System Operation Testing and Adjustin C10 y C12

RENR2235-04
June 2004
Systems Operation
Testing and Adjusting
C-10 and C-12 Truck Engines
CPD1-Up (Engine)
2KS1-Up (Engine)
3CS1-Up (Engine)
i01658146
Important Safety Information

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

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique 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
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
3
Table of Contents
Table of Contents Flywheel Housing - Inspect ................................... 81

Vibration Damper - Check .................................... 83
Compression Brake
Systems Operation Section Slave Piston Lash - Adjust .................................... 85
Control Valve (Compression Brake) - Test ............ 86
Engine Design ....................................................... 4
Solenoid Valve (Compression Brake) - Test ......... 87
Engine Design ....................................................... 4
General Information ................................................ 5
Electrical System
Electronic Control System Components ................. 6
Battery - Test ......................................................... 90
Fuel System ........................................................... 8
Charging System - Test ........................................ 90
Air Inlet and Exhaust System ............................... 22
Electric Starting System - Test .............................. 91
Lubrication System .............................................. 25
Engine Oil Pressure Sensor - Test ........................ 91
Cooling System .................................................... 29
Pinion Clearance - Adjust ..................................... 91
Basic Engine ......................................................... 32
Pinion Clearance - Adjust ..................................... 92
Rear Power Take-Off (RPTO) ............................... 34
Compression Brake .............................................. 34
Electrical System ................................................. 37 Index Section
Index ..................................................................... 94
Testing and Adjusting Section
Fuel System
Fuel System - Inspect ........................................... 41
Air in Fuel - Test .................................................... 41
Electronic Unit Injector - Adjust ............................. 42
Electronic Unit Injector - Test ................................ 43
Finding Top Center Position for No. 1 Piston ........ 43
Fuel Quality - Test ................................................. 45
Fuel System - Prime ............................................. 46
Fuel System Pressure - Test ................................. 48
Gear Group (Front) - Time .................................... 53
Air Inlet and Exhaust System

Air Inlet and Exhaust System - Inspect ................. 54
Turbocharger - Inspect .......................................... 56
Inlet Manifold Pressure - Test ............................... 59
Exhaust Temperature - Test .................................. 60
Aftercooler - Test ................................................... 60
Engine Crankcase Pressure (Blowby) - Test ........ 63
Compression - Test ............................................... 63
Engine Valve Lash - Inspect/Adjust ...................... 64
Lubrication System
Engine Oil Pressure - Test .................................... 66
Engine Oil Pump - Inspect .................................... 68
Excessive Bearing Wear - Inspect ........................ 69
Excessive Engine Oil Consumption - Inspect ....... 69
Increased Engine Oil Temperature - Inspect ........ 69
Cooling System
Cooling System - Check (Overheating) ................ 70
Cooling System - Inspect ...................................... 72
Cooling System - Test ........................................... 72
Water Temperature Regulator - Test ..................... 77
Water Pump - Test ................................................ 77
Basic Engine
Piston Ring Groove - Inspect ................................ 78
Connecting Rod Bearings - Inspect ...................... 78
Main Bearings - Inspect ........................................ 78
Cylinder Block - Inspect ........................................ 78
Cylinder Liner Projection - Inspect ........................ 79
Flywheel - Inspect ................................................. 80
4
Systems Operation Section
Systems Operation Section i00980375
Engine Design
i00980518
SMCS Code: 1000
Engine Design S/N: CPD1-Up
SMCS Code: 1000 S/N: 2KS1-Up
S/N: 3CS1-Up
g00386924
Illustration 2
g00386924 Cylinder and Valve Location
Illustration 1
Cylinder and Valve Location (A) Exhaust valves
(B) Inlet valves
(A) Exhaust valves
(B) Inlet valves
Bore ........................................ 130.0 mm (5.12 inch)
Bore ........................................ 125.0 mm (4.92 inch)
Stroke ..................................... 150.0 mm (5.91 inch)
Stroke ..................................... 140.0 mm (5.51 inch)
Displacement ....................................... 12 L (732 in3)
Displacement .................................... 10.3 L (629 in3)
Cylinder arrangement ..................................... In-line
Cylinder arrangement ..................................... In-line
Valves per cylinder .................................................. 4
Valves per cylinder .................................................. 4
In order to check the engine valve lash setting, the
In order to check the engine valve lash setting, the engine must be cold and the engine must be stopped.
engine must be cold and the engine must be stopped. Engine valve lash settings
Engine valve lash settings Inlet ..................................... 0.38 mm (.015 inch)
Inlet ..................................... 0.38 mm (.015 inch) Exhaust ............................... 0.64 mm (.025 inch)
Exhaust ............................... 0.64 mm (.025 inch) Engine compression brake .. 1.02 mm (.040 inch)
Engine compression brake .. 0.64 mm (.025 inch)
Type of combustion ........................... Direct Injection
Type of combustion ........................... Direct Injection
Firing Order ................................... 1 - 5 - 3 - 6 - 2 - 4
Firing Order ................................... 1 - 5 - 3 - 6 - 2 - 4
The crankshaft rotation is viewed from the
The crankshaft rotation is viewed from the flywheel end of the engine. Crankshaft
flywheel end of the engine. Crankshaft rotation .......................................... Counterclockwise
rotation .......................................... Counterclockwise
Note: The front end of the engine is opposite of the
Note: The front end of the engine is opposite of the flywheel end of the engine. The left side of the engine
flywheel end of the engine. The left side of the engine and the right side of the engine are viewed from the
and the right side of the engine are viewed from the flywheel end of the engine. The No. 1 cylinder is the
flywheel end of the engine. The No. 1 cylinder is the front cylinder.
front cylinder.
5
i01797236
NOTICE
General Information Excessive ether (starting fluid) can cause piston and
ring damage. Use ether for cold weather starting pur-
SMCS Code: 1000 poses only.
C-10 Truck Engines and C-12 Truck Engines
are in-line six cylinder arrangements. C-10 Truck
Engines have a bore of 125.0 mm (4.92 inch) and a
Cold Mode Operation
stroke of 140.0 mm (5.51 inch). The displacement
The ECM will set the cold start strategy when the
is 10.3 L (629 in3). C-12 Truck Engines have a bore
coolant temperature is below 18 °C (64 °F).
of 130.0 mm (5.12 inch) and a stroke of 150.0 mm
(5.91 inch). The displacement is 12 L (732 in3). Both
When the cold start strategy is activated, low idle rpm
engines have a firing order sequence:1, 5, 3, 6, 2, and
will be increased to 1000 rpm and the engine’s power
4. The rotation of these engines is counterclockwise
will be limited.
when the engine is viewed from the flywheel end of
the engine. These engines utilize a turbocharger and
Cold mode operation will be deactivated when any of
an air-to-air aftercooler.
the following conditions have been met:
The Electronic Unit Injector system (EUI) eliminates
many of the mechanical components that are • Coolant temperature reaches 18 °C (64 °F).
traditionally used in the fuel injector assembly. The
EUI also provides increased control of the timing and • The engine has been running for fourteen minutes.
increased control of the fuel air mixture. The timing
Cold mode operation varies the fuel injection amount
advance is achieved by precise control of the fuel
for white smoke cleanup. Cold mode operation also
injection timing. Engine rpm is controlled by adjusting
varies the timing for white smoke cleanup. The
the injection duration.
engine operating temperature is usually reached
before the walk-around inspection is completed. The
Engines (S/N: 3CS1-11999) and (S/N: 2KS1-39999)
engine will idle at the programmed low idle rpm in
have a special pulse wheel, which is mounted to the
order to be put in gear.
crankshaft gear. The special pulse wheel provides
information to the Engine Control Module (ECM) for
detection of cylinder position and engine rpm. NOTICE
Do not move the vehicle with the engine in the cold
Engines (S/N: 3CS12000-UP), (S/N: 2KS40000-UP), mode condition. Engine power could be noticeably re-
and (S/N: CPD1-UP) have a special crankshaft duced. At a vehicle speed above 8 km/h (5 mph), low
gear that provides information to the Engine Control idle rpm will be reduced to the customer programmed
Module (ECM) for detection of cylinder position and low idle and the power will still be reduced.
engine rpm.
After the cold mode is completed, the engine should
The engine has built-in diagnostics in order to ensure
be operated at low rpm until normal operating
that all of the components are operating properly.
temperature is reached. The engine will reach normal
In the event of a system component failure, the
operating temperature faster when the engine is
operator will be alerted to the condition by a check
operated at low rpm and low power demand.
engine light. The check engine light is located on the
dashboard. An electronic service tool can be used
to read the numerical code of the faulty component Customer Specified Parameters
or condition. Also, the cruise control switches can
be used to flash the code on the check engine light. The engine is capable of being programmed for
Intermittent faults are logged and stored in memory. several customer specified parameters. For a brief
explanation of each of the customer specified
parameters, see the Operation and Maintenance
Starting The Engine Manual.
The engine’s ECM will automatically provide the
correct amount of fuel in order to start the engine.
Do not hold the throttle down while the engine is
cranking. If the engine fails to start in 30 seconds,
release the starting switch. Allow the starting motor
to cool for two minutes before the starting motor is
used again.
6
i00980925
Electronic Control System

Components
SMCS Code: 1900
g00499282
Illustration 3
Top view
7
g00499283
Illustration 4
Front view and left side view
(1) Coolant temperature sensor (4) Atmospheric pressure sensor (7) Camshaft position sensor
(2) Inlet air temperature sensor (5) Fuel temperature sensor (8) Oil pressure sensor
(3) Boost pressure sensor (6) Crankshaft position sensor (9) Electronic control module (ECM)
The electronic control system is integrally designed • Voltage

into the engine’s fuel system and the engine’s air
inlet and exhaust system in order to electronically • Frequency
control the fuel delivery and the injection timing. The
electronic control system provides increased timing • Pulse width
control and fuel air ratio control in comparison to
conventional mechanical engines. Injection timing The variation of the signal is in response to a change
is achieved by precise control of injector firing time, in some specific system of the vehicle. The electronic
and engine rpm is controlled by adjusting the firing control module sees the input sensor signal as
duration. The ECM energizes the solenoid in the unit information about the condition, environment, or
injector in order to start the injection of fuel. Also, operation of the vehicle.
the ECM de-energizes the unit injector solenoids in
order to stop injection of fuel. Refer to the Systems A control component (ECM) receives the input
Operation, “Fuel System” topic for a complete signals. Electronic circuits inside the control
explanation of the fuel injection process. component evaluate the signals from the input
components. These electronic circuits also supply
The engine uses the following types of electronic electrical energy to the output components of the
components: system. The electrical energy that is supplied to
the output components is based on predetermined
• Inputs combinations of input signal values.
• Controls An output component is one that is operated by a

control module. The output component receives
• Outputs electrical energy from the control component. The
output component uses that electrical energy in one
An input component is one that sends an electrical of two ways. The output component can use that
signal to the ECM. The signal that is sent varies in electrical energy in order to perform work. The output
one of the following ways: component can use that electrical energy in order to
provide information.
8
1. As an example, a moving solenoid plunger will

perform work. By performing work, the component
has functioned in order to regulate the vehicle.
2. As an example, a dash panel light or an alarm will

provide information to the operator of the vehicle.
These electronic components provide the ability

to electronically control the engine operation.
Engines with electronic controls offer the following
advantages:
• Improved performance
• Improved fuel consumption
• Reduced emissions levels
Table 1
Electrical Connectors and Functions
Connector Function
J1/P1 ECM connector (70 pin
OEM harness)
J2/P2 ECM connector (70 pin
engine harness)
J100/P100 Coolant temperature
sensor connector (2 pin)
J103/P103 Intake manifold air
temperature sensor
connector (2 pin)
J105/P105 Fuel temperature sensor
connector (2 pin)
J200/P200 Boost pressure sensor
connector (3 pin)
J201/P201 Oil pressure sensor
connector (3 pin)
J203/P203 Atmospheric pressure
J300/P300 Fuel injector connector
(12 pin)
J400/P400 Engine timing calibration
probe connector (2 pin)
J401/P401 Crankshaft position sensor
connector (2 pin)
J402/P402 Camshaft position sensor
connector (2 pin)
J403/P403 Accelerator pedal position
i01532739
Fuel System
SMCS Code: 1250
9
g00647085
Illustration 5
(1) Crankshaft position sensor (14) Engine coolant temperature sensor (27) 2 Lamp outputs
(2) Camshaft position sensor (15) Inlet air temperature sensor (28) Timing calibration connector
(3) Injectors (16) Fuel temperature sensor (29) 6 Programmable outputs
(4) Retarder solenoid (17) Ambient air temperature (30) Cooling fan relay or solenoid
(5) Fuel supply rail (18) Engine coolant level sensor (31) Engine retarder switch
(6) Boost pressure sensor (19) Accelerator pedal (32) PTO on/off & set/resume switches
(7) 2 Micron secondary fuel filter (20) Accelerator pedal position sensor (33) Cruise on/off & set/resume switches
(8) Atmospheric pressure sensor (21) Batteries (34) 7 Programmable inputs
(9) Fuel pump (22) Electronic Control Module (ECM) (35) Vehicle speed sensor
(10) Primary fuel filter (23) SAE J1587/J1708 Data link (36) Speedometer & tachometer
(11) Fuel tank (24) SAE J1922/J1708 Data link (37) Service brake pedal position switches.
(12) Fuel pressure regulator (25) SAE J1939 Data link (38) Neutral & clutch pedal position switches
(13) Engine oil pressure sensor (26) Warning and check engine lamps (39) keyswitch
The Electronic Unit Injector system consists of the There are five major components of the Electronic
following systems: the mechanical system and the Unit Injector fuel system:
electronic system. The mechanical system is made
up of the low pressure fuel supply system and the • Electronic Unit Injectors
electronic unit injectors. The electronic system
provides complete electronic control of all engine • Fuel transfer pump
functions. The electronic control system consists
of the following three types of components: input, • Electronic Control Module
control, and output.
• Sensors
Most changes to engine horsepower or to the
performance are accomplished by installing new • Actuators
electronic software or upgrading mechanical
components.
10
The Electronic Unit Injectors produce fuel injection

pressures up to 207000 kPa (30000 psi). The
Electronic Unit Injectors also fire up to 19 times
per second at rated speed. The fuel transfer pump
supplies the injectors by drawing fuel from the
tank and by pressurizing the tank between 60
and 125 PSI. The ECM is a powerful computer
which controls all major engine functions. Sensors
are electronic devices which monitor engine
performance parameters. Engine performance
parameters measure pressure, temperature and
speed. This information is sent to the ECM via a
signal voltage. Actuators are electronic devices which
use electronic currents from the ECM to change
engine performance. An example of an actuator is
the Injector solenoid.
Low Pressure Fuel System
g00647032
Illustration 6
11
(1) Crankshaft position sensor (14) Engine coolant temperature sensor (27) 2 Lamp outputs
(2) Camshaft position sensor (15) Inlet air temperature sensor (28) Timing calibration connector
(3) Injectors (16) Fuel temperature sensor (29) 6 Programmable outputs
(4) Retarder solenoid (17) Ambient air temperature (30) Cooling fan relay or solenoid
(5) Fuel supply rail (18) Engine coolant level sensor (31) Engine retarder switch
(6) Boost pressure sensor (19) Accelerator pedal (32) PTO on/off & set/resume switches
(7) 2 Micron secondary fuel filter (20) Accelerator pedal position sensor (33) Cruise on/off & set/resume switches
(8) Atmospheric pressure sensor (21) Batteries (34) 7 Programmable inputs
(9) Fuel pump (22) Electronic Control Module (ECM) (35) Vehicle speed sensor
(10) Primary fuel filter (23) SAE J1587/J1708 Data link (36) Speedometer and tachometer
(11) Fuel tank (24) SAE J1922/J1708 Data link (37) Service brake pedal position switches.
(12) Fuel pressure regulator (25) SAE J1939 Data Link (38) Neutral & clutch pedal position switches
(13) Engine oil pressure sensor (26) Warning and check engine lamps (39) keyswitch
The low pressure fuel system supplies fuel from The fuel filter base contains a hand operated fuel
the fuel tank to the injectors. The low pressure fuel priming pump. The fuel priming pump removes air
system has three basic functions: from the system when a fuel filter has been changed
or a unit injector has been changed. The priming
• The low pressure fuel system supplies fuel to the pump pulls fuel from the tank, around the transfer
injectors for combustion. pump and into the filter. The transfer pump pushes
fuel through the supply passage in the cylinder head
• The low pressure fuel system supplies fuel to the and back to the tank.
injectors for cooling.
The fuel pressure regulator consists of a spring
• The low pressure fuel system supplies fuel to the loaded check valve. The pressure relief valve opens
fuel system in order to remove air. at approximately 60 to 125 PSI. When the engine is
in the off position and the fuel pressure drops below
The major parts in a low pressure fuel system consist 60 PSI, the check valve closes. The check valve
of the following components: closes in order to prevent the fuel in the cylinder
head from draining back into the fuel tank. Retaining
• fuel tank the fuel in the head maintains a supply of fuel for the
injectors during startup requirement.
• fuel transfer lines
The electronic control module controls major engine
• primary fuel filter or water separator functions. Sensors are electronic devices that monitor
engine performance parameters. The pressure
• fuel transfer pump sensor, the temperature sensor and the speed sensor
provide information to the electronic control module
• secondary fuel filter by a signal voltage. Actuators are electronic devices
which use electrical currents from the electronic
• fuel priming pump control module to change engine performance. An
example of an actuator is an injector solenoid.
• fuel pressure regulator valve
The electronic unit injectors, the fuel transfer pump,
the electronic control module, sensors, and actuators
are part of the low pressure fuel system.
In the low pressure fuel system, the fuel is pulled

from the fuel tank to the primary fuel filter or to the
water separator. The primary fuel filter removes large
debris from the fuel before the fuel flows into the
transfer pump. The fuel transfer pump is a gear pump
that contains a pressure relief valve. Fuel flows from
the outlet port of the transfer pump to the secondary
fuel filter. All 1999 and newer engines use a 2 micron
fuel filter. The 2 micron filter removes small abrasive
contaminants from the fuel system, which can cause
damage to the unit injectors.
12
Electronic Controls • automatic altitude compensation

The electronic control system provides complete • variable injection timing
electronic control of all engine functions. The
electronic control system consists of the following • electronic engine speed governing
three types of components: input, control, and
output. Sensors monitor engine operating conditions. These features result in the following items: precise
This information is sent to the Electronic Control engine speed control, very little smoke, faster cold
Module. The ECM has three main functions. The starting, and built-in engine protection.
ECM provides power for the engine electronics and
monitors input signals from the engine sensors. The electronic control module consists of the
The ECM also acts as a governor to control engine following two main components: the electronic control
rpm. The ECM stores active faults, logged faults, module and the personality module.
and logged events. The Personality Module is the
software in the ECM which contains the specific maps The ECM is a computer and the personality module
that define power, torque, and RPM of the engine. is the software for the computer. The personality
The ECM sends electrical current to the output module contains the operating maps. The operating
components in order to control engine operation. maps define the following characteristics of the
The ECM has the following connectors: two 70 pin engine:
harness connectors, one engine harness connector,
and one vehicle harness connector. The vehicle • Horsepower
harness connects the ECM to the engine control
portion of the vehicle harness. The engine control • Torque curves
portion includes the following components.
• Rpm
• accelerator pedal position sensor
• Other characteristics
• vehicle speed sensor
The ECM, the personality module, the sensors, and
• transmission the unit injectors work together in order to control
the engine. The ECM, the personality module, the
• brake sensors, and the unit injectors can not control the
engine alone.
• clutch switches
The ECM determines a desired rpm that is based
• cruise control on the following criteria:
• PTO switch • Throttle signal

• data links • Certain diagnostic codes
• check engine light • Vehicle speed signal
• warning light The ECM maintains the desired engine rpm by
sensing the actual engine rpm. The ECM calculates
• engine retarder switch the fuel amount that needs to be injected in order to
achieve the desired rpm.
• speedometer
Fuel Injection Timing and Delivery
• tachometer
The ECM controls the injected fuel amount by varying
• cooling fan solenoid the signals to the unit injectors. The unit injectors
will inject fuel ONLY if the unit injector solenoid is
The following list of features are part of the electronic energized. The ECM sends a 90 volt signal to the
control system: solenoid for energizing the solenoid. By controlling
the timing of the 90 volt signal, the ECM controls
• cold start strategy injection timing. By controlling the duration of the 90
volt signal, the ECM controls the injected fuel amount.
• oil pressure
• coolant temperature warning indicator
13
Injection timing is determined by engine rpm, and

other engine data. The ECM senses the top center
position of cylinder number 1 from the signal that
is provided by the engine speed sensor. The ECM
decides when the injection should occur relative to
the top center position. The ECM provides the signal
to the unit injector at the desired time.
Unit Injector Mechanism
g00626836
Illustration 7
Typical examples of Electronic Unit Injector fuel systems.
(1) Adjusting nut (3) Unit injector (5) Camshaft
(2) Rocker arm assembly (4) Push rod
Injection Actuation System

The unit injector pressurizes the fuel. The correct
amount of fuel is then injected into the cylinder block
at precise times. The ECM determines the injection
timing and the amount of fuel that is delivered. The
unit injector is operated by a camshaft lobe and a
rocker arm. The camshaft has three camshaft lobes
for each cylinder. Two lobes operate the inlet and
exhaust valves, and the other lobe operates the unit
injector mechanism. Force is transferred from the
unit injector lobe on the camshaft (6) through the
lifter to the pushrod (4). The force of the push rod
is transferred through rocker arm assembly (2) and
to the top of the unit injector. The adjusting nut (1)
allows setting of the unit injector adjustment. Refer
to Systems Operation/Testing and Adjusting, “Unit
Injector Adjustment” for the proper setting of the unit
injector adjustment.
14
Unit Injector
g00626752
Illustration 8
(1) Solenoid (3) Plunger (5) Nozzle Assembly
(2) Tappet (4) Barrel
Operation of the Fuel Injector

The operation of the Electronic Control Unit (EUI)
consists of the following four stages: Pre-injection,
Injection, End of injection, and Fill. Unit injectors use
a plunger and barrel to pump high pressure fuel into
the combustion chamber. Components of the injector
include the tappet, the plunger, the barrel and nozzle
assembly. Components of the nozzle assembly
include the spring, the nozzle check, and a nozzle
tip. The cartridge valve is made up of the following
components: solenoid, armature, poppet valve, and
poppet spring.
The injector is mounted in an injector bore in the

cylinder head which has an integral fuel supply
passage. The injector sleeve separates the injector
from the engine coolant in the water jacket. Some
engines use a stainless steel sleeve. The stainless
steel sleeve fits into the cylinder head with a light
press fit.
15
g00660656
Illustration 9
Pre-injection
(A) Fuel supply pressure
(B) Injection pressure
(C) Moving parts
(D) Mechanical movement
(E) Fuel movement.
16
Pre-injection metering starts with the injector plunger

and the injector tappet at the top of the fuel injection
stroke. When the plunger cavity is full of fuel, the
poppet valve is in the open position and the nozzle
check is in the open position. Fuel leaves the plunger
cavity when the rocker arm pushes down on the
tappet and the plunger. Fuel flow that is blocked
by the closed nozzle check valve flows past the
open poppet valve to the fuel supply passage in the
cylinder head. If the solenoid is energized, the poppet
valve remains open and the fuel from the plunger
cavity continues flowing into the fuel supply passage.
17
g00660658
Illustration 10
Injection
(A) Fuel supply pressure.
(C) Moving parts
(E) Fuel movement.
18
To start injection, the Electronic Control Module

