enough to send air

b. The fan must be measu red restriction is still higher than
c. If the measured
through most of the area of the radiator the maximum permissi
permissible
ble restriction, check the
core. Ensure that the size of the fan and the air inlet piping for a restriction.
of the fan are according to the OEM
position of
specifications. 14. Check for a restriction in the exhaust system.
A restriction of the air that is coming out of the
c. The fan shr oud
oud and the radiator baffling must can cause high cylinder temperatures.
engine can cause
be the proper size. The fan shroud and the
radiatorr baffling
radiato baffling must be positioned
positioned correctly
correctly.. a. Make a visual inspection of the exhaust
The size of the
the fan shroud and the position Check for damage to exhaust piping.
system. Check
of the fan shroud should meet the OEM Also, check for a damaged muffler. If no
specifications. The size of the radiator baffling damage is found, check the exhaus
exhaustt system for
position of the radiator baffling should
and the position restriction. Refer to Testing and Adjusting,
a restriction.
meet the OEM specifications. “Air Inlet and Exhaust System - Inspect”.
11. Check for loose

loose drive belts. b. If the measured
mea sured restriction is higher than the
maximum permissible restriction, there is a
a. A loose fan drive belt will cause a reduction restriction in the exhaust system. Repair the
in the air flow
flow across the radiator. Check the exhaust system, as required.
exhaust
fan drive belt for proper belt tension. Adjust
the tension of the fan drive belt, if necessary. c. Ensure that the exhaust gas is not being drawn
Refer to Operation
to Operation and Maintenance
Maintenance Manual, into the cooling
the cooling air inlet.
“Belt - Inspect”.
15. Check the shunt line. The shunt line must be
water pump drive belt will cause a
b. A loose water submerged
submerg ed in the expansion tank. A restriction
reduction
reduction in coolant flow through the radiator. of the shunt line from the radiator top tank to the
Check the water pump drive belt for proper belt engine water pump inlet will cause a reduction
tension.. Adjust the tension of the water pump
tension in water pump
pump efficiency. A reduction in water
drive belt, if necessary. Refer to Operation and pump efficiency will result in low coolant flow and
Maintenance
Mainten ance Manual, “Belt - Inspect
Inspect”.
”. overheating.
12. Check the cooling system hoses and clamps. 16. Check the water temperature regulato
regulator.
r. A water
Damaged hoses with leaks can normally be seen. temperature regulator that does not open, or a
that have no visual leaks can soften during
Hoses that temperature regulator that only opens part
water temperature
operation. The soft areas of the hose can become of the way can cause overheating. Refer to Testing
kinked or crushed during operation. These areas and Adjusting, “Water Temperature Regulator -
the hose can cause a restriction in the coolant
of the hose Test”..
Test”
flow. Hoses can become soft. Also, hoses can
get cracks after a period of time. The inside of a 17. Check the water pump. A water pump with a
can deteriorate, and the loose particles of
hose can damaged
damag ed impeller does not pump enough coolant
the hose can cause a restriction of the coolant for correct engine cooling. Remove the water
flow. Refer to Operation and Maintenance Manual, pump and check for damage to the impeller. Refer
es and Clamps Inspect/Replace .
Hoses
Hos Testing and Adjustin
to Testing Adjusting,
g, Water Pump Test .
70 RENR7572-06
Adjusting Section
18. Check the air flow through the engine 1. Check the coolant level in the cooling system.
compartment.
compart ment. The air flow through the radiator Refer to Operation
Operation and Maintenance Manual,
comes out of the engine compartment. Ensure “Cooling System Coolant Level - Check”.
that the filters, the air conditioner, and similar
installed in a way that prevents the
items are not installed qual ity of the coolant. The coolant
2. Check the quality
free flow of air through the engine compartment. should have the followin
following
g propert
properties:
ies:
aftercooler. A restriction of air flow

19. Check the aftercooler. • Color that is similar
similar to new coolant
through the air to airCheck
aftercooler (if equipped) can
cause overheating.
overheat ing. for debris or deposits • Odor that is similar to new coolant
p revent the free flow of air through
which would prevent
the aftercooler.
aftercooler. Refer to Testing and Adjust
Adjusting,
ing, • Free from dirt and debris
“Aftercooler - Test”.
coolant does not have these properties,
If the coolant does
20. Consider high outside temperatures. When drain the system and flush the system. Refill
outside temperatures are too high for the rating the cooling system with the correct mixture
of the cooling
cooling system, there is not enough of a of water, antifreeze
antifreeze,, and coolan
coolantt conditi
conditioner
oner..
temperature
tempera ture difference between the outside air Refer to the Operation and Maintenance Manual
and coolant temperatures. for your engine in order to obtain coolant
recommendations.
recommendat ions.
21. Consider high altitude operation. The cooling
capacity of the cooling system goes down as 3. Look for leaks in the system.
engine is operated at higher altitudes. A
the engine is
pressurized
pressurized cooling system that is large enough to Note: A
Note: A small amount of coolant leakage across
keep the coolant from boiling must be used. the surface of the water pump seals is normal. This
leakage is r equired
equired in order to provide lubrication for
22. The engine may be running in the lug condition. this type of seal. A hole is provided in the water pump
When the load that is applied to the engine is housing in order to allow this coolant/seal lubricant
large, the engine will run in the lug condition.
too large, from the pump housing. Intermittent leakage
to drain from
When the engine is running in the lug condition, of small amounts of coolant from this hole is not an
engine rpm does not increase with an increase of indication of water pump seal failure.
This lower engine rpm causes a reduction in
fuel. This
air flow through the radiator. This lower engine 4. Ensure that the air flow through the radiator does
rpm also causes a reduction in coolant flow not have a restriction. Look for bent core fins
through the
through the system. This combination of less air the folded cores of the radiator. Also, look
between the
and less coolant flow during high input of fuel will for debris between the folded cores of the radiator.
radiator.
cause above normal heating.
the drive belts for the fan.
5. Inspect the
i02501084
6. Check for damage to the fan blades.
Cooling System - Inspect 7. Look for air or combustion gas in the cooling
SMCS Code: 1350-040
Code: 1350-040 system.
Cooling systems that are not regularly inspected are 8. Inspect the filler cap, and check the surface that
the cause for increased engine temperatures. Make seals the filler cap. This surface must be clean.
a visual inspection of the cooling system before any
tests are performed. i02281020
Cooling System - Test

SMCS Code: 1350-040; 1350-081
Code: 1350-040;
Personal
der pressure. This engine has a pressure type cooling system. A
pressur e type cooling system has two advantages.
If a pr essure
essure indication
indication is shown on the indicator,
indicator, The cooling system can be operated in a safe manner
push the release valve in order to relieve pressure at a temperature higher than the normal boiling point
radiator. of water.
(steam) of
(steam)