(ECM) sends a current to the solenoid on the
cartridge valve. The solenoid creates a magnetic field
which attracts the armature. When the solenoid is
energized, the armature assembly will lift the poppet
valve so the poppet valve contacts the poppet seat.
This is the closed position. Once the poppet valve
closes, the flow path for the fuel that is leaving the
plunger cavity is blocked. The plunger continues
to push fuel from the plunger cavity and the fuel
pressure builds up. When the fuel pressure reaches
approximately 34500 kPa (5000 psi), the force of
the high pressure fuel overcomes the spring force.
This holds the nozzle check in the closed position.
The nozzle check moves off the nozzle seat and the
fuel flows out of the injector tip. This is the start of
injection.
19
g00660660
Illustration 11
End of injection
(A) Fuel supply pressure (C) Moving parts
20
Injection is continuous while the injector plunger

moves in a downward motion and the energized
solenoid holds the poppet valve closed. When
injection pressure is no longer required, the Electronic
Control Module (ECM) stops current flow to the
solenoid. When the current flow to the solenoid stops,
the poppet valve opens. The poppet valve is opened
by the fuel injector spring and the fuel pressure.
High pressure fuel can now flow around the open
poppet valve and into the fuel supply passage. This
results in a rapid drop in injection pressure. When the
injection pressure drops to approximately 24000 kPa
(3500 psi), the nozzle check closes and injection
stops. This is the end of injection.
21
g00795649
Illustration 12
Fill
(A) Fuel supply pressure
(C) Moving parts
(E) Fuel movement.
22
When the plunger reaches the bottom of the barrel, i00981318

fuel is no longer forced from the plunger cavity.
The plunger is pulled up by the tappet and the Air Inlet and Exhaust System
tappet spring. The upward movement of the plunger
causes the pressure in the plunger cavity to drop SMCS Code: 1050
below fuel supply pressure. Fuel flows from the fuel
supply passage around the open poppet and into the
plunger cavity as the plunger travels upward. When
the plunger reaches the top of the stroke, the plunger
cavity is full of fuel and fuel flow into the plunger
cavity stops. This is the beginning of pre-injection.
g00411724
Illustration 13
Air inlet and exhaust system components
(1) Aftercooler
(2) Air inlet
(3) Turbocharger compressor wheel
(4) Inlet valves
(5) Exhaust valves
(6) Turbocharger turbine wheel
(7) Exhaust outlet
(8) Inlet manifold
(9) Exhaust manifold
23
The components of the air inlet and exhaust system • Compression

control the quality of air and the amount of air that
is available for combustion. The components of • Power
the air inlet and exhaust system are the following
components: • Exhaust
• Air cleaner Exhaust gases from exhaust manifold (9) enter the
turbine side of the turbocharger in order to turn
• Turbocharger turbocharger turbine wheel (6). The turbine wheel is
connected to the shaft that drives the compressor
• Aftercooler wheel. Exhaust gases from the turbocharger pass
through exhaust outlet (7), a muffler and an exhaust
• Cylinder head stack.
• Valves and valve system components Turbocharger

• Piston and cylinder
• Exhaust manifold
Inlet air is pulled through the air cleaner into air inlet
(2) by turbocharger compressor wheel (3). The air is
compressed and heated to about 150 °C (300 °F)
before the air is forced to aftercooler (1). As the
air flows through the aftercooler the temperature of
the compressed air lowers to about 43 °C (110 °F).
Cooling of the inlet air increases combustion
efficiency. Increased combustion efficiency helps
achieve the following benefits:
• Lower fuel consumption

• Increased horsepower output
Aftercooler (1) is a separate cooler core that is
mounted in front of the engine radiator. The engine
fan and the ram effect of the vehicle’s forward motion
g00294193
moves ambient air across both cores. This cools the Illustration 14
turbocharged inlet air and the engine coolant. Turbocharger
(1) Air inlet
From the aftercooler, air is forced into inlet manifold (2) Compressor housing
(8). Air flow from the inlet chambers into the cylinders (3) Compressor wheel
is controlled by inlet valves (4). There are two inlet (4) Bearing
valves and two exhaust valves (5) for each cylinder. (5) Oil Inlet port
(6) Bearing
The inlet valves open when the piston moves down (7) Turbine housing
on the intake stroke. When the inlet valves open, (8) Turbine wheel
cooled compressed air from the inlet port is pulled (9) Exhaust outlet
into the cylinder. The inlet valves close and the piston (10) Oil outlet port
(11) Exhaust inlet
begins to move up on the compression stroke. The
air in the cylinder is compressed. When the piston
is near the top of the compression stroke, fuel is The turbocharger is installed on the center section
injected into the cylinder. The fuel mixes with the of the exhaust manifold. All the exhaust gases
air and combustion starts. During the power stroke, from the engine go through the turbocharger. The
the combustion force pushes the piston downward. compressor side of the turbocharger is connected
The exhaust valves open and the exhaust gases to the aftercooler by pipe.
are pushed through the exhaust port into exhaust
manifold (9) as the piston rises on the exhaust The exhaust gases enter turbine housing (7) through
stroke. After the exhaust stroke, the exhaust valves exhaust inlet (11). The exhaust gases then push the
close and the cycle starts again. The complete cycle blades of turbine wheel (8). The turbine wheel is
consists of four strokes: connected by a shaft to compressor wheel (3).
• Inlet
24
Clean air from the air cleaners is pulled through Bearings (4) and (6) for the turbocharger use engine
compressor housing air inlet (1) by the rotation of oil under pressure for lubrication. The oil comes in
compressor wheel (3). The action of the compressor through oil inlet port (5). The oil then goes through
wheel blades causes a compression of the inlet air. passages in the center section in order to lubricate
This compression gives the engine more power by the bearings. Oil from the turbocharger goes out
allowing the engine to burn more air and more fuel through oil outlet port (10) in the bottom of the
during combustion. center section. The oil then goes back to the engine
lubrication system.
When the load on the engine increases, more fuel is
injected into the cylinders. The combustion of this
additional fuel produces more exhaust gases. The
Valve System Components
additional exhaust gases cause the turbine and the
compressor wheels of the turbocharger to turn faster.
As the compressor wheel turns faster, more air is
forced into the cylinders. The increased flow of air
gives the engine more power by allowing the engine
to burn the additional fuel with greater efficiency.
g00499925 g00411726
Illustration 15 Illustration 16
Typical example of a turbocharger with a wastegate Valve system components
(12) Canister (1) Valve bridge
(13) Actuating lever (2) Valve rotator
(3) Rocker arm
Some turbochargers use a wastegate. The wastegate (4) Pushrod
(5) Valve springs
is controlled by boost pressure. At high boost (6) Valves
pressures, the wastegate opens. The wastegate (7) Valve guide
closes in order to increase boost pressure. With this (8) Camshaft
arrangement, the turbocharger can be designed to (9) Lifter
be more effective at lower engine speeds.
The valve system components control the flow of
When the engine is operating under conditions of low inlet air into the cylinders during engine operation.
boost, a spring pushes on a diaphragm in canister The valve system components also control the flow
(12). This action moves actuating lever (13) in order of exhaust gases out of the cylinders during engine
to close the valve of the wastegate. Closing the valve operation.
of the wastegate allows the turbocharger to operate
at maximum performance. The crankshaft gear drives the camshaft gear through
an idler gear. Camshaft (8) must be timed to the
As the boost pressure increases against the crankshaft in order to get the correct relation between
diaphragm in canister (12), the valve of the wastegate the piston movement and the valve movement.
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 around the
turbine wheel of the turbocharger.
Note: The turbocharger with a wastegate is preset at

the factory and no adjustment can be made.
25
The camshaft has three camshaft lobes for each

cylinder. Two lobes operate the inlet and exhaust
valves, and one operates the unit injector mechanism.
As the camshaft turns, the camshaft lobes cause
lifter (9) to move pushrod (4) up and down. Upward
movement of the pushrod against rocker arm (3)
results in downward movement (opening) of valves
(6).
Each cylinder has two inlet valves and two exhaust

valves. Valve springs (5) close the valves when the
lifters move down. Valve rotators (2) cause the valves
to rotate while the engine is running. The rotation of
the valves keeps the carbon deposits on the valves
to a minimum. Also, the rotation gives the valves
longer service life.
i01628490
Lubrication System
SMCS Code: 1300
g00421798
Illustration 17
Lubrication system schematic
(1) Piston cooling jets (9) Primary engine oil filter
(2) Main oil gallery in cylinder block (10) Engine oil pump
(3) Engine oil pressure sensor (11) Secondary oil filter
(4) Oil flow to valve mechanism (12) Oil cooler bypass valve
(5) Camshaft journals (13) Engine oil cooler
(6) Oil filter bypass valve (14) Oil pan sump
(7) Main bearings (15) High pressure relief valve
(8) Signal line (16) Oil pump bypass valve
26
g00421818
Illustration 18
Right side of engine
(9) Primary engine oil filter
(10) Engine oil pump
(11) Secondary oil filter (not shown)
(13) Engine oil cooler
(17) Engine oil filler
(18) Oil supply line to turbocharger
(19) Oil drain line from turbocharger
The lubrication system supplies 110 °C (230 °F)

filtered oil at approximately 275 kPa (40 psi) at rated
engine operating conditions. Oil pump bypass valve
(16) is controlled by the engine oil manifold pressure,
rather than the oil pump pressure. The engine oil
manifold pressure is independent of the pressure
drop that is caused by the engine oil filter and the
engine oil cooler.
Oil cooler bypass valve (12) maintains the engine

oil temperature to 110 °C (230 °F). High pressure
relief valve (15), which is located in the filter base,
protects the filters and other components during cold
starts. The opening pressure of the high pressure
relief valve is 695 kPa (100 psi). Secondary oil filter
(11) is a five micron filter which filters five percent
of the oil flow before returning the oil to the sump.
The opening pressure of the oil filter bypass valve is
170 kPa (25 psi). Engine oil pressure sensor (3) is
part of the engine protection system.
The turbocharger cartridge bearings are lubricated by

oil supply line (18) from the main oil gallery, and oil
drain line (19) returns the oil flow to the sump.
27
Oil Flow Through The Lubrication

System
g00421838
Illustration 19
Oil flow through engine
(1) Oil flow to the piston, piston cooling jets, (5) Oil from engine oil cooler (12) Oil filter bypass valve
valve mechanism, camshaft journals, (6) High pressure relief valve (13) Passage to primary engine oil filter
crankshaft main bearings, and the (7) Oil from engine oil pump (14) Oil cooler bypass valve
turbocharger (8) Oil to engine oil cooler (15) Oil pump bypass valve
(2) Main oil gallery in cylinder block (9) Passage to primary engine oil filter (16) Oil pump bypass drain
(3) Oil drains to sump (10) Filtered oil (17) Passages to secondary oil filter
(4) Cylinder block (11) Bypassed oil
The engine oil pump is mounted to the back of the High pressure relief valve (6) regulates high pressure
front gear train on the lower right hand side of the in the system. The high pressure relief valve will allow
engine. The engine oil pump is driven by an idler the oil to return to the sump when the oil pressure
gear from the crankshaft gear. Oil is pulled from reaches 695 kPa (100 psi). The oil then flows through
the sump through oil pump bypass valve (15) on the engine oil cooler. The engine oil cooler uses
the way to the engine oil cooler. The bypass valve engine coolant in order to cool the oil. The oil cooler
controls the oil pressure from the engine oil pump. bypass valve (14) directs the oil flow through the
The engine oil pump can supply excess oil for the engine oil cooler by two different methods.
lubricating system. When this situation is present, the
oil pressure increases and the bypass valve opens. Oil cooler bypass valve (14) will close when the oil
The open bypass valve allows the excess oil to return temperature exceeds the following temperatures
to the sump. 100 °C to 103 °C (212 °F to 217 °F). Closing of the
bypass valve will direct the oil through the engine oil
cooler (13). If the oil reaches a temperature of 127 °C
(260 °F) the bypass valve would close directing the
oil flow through the engine oil cooler (13).
28
The oil bypass valve (14) is normally closed if the An oil cooling chamber is formed by the following
pressure across the engine oil cooler is less than pieces: the lip forge at the top of the skirt of the piston
155 ± 17 kPa (22 ± 3 psi). This will direct the oil (19) and the cavity behind the ring grooves in the
through the engine oil cooler (13). crown. Oil flow from the piston cooling jet enters the
cooling chamber through a drilled passage in the
Approximately five percent of the oil flow is directed skirt. The oil then returns to the sump through the
through an orificed passage that leads to secondary clearance gap between the crown and the skirt. Four
oil filter (17) (if equipped). The oil flows through the holes that are drilled from the piston oil ring groove
bypass filter and to the engine oil sump. The main oil to the interior of the piston drain excess oil from the
flow now flows toward the primary engine oil filter. oil ring.
When the oil pressure differential across oil filter
bypass valve (12) reaches 170 kPa (25 psi), the valve
allows the oil flow to bypass the primary engine oil
filter in order to lubricate the engine parts. The bypass
valve provides immediate lubrication to the engine
components when there is a restriction in the primary
engine oil filter due to the following conditions:
• Cold oil with high viscosity

• Plugged primary engine oil filter
Note: Refer to Specifications, “Engine Oil Filter
Base” for a cross section of the valves in the engine
oil filter base.
g00481403
Illustration 21
Left front side of engine
(21) Breather
(22) Hose
(23) Cylinder head
Breather (21) allows engine blowby to escape from

the crankcase. The engine blowby is discharged into
the atmosphere through hose (22). This prevents
pressure from building up that could cause seals or
gaskets to leak.
g00500000
Illustration 20
Interior of cylinder block
(18) Piston cooling jet
(19) Piston
(20) Connecting rod
Filtered oil flows through main oil gallery (2) in the

cylinder block to the following components:
• Piston cooling jets (18)

• Valve mechanism
• Camshaft bearings
• Crankshaft main bearings
• Turbocharger
29
i00984278 • Cylinder liners (9)

Cooling System • Air compressor (not shown)
SMCS Code: 1350 • Coolant conditioner element (not shown)
Coolant Flow Note: In air-to-air aftercooled systems, a coolant
mixture with a minimum of 30 percent ethylene glycol
base antifreeze must be used for efficient water
pump performance. This mixture keeps the cavitation
temperature range of the coolant high enough for
efficient performance.
g00423399
Illustration 23
Typical right side of engine
(1) Temperature regulator housing
(4) Water pump
g00423398
Illustration 22
Cooling system schematic
(1) Temperature regulator housing
(2) Radiator
(3) Bypass tube
(4) Water pump Illustration 24
g00423400
(6) Return manifold Typical rear of engine
(7) Supply manifold in the block (6) Return manifold
(8) Cylinder head
(9) Cylinder liner
Water pump (4) pulls the coolant from the bottom
The water pump is driven by a gear. The water pump of radiator (2) by using the impeller’s rotation. The
is located on the right hand side of the engine. The water pump is located on the right hand side of the
water pump supplies the coolant for the engine front timing gear housing.
cooling system. The coolant is supplied to the
following components:
• Engine oil cooler (5)

• Cylinder head (8)
30
The water pump impeller is rotated at 1.17 times Temperature Regulator Housing
the engine speed by an idler gear. The idler gear is
turned by the crankshaft gear. The water pump shaft
is supported by two ball bearings. One ball bearing
is located in the water pump housing. The other ball
bearing is located in the front timing gear housing.
The water pump impeller face is open. The impeller
vane is radial. The impeller is made out of cast iron.
The rear cover is an aluminum die casting. The water
pump seal is a cartridge seal that is located on the
inlet side of the water pump in order to provide good
water flow around the seal for cooling.
The coolant is pumped through engine oil cooler (5)

to supply manifold (7). The supply manifold, which
is located in the cylinder block, distributes coolant
g00500620
around the upper portion of the cylinder liners. At Illustration 25
each cylinder, the coolant flows from the cylinder liner Typical right front side of engine
to the cylinder head. The cylinder head is divided into (1) Temperature regulator housing
single cylinder cooling sections. In the cylinder head, (2) Coolant temperature sensor
the coolant flows across the center of the cylinder
and across the injector seat boss. At the center of
the cylinder, the coolant flows around the injector
sleeve over the exhaust port. The coolant then
exits into return manifold (6). The return manifold
collects the coolant from each cylinder and the return
manifold directs the flow to temperature regulator
housing (1). When the coolant temperature regulator
is in the closed position, the coolant flows through
the coolant temperature regulator. This allows the
coolant to flow directly back to the water pump for
recirculation by bypassing the radiator. When the
coolant temperature regulator is in the open position,
the coolant is directed through the radiator and back
to the water pump inlet.
Supply Manifold
Cooling is provided for only the portion of the cylinder
liner above the seal in the cylinder block. The coolant
enters the cylinder block at each cylinder through
slits in the supply manifold. The supply manifold is
an integral casting in the cylinder block. The coolant
flows around the circumference of the cylinder liner
and into the cylinder head through a single drilled
passage for each liner. The coolant flow is split at
each cylinder liner so that 60 percent flows around
the cylinder liner and the remainder flows directly to g00423403
the cylinder head. Illustration 26
Temperature regulator housing
(3) Return manifold
(4) Coolant temperature regulator
31
The coolant temperature regulator is a full flow

bypass type that is used to control the outlet
temperature of the coolant. When the engine is cold,
coolant temperature regulator (4) is in the closed
position. This allows the coolant to flow through the
coolant temperature regulator from return manifold
(3). This allows the coolant to bypass the radiator.
The coolant goes directly to the water pump for
recirculation. As the coolant temperature increases,
the coolant temperature regulator begins to open
directing some of the coolant to the radiator and
bypassing the remainder to the water pump inlet.
At the full operating temperature of the engine,
the coolant temperature regulator moves to the
open position. This allows all the coolant flow to be
directed to the radiator. The coolant then goes to the
water pump. This route provides the maximum heat
release from the coolant. A vent line is recommended
from the manifold to the radiator overflow tank in
order to provide venting for the cooling system. The
recommended vent line is a #4 Aeroquip.
Coolant Conditioner (If Equipped)
g00423404
Illustration 27
(1) Engine oil cooler elbow (5) Engine oil cooler
(2) Outlet hose (6) Coolant flow from water pump
(3) Inlet hose (7) Coolant conditioner element
(4) Coolant flow to cylinder head (8) Coolant conditioner base
Some conditions of operation can cause pitting on

critical engine components. This pitting is caused by
corrosion or by cavitation erosion. The addition of a
corrosion inhibitor can keep this type of damage to
a minimum.
32
Coolant conditioner element (7) is a spin-on element Coolant for Air Compressor
that is similar to the fuel filter and to the engine oil
filter elements. The coolant conditioner element
attaches to coolant conditioner base (8) that is
mounted on the engine. Coolant flows from the water
pump through inlet hose (3) and into the coolant
conditioner base. The coolant that is conditioned
then flows through outlet hose (2) into engine oil
cooler elbow (1). There is a constant flow through the
coolant conditioner element.
The element has a specific amount of inhibitor for

acceptable cooling system protection. As the coolant
flows through the element, the corrosion inhibitor,
which is a dry material, disperses into the coolant.
The coolant and the inhibitor are mixed to the correct
g00501085
concentration. Two basic types of elements are Illustration 28
used for the cooling system, the precharge and Typical air compressor
the maintenance elements. Each type of element (1) Outlet hose
has a specific use. Each type of element must be (2) Inlet hose
used correctly to get the necessary concentration (3) Air compressor
for cooling system protection. The elements also
contain a filter. Even after the conditioner material is The coolant that is used for air compressor (3) comes
dispersed, the elements should be left in the system from the cylinder head through inlet hose (2). The
so the coolant flows through the filter. coolant exits the air compressor through outlet hose
(1) and flows back to the cylinder head.
The precharge coolant conditioner element has more
than the normal amount of corrosion inhibitor. The
i01459203
precharge coolant conditioner element is used when
a system is first filled with new coolant. This element
must add enough corrosion inhibitor in order to
Basic Engine
bring the complete cooling system up to the correct SMCS Code: 1200
concentration.
The maintenance elements have a normal amount of Cylinder Block

inhibitor and the maintenance elements are installed
at each change interval. The maintenance elements The cylinder block is a unique design with a deep
provide enough inhibitor in order to keep the corrosion counterbore that supports the cylinder liner. The
protection at an acceptable level. In order to provide cylinder block also forms the coolant jacket. Two
the cooling system with protection, maintenance oil manifolds are provided in the cylinder block for
elements are installed at specific intervals. engine lubrication. The manifold on the lower right
side of the cylinder block provides oil to the following
components:
• Piston cooling jets

• Crankshaft bearings
• Oil filter base
The manifold on the upper left side of the cylinder
block provides oil to the following components:
• Camshaft bearings
• Valve mechanism
The manifold on the right supplies oil to the manifold
on the left. The oil travels through the cut above the
number one main bearing and the cut above the
number four main bearing.
33
The pistons have three rings:
• Compression ring
• Intermediate ring
• Oil ring
Rings (2) are located in grooves in steel crown (5).
The rings seal the crankcase from the combustion
gases and the rings also provide control of the
engine oil. The design of compression ring (1) is a
barrel face with a plasma face coating. The design
of intermediate ring (3) is a tapered shape and a
chrome finish. Oil ring (4) is double railed with a coil
spring expander. The oil ring has a ground profile
and a chrome finish.
g00762739
Illustration 29
Cylinder liners (1) are seated on a ridge (4) in the

middle of the cylinder wall between the crankcase
and the coolant jacket. The ridge is created by a
counterbore in the cylinder block. The cylinder liners
have a lip (2) which rests on the ridge. The seals of
the coolant jacket are located in the upper regions
and middle regions of the cylinder liners. The lower
barrier uses a D-ring seal (3) that is located above the
seating surface of the cylinder liner. The upper barrier g00762786
Illustration 31
is the head gasket which is above the coolant jacket.
Connecting rod (8) is a conventional design. The
The cylinder block has seven main bearings in order
cap is fastened to the shank by two bolts (9) that are
to support the crankshaft. The main bearing caps are
threaded into the shank. Each side of the small end
fastened to the cylinder block with two bolts per cap.
of the connecting rod (7) is machined at an angle
of 12 degrees in order to fit within the piston cavity.
Pistons, Rings, and Connecting This allows a larger surface area on the piston, and
Rods connecting rod in order to minimize bearing load.
Crankshaft
The crankshaft converts the linear motion of the
pistons into rotational motion. The crankshaft drives
a group of gears (front gear train) on the front of the
engine. The front gear train provides power for the
following components:
• Camshaft
• Water pump
• Engine oil pump
g00762765
Illustration 30
• Air compressor
The piston is a two-piece articulated piston. The • Fuel transfer pump
piston has a forged steel crown (5) and a forged
aluminum skirt (6). Both parts are retained by the • Accessory drive
piston pin to the small end of the connecting rod.
34
The crankshaft is held in place by seven main The viscous vibration damper is installed on the front
bearings. The oil holes and the oil grooves in the of the crankshaft. The viscous vibration damper has
shell of the upper bearing supply oil to the connecting a weight in a case. The space between the weight
rod bearings. The oil holes for the connecting rod and the case is filled with a viscous fluid. The weight
bearings are located at the following main bearing moves in the case in order to limit the torsional
journals: 2, 3, 5, and 6. vibration.
Hydrodynamic seals are used at both ends of the

i00984742
crankshaft to control oil leakage. The hydrodynamic
grooves in the seal lip move lubrication oil back into
the crankcase as the crankshaft turns. The front
Rear Power Take-Off (RPTO)
seal is located in the front housing. The rear seal is SMCS Code: 1165-RE
installed in the flywheel housing.
The Rear Power Take-Off (RPTO) is an integral part
Camshaft of the flywheel housing. The rear power take-off
provides continuous live power through the following
direct drive gears:
• Crankshaft gear
• Idler gear
• Output shaft gear
These gears are driven off the rear of the crankshaft.
i01797547
Compression Brake
g00762808
Illustration 32
SMCS Code: 1119; 1129
The camshaft has three lobes at each cylinder in
The compression brake is powered from the ECM.
order to operate the unit injector, the exhaust valves,
The compression brake helps the operator to slow
and the inlet valves. Seven bearings support the
the vehicle on grades, in curves, or for a necessary
camshaft. The camshaft is driven by an idler gear
speed reduction. The service brakes should not be
that is turned by the crankshaft in the front gear
used continuously on long descending grades. The
train. Each bearing journal is lubricated from the oil
service brakes are assisted by the compression
manifold in the cylinder block. A thrust pin that is
brake. The engine crankshaft is turned by the rear
located at the rear of the block positions the camshaft
wheels during downhill operation or during any slow
through a circumferential groove. The groove is
down condition. The engine crankshaft is turned
machined at the rear of the camshaft. Timing of the
through the differential, through the drive shaft,
camshaft is accomplished by aligning marks on the
through the transmission, and through the clutch. An
crankshaft gear, idler gear, and camshaft gear with
application of a braking force can be made to the
each other.
engine piston in order to reduce the speed of the
vehicle.
Vibration Damper
The force from combustion in the cylinders and from
driveline components will cause the crankshaft to
twist. This is called torsional vibration. If the vibration
is too great, the crankshaft will be damaged. Driveline
components can excite torsional stress. This stress
will cause damage to components. The vibration
damper limits the torsional vibrations to an acceptable
amount in order to prevent damage to the crankshaft.
35
When the compression brake is activated, braking The control circuit for the compression brake permits
power is accomplished by opening the engine’s the operation of either one, two, or all three of
exhaust valves. The exhaust valves are opened near the compression brake housing assemblies. This
the top of the compression stroke in order to release provides progressive braking capabilities with the
the highly compressed air into the exhaust system. retarding effect of two cylinders, of four cylinders, or
The compression brake can only be activated when of all six cylinders in the engine.
the engine is in the no-fuel position. Thus, combustion
does not occur and no positive force is produced Performance of the Compression
on the piston. The compressed air pressure that is
released to the atmosphere prevents the energy from Brake
returning to the engine piston on the power stroke.
The result is a loss of energy since the work that is
done by the compression of the cylinder charge is
not returned by the expansion process. This loss
of energy is taken from the rear wheels. The rear
wheels provide the braking action for the vehicle.
g00501265
g00427859
Compression brake Performance of the compression brake
(1) Control valve
(2) Lead wire The performance of the compression brake, which is
(3) Bolt assembly
(4) Slave piston shown in the graph, represents an engine with the
(5) Solenoid valve three housing assemblies that are activated in order
(6) Master piston to stop the vehicle. The compression brake should
(7) Stud and nut not be activated when the engine rpm is above 2300.
The maximum engine power rating is 2100 rpm. At
The compression brake consists of three identical this level, the amount of braking that is produced by
housing assemblies. A housing assembly is installed the compression brake is approximately 315 to 325
in each of the valve mechanism compartments horsepower.
above the rocker arms and above the rocker arm
shaft. Each housing assembly is positioned over two
cylinders. The housing assembly is mounted to the
supports for the rocker arm shaft with studs and nuts
(7). The housing assemblies are supported on the
cylinder head with bolt assembly (3). The exhaust
bridge assembly is used to transfer force from slave
piston (4) to the exhaust valve. The brake logic signal
for the compression brake is carried to solenoid valve
(5) by lead wire (2). This is done in order to activate
the compression brake on the two cylinders of the
engine.
A spacer is used on the top of the valve cover base

in order to provide space for the installation of the
compression brake and of the valve cover. When the
compression brake is installed, the height increases
approximately 63.5 mm (2.50 inch).
36
Operation of the Compression

Brake
g00501985
Illustration 35
Schematic for master-slave circuit
(1) Rocker arm shaft oil passage (8) Master piston (15) Oil drain passage
(2) Solenoid valve (9) Engine oil pump (16) Low pressure oil passage
(3) Lead wire (10) Spring (17) Ball check valve
(4) Spring (11) Engine oil pan (18) Exhaust valve rocker arm
(5) Control valve (12) Fuel injector rocker arm (19) Exhaust valve
(6) High pressure oil passage (13) Fuel injector pushrod (20) Exhaust bridge assembly
(7) Slave piston adjustment screw (14) Slave piston
The compression brake is operated by engine

oil that is distributed around the studs. This oil is
supplied through the supports for the rocker arm
shaft. Solenoid valve (2) controls the oil flow in the
compression brake housing.
37
When the solenoid is activated by a signal from the When solenoid valve (2) is in the Off position, the
logic for the compression brake, solenoid valve (2) engine oil supply passage is closed and oil drain
moves downward. This causes oil drain passage (15) passage (15) is opened. This allows oil to drain from
to engine oil pan (11) to be closed. At the same time, underneath control valve (5). This also allows spring
low pressure oil passage (16) to control valve (5) is (4) to push the control valve to the bottom of the
opened. As low pressure oil passage (16) is filled chamber. This position allows oil from high pressure
with engine oil, the control valve is pushed upward in oil passage (6) to drain into the chamber above the
the chamber against the force of spring (4). At this control valve’s piston. This chamber vents to the
position, a groove in control valve (5) is in alignment outside of the compression brake housing. Spring
with high pressure oil passage (6). Slave piston (10) now moves master piston (8) to the retracted
(14) and master piston (8) are supplied by the high position away from fuel injector rocker arm (12).
pressure oil passage. Engine oil pressure will now The time that is necessary for the system to stop
lift ball check valve (17). High pressure oil passage operation is approximately 1/10 of a second. The
(6) and the chambers behind the slave pistons and compression brake will not be able to operate until
behind the master pistons will be filled with engine solenoid (2) is activated again.
oil pressure. This pressure moves the master piston
downward until contact is made with fuel injector
i01984666
rocker arm (12). When upward motion is initiated
on the master piston, the pressure increases above
the current level of the engine supply pressure. This
Electrical System
causes ball check valve (17) to seat. The system is SMCS Code: 1400; 1550; 1900
now operating in conjunction with the exhaust valve
and with the injector rocker mechanism. When the
solenoid is activated, the compression brake could Grounding Practices
be operable within 1/5 of a second.
Proper grounding for the machine electrical system
Fuel injector pushrod (13) will begin to move upward and engine electrical systems is necessary for
on the pumping stroke of the electronically controlled proper machine performance and reliability. Improper
unit injector. When this occurs, fuel injector rocker grounding will result in uncontrolled electrical circuit
arm (12) makes contact with extending master piston paths and unreliable electrical circuit paths.
(8). As the master piston begins to move upward, the
oil pressure increases in high pressure oil passage Uncontrolled engine electrical circuit paths can result
(6). This happens because ball check valve (17) will in damage to main bearings, crankshaft bearing
not allow oil to exit. The upward movement of the journal surfaces, and aluminum components.
fuel injector rocker arm creates a constant increase
in pressure. This forces the slave piston downward To ensure proper functioning of the vehicle and
against the screw assembly in exhaust bridge engine electrical systems, an engine-to-frame ground
assembly (20). The slave piston moves downward strap with a direct path to the negative battery post
with enough force to open exhaust valve (19). must be used. This may be provided by way of a
starting motor ground, a frame to starting motor
Note: Only one of the two exhaust valves for each ground, or a direct frame to engine ground.
cylinder on this engine is used in the operation of the
compression brake. An engine-to-frame ground strap must be used in
order to connect the grounding stud of the engine to
This master-slave circuit is designed to move the the frame of the vehicle and to the negative battery
master piston (8). The master piston is moved post.
when the engine is on the compression stroke. The
master-slave circuit is designed so that slave piston
(14) opens one exhaust valve of the same cylinder
only on the compression stroke. This occurs slightly
before the piston reaches the top center position.
The braking force is constant. The operation of the
compression brake of a cylinder is caused by the
motion of the valve mechanism of that cylinder.
This causes the firing sequence of the valves to be
identical to the firing order of the engine.
38
NOTICE
When boost starting an engine, the instructions in Sys-
tems Operation, “Engine Starting” should be followed
in order to properly start the engine.
This engine may be equipped with a 12 volt starting

system or a 24 volt starting system. Only equal voltage
for boost starting should be used. The use of a higher
voltage will damage the electrical system.
The Electronic Control Module (ECM) must be dis-

connected at the “J1/P1” and “J2/P2” locations before
welding on the vehicle.
The engine has several input components which are

electronic. These components require an operating
voltage.
Unlike many electronic systems of the past, this

g01028488 engine is tolerant to common external sources of
Illustration 36
electrical noise. Buzzers that use electrical energy
Typical example can cause disruptions in the power supply. If buzzers
Grounding Stud To Battery Ground (“-”) are used anywhere on the machine, the engine
electronics should be powered directly from the
battery system through a dedicated relay. The engine
electronics should not be powered through a common
power bus with other key switch activated devices.
Engine Electrical System

The electrical system has the following separate
circuits:
• Charging
• Starting (If equipped)
Illustration 37
g01028479 • Accessories with low amperage
Typical example
Some of the electrical system components are used
Alternate Grounding Stud To Battery Ground (“-”)
in more than one circuit. The following components
are common in more than one circuit:
The engine must have a wire ground to the battery.
Ground wires or ground straps should be combined

• Battery or batteries
at ground studs that are only for ground use. All of
the grounds should be tight and free of corrosion.
• Circuit breakers
All of the ground paths must be capable of carrying

• Battery cables
any likely current faults. An AWG #0 or larger wire is
recommended for the grounding strap to the cylinder
• Ammeter
head. The charging circuit is in operation when the engine
is running. An alternator makes electricity for the
The engine alternator should be battery ground charging circuit. A voltage regulator in the circuit
with a wire size that is capable of managing the full controls the electrical output in order to keep the
charging current of the alternator. battery at full charge.
The starting circuit is activated only when the start

switch is activated.
39
The accessory circuit with the low amperage and the The voltage regulator is a solid-state electronic
charging circuit are connected through the ammeter. switch. The voltage regulator senses the voltage in
The starting circuit is not connected through the the system. The voltage regulator switches ON and
ammeter. OFF many times per second in order to control the
field current for the alternator. The alternator uses
the field current in order to generate the required
Charging System Components voltage output.
Alternator
NOTICE
The alternator is driven by a belt from the crankshaft Never operate the alternator without the battery in the
pulley. This alternator is a three-phase, self-rectifying circuit. Making or breaking an alternator connection
charging unit, and the regulator is part of the with heavy load on the circuit can cause damage to
alternator. the regulator.
The alternator design has no need for slip rings

and the only part that has movement is the rotor
assembly. All conductors that carry current are
stationary. The following conductors are in the circuit:
• Field winding
• Stator windings
• Six rectifying diodes
• Regulator circuit components
The rotor assembly has many magnetic poles that
g00425518
look like fingers with air space between each of the Illustration 38
opposite poles. The poles have residual magnetism. Typical alternator components
The residual magnetism produces a small magnetic (1) Regulator
field between the poles. As the rotor assembly (2) Roller bearing
begins to turn between the field winding and the (3) Stator winding
stator windings, a small amount of alternating current (4) Ball bearing
(AC) is produced. The AC current is produced in the (5) Rectifier bridge
(6) Field winding
stator windings from the small magnetic field. The (7) Rotor assembly
AC current is changed to direct current (DC) when (8) Fan
the AC current passes through the diodes of the
rectifier bridge. The current is used for the following
applications: Starting System Components
• Charging the battery Starting Solenoid
• Supplying the accessory circuit that has the low

amperage
• Strengthening the magnetic field

The first two applications use the majority of the
current. As the DC current increases through the
field windings, the strength of the magnetic field is
increased. As the magnetic field becomes stronger,
more AC current is produced in the stator windings.
The increased speed of the rotor assembly also
increases the current and voltage output of the
alternator.
g00317613
Illustration 39
Typical starting solenoid
40
When two sets of solenoid windings are used, the

windings are called the hold-in winding and the
pull-in winding. Both sets of windings have the same
number of turns around the cylinder, but the pull-in
winding uses a wire with a larger diameter. The wire
with a larger diameter produces a greater magnetic
field (1). When the start switch is closed, part of the
current flows from the battery through the hold-in
windings. The rest of the current flows through the
pull-in windings to the motor terminal. The current
then flows through the motor to ground. Solenoid
(2)is fully activated when the connection across the
battery and the motor terminal is complete. When
solenoid (2) is fully activated, the current is shut
g00425521
off through the pull-in windings. At this point, only
Illustration 40 the smaller hold-in windings are in operation. The
Typical starting motor components hold-in windings operate for the duration of time that
(1) Field is required in order to start the engine. Solenoid (2)
(2) Solenoid will now draw less current from the battery, and the
(3) Clutch heat that is generated by solenoid (2) will be kept at
(4) Pinion
(5) Commutator an acceptable level.
(6) Brush assembly
(7) Armature
The starting solenoid (2) is an electromagnetic switch

that performs the following basic operations:
• The starting solenoid (2) closes the high current

starting motor circuit with a low current start switch
circuit.
• The starting solenoid (2) engages the starter motor

pinion (4) with the ring gear.
Solenoid (2) has windings (one or two sets) around

a hollow cylinder. A spring loaded plunger (core) is
inside of the cylinder. The plunger can move forward
and backward. When the start switch is closed and
electricity is sent through the windings, a magnetic
field (1) is made. The magnetic field (1) pulls the
plunger forward in the cylinder. This moves the shift
lever in order to engage the pinion drive gear with the
ring gear. The front end of the plunger then makes
contact across the battery and motor terminals of
solenoid (2). Next, the starting motor begins to turn
the flywheel of the engine.
When the start switch is opened, current no longer

flows through the windings. The spring now pushes
the plunger back to the original position. At the same
time, the spring moves the pinion gear away from
the flywheel.
41
Testing and Adjusting 2. Install a 2P-8278 Fuel Flow Tube (Sight Gauge)
in the fuel return line. When possible, install the
Section sight gauge in a straight section of the fuel line
that is at least 304.8 mm (12 inches) long. Do not
install the sight gauge near the following devices
that create turbulence:
Fuel System
• Elbows
i01881094
• Relief valves
Fuel System - Inspect • Check valves
SMCS Code: 1250-040
Observe the fuel flow during engine cranking.
A problem with the components that send fuel to Look for air bubbles in the fuel. If there is no fuel
the engine can cause low fuel pressure. This can in the sight gauge, prime the fuel system. Refer
decrease engine performance. to Testing and Adjusting, “Fuel System - Prime”
for more information. If the engine starts, check
1. Check the fuel level in the fuel tank. Ensure that for air in the fuel at varying engine speeds. When
the vent in the fuel cap is not filled with dirt. possible, operate the engine under the conditions
which have been suspect of air in the fuel.
2. Check all fuel lines for fuel leakage. The fuel lines
must be free from restrictions and faulty bends.
Verify that the fuel return line is not collapsed.
3. Install a new fuel filter.
4. Cut the old filter open with the 175-7546 Oil Filter
Cutter. Inspect the filter for excess contamination.
Determine the source of the contamination. Make
the necessary repairs.
5. Service the primary fuel filter (if equipped).
6. Operate the hand priming pump (if equipped).

If excessive resistance is felt, inspect the fuel
pressure regulating valve. If uneven resistance is
felt, test for air in the fuel. Refer to Testing and
Adjusting, “Air in Fuel - Test” for more information.
7. Remove any air that may be in the fuel system.

Refer to Testing and Adjusting, “Fuel System -
g00578151
Prime”. Illustration 41
2P-8278 Fuel Flow Tube (Sight Gauge)
i01459442 (1) A steady stream of small bubbles with a diameter of
approximately 1.60 mm (0.063 inch) is an acceptable amount
Air in Fuel - Test of air in the fuel.
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch)
are also acceptable if there is two seconds to three seconds
SMCS Code: 1280-081 intervals between bubbles.
(3) Excessive air bubbles in the fuel are not acceptable.
This procedure checks for air in the fuel. This
procedure also assists in finding the source of the air. 3. If excessive air is seen in the sight gauge in the
fuel return line, install a second sight gauge at the
1. Examine the fuel system for leaks. Ensure that inlet to the fuel transfer pump. If a second sight
the fuel line fittings are properly tightened. Check gauge is not available, move the sight gauge from
the fuel level in the fuel tank. Air can enter the the fuel return line and install the sight gauge
fuel system on the suction side between the fuel at the inlet to the fuel transfer pump. Observe
transfer pump and the fuel tank. the fuel flow during engine cranking. Look for air
bubbles in the fuel. If the engine starts, check for
air in the fuel at varying engine speeds.
42
If excessive air is not seen at the inlet to the fuel i01860816

transfer pump, the air is entering the system after
the fuel transfer pump. Proceed to Step 6. Electronic Unit Injector - Adjust
If excessive air is seen at the inlet to the fuel SMCS Code: 1290-025
transfer pump, air is entering through the suction
side of the fuel system.
To avoid personal injury, always wear eye and face

protection when using pressurized air.
NOTICE
To avoid damage, do not use more than 55 kPa (8 psi)
to pressurize the fuel tank.
4. Pressurize the fuel tank to 35 kPa (5 psi). Do g00948810

Illustration 42
not use more than 55 kPa (8 psi) in order to
avoid damage to the fuel tank. Check for leaks in Injector Mechanism
the fuel lines between the fuel tank and the fuel (1) Rocker arm
transfer pump. Repair any leaks that are found. (2) Adjusting screw
(3) Locknut
Check the fuel pressure in order to ensure that
the fuel transfer pump is operating properly. For
Follow the procedure in order to adjust your
information about checking the fuel pressure, see
Electronic unit injectors:
Testing and Adjusting, “Fuel System Pressure -
Test”.
1. Put the No. 1 piston at the top center position
on the compression stroke. Refer to Systems
5. If the source of the air is not found, disconnect
Operation/Testing and Adjusting, “Finding Top
the supply line from the fuel tank and connect an
Center Position for No. 1 Piston”.
external fuel supply to the inlet of the fuel transfer
pump. If this corrects the problem, repair the fuel
a. Cylinder 3, 5, and 6 can be adjusted with
tank or the stand pipe in the fuel tank.
cylinder 1 at TC compression stroke.
6. If the injector sleeve is worn or damaged,
b. Loosen the jam nut.
combustion gases may be leaking into the fuel
system. Also, if the O-rings on the injector sleeves
c. Turn the adjusting screw until the screw makes
are worn, missing, or damaged, combustion gases
contact with the electronic unit injector.
may leak into the fuel system.
d. Turn the adjusting screw through 180 degrees
in a clockwise direction.
e. Tighten the jam nut to a torque of 55 ± 10 N·m

(41 ± 7 lb ft).
2. Rotate the engine in the normal operating direction

by 360 degrees. Cylinder 1 will now be on TC
exhaust stroke.
a. Cylinder 1, 2, and 4 can be adjusted with

cylinder 1 at TC exhaust stroke.
b. Loosen the jam nut.
c. Turn the adjusting screw until the screw makes

contact with the electronic unit injector.
43
d. Turn the adjusting screw through 180 degrees 5. Remove the suspect unit injector and check the
in a clockwise direction. unit injector for signs of exposure to coolant.
Refer to Disassembly and Assembly Manual,
e. Tighten the jam nut to a torque of 55 ± 10 N·m “Electronic Unit Injector - Remove”. Exposure to
(41 ± 7 lb ft). coolant will cause rust to form on the injector.
If the unit injector shows signs of exposure to
coolant, remove the injector sleeve and inspect
i01779471
the injector sleeve. Refer to Disassembly and
Electronic Unit Injector - Test Assembly Manual, “Electronic Unit Injector Sleeve
- Remove”. Replace the injector sleeve if the
SMCS Code: 1290-081 injector sleeve is damaged. Check the unit injector
for an excessive brown discoloration that extends
This procedure assists in identifying the cause for beyond the injector tip. If excessive discoloration
an injector misfiring. Perform this procedure only is found, check the quality of the fuel. Refer
after performing the Cylinder Cutout Test. Refer to to Testing and Adjusting, “Fuel Quality - Test”.
Troubleshooting for more information. Replace the seals on the injector and reinstall
the injector. Refer to Disassembly and Assembly
1. Check for air in the fuel, if this procedure has not Manual, “Electronic Unit Injector - Install”. Also
already been performed. Refer to Testing and refer to Disassembly and Assembly Manual,
Adjusting, “Air in Fuel - Test”. “Electronic Unit Injector Sleeve - Install”.
6. If the problem is not resolved, replace the suspect

injector with a new injector.
Electrical shock hazard. The electronic unit injec-

i01901780
tor system uses 90-120 volts.
Finding Top Center Position
2. Remove the valve cover and look for broken
parts. Repair any broken parts or replace any
for No. 1 Piston
broken parts that are found. Inspect all wiring to SMCS Code: 1105-531
the solenoids. Look for loose connections. Also
look for frayed wires or broken wires. Ensure
that the connector for the unit injector solenoid is Standard Flywheel Housing
properly connected. Perform a pull test on each
of the wires. Refer to Troubleshooting, “Electrical Table 2
Connectors - Inspect”. Inspect the posts of the Required Tools
solenoid for arcing. If arcing or evidence of arcing
is found, remove the cap assembly. Refer to Part
Part Name Quantity
Number
Disassembly and Assembly Manual, “Electronic
Unit Injector - Remove”. Clean the connecting 214-7340 Reverse Ratchet 1
posts. Reinstall the cap assembly and tighten
the solenoid nuts to a torque of 2.5 ± 0.25 N·m 9S-9082 Engine Turning Tool 1
(22 ± 2 lb in). Refer to Disassembly and Assembly 5P-7305 Engine Turning Tool 1
Manual, “Electronic Unit Injector - Install”.
136-4632 Timing Pin 1
3. Check the valve lash setting for the cylinder of 139-7063 Timing Pin Adapter 1
the suspect unit injector. Refer to Testing and
Adjusting, “Engine Valve Lash - Inspect/Adjust”. 139-7064 Timing Pin Adapter 1
4. Ensure that the bolt that holds the unit injector is

tightened to the proper torque. If necessary, loosen
the bolt that holds the unit injector and tighten the
bolt to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
44
4. The inlet and exhaust valves for the No. 1

cylinder are fully closed if No. 1 piston is on the
compression stroke and the rocker arms can be
moved by hand. If the rocker arms cannot be
moved and the valves are slightly open, the No. 1
piston is on the exhaust stroke.
Note: When the actual stroke position is identified,

and the other stroke position is needed, remove the
Timing Pin from the hole in the flywheel. Then turn
the flywheel by 360 degrees in the direction of normal
engine rotation and reinstall the Timing Pin into the
hole in the flywheel.
g00780199
Note: Never turn the engine by the crankshaft
Illustration 43 vibration damper. The crankshaft vibration damper is
Typical Example a precision part. Major engine failure may be caused
by damage to the crankshaft vibration damper.
(1) Flywheel Housing
(2) Timing Hole Plug Procedure for Engines that have a