RENR7572-06 71
Testing and Adjust
Adjusting
ing Section
This type of system prevents cavitation in the water Test Tools For Cooling System
pump. Cavitati
Cavitation is the forming of low pressure
bubbles in liquids that are caused by mechanical Table 16
forces. The formation of an air pocket or a steam To
Tools
ols Needed
this type of cooling system is difficult.
pocket in this type
Part
Part Name Quantity
Number
4C-6500 Digital Thermometer 1
8T-2700 Blowby/Air Flow Indicator 1
9S-8140 Pressurizing Pump 1
9U-7400 Multitach Tool Group
or or 1
1U-6602 Photo-Tachometer
245-5829 Coolant/Battery Tester Gp 1
g00921815
Illustration 62 Making contact with a running engine can cause
Boiling point of water burns from hot parts and can cause injury from
rotating
rotating parts.
Remember that temperature and pressure work
together. When a diagnosis is made of a cooling When working
contact onparts
with hot an engine that is running,
and rotating parts. avoid
system problem, temperature and pressure must be
checked.
check ed. Cooling system pressure will have an effect
on the cooling system temperature. For an example,
refer to Illustration 62. This will show the effect of
pressure on the boiling point (steam) of water. This
will also show the effect of height above sea level.
Personal
Perso nal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot

and under pressure
pressure.. The radiat
radiator
or and all lines
lines
to heaters
steam. Any or the engine
contact contain
can cause hotburns.
severe coolant or g00876179
Illustration 63
4C-6500 Digital Thermometer
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
enough to touch with your bare hand. The 4C-6500 Digital Thermometer is used in the
diagnosis of overheating conditions and in the
Cooling Sys
Cooling System
tem Con
Conditi
ditione
onerr contain
contains
s alk
alkali.
ali. Av
Avoid
oid diagnosis of overcooling conditions. This group can
contact with skin and eyes. be used to check temperatures in several different
parts of the cooling system. Refer to the tool’s
Operating Manual for the testing procedure.
The coolant level must be to the correct level in order
to check the coolant system. The engine must be
cold and the engine must not be running.
After the engine is cool, loosen the pressure cap

in order to relieve the pressure out of the cooling
system. Then remove the pressure cap.
The level of the coolant should not be more than

13 mm (0.5 inch) from the bottom of the filler pipe. If
the cooling system is equipped with a sight glass,
the coolant should be to the proper level in the sight
glass.
72 RENR7572-06
Adjusting Section
g00286269 g00296064
8T-2700 Blowby/Air Flow Indicator 1U-6602 Photo-Tachometer
The 8T-2700 Blowby/Air Flow Indicator is used to The 1U-6602 Photo-Tachomet

Photo-Tachometer er is a
check the air flow through the radiator core. Refer to photo-tachometer that is held by hand for
Speciall Instruction,
Specia Instruction, SEHS8712, “Using the 8T-2700 general use. The 1U-6602 Photo-Tachometer is a
Blowby/Air Flow Indicator” for the test procedure for phototach, so this tachometer only registers basic
checking blowby. input frequency on any visible, rotating part. The basic
input frequency equals one revolution per a piece
of reflective
does tape.the
not replace The 1U-6602 Photo-T
Photo-Tachometer
achometer
9U-7400 Multitach Tool Group.
g00286276
g00286276
Illustration 65
9U-7400 Multitach Tool Group
g00286369
9U-7400 Multitach Tool Group is used to
The 9U-7400 Illustration 67
check the fan speed. Refer to Operating Manual, 9S-8140 Pressurizing Pump
NEHS0605, “9U-7400 Multitach Tool Group ” for the
procedure.
testing procedure. The 9S-8140 Pressurizing Pump is used to test the
filler caps. This pressurizing pump is also used to
The 9U-7400 Multitach Tool Group can measure pressure test the cooling system for leaks.
rpm from a magnetic pickup. This magnetic
engine rpm
pickup is located in the flywheel housing. The
magnetic pickup also uses the ability to measure
engine r pm
pm from visual engine parts that are rotating.

RENR7572-06 73
Testing and Adjust
Adjusting
ing Section
g00439083 g01096114
245-5829 Coolant/Battery Tester Gp Typical schematic of filler cap
(1) Sealing surface of both filler cap and radiator
Check the coolant frequently in cold weather for
the proper glycol concentration. Use the 245-5829
Coolant/Battery Tester Gp in order to ensure
adequate freeze protection. The tester gives
immediate, accurate readings. The tester can be Personal injury can result from hot coolant, steam
used for antifreeze/cool
antifreeze/coolants
ants that contai
contain
n ethylene
ethylene or and alkali.
propylene glycol. At ope

operat
rating
ing temp
tempera
eratur
ture,
e, eng
engine
ine coo
coolant
lant is hot
an
and underr pr ess
d unde essure
ure.. The radiator
radiator and all line
lines
s
Making the Correct Antifreeze to heaters or the engine contain hot coolant or
Mixtures steam. Any contact can cause severe burns.
Refer to the Operation and Maintenance Manual Remove filler cap slowly to relieve pressure only
for the correct coolant recommendations for your when engine is stopped and radiator cap is cool
individual application. touch with your bare hand.
enough to touch
Cooling Sys
Cooling System
tem Con
Conditi
ditione
onerr con
contain
tains
s alk
alkali.
ali. Avoid
Avoid
Checking the Filler Cap with skin and eyes.
contact with
Table 17
Tools Needed To check for the amount of pressure that opens the
filler cap,
cap, use the following procedure:
Part
Part Name Quantity
Number 1. After the engine cools, carefully loosen the filler
9S-8140 Pressurizing Pump 1 Slowly release the pressure from the cooling
cap. Slowly
system. Then, remove the filler cap.
One cause for a pressure loss in the cooling system Carefully inspect the filler cap. Look for any
can be a damaged seal on the radiator filler cap. damage to the seals and to the sealing surface.
Inspect the following components for any foreign
substances:
substance s:
• Filler cap
• Seal
• Surface f oorr seal
Remove any deposits that are found on these
items, and
and remove any material that is found on
these items.
the filler cap on the 9S-8140 Pressurizing

2. Install the
Pump.

74 RENR7572-06
Adjusting Section
3. Look at the gauge for the exact pressure that • You do not observe any outside leakage.
opens the filler
filler cap.
• The reading remains
remains steady after five minutes.
4. Compare the gauge’s reading with the opening
pressure
pressu that is listed on the filler cap.
re that is th e cooling system has leakage only if
The inside of the
the followin
following
g conditions
conditions exist:
5. If the filler cap is damaged, replace the filler cap.
• The reading on the
on the gauge goes down.
Testing The Radiator And Cooling • You do not observe any outside leakage.
System For Leaks
Make any repairs, as required.
Table 18
Tools Needed Test For The Water Temperature