Rear Power Take-Off
(3) Cover Bolt
Table 3
(4) Cover Required Tools
1. Remove two bolts (3) and remove cover (4) from Part Number Part Name Quantity
flywheel housing (1) in order to open the turning 9U-6639 Ratchet Wrench 1
hole.
208-0888 Engine Turning Tool 1
2. Thread the 136-4632 Timing Pin with the proper 208-9387 Pin 1
Timing Pin Adapter into the timing hole. The timing
hole is located approximately 127 to 152 mm 208-9388 Adapter 1
(5.0 to 6.0 inch) above the turning hole for the
engine turning tool in the flywheel housing.
Use the 9S-9082 Engine Turning Tool and a
214-7340 Reverse Ratchet to turn the engine
flywheel. Turn the flywheel in the direction of
engine rotation. The direction of engine rotation is
counterclockwise, as the engine is viewed from
the flywheel end. Turn the flywheel until the Timing
Pin engages with the hole in the flywheel.
Note: 5P-7305 Engine Turning Tool may be used in

certain applications if the 9S-9082 Engine Turning
Tool will not fit the flywheel housing.
Note: If the flywheel is turned beyond the point of

engagement, the flywheel must be turned in the
direction that is reverse of normal engine rotation.
Turn the flywheel by approximately 30 degrees. Then
turn the flywheel in the direction of normal rotation
until the Timing Pin engages with the hole in the
flywheel. This procedure removes the play from the
gears when the No. 1 piston is at the top center g00837908
Illustration 44
position.
Typical Rear Power Take-Off
3. Remove the front valve mechanism cover from (1) Cover
the engine. (2) Bolt
(3) Flywheel housing
(4) Timing hole
45
1. Remove two bolts (2) in order to remove cover Checking and Calibrating the
(1) from flywheel housing (3). This will allow you
to use 208-0888 Engine Turning Tool to rotate
Electronic Injection Timing With
the engine. the Electronic Service Tool
2. Remove the plug in the timing hole (4). Place the Refer to Troubleshooting, “Engine Speed/Timing
208-9387 Pin through the hole of the 208-9388 Sensor - Calibrate” for the proper procedure to
Adapter. This will allow you to install the tool calibrate the electronic injection timing.
without removing the ECM. Thread the 208-9387
Adapter into the flywheel housing. The timing
i01370330
hole is located approximately 127 to 152 mm
(5.0 to 6.0 inch) above the bore for the starter
motor in the flywheel housing.
Fuel Quality - Test
SMCS Code: 1280-081
3. Install the 208-0888 Engine Turning Tool into
the splines of the hydraulic pump drive gear This test checks for problems regarding fuel quality.
in flywheel housing (3). Turn the engine in the Refer to Diesel Fuels and Your Engine, SEBD0717
direction of normal rotation. Rotation of the engine for additional details.
is viewed from the flywheel housing. Rotation of
the engine is counterclockwise. The 208-0888 Use the following procedure to test for problems
Engine Turning Tool needs to rotate the same regarding fuel quality:
direction as the crankshaft. Rotate the engine
with the 208-0888 Engine Turning Tool and the 1. Determine if water and/or contaminants are
9U-6639 Ratchet Wrench. present in the fuel. Check the water separator (if
equipped). If a water separator is not present,
Note: If the flywheel is turned beyond the point of proceed to Step 2. Drain the water separator, if
engagement, the flywheel must be turned in the necessary. A full fuel tank minimizes the potential
direction that is reverse of normal engine rotation. for overnight condensation.
Turn the flywheel by approximately 30 degrees. Then
turn the flywheel in the direction of normal rotation Note: A water separator can appear to be full of fuel
until the Timing Pin engages with the hole in the when the water separator is actually full of water.
flywheel. This procedure removes the play from the
gears when the No. 1 piston is at the top center 2. Determine if contaminants are present in the
position. fuel. Remove a sample of fuel from the bottom
of the fuel tank. Visually inspect the fuel sample
4. Remove the front valve mechanism cover from for contaminants. The color of the fuel is not
the engine. necessarily an indication of fuel quality. However,
fuel that is black, brown, and/or similar to sludge
5. The inlet and exhaust valves for the No. 1 can be an indication of the growth of bacteria or
cylinder are fully closed if No. 1 piston is on the oil contamination. In cold temperatures, cloudy
compression stroke and the rocker arms can be fuel indicates that the fuel may not be suitable for
moved by hand. If the rocker arms cannot be operating conditions. The following methods can
moved and the valves are slightly open, the No. 1 be used to prevent wax from clogging the fuel
piston is on the exhaust stroke. filter:
Note: When the actual stroke position is identified, • Fuel heaters
and the other stroke position is needed, remove the
Timing Pin from the hole in the flywheel. Then turn • Blending fuel with additives
the flywheel by 360 degrees in the direction of normal
engine rotation and reinstall the Timing Pin into the • Utilizing fuel with a low cloud point such as
hole in the flywheel. kerosene
Note: Never turn the engine by the crankshaft Refer to Operation and Maintenance Manual,
vibration damper. The crankshaft vibration damper is “Fuel Recommendations” for more information.
a precision part. Major engine failure may be caused
by damage to the crankshaft vibration damper. 3. Check fuel API with a 9U-7840 Fluid and Fuel
Calibration Gp for low power complaints. The
acceptable range of the fuel API is 30 to 45 when
the API is measured at 15 °C (60 °F), but there is
a significant difference in energy within this range.
Refer to Tool Operating Manual, NEHS0607 for
API correction factors when a low power problem
is present and API is high.
46
Note: A correction factor that is greater than 1.000 Review the following illustrations in order to locate
may be the cause of low power and/or poor fuel the components for your application. Locate the air
consumption. purge plug (1), fuel priming pump (2) (if equipped),
and the ball valve assembly (3) (if equipped).
4. If fuel quality is still suspected as a possible
cause to problems regarding engine performance,
disconnect the fuel inlet line, and temporarily
operate the engine from a separate source of
fuel that is known to be good. This will determine
if the problem is caused by fuel quality. If fuel
quality is determined to be the problem, drain the
fuel system and replace the fuel filters. Engine
performance can be affected by the following
characteristics :
• Cetane number of the fuel

• Air in the fuel
g00995175
• Other fuel characteristics Illustration 45
Fuel filter base that is mounted directly to the fuel supply manifold
i01909716
Typical example
(1) Air purge plug
Fuel System - Prime (2) Hand priming pump (if equipped)
SMCS Code: 1258-548
Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately. g00995236
Illustration 46
Fuel filter base that is mounted directly to the fuel supply manifold
NOTICE Typical example
Do not allow dirt to enter the fuel system. Thoroughly (1) Air purge plug
clean the area around a fuel system component that (2) Hand priming pump (if equipped)
will be disconnected. Fit a suitable cover over discon- (3) Ball valve assembly (if equipped)
nected fuel system component.
If the fuel system runs out of fuel or if air is introduced

into the fuel system, the system must be primed prior
to starting the engine.
Before you begin this procedure, check that the

following conditions are satisfied:
• Ensure that the fuel tanks are filled with clean

diesel fuel.
• Turn the key switch to the OFF position.

47
g00995241 g00995967
Fuel filter base that is mounted remotely Ball valve assembly
Typical example (3a) The valve is in the open position for normal engine operation.
(3b) The valve is in the closed position in order to prime the fuel
(1) Air purge plug
system.
(2) Hand priming pump (if equipped)
2. If the fuel system is equipped with a ball valve

assembly (3), close the valve (3b).
3. Operate the hand priming pump. While you

operate the hand priming pump, observe the air
purge plug for the presence of fuel.
a. When a small drop of fuel appears at the

threads of the air purge plug, close and tighten
the plug.
Note: Failure to tighten all fittings could result in

serious fuel leaks.
Illustration 48
g00995289 b. Clean any residual fuel from the engine
Fuel filter base that is mounted remotely
components.
Typical example
4. Continue to operate the fuel priming pump until a
(1) Air purge plug strong resistance is felt.
(2) Hand priming pump (if equipped)
(3) Ball valve assembly (if equipped)
5. Secure the hand priming pump.
Either of the following procedures may be followed
in order to prime the fuel system. 6. Attempt to start the engine.
NOTICE
Hand Priming the Fuel System Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
1. Open air purge plug (1) for three full turns. Do not
minutes before cranking the engine again.
remove this plug.
a. Crank the engine for 30 seconds. Allow the

starter motor to cool for 2 minutes after each
30 second interval.
b. Repeat Step 6.a until the engine starts and

runs. If the engine runs rough, continue to
operate the engine at low idle until the engine
runs smoothly.
48
c. If the fuel system is equipped with a ball valve 4. If the fuel system is equipped with a ball valve
assembly that has been closed, allow the assembly that has been closed, allow the engine
engine to operate for 30 seconds and then to operate for 30 seconds and then open the valve
open the valve (3a). (3a).
Note: If the ball valve is left in the closed position Note: If the ball valve is left in the closed position
for extended periods of time, damage to the fuel for extended periods of time, damage to the fuel
injectors may occur. injectors may occur.
If the engine will not start, further priming is 5. Once the engine runs smoothly, stop the engine.
necessary. If the engine starts but the engine Turn the key switch to the OFF position.
continues to misfire or smoke, further priming is
necessary. If the engine will not start, further priming is
necessary. If the engine starts but the engine
continues to misfire or smoke, further priming is
Priming Procedure by Engine necessary.
Cranking
1. Open air purge plug (1) for three full turns. Do not i01911798
remove this plug.

Fuel System Pressure - Test
2. If the fuel system is equipped with a ball valve
SMCS Code: 1250-081; 1256-081
assembly (3), close the valve (3b).
Note: Use a suitable container to catch the fuel while NOTICE

you crank the engine. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened

NOTICE component life.
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. NOTICE
Care must be taken to ensure that fluids are contained
3. Use engine cranking to prime the fuel system. during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
a. Crank the engine for 30 seconds. Allow the collect the fluid with suitable containers before open-
starter motor to cool for 2 minutes after each ing any compartment or disassembling any compo-
30 second interval. nent containing fluids.
Note: After four or five intervals, most of the air Refer to Special Publication, NENG2500, “Caterpillar
should be purged from the system. Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
b. While you crank the engine, observe air purge products.
plug (1). When a small drop of fuel appears
at the threads of the air purge plug, close and Dispose of all fluids according to local regulations and
tighten the plug. mandates.
Note: Failure to tighten all fittings could result in

serious fuel leaks.
Low Fuel Pressure
Low fuel pressure can cause low power. Low fuel
c. Clean any residual fuel from the engine
pressure can also cause cavitation of the fuel which
components.
can damage the fuel injectors.
d. Repeat Step 3.a until the engine starts and
The following conditions can cause low fuel pressure:
runs. If the engine runs rough, continue to
operate the engine at low idle until the engine
runs smoothly. • Plugged fuel filters
• Debris in the check valves for the fuel priming
pump
49
• Sticking or worn fuel pressure relief valve in the

fuel transfer pump
• Severe wear on return fuel pressure regulating

valve in the fuel filter base or adapter assembly
• Worn gears in the fuel transfer pump

• Pinched fuel lines or undersized fuel lines
• Old fuel lines that have a reduced interior diameter
that was caused by swelling
• Fuel lines with deteriorating interior surfaces

g00293196
Illustration 50
• Pinched fuel line fittings or undersized fuel line
fittings 1U-5470 Engine Pressure Group
• Debris in the fuel tank, fuel lines, or fuel system Reference: Special Instruction, SEHS8907, “Using
components that may create restrictions the 1U-5470 Engine Pressure Group”
Reference: Operation Manual, NEHS0818, “Using

High Fuel Pressure the 198-4240 Digital Pressure Indicator”
Excessive fuel pressure can cause fuel filter gaskets
to rupture. The following conditions can cause high Fuel System Identification
fuel pressure:
Refer to the following illustrations in order to identify
• Plugged orifices in the fuel pressure regulating the fuel system for your application. Locate the
valve pressure testing ports in order to measure the
different fuel system pressures.
• Stuck fuel pressure relief valve in the fuel transfer
pump
• Pinched fuel return line
Checking Fuel Pressure

Table 4
Required Toolings
Part
Tool Part Name Quantity
Number
Engine Pressure
1U-5470 Group
A or or 1 Illustration 51
g00996187
198-4240 Digital Pressure
Fuel filter base that is mounted directly to the fuel manifold
Indicator
Typical example
(1) Test location for unfiltered fuel pressure
(2) Test location for filtered fuel pressure
50
g00996311 g00996149
Applications with a fuel adapter Applications with a fuel adapter
Typical example Typical example
(1) Test location for unfiltered fuel pressure (1) Test location for unfiltered fuel pressure
(2) Test location for filtered fuel pressure (2) Test location for filtered fuel pressure
Applications with a Quick Connect Coupler Measuring Unfiltered Fuel Pressure

Some applications may be equipped with a quick
connect coupler. Refer to these illustrations for the
location and the purpose of the fuel pressure tap.
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. Clean up fuel
spills immediately.
A high pressure fuel line must be disconnected.

To avoid personal injury or fire from fuel spray,
the engine must be stopped before the fuel line
is disconnected.
Use the following procedure to measure the unfiltered

fuel pressure:
1. Refer to “Fuel System Identification” in order to

identify the correct location for measuring the
unfiltered fuel pressure. Install Tooling (A) into
pressure test location (1) in order to measure the
unfiltered fuel pressure.
g00996062 Note: A fuel sensor may be installed in one of the
Illustration 53
Fuel filter base that is mounted directly to the fuel manifold ports that are indicated in the illustrations. If a fuel
Typical example
sensor is installed in the port, install a tee fitting into
the port. Install the sensor and Tooling (A) onto this
(1) Test location for unfiltered fuel pressure
(2) Test location for filtered fuel pressure
tee prior to operating the engine. Ensure that the tee
and all fuel fittings are securely tightened. Failure to
tighten all fittings could result in serious fuel leaks.
Clean any residual fuel from the engine

components.
2. Start the engine.

51
3. Record the pressure reading that is on Tooling Fuel Filter Differential Pressure
(A) for engine speeds of 1800 rpm and 2100 rpm.
The test should be performed with no load on the Calculate the fuel filter’s differential pressure by
engine. subtracting the filtered fuel pressure from the
unfiltered fuel pressure. For best results, use the
4. Stop the engine and remove Tooling (A) from the pressures that have been measured at an engine
fuel system. speed of 1800 rpm.
Measuring Filtered Fuel Pressure Typically, the differential pressure for a new fuel filter
will not exceed the 35 kPa (5.0 psi).
As abrasive particles collect in the fuel filter, the

pressure differential across the filter will increase.
Fuel leaked or spilled onto hot surfaces or elec- When a filter becomes plugged, the pressure
trical components can cause a fire. Clean up fuel differential may increase as much as 69 kPa
spills immediately. (10.0 psi) before a significant power loss is detected
by the operator. Low filtered fuel pressure will cause
cavitation of the fuel and internal damage to the unit
injectors. The pressure differential across the fuel
filter should not exceed 69 kPa (10.0 psi).
A high pressure fuel line must be disconnected.
To avoid personal injury or fire from fuel spray, If a high differential pressure exists, replace the fuel
the engine must be stopped before the fuel line filter. Refer to Testing and Adjusting, “Fuel System
is disconnected. - Prime” for information on priming the fuel system
after you replace the fuel filter.
1. Refer to “Fuel System Identification” in order
to identify the correct location for measuring Fuel Pressure Relief Valve
the filtered fuel pressure. Install Tooling (A) into
pressure test location (2) in order to measure the
filtered fuel pressure.
Note: A fuel sensor may be installed in one of the

ports that are indicated in the illustrations. If a fuel
sensor is installed in the port, install a tee fitting into
the port. Install the sensor and Tooling (A) onto this
tee prior to operating the engine. Ensure that the tee
and all fuel fittings are securely tightened. Failure to
tighten all fittings could result in serious fuel leaks.
Clean any residual fuel from the engine

components.
g00996532
Illustration 55
2. Start the engine.
Fuel transfer pump
3. Record the pressure reading that is on Tooling Typical example
(A) for engine speeds of 600 rpm and 1800 rpm. (3) Fuel pressure relief valve
The test should be performed with no load on the
engine. The fuel pressure relief valve (3) is an internal
component that is located in the fuel transfer pump.
Note: Excessive needle movement at the gauge may The relief valve is used to regulate the maximum
be present. Fuel pressure readings near the fuel pressure for the fuel system. Refer to Illustration 55
supply manifold will be affected by pressure spikes. in order to locate the pressure relief valve.
The pressure spikes are caused by excess fuel that
is returning to the fuel system from the injectors. The maximum unfiltered fuel pressure at an engine
If the gauge is connected with a suitable length of speed of 2100 rpm ..................... 715 kPa to 785 kPa
hose, the air in the hose will absorb the spikes. (103.7 psi to 113.9 psi)
This will give you an average reading and a steady
needle. Ensure that the gauge is elevated above the The fuel pressure relief valve is not a serviceable
pressure measuring port during the test. component. If the operation of the fuel pressure relief
valve is suspect, replace the fuel transfer pump.
4. Stop the engine and remove Tooling (A) from the
fuel system.
52
Fuel Pressure Regulating Valve Pressure Regulator Assembly that is

Self-Contained
The pressure regulator valve is used in order to
maintain an optimum operating pressure within the
low pressure fuel system. If the filtered fuel pressure
is low, the pressure regulator valve may be worn or
stuck in the open position.
There are two types of fuel pressure regulating

valves that are available for this engine. The
integral pressure regulator valve has been replaced
with the new pressure regulator assembly that is
self-contained.
Integral Pressure Regulator Valve
g00996664
Illustration 57
Location of the pressure regulator assembly
Typical example
(5) Pressure regulator assembly
This pressure regulator assembly (5) is a serviceable

component. The pressure regulator valve is located in
the fuel filter base or in the fuel adapter. This regulator
valve is used in order to maintain an optimum
operating pressure within the low pressure fuel
system. Refer to Illustration 57 in order to locate the
pressure regulator assembly that is self-contained.
g00996544
Illustration 56
The filtered fuel pressure at an engine speed of 600
Location of the fuel pressure regulator valve rpm ........... 450 kPa to 600 kPa (65.3 psi to 87.0 psi)
Typical example
(4) Fuel pressure regulator valve This type of fuel pressure regulator valve is a
serviceable component. If the operation of the fuel
The integral pressure regulator valve (4) is an internal pressure regulator valve is suspect, replace the
component that is located in the fuel filter base or pressure regulator assembly.
in the fuel adapter. The pressure regulator valve
is used in order to maintain an optimum operating
pressure within the low pressure fuel system. Refer
to Illustration 56 in order to locate the pressure
regulator valve.
The filtered fuel pressure at an engine speed of 600

rpm ........... 450 kPa to 600 kPa (65.3 psi to 87.0 psi)
If the filtered fuel pressure is not within specifications,

remove the fuel pressure regulator valve and the
valve spring. Inspect the components for wear or
damage. If there is visible signs of wear or damage
to the valve, replace the valve. Check the spring for
distortion. Refer to Specifications, “Fuel Lines” for
information that relates to the specifications for the
spring. If necessary, replace the spring. Retest the
filtered fuel pressure after the replacement of any
components.
53
i01779472
Gear Group (Front) - Time

SMCS Code: 1206-531
g00430184
Illustration 58
Front Gear Group
(1) Camshaft gear and timing reference ring
(2) Timing marks
(3) Idler gear
(4) Crankshaft gear
The basis for correct fuel injection timing and valve

mechanism operation is determined by the timing
reference ring and the alignment of the front gear
group. The timing reference ring is located on the end
of the camshaft. The timing reference ring is used to
measure crankshaft rotation. During installation of
the front gear, timing marks (2) on idler gear (3) must
be in alignment with the timing marks on crankshaft
gear (4) and the timing marks on camshaft gear (1).
Refer to Disassembly and Assembly, “ Gear Group

(Front) - Remove” and Disassembly and Assembly, “
Gear Group (Front) - Install”.
Note: If timing reference ring (1) is installed backward

the engine will not start.
Check for proper alignment of the camshaft gear and

timing reference ring (1) on the camshaft assembly.
Inspect the key between the timing reference ring
and the camshaft gear. Check the teeth on the timing
ring. The teeth should not be defaced. The teeth
should have sharp clean edges and the teeth should
be free of contaminants.
Note: The electronic injection timing must be

calibrated after reassembly of the front gear train.
Refer to Troubleshooting, “ Engine Speed/Timing
Sensor - Calibrate”.
54
Air Inlet and Exhaust 3. Check for dirt tracks on the clean side of the
engine air cleaner element. If dirt tracks are
System observed, contaminants are flowing past the
engine air cleaner element and/or the seal for the
engine air cleaner element.
i01778359
Air Inlet and Exhaust System

- Inspect Hot engine components can cause injury from
burns. Before performing maintenance on the
SMCS Code: 1050-040 engine, allow the engine and the components to
cool.
Air Inlet Restriction
There will be a reduction in the performance of the
engine if there is a restriction in the air inlet system or
the exhaust system. Making contact with a running engine can cause
burns from hot parts and can cause injury from
Table 5 rotating parts.
Required Tools
When working on an engine that is running, avoid
Part contact with hot parts and rotating parts.
Part Name Quantity
Number
1U-5470 Engine Pressure Group 4. Use the differential pressure gauge of the
or or 1
1U-5470 Engine Pressure Group.
198-4240 Digital Pressure Indicator
g00293196
Illustration 59
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 g00580368
Illustration 60
Engine Pressure Group. Refer to Operation Manual,
NEHS0818, “Using the 198-4240 Pressure Indicator (1) Air cleaner
(2) Test location
Tool Gp” for the instructions that are needed to use
the 198-4240 Pressure Indicator Tool Gp.
a. Connect the vacuum port of the differential
1. Inspect the engine air cleaner inlet and ducting pressure gauge to test location (2). Test
in order to ensure that the passageway is not location (2) can be located anywhere along the
blocked or collapsed. air inlet piping after the engine air cleaner but
before the turbocharger.
2. Inspect the engine air cleaner element. Replace
a dirty engine air cleaner element with a clean b. Leave the pressure port of the differential
engine air cleaner element. pressure gauge open to the atmosphere.
55
c. Start the engine. Run the engine in the no-load

condition at high idle.
Hot engine components can cause injury from
d. Record the value.
engine, allow the engine and the components to
e. Multiply the value from Step 4.d by 1.8.
cool.
f. Compare the result from Step 4.e to the
appropriate values that follow.
The air flow through a used engine air cleaner Making contact with a running engine can cause
may have a restriction. The air flow through a
plugged engine air cleaner will be restricted to some
rotating parts.
magnitude. In either case, the restriction must not be
more than the following amount:
Maximum restriction ........ 6.2 kPa (25 in of H2O) contact with hot parts and rotating parts.
The air flow through a new engine air cleaner element Use the differential pressure gauge of the 1U-5470
must not have a restriction of more than the following Engine Pressure Group in order to measure back
amount: pressure from the exhaust. Use the following
procedure in order to measure back pressure from
Maximum restriction ........ 3.7 kPa (15 in of H2O)
the exhaust:
Exhaust Restriction
Back pressure is the difference in the pressure
between the exhaust at the outlet elbow and the
atmospheric air.
Table 6
Required Tools
Part
Part Name Quantity
Number
or or 1
198-4240 Digital Pressure Indicator
g00583322
Illustration 62
(1) Muffler
(2) Test location
1. Connect the pressure port of the differential

pressure gauge to test location (2). Test location
(2) can be located anywhere along the exhaust
piping after the turbocharger but before the
g00293196
muffler.
Illustration 61
1U-5470 Engine Pressure Group 2. Leave the vacuum port of the differential pressure
gauge open to the atmosphere.
Refer to Special Instruction, SEHS8907, “Using
the 1U-5470 Engine Pressure Group” for the 3. Start the engine. Run the engine in the no-load
instructions that are needed to use the 1U-5470 condition at high idle.
NEHS0818, “Using the 198-4240 Pressure Indicator 4. Record the value.
the 198-4240 Pressure Indicator Tool Gp. 5. Multiply the value from Step 4 by 1.8.
56
6. Compare the result from Step 5 to the value that Maximum back pressure for engines with a
follows. Catalytic converter/muffler .................... 14.9 kPa
(60 inch of H2O)
Back pressure from the exhaust must not be more
than the following amount: If the maximum back pressure is within the allowable
limits, refer to Troubleshooting, “Low Power/Poor or
Maximum back pressure ...................... 10.0 kPa No Response to Throttle”.
(40 inch of H2O)
If the back pressure exceeds 14.9 kPa
Catalytic Converter/Muffler (60 inch of H2O), replace the catalytic
converter/muffler.
i02015684
Turbocharger - Inspect
SMCS Code: 1052-040
Hot engine components can cause injury from

engine, allow the engine and the components to
cool.
Personal injury can result from rotating and mov-

ing parts.
g00678914
Illustration 63 Stay clear of all rotating and moving parts.
Typical example
(1) Catalytic converter/muffler Never attempt adjustments while the machine is
(2) Test location moving or the engine is running unless otherwise
(3) Exhaust piping specified.
(4) Turbocharger
The machine must be parked on a level surface
1. Connect the pressure port of the differential and the engine stopped.
pressure gauge to test location. The test location
should be located on a straight length of exhaust
pipe. This back pressure tap should be located NOTICE
as close as possible to the turbocharger or the Keep all parts clean from contaminants.
exhaust manifold.
2. Leave the vacuum port of the differential pressure component life.
gauge open to the atmosphere.
3. Start the engine. Run the engine in the no-load

condition at high idle until the engine reaches
normal operating temperature.
4. Record the value.
5. Multiply the value from Step 4 by 1.8.
6. Compare the result from Step 5 to the value that

follows.
Back pressure from the exhaust must not be more

than the following amount:
57
3. Turn the rotating assembly by hand. While you

NOTICE turn the assembly, push the assembly sideways .
Care must be taken to ensure that fluids are contained The assembly should turn freely. The compressor
during performance of inspection, maintenance, test- wheel should not rub the compressor housing.
ing, adjusting and repair of the product. Be prepared to Replace the turbocharger if the compressor wheel
collect the fluid with suitable containers before open- rubs the compressor wheel housing. If there is no
ing any compartment or disassembling any compo- rubbing or scraping, go to Step 4.
nent containing fluids.
4. Inspect the compressor and the compressor
Refer to Special Publication, NENG2500, “Caterpillar wheel housing for oil leakage. An oil leak from
Tools and Shop Products Guide” for tools and supplies the compressor may deposit oil in the aftercooler.
suitable to collect and contain fluids on Caterpillar Drain and clean the aftercooler if you find oil in
products. the aftercooler.
Dispose of all fluids according to local regulations and a. Check the oil level in the crankcase. If the oil
mandates. level is too high, adjust the oil level.
b. Inspect the air cleaner element for restriction. If

Before you begin inspection of the turbocharger, restriction is found, correct the problem.
be sure that the inlet air restriction is within the
specifications for your engine. Be sure that the c. Inspect the engine crankcase breather. Clean
exhaust system restriction is within the specifications the engine crankcase breather or replace
for your engine. Refer to Systems Operation/Testing the engine crankcase breather if the engine
and Adjusting, “Air Inlet and Exhaust System - crankcase breather is plugged.
Inspect”.
d. Remove the oil drain line for the turbocharger.
The condition of the turbocharger will have definite Inspect the drain opening. Inspect the oil drain
effects on engine performance. Use the following line. Inspect the area between the bearings of
inspections and procedures to determine the the rotating assembly shaft. Look for oil sludge.
condition of the turbocharger. Inspect the oil drain hole for oil sludge. Inspect
the oil drain line for oil sludge in the drain
• Inspection of the Compressor and the Compressor line. If necessary, clean the rotating assembly
Housing shaft. If necessary, clean the oil drain hole. If
necessary, clean the oil drain line.
• Inspection of the Turbine Wheel and the Turbine
Housing e. If Steps 4.a through 4.d did not reveal the
source of the oil leakage, the turbocharger has
• Inspection of the Wastegate internal damage. Replace the turbocharger.
Inspection of the Compressor and Inspection of the Turbine Wheel

the Compressor Housing and the Turbine Housing
Remove air piping from the compressor inlet. Remove the air piping from the turbine housing.
1. Inspect the compressor wheel for damage from a
foreign object. If there is damage, determine the
source of the foreign object. As required, clean
the inlet system and repair the intake system.
Replace the turbocharger. If there is no damage,
go to Step 3.
2. Clean the compressor wheel and clean the

compressor housing if you find buildup of foreign
material. If there is no buildup of foreign material,
go to Step 3.
58
a. Remove the oil drain line for the turbocharger.

Inspect the drain opening. Inspect the area
between the bearings of the rotating assembly
shaft. Look for oil sludge. Inspect the oil drain
hole for oil sludge. Inspect the oil drain line
for oil sludge. If necessary, clean the rotating
assembly shaft. If necessary, clean the drain
opening. If necessary, clean the drain line.
b. If crankcase pressure is high, or if the oil drain

is restricted, pressure in the center housing
may be greater than the pressure of turbine
housing (1). Oil flow may be forced in the wrong
direction and the oil may not drain. Check the
crankcase pressure and correct any problems.
c. If the oil drain line is damaged, replace the oil

drain line.
d. Check the routing of the oil drain line. Eliminate

any sharp restrictive bends. Make sure that
Illustration 64
g00763164 the oil drain line is not too close to the engine
(1) Turbine Housing
exhaust manifold.
(2) Turbine Wheel
(3) Turbocharger e. If Steps 4.a through 4.d did not reveal the
source of the oil leakage, turbocharger (3) has
1. Inspect the turbine for damage by a foreign object. internal damage. Replace turbocharger (3).
If there is damage, determine the source of the
foreign object. Replace turbocharger (3). If there Inspection of the Wastegate
is no damage, go to Step 2.
Note: All engines are not equipped with waste gates.
2. Inspect turbine wheel (2) for buildup of carbon and
other foreign material. Inspect turbine housing (1) The wastegate controls the amount of exhaust gas
for buildup of carbon and foreign material. Clean that is allowed to bypass the turbine side of the
turbine wheel (2) and clean turbine housing (1) if turbocharger. This valve then controls the rpm of the
you find buildup of carbon or foreign material. If turbocharger.
there is no buildup of carbon or foreign material,
go to Step 3. When the engine operates in conditions of low
boost (lug), a spring presses against a diaphragm
3. Turn the rotating assembly by hand. While you in the canister. The actuating rod will move and the
turn the assembly, push the assembly sideways. wastegate will close. Then, the turbocharger can
The assembly should turn freely. Turbine wheel (2) operate at maximum performance.
should not rub turbine wheel housing (1). Replace
turbocharger (3) if turbine wheel (2) rubs turbine When the boost pressure increases against the
housing (1). If there is no rubbing or scraping, go diaphragm in the canister, the wastegate will open.
to Step 4. The rpm of the turbocharger becomes limited. The
rpm limitation occurs because a portion of the
4. Inspect the turbine and turbine housing (1) for oil exhaust gases bypass the turbine wheel of the
leakage. Inspect the turbine and turbine housing turbocharger.
(1)for oil coking. Some oil coking may be cleaned.
Heavy oil coking may require replacement of The following levels of boost pressure indicate a
the turbocharger. If the oil is coming from the problem with the wastegate:
turbocharger center housing go to Step 4.a.
Otherwise go to “Inspection of the Wastegate”.
• Too high at full load conditions
• Too low at all lug conditions
Note: The housing assembly for the wastegate is
preset at the factory and no adjustments can be
made.
59
On a turbocharged, aftercooled engine, a change

NOTICE in the fuel rating will change the horsepower. A
If the high idle rpm or the engine rating is higher than change in the fuel rating will change the inlet manifold
given in the Technical Marketing Information (TMI) pressure. If the fuel is rated above 35 API, the inlet
for the height above sea level at which the engine is manifold pressure can be less than the pressure
operated, there can be damage to engine or to tur- given in the TMI (Technical Marketing Information).
bocharger parts. Damage will result when increased The pressure will also be less than the pressure that
heat and/or friction due to the higher engine output is listed on the Fuel Setting And the Related Service
goes beyond the engine cooling and lubrication sys- Information System. If the fuel is rated below 35
tem’s abilities. API, the inlet manifold pressure can be more than
the pressure listed in the TMI (Technical Marketing
Information). The pressure will also be more than the
The boost pressure controls the maximum rpm of the pressure that is listed on the Fuel Setting And the
turbocharger, because the boost pressure controls Related Service Information System.
the position of the wastegate. The following factors
also affect the maximum rpm of the turbocharger: Note: Ensure that the air inlet and the exhaust
are not restricted when you are checking the inlet
• The engine rating manifold pressure.
• The horsepower demand on the engine
• The high idle rpm
• The height above sea level for engine operation
• Inlet air restriction
• Exhaust system restriction
i01778375
Inlet Manifold Pressure - Test

g00434159
SMCS Code: 1058-081 Illustration 65
Pressure test location on inlet manifold
The efficiency of an engine can be checked by (1) Plug
making a comparison of the pressure in the inlet
manifold with the information given in the TMI Table 7
(Technical Marketing Information). The information
Required Tools
is also listed on the Fuel Setting and the Service
Information System. This test is used when there is a Part
Part Name Quantity
decrease of horsepower from the engine, yet there is Number
no real sign of a problem with the engine. 1U-5470 Engine Pressure Group
or or 1
The correct pressure for the inlet manifold is listed 198-4240 Digital Pressure Indicator
in the TMI (Technical Marketing Information). The
correct pressure is also on the Fuel Setting And the
related Service Information System. Development
of this information is performed under the following
conditions:
• 99 kPa (29.7 in Hg) dry barometric pressure

• 29 °C (85 °F) outside air temperature
• 35 API rated fuel
g00293196
Illustration 66
60
Refer to Special Instruction, SEHS8907, “Using i01099953

the 1U-5470 Engine Pressure Group” for the
instructions that are needed to use the 1U-5470 Aftercooler - Test
NEHS0818, “Using the 198-4240 Pressure Indicator SMCS Code: 1063-081
Table 9
the 198-4240 Pressure Indicator Tool Gp.
Tools Needed
Use the following procedure in order to measure the
Part
inlet manifold pressure: Part Name Quantity
Number
1. Remove plug (1) from the inlet manifold. 1U-5470 Engine Pressure Group 1
FT-1984 Aftercooler Testing Group 1
2. Connect the 1U-5470 Engine Pressure Group to
the inlet manifold at the pressure test location. FT-1438 Aftercooler (Dynamometer 1
Test)
4. Compare the value that was recorded in Step 3 to Visual Inspection

the pressure that is given in the TMI (Technical
Marketing Information). The correct pressure Inspect the following parts at each oil change:
is also given in the Fuel Setting And Related
Information Microfiche. • Air lines
• Hoses
i01582969
Exhaust Temperature - Test • Gasket joints
SMCS Code: 1088-081
Table 8 Pressurized air can cause personal injury. When

Required Tools pressurized air is used for cleaning, wear a pro-
tective face shield, protective clothing, and pro-
Part tective shoes.
Part Name Qty
Number
164-3310 Infrared Thermometer 1 Ensure that the constant torque hose clamps are
tightened to the correct torque. Check the truck
When the engine runs at low idle, the temperature of manufacturer’s specifications for the correct torque.
an exhaust manifold port can indicate the condition Check the welded joints for cracks. Ensure that
of a fuel injection nozzle. the brackets are tightened in the correct positions.
Ensure that the brackets are in good condition. Use
A low temperature indicates that no fuel is flowing to compressed air to clean any debris or any dust from
the cylinder. An inoperative fuel injection nozzle or the aftercooler core assembly. Inspect the cooler
a problem with the fuel injection pump could cause core fins for the following conditions:
this low temperature.
• Damage
A very high temperature can indicate that too much
fuel is flowing to the cylinder. A malfunctioning • Debris
fuel injection nozzle could cause this very high
temperature. • Corrosion
Use the 164-3310 Infrared Thermometer to check Use a stainless steel brush to remove any corrosion.
exhaust temperature. The Operator’s Manual, Ensure that you use soap and water.
NEHS0630 contains the complete operating and
maintenance instructions for the 164-3310 Infrared Note: When parts of the air-to-air aftercooler system
Thermometer. are repaired, a leak test is recommended. When
parts of the air-to-air aftercooler system are replaced,
a leak test is recommended.
61
The use of winter fronts or shutters is discouraged Aftercooler Core Leakage

with air-to-air aftercooled systems. Winter fronts
can only be used on certain truck models. On these
trucks, tests have shown that the engine jacket
water will overheat before the inlet manifold air
temperature is excessive. These trucks use sensors
and indicators that are installed in order to indicate
engine operating conditions before excessive inlet
manifold air temperatures are reached. Check with
the truck manufacturer about the use of both winter
fronts and shutters.
Inlet Manifold Pressure

Normal inlet manifold pressure with high exhaust
temperature can be caused by blockage of the fins of
the aftercooler core. Clean the fins of the aftercooler
core. Refer to “Visual Inspection” for the cleaning
procedure.
Low inlet manifold pressure and high exhaust

manifold temperature can be caused by any of the
following conditions:
Plugged air cleaner – Clean the air cleaner or

replace the air cleaner, as required. Refer to the
Operation and Maintenance Manual, “Engine Air
Cleaner Element - Clean/Replace”.
g00295702
Blockage in the air lines – Blockage in the air lines Illustration 67
between the air cleaner and the turbocharger must FT-1984 Aftercooler Testing Group
be removed. (1) Regulator and valve assembly
(2) Nipple
Aftercooler core leakage – Aftercooler core (3) Relief valve
leakage should be pressure tested. Refer to (4) Tee
(5) Coupler
“Aftercooler Core Leakage” topic for the testing (6) Aftercooler
procedure. (7) Dust plug
(8) Dust plug
Leakage of the induction system – Any leakage (9) Chain
from the pressure side of the induction system should
be repaired. A low power problem in the engine can be the result
of aftercooler leakage. Aftercooler system leakage
Inlet manifold leak – An inlet manifold leak can be can result in the following problems:
caused by the following conditions: loose fittings and
plugs, missing fittings and plugs, damaged fittings • Low power
and plugs, and leaking inlet manifold gasket.
• Low boost pressure
• Black smoke
• High exhaust temperature
NOTICE
Remove all air leaks from the system to prevent en-
gine damage. In some operating conditions, the en-
gine can pull a manifold vacuum for short periods of
time. A leak in the aftercooler or air lines can let dirt
and other foreign material into the engine and cause
rapid wear and/or damage to engine parts.
62
A large leak of the aftercooler core can often be Air System Restriction
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 or to the radiator brackets to prevent
possible injury while you are testing. 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 with the FT-1984 Aftercooler
Testing Group.
Note: Installation of additional hose clamps on the

hump hoses is recommended in order to prevent
the hoses from bulging while the aftercooler core is g00581364
Illustration 68
being pressurized.
Pressure measurements should be taken at the inlet
NOTICE manifold (1) and at the turbocharger outlet (2).
Do not use more than 240 kPa (35 psi) of air pressure
or damage to the aftercooler core can be the result. Use the differential pressure gauge of the 1U-5470
Engine Pressure Group. Use the following procedure
3. Install the regulator and valve assembly (1) on the in order to measure the restriction of the aftercooler:
outlet side of the aftercooler core assembly. Also,
attach the air supply. 1. Connect the vacuum port of the differential
pressure gauge to port (1).
4. Open the air valve and pressurize the aftercooler
to 205 kPa (30 psi). Shut off the air supply. 2. Connect the pressure port of the differential
pressure gauge to port (2).
5. Inspect all connection points for air leakage.
6. The aftercooler system’s pressure should not drop
more than 35 kPa (5 psi) in 15 seconds. The air lines and the cooler core must be inspected
for internal restriction when both of the following
7. If the pressure drop is more than the specified conditions are met:
amount, use a solution of soap and water to check
all areas for leakage. Look for air bubbles that will • Air flow is at a maximum level.
identify possible leaks. Replace the aftercooler
core, or repair the aftercooler core, as needed. • Total air pressure drop of the charged system
exceeds 13.5 kPa (4 in Hg).
If a restriction is discovered, proceed with the

following tasks, as required:
To help prevent personal injury when the tooling is
removed, relieve all pressure in the system slowly • Clean
by using an air regulator and a valve assembly.
• Repair
8. After the testing, remove the FT-1984 Aftercooler
Testing Group. Reconnect the air pipes on both • Replacement
sides of the aftercooler core assembly.
63
Turbocharger Failure i01096015
Engine Crankcase Pressure

(Blowby) - Test
Personal injury can result from air pressure.
SMCS Code: 1215; 1317
Personal injury can result without following prop- Table 10
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing. Tools Needed
Part
Maximum air pressure at the nozzle must be less Part Name Quantity
Number
than 205 kPa (30 psi) for cleaning purposes.
8T-2700 Blowby/Air Flow Indicator 1
If a turbocharger failure occurs, remove the air-to-air

aftercooler core. Internally flush the air-to-air Damaged pistons or rings can cause too much
aftercooler core with a solvent that removes oil pressure in the crankcase. This condition will cause
and other foreign substances. Shake the air-to-air the engine to run rough. There will be more than the
aftercooler core in order to eliminate any trapped normal amount of fumes (blowby) rising from the
debris. Wash the aftercooler with hot, soapy water. crankcase breather. The breather can then become
Thoroughly rinse the aftercooler with clean water and restricted in a very short time, causing oil leakage
blow dry the aftercooler with compressed air. Blow at gaskets and seals that would not normally have
dry the assembly in the reverse direction of normal leakage. Blowby can also be caused by worn valve
air flow. To make sure that the whole system is clean, guides or by a failed turbocharger seal.
carefully inspect the system.
NOTICE
Do not use caustic cleaners to clean the air-to-air af-
tercooler core.
Caustic cleaners will attack the internal metals of the

core and cause leakage.
Dynamometer Test
In hot ambient temperatures, chassis dynamometer
tests for models with an air-to-air aftercooler can
add a greater heat load to the jacket water cooling Illustration 69
g00286269
system. Therefore, the jacket water cooling system’s 8T-2700 Blowby/Air Flow Indicator
temperature must be monitored. The following
measurements may also need a power correction The 8T-2700 Blowby/Air Flow Indicator is used
factor: to check the amount of blowby. Refer to Special
Instruction, SEHS8712, “Using the 8T-2700
• Inlet air temperature Blowby/Air Flow Indicator” for the test procedure for
checking the blowby.
• Fuel API rating
• Fuel temperature i01120286
• Barometric pressure Compression - Test

With dynamometer tests for engines, use the SMCS Code: 1215
FT-1438 Aftercooler (Dynamometer Test). This tool
provides a water cooled aftercooler in order to control An engine that runs roughly can have a leak at the
the inlet air temperature to 43 °C (110 °F). valves. An engine that runs roughly can also have
valves that need an adjustment. Remove the head
and inspect the valves and valve seats. This is
necessary to find those small defects that would not
normally cause problems. Repairs of these problems
are normally performed when you are reconditioning
the engine.
64
i01896573 If the measurement is not within this range, an

adjustment is necessary. Refer to “Valve Lash
Engine Valve Lash - Adjustment” for the proper procedure.
Inspect/Adjust
Valve Lash Adjustment
SMCS Code: 1102-025
To prevent possible injury, do not use the starter

to turn the flywheel.
Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-
suring valve clearance.
This engine uses high voltage to control the fuel g00386924

injectors. Illustration 70
Cylinder and valve location
Disconnect electronic fuel injector enable circuit (A) Exhaust valves
connector to prevent personal injury. (B) Inlet valves
Do not come in contact with the fuel injector ter- Table 12

minals while the engine is running. Engine Valve Lash Setting
Valves Valve Lash Setting
Note: Valve lash is measured between the rocker
arm and the valve bridge. All measurements and 0.38 ± 0.08 mm
Inlet
adjustments must be made with the engine stopped (0.015 ± 0.003 inch)
and the valves fully closed. 0.64 ± 0.08 mm
Exhaust
(0.025 ± 0.003 inch)
Valve Lash Check
Adjust the valve lash while the engine is stopped.
An adjustment is not necessary if the measurement Use the following procedure to adjust the valve lash:
of the valve lash is in the acceptable range. Check
the valve lash while the engine is stopped. The valve 1. Put the No. 1 piston at the top center position.
lash setting is specified in Table 11. Refer to Testing and Adjusting, “Finding the Top
Center Position For No. 1 Piston”.
Table 11
Quick Reference for Engine Valve Lash Setting Note: If the engine is equipped with an engine
C-10 and C-12 Engines compression brake, loosen the adjusting screw for
the lash on the slave piston for the compression
Inlet Valves Exhaust Valves
brake prior to adjusting the engine valve lash. Refer
0.38 ± 0.08 mm 0.64 ± 0.08 mm to the Testing and Adjusting, “Slave Piston Lash -
Valve Lash
Setting
(0.015 ± 0.003 (0.025 ± 0.003 Adjust” for information that relates to the adjustment
inch) inch) of the slave piston lash for the engine compression
brake.
TC
Compression 1-2-4 1-3-5
Stroke 2. Before any adjustments are made, lightly tap the
rocker arm at the top of the adjustment screw with
TC Exhaust a soft mallet. This will ensure that the lifter roller
3-5-6 2-4-6
Stroke(1) seats against the camshaft’s base circle.
Firing Order 1-5-3-6-2-4(2) Note: Refer to Table 12 for the appropriate engine
valve lash setting.
(1) 360° from TC compression stroke
(2) The No. 1 cylinder is at the front of the engine.
65
3. Make an adjustment to the valve lash on the inlet 5. Remove the timing bolt and turn the flywheel by
valves for cylinders 1, 2, and 4. 360 degrees in the direction of engine rotation.
This will put the No. 6 piston at the top center
position on the compression stroke. Install the
timing bolt in the flywheel.
6. Before any adjustments are made, 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.
7. Make an adjustment to the valve lash on the inlet

valves 3, 5, and 6.
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
g00481639
Illustration 71 camshaft’s base circle.
Engine valve lash adjustment
Typical example b. Loosen the adjustment locknut.
(1) Rocker arm
(2) Adjustment locknut c. Place the appropriate feeler gauge between
rocker arm and the valve bridge. Then, turn
a. Loosen adjustment locknut (2). the adjustment screw in a clockwise direction.
Slide the feeler gauge between the rocker arm
b. Place the appropriate feeler gauge between and the valve bridge. Continue turning the
rocker arm and the valve bridge. Then, turn adjustment screw until a slight drag is felt on
the adjustment screw in a clockwise direction. the feeler gauge. Remove the feeler gauge.
and the valve bridge. Continue turning the d. Tighten the adjustment locknut to a torque
adjustment screw until a slight drag is felt on of 30 ± 7 N·m (22 ± 5 lb ft). Do not allow
the feeler gauge. Remove the feeler gauge. the adjustment screw to turn while you are
tightening the adjustment locknut. Recheck
c. Tighten the adjustment locknut to a torque the valve lash after tightening the adjustment
of 30 ± 7 N·m (22 ± 5 lb ft). Do not allow locknut.
the adjustment screw to turn while you are
tightening the adjustment locknut. Recheck 8. Make an adjustment to the valve lash on the
the valve lash after tightening the adjustment exhaust valves for cylinders 2, 4, and 6.
locknut.
a. Loosen adjustment locknut (2).
4. Make an adjustment to the valve lash on the
exhaust valves for cylinders 1, 3, and 5. b. Place the appropriate feeler gauge between
rocker arm and the valve bridge. Then, turn
a. Loosen adjustment locknut (2). the adjustment screw in a clockwise direction.
b. Place the appropriate feeler gauge between and the valve bridge. Continue turning the
rocker arm and the valve bridge. Then, turn adjustment screw until a slight drag is felt on
the adjustment screw in a clockwise direction. the feeler gauge. Remove the feeler gauge.
and the valve bridge. Continue turning the c. Tighten the adjustment locknut to a torque
adjustment screw until a slight drag is felt on of 30 ± 7 N·m (22 ± 5 lb ft). Do not allow
the feeler gauge. Remove the feeler gauge. the adjustment screw to turn while you are
tightening the adjustment locknut. Recheck
c. Tighten the adjustment locknut to a torque the valve lash after tightening the adjustment
of 30 ± 7 N·m (22 ± 5 lb ft). Do not allow locknut.
the adjustment screw to turn while you are
tightening the adjustment locknut. Recheck 9. Remove the timing bolt from the flywheel after all
the valve lash after tightening the adjustment adjustments to the valve lash have been made.
locknut. Reinstall the timing cover on the flywheel housing.
For information that relates to the adjustment of the

electronic unit injector, refer to Testing and Adjusting,
“Electronic Unit Injector - Adjust”.
66
Lubrication System
i01885008
Engine Oil Pressure - Test

SMCS Code: 1304-081
The engine oil pressure may be checked

electronically by using the electronic service tool.
The engine oil pressure can be measured with the
electronic service tool. Refer to Troubleshooting for
information on the use of the electronic technician.
g00296486
Illustration 72
Measuring Engine Oil Pressure 1U-5470 Engine Pressure Group
Tool (A) measures the oil pressure in the system.