Part
Part Name Quantity Gauge
Number
Table 19
9S-8140 Pressurizing Pump
Pressurizing 1
To
Tools
ols Needed
Use the following procedure in order to check the Part
Part Name Quantity
cooling system for leaks: Number
4C-6500 Digital Thermometer
or or 1
2F-7112 Thermometer
Personal injury can result from hot coolant, steam
Personal
and alkali.
At operating temperature, engine coolant is hot

and under pressure
pressure.. The radiat
radiator
or and all lines
lines Personal injury can result from escaping fluid un-
Personal
to heaters or the engine contain hot coolant or der pressure.
steam. Any contact can cause severe burns.
If a pressure indication is shown on the indicator,
Remove filler cap slowly to relieve pressure only push the release valve in order to relieve pressure
when engine is stopped and radiator cap is cool removing any hose from the radiator.
before removing
enough to touch with your bare hand.
Cooling
Cooling Sys
System
tem Con
Conditi
ditione
onerr contain
contains
s alk
alkali.
ali. Av
Avoid
oid
contact with skin and eyes.
1. After the engine is cool, loosen the filler cap slowly burns
rotating
rotatingfrom hot parts and can cause injury from
parts.
and allow pressure out of the cooling system.
Then remove the filler cap from the radiator. When working on an engine that is running, avoid
2. Ensure that the coolant level is above the top of
the radiator core.
Check the accuracy of the water temperature
3. Install the 9S-8140 Pressurizing Pump onto the indicator or water temperature sensor if you find
radiator. either of the following conditions:
4. Take the pressure reading on the gauge to 20 kPa • The engine runs
runs at a tempera
temperature
ture that is too hot,
(3 psi) more than the pressure on the filler cap. but a normal temperature is indicated. A loss of
coolant is found.
5. Check the radiator for leakage on the outside.
• The engine runs at a normal temperature,
temperature, but a
hot temperature is indicated. No loss of coolant
6. Check all connection
check the points for leakage, and
hoses for leakage. is found.
Caterpillar Electro
Caterpillar Electronic
nic Technicia
Technician
n (ET) can also be
The cooling system does not have leakage only if the
following conditions exist:. used to read the coolant temperature of the engine.

RENR7572-06 75
Testing and Adjust
Adjusting
ing Section
2. Heat water in a pan until the temperature of

the water is equal
equal to the fully open temperature
of the water temperature regulator. Refer to
Specifications, “Water Temperature Regulator”
open temperature of the water
for the fully open
temperature regulator. Stir the water in the pan.
This will distribute
distribute the temper
temperature
ature throughout the
pan.
3. Hang the water temperature regulator in the pan

The water tempera
of water. The water temperature
ture regulator must
be below the surface of the water. The water
temperature regulator must be away from the
th e bottom of the pan.
sides and the
g01141597
Illustration 70 4. Keep the water at the correct temperature for ten
Test location minutes.
(1) Plug
5. After ten minutes, remove the water temperature
Remove the plug (1) from one of ports in the water regulator. Immediately measure the opening
regulator. Immediately
manifold. Install one of the following thermometers in of the water temperature regulator. Refer to
the open port: Specifications, “Water Temperature Regulator”
minimum opening distance of the
for the minimum
• The 4C-6500 Digital Thermome
Thermometer
ter water temperature regulator at the fully open
temperature.
• The 2F-7112 Thermometer
If the distance is less than the amount listed in the
A temperature indicator of known accuracy can also manual, replace the water temperature regulator
regulator..
be used to make this check.
i01849228
Start the engine. Run the engine until the temperature
reaches the desired range according to the test Water Pump - Test
thermometer
thermom eter.. If necessary
necessary,, place a cover over part of
the radiator in order to cause a restriction of the air SMCS Code: 1361-081
Code: 1361-081
flow. The reading on the water temperature indicator
should agree with the test thermometer within the Table 20
tolerance range of the water temperature indicator.
Required Tools
Part
i01666401 Part Name Quantity
Number
Water Temperature
Temperature Regulator 6V-7775 Air Pressure Gauge 1
- Test 8J-7844 Adapter Fitting 1
3K-0360 O-Ring Seal 1
Code: 1355-081-ON; 1355-081
SMCS Code:
5P-2725 Probe Seal Adapter 1
164-2192 Pressure Probe(1) 1
5P-4487 Adapter 1
Personal
der pressure. 5P-2720 Probe Adapter 1
(1) If port (1) is used, two tools are required.
If a pressure indication is shown on the indicator,
push the release valve in order to relieve pressure
radiator.
1. Remove the water temperature regulator

regulator from the
engine.

76 RENR7572-06
Adjusting Section
g00296313
Illustration 71
Pressure test ports for the water pump (Typical example)
(1) Port (alternate heater supply)
(2) Port (engine diagnosis)
(3) Port (heater return line)

burns from hot
hot parts and can cause injury from
rotating parts.
working on an engine that is running, avoid

When working on
The pressure rise is the difference between inlet

pressure rise
pressure and outlet pressure. The pressure rise
indicates if the water pump operates correctly. Port
Port (2) represent the water pump outlet
(1) and Port (2)
pressure. Port (3) represents the water pump inlet
pressure.
To measure the pressure rise, compare inlet pressure

with outlet pressure. Calculate the difference between
the pressure
pressurise
pressure re of the inlet
must add upporttoand the outletofports.
a minimum 80 kPaThe
(12 psi) under both of the following conditions:
• The engine is at operating temperature.

temperature.
• The engine operates
engine operates at full load condition.

RENR7572-06 77
Testing and Adjust
Adjusting
ing Section
Basic Engine
i01432013
Piston Ring Groove - Inspect

SMCS Code: 1214-040
Code: 1214-040
The 186-0190 Piston Ring Groove Gauge Gp is

available to check the top ring groove in the piston.
Refer to the instruction card with the tool for the
correct use of the 186-0190 Piston Ring Groove
Gauge Gp.
g00285686
Illustration 72
i01284843
1P-3537 Dial Bore Gauge Group
Main Bearings - Inspect
If the main bearing caps are installed without
Code: 1203-040 bearings, the bore in the block for the main bearings
can be checked. Tighten the nuts on the bearing caps
Main be
Main bear
aring
ingss are av
avail
ailab
able
le wi
with
th 0.25
0.25 mm (0.
(0.01
010
0 in
inch
ch)) to the torque that is given in Specifications, “Cylinder
mm (0.020 inch) smaller inside diameter
and a 0.50 mm (0.020 Block”. Alignment
Alignment error in the bores must not be more
than the original size bearings. These bearings are than 0.08 mm (0.003 inch).
for crankshafts that have been ground. The 1P-3537 Dial Bore Gauge Group can be used
Main bearings are also available with a larger outside
outside to check the size of the bore.
diameter than the original size bearings. These
are used for the cylinder blocks with the
bearings are i02281052
main bearing bore that is made larger than the bore’s
original size. The size that is available has a 0.50 mm Flywheel - Inspect
(0.020 inch)
inch) outside diameter that is larger than the
originall size bearin
origina bearings.
gs. SMCS Code:
Code: 1156-040
Refer to Sp ecial Instruction, SMHS7606, “Use of

Special Table 22
1P-4000 Line Boring Tool Group” for the instructions To
Tools
ols Needed
that are needed to use the 1P-4000 Line Boring Tool
The 1P-4000 Line Boring Tool Group is used
Group. The Part
Part Name Quantity
in order to check the alignment of the main bearing Number
bores. The 1P-3537 Dial Bore Gauge Group can be 8T-5096 Dial Indicator Gp 1
used to check
check the size of the bore. Refer to Special
Instruction,
Instruction, GMG00981, “1P-3537 Dial Bore Gauge
Group” for the instructions that are needed to use the
1P-3537 Dial Bore Gauge Group.
i02487145
Cylinder Block - Inspect

SMCS Code: 1201-040
Code: 1201-040
Table 21
Required Tools
Part
Part Name
Name Quantity
Number
1P-3537 Dial Bore Gauge Group 1

78 RENR7572-06
Adjusting Section
Face Runout (axial eccentricity) of Bore Runout (radial eccentricity) of
the Flywheel the Flywheel
Illustration 73 g00286049 Illustration 74 g01141609

Checking face runout of the flywheel Checking bore runout of the flywheel
(1) 7H-1945 Holding Rod
1. Refer to Illustration 73 and install the dial indicator. (2) 7H-1645 Holding Rod
Always put a force on the crankshaft in the same (3) 7H-1942 Dial Indicator
(4) 7H-1940 Universal Attachment
direction before the dial indicator is read. This will
remove any crankshaft
crankshaft end clearance.
clearance.
1. Install 7H-1942 Dial Indicator (3). Make an
2. Set the dial indicator to read 0.0 mm (0.00 inch). adjustment
adjustm ent of 7H-1940 Universal Attachment
(4) so the dial indicator makes contact on the
3. Turn the flywheel at intervals of 90 degrees and flywheel.
read the dial indicator.
2. Set the dial indicator to read 0.0 mm (0.00 inch).
4. Take the measurements at all four points. The
difference
difference between the lower measuremen
measurements ts and 3. Turn the flywheel at intervals of 90 degrees and
the higher measurements that are performed at read the dial indicator.
all four points must not be more than 0.15 mm
(0.006 inch), which is the maximum permissible 4. Take the measurements at all four points. The
face runout (axial eccentricity) of the flywheel. difference
difference between the lower measurement
measurements s and
the higher measurements that are performed at
all four points must not be more than 0.15 mm
(0.006 inch), which is the maximum permissible
face runout (radial eccent
eccentricity)
ricity) of the flywheel.

RENR7572-06 79
Testing and Adjust
Adjusting
ing Section
If you use any other method except the method that

is given here, always
always remember that the bearing
clearance must be removed in order to receive the
correct measurements.
1. Fasten a dial indicator to the flywheel so the anvil

of the dial indicator will contact the face of the
flywheell hou
flywhee sing.
housing.
2. Put a force on the crankshaft toward the rear

dial indicator is read at each point.
before the dial
g00286058
Illustration 75
Flywheel clutch pilot bearing bore
5. To find the runout (eccentrici

(eccentricity)
ty) of the pilot bearing
bore, use the preceding procedure.
6. The runout (eccentricity) of the bore for the pilot

bearing in the flywheel must not exceed 0.13 mm
(0.005 inch).
i02281054 g00285932
Illustration 77
Flywheel Housing - Inspect face runout of the flywheel housing

Checking face

Code: 1157-040 3. Turn the flywheel while the dial indicator is set at
(0.00 inch) at location (A). Read the dial
0.0 mm (0.00
Table 23 indicator at locations (B), (C) and (D).
Tools Needed
4. The differ ence
ence between the lower measurements
measurements
Part and the higher measurements that are performed
Part Name Quantity
Number at all four points must not be more than 0.30 mm
8T-5096 Dial Indicator Gp 1 inch), which is the maximum permissible
(0.012 inch),
face runout (axial eccentricity) of the flywheel
housing.
Face Runout (Axial Eccentricity) of
the Flywheel Housing Bore Runout (Radial Eccentricity)
of the Flywheel Housing
g00285931
Illustration 76
g00285934
8T-5096 Dial Indicator Illustration 78
8T-5096 Dial Indicator

80 RENR7572-06
Adjusting Section
1. Fasten a dial indicator to the flywheel so the anvil 6. Turn the flywheel counterclockwise in order to
of the dial indicator
indi cator will contact the bore of the put the dial indicator
indicator at position (C). Write the
flywheel housing. measurement in the chart.
flywheel counterclockwise in order to

7. Turn the flywheel
put the dial indicator at position (D). Write the
measurement in the chart.
8. Add the lines together in each column.

smaller number from the larger
9. Subtract the smaller
number in column B and column D. Place this
number on line III. The result is the horizontal
eccentricity
eccentricit y (out of round). Line III in column C is
the vertical eccentricity.
g00285932
Illustration 79
Checking bore runout of the flywheel housing
g00285936
Illustration 80
g00286046
Illustration 81
2. While the dial indicator is in the position at location
(C) adjust the dial indicator to 0.0 mm (0.00 inch). Graph for total eccentricity
Push the crankshaft upward against the top of (1) Total vertical eccentricity
the bearing. Refer to Illustration 80. Write the (2)

(3) Total horizontal
Acceptable valueeccentricity
measurement for bearing clearance on line 1 in (4) Unacceptable value
column (C).
10. Find the intersection of the eccentricity lines
Note: Write the measurements for the dial indicator
Note: Write (vertical and horizontal) in Illustration 81.
with the correct notations. This notation is necessary
for making the calculations
calculations in the chart correctly
correctly.. 11. If the point of the intersection is in the
ACCEPTABLE range, ra nge, the bore is in alignment.
3. Divide the measurement
measurement from Step 2 by two. Write If the point of intersection is in the NOT
this number on line 1 in columns (B) and (D). ACCEPTABLE range, the flywheel housing must
be chang
changed.
ed.
4. Turn the flywheel in order to put the dial indicator
at position (A). Adjust the dial indicator to 0.0 mm
(0.00 inch).
5. Turn the flywheel counterclockwise in order to

put the dial indicator at position (B). Write the
measurements in the chart.