This engine tool group can read the oil pressure
Work carefully around an engine that is running. inside the oil manifold.
Engine parts that are hot, or parts that are moving,
can cause personal injury. Note: Refer to Special Instruction, SEHS8907, “Using
the 1U-5470 Engine Pressure Group” for more
information. Refer to Operating Manual, NEHS0818,
NOTICE “Using the 198-4240 Pressure Indicator Tool Group”
Keep all parts clean from contaminants. for more information.

component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and

mandates.
Table 13
Required Tools
Part
Tool Number Part Name Quantity
Engine Pressure
1U-5470 Group g00977330
A or or 1 Illustration 73
198-4240 Pressure Indicator Oil gallery plug
Tool Group (1) Plug
1. Install Tool (A) into oil gallery plug (1).

67
Note: Engine oil pressure to the camshaft and main • Engine oil level is low. Refer to Step 1.
bearings should be checked on each side of the
cylinder block at oil gallery plug (1). • Engine oil is contaminated. Refer to Step 2.
2. Start the engine. Run the engine with SAE 15W40 • The engine oil bypass valves are open. Refer to
oil. Refer to Operation and Maintenance Manual, Step 3.
“Engine Oil” for the recommendations of engine
oil. • The engine lubrication system is open. Refer to
Step 4.
3. Record the value of the engine oil pressure when
the engine is at operating temperature 100 °C • The oil pickup tube has a leak or a restricted inlet
(212 °F). screen. Refer to Step 5.
The minimum engine oil pressure at 1800 • The engine oil pump is faulty. Refer to Step 6.
rpm should be approximately 275 to 414 kPa
(40 to 59 psi). Minimum engine oil pressure at low • Engine Bearings have excessive clearance. Refer
idle rpm (600 to 800 rpm) should be approximately to Step 7.
68 kPa (10 psi).
1. Check the engine oil level in the crankcase. The
4. Compare the recorded engine oil pressure with oil level can possibly be too far below the oil pump
the oil pressure indicators on the instrument panel supply tube. This will cause the oil pump not to
and the engine oil pressure that is displayed on have the ability to supply enough lubrication to the
the electronic service tool. engine components. If the engine oil level is low
add engine oil in order to obtain the correct engine
5. An engine oil pressure indicator that has a defect oil level. Refer to Operation and Maintenance
or an engine oil pressure sensor that has a defect Manual, “Engine Oil” for the recommendations of
can give a false indication of a low oil pressure or engine oil.
a high oil pressure. If there is a notable difference
between the engine oil pressure readings make 2. Engine oil that is contaminated with fuel or coolant
necessary repairs. will cause low engine oil pressure. High engine
oil level in the crankcase can be an indication
6. If low engine oil pressure is determined, refer to of contamination. Determine the reason for
“Reasons for Low Engine Oil Pressure”. contamination of the engine oil and make the
necessary repairs. Replace the engine oil with the
7. If high engine oil pressure is determined, refer to approved grade of engine oil. Refer to Operation
“Reason for High Engine Oil Pressure”. and Maintenance Manual, “Engine Oil” for the
recommendations of engine oil.
Reasons for Low Engine Oil
NOTICE
Pressure Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
NOTICE Caterpillar could result in severe engine damage to
Keep all parts clean from contaminants. the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
Contaminants may cause rapid wear and shortened the engine lubricating system. Only use oil filters
component life. recommended by Caterpillar.
NOTICE 3. If the engine oil bypass valves are held in the

Care must be taken to ensure that fluids are contained open position, a reduction in the oil pressure can
during performance of inspection, maintenance, test- be the result. This may be due to debris in the
ing, adjusting and repair of the product. Be prepared to engine oil. If the engine oil bypass valves are
collect the fluid with suitable containers before open- stuck in the open position, remove each engine
ing any compartment or disassembling any compo- oil bypass valve and clean each bypass valve
nent containing fluids. in order to correct this problem. You must also
clean each bypass valve bore. Install new engine
Refer to Special Publication, NENG2500, “Caterpillar oil filters. New engine oil filters will prevent more
Tools and Shop Products Guide” for tools and supplies debris from causing this problem. For information
suitable to collect and contain fluids on Caterpillar on the repair of the engine oil bypass valves, refer
products. to Disassembly and Assembly, “Engine Oil Filter
Base - Disassemble”.
Dispose of all fluids according to local regulations and
mandates.
68
4. An oil line or an oil passage that is open, broken,

or disconnected will cause low engine oil pressure. NOTICE
An open lubrication system could be caused by Care must be taken to ensure that fluids are contained
a piston cooling jet that is missing or damaged. during performance of inspection, maintenance, test-
Determine the reason for an open lubrication ing, adjusting and repair of the product. Be prepared to
system of the engine and make the necessary collect the fluid with suitable containers before open-
repairs. ing any compartment or disassembling any compo-
Note: The piston cooling jets direct engine oil toward
the bottom of the piston in order to cool the piston. Refer to Special Publication, NENG2500, “Caterpillar
This also provides lubrication for the piston pin. Tools and Shop Products Guide” for tools and supplies
Breakage, a restriction or incorrect installation of the suitable to collect and contain fluids on Caterpillar
piston cooling jets will cause seizure of the piston. products.
5. The inlet screen of the oil pickup tube for the Dispose of all fluids according to local regulations and
engine oil pump can have a restriction. This mandates.
restriction will cause cavitation and a loss of
engine oil pressure. Check the inlet screen on
the oil pickup tube and remove any material that Engine oil pressure will be high if the engine oil
may be restricting engine oil flow. Low engine oil bypass valves become stuck in the closed position
pressure may also be the result of the oil pickup and the engine oil flow is restricted. Foreign matter
tube that is drawing in air. Check the joints of the in the engine oil system could be the cause for the
oil pickup tube for cracks or a damaged O-ring restriction of the oil flow and the movement of the
seal. Remove the engine oil pan in order to gain engine oil bypass valves. If the engine oil bypass
access to the oil pickup tube and the oil screen. valves are stuck in the closed position, remove
Refer to Disassembly and Assembly, “Engine Oil each bypass valve and clean each bypass valve in
Pan - Remove and Install” for more information. order to correct this problem. You must also clean
each bypass valve bore. Install new engine oil
6. Check the following problems that may occur to filters. New engine oil filters will prevent more debris
the engine oil pump. from causing this problem. For information on the
repair of the engine oil filter bypass valve, refer to
a. Air leakage in the supply side of the oil pump Disassembly and Assembly, “Engine Oil Filter Base -
will also cause cavitation and loss of oil Disassemble”.
pressure. Check the supply side of the oil pump
and make necessary repairs. For information NOTICE
on the repair of the engine oil pump, refer to Caterpillar oil filters are built to Caterpillar speci-
Disassembly and Assembly, “Engine Oil Pump fications. Use of an oil filter not recommended by
- Remove”. Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
b. Oil pump gears that have too much wear will the larger waste particles from unfiltered oil entering
cause a reduction in oil pressure. Repair the the engine lubricating system. Only use oil filters
engine oil pump. For information on the repair recommended by Caterpillar.
of the engine oil pump, refer to Disassembly
and Assembly, “Engine Oil Pump - Remove”.
i01398317
7. Excessive clearance at engine bearings will
cause low engine oil pressure. Check the Engine Oil Pump - Inspect
engine components that have excessive bearing
clearance and make the necessary repairs. SMCS Code: 1304-040
The inlet screen of the supply tube for the engine

Reason for High Engine Oil oil pump can have a restriction. This will cause
Pressure cavitation and a loss of oil pressure. Air leakage in
the supply side of the engine oil pump will also cause
NOTICE cavitation and loss of oil pressure. If the bypass valve
Keep all parts clean from contaminants. for the engine oil pump is held in the open position,
the lubrication system cannot achieve maximum
Contaminants may cause rapid wear and shortened pressure. Oil pump gears that have too much wear
component life. will cause a reduction in the oil pressure.
69
If any part of the engine oil pump is worn enough • Incorrect installation of the compression ring and/or
in order to affect the performance of the engine oil the intermediate ring
pump, the engine oil pump must be replaced. Refer
to Specifications, “Engine Oil Pump” for clearances. • Leaks past the seal rings in the turbocharger shaft
• Overfilling of the crankcase
i01126690
Excessive Bearing Wear - • Wrong dipstick or guide tube

Inspect • Sustained operation at light loads
SMCS Code: 1203-040; 1211-040; 1219-040 Excessive consumption of engine oil can also
result if engine oil with the wrong viscosity is used.
When some components of the engine show bearing Engine oil with a thin viscosity can be caused by fuel
wear in a short time, the cause can be a restriction in leakage into the crankcase or by increased engine
an oil passage. temperature.
An engine oil pressure indicator may show that there

is enough oil pressure, but a component is worn i01366050
due to a lack of lubrication. In such a case, look at

the passage for the oil supply to the component.
Increased Engine Oil
A restriction in an oil supply passage will not allow Temperature - Inspect
enough lubrication to reach a component. This will
result in early wear. SMCS Code: 1348-040
When the engine is at operating temperature and

i01794028
the engine is using SAE 15W40 oil, the maximum
Excessive Engine Oil oil temperature should be 110 °C (230 °F). This is
the temperature of the oil after passing through the
Consumption - Inspect oil cooler.
SMCS Code: 1348-040 If the oil temperature is high, then check for a
restriction in the oil passages of the oil cooler. A
Engine Oil Leaks on the Outside of restriction in the oil cooler will not cause low oil
pressure in the engine.
the Engine
Determine if the oil cooler bypass valve is held in the
Check for leakage at the seals at each end of the open position. This condition will allow the oil to pass
crankshaft. Look for leakage at the gasket for the through the valve instead of the oil cooler. The oil
engine oil pan and all lubrication system connections. temperature will increase.
Look for any engine oil that may be leaking from
the crankcase breather. This can be caused by
combustion gas leakage around the pistons. A dirty
crankcase breather will cause high pressure in the
crankcase. A dirty crankcase breather will cause the
gaskets and the seals to leak.
Engine Oil Leaks into the

Combustion Area of the Cylinders
Engine oil that is leaking into the combustion area of
the cylinders can be the cause of blue smoke. There
are several possible ways for engine oil to leak into
the combustion area of the cylinders:
• Leaks between worn valve guides and valve stems

• Worn components or damaged components
(pistons, piston rings, or dirty return holes for the
engine oil)
70
Cooling System 4. Check the fan clutch, if equipped. A fan clutch

or a hydraulic driven fan that is not turning at
the correct speed can cause improper air speed
i01460276 across the radiator core. The lack of proper air flow
across the radiator core can cause the coolant not
Cooling System - Check to cool to the proper temperature differential.
(Overheating) 5. Check the water temperature gauge. A water
SMCS Code: 1350-535 temperature gauge which does not work correctly
will not show the correct temperature. Refer to
Above normal coolant temperatures can be caused Testing and Adjusting, “Cooling System - Inspect”.
by many conditions. Use the following procedure
to determine the cause of above normal coolant 6. Check the sending unit. In some conditions, the
temperatures: temperature sensor in the engine sends signals
to a sending unit. The sending unit converts these
signals to an electrical impulse which is used by a
mounted gauge. If the sending unit malfunctions,
the gauge can show an incorrect reading. Also if
Personal injury can result from escaping fluid un- the electric wire breaks or if the electric wire shorts
der pressure. out, the gauge can show an incorrect reading.
If a pressure indication is shown on the indicator, 7. Check the radiator.

push the release valve in order to relieve pressure
before removing any hose from the radiator. a. Check the radiator for a restriction to coolant
flow. Check the radiator for debris, dirt, or
deposits on the inside of the radiator core.
1. Check the coolant level in the cooling system.
Debris, dirt, or deposits will restrict the flow of
Refer to Operation and Maintenance Manual,
coolant through the radiator.
“Cooling System Coolant Level - Check”. If the
coolant level is too low, air will get into the cooling
b. Check for debris or damage between the fins
system. Air in the cooling system will cause a
of the radiator core. Debris between the fins of
reduction in coolant flow and bubbles in the
the radiator core restricts air flow through the
coolant. Air bubbles will keep coolant away from
radiator core. Refer to Testing and Adjusting,
the engine parts, which will prevent the transfer of
“Cooling System - Inspect”.
heat to the coolant. Low coolant level is caused by
leaks or incorrectly filling the radiator.
c. Ensure that the radiator size is according to the
OEM’s specifications. An undersized radiator
2. Check the mixture of antifreeze and water. The
does not have enough area for the effective
mixture should be approximately 50 percent
release of heat. This may cause the engine to
water and 50 percent antifreeze with 3 to 6
run at a temperature that is higher than normal.
percent coolant conditioner. Refer to Operation
The normal temperature is dependent on the
and Maintenance Manual, “General Coolant
ambient temperature.
Information”. If the coolant mixture is incorrect,
drain the system. Put the correct mixture of water,
8. Check the filler cap. A pressure drop in the
antifreeze and coolant conditioner in the cooling
radiator can cause the boiling point to be lower.
system.
This can cause the cooling system to boil. Refer
to Testing and Adjusting, “Cooling System - Test”.
3. Check for air in the cooling system. Air can enter
the cooling system in different ways. The most
9. Check the fan and/or the fan shroud.
common causes of air in the cooling system
are not filling the cooling system correctly and
a. The fan must be large enough to send air
combustion gas leakage into the cooling system.
through most of the area of the radiator
Combustion gas can get into the system through
core. Ensure that the size of the fan and the
inside cracks, a damaged cylinder head, or a
position of the fan are according to the OEM
damaged cylinder head gasket. Air in the cooling
specifications.
system causes a reduction in coolant flow and
bubbles in the coolant. Air bubbles keep coolant
b. The fan shroud must be the proper size and
away from the engine parts, which prevents the
the fan shroud must be positioned correctly.
transfer of heat to the coolant.
Ensure that the size of the fan shroud and the
position of the fan shroud are according to the
OEM specifications.
71
10. Check for loose drive belts. A loose fan drive belt 14. Check the shunt line, if the shunt system is
will cause a reduction in the air flow across the used. The shunt line must be submerged in the
radiator. Check the fan drive belt for proper belt expansion tank. A restriction of the shunt line
tension. Adjust the tension of the fan drive belt, if from the radiator top tank to the engine water
necessary. Refer to Operation and Maintenance pump inlet will cause a reduction in water pump
Manual, “Belt - Inspect”. efficiency. A reduction in water pump efficiency
will result in low coolant flow and overheating.
11. Check the cooling system hoses and clamps.
Damaged hoses with leaks can normally be seen. 15. Check the water temperature regulator. A water
Hoses that have no visual leaks can soften during temperature regulator that does not open, or a
operation. The soft areas of the hose can become water temperature regulator that only opens part
kinked or crushed during operation. These areas of the way can cause overheating. Refer to Testing
of the hose can cause a restriction in the coolant and Adjusting, “Water Temperature Regulator -
flow. Hoses become soft and/or get cracks Test”.
after a period of time. The inside of a hose can
deteriorate, and the loose particles of the hose 16. Check the water pump. A water pump with a
can cause a restriction of the coolant flow. Refer damaged impeller does not pump enough coolant
to Operation and Maintenance Manual, “Hoses for correct engine cooling. Remove the water
and Clamps - Inspect/Replace”. pump and check for damage to the impeller. Refer
to Testing and Adjusting, “Water Pump - Test”.
12. Check for a restriction in the air inlet system.
A restriction of the air that is coming into the 17. Check the air flow through the engine
engine can cause high cylinder temperatures. compartment. The air flow through the radiator
High cylinder temperatures cause higher than comes out of the engine compartment. Ensure
normal temperatures in the cooling system. Refer that the filters, air conditioner, and similar items
to Testing and Adjusting, “Air Inlet and Exhaust are not installed in a way that prevents the free
System - Inspect”. flow of air through the engine compartment.
a. If the measured restriction is higher than the 18. Check the aftercooler. A restriction of air flow
maximum permissible restriction, remove the through the air to air aftercooler (if equipped) can
foreign material from the engine air cleaner cause overheating. Check for debris or deposits
element or install a new engine air cleaner which would prevent the free flow of air through
element. Refer to Operation and Maintenance the aftercooler. Refer to Testing and Adjusting,
Manual, “Engine Air Cleaner Element - “Aftercooler - Test”.
Clean/Replace”.
19. Consider high outside temperatures. When
b. Check for a restriction in the air inlet system outside temperatures are too high for the rating
again. of the cooling system, there is not enough of a
temperature difference between the outside air
c. If the measured restriction is still higher than and coolant temperatures.
the maximum permissible restriction, check the
air inlet piping for a restriction. 20. Consider high altitude operation. The cooling
capacity of the cooling system goes down as
13. Check for a restriction in the exhaust system. the engine is operated at higher altitudes. A
A restriction of the air that is coming out of the pressurized cooling system that is large enough to
engine can cause high cylinder temperatures. keep the coolant from boiling must be used.
a. Make a visual inspection of the exhaust 21. The engine may be running in the lug condition.
system. Check for damage to exhaust piping or When the load that is applied to the engine is
for a damaged muffler. If no damage is found, too large, the engine will run in the lug condition.
check the exhaust system for a restriction. When the engine is running in the lug condition,
Refer to Testing and Adjusting, “Air Inlet and engine rpm does not increase with an increase of
Exhaust System - Inspect”. fuel. This lower engine rpm causes a reduction in
air flow through the radiator. This lower engine
b. If the measured restriction is higher than the rpm also causes a reduction in coolant flow
maximum permissible restriction, there is a through the system. This combination of less air
restriction in the exhaust system. Repair the and less coolant flow during high input of fuel will
exhaust system, as required. cause above normal heating.
72
i01390078 7. Look for air or combustion gas in the cooling

system.
Cooling System - Inspect
8. Inspect the filler cap, and check the surface that
SMCS Code: 1350-040 seals the filler cap. This surface must be clean.
Cooling systems that are not regularly inspected are
the cause for increased engine temperatures. Make i01786951
a visual inspection of the cooling system before any
tests are performed. Cooling System - Test
SMCS Code: 1350-040; 1350-081
This engine has a pressure type cooling system. A

Personal injury can result from escaping fluid un- pressure type cooling system has two advantages.
der pressure. The cooling system can be operated in a safe manner
at a temperature higher than the normal boiling point
If a pressure indication is shown on the indicator, (steam) of water.
before removing any hose from the radiator. This type of system prevents cavitation in the water
pump. Cavitation is the forming of low pressure
bubbles in liquids that are caused by mechanical
1. Check the coolant level in the cooling system.
forces. It is more difficult to create an air pocket or a
Refer to Operation and Maintenance Manual,
steam pocket with this type of cooling system.
“Cooling System Coolant Level - Check”.
2. Check the quality of the coolant. The coolant

should have the following properties:
• Color that is similar to new coolant

• Odor that is similar to new coolant
• Free from dirt and debris
If the coolant does not have these properties,
drain the system and flush the system. Refill
the cooling system with the correct mixture of
water, antifreeze, and coolant conditioner. Refer
to Operation and Maintenance Manual, “General Illustration 74
g00286266
Coolant Information”.
Boiling point of water
3. Look for leaks in the system.
Remember that temperature and pressure work
Note: A small amount of coolant leakage across together. When a diagnosis is made of a cooling
the surface of the water pump seals is normal. This system problem, temperature and pressure must be
leakage is required in order to provide lubrication for checked. Cooling system pressure will have an effect
this type of seal. A hole is provided in the water pump on the cooling system temperature. For an example,
housing in order to allow this coolant/seal lubricant refer to Illustration 74. This will show the effect of
to drain from the pump housing. Intermittent leakage pressure on the boiling point (steam) of water. This
of small amounts of coolant from this hole is not an will also show the effect of height above sea level.
indication of water pump seal failure.
4. Ensure that the airflow through the radiator does

not have a restriction. Look for bent core fins
between the folded cores of the radiator. Also, look
for debris between the folded cores of the radiator.
5. Inspect the drive belts for the fan.
6. Check for damage to the fan blades.