RENR7572-06 81
Testing and Adjust
Adjusting
ing Section
i02487784 Viscous Vibration Damper (If

Vibration Damper - Check Equipped)
Code: 1205-535
Vibration Damper (If

Rubber Vibration
Equipped)
g01124289
Illustration 82 Illustration 83 g01124414
Vibration damper and pulley
Viscous vibration damper
(1) Adapter
(1) Pulley
(2) Rubber
(2) Weight
(3) Damper assembly
(3) Case
(4) Bolt
(5) Crankshaft pulley
Damage to the vibration damper or failure of the
The vibration damper is installed on the front of vibration damper will increase vibrations. This will
crankshaft. The space in the damper assembly (3) is result in damage to the crankshaft.
filled with rubber (2). The vibration damper limits the
torsional vibration. Replace the damper if any of the following conditions
exist:
Replace the damper if any of the following conditions
exist: • The damper is dented,
dented, cracked, or fluid is leaking
from the damper.
• The damper is dented
dented or cracked.
• The paint on the damper is discolored from
• The paint on the damper is discolored from heat. excessive heat.
• There is a large amount

amount of gear train wear that is • The damper is bent.
not caused by lack of oil.
• The bolt holes
holes are worn or there is a loose fit for
• Analysis
Analysis of the oil has revealed that the front main the bolts.
bearing is badly worn.
• The engine has had a crankshaft failure due to
• The engine has had
had a failure because of a broken torsional forces.
crankshaft.
NOTICE
Inspect the viscous vibration damper for signs of leak-
ing and for signs of damage to the case. Either of
these conditions can cause the weight to contact the
case. This contac
contactt can affect damper operation.
operation.

82 RENR7572-06
Adjusting Section
Electrical System i02482495
Battery - Test
i02517996
Code: 1401-081
Alternator - Test
Most of the tests of the electrical system can be done
Code: 1405-081 The wiring insulation must be in good
on the engine. The
condition.
clean, andThe
bothwire and cablemust
components connections
be tight. must be
Regulator
Alternator Regulator
The charging rate of the alternator should be
when an alternator is charging the battery
checked when an
too much. The charging rate of the alternator should disconnect any charging unit circuit or bat-
Never disconnect
be checked when an alternator is not charging the tery circuit cable from the battery when the charg-
enough. Make referen
battery enough. reference
ce to the Specificatio
Specifications
ns ing unit is operated. A spark can cause an explo-
module in order to find all testing specifications for the flammable vapor mixture of hydro-
sion from the flammable
the alternators
alternators and regulators. gen and oxyoxygen
gen that is releas
released
ed fro
from
m the elec-
trolyte through the battery outlets. Injury to per-
No adjustment can be made in order to change the be the result.
sonnel can be the
rate of charge on the alternator regulators. If the
rate of char ge
ge is not correct, a replacement of the
regulator is necessary. The battery circuit is an electrical load on the charging
load is variable because of the condition of
unit. The load
The Alternator Pulley Nut
Tightening The
Tightening the charge in the battery.
NOTICE
charging unit will be damaged if the connections
The charging
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
the load from the battery is lost and because
because the load
there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and other
electricall components.
electrica components.
g01247292
Illustration 84
Tools for tightening the alternator pulley nut
(1) 8T-9293 Torque Wrench g00859857
Illustration 85
(2) 8S-1588 Adapter
(3) 2P-8267 Hex Bit Socket 177-2330 Battery Analyzer
(4) 8H-8517 Combination Wrench (1-1/8 inch)
(5) 8T-5314 Adapter Socket
Tighten the nut that holds the pulley with the tools
shown.
torque. Refer to the Specifications module for the

RENR7572-06 83
Testing and Adjust
Adjusting
ing Section
i02482986
Charging System - Test

Code: 1406-081
The condition of charge in the battery at each

inspection will show if the charging system is
regular inspection
operating
the batterycorrectly. An adjustment
is constantly is necessary
in a low condition when
of charge
amount of water is needed. A large amount
or a large amount
of water would be more than one ounce of water per
a cell per a week or per every 100 service hours.
When it is possible, make a test of the charging

unit and voltage regulator on the engine, and use
components that are a permanent part of
wiring and components
the system. Off-engine testing or bench testing will
give a test of the charging unit and voltage regulator
operation. This
operation. This testing will give an indication of
needed repair. After repairs are made, perform a test
g00283565 in order to prove that the units have been repaired to
Illustration 86
the original condition of operation.
origina
4C-4911 Battery Load Tester
Use the 4C-4911 Battery Load Tester or the See Special

System Instruction,
oting”REHS0354,
Troubleshooting”
Troublesho “Charging
for the correct proce
procedures
dures
177-2330 Battery Analyzer in order to test a battery to use to test the charging system. This publication
that does not maintain a charge when the battery also contains the specifications to use when you test
is active. The 4C-4911 Battery Load Tester and charging syste
the charging system.
m.
the 177-2330 Battery Analyzer are portable units.
The 4C-4911 Battery Load Tester or the 177-2330
Battery Analyzer can be used under field conditions Tools For The Charging
Test Tools For
and under high temperatures.
temperatures. The tester can be used System
to load test all 6, 8, and 12 Volt batteries. This tester
has two heavy-duty load cables that can easily be Table 24
fastened to the battery terminals. A load adjustment ed
To
Tools
ols Need
Needed
knob is located on the top of the tester. The load
adjustment knob permits the current that is being Part
Part Name Quantity
drawn from the battery to be adjusted to a maximum Number
of 1000 amperes. The tester is cooled by an internal 225-8266 Ammeter Tool Gp 1
fan that is automatically activated when a load is
applied. 237-5130 Digital Multimeter Gp
or or 1
The tester has a built-in LCD. The LCD is a digital 146-4080 Multimeter Gp
Digital Multimeter
voltmeter. The LCD is a digital meter that will
also display the amperage. The digital voltmeter
225-8266 Ammeter Tool Gp
accurately measures the battery voltage at the battery
through wires for tracing. These wires are buried
inside the load cables. The digital meter, that displays
the amperage, accurately displays the current that is
being drawn from the battery which is being tested.
Note: Refer
Note: Refer to Operating Manual, SEHS9249, “Use
of 4C-4911 Battery Load Tester for 6, 8, and 12
Volt Lead Acid Batteries” for detailed instruction
on the use of the 4C-4911 Battery Load Tester.
Refer to Operating Manual, NEHS0764, “Using the
177-2330 Battery Analyzer” for detailed instruct
instruction
ion
on the use of the 177-2330 Battery Analyzer.
See Specia
Speciall Instru
Instruction,
ction, SEHS7633, “Battery TTest
est
Procedure” for the correct procedures to use when
you test the battery. This publication also contains Illustration 87
g01012117
the specifications to use when you test the battery.
225-8266 Ammeter Tool Gp
84 RENR7572-06
Adjusting Section
The 225-8266 Ammeter Tool Gp is completely The 237-5130 Digital Multimeter Gp and the
portable. This ammeter
This ammeter is a self-contained instrument 146-4080 Digit
Digital
al Multimeter Gp are portable
that measures electrical currents without breaking
breaking hand-held service tools with a digital display. These
the circuit and without disturbing the conductor’s multimeters are built with extra protection against
insulation. field applications. Both multimeters
damage in field
are equipped with 7 functions and 29 ranges. The
The ammeter contains a digital display that is used 237-5130 Digital Multimeter Gp and the 146-4080
current directly within a range between 1
to monitor current Multimeter Gp have an instant ohms indicator.
Digital Multimeter
ampere and 1200 amperes. If an optional 6V-6014 This indicator permits checking continuity for a fast
Cable is connected between this ammeter and a inspection
inspection of the circuits. These multimeters can also
multimeter, current readings can be viewed
digital multimeter, troubleshooting
be used for troubles hooting capacitors that have
directly from the display of the multimeter. The small values.
values.
multimeter
multimet er should be used under only one condition:
condition:
i02483828
• the readings are less than 1 ampere.
A lever opens the
opens the ammeter’s jaws over a conductor.
Electric Starting System - Test
The conductor’s diameter can not be larger than SMCS Code: 1 450-081
Code: 1450-081
19 mm (0.75 inch).
Most of the tests of the electrical system can be
The spring loaded jaws close around the conductor e ngine. The wiring insulation must be
done on the engine.
for measuring the current. A trigger switch controls in good condition. The wire and cable connections
ammeter. The trigger switch can be locked into
the ammeter. must be clean, and both components must be tight.
the ON position or into the OFF position. The batter y must be fully charged. If the on-engine
test shows a defect in a component, remove the
After the trigger has been working and the trigger is component for more testing.
turned to the OFF position, the reading appears in
the digital display for five seconds. This accurately The starting system consists of the following
currents in areas with a limited access.
measures currents components:
For example, these areas include areas that are
beyond the operator’s sight. For DC operation, an
• Keyswitch
contains a zero contro
ammeter contains control,
l, and batteries inside
the handle supply the power.
• Starting motor
motor solenoid
237-5130 Digital Multimeter Gp or • Starting motor

146-4080 Digital Multimeter Gp
Table 25
To
Tools
ols Needed
Needed
Part Number Part Name QTY
237-5130
or Digital Multimeter 1
146-4080
g00283566
Illustration 88
30 Digital
237-5130
237-51 Multimeter Gp or 146-4080 Digital Multimeter
Gp
g00283566
Illustration 89
237-5130 Digital Multimeter or the 146-4080 Digital Multimeter

RENR7572-06 85
Testing and Adjust
Adjusting
ing Section
The 237-5130 Digital Multimeter Gp and the Fasten one multimeter lead to the start switch at the
146-4080 Digit
Digital
al Multimeter Gp are portable terminal connection
connection for the wire from the battery.
hand-held service tools with a digital display. These Fasten the other lead to a good ground. A zero
multimeters are built with extra protection against reading indicates a broken circuit from the battery.
field applications. Both multimeters
damage in field Make a check of the
the circuit breaker and wiring. If
are equipped with 7 functions and 29 ranges. The there is a voltage reading, the problem is in the start
237-5130 Digital Multimeter Gp and the 146-4080 switch or in the wires for the start switch.
Multimeter Gp have an instant ohms indicator.
Digital Multimeter indicator.
This indicator permits checking continuity for a fast Starting motors that operate too slowly can have an
inspection
inspec tion of the circuits. These multimeters can also overload because of too much friction in the engine
troubleshootin
be used for trouble shootingg capacitors
capacitors that have being started. Slow operation of the starting
that is being started.
small values.
values. motors can also be caused by a short circuit, loose
connections and/or dirt in the motors.
Note: Refer to
Note: Refer to Special Instruction, SEHS7734 for
complete information for the use of the 237-5130
i01881539
Digital Multimeter. Refer to Operation Manual,
NEHS0678 for for complete information for the use of
the 146-4080 Digital Multimeter.
Engine Oil Pressure Sensor -
Test
multimeter in the DCV range to find starting
Use the multimeter
system components which do not function. SMCS Code: 1924-081
Code: 1924-081
start control switch in order to activate the

Move the start Refer to the Troubleshooting, “Engine Pressure
starting
starting solenoids.
solenoids. The starting solenoid’s
solenoid’s operation Sensor Open Or Short Circuit - Test” for information
can be heard as the pinions of the starting motors are on checking the
checking the engine oil pressure sensor.
with the ring gear on the engine flywheel.
engaged with
i02237991
If a solenoid for a starting motor will not operate, it
possible that the current from the battery did not
is possible Pinion Clearance - Adjust
reach the solenoid. Fasten one lead of the multimeter
to the terminal connection for the battery cable on the SMCS Code: 1454-025
Code: 1454-025
solenoid.. Touch the other lead to a good ground. A
solenoid
zero reading indicates that there is a broken circuit
from the battery. More testing is necessary when Electric Starting Motor
there is a
is a voltage reading on the multimeter.
When the solenoid is installed, make an adjustment
The solenoid operation also closes the electric circuit of the pinion clearance. The adjustment can be made
motor. Connect one lead of the multimeter
to the motor. with the starting motor removed.
to the terminal connection of the solenoid that is
fastened to the motor. Touch the other lead to a good
ground. Activate
ground. Activate the starting solenoid and look at the
multimeter. A reading of the battery voltage shows
that the problem is in the motor. The motor must be
removed
remove d for further testing. A zero reading on the
multimeter shows that the solenoid contacts do not
close. This is an indication of the need for repair to
solenoid or an adjustment to be made to the
the solenoid
pinion clearance for the starting motor.
Perform a test. Fasten one multimeter lead to the