73
Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
Cooling System Conditioner contains alkali. Avoid Illustration 75

g00286267
contact with skin and eyes. 4C-6500 Digital Thermometer
The coolant level must be to the correct level in order The 4C-6500 Digital Thermometer is used in the
to check the coolant system. The engine must be diagnosis of overheating conditions and in the
cold and the engine must not be running. diagnosis of overcooling conditions. This group can
be used to check temperatures in several different
After the engine is cool, loosen the pressure cap parts of the cooling system. Refer to Operating
in order to relieve the pressure out of the cooling Manual, NEHS0554, “4C-6500 Digital Thermometer
system. Then remove the pressure cap. Group” for the testing procedure.
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.
Test Tools For Cooling System

Table 14
Required Tools
Part
Part Name Quantity
Number
4C-6500 Digital Thermometer 1 Illustration 76
g00286269
8T-2700 Blowby/Air Flow Indicator 1 8T-2700 Blowby/Air Flow Indicator
9S-8140 Pressurizing Pump 1 The 8T-2700 Blowby/Air Flow Indicator is used to

9U-7400 Multitach Tool Group 1 check the air flow through the radiator core. Refer to
Special Instruction, SEHS8712, “Using the 8T-2700
1U-7297 1 Blowby/Air Flow Indicator” for the test procedure for
or Coolant/Battery Tester checking blowby.
1U-7298
Making contact with a running engine can cause

rotating parts.

contact with hot parts and rotating parts.
74
Check the coolant frequently in cold weather for

the proper glycol concentration. Use either the
1U-7297 Coolant/Battery Tester or the 1U-7298
Coolant/Battery Tester in order to ensure adequate
freeze protection. The testers are identical except for
the temperature scale. The testers give immediate,
accurate readings. The testers can be used for
coolants that contain ethylene or propylene glycol.
Making the Correct Antifreeze

Mixtures
Adding pure antifreeze as a makeup solution for the
g00286276
cooling system top-off is an unacceptable practice.
Illustration 77 Adding pure antifreeze increases the concentration
9U-7400 Multitach of antifreeze in the cooling system. This increases
the concentration of the dissolved solids and the
The 9U-7400 Multitach Tool Group is used to undissolved chemical inhibitors in the cooling system.
check the fan speed. Refer to Operating Manual, Add the coolant/water mixture to the same freeze
NEHS0605, “9U-7400 Multitach Tool Group ” for the protection as your cooling system. The following chart
testing procedure. assists in determining the concentration of antifreeze
to use. Refer to Operation and Maintenance Manual,
“General Coolant Information”.
Table 15
Antifreeze Concentrations
Temperature Concentration
30% antifreeze and
Protection to −15 °C (5 °F)
70% water
Protection to −23 °C 40% antifreeze and
(−10 °F) 60% water
Protection to −37 °C 50% antifreeze and
(−34 °F) 50% water
Illustration 78
g00286369 Protection to −51 °C 60% antifreeze and
(−60 °F) 40% water
9S-8140 Pressurizing Pump
The 9S-8140 Pressurizing Pump is used to test the Checking the Filler Cap
filler caps. This pressurizing pump is also used to
pressure test the cooling system for leaks. Table 16
Required Tools
Part
Part Name Quantity
Number
9S-8140 Pressurizing Pump 1
One cause for a pressure loss in the cooling system

can be a damaged seal on the radiator filler cap.
g00439083
Illustration 79
1U-7297 Coolant/Battery Tester or 1U-7298 Coolant/Battery
Tester
75
4. Compare the gauge’s reading with the opening

pressure that is listed on the filler cap.
5. If the filler cap is damaged, replace the filler cap.
Testing The Radiator And Cooling

System For Leaks
Table 17
Required Tools
Part
Part Name Quantity
Number
g00296067 9S-8140 Pressurizing Pump 1

Illustration 80
Typical schematic of filler cap
Use the following procedure in order to check the
(1) Sealing surface of both filler cap and radiator
cooling system for leaks:

and alkali.
and alkali.
Cooling System Conditioner contains alkali. Avoid
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.
contact with skin and eyes.
To check for the amount of pressure that opens the

1. After the engine is cool, loosen the filler cap slowly
filler cap, use the following procedure:
and allow pressure out of the cooling system.
Then remove the filler cap from the radiator.
1. After the engine cools, carefully loosen the filler
cap. Slowly release the pressure from the cooling
2. Ensure that the radiator is full of coolant.
system. Then, remove the filler cap.
3. Install the 9S-8140 Pressurizing Pump onto the
Carefully inspect the filler cap. Look for any
radiator.
damage to the seals and to the sealing surface.
Inspect the following components for any foreign
4. Take the pressure reading on the gauge to 20 kPa
substances:
(3 psi) more than the pressure on the filler cap.
The pressure on a typical filler cap is 48.3 kPa
• Filler cap (7 psi) to 103.42 kPa (15 psi).
• Seal 5. Check the radiator for leakage on the outside.
• Surface for seal 6. Check all connection points for leakage, and
check the hoses for leakage.
Remove any deposits that are found on these
items.
The cooling system does not have leakage only if the
following conditions exist:.
2. Install the filler cap on the 9S-8140 Pressurizing
Pump.
• You do NOT observe any outside leakage.
3. Look at the gauge for the exact pressure that
opens the filler cap. • The reading remains steady after five minutes.
76
Note: Check the engine oil for evidence of coolant

leakage.
The inside of the engine cooling system has leakage
only if the following conditions exist:
rotating parts.
• The reading on the gauge goes down. When working on an engine that is running, avoid
contact with hot parts and rotating parts.
• You do NOT observe any outside leakage.
• Evidence of coolant on the engine oil gauge. Check the accuracy of the coolant temperature
indicator or coolant temperature sensor if you find
Make any repairs, as required. either of the following conditions:
A cooling system pressure test should be performed if • The engine runs at a temperature that is too hot,
the following conditions are met: Coolant is observed but a normal temperature is indicated. A loss of
on the oil gauge. and Unusually high levels of high coolant is found.
sodium are found during a SOS analysis.
• The engine runs at a normal temperature, but a
The following steps are an outline of the cooling hot temperature is indicated. No loss of coolant
system pressure test: is found.
• Drain the engine oil. Coolant temperature can also be read on the display
screens of the Electronic Service Tool.
• Remove the oil pan.
• Connect the 9S-8140 Pressurizing Pump.
• Pressurize the system to 20 kPa (3 psi) more than
the pressure on the filler cap.
• Inspect the inside of the engine block for coolant.

• Inspect the weep hole.
Test For The Water Temperature

Gauge
Table 18 g00438983
Illustration 81
Required Tools Typical example
(1) Ports
Part
Part Name Quantity
Number
Remove the plug from one of ports (1). Install one of
4C-6500 Digital Thermometer 1 the following thermometers in the open port:
or or
2F-7112 Thermometer • The 4C-6500 Digital Thermometer
• The 2F-7112 Thermometer
A temperature indicator of known accuracy can also
Personal injury can result from escaping fluid un- be used to make this check.
der pressure.
Start the engine. Run the engine until the temperature
If a pressure indication is shown on the indicator, reaches the desired range according to the test
push the release valve in order to relieve pressure thermometer. If necessary, place a cover over part of
before removing any hose from the radiator. the radiator in order to cause a restriction of the air
flow. The reading on the water temperature indicator
should agree with the test thermometer within the
tolerance range of the coolant temperature indicator.
77
i01666401
Water Temperature Regulator

- Test
SMCS Code: 1355-081; 1355-081-ON
Personal injury can result from escaping fluid un-

der pressure.
If a pressure indication is shown on the indicator,

before removing any hose from the radiator.
1. Remove the water temperature regulator from the

engine.
2. Heat water in a pan until the temperature of

g00439003
the water is equal to the fully open temperature Illustration 82
of the water temperature regulator. Refer to Typical example
Specifications, “Water Temperature Regulator” (1) Port
for the fully open temperature of the water (2) Coolant temperature sensor
temperature regulator. Stir the water in the pan. (3) Water manifold assembly
This will distribute the temperature throughout the (4) Water outlet
(5) Coolant temperature regulator
pan. (6) Bypass line
(7) Water pump
3. Hang the water temperature regulator in the pan (8) Port
of water. The water temperature regulator must
be below the surface of the water. The water
temperature regulator must be away from the
sides and the bottom of the pan.
4. Keep the water at the correct temperature for ten burns from hot parts and can cause injury from
minutes. rotating parts.
5. After ten minutes, remove the water temperature When working on an engine that is running, avoid
regulator. Immediately measure the opening contact with hot parts and rotating parts.
of the water temperature regulator. Refer to
Specifications, “Water Temperature Regulator” Perform the following procedure in order to determine
for the minimum opening distance of the if the water pump is operating correctly:
water temperature regulator at the fully open
temperature. 1. Remove the plug from port (1).
If the distance is less than the amount listed in the 2. Install the 6V-7775 Air Pressure Gauge in port
manual, replace the water temperature regulator. (1).
3. Start the engine. Run the engine until the coolant

i01467399
is at operating temperature.
Water Pump - Test 4. Note the water pump pressure. The water pump
SMCS Code: 1361-040; 1361-081 pressure should be 100 to 125 kPa (15 to 18 psi).
Table 19
Tools Needed
Part
Part Name Quantity
Number
6V-7775 Air Pressure Gauge 1
78
Basic Engine Refer to Special Instruction, SMHS7606, “Use of

1P-4000 Line Boring Tool Group” for the instructions
that are needed to use the 1P-4000 Line Boring Tool
i01124208 Group. The 1P-4000 Line Boring Tool Group is used
in order to check the alignment of the main bearing
Piston Ring Groove - Inspect bores. The 1P-3537 Dial Bore Gauge Group can be
used to check the size of the bore. Refer to Special
SMCS Code: 1214-040 Instruction, GMG00981, “1P-3537 Dial Bore Gauge
Group” for the instructions that are needed to use the
The pistons of the engine have a keystone design 1P-3537 Dial Bore Gauge Group.
ring groove. The piston rings are a keystone ring.
The 1U-6431 Piston Ring Groove Gauge is available
to check the top ring groove in the piston. Use the i01854009
8T-3149 Plug Gauge that is part of this Gauge
Group to check the top ring groove on the piston. Cylinder Block - Inspect
Refer to the instruction card for correct use of the
1U-6431 Piston Ring Groove Gauge. SMCS Code: 1201-040
Table 20
i02115124 Required Tools
Connecting Rod Bearings - Part
Part Name Quantity
Number
Inspect
1P-3537 Dial Bore Gauge Group 1
SMCS Code: 1219-040
The connecting rod bearings fit tightly in the bore in

the rod. If there is excess movement between the
connecting rod and the crankshaft, check the bore
size. This can be an indication of wear because of a
loose fit. Refer to the Guideline For Reusable Parts,
SEBF8009, “Main and Connecting Rod Bearings”.
Connecting rod bearings are available with 0.508 mm

(0.0200 inch) and 0.762 mm (0.0300 inch) smaller
inside diameter than the original size bearings. These
bearings are for crankshafts that have been ground.
i01125517 g00285686
Illustration 83
Main Bearings - Inspect 1P-3537 Dial Bore Gauge Group
SMCS Code: 1203-040 If the main bearing caps are installed without
bearings, the bore in the block for the main bearings
Main bearings are available with 0.508 mm can be checked. Tighten the nuts on the bearing caps
(0.0200 inch) and a 0.762 mm (0.0300 inch) smaller to the torque that is given in Specifications, “Cylinder
inside diameter than the original size bearings. These Block”. Alignment error in the bores must not be more
bearings are for crankshafts that have been ground. than 0.08 mm (0.003 inch).
Main bearings are also available with a larger outside The 1P-3537 Dial Bore Gauge Group can be used
diameter than the original size bearings. These to check the size of the bore. Refer to Special
bearings are used for the cylinder blocks with the Instruction, GMG00981, “1P-3537 Dial Bore Gauge
main bearing bore that is made larger than the Group” for the instructions that are needed to use the
bore’s original size. The size that is available has 1P-3537 Dial Bore Gauge Group.
a 0.508 mm (0.0200 inch) outside diameter that is
larger than the original size bearings.
79
i01900664 3. Tighten bolts (1) evenly according to the following

procedure:
Cylinder Liner Projection -
Inspect First tighten each bolt to the following
torque. ........................................ 27 N·m (20 lb ft)
SMCS Code: 1216-040
Then tighten each bolt to the following
Table 21 torque. ........................................ 54 N·m (40 lb ft)
Required Tools
Then tighten each bolt to the following
Part torque. ........................................ 68 N·m (50 lb ft)
Part Name Quantity
Number
8T-0455 Liner Projection Tool Group 1
Again tighten each bolt to the following
torque. ........................................ 68 N·m (50 lb ft)
1. Clean the cylinder liner flange and the cylinder

block surface. Remove any nicks on the top of
the cylinder block.
Table 22
Required Components
Quantity Quantity
Part
Item Description for One for Six
Number
Cylinder Cylinders
1 8T-4193 Bolt 6 36
2 Hard
2S-5658 6 36
Washer
g00737184
3 8F-1484 Washer 6 36 Illustration 85
4 7K-1977 Washer 6 36 8T-0455 Liner Projection Tool Group

(5) Bolt
(6) Dial indicator
(7) Gauge body
(8) Gauge block
4. Loosen bolt (5) until dial indicator (6) can be

moved. Place gauge body (7) and dial indicator
(6) on the long side of gauge.
5. Slide dial indicator (6) into the correct position.

When the point of the dial indicator contacts
gauge block (8), the dial indicator is in the
correct position. Slide the dial indicator until
the needle of the gauge makes a quarter of a
revolution clockwise. The needle should be in a
vertical position. Tighten bolt (5) and zero the dial
g00441535
Illustration 84 indicator.
Location of the components
(1) Bolt
(2) Washer
(3) Washer
(4) Washer
2. The components should be assembled in the

order that is shown in Illustration 84. 7K-1977
Washer (4) is made of a cotton fabric that is
impregnated with resin. The washer will not
damage the sealing surface of the cylinder block.
Note: Inspect the washer before measuring the liner

projection. Replace the washer if the washer is worn
or damaged.
80
i01461420
Flywheel - Inspect
SMCS Code: 1156-040
Table 24
Required Tools
Part
Description Qty
Number
8T-5096 Dial Indicator 1
g00326384
Face Runout (Axial Eccentricity) of
Illustration 86
Measure the liner projection.
the Flywheel
(1) Dial indicator
(2) Gauge body
6. Place gauge body (7) on the plate for the cylinder

block. The indicator point should be on the liner
flange. Read the dial indicator in order to find the
amount of liner projection. Check the projection
at four locations (every 90 degrees) around each
cylinder liner.
Table 23
Specifications
0.040 to 0.200 mm
Liner Projection
(0.0016 to 0.0079 inch)
Maximum Variation in
0.050 mm (0.0020 inch)
Each Liner
Maximum Average
Variation Between 0.050 mm (0.0020 inch)
Adjacent Liners
g00286049
Maximum Variation Illustration 87
0.100 mm (0.0040 inch)
Between Liners Checking face runout of the flywheel
7. If a liner does not meet the recommended cylinder 1. Refer to Illustration 87 and install the dial indicator.
liner projection specification, check the following Always put a force on the crankshaft in the same
parts: direction before the dial indicator is read. This will
remove any crankshaft end clearance.
• The depth of the cylinder block bore should be
100.00 ± 0.03 mm (3.937 ± 0.001 inch). 2. Set the dial indicator to read 0.0 mm (0.00 inch).
• The liner flange should be 100.12 ± 0.03 mm 3. Turn the flywheel at intervals of 90 degrees
(3.942 ± 0.001 inch). and read the dial indicator. Refer to Testing and
Adjusting, “Finding Top Center Position for No.
If the dimensions for the liner flange do not 1 Piston”.
match the specifications, replace the liner. Then
repeat the liner projection measurements. If the 4. Take the measurements at all four points. The
dimensions for the depth of the cylinder block difference between the lower measurements and
bore do not match the specifications, replace the the higher measurements that are performed at
cylinder block. Then repeat the liner projection all four points must not be more than 0.15 mm
measurements. (0.006 inch), which is the maximum permissible
face runout (axial eccentricity) of the flywheel.
81
Bore Runout (Radial Eccentricity)

of the Flywheel
g00286058
Illustration 89
Flywheel clutch pilot bearing bore
5. To find the runout (eccentricity) 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).
g00286054
Illustration 88
Checking bore runout of the flywheel i01461438
(1) 7H-1945 Holding Rod
(2) 7H-1645 Holding Rod Flywheel Housing - Inspect
(3) 7H-1942 Dial Indicator
(4) 7H-1940 Universal Attachment
SMCS Code: 1157-040
1. Install 7H-1942 Dial Indicator (3). Make an Table 25
adjustment of 7H-1940 Universal Attachment
(4) so the dial indicator makes contact on the Tools Needed
flywheel. Part
Part Name Quantity
Number
2. Set the dial indicator to read 0.0 mm (0.00 inch).
8T-5096 Dial Indicator 1
3. Turn the flywheel at intervals of 90 degrees and
read the dial indicator. Face Runout (Axial Eccentricity) of
4. Take the measurements at all four points. The the Flywheel Housing
difference between the lower measurements 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 eccentricity) of the flywheel.
g00285931
Illustration 90
8T-5096 Dial Indicator
82
If you use any other method except the method that 1. Fasten a dial indicator to the flywheel so the anvil
is given here, always remember that the bearing of the dial indicator will contact the bore of the
clearance must be removed in order to receive the flywheel housing.
correct measurements.
1. Fasten a dial indicator to the flywheel so the anvil

of the dial indicator will contact the face of the
flywheel housing.
2. Use a rubber mallet and tap the crankshaft toward

the rear before the dial indicator is read at each
point.
g00285932
Illustration 93
Checking bore runout of the flywheel housing
g00285932
Illustration 91
Checking face runout of the flywheel housing
3. Turn the flywheel while the dial indicator is set at

0.0 mm (0.00 inch) at location (A). Read the dial
indicator at locations (B), (C) and (D).
4. The difference between the lower measurements

g00763974
and the higher measurements that are performed Illustration 94
at all four points must not be more than 0.38 mm
(0.015 inch), which is the maximum permissible 2. While the dial indicator is in the position at location
face runout (axial eccentricity) of the flywheel (C) adjust the dial indicator to 0.0 mm (0.00 inch).
housing. Push the crankshaft upward against the top of
the bearing. Refer to Illustration 94. Write the
measurement for bearing clearance on line 1 in
Bore Runout (Radial Eccentricity) column (C).
of the Flywheel Housing
Note: Write the measurements for the dial indicator
with the correct notations. This notation is necessary
for making the calculations in the chart correctly.
3. Divide the measurement from Step 2 by two. Write

this number on line 1 in columns (B) and (D).
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.
g00285934
Illustration 92
8T-5096 Dial Indicator
83
6. Turn the flywheel counterclockwise in order to i02101921

put the dial indicator at position (C). Write the
measurement in the chart. Vibration Damper - Check
7. Turn the flywheel counterclockwise in order to SMCS Code: 1205-535
put the dial indicator at position (D). Write the
measurement in the chart. Rubber Vibration Damper (If
8. Add the lines together in each column. Equipped)
9. Subtract the smaller number from the larger
number in column B and column D. Place this
number on line III. The result is the horizontal
eccentricity (out of round). Line III in column C is
the vertical eccentricity.
g00681808
Illustration 96
Vibration damper and pulley
(1) Adapter
(2) Rubber
(3) Damper assembly
(4) Bolt
(5) Crankshaft pulley
The vibration damper is installed on the front of

crankshaft. The space in the damper assembly (3) is
filled with rubber (2). The vibration damper limits the
torsional vibration.
Illustration 95
g00286046 Replace the damper if any of the following conditions
Graph for total eccentricity
exist:
(1) Total vertical eccentricity
(2) Total horizontal eccentricity • The damper is dented or cracked.
(3) Acceptable value
(4) Unacceptable value • The paint on the damper is discolored from heat.
10. Find the intersection of the eccentricity lines • There is a large amount of gear train wear that is
(vertical and horizontal) in Illustration 95. not caused by lack of oil.
11. If the point of the intersection is in the “Acceptable” • Analysis of the oil has revealed that the front main
range, the bore is in alignment. If the point of bearing is badly worn.
intersection is in the “Not acceptable” range, the
flywheel housing must be changed. • The engine has had a failure because of a broken
crankshaft.
84
Viscous Vibration Damper (If

Equipped)
g00750399
Illustration 97
Viscous vibration damper
(1) Crankshaft pulley
(2) Weight
(3) Case
Damage to the vibration damper or failure of the

vibration damper will increase vibrations. This will
result in damage to the crankshaft.
Replace the damper if any of the following conditions

exist:
• The damper is dented, cracked, or fluid is leaking

from the damper.
• The paint on the damper is discolored from

excessive heat.
• The damper is bent.