Perform
terminal connection for the small wire at the solenoid
and fasten the other lead to the ground. Look at
multimeter and activate the starting solenoid.
the multimeter g01134792
Illustration 90
A voltage reading shows that the problem is in the
solenoid. A zero reading indicates that the problem is Connection for checking pinion clearance
Connection
the start switch or the wires for the start switch.
in the (1) Ground terminal
(2) Switch terminal
(3) Connector to the motor
1. Install the solenoid withou

withoutt connector (3) from the
MOTOR connections
connections (termin
(terminal)
al) on the soleno
solenoid
id
motor.
to the motor.
86 RENR7572-06
Adjusting Section
2. Connect a battery, that has the same voltage as

the solenoid, to
to the “SW” terminal (2).
3. Connect the other side of the battery to connector

(3).
4. For a moment, connect a wire from the solenoid

(terminal),, which is marked “MOTOR”,
connection (terminal)
to the ground connection (terminal). The pinion
will shift to the crank position and the pinion will
until the battery is disconnected.
stay there until
g01097827
Illustration 91
(4) Shaft nut
(5) Pinion
(6) Pinion clearance
5. Push the pinion toward the end with the

commutator in order to remove free movement.
6. Pinion clearance (6) must be 9.1 mm (0.36 inch).
7. In order to adjust the pinion cleara

clearance,
nce, remove the
plug and turn the shaft nut (4).
8. After the adjustment is completed, install the

plug over the nut (4) and install the connector (3)
between
betwee n the MOTOR terminal
terminal on the solenoid and
the starter motor.

RENR7572-06 87
Index Section
Index
A System...........
Electrical System.
Electrical .....................
.......................
.......................
........... 35, 82
Charging
Chargin g System ComponComponents ents ..........
......................
................
.... 36
Aftercooler - Test ......
..................
.........................
.........................
....................
........ 57 Engine Electrical
Electrical System ......................
..................................
.............. 36
Aftercooler Core Leakage...............................
Leakage.................................. ... 58 Practices ...........................
Grounding Practices .......................................
...............
... 35
Air System Restriction........
Restriction....................
.........................
....................
....... 59 Starting
Startin g System Components ........... .......................
.................
..... 37
Dynamometer
Dynamo meter Test..............
est..........................
........................
...................
....... 59 Electronic
Electro nic Control System Components.............
Components.................. ..... 7
Turbocharger Failure
Failure .................................
.........................................
........ 59 Unit Injector - Tes
Electronic Unit Test.....................
t................................
............. 41
Visual
Visu al Inspection.................
Inspection.............................
........................
...................
....... 57 Engine Crankcase Pressure (Blowby) - Test......... 60
Air in Fuel - Test...........
est.......................
........................
........................
..................
...... 39 Engine Oil Pressure - Test..............
est..........................
.......................
........... 63
Air Inlet and Ex haust System ..................
Exhaust ..........................
........ 23, 49 Engine Oil Pressure
Measuring Engine Pressure ............
.........................
............. 63
Air Inlet Heater .........................
............ .........................
.........................
............... 26 Reason for High Engine Oil Pressure................ 65
Turbochar
Tur bocharger
ger ......................
..................................
.......................
...................
........ 24 Reasons for Low Engine Oil Pressure............... 64
Components.....................
Valve System Component s................................
........... 26 Pressure Sensor - Test .........
Engine Oil Pressure ....................
...............
.... 85
Air Inlet and Exhaust System - Inspect..................
Inspect........... ....... 49 Engine Speed - Check...
Check...............
.......................
.......................
.................
..... 40
Air Inlet Restriction .........................
............ ..........................
....................
....... 49 Engine Valve
Valve Lash - Inspec
Inspect/Adjus
t/Adjustt ......................
........................ 60
Pressure for Diesel Particulate
Exhaust Back Pressure Valve Lash and Valve Val ve Bridge
Bridge Adjustment
Adjustment .......... 61
Filters (If Equipped)................
Equipped)...........................
.......................
...............
... 51 Valve Lash Check ............
........................
.......................
......................
........... 60
Exhaust Back Pressure for Mufflers and Catalytic Excessive
Excess ive Bearing Wear - Inspect..............
Inspect.........................
........... 66
Converters.......
Convert ers...................
........................
........................
........................
.............. 50 Excessive Engine
Engine Oil Consumption - Inspect........ 66
Exhaustt Restriction
Exhaus Restriction .......................
...................................
.....................
......... 50 Oil Leakage Into Combustion Area Of
Alternator - Test ............
........................
........................
........................
.................
..... 82 Cylinders
Cylind ers ............
........................
.......................
.......................
.......................
........... 66
Alternator Regulator...............
Regulator..........................
.......................
.................
..... 82 Oil Leakage On Outside
Outside Of Engine.................... 66
Exhaust Temperature - Test................................... 57
B
F
Basic Engine........................
Engine....................................
........................
................
.... 32, 77
Camshaft..........
Camsha ft......................
........................
........................
........................
..............
.. 34 Center Position for No. 1 Piston......... 42
Finding Top Center
Crankshaft......
Cranks haft..................
........................
........................
........................
................
.... 33 Calibrate the Electronic Injection Timing With the
Cylinder
Cylind er Block And Head....................
Head................................
...............
... 32 Electronic
Electro nic Servic
Service e Tool..............
ool..........................
.......................
........... 43
Piston,, Rings And
Piston Connecting Rods.................. 32
And Connecting Flywheell - Inspe
Flywhee Inspec ct...........
t.......................
........................
........................
...............
... 77
Vibration
Vibra tion Damper................................
Damper............................................
...............
... 33 Bore Runout (radial eccentricity) of the
Battery - Test ....................
................................
........................
........................
.............. 82 Flywheel
Flywhe el .......................
...................................
........................
........................
............ 78
Face Runout (axial (axial eccentricity) of the
Flywheel
Flywhe el .......................
...................................
........................
........................
............ 78
C Flywheell Housin
Flywhee Housing g - Inspec
Inspectt ..................
..............................
.................
..... 79
Bore Runout (Radial(Radial Eccentricity) of the Flywheel
Charging System - Test ..........
Charging ......................
.......................
...................
........ 83 Housing
Housin g ............
........................
........................
........................
........................
............ 79
Test Tools For The Charging System................. 83 Face Runout (Axial Eccentricity) of the Flywheel
Cooling System ..........................
............................................... 30, 68
..................... Housing
Housin g ............
........................
........................
........................
........................
............ 79
Coolantt Conditioner
Coolan Conditioner (If Equipp Equipped)......
ed)..................
................
.... 31 Fuel Quality - Test........
est....................
........................
........................
..................
...... 43
Coolant For Air Compressor (If Equipped)......... 31 Fuel System.
System............
.......................
........................
........................
...................
....... 9, 39
Cooling System - CheckCheck (Overheating)................. 68 Description .........................
Component Description .....................................
............ 10
Cooling System - Inspec
Inspect............
t........................
........................
...............
... 70 HEUI Fuel Injecto
Injectorr (Operation)
(Operation) ..............
..........................
............ 18
Cooling System - Test......
est.................
.......................
.......................
...............
.... 70 HEUI Fuel System Operation Operation............
........................
.................
..... 12
Checking
Check Filler Cap...................
ing the Filler Cap..............................
...................
........ 73 (Components)...................
HEUI Injector (Components )..............................
........... 16
Making the Correct Antifreeze Mixtures............. 73 Introduction
Introdu ction ...........
.......................
........................
........................
.......................
........... 9
Test For The Water Tempera Temperature ture Gauge ...........
........... 74 Fuel System - Inspec
Inspect....................
t................................
........................
............ 39
Cooling System .......................
Test Tools For Cooling ..........................
... 71 Operation Of Individual
Checking The Operation
Testing The Radiator And Cooling System For Cylinders
Cylind ers ............
........................
.......................
.......................
.......................
........... 39
Leaks..............
Leaks.. ........................
........................
.......................
.......................
...............
... 74 Initial Inspection
Inspection of the Fuel System System ............
..................
...... 39
Cylinder Block - Inspect.............
Inspect........................
.......................
.................
..... 77 Inspection of the Fuel F uel System during Engine
Operation
Operati on ...........
.......................
........................
........................
......................
.......... 39
Fuel System - Prime......................
Prime..................................
.......................
............. 44
E Pressure - Test ............
Fuel System Pressure ........................
.....................
......... 45
High Fuel Pressure ......................
...................................
......................
......... 46
Electric Starting System - Test..................
est.............................
.............
.. 84 Low Fuel Pressur
Pressure e ............
........................
........................
.....................
......... 45
Fuel System......................... 47
Tests for the HEUI Fuel
Type
Type I Fuel System ...........
.......................
........................
.....................
......... 46
Type
Type II Fuel System ..........
......................
........................
.....................
......... 46
G W
Gear Group (Front) - Time.....

Time.................
........................
....................
........ 47 Water Pump - Test...................
Water est...............................
........................
..................
...... 75
Generall Information................
Genera Information............................
........................
.....................
......... 4 Water Temperature Regulator - Test ..................... 75
Operation..........................
Cold Mode Operation.............. ........................
.................
..... 6
Starting The Engine ........................
....................................
.....................
......... 6
I
Safety Information
Importantt Safety
Importan Information ............
........................
.......................
........... 2
Increased Engine Oil Temperat
Increased Temperature
ure - Inspect
Inspect ......... 66
Inlet Manifold Pressure - Test...........
est ......................
.....................
.......... 56
Lubrication
Lubrication System ...........
.......................
.......................
...................
........ 27, 63
Main Bearings - Inspect........

Bearings - Inspect....................
........................
.....................
......... 77
Pinion Clearance
Clearance - Adjust..................
Adjust..............................
....................
........ 85
Electric Star ting
ting Motor.................
Motor.............................
.......................
........... 85
Piston Ring Groove - Inspect............
Inspect........................
.....................
......... 77
Take-Off (RPTO)........................
Rear Power Take-Off (RPTO)................................
........ 35
Systems
Systems Operation
Operation Section............................
Section.....................................
......... 4
Table of Contents...........
Contents.......................
........................
........................
..................
...... 3
Testing and Adjusting Section ............................... 39
Turbocharger -
- Inspect ...........
.......................
.......................
...................
........ 53
Inspection
Inspec tion of the Compressor and the Compres Compressor sor
Housing............................
Housing........................................
.......................
....................
......... 54
Inspection of the
the Turbine Wheel and the Turbine
Housing............................
Housing........................................
.......................
....................
......... 54
Inspection
Inspec tion of the Wastegat
Wastegate e ..............................
.............................. 55
Vibration Damper - Check ...........

Vibration ......................
.......................
...............
... 81
Rubberr Vibration
Rubbe Vibration Damper (If Equipped)............
Equipped).............. 81
Vibration Damper (If Equipped)............ 81
Viscous Vibration

PDF c7 Specifications Systems Operation Testing and Adjusting - Caterpillar

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PDF c7 Specifications Systems Operation Testing and Adjusting - Caterpillar

Uploaded by

Copyright:

Available Formats

Important Safety Information

The meaning of this safety alert symbol is as follows:

Failure to heed this warning can lead to prema-

Table of Contents Electric Starting System - Test ....................

Testing and Adjusting Section

Fuel System Pressure

Air Inlet and Exhaust System

Systems Operation Section

The engine has built-in diagnostics in order to ensure

Starting The Engine

Cold Mode Operation

Electronic Control System

• Input component • Improvement in performance

control component (ECM) receives the input signals

• Engine Control Module (ECM) (18)

Component Description Engine Control Module (ECM)

Low actuation pressure of the oil results in low

Pump Pressure Regulator

pressure regulator is an actuator that

(9) IAP sensor

The fuel transfer pump is a gear pump. The pump is

HEUI Fuel System Operation

Injection Actuation System

Control pressure is determined by the amount of • Desired actuation pressure

• The ECM monitors actual actuation pressure

Valve Operation (ENGINE CRANKING) Valve Operation (RUNNING ENGINE)

Refer to Illustration 11. The HEUI injector consists

• Upper end, or actuator (A)

• Lower end, or nozzle

The upper end (A) consists of the following items:

The middle of the injector (B) contains the following

• Intensifier piston (8)

• Nozzle case (12)

HEUI Fuel Injector (Operation)

The split injection cycle has five phases of injection:

Refer to Illustration 12. The injector is in the phase Pilot Injection

The spool valve (6) is held in the top of the bore

Refer to Illustration 13. Pilot injection occurs when Injection Delay

p ressure under the spool causes a

Pilot in jection will continue if the following conditions

• The spool remains open.

Refer to Illustration 14. Injection delay begins when Main Injection

Actuation pressure increases under the spool valve

Refer to Illustration 15. Main injection begins when Fill

(1) Solenoid i01902820

Refer to Illustration 16. The fill cycle begins when the

Aftercooler core (2) is a separate cooler core. • Exhaust stroke

Clean air from the air cleaners is pulled through

When the load on the engine increases, more fuel is

As the boost pressure through line (14) increases

Valve System Components Heater

Under the proper conditions, the ECM turns on

• Jacket water coolant

• Inlet manifold air temperature

inlet air into

valves (5) and (6). The airThe heater

During engine cranking, when the sum of the coolant

After the engine has started, the same combination

The two strategies are continuous and intermittent.

When one of the temperature sensors fails, the

• Coolant temperature sensor

Inlet air temperature sensor