• The bolt holes are worn or there is a loose fit for
the bolts.
• The engine has had a crankshaft failure due to

torsional forces.
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 contact can affect damper operation.
85
Compression Brake Use the following procedure to adjust the slave piston
lash on cylinders 1, 3, and 5:
i02120918 1. Put No. 1 piston at the top center position on the

compression stroke.
Slave Piston Lash - Adjust
SMCS Code: 1119-025
To prevent possible injury, do not use the starter

to turn the flywheel.
Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-
suring valve clearance.
g00481680
Illustration 98
This engine uses high voltage to control the fuel Compression brake
injectors. (1) Adjustment screw and locknut
(2) Slave piston
Disconnect electronic fuel injector enable circuit (3) Actuating pin
connector to prevent personal injury.
2. Loosen adjustment locknut (1).
Do not come in contact with the fuel injector ter-
minals while the engine is running. 3. Place the appropriate feeler gauge between
slave piston (2) and screw assembly (3). Turn the
adjustment screw in a clockwise direction. Slide
Note: The engine valve lash must be adjusted before the feeler gauge between the slave piston and the
adjusting the slave piston lash. screw assembly. Continue turning the adjustment
screw until a slight drag is felt on the feeler gauge.
Reference: Testing and Adjusting, “Air Inlet and Remove the feeler gauge.
Exhaust System”
4. Tighten adjustment locknut (1) to a torque of
Table 26
35 N·m (25 lb ft). Recheck the slave piston lash
Slave Piston Lash Setting after tightening the locknut.
Jake Brake Compression Brakes
5. Continue to check the slave piston lash for each
Serial Number Prefix Slave Piston Lash
Setting of the cylinders that have been designated for
adjustment. After each adjustment, tighten the
3CS1-UP 0.64 ± 0.08 mm locknut for the valve adjustment screw to a torque
2PN1-UP (0.025 ± 0.003 inch) of 35 N·m (25 lb ft) and recheck the slave piston
8YS1-UP lash adjustment.
CPD1-UP 1.02 ± 0.08 mm
9SM1-UP (0.040 ± 0.003 inch) 6. Remove the timing bolt and turn the flywheel by
2KS1-UP 360 degrees in the direction of engine rotation.
9NS1-UP This will put No. 6 piston at the top center position
on the compression stroke. Install the timing bolt
1YN1-UP 1.14 ± 0.08 mm
(0.045 ± 0.003 inch) in the flywheel.
MBJ1-UP 1.40 ± 0.08 mm Reference: Testing and Adjusting, “Finding the

MBL1-UP (0.055 ± 0.003 inch) Top Center Position For No. 1 Piston”
Note: Slave piston lash is measured between the Follow steps 2 through 5 in order to adjust the
slave piston and the actuating pin that is on the slave piston lash on cylinders 2, 4, and 6.
exhaust valve bridge. Adjustments to the slave piston
must be completed while the engine is stopped and 7. Remove the timing bolt from the flywheel after all
the exhaust valves are closed. adjustments have been made. Reinstall the timing
cover on the flywheel housing.
86
Reference: Refer to Troubleshooting, “Retarder

Solenoid Circuits Test” for information that is related
to testing the compression brake circuit.
Reference: Refer to Testing and Adjusting, “Fuel

System” for information that is related to the
adjustment of the electronic unit injector.
i01126056
Control Valve (Compression

Brake) - Test
SMCS Code: 1119-081-V4
Oil Pressure Test

Ensure that the engine oil pressure is within the
correct operating range before performing any tests
on the compression brake. Low engine oil pressure
g00514378
can cause weak braking or no braking at all. High Illustration 99
engine oil pressure may cause the compression 149-6111 Oil Pressure Test Kit
brake not to operate at all. Refer to Testing and (1) Pressure gauge
Adjusting, “Engine Oil Pressure - Test”. (2) Seals
(3) Control valve removal tool
To properly troubleshoot the compression brake, the (4) Control valve test body
(5) Control valve adapter
technician must know the oil pressure reading at (6) Solenoid valve adapter
the compression brake housings. The oil pressure
reading on the oil pressure gauge in the instrument 1. Assemble pressure gauge (1), control valve test
panel does not provide the same information as body (4), and control valve adapter (5). Hand
the oil pressure reading at the compression brake tighten the adapter assembly.
housings.
2. While the engine is not running, remove the control
Low oil pressure in the compression brake housings valve. Refer to Disassembly and Assembly,
may cause weak braking or no braking at all. If the “Compression Brake - Disassemble”.
oil pressure in the compression brake housings is too
high, the compression brake may not operate at all.
High oil pressure may also prevent the compression
brake from shutting off.
Oil Pressure Test at Control Valve
Work carefully around an engine that is running.

can cause personal injury.
Table 27
Tools Needed
Part
Part Name Quantity
Number
149-6111 Oil Pressure Test Kit 1
g00514468
Illustration 100
87
3. Insert the adapter assembly into bore (7) for i01126281

the control valve. Hold the adapter assembly
approximately 3.1750 mm (0.125 inch) above the Solenoid Valve (Compression
bottom of the bore in order to allow the oil to enter Brake) - Test
the adapter assembly.
SMCS Code: 1119-081-JV
4. Start the engine. Ensure that the switch for the
compression brake is in the OFF position.
Oil Pressure Test
Ensure that the engine oil pressure is within the
correct operating range before performing any tests
on the compression brake. Low engine oil pressure
can cause weak braking or no braking at all. High
engine oil pressure may cause the compression
brake not to operate at all. Refer to Testing and
Adjusting, “Engine Oil Pressure - Test”.
To properly troubleshoot the compression brake, the

technician must know the oil pressure reading at
the compression brake housings. The oil pressure
reading on the oil pressure gauge in the instrument
panel does not provide the same information as
Illustration 101
g00514472 the oil pressure reading at the compression brake
housings.
5. Hold the adapter assembly in place and depress
solenoid armature (8). Record the oil pressure Low oil pressure in the compression brake housings
reading. may cause weak braking or no braking at all. If the
oil pressure in the compression brake housings is too
Note: Hold the solenoid on only long enough to high, the compression brake may not operate at all.
obtain the oil pressure reading. The oil pressure may High oil pressure may also prevent the compression
be too low at idle in order to operate the compression brake from shutting off.
brake. This condition is normal.
Oil Pressure Test at Solenoid Valve
6. Increase the engine speed by 400 rpm.
7. Repeat Steps 5 and 6 up to the rated engine rpm.

Work carefully around an engine that is running.
8. Stop the engine. Install the control valve. Refer to
Disassembly and Assembly, “Compression Brake
can cause personal injury.
- Assemble”.
The oil pressure readings at the control valve Table 28

above 1000 rpm should be 275 ± 105 kPa Tools Needed
(40 ± 15 psi).
Part
Part Name Quantity
• If the oil pressure readings at the control valve Number
are within the specified range, there is not a 149-6111 Oil Pressure Test Kit 1
problem with the oil pressure in the compression
brake.
• If the oil pressure readings at the control

valve are below the specified range, proceed
to Testing and Adjusting, “Solenoid Valve
(Compression Brake) - Test”.
• If the oil pressure readings at the control valve

are above the specified range, the engine
oil pressure is too high. Refer to Testing and
Adjusting, “Engine Oil Pressure - Test”.
88
4. Lubricate the seals with clean engine oil and

install the adapter assembly in bore (7) for the
solenoid valve. Hand tighten the adapter assembly
and then tighten the adapter assembly for an
additional 1/4 turn.
5. Start the engine. Ensure that the switch for the

compression brake is in the OFF position.
6. Record the oil pressure reading.
7. Increase the engine speed by 400 rpm.
8. Repeat Steps 6 and 7 up to the rated engine rpm.
9. Stop the engine. Install the solenoid valve. Refer

to Disassembly and Assembly, “Compression
Brake - Assemble”.
Compare the oil pressure readings from the

solenoid valve to the oil pressure readings
Illustration 102
g00514378 from the Testing and Adjusting, “Control Valve
149-6111 Oil Pressure Test Kit
(Compression Brake) - Test”.
(1) Pressure gauge
(2) Seals • If the oil pressure at the solenoid valve is
(3) Control valve removal tool higher than the oil pressure at the control valve,
(4) Control valve test body continue with Steps 10 through 15.
(5) Control valve adapter
(6) Solenoid valve adapter
• If the oil pressure at the solenoid valve is the
same pressure as the oil pressure at the control
1. Attach pressure gauge (1) to solenoid valve valve, the oil pressure to the compression
adapter (6). brake is too low. Refer to Testing and Adjusting,
“Engine Oil Pressure - Test”.
2. Remove the solenoid valve and the three seals
from the compression brake housing. Refer to 10. Start the engine.
Disassembly and Assembly, “Compression Brake
- Disassemble”. 11. Disconnect the wires from each solenoid valve
except for the solenoid valve that is being tested
3. Install three seals (2), which are included in in order to check each solenoid valve individually.
the 149-6111 Oil Pressure Test Kit. Place the
smallest seal in the bottom of the bore for the
solenoid. Install the other two seals on solenoid
valve adapter (6).
g00514472
Illustration 104
12. Turn the switch for the compression brake to the

g00514470
ON position. Observe the movement of solenoid
Illustration 103 armature (8). The solenoid armature should snap
down fully. Push down on the solenoid armature in
order to verify that the solenoid is fully actuated.
89
If the solenoid valve fully actuates, proceed to

Step 14. Otherwise, continue to Step 13.
13. Check the voltage at the terminals on the solenoid

valve. There should be at least ten volts at the
terminals.
Insufficient voltage at the terminals indicates that

there are either poor connections in the circuit or
that battery voltage is low. Verify proper battery
voltage. Check the condition of the connections
and clean the connections.
Replace the solenoid valve if both of the following

conditions exist:
• The solenoid valve is receiving the correct

voltage.
• The solenoid valve does not actuate fully.

14. Look for excessive oil leakage from the bottom
of the compression brake housing opposite
the solenoid valve. While the solenoid valve is
electrically actuated, leakage should be no more
than two drops per second. Replace the solenoid
valve if there is excessive leakage.
Note: When the solenoid valve is deactivated, oil

will dump from the solenoid valve. This is a normal
condition that should not be confused with oil leakage
while the solenoid valve is electrically actuated.
15. Repeat Steps 11 through 14 for each solenoid

valve.
90
Electrical System When it is possible, make a test of the charging

unit and voltage regulator on the engine, and use
wiring and components that are a permanent part of
i01126605 the system. Off-engine testing or bench testing will
give a test of the charging unit and voltage regulator
Battery - Test operation. This testing will give an indication of
needed repair. After repairs are made, perform a test
SMCS Code: 1401-081 in order to prove that the units have been repaired to
the original condition of operation.
Most of the tests of the electrical system can be done
on the engine. The wiring insulation must be in good
condition. The wire and cable connections must be Test Tools For The Charging
clean, and both components must be tight. System
Table 29
Tools Needed
Never disconnect any charging unit circuit or bat- Part
tery circuit cable from the battery when the charg- Part Name Quantity
Number
ing unit is operated. A spark can cause an explo-
sion from the flammable vapor mixture of hydro- 225-8266 Ammeter 1
gen and oxygen that is released from the elec- 237-5130 Digital Multimeter
trolyte through the battery outlets. Injury to per- or or 1
sonnel can be the result. 146-4080 Digital Multimeter
The battery circuit is an electrical load on the charging 225-8266 Ammeter

unit. The load is variable because of the condition of
the charge in the battery.
NOTICE
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
because the load from the battery is lost and because
there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and other
electrical components.
See Special Instruction, SEHS7633, “Battery Test

Procedure” for the correct procedures to use to
g01012117
test the battery. This publication also contains the Illustration 105
specifications to use when you test the battery. 225-8266 Ammeter
The 225-8266 Ammeter is completely portable. This

i02101972
ammeter is a self-contained instrument that measures
Charging System - Test electrical currents without breaking the circuit and
without disturbing the conductor’s insulation.
SMCS Code: 1406-081
The ammeter contains a digital display that is used
The condition of charge in the battery at each to monitor current directly within a range between 1
regular inspection will show if the charging system is ampere and 1200 amperes. If an optional 6V-6014
operating correctly. An adjustment is necessary when Cable is connected between this ammeter and a
the battery is constantly in a low condition of charge digital multimeter, current readings can be viewed
or a large amount of water is needed. A large amount directly from the display of the multimeter. This can
of water would be more than one ounce of water per be accomplished under only one condition:
a cell per a week or per every 100 service hours.
• the readings are less than 1 ammeter.
91
A lever opens the ammeter’s jaws over a conductor. i01833081

The conductor’s diameter can not be larger than
19 mm (0.75 inch). Electric Starting System - Test
The spring loaded jaws close around the conductor SMCS Code: 1450-081
for measuring the current. A trigger switch controls
the ammeter. The trigger switch can be locked into Most of the tests of the electrical system can be
the ON position or into the OFF position. done on the engine. The wiring insulation must be
in good condition. The wire and cable connections
After the trigger has been working and the trigger is must be clean, and both components must be tight.
turned to the OFF position, the reading appears in The battery must be fully charged. If the on-engine
the digital display for five seconds. This accurately test shows a defect in a component, remove the
measures currents in areas with a limited access. component for more testing.
For example, these areas include areas that are
beyond the operator’s sight. For DC operation, an The starting system consists of the following four
ammeter contains a zero control, and batteries inside components:
the handle supply the power.
• Keyswitch
Note: Refer to Special Instruction, SEHS8420
for more information about using the 225-8266 • Start relay
Ammeter.
• Starting motor solenoid
237-5130 Digital Multimeter or 146-4080
• Starting motor
Digital Multimeter
Trouble with the starting system could be caused by
the battery or by charging system problems. If the
starting system is suspect, refer to Service Manual,
SENR3581, “37-MT, 41-MT & 42-MT Series Starting
Motors”. This publication contains troubleshooting
for the starting system, test procedures, and
specifications.
i01530390
Engine Oil Pressure Sensor -

Test
SMCS Code: 1924-081
g00283566
Illustration 106
237-5130 Digital Multimeter or 146-4080 Digital Multimeter Refer to the Troubleshooting, RENR2238, “Engine
Oil Pressure Sensor Open Or Short Circuit Test”
The 237-5130 Digital Multimeter or the 146-4080 for information on checking the engine oil pressure
Digital Multimeter is a hand-held service tool with sensor.
a digital display, that is completely portable. This
multimeter is built with extra protection against
i01530581
damage in field applications. The multimeter is
equipped with 7 functions and 29 ranges. The
237-5130 Digital Multimeter or the 146-4080
Pinion Clearance - Adjust
Digital Multimeter has an instant ohms indicator. SMCS Code: 1454-025
This indicator permits checking continuity for a fast
inspection of the circuits. The multimeter can also be
used for troubleshooting capacitors that have small Electric Starting Motor
values.
When the solenoid is installed, make an adjustment
Note: Refer to Special Instruction, SEHS7734 for of the pinion clearance. The adjustment can be made
complete information for the use of the 237-5130 with the starting motor removed.
Digital Multimeter. Refer to Operation Manual,
NEHS0678 for complete information for the use of
the 146-4080 Digital Multimeter.
92
7. In order to adjust the pinion clearance, 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 the MOTOR terminal on the solenoid and
the starter motor.
i01357620
Pinion Clearance - Adjust

SMCS Code: 1454-025
g00301360 S/N: 2KS1-Up

Illustration 107
Connection for checking pinion clearance S/N: 3CS1-Up
(1) Connector to the motor
(2) Switch terminal When the solenoid is installed, make an adjustment
(3) Ground terminal of the pinion clearance. The adjustment should be
made with the starting motor removed.
1. Install the solenoid without connector (1) from the
MOTOR connections (terminal) on the solenoid
to the motor.
2. Connect a battery, that has the same voltage as

the solenoid, 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

connection (terminal), which is marked “MOTOR”,
to the ground connection (terminal). The pinion
will shift to the crank position and the pinion will
stay there until the battery is disconnected.
g00716453
Illustration 109
Connections for pinion clearance check
(4) Starting motor negative wire
1. Disconnect the starting motor negative wire (4)

from the “G” ground terminal of the solenoid.
2. Connect the batteries to the solenoid per

Illustration 109. The Illustration shows a 24
volt system with two 12 volt batteries that are
connected in series to a starting motor. Connect
four 8 volt batteries in series for a 32 volt system.
Connect eight 8 volt batteries in series for a 64 volt
system. Connect the positive side of the battery
g00283574 cable to the “S” terminal of the starting motor
Illustration 108
solenoid. Connect the negative side of the battery
Typical example cable to the “G” terminal of the starting motor .
(4) Shaft nut
(5) Pinion 3. Temporarily, touch a wire from the “G” terminal
(6) Pinion clearance
to the “Mtr” terminal. The pinion will shift to the
crank position and the pinion will stay there until
5. Push the pinion toward the end with the
the battery is disconnected.
commutator in order to remove free movement.
6. Pinion clearance (6) must be 9.1 mm (0.36 inch).

93
g00716455
Illustration 110
Pinion clearance check
(1) Adjustment nut
(2) Pinion drive housing
(3) Pinion
(X) pinion clearance
4. Push the pinion toward the commutator in order to

remove free movement.
5. Measure the clearance (X) from the pinion to the

pinion drive housing. Pinion clearance (X) must be
9.10 ± 0.8 mm (0.36 ± 0.03 inch).
6. If the clearance is not correct, remove the plug on

the shift lever housing (2). Turn the adjustment nut
(1) until the clearance is correct. Turning the nut
clockwise will decrease the clearance (X).
Note: The plunger may turn when the adjustment nut

(1) is being turned. If the plunger turns, disconnect
the battery from the solenoid. Remove the solenoid
from the starting motor. Hold the plunger from turning
and adjust the nut (1). This procedure may need to be
performed several times until the correct clearance
is obtained.
7. Disconnect the batteries and install the plug into

the shift lever housing.
94
Index Section
Index
A E
Aftercooler - Test ................................................... 60 Electric Starting System - Test............................... 91

Aftercooler Core Leakage .................................. 61 Electrical System ............................................. 37, 90
Air System Restriction........................................ 62 Charging System Components .......................... 39
Dynamometer Test............................................. 63 Engine Electrical System ................................... 38
Turbocharger Failure ......................................... 63 Grounding Practices .......................................... 37
Visual Inspection................................................ 60 Starting System Components ............................ 39
Air in Fuel - Test..................................................... 41 Electronic Control System Components.................. 6
Air Inlet and Exhaust System .......................... 22, 54 Electronic Unit Injector - Adjust ............................. 42
Turbocharger ..................................................... 23 Electronic Unit Injector - Test................................. 43
Valve System Components................................ 24 Engine Crankcase Pressure (Blowby) - Test ......... 63
Air Inlet and Exhaust System - Inspect.................. 54 Engine Design ......................................................... 4
Air Inlet Restriction............................................. 54 Engine Oil Pressure - Test..................................... 66
Exhaust Restriction ............................................ 55 Measuring Engine Oil Pressure ......................... 66
Reason for High Engine Oil Pressure ................ 68
Reasons for Low Engine Oil Pressure ............... 67
B Engine Oil Pressure Sensor - Test ........................ 91
Engine Oil Pump - Inspect..................................... 68
Basic Engine.................................................... 32, 78 Engine Valve Lash - Inspect/Adjust ....................... 64
Camshaft............................................................ 34 Valve Lash Adjustment ...................................... 64
Crankshaft.......................................................... 33 Valve Lash Check .............................................. 64
Cylinder Block .................................................... 32 Excessive Bearing Wear - Inspect......................... 69
Pistons, Rings, and Connecting Rods ............... 33 Excessive Engine Oil Consumption - Inspect........ 69
Vibration Damper ............................................... 34 Engine Oil Leaks into the Combustion Area of the
Battery - Test ......................................................... 90 Cylinders .......................................................... 69
Engine Oil Leaks on the Outside of the Engine.. 69
Exhaust Temperature - Test................................... 60
C
Charging System - Test ......................................... 90 F

Test Tools For The Charging System................. 90
Compression - Test................................................ 63 Finding Top Center Position for No. 1 Piston......... 43
Compression Brake ......................................... 34, 85 Checking and Calibrating the Electronic Injection
Operation of the Compression Brake................. 36 Timing With the Electronic Service Tool ........... 45
Performance of the Compression Brake............ 35 Procedure for Engines that have a Rear Power
Connecting Rod Bearings - Inspect....................... 78 Take-Off............................................................ 44
Control Valve (Compression Brake) - Test ............ 86 Standard Flywheel Housing ............................... 43
Oil Pressure Test................................................ 86 Flywheel - Inspect.................................................. 80
Cooling System ............................................... 29, 70 Bore Runout (Radial Eccentricity) of the
Coolant Conditioner (If Equipped)...................... 31 Flywheel ........................................................... 81
Coolant Flow ...................................................... 29 Face Runout (Axial Eccentricity) of the
Coolant for Air Compressor ............................... 32 Flywheel ........................................................... 80
Supply Manifold ................................................. 30 Flywheel Housing - Inspect ................................... 81
Temperature Regulator Housing ........................ 30 Bore Runout (Radial Eccentricity) of the Flywheel
Cooling System - Check (Overheating) ................. 70 Housing ............................................................ 82
Cooling System - Inspect....................................... 72 Face Runout (Axial Eccentricity) of the Flywheel
Cooling System - Test............................................ 72 Housing ............................................................ 81
Checking the Filler Cap...................................... 74 Fuel Quality - Test.................................................. 45
Making the Correct Antifreeze Mixtures............. 74 Fuel System....................................................... 8, 41
Test For The Water Temperature Gauge ........... 76 Electronic Controls............................................. 12
Test Tools For Cooling System .......................... 73 Injection Actuation System................................. 13
Testing The Radiator And Cooling System For Low Pressure Fuel System ................................ 10
Leaks................................................................ 75 Operation of the Fuel Injector ............................ 14
Cylinder Block - Inspect......................................... 78 Unit Injector........................................................ 14
Cylinder Liner Projection - Inspect......................... 79 Unit Injector Mechanism .................................... 13
Fuel System - Inspect............................................ 41
95
Index Section
Fuel System - Prime .............................................. 46 Turbocharger - Inspect .......................................... 56

Hand Priming the Fuel System .......................... 47 Inspection of the Compressor and the Compressor
Priming Procedure by Engine Cranking............. 48 Housing ............................................................ 57
Fuel System Pressure - Test ................................. 48 Inspection of the Turbine Wheel and the Turbine
Checking Fuel Pressure..................................... 49 Housing ............................................................ 57
High Fuel Pressure ............................................ 49 Inspection of the Wastegate .............................. 58
Low Fuel Pressure ............................................. 48
V
G
Vibration Damper - Check ..................................... 83
Gear Group (Front) - Time..................................... 53 Rubber Vibration Damper (If Equipped)............. 83
General Information................................................. 5 Viscous Vibration Damper (If Equipped) ............ 84
Cold Mode Operation........................................... 5
Customer Specified Parameters .......................... 5
Starting The Engine ............................................. 5 W
Water Pump - Test................................................. 77

I Water Temperature Regulator - Test ..................... 77
Important Safety Information ................................... 2

Increased Engine Oil Temperature - Inspect ......... 69
Inlet Manifold Pressure - Test ................................ 59
Lubrication System .......................................... 25, 66

Oil Flow Through The Lubrication System......... 27
Main Bearings - Inspect......................................... 78
Pinion Clearance - Adjust ................................ 91–92

Electric Starting Motor........................................ 91
Piston Ring Groove - Inspect................................. 78
Rear Power Take-Off (RPTO)................................ 34
Slave Piston Lash - Adjust..................................... 85

Solenoid Valve (Compression Brake) - Test .......... 87
Oil Pressure Test................................................ 87
Systems Operation Section ..................................... 4
Table of Contents..................................................... 3
Testing and Adjusting Section ............................... 41
©2004 Caterpillar
All Rights Reserved Printed in U.S.A.

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RENR2235-04

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Flywheel Housing - Inspect ................................... 81

Air Inlet and Exhaust System

Systems Operation Section i00980375

Electronic Control System

The electronic control system is integrally designed • Voltage

• Controls An output component is one that is operated by a

1. As an example, a moving solenoid plunger will

2. As an example, a dash panel light or an alarm will

These electronic components provide the ability

The Electronic Unit Injectors produce fuel injection

Low Pressure Fuel System

In the low pressure fuel system, the fuel is pulled

Electronic Controls • automatic altitude compensation

• PTO switch • Throttle signal

Injection timing is determined by engine rpm, and

Unit Injector Mechanism

Injection Actuation System

Operation of the Fuel Injector

The injector is mounted in an injector bore in the

Pre-injection metering starts with the injector plunger

To start injection, the Electronic Control Module

Injection is continuous while the injector plunger

When the plunger reaches the bottom of the barrel, i00981318

The components of the air inlet and exhaust system • Compression

• Valves and valve system components Turbocharger

• Lower fuel consumption

Note: The turbocharger with a wastegate is preset at

The camshaft has three camshaft lobes for each

Each cylinder has two inlet valves and two exhaust

The lubrication system supplies 110 °C (230 °F)

Oil cooler bypass valve (12) maintains the engine

The turbocharger cartridge bearings are lubricated by

Oil Flow Through The Lubrication

• Cold oil with high viscosity

Breather (21) allows engine blowby to escape from

Filtered oil flows through main oil gallery (2) in the

• Piston cooling jets (18)

i00984278 • Cylinder liners (9)

• Engine oil cooler (5)

The coolant is pumped through engine oil cooler (5)

The coolant temperature regulator is a full flow

Coolant Conditioner (If Equipped)

Some conditions of operation can cause pitting on

The element has a specific amount of inhibitor for

The maintenance elements have a normal amount of Cylinder Block

• Piston cooling jets

The pistons have three rings:

Cylinder liners (1) are seated on a ridge (4) in the

Hydrodynamic seals are used at both ends of the

A spacer is used on the top of the valve cover base

Operation of the Compression

The compression brake is operated by engine

This engine may be equipped with a 12 volt starting

The Electronic Control Module (ECM) must be dis